ToR Compliance - Environmental Clearance

Powered by TCPDF (www.tcpdf.org)

http://www.tcpdf.org

ToR Compliance

ToR Compliance: Expansion of Sugar Mill from 2,500 to 6,000 TCD and Distillery from 30 to 55 KLPD M/s. Shreenath Mhaskoba Sakhar Karkhana, Patethan, Pune

Compliance of Terms of Reference for the expansion of sugar mill from 2500 to 6000 TCD and molasses based distillery from 30 to 55 KLPD

M/s. Shreenath Mhaskoba Sakhar Karkhana Ltd.

Village: Shreenathnagar Patethan, Post: Rahu, Tal: Daund, Dist: Pune

Maharashtra-412207

This project was submitted to MoEFCC (EAC) in Aug 2017 for ToR for preparation of EIA

report. The EAC considered the project and prescribed the standard ToR for undertaking

details EIA study. The pointwise compliance of compliance of ToRs is given in the table

below

A. Model TOR by MoEF&CC (April 2015)

# Points of TOR Compliance

1. Executive Summary Prepared, bound separately and

submitted along with EIA report

2. Details of the EIA Consultant including NABET

accreditation

Vasantdada Sugar Institute

Manjari (Bk), Pune, Maharashtra-

412307

Accredited by QCI/NABET;

Certificate No.:

NABET/EIA/1417/SA 0014

3. Information about the project proponent Details are given in Chapter I, Point

1.3, Page 1-2

4. Importance and benefits of the project Details are given in Chapter I, Point

1.5, Page 1-3

5. Cost of project and time of completion Details are given in Chapter II, Point

2.16, Table 2.17 and 2.18 Page 2-46

6. Products with capacities for the

proposed project

Details are given in Chapter II, Table

2.2, Page 2-3

7. If expansion project, details of existing products

with capacities and whether adequate land is

available for expansion, reference of earlier EC if

any

This is expansion of sugar unit and

molasses based distillery project.

Earlier capacities given in Chapter II,

point 2.2 page 2-1

Land Breakup given in Chapter II,

Point 2.7.4, Table 2.5, Page 2-11

ToR Compliance



8. List of raw materials required and their

source along with mode of transportation

Details are given in Chapter II, Please

refer to Table 2.4, Page 2-10

9. Other chemicals and materials required

with quantities and storage capacities

Details are given in Chapter II, Please

refer to Table 2.4, Page 2-10

10. Details of Emission, effluents, hazardous

waste generation and their management

Details are given in Chapter II, Point

2.13, Table 2.9, Page 2-21

11. Requirement of water, power, with source of

supply, status of approval, water balance

diagram, man-power requirement (regular and

contract)

Water requirement for the proposed

project will be met from Bhima River.

Water drawl permission is attached

as Annexure VI. Details are given in

Chapter II, Point 2.7.5, 2.7.7, Table

2.6 and 2.7, Page 2-12 to 2-14,

manpower requirement in Table 2.2

on page 2-5

12. Process description along with major

equipment’s and machineries, process flow

sheet (quantitative) from raw material to

products to be provided

Details are given in Chapter II, Point

2.8, Page 2-16 to 2-19

13. Hazard identification and details of proposed

safety systems

Please refer to Chapter VII, Point

7.2.1, Page 7-4

14. Copy of all the Environmental Clearance(s)

including Amendments thereto obtained for the

project from MOEF/SEIAA shall be attached as

an Annexure. A certified copy of the latest

Monitoring Report of the Regional Office of the

Ministry of Environment and Forests as per

circular dated 30th May, 2012 on the status of

compliance of conditions stipulated in all the

existing environmental clearances including

Amendments shall be provided. In addition,

status of compliance of Consent to Operate for

the ongoing /existing operation of the project

EC was applicable only to existing

distillery since existing sugar mill

capacity is 2500 TCD

EC of distillery is attached as

Annexure VIII- A

Consent for sugar mill & distillery is

attached as Annexure VII- A & B

ToR Compliance



from SPCB shall be attached with the EIA-EMP

report

15. In case the existing project has not obtained

environmental clearance, reasons for not taking

EC under the provisions of the EIA Notification

1994 and/or EIA Notification 2006 shall be

provided. Copies of Consent to Establish/No

Objection Certificate and Consent to Operate (in

case of units operating prior to EIA Notification

2006, CTE and CTO of FY 2005-2006) obtained

from the SPCB shall be submitted. Further,

compliance report to the conditions of consents

from the SPCB shall be submitted

Existing sugar mill capacity is 2500

TCD hence EC is not applicable

Consent for sugar mill is attached as

Annexure VII B

16. Location of the project site covering village,

Taluka/Tehsil, District and State, Justification

for selecting the site, whether other sites were

considered

Details are given in Chapter I, Please

refer to Point 1.2, Figure 1.1 Page 1-1

and Point 2.4 Page 2-2

17. A toposheet of the study area of radius of 10km

and site location on 1:50,000/1:25,000 scale on

an A3/A2 sheet. (including all eco-sensitive

areas and environmentally sensitive places)

Please refer to Annexure I (B) for

Toposheet

18. Details with respect to option analysis for

selection of site

Please refer to Chapter V, Point 5.1,

Page 5-1

19. Co-ordinates (lat-long) of all four corners of the

site

Please refer to Chapter III, Point

3.3.1, Page 3-1

20. Google map-Earth downloaded of the project

site

Please refer to Chapter III, Figure 3.1,

Page 3-3

21. Layout maps indicating existing unit as well as

proposed unit indicating storage area, plant

area, greenbelt area, utilities etc. If located

within an Industrial area/Estate/Complex,

layout of Industrial area indicating location of

unit within the Industrial area/Estate

Please refer to Chapter I, Figure 1.1,

Page 1-3 and Chapter II, Figure 2.1,

Page 2-6

ToR Compliance



22. Photographs of the proposed and existing (if

applicable) plant site. If existing, show

photographs of plantation/greenbelt, in

particular

Please refer to Chapter II, Figure 2.20

A & Figure 2.20 B Page2-44 & 2-45

23. Landuse break-up of total land of the project site

(identified and acquired), government/private -

agricultural, forest, wasteland, water bodies,

settlements, etc shall be included. (not required

for industrial area)


3.3.2.2, Table 3.3 Page 3-6

24. A list of major industries with name and type

within study area (10km radius) shall be

incorporated. Land use details of the study area

Please refer to Chapter III, Table 3.16

25. Geological features and Geo-hydrological status

of the study area shall be included

Please refer to Chapter III, Point 3.4.4

Page 3-19 and Point 3.5.1 and 3.5.2

Page 3-24

26. Details of Drainage of the project upto 5km

radius of study area. If the site is within 1 km

radius of any major river, peak and lean season

river discharge as well as flood occurrence

frequency based on peak rainfall data of the past

30 years. Details of Flood Level of the project site

and maximum Flood Level of the river shall also

be provided (mega green field projects)

Please refer to Chapter III, Figure 3.6

Page 3-14, Table 3.1 and 3.2, Page 3-

2 to 3-3

27. Status of acquisition of land. If acquisition is not

complete, stage of the acquisition process and

expected time of complete possession of the land

Land is already in possession of

factory. Please refer Chapter No. II,

Point No. 2.7.4, Page 2-11

28. R&R details in respect of land in line with state

Government policy

Not Applicable

29. Permission and approval for the use of forest

land (forestry clearance), if any, and

recommendations of the State Forest

Department (if applicable)

Not Applicable

ToR Compliance



30. Land use map based on High resolution satellite

imagery (GPS) of the proposed site delineating

the forestland (in case of projects involving

forest land more than 40 ha)


3.3.2.2, Figure 3.2 Page 3-6 & 3-7

31. Status of Application submitted for obtaining the

stage I forestry clearance along with latest status

shall be submitted

No forest land is used for the

proposed project

32. The projects to be located within 10 km of the

National Parks, Sanctuaries, Biosphere

Reserves, Migratory Corridors of Wild Animals,

the project proponent shall submit the map duly

authenticated by Chief Wildlife Warden showing

these features vis-à-vis the project location and

the recommendations or comments of the Chief

Wildlife Warden thereon

Not Applicable.

No National Parks, Sanctuaries,

Biosphere Reserves, Migratory

Corridors of Wild Animals located

within 10 km radius of the project

site, Details are given in Chapter III

point 3.3.1 Table 3.1 Page 3-2

33. Wildlife Conservation Plan duly authenticated

by the Chief Wildlife Warden of the State

Government for conservation of Schedule I

fauna, if any exists in the study area

Not Applicable

34. Copy of application submitted for clearance

under the Wildlife (Protection) Act, 1972, to the

Standing Committee of the National Board for

Wildlife

Not Applicable

35. Determination of atmospheric inversion level at

the project site and site-specific micro-

meteorological data using temperature, relative

humidity, hourly wind speed and direction and

rainfall

Please refer to Chapter III point

3.3.1.1 and Table 3.2 Page 3-3 and

Chapter IV, Point 4.3.2.1.1, Page 4-9

36. AAQ data (except monsoon) at 8 locations for

PM10, PM2.5, SO2, NOX, CO and other parameters

relevant to the project shall be collected. The

monitoring stations shall be based CPCB

guidelines and take into account the pre-

Please refer to Annexure 10 and

Chapter III, Table 3.5 Page 3-11,

Point 3.4.5, Table 3.9 Page 3-21

ToR Compliance



dominant wind direction, population zone and

sensitive receptors including reserved forests

37. Raw data of all AAQ measurement for 12 weeks

of all stations as per frequency given in the

NAQQM Notification of Nov. 2009 along with -

min., max., average and 98% values for each of

the AAQ parameters from data of all AAQ

stations should be provided as an annexure to

the EIA Report

Please refer to Annexure 10 and

Chapter III, Point 3.4.5, Table 3.9

Page 3-21

38. Surface water quality of nearby River (100m

upstream and downstream of discharge point)

and other surface drains at eight locations as per

CPCB/MoEF&CC guidelines

Please refer to Chapter No. III, Table

3.5 Page 3-11 and Table 3.7 Page 3-

15

39. Whether the site falls near to polluted stretch of

river identified by the CPCB/MoEF&CC, if yes

give details

Not Applicable

Site does not fall near to polluted

stretch of river identified by the

CPCB/MoEF&CC, if yes give details

40. Ground water monitoring at minimum at 8

locations shall be included


Page 3-17

41. Noise levels monitoring at 8 locations within the

study area


Page 3-24

42. Soil characteristic as per CPCB guidelines Please refer to Chapter III, Table 3.6

Page 3-13

43. Traffic study of the area, type of vehicles,

frequency of vehicles for transportation of

materials, additional traffic due to proposed

project, parking arrangement etc.


3.8.1, Table 3.17

44. Detailed description of flora and fauna

(Terrestrial and aquatic) existing in the study

area shall be given with special reference to rare,

endemic and endangered species. If Schedule-I

fauna are found within the study area, a Wildlife

Please refer Annexure-XII for list of

flora & fauna existing in the study

area.

No schedule-I fauna was found in the

study area.

ToR Compliance



Conservation Plan shall be prepared and

furnished

45. Socio-economic status of the study area Please refer to Chapter III, Point 3.7,

Page 3-28 to 3-30

46. Assessment of ground level concentration of

pollutants from the stack emission based on

site-specific meteorological features. In case the

project is located on a hilly terrain, the AQIP

Modeling shall be done using inputs of the

specific terrain characteristics for determining

the potential impacts of the project on the AAQ.

Cumulative impact of all sources of emissions

(including transportation) on the AAQ of the

area shall be assessed. Details of the model used

and the input data used for modeling shall also

be provided. The air quality contours shall be

plotted on a location map showing the location

of project site, habitation nearby, sensitive

receptors, if any.

Please refer to Chapter IV, Point

4.3.2.1.1 and 4.3.2.2, Page 4-9 to 4-14

47. Water Quality modeling - in case of discharge in

water body

No discharge in water body as ‘Zero

liquid discharge’ will be achieved

48. Impact of the transport of the raw materials and

end products on the surrounding environment

shall be assessed and provided. In this regard,

options for transport of raw materials and

finished products and wastes (large quantities)

by rail or rail-cum road transport or convey or

cum- rail transport shall be examined

Please refer to Chapter II and IV,

Point 4.3.1, Page 4-5

49. A note on treatment of wastewater from

different plant operations, extent recycled and

reused for different purposes shall be included.

Complete scheme of effluent treatment.

Characteristics of untreated and treated

Please refer to Chapter V, Point 5.3

ToR Compliance



effluent to meet the prescribed standards of

discharge under E(P) Rules

50. Details of stack emission and action plan for

control of emissions to meet standards


4.3.2.1.1, Page 4-9

51. Measures for fugitive emission control Please refer to Chapter IV, Point

4.3.3, Page 4-12

52. Details of hazardous waste generation and their

storage, utilization and management. Copies of

MOU regarding utilization of solid and

hazardous waste in cement plant shall also be

included. EMP shall include the concept of

waste-minimization, recycle/reuse/recover

techniques, Energy conservation, and natural

resource conservation.


4.5.1.1, Page 4-16

53. Proper utilization of fly ash shall be ensured as

per Fly Ash Notification, 2009. A detailed plan of

action shall be provided


4.3.2.1, Page 4-6

54. 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.

Please refer to Chapter IX point 9.4

Page 9-11

55. Action plan for rainwater harvesting measures

at plant site shall be submitted to harvest

rainwater from the roof tops and storm water

drains to recharge the ground water and also to

use for the various activities at the project site to

conserve fresh water and reduce the water

requirement from other sources

Please refer to Chapter IX, Point

9.3.3.2, Table 9.2 Page 9-10

ToR Compliance



56. Total capital cost and recurring cost/annum for

environmental pollution control measures shall

be included

Please refer to Chapter II, Point 2.16,

Page 2-46

Chapter IX, Point 9.8, Table 9.8 Page

9-18

57. Action plan for post-project environmental

monitoring shall be submitted

Please refer to Chapter VI

58. Onsite and Offsite Disaster (natural and

Man-made) Preparedness and Emergency

Management Plan including Risk Assessment

and damage control. Disaster management plan

should be linked with District Disaster

Management Plan

Please refer to Chapter VII, Point 7.9

Page 7-20 and Point 7.11 Page 7-27

59. Plan and fund allocation to ensure the

occupational health & safety of all contract and

casual workers

Please refer to Chapter XI, Table 9.8

60. Details of exposure specific health status

evaluation of worker. If the workers' health is

being evaluated by pre designed format, chest x

rays, Audiometry, Spirometry, Vision testing

(Far & Near vision, colour vision and any other

ocular defect) ECG, during pre placement and

periodical examinations give the details of the

same. Details regarding last month analyzed

data of above mentioned parameters as per age,

sex, duration of exposure and department wise.

Please refer to Annexure No. XIII

61. Details of existing Occupational & Safety

Hazards. What are the exposure levels of

hazards and whether they are within

Permissible Exposure level (PEL). If these are

not within PEL, what measures the company has

adopted to keep them within PEL so that health

of the workers can be preserved

Please refer to Chapter VII and

Chapter IX Point 9.5 Page 9-14

ToR Compliance



62. Annual report of heath status of workers with

special reference to Occupational Health and

Safety.

Please refer to Chapter IX Point 9.5

Page 9-14

63. Does the company have a well laid down

Environment Policy approved by its Board of

Directors? If so, it may be detailed in the EIA

report.

Not available

64. Does the Environment Policy prescribed for

standard operating process / procedures to

bring into focus any infringement / deviation /

violation of the environmental or forest norms

/conditions? If so, it may be detailed in the EIA

Not available

65. 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

Please refer to Chapter IX, Figure 9.5,

Page 9-20

66. Does the company have system of reporting of

non compliances / violations of environmental

norms to the Board of Directors of the company

and / or shareholders or stakeholders at large?

This reporting mechanism shall be detailed in

the EIA report

Please refer to Chapter VI, Table

6.5b and 6.6a Page 6-7

67. 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.

Please refer to Chapter IX, Point 9.5

& 9.6 Table 9.7 Page 9-14 to 9-18

68. Adequate funds (at least 2.5 % of the project

cost) shall be earmarked towards the Enterprise

Social Commitment based on Public Hearing

issues and item-wise details along with time

bound action plan shall be included. Socio-

Please refer to Chapter IX, Table 9.7,

Page 9-17

ToR Compliance



economic development activities need to be

elaborated upon

69. 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 pending

F70. A tabular chart with index for point wise

compliance of above TOR

Given in EIA Report

B. Specific terms of reference for EIA studies for sugar industry


1 Complete process flow diagram describing each unit, its

processes and operations in production of sugar, along

with material and energy inputs and outputs (material

and energy balance).

Please refer to Chapter II,

Point 2.8, Figure 2.3 Page 2-

16, 2-17

2 Details on water balance including quantity of effluent

generated, recycled & reused. Efforts to minimize

effluent is charge and to maintain quality of receiving

water body.


Point 2.7.5, Table 2.6 Page 2-

12, 2-13

3 Details of effluent treatment plant, inlet and treated

water quality with specific efficiency of each treatment

unit in reduction in respect to fall concerned / regulated

environmental parameters.


Point No 2.14.1, Figure No.

2.7 Page 2-22 to 2-25

4 Number of working days of the sugar production unit. Please refer to Chapter II,

Point 2.5, Table 2.2 Page 2-3

5 Details of the use of steam from the boiler. Please refer to Chapter II,

Point 2.7.6 Page 2-14

ToR Compliance



6 Details of proposed source-specific pollution control

schemes and equipment’s to meet the national

standards.


Point 2.14.1, Figure 2.7,

Page2-22 to 2-25, Point

2.14.4, 2.14.5 & 2.14.6 Page

2-38 to 2-40

7 Collection, storage, handling and transportation of

molasses


Point 2.7.2 table 2.4 Page 2-9

8 Collection, storage and handling of bagasse and press

mud.


Point 2.7.3 Page 2-10

9 Fly ash management plan for coal based and bagasse

and action plan

Please refer to Chapter IV,

Point 4.3.2.1.1, Page 4-9

10 Details on water quality parameters such as

Temperature, Colour, pH, BOD, COD, Total Kjeldhal

Nitrogen, Phosphates, Oil & Grease, Total Suspended

Solids, Total Coli form bacteria etc.

Please refer to Chapter III,

Table 3.5 Page 3-11 and

Table 3.7 Page 3-15

11 Details on existing ambient air quality and expected,

stack and fugitive emissions for PM10, PM2.5, SO2*,

NOx*, etc., and evaluation of the adequacy of the

proposed pollution control devices to meet standards

for point sources and to meet AAQ standards. (*-As

applicable)

Please refer to Annexure 10

and Chapter III, Point 3.4.5

Page 3-21, Table 3.5 Page 3-

11, Table 3.9 Page 3-21

C. Specific terms of reference for EIA studies for Distilleries


1 List of existing distillery units in the study area along

with their capacity and sourcing of raw material.


3.7.4.3 Table 3.16 Page 3-30

2 Number of working days of the distillery unit. Please refer to Chapter II, Point

2.5, Table 2.2 Page 2-3

3 Details of raw materials such as molasses/grains,

their source with availability.

Please refer to Chapter II, Table

2.4 Page 2-10

4 Details of the use of steam from the boiler. Please refer to Chapter II, Point

2.7.6 Page 2-14

ToR Compliance


5 Surface and Ground water quality around proposed

spent wash storage lagoon, and compost yard.

Please refer to Chapter III, Table

3.7 and 3.8 Page 3-15 to 3-18

6 Plan to reduce spent wash generation within 6-8

KL/KL of alcohol produced.

Please refer to Chapter II, point

2.8 Page 2-16 and Figure 2.4

Page 2-19

7 Proposed effluent treatment system for

molasses/grain based distillery (spent wash, spent

lees, condensate and utilities) as well as domestic

sewage and scheme for achieving zero effluent

discharge (ZLD).


2.14.2 and Figure 2.8, 2.9 and

2.10 Page 2-27 to 2-30

8 Proposed action to restrict fresh water consumption

within 10 KL/KL of alcohol production


2.7.5 and Table 2.6 Page 2-12

9 Details about capacity of spent wash holding tank,

material used, design consideration. No. of

peizometers to be proposed around spent wash

holding tank.

Please refer to Chapter II, Figure

2.11 Page 2-34

10 Action plan to control ground water pollution Please refer to Chapter II, Figure

2.12, 2.13 and 2.14

11 Details of solid waste management including

management of boiler ash, yeast, etc. Details of

incinerated spent wash ash generation and its

disposal.

Please refer to Chapter II, Point

2.14.6 Page 2-38

12 Details of bio-composting yard (if applicable). Please refer to Chapter II, Point

2.14.2.3 A Page 2-28

13 Action plan to control odour pollution. Please refer to Chapter II, Point

2.14.2.3 Figure 2.10, Page 2-27

and 2-28

14 Arrangements for installation of continuous online

monitoring system (24x7 monitoring device)

Please refer to Chapter IX, Table

9.8 & 9.9 Page 9-18

Contents

EIA Report: Expansion of Sugar Mill from 2,500 to 6,000 TCD and Distillery from 30 to 55 KLPD M/s. Shreenath Mhaskoba Sakhar Karkhana, Patethan, Pune

CONTENTS OF REPORT

CHAPTER PARTICULARS PAGE No.

I INTRODUCTION

1.1 Introduction 1-1

1.2 Purpose of the report 1-1

1.3 Identification of project and project proponent 1-2

1.4 Preliminary project information 1-2

1.5 Importance of project to the country 1-3

1.6 Scope of the study 1-4

1.7 Environmental Legislation 1-4

1.8 Structure of the report 1-4

II PROJECT DESCRIPTION


2.2 Type of project 2-1

2.3 Need for the project 2-1

2.4 Selection of site 2-2

2.5 Project highlights 2-3

2.6 Size or magnitude of operation 2-6

2.7 Infrastructure 2-9

2.7.1 Sugarcane 2-9

2.7.2 Molasses 2-9

2.7.3 Press mud 2-10

2.7.4 Land 2-11

2.7.5 Water 2-12

2.7.6 Steam 2-14

2.7.7 Power 2-14

2.7.8 Fuel 2-15

2.7.8.1 Fuel Composition 2-16

2.8 Process description 2-16

2.9 Fire protection system 2-20

Contents



2.10 Bagasse handling system 2-20

2.11 Ash handling system 2-20

2.12 Manpower 2-20

2.13 Environmental aspects 2-21

2.14 Pollution aspect 2-22

2.14.1 Sugar Unit 2-22

2.14.1.1 ETP; Primary treatment 2-25

2.14.1.2 Secondary treatment 2-26

2.14.2 Distillery Unit 2-27

2.14.2.1 Primary Treatment for Spentwash 2-27

2.14.2.2 Secondary treatment for Spentwash - MEE 2-30

2.14.2.3 Tertiary treatment for Spentwash 2-30

2.14.3 Sewage 2-38

2.14.4 Air emissions and Control measures 2-38

2.14.5 Noise Control 2-39

2.14.6 Solid waste generation and management 2-40

2.14.7 Hazardous waste 2-40

2.15 Greenbelt development 2-41

2.16 Cost of the project 2-46

III BASELINE ENVIRONMENTAL STATUS 3.1 Introduction 3-1

3.2 Methodology of Baseline Study 3-1

3.3 Description of Study Area 3-1

3.3.1 Description of Site and surrounding features 3-1

3.3.1.1 Access to the site 3-3

3.3.2 Land Use Pattern 3-4

3.3.2.1 Methodology 3-4

3.3.2.2 Land use/ land cover classes details 3-6

3.3.3 Climatic conditions of the Daund Taluka 3-7

3.3.3.1 Rainfall 3-7

Contents



3.3.3.2 Temperature 3-8

3.3.3.3 Relative humidity 3-8

3.3.3.4 Cloudiness 3-8

3.3.3.5 Winds 3-8

3.3.3.5.1 Wind speed and wind direction 3-9

3.4 Environment monitoring data on soil, water, air and noise aspects

3-10

3.4.1 Soil: general characteristics for the district 3-11

3.4.1.1 Soil characteristics 3-12

3.4.1.2 Observations 3-13

3.4.2 Hydrology 3-14

3.4.3. Physico-chemical characteristics of surface water 3-14

3.4.3.1 Physico-chemical characteristics of ground water 3-19

3.4.4 Hydrogeology 3-19

3.4.4.1 Major ground water problems and issues 3-21

3.4.5 Air environment 3-21

3.4.5.1 Observations 3-23

3.4.6 Noise environment 3-23

3.4.6.1 Method of monitoring 3-24

3.4.6.2 Parameters measured 3-24

3.5 Geography and geology 3-24

3.5.1 Geography 3-24

3.5.2 Geology 3-25

3.5.2.1 Minerals 3-25

3.6. Biological environment 3-26

3.6.1 Methodology 3-26

3.6.2 Floral diversity of study area 3-27

3.6.3 Faunal diversity of study area 3-27

3.6.4 Observations within 10 km surrounding study area 3-27

3.7 Socio-economic environment 3-28

Contents



3.7.1 Introduction 3-28

3.7.2 Methodology 3-28

3.7.3 Sources of information 3-28

3.7.4 Social profile 3-28

3.7.4.1 Demography 3-29

3.7.4.2 Literacy levels 3-29

3.7.4.3 Occupation structure 3-30

3.7.4.4 Settlement details 3-30

3.7.4.5 Availability of infrastructure 3-30

3.7.5 Social activities initiated and implemented by SMSKL

3-32

3.8 Other aspects 3-33

3.8.1 Traffic details 3-33

IV ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES


4.2 Construction phase 4-1

4.2.1 Land transformation 4-2

4.2.2 Air environment 4-2

4.2.3 Water environment 4-3

4.2.4 Ecology 4-4

4.2.5 Natural resources 4-4

4.2.6 Socio-economic aspects 4-4

4.3 Operation Phase : Air pollution 4-5

4.3.1 Transportation 4-5

4.3.1.1 Preventive, control and mitigation measures 4-5

4.3.2 Manufacturing process 4-6

4.3.2.1 Emissions due to burning of fuel 4-6

4.3.2.1.1 Dispersion modeling for air pollutants 4-9

4.3.2.2 Prediction 4-11

4.3.3 Other sources of air pollution 4-12

Contents



4.3.4 Impact assessment 4-13

4.3.5 Noise 4-13

4.4 Water environment 4-14

4.4.1 Preventive, control and mitigation measures 4-14

4.4.1.1 Reuse of water (after proper treatment) 4-14

4.4.1.2 Recycle of water 4-14

4.4.1.3 Conservation of water 4-14


4.5 Soil environment 4-15

4.5.1 Preventive, control and mitigation measures 4-16

4.5.1.1 Hazardous waste 4-16


4.6 Ecology and biodiversity 4-16

4.7 Impact socio-economic environment 4-20

4.8 Impact on physiography, geology and hydro-geology (drainage)

4-21

4.9 Other impact: Traffic 4-21

4.10 Summary 4-21

V ANALYSIS OF ALTERNATIVES 5.1 Alternative Site 5-1

5.2 Manufacturing process 5-1

5.2.1 Effluent Treatment Technologies 5-1

VI ENVIRONMENTAL MONITORING PROGRAMME 6.1 Introduction 6-1

6.2 Environmental management cell 6-1

6.2.1 Monitoring Plan 6-3

6.2.1.1 Water Environment 6-3

6.2.1.2 Air Environment 6-3

6.2.1.3 Noise Environment 6-3

6.2.1.4 Soil Environment 6-3

6.2.1.5 Other Conditions 6-4

Contents



6.2.3 Flow measurement 6-5

VII ADDITIONAL STUDIES (RISK ASSESSMENT AND DISASTER MANAGEMENT)

7.1 Safety 7-1

7.1.1 Goals or Targets of safety 7-1

7.1.2 Procedures in case of accidents 7-2

7.2 Risk assessment and risk management 7-3

7.2.1 Hazard identification 7-4

7.2.1.1 Broad Categories of hazard 7-4

7.3 Probable risk factors 7-6

7.3.1 Fire in fuel storage yard 7-6

7.3.2 Mechanical Injury to Body Parts 7-7

7.3.3 Mitigation measures for fire hazards 7-8

7.3.4 Boiler operations 7-10

7.4 Qualitative risk assessment 7-10

7.5 Mitigation 7-14

7.5.1 Basic Design of the Sugar Unit 7-14

7.5.2 Steam Generating System 7-14

7.5.3. Turbo Generator System 7-14

7.5.4 Bagasse Handling 7-14

7.5.5 Milling Section 7-15

7.5.6 Control and Instrumentation 7-15

7.6 Risk Mitigation Measures : Fire Hazard 7-15

7.6.1 Fire Fighting System 7-15

7.6.1.1 Fire Extinguisher 7-15

7.6.1.2 Classification of Fire 7-15

7.6.1.3 Use of Fire Fighting Equipment 7-16

7.6.1.4 Fire Evacuation 7-16

7.6.1.5 Procedure For In Case Of Fire 7-16

7.6.1.6 Ventilation 7-17

Contents



7.6.1.7 First Aid 7-17

7.7 Other Measures 7-18

7.8 Safety Organization 7-19

7.9 Onsite Emergency Plan 7-20

7.9.1 Introduction 7-20

7.9.2 Objectives 7-21

7.9.3 Identification and Assessment of Hazard 7-21

7.9.4 Emergency Control Centre 7-21

7.9.5 Responsibilities of Works Manager 7-22

7.9.6 Emergency Siren 7-22

7.9.7 Wind Direction 7-23

7.9.8 Organization Chart for Dealing Emergencies 7-23

7.9.9 First Information 7-24

7.9.10 Brief Responsibilities 7-24

7.9.10.1 Chief Incident Controller 7-24

7.9.10.2 Site Incident Controller 7-24

7.9.10.3 Safety and Engineering Team 7-24

7.9.10.4 First-Aid Team 7-24

7.9.10.5 Fire Team , Security Team 7-24

7.9.10.6 Liaison Team 7-25

7.10 Responsibity In Details 7-25

7.10.1 Chief Incident Controller 7-25

7.10.2 Site Incident Controller 7-25

7.10.3 Safety Team and Engineering Team 7-26

7.10.4 Fire Team and Security Team 7-26

7.10.5 First-Aid Team 7-27

7.10.6 Responsibility of Non-Emergency Employees and Visitors

7-27

7.10.7 Key Emergency Personnel 7-27

7.10.8 Emergency Staff 7-27

Contents



7.11 Off-site emergency plan 7-27

7.12 Public hearing minutes 7-32

VIII PROJECT BENEFITS ANALYSIS 8.1 Project Benefits – for the project proponent 8-1

8.2 Project Benefits – for the local society 8-1

8.3 Benefits to country – Alcohol as a fuel 8-2

8.4 Environmental Benefit Analysis 8-2

IX ENVIRONMENTAL MANAGEMENT PLAN 9.1 Overview 9-1

9.1.1 Objectives of EMP 9-1

9.2 EMP for construction phase 9-1

9.3 EMP for operation phase 9-2

9.3.1 Air Environment 9-6

9.3.1.1 Others Emission 9-6

9.3.2 Noise environment 9-6

9.3.3 Water environment 9-7

9.3.3.1 CREP guidelines for molasses based distilleries 9-8

9.3.3.2 Rainwater Harvesting 9-10

9.3.4 Land environment 9-10

9.3.4.1 Hazardous waste management 9-11

9.4 Greenbelt development 9-11

9.5 Safety, occupational health management 9-14

9.6 EMP for Social Environment 9-16

9.7 Environmental Monitoring Programme 9-18

9.8 Budgetary Allocation And Decision Making 9-18

X SUMMARY AND CONCLUSION 10.1 Salient features of the project 10-1

10.2 Conclusion 10-2

XI DISCLOSURE OF CONSULTANT 11.1 Consultant - Vasantdada Sugar Institute 11-1

11.2 Project team of EIA study 11-2

Contents


LIST OF TABLES


I INTRODUCTION


Table 2.1 Cane availability in the command area of the mill-

Data for last five years

2-2

Table 2.2 Highlights of the project 2-3

Table 2.3 Expected performance of the sugar mill for next

five years

2-9

Table 2.4 Availability of raw materials, finished good product

and mode of transport

2-10

Table 2.5 Land Breakup 2-11

Table 2.6 Water Balance 2-12

Table 2.7 Power requirement 2-14

Table 2.8 Bagasse generation and net consumption estimate

for the proposed project

2-15

Table 2.9 Overview of environment management processes 2-21

Table 2.10 Important characteristics of raw spentwash 2-27

Table 2.11 Desired characteristics of bio-compost 2-31

Table 2.12 Composting requirements 2-32

Table 2.13 Mass balance for compost 2-32

Table 2.14 Solid waste generation and disposal 2-38

Table 2.15 Solid waste generation and disposal 2-38

Table 2.16 Tree species in existing green belt 2-39

Table 2.17 Proposed project cost details 2-43

Table 2.18 Project implementation scheduled 2-43

III BASELINE ENVIRONMENTAL STATUS

Table 3.1 Important Features around the Project Site 3-2

Table 3.2 Summary of Environmental features of study area 3-3

Contents



Table 3.3 Land use/Land cover statistics of the ten square

km area

3-6

Table 3.4 Annual rainfall for Daund taluka 3-8

Table 3.5 Monitoring Locations 3-11

Table 3.6 Soil analysis results for samples collected from the

study area

3-13

Table 3.7 Analysis report - Surface water sources from the

study area

3-15

Table 3.8 Analysis report - Groundwater sources from the

study area

3-17

Table 3.9 Baseline Ambient Air Quality data 3-21

Table 3.10 Noise Monitoring Results in dB(A) 3-24

Table 3.11 Religious status of Daund Taluka 3-28

Table 3.12 Number and percentage of Scheduled Caste and

Scheduled Tribe population in Daund Taluka, 2011

3-29

Table 3.13 Sex ratio by sub district 3-29

Table 3.14 Demographic details with respect to SC and ST

Population

3-29

Table 3.15 Number of literates and illiterates, literacy rate by

sex in sub-Districts, 2011

3-30

Table 3.16 List of Industries in the surrounding area 3-30

Table 3.17 Average Traffic per day 3-33

IV ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION

MEASURES

Table 4.1 General characteristics of bagasse 4-6

Table 4.2 Dispersion Model Input Data 4-9

Table 4.3 Resultant Concentrations Due To Incremental GLC's 4-11

Table 4.4 Solid Waste and its Management 4-16

Contents



Table 4.5 Summary of Impact Assessment and Environment

management plan proposed for the respective

aspect

4-22

V ANALYSIS OF ALTERNATIVES

VI ENVIRONMENTAL MONITORING PROGRAMME

Table 6.1 Composition of Environment Management Cell 6-2

Table 6.2 Analysis of environmental parameters and its

reporting schedule

6-4

Table 6.3 Suggested schedule for maintenance of waste water

treatment unit

6-4

Table 6.4a Format for Water Consumption Reporting

Schedule – Sugar mill

6-5

Table 6.4b Format for Water Consumption Reporting

Schedule - Distillery

6-6

Table 6.5a Format for Pollutant Generation Reporting

Schedule – Sugar mill

6-6

Table 6.5b Format for Pollutant Generation Reporting

Schedule - Distillery

6-7

Table 6.6a Format for Pollutant Disposal Reporting Schedule –

Sugar Mill

6-7

Table 6.6b Format for Pollutant Disposal Reporting Schedule 6-8

Table 6.7 Format for Biocompost Reporting Schedule 6-8

VII ADDITIONAL STUDIES (RISK ASSESSMENT AND DISASTER

MANAGEMENT)

Table 7.1 NFPA (national fire protection association) rating 7-7

Table 7.2 Hazardous areas in a molasses based distillery

attached to sugar mill.

7-8

Table 7.3 Probability of occurrence of hazard 7-10

Table 7.4 Severity – Impact intensity 7-10

Table 7.5 Mitigation measures for identified hazards 7-11

Contents



VIII PROJECT BENEFITS ANALYSIS

IX ENVIRONMENTAL MANAGEMENT PLAN

Table 9.1 Environment management plan: Operation Phase 9-2

Table 9.2 Details of rainwater harvesting and storage 9-10

Table 9.3 Management of Solid Waste 9-11

Table 9.4 Tree Plantation Details 9-11

Table 9.5 List of recommended species for greenbelt

development

9-12

Table 9.6 Flowering and foliage shrubs proposed for

greenbelt

9-13

Table 9.7 Financial provision for ESC (CSR) activities

planned for next five years

9-17

Table 9.8 Budgetary allocations for environment

management (Sugar Unit)

9-18

Table 9.9 Budgetary allocations for environment

management (Distillery Unit)

9-19

X SUMMARY AND CONCLUSION

Table 10.1 Salient features of Proposed Project 10-1

XI DISCLOSURE OF CONSULTANT

Contents


LIST OF FIGURES


I INTRODUCTION

Figure 1.1 Project site location map 1-3


Figure 2.1 Satellite image showing location of proposed

sugar and distillery unit

2-6

Figure 2.2

(A)

Layout of proposed sugar unit 2-7

Figure 2.2

(B)

Layout of proposed distillery unit 2-8

Figure 2.3 Flow chart of sugar manufacturing process 2-17

Figure 2.4 Schematic of RS/ENA/AA manufacturing process 2-19

Figure 2.5 Existing Fire Fighting System 2-20

Figure 2.6 Flowchart of effluent generation and

management from Sugar unit

2-22

Figure 2.7 Schematics of Effluent treatment plant 2-23

Figure 2.8 Flowchart for Spent wash treatment and disposal 2-26

Figure2.9 Multiple Effect Evaporation (MEE) System 2-27

Figure 2.10 Aero tiller/ mixing machine for mixing up the

windrow

2-28

Figure 2.11 Sectional view of Spentwash storage lagoon 2-34

Figure 2.12 Existing Compost yard with Leachate gutter 2-34

Figure 2.13 Sectional view of compost yard 2-35

Figure 2.14 Sectional view of Leachate Gutter 2-35

Figure 2.15 Existing HDPE pipelines for carrying Spentwash 2-36

Figure 2.16 Existing Spentwash storage lagoon 2-36

Figure 2.17 Existing Venturi Wet Scrubber With Chimney 2-37

Figure 2.18 DG set with acoustic enclosure 2-37

Figure 2.19 Existing Greenbelt 2-40

Contents



Figure 2.20

(A)

Layout of Existing Greenbelt (Sugar unit) 2-41

Figure 2.20

(B)

Layout of Existing Greenbelt (Distillery unit) 2-42

III BASELINE ENVIRONMENTAL STATUS

Figure 3.1 Satellite image showing site and surrounding

area

3-3

Figure 3.2 Land use/land cover map of the study area 3-7

Figure 3.3 Wind rose 3-9

Figure 3.4 Wind class frequency distribution 3-10

Figure 3.5 Monitoring location map 3-10

Figure 3.6 Drainage map of the study area 3-14

Figure 3.7 Hydrogeology of Pune district 3-20

Figure 3.8 Geological and mineral map of Maharashtra 3-26

IV ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION

MEASURES

Figure 4.1 Isopleths showing incremental ground level

concentration of particulate matter (Short Term

24 Hourly) during cane crushing season

4-10


concentration of SO2 (Short Term 24 Hourly)

during cane crushing season

4-10


concentration of SO2 (Short Term 24 Hourly)

during off-season – bagasse + biogas as a fuel

4-11

V ANALYSIS OF ALTERNATIVE TECHNOLOGY

VI ENVIRONMENTAL MONITORING PROGRAMME

Figure 6.1 Schematics of Environment Management Cell 6-2

Contents



VII ADDITIONAL STUDIES

(SAFETY, RISK &DISASTER MANAGEMENT)

Figure 7.1 Schematic of procedure in case of accident 7-2

Figure 7.2 Bagasse yard with fire fighting system 7-8

VIII PROJECT BENEFIT ANALYSIS

IX ENVIRONMENTAL MANAGEMENT PLAN

Figure 9.1 Schematic of Water Management 9-7

Figure 9.2 Rain water harvesting and storm water drainage

layout

9-10

Figure 9.3 Schematics of waste Management 9-11

Figure 9.4 Schematics of greenbelt development 9-14

Figure 9.5 Decision making and its implementation

hierarchy (from top to bottom) and reporting

hierarchy (bottom to top ) for environmental

conditions/ Compliances

9-20

X SUMMARY AND CONCLUSION

XI DISCLOSURE OF CONSULTANT

Figure 11.1 Activities of Department of Environmental

Science

11-1

ABBREVIATIONS

EIA Report: M/s. Shreenath Mhaskoba Sakhar Karkhana Ltd. Patethan, Pune Proposed Expansion of Sugar and Molasses Based Distillery unit i

LIST OF ABBREVIATIONS

ABBREVIATION FULL FORM

AA Absolute alcohol/ anhydrous alcohol

ACF Activated charcoal filter

AP Air pollution

AAQ Ambient Air quality

AQ Air Quality

BOD Biological Oxygen Demand

COD Chemical Oxygen Demand

CPCB Central Pollution Control Board

CREP Corporate Responsibility For Environmental Protection

DG Diesel Generator

DO Dissolved Oxygen

EC Environmental Clearance

EIA Environmental Impact Assessment

EMP Environment Management Plan

ENA Extra Neutral Alcohol

EPA Environmental (Protection) Act

FAE Functional Area Expert

GLC Ground Level Concentration

SHE Safety, Health and Environment

HWMH Hazardous Waste (Management & Handling) Rules

ID Induced Draft

IMD Indian Meteorological Department

IMFL Indian Made Foreign Liquor

IS Indian Standard

KLPD or KLD Kilo Liter Per Day

MINAS Minimal National Standards

MOC Material of construction

MoEFCC Ministry of Environment, Forests and Climate Change

MPCB Maharashtra Pollution Control Board

MS Mild steel

MSDS Material Safety Datasheet

ABBREVIATIONS

EIA Report: M/s. Shreenath Mhaskoba Sakhar Karkhana Ltd. Patethan, Pune Proposed Expansion of Sugar and Molasses Based Distillery unit ii

ABBREVIATION FULL FORM

MTD Metric Ton Per Day

NAAQS National Ambient Air Quality Standard

NABET National Accreditation Board for Education & Training

OSHA Occupational Safety And Health Administration

PEL Permissible Exposure Limit

PM Particulate Matter

ppm Parts per million

PPE Personal Protective Equipments

RM Raw material

RO Reverse Osmosis

RS Rectified Spirit

SPCB State Pollution Control Board

SPL Sound Pressure Level

SPM Suspended Particulate Matter

SS Suspended Solids

STG Steam Turbine Generator

TCD Ton Crush per Day

TDS Total Dissolved Solid

TLV Threshold Limit Value

TPH Tons Per Hour

TPD Tons Per Day

VSI Vasantdada Sugar Institute

Annexure

EIA Report Annexure: Proposed Expansion of Sugar unit from 2,500 to 6,000 TCD and Molasses Based Distillery unit from 30 to 55 KLPD M/S. Shreenath Mhaskoba Sakhar Karkhana Ltd. Patethan, Pune

List of Annexure Annexure

Number Particulars

I A) Site Location Map

B) Toposheet

II Satellite image showing monitoring location within10km study area

III Layout of proposed sugar unit

IV Layout of proposed distillery unit

V NOC from village panchayat

VI Water drawl permission

VII A. Consent to operate (Distillery)

B. Consent to operate (Sugar unit)

VIII A. Environmental Clearance of Distillery

B. Certified Compliance report

IX Approved Terms of Reference (ToR) for the proposed project

X Monitoring Reports of :

A) Ambient Air Quality

B) Noise

C) Water

D) Soil

XI Socio-economic data: Demographic details of Daund Taluka

XII List of Flora & Fauna of the study area

XIII A. Sample copy of medical checkup report of employee

B. Safety Training Report

XIV A. Existing Greenbelt Layout of sugar unit

B. Existing Greenbelt Layout of distillery unit

XV A. Piezometric well

B. Groundwater analysis report

XVI

Continuous online monitoring system

A. For distillery unit

B. For sugar unit

Chapter I

EIA Report: Expansion of Sugar Mill from 2,500 to 6,000 TCD and Distillery from 30 to 55 KLPD M/s. Shreenath Mhaskoba Sakhar Karkhana, Patethan, Pune 1-1

Chapter I

INTRODUCTION

1.1 INTRODUCTION

The sugar industry is the second largest agro-based industry in India and provides

direct/indirect livelihood to millions of people. India is the worlds second largest producer of

sugarcane and sugar with the state of Maharashtra being the top sugar producing state. The

growth of sugar industry in the state started prior to independence in the private sector and in

the co-operative sector since 1950. The growth of this industry has certainly helped to improve

socio-economic life of the rural parts of the state.

The industry is characterized by the phenomenon of cyclicality i.e. cycles of boom and bust. This

affects the financial viability of the industry. Sugar mills cannot maintain their financial health

on a single product i.e. sugar. Hence, it is necessary to develop a sugar mill into affiliated

chemical complex and use the valuable byproducts more profitably.

Molasses is a very important by-product of the sugar industry. The profit earned by conversion

of molasses to alcohol is much higher than the value realised by sale of molasses. There is a

good demand for alcohol in the country as production and consumption of alcohol in India is

quite balanced. Alcohol has assumed a very important place in the economy of the country after

the ethanol blending program started in the country. The importance and utility of alcohol is

well known as an industrial raw material for manufacturing of a variety of organic chemicals

including pharmaceuticals, cosmetics, potable alcohol etc.

1.2 PURPOSE OF THE REPORT

The purpose of this report is to get an Environmental Clearance for expansion of sugar unit from

2,500 to 6,000 TCD and molasses based distillery unit from 30 to 55 KLPD of M/s. Shreenath

Mhaskoba Sakhar Karkhana Ltd., at village Shreenathnagar Patethan, Taluka Daund, Dist-Pune

by carrying out EIA studies. The notification no. S.O. 1533 promulgated on 14th September 2006

has covered sugar and distillery industry under Section 5(j) and 5(g) respectively. Since the

project involves expansion of distillery project it is placed under category ‘A’. This report

presents the environmental impact analysis of the proposed sugar and distillery expansion

project. The adverse impacts can be minimized by using appropriate control or mitigation

measures. The structure of the EIA report is as per the guidelines of the EIA notification, 2006

(Appendix III).

Chapter I


1.3 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT

Shreenath Mhaskoba Sakhar Karkhana Ltd., (SMSKL) is one of the progressive sugar

factories in Maharashtra, set up in the year 2002-03 and is registered under the Government of

Maharashtra, Registration no. 1622100210937 (Re-validation date 22/12/2016). Shri.

Pandurang Raut is Chairman and Managing Director of the factory. The present installed

capacity of the sugar mill is 2,500 TCD along with molasses-based distillery unit of 30 KLPD. The

Management of the factory has undertaken extensive cane development activities in its

command area (i.e. area of operations), hence sugarcane area has increased over a period of

time. Considering the increased availability of sugarcane, the factory has decided to expand its

crushing capacity from 2,500 TCD to 6,000 TCD (operating capacity). Because of increase in the

crushing capacity, the production of byproduct like molasses will also increase. Considering this,

the management of SMSKL has decided to enhance the capacity of existing distillery unit from

30 KLPD to 55 KLPD, to improve its financial viability.

1.4 PRELIMINARY PROJECT INFORMATION

Name of the Industry M/s. Shreenath Mhaskoba Sakhar Karkhana Ltd.

Size of the project Expansion of sugar unit from 2,500 to 6,000 TCD and distillery

unit from 30 to 55 KLPD

Location of the project Shreenathnagar Patethan, Taluka Daund, Dist. Pune,

Maharashtra-412207

Geographical Location 18°36’20.38’’N and 74°13’39.60’’E

Altitude 551m above MSL

Nearest City/Town Patethan approx. 2.50 km from the project site

Nearest Railway station Yavat and Urali Kanchan railway station approx. 16 km and 20

km respectively from the project site

Nearest National/ State

Highway

NH-9 (Pune-Machilipatnam) approx. 16 km from project site

SH-27 (Pune-Ahmednagar) approx. 18 km from project site

Nearest Airport Pune, 35 km from the project site

Chapter I


Figure 1.1: Project Site Location Map

1.5 IMPORTANCE OF PROJECT TO THE COUNTRY

India is one of the largest producers of sugarcane as well as sugar in the world. The sugarcane

is a cash crop for farmers. There are about 564 installed sugar factories in India. Most of the

sugar industries are located in rural areas providing employment to rural masses. Sugar

factories from Maharashtra are the backbone of rural economy. These factories have

contributed for the development of economy as well as infrastructure in rural areas, generated

ample of employment opportunity to local people.

As an agro based industry, Sugar industry in India is dependent on monsoon. Its financial

viability drastically gets affected due to weather conditions as well as market. Therefore, it is

imperative to explore the alternative products from the available resources so as improve its

financial stability. The importance of alcohol especially for the ethanol blending program in the

the energy security of the country cannot be over empahsized. In addition to reducing the

petroleum imports and saving precious foreign exchange, the use of fuel ethanol also helps to

Chapter I


reduce air pollution. This is also a major achievement considering the status of air pollution in

most cities n India.

1.6 SCOPE OF THE STUDY

The notification SO-1533, issued by the Ministry of Environment Forests & Climate Change

(MoEF&CC), Government of India, in September 2006 and it amendments till date, specify

thatcane crushing capacity greater than 5,000 TCD are placed under category ‘B’.The distillery

project is placed under category ‘A’. As per the guidelines this project is appraised by the Expert

Appriasal Committee (EAC) at central level. Therefore, the application for ‘Environmental

Clearance’ (EC) was submitted to EAC at MoEF&CC.

In order to assess the likely impacts arising out of the proposed expansion project and having a

high degree of concern for the environment, M/s. Shreenath Mhaskoba Sakhar Karkhana Ltd.,

(SMSKL) has taken services of Vasantdada Sugar Institute (VSI), Manjari (Bk.), Pune to carry out

the study on Environmental Impact Assessment (EIA). VSI is a renowned institute, providing

research, technical and consultancy services to the sugar and distillery industries, since 1975.

VSI is accredited by NABET for carrying out EIA studies for the sugar,distillery and thermal

power (biomass based) projects.

1.7 ENVIRONMENTAL LEGISLATION

The key environmental legislation relevant to the project are given below-

i) Wildlife Protection Act, 1972

ii) Forest Conservation Act, 1980

iii) Water (Prevention & Control of Pollution) Act, 1974

iv) Air (Prevention & Control of Pollution) Act, 1981

v) Environment Protection Act, 1986

vi) Public Liability Insurance Act, 1991

vii) Noise Pollution (Regulation & Control) Rule, 2000

viii) Solid Waste (Management and Handling) Rule, 2000

ix) Biological Diversity Act, 2002

x) Environmental Impact Assessment Notification, 2006

xi) Hazardous Waste (Management, Handling and Transboundary Movement)

Rules, 2008

1.8 STRUCTURE OF THE REPORT

The entire report has been prepared, in line with the generic structure of the EIA report as per

the Appendix III of the EIA Notification,2006. The report comprises of 11 chapters and the

Chapter I


relevant supporting documents are in the form of annexures. Executive Summary in English &

Marathi is prepared and bound separately.

Chapter 1: Introduction

This chapter provides the purpose of the report, background information of the proposed

project, brief description of nature, size and location of the project, objectives of the project,

scope and organization of the study. The key environmental legislation and the standards

relevant to the project and the methodology have also been described in this chapter.

Chapter 2: Project Description

This chapter deals with the need of the project, location, environmental setting of the project,

details of project, other technical and design details and sources of pollution from the proposed

activity and measures proposed to control pollution.

Chapter 3: Baseline Environmetal Status

Thischapter presents the methodology and findings of field studies undertaken to establish the

environmental baseline conditions, which is also supplemented by secondary published

literature.

Chapter 4: Anticipated Environmental Impacts & Mitigation Measures

This chapter details the inferences drawn from the environmental impact assessment of the

proposed project during various phases of project advancement, such as design, location of

project, construction and regular operations. It also describes the overall impacts of the

proposed project activities and underscores the areas of concern, which need mitigation

measures.

Chapter 5: Analysis of Alternatives (Technology & Site)

The technology and project site alternatives are discussed in the chapter.

Chapter 6: Environmental Monitoring Program

Environmental monitoring requirements for effective implementation of mitigation measures

have been delineated in this chapter

Chapter 7: Additional Studies (Risk Assessment & Disaster Management Plan)

The chapter describes public consultation issues & various risks associated during operational

stage of the project such as fuel storage, chemical storage fire etc. A disaster management plan

to minimize the risks or to combat the associated risks is also discussed.

Chapter 8: Project Benefits

This chapter describes various benefits of the project to the community in the vicinity and as

well as to the region on the whole.

Chapter 9: Environmental Management Plan (EMP)

Chapter I


This chapter provides recommendations/Environment Management Plan (EMP) including

mitigation measures for minimizing the negative environmental impacts of the project and

preparation of adequate Environmental Management Plan.

Chapter 10: Summary & Conclusion

This chapter highlights the expected benefits of the proposed project to the socio-economic

scenario in the study area and to the country as a whole.

Chapter 11: Disclosure of Consultant

This chapter provides the disclosure of consultants engaged to carry out the EIA study.

*Annexure

Chapter II


Chapter II

PROJECT DESCRIPTION

2.1 INTRODUCTION

Sugarcane is one of the important cash crops in India and the sugar industry contributes

significantly to Indian economy. With more than 45 million sugarcane growers in the country,

the bulk of the rural population in India depends on this industry. India ranks second in terms of

the World’s sugar production however most of the sugar produced is consumed in the country

itself. Maharashtra is a key player in the Indian sugar industry. The sugar industry is

characterized by cyclicality i.e. going through cycles of boom and bust which depends upon the

world sugar market and also various environmental factors. To keep this industry sustainable

on a long term, it is important to utilize the available resources efficiently and focus on the

byproducts by initiating allied activities such as cogeneration and distillery.

2.2 TYPE OF PROJECT

The sugar as well as molasses-based distillery unit are both agro-based industries. It is

proposed to enhance the capacity of sugar unit from 2,500 TCD to 6,000 TCD (operational

capacity) and of distillery from 30 KLPD to 55KLPD. A cogeneration unit of 10 MW also exists in

the same premises which is operational only during cane crushing season. In addition, the sugar

mill has an old idle steam turbine generator (STG) of 3 MW which will be brought in operation.

In case of proposed project, sugar industry is placed under 5 (j) – ‘B’ category and distillery is

placed in 5 (g) - as ‘A’ category as per EIA Notification, 2006 (as amended till the date). Both the

projects are clubbed/integrated for the environmental clearance process and therefore, the

proposed activity will be appraised at central (EAC) level.

2.3 NEED FOR THE PROJECT

India is one of the largest producers of sugarcane as well as sugar in the world. The sugarcane is

a cash crop for farmers. There are about 564 installed sugar and about 400 distillery units in

India. Most of the sugar and distillery industries are located in rural areas providing

employment to rural masses. Sugar factories from Maharashtra are the backbone of rural

economy. The alcohol production in the year 2015-16 was 2,325 million liters and 2,125 million

liters for the year 2016-17. These factories have contributed for the development of economy as

well as infrastructure in rural areas.

The project proponent is a private sugar mill located in Pune district of Maharashtra. The

cultivation of sugarcane is increasing every year in the command area of the mill and it is

anticipated to grow gradually for next few seasons. In addition, the sugar mill is having plans to

promote and support the cane development programme, in its command area. The last five

years’ performance of the mill is given in Table 2.1.

Chapter II


Table 2.1: Cane availability in the command area of the mill - data for last five years

Sr.

No. Particulars

Seasons

2013-14 2014-15 2015-16 2016-17 2017-18

1. Sugarcane Area* (Ha) 7,769 8,164 8,701 8,341 9,448

2. Cane crushed (TPA) 373,196 524686 461,382 192,911 553,754

3. Bagasse production (% on

cane) 28.50 28.85 28.38 28.25 28.32

4. Molasses (TPA) 15,325 21,700 20,190 8015 2251

5. Press mud Production (TPA) 16,644 21,512 16,563 6616 20489

*includes cane area of non-member farmers

As an agro based industry, sugar industry in India is dependent on monsoon. Its financial

viability is strongly impacted by weather as well as market conditions. Therefore, it is

imperative for the industry to explore alternative products from the available resources to

buffer itself from the ups and downs of cyclicality. Molasses based distillery is one such

alternative as the raw material availability i.e. molasses is fulfilled in-house. SMSKL already has

a 30 KLPD distillery, however with capacity enhancement of sugar mill, the availability of

molasses will increase. This can be utilized onsite if the capacity of the existing distillery is

enhanced. Hence, for better utilization of molasses and for realization of higher revenue, the

management has decided to enhance the capacity of distillery to 55 KLPD.

In India, three types of alcohol are produced i.e. rectified spirit (RS), extra neutral alcohol (ENA)

and anhydrous alcohol (AA). Of these, RS is widely used for industrial, scientific and medical

applications. The demand for RS is high and ever increasing. ENA is used for making liquors and

other alcoholic beverages. The requirement for this is also increasing. AA is a fuel alcohol used

for blending with petrol in the ratio of maximum 9:1. The policy for ethanol blending with petrol

in the country has boosted the requirement for AA and has been a major thrust for this type of

alcohol.

2.4 SELECTION OF SITE

This is an expansion of existing sugar and distillery unit so there is no re-habilitation and

resettlement issue.

1. The present site fulfills the industrial site selection criteria of MoEFCC/CPCB/MPCB i.e. site is

>500 m away from high flood line (HFL) of nearby river, it is >500 m away from state/national

highway, railway line. There is no protected area such as sanctuary, national park, biosphere

reserve within25km radius of the proposed site. There is no defense installation, recreation site,

etc. within 25 km radius of the site. Bhima River is about 2.1 km away from the proposed

industrial site.

Chapter II


2. Availability of raw material: The basic raw material for the proposed project is sugarcane,

bagasse and molasses. As per details given in Table 2.3, due to increase in cane availability in

the area, the cane crushing will increase and so will the availability of bagasse as well as

molasses for the proposed expansion project.

3. Availability of infrastructure/facilities: Proposed site is well connected by Pune-Solapur-

Hyderabad National Highway(NH.65), and Pune-Nagar-Aurangabad national highway (NH 27).

The nearest airport to the site is Pune which is about 40 km, whereas the nearest railway

station is Yawat and Urali-Kanchan, which are approx. 13 km and 16 km away from the site,

respectively. Apart from this, water and electricity is also available in the area. Reasonably good

infrastructure, support facilities and labor etc. are available in the vicinity.

2.5 PROJECT HIGHLIGHTS

The mill already has the main infrastructure in the form of land, water, power and raw material.

Adequate land/space available with the mill to accommodate the proposed expansion. Water

drawl permission is available to lift water from the Bhima river. The satellite image of the

proposed project is shown in Fig. 2.1 and layout for sugar and distillery unit are shown in Fig.

2.2(A) and (B) respectively.

Table 2.2: Highlights of the Project

1. Project Proponent M/s. Shreenath Mhaskoba Sakhar Karkhana Ltd., (SMSKL)

2. Project Expansion of Sugar unit from 2,500 to 6,000 TCD and

Molasses based distillery unit from 30 to 55 KLPD

3. Location of the

project

Existing mill premises at Shreenathnagar, Patethan, Tal: Daund, Dist.:

Pune, Maharashtra-412207

PROJECT CONCEPT

4. Working days per

annum

Sugar: Average 180 days and maximum 220 days

Distillery: maximum 270 days

5. Product Sugar Unit

White Sugar (11.25% on cane) 675 TPD

Bagasse Generation (28.50% on cane) 1,710 TPD

Molasses (4% on cane) 240 TPD

Press mud (4% on cane) 240 TPD

Distillery Unit

Rectified spirit&

Impure spirit (5%) OR

55 KLPD

ENA&

Impure spirit (6 %) OR

55 KLPD

Chapter II


Fuel Alcohol&

Impure spirit (5%)

55 KLPD

Byproduct/s Fusel oil 110 L/day

Biogas 18,190 m3/day

Compost 10446.5 tons per annum

6. Effluent Treatment

System

For sugar effluent: Activated sludge process based having Primary

and Secondary treatment units.

For distillery Spentwash: Biomethanation followed by multi-effect

evaporation (MEE) followed by bio-composting

For Spent lees, condensate and other effluent: Primary treatment

followed by anaerobic and aerobic at secondary stage followed by

tertiary treatment

7. Air Pollution

Control Systems

Existing venturi wet scrubber will be used as air pollution control

device

INFRASTRUCTURE

8. Land Total land available with the mill = 77acres

Land allocated for proposed expansion = ~10.00 acre (Distillery 7.5 +

2.5 acres greenbelt)

Greenbelt: Existing 12 acres green belt will be increased by 2.5 acre

No need of acquisition of additional land as the proposed project will

be set up in existing mill premises only

9. Main Raw Material

Sugar Unit

Sugarcane 6,000 TPD

Lime (0.14 % on cane) 8.40 TPD

Sulphur (0.04 % on cane) 2.4 TPD

Distillery Unit

Molasses 205 TPD

Nutrient N,P 185 kg/d

Turkey Red Oil (TRO) 275 kg/d

10. Steam During season: 92 TPH for sugar and 08 TPH for distillery = 100 TPH

During off-season: 08 TPH for distillery unit

11. Fuel Bagasse: 1,091TPD (1,054 TPD with biogas)– during season Source:

Own sugar unit

Biogas: 18,190 m3/D Source: Own sugar mill, Biogas unit

Chapter II


Bagasse as a fuel: 87.37 TPD (50 TPD with biogas) – off during season

12. Boiler Existing two of bagasse fired boilers;72 TPH and 32 TPH @

temperature 440±10°C

These two boilers are adequate to generate required steam, for

proposed project.

During off-season, existing 32 TPH boiler will be used or a standalone

8 TPH biogas fired boiler will be used for distillery operations.

13. Stack height and

Inner diameter

Existing 65 m height and 2.9 m inner diameter

Distillery stack: 32 m for 8 TPH boiler (Standby if this boiler used)

14. Power and its

Source

During Season:

For Sugar + Distillery = 6.5 MW

Source: In-house (Captive) The mill is having STG of 10 MW capacity

During Off-Season:

For distillery and miscellaneous purpose (Sugar unit) = 1.5 MW

Source: Another STG of 3 MW cogeneration unit or State Electricity

Board

15. Total Water

Requirement and

its Source

Sugar unit

18,540 m3/season (103 m3/day x 180 days)

25 m3/day during off-season

Distillery unit

417 m3/day x 270 days = 1,12,590 cu.m.

Total 1,35,630 cum Permission available for 160,000 cum/ Year.

Source: Bhima river – with permission from Irrigation Dept.

16. Manpower Existing: Permanent 129 +Seasonal & daily wages 292 = 421

Proposed:164 (Including Permanent+ Seasonal& daily wage labour)

Total : 585

17. Green belt Existing 12 acres + Proposed ~2.5 acre = TOTAL 14.5 acres

FINANCIAL ASPECT

19. Project Cost (Rs. in

lakhs)

Rs. 5,669.10 (Sugar unit Rs. 2295.10 + Distillery Rs. 3374)

20. Capital expenses for

EMP (Rs. in lakhs)

Rs. 403.90 lakhs (Sugar unit Rs. 64.9 + Distillery Rs. 339)

Chapter II


2.6 SIZE OR MAGNITUDE OF OPERATION

For sugar unit: Capacity enhancement of existing unit of 2,500 to 6,000 TCD

For distillery: Capacity enhancement from 30 to 55 KLPD.

Figure 2.1: Satellite image showing location of proposed Sugar and distillery unit

Distillery Unit

Sugar Unit

Chapter II


Figure 2.2(A): Layout of proposed Sugar unit

Chapter II


Figure 2.2(B): Layout of proposed distillery unit

Chapter II


2.7 INFRASTRUCTURE

The prime infrastructure required for the project is land. SMSKL is having adequate land/space

within the existing sugar mill for the expansion of proposed project.

2.7.1 Sugarcane

Sugarcane is an agro based product and the main raw material for the proposed project. The

viability of the proposed expansion of sugar and distillery unit depends on the availability of

sugarcane. Keeping this in view, the mill management has actively engaged in cane development

activities for enhanced sugarcane yield. The expected performance of sugar mill for the next five

years is given in Table2.4

Table 2.3: Expected performance of sugar mill for next four years

Sr.

No.

Particulars Seasons

2018-19 2019-20 2020-21 2021-22

1. Overall cane availability (MT) 11,20,000 11,75,000 12,00,000 12,25,500

2. Cane crushing by the Mill (MT) 9,60,000 9,90,000 10,20,000 10,80,000

3. Expected Sugar Recovery (%) 11.25 11.25 11.25 11.25

4. Molasses (T @04% on cane) 38,400 39,600 40,800 43,200

5. Press mud (MT) 38,400 39,600 40,800 43,200

2.7.2 Molasses

Molasses is a byproduct of sugar mill therefore; it will be easily available for the proposed

expansion of distillery unit as a raw material. It will be available from in-house only. The

requirement of molasses will be 205TPD or around 55,350 TPA and expected maximum

molasses production is around 43,200 TPA (considering average season of 180 days).

Therefore, deficit molasses of approx. 12,150 MT will be procured from nearby sugar mills. In

case of bumper season, the molasses generation will be 52,800 Tons. The product wise raw

material consumption is given in Table 2.2.

Chapter II


Table 2.4: Availability of raw materials, finished good product and mode of transport

Transport mode

Estimated quantity

Source market

Final product Estimated quantity

By Road- through Tanker

205 TPD Own mill, Maharashtra, India

Rectified spirit + Impure spirit (5%)

55 KLPD

By road

OR ENA + Impure spirit (6 %)

55 KLPD

OR Fuel Alcohol + Impure spirit (5%)

55 KLPD

Press mud 23,760 TPA Own mill

Compost By Road- Truck/Tempo

Nutrients N, P 185 Kg/day Pune,

Ahmednagar,

Mumbai

- -

By Road- Truck/Tempo - 275 Kg/day

Utilities

Fuel:

Bagasse

Biogas

45.45 TPH

18,190

m3/day

Own Sugar

and distillery

unit

- - Bagasse by conveyor Biogas through closed pipeline

Water(daily)

Sugar unit

Distillery

103m3/d

417 m3/d

Bhima River - - Through closed pipeline

Steam Maximum

100 TPH

Sugar mill

already has

two boilers of

70 TPH and 32

TPH

- - -

Power ~6.5MW

(for Sugar &

distillery for

season) and

1.5 MW

(during off-

season for

distillery)

Captive –

from10 +3

MW TG set

during season

and external

during off-

season

- - -

2.7.3 Press mud

Considering expansion of sugar mill, estimated press mud generation will be around 43,200

tons per annum (Considering 180 days of crushing @04% on cane). It will be mixed with the

concentrated spentwash in the ratio of 1:1to produce biocompost.

Chapter II


2.7.4 Land

The total land available with the mill is 77 acres so no need of acquisition of additional land and

the proposed project will be set up in existing mill premises only. Details of land breakup given

in the following table.

Table2.5: Land breakup

Description Existing Area

(in m2)

Provision for

Proposed Project

(In m2)

TOTAL

A) Sugar Unit

Cane yard 8,300 2,000 10,300

Mill and boiling Section 3,037 1,556 4,593

Office (Engg and Prod) 316 - 316

Boiler section (Boiler, Ash pit,

Chimney)

2,086 - 2,086

Bagasse yard and handling

equipment

3,348 - 3,348

Power house and Switch Yard 930 - 930

Water reservoir, Hot & Cold water

tank, RO & CT

415 100 515

Sugar godowns (three) 4,375 2,000 6,375

ETP, Spray pond and Molasses tanks 2,894 4,600 7,494

Main factory Building, Store Security

& Time office

609 200 809

Toilet Blocks 35 20 55

Parking 124 100 224

Roads 2,300 - 2,300

Total For Sugar Unit 26,469

(~6.62 acres)

10,576

(~2.64 acres)

37,045

(9.26 acres)

B) Distillery unit

Distillery, including product storage,

roads, CT, etc.

16,400 12,000 28,400

Storage lagoons and bio digesters 23,150 6,000 29,150

Compost yard, storage of PM and

Compost

30,600 1,400 32,000

R& D project 13,200 - 13,200

Total For Distillery Unit 83,350 19,400

Chapter II


Description Existing Area

(in m2)

Provision for

Proposed Project

(In m2)

TOTAL

(~20.84 acres) (4.85 acres) 25.75 acres

C) Greenbelt 48,000

(12 acres)

10,000

(2.5 acres)

58,000

(14.5 acres)

D) Agricultural land 28,000

(7 acres)

- 28,000

(7 acres)

E) Colony and other allied

activities

30,060

(7.52 acres

30,060

(7.52 acres)

F) Undeveloped land (for

future development)

92,100

(23.02 acres)

- 52,124

(~13.03

acres)

TOTAL LAND 308,000

77.00 acres

308,000

77.00

2.7.5 Water

Presently, the mill is having permission to draw water from Bhīma River. In the proposed

expansion, water requirement will get fulfilled from the same source. This requirement (given

in table 2.6) is estimated to be within the existing water drawl limit of 160,000 cubic meter per

annum. The mill doesn’t require any new permission to draw additional fresh water.

Table 2.6: Water Balance

A) Sugar unit at operational capacity of 6,000 TCD

A) WATER INPUT (Daily requirement) m3/day

RO Water For Boiler feed (@100 TPH) 2,400

Milling section (including washing@ 30% on cane crush) 1,800

Water For condenser/boiler parts cooling, Vacuum Pump & Others 900

Other Domestic Usage 43

Total Water Input 5,143

B) WATER OUTPUT

Steam Condensate 2,160

Cooling water from turbine and boiler parts pump and gland 900

Domestic Consumption 09

Excess condensate water from cane @70% on cane crushing 4,200

Chapter II


Effluent 600

Spray pond over flow water 600

Total Water Output 8,469

Domestic waste will not be available for recycle/reuse

Net water available for recycle

8,460

C) RECYCLE WATER STREAMS (FOR SUGAR AND COGENERATION UNIT)

Steam Condensate 2,160

Water For condenser/boiler parts cooling, Vacuum Pump & Others 900

TOTAL 3,060

Excess condensate water will be used to fulfil requirement of (8460 - 3060) 5,400

Water in product , by-product and effluent

Water loss in bagasse@ 50% moisture 855

Water loss in press mud @ 70% moisture on production @ 4% on cane crushed 168

Water loss in molasses @ 12% moisture on production @ 4% on cane crush 29

TOTAL 1,052

D) WATER RECYCLE STREAMS

Condensate water for imbibition (including washing @30% on cane crush) 1,800

Condensate water recycle for vacuumed filter @5% on cane crush 300

Molasses movement water @6% on cane crush 360

Milk of lime preparation @3% on cane crush 180

Centrifugal section for sugar washing @5% on cane crush 300

Excess condensate recycle to boiler make up water 240

TOTAL 3,180

Excess condensate available for proposed unit m3/day (5400 – 1052- 3180) 1,168

According to the above table, 1,168 cu.m. excess condensate water from sugar mill will be

available after recycling. It will be partially recycled in process of distillery unit and remaining

will be utilized for irrigation. Therefore, fresh water will be required mainly for drinking

purpose and in minor quantity for process, which is as follows.

For domestic purpose: 43m3/day

Overall for plant:60m3/day

TOTAL (day-to-day fresh water requirement) = 103 m3/day

Chapter II


B) Distillery unit

Distillery Water Requirement (in m3/day)

Particulars Intake Consumption

and Losses

Generated

Effluent

Recycle

and Reuse

Daily Net

Requirement

Industrial Process 550.0 55.0 160.0 335.0* 215.0

Cooling Purpose 192.0 100.0 92.0 00 192.0

Domestic 10.0 03.0 7.0 00 10.0

Total 752.0 158.0 259.0 335.0 417.0

Net fresh water requirement for distillery unit = 417 m3/day

*Condensate of MEE + treated water from CPU will be recycled

2.7.6 Steam In the proposed scheme maximum 100 TPH steam will be required. During seasonal operation,

the industry will fulfill its steam requirement from its own two (70 TPH + 32 TPH)102 TPH

capacity boilers. During off-season, 32 TPH boiler will be used for distillery unit.

Existing Steam balance

Sugar: 43 TPH = 1032 TPD

Distillery: 4 TPH = 96 TPD

Total:47 TPH =1128 TPD

Proposed steam balance

Sugar: 92 TPH =2208 TPD

Distillery: 8 TPH =192 TPD

Total: 100 TPH = 2400 TPD

2.7.7 Power

The power required for the proposed sugar and distillery unit will be 6.5 MW which will be met

through captive generation. SMSKL is having cogeneration unit of 10 MW and they have planned

to re-operate an idle STG of 3MW (total operating capacity will be 13 MW). Thus, the required

power will be sourced from this captive power station during cane crushing season. The surplus

power of 6.5 MW will be exported to state electricity board grid. During off-season, power

requirement will be 1.5 MW which will be purchased from state electricity board.

Chapter II


Table 2.7: Power requirement

Sr. No. Particulars Requirement Source

During Season

1. Power (Sugar + Distillery) 6.5 MW In-house (Captive)

During Off-Season

2. Power (Distillery + Sugar unit – miscellaneous

purpose)

1.5 MW In-house

(Captive)/State

Electricity Board

2.7.8 Fuel

Bagasse and biogas will be used as fuel for the project, both of which are generated onsite. The

details of and biogas generation with consumption are given in following table.

Table 2.8: Bagasse generation and net consumption estimates for the proposed project

During crushing season (180 days)

Description TPD T/ season

Cane crushing rate @ 6000 TCD 6,000 10,80,000

Average bagasse production @ 28.5% on cane 1,710 3,07,800

Bagasse requirement for existing sugar, cogeneration and

distillery [email protected] (f:s = 1:2.2)

1,091 1,96,380

Bagasse saved (generation – consumption) 619 1,11,420

Bagasse saved during season due to use of biogas

Biogas generation 18,190m3 per day

1000m3 of biogas = 2.05tons of bagasse

bagasse saving for 120 days (60 days stabilization period)

37.3 4,476 (for 120 days)

Total bagasse saved during season for use in off season 1,15,896

During off season (off season 90 days)

Description TPD Total

Actual Bagasse requirement 87.27 7,854.3

Biogas generation (m3) 18,190 1,637100

Bagasse saved due to use of biogas as fuel

(1000m3 of biogas = 2.05mt of bagasse)

37.3 3,357

Bagasse saved due to use of biogas as fuel 50 4,500

In off-season, 32 TPH boiler and 3mw turbine of sugar unit will be used for generation of steam and

power for distillery operation.

Chapter II


2.7.8.1 Fuel Composition

2.8 PROCESS DESCRIPTION

A) SUGAR UNIT

The major units of operations of sugar mill are given below-

Extraction of Juice

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

chips before being subjected to crushing in a milling tandem comprising 5 Nos mill tandem of 3

and 2 TRPF each. In the best milling practice, more than 95% of the sugar of cane gets extracted

into the juice.

Clarification

The treated juice on boiling fed to continuous clarifier from which the clear juice is decanted

while the settled impurities known as mud is sent to rotary drum vacuum filter for removal of

unwanted stuff called filter cake. It is discarded or returned to the field as fertilizer.

Evaporation

Clear Juice is evaporated from 15o Bx. to 60o Bx. in evaporator

Pan boiling

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

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

syrup is evaporated until saturated with sugar. At this point “seed grain” is added to serve as a

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

Centrifugation

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

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

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

after the sugar is “purged” it is cut down leaving the centrifuge ready for another charge of

massecuite.

Composition of biogas (from spent wash) Composition of dry bagasse

Parameter Value (%) Parameter Value (%)

Methane 55-60 Cellulose 45-55

Carbon dioxide 35-40 Hemi cellulose 20-25

H2S 1-1.5 Lignin 18-24

Other Gases 0-0.5 Ash 1.5-2

Waxes <1

Chapter II


Gradation & Packing

The final product in the form of sugar crystal is dropped through pan section and this sugar is

graded and picked in 50 kg bags. The grade of the sugar depends on the size of the crystal viz.

Small (S), Medium (M) and Large (L).

Figure 2.3: Flowchart of Sugar Manufacturing Process

Cane Supply

Milling

Sulphitation

Clarification

Evaporation

Pan boiling

Crystallizer

Centrifugals

Sugar

Packing

Boiler

Lime & Sulphur House

Rotary vacuum filter

Bagasse

Press mud

Juice

Steam

Chapter II


B) DISTILLERY UNIT

SMSKLhasdecided to adopt Zero Liquid Discharge (ZLD) for the proposed 55KLPD distillery

unit. The characteristics of manufacturing process are given below and a schematic is shown in

Fig. 2.4.

Manufacturing Process: It involves fermentation and distillation

Fermentation

Molasses is the chief raw material used for production of alcohol. Molasses contains around

50% sugars, of which 30 to 33% are cane sugar and the rest are reducing sugars. Yeast strains

of the species Saccharomyces cerevisieae, convert sugars present in the molasses to alcohol. The

continuous fermentation process involves addition of fresh nutrients medium either

continuously or intermittent withdrawal of portion of nutrient for recovery of fermentation

products. In continuous process, fermenter is in constant use with little shut down and requires

only initial inoculation of yeast culture. Hence, continuous fermenation process will be adopted

in the proposed unit.

Distillation

After fermentation, the next stage in the manufacturing process is to separate alcohol from

fermented wash and to concentrate it to 95% through the process of distillation. This is called

Rectified Spirit (RS). After separation of alcohol, the remaining part is the effluents i.e.

spentwash and spent lees.

Re-distillation to manufacture Extra Neutral Alcohol (ENA)

ENA is prepared by re-distillation of the rectified spirit (RS) for the removal of impurities like

higher alcohols, aldehydes and methyl alcohol. This is done by, remixing rectified spirit with soft

water and distilling it in the ENA column.

Anhydrous Alcohol (AA)

Anhydrous alcohol is an important product required by industry. As per IS specification it is

nearly 100% pure or water free alcohol. It is not possible to remove remaining water from

rectified spirit by straight distillation as ethyl alcohol forms a constant boiling mixture with

water at this concentration and is known as azeotrope. Therefore, special process for removal of

water is required for manufacture of anhydrous alcohol.

The various processes used for dehydration of alcohol are as follows-

i) Azeotropic Distillation

ii) Molecular Sieves

iii) Pervaporation / Vapour permeation system

Chapter II


Figure 2.4: Schematic of RS/ENA/AA manufacturing process

Storage of Raw materials/Product

The SMSKL has 03 godowns for storage of sugar each of 1.0 lakh quintal capacity. Construction

of2 additional godowns of 1.0 lakh capacity each is proposed. Two existing molasses storage

tank have capacities 3,000 MT and 4,000 MT respectively and additional tank of 8,500MT is

proposed. There are separate storage tanks for RS, ENA and ethanol. Details are given below-

Sr. No. Products Name Number of tank Total capacity in liters

1. Absolute Alcohol (Ethanol) 01 7,00,363

2. Impure Spirit 01 2,11,488

3. Extra Neutral Alcohol (ENA) 02 14,00,512

4. Rectified Spirit (RS) 02 14,00,462

5. Fusel Oil 01 20,133

6 Proposed ethanol storage tank 01 20,00,000

Distillation

Analyzer column PR Column RE Column Exhaust column Reboiler

Fermentation

Yeast propagate with molasses in

sterilize separate vessel

Molasses Storage (MS) tank

Molasses weighed and diluted

Spentwash/ Spentlees

Yeast sludge to

bio-compost

CO2

Scrubber

RS/ENA/AA &Fusel

oil

Chapter II


2.9 FIRE PROTECTION SYSTEM

In distillery unit, fire protection system shall be provided in accordance to OISD-117 and LPA

regulations. The firefighting system will consist of a hydrant network, piping etc. Fire protection

system will also include one electric driven pump, one diesel engine driven pump, one jockey

pump, piping, basin etc. Water hydrants will be provided at all strategic points. A suitable Fire

ring system as per the guidelines of TAC will be incorporated. Non-flame proof and flame proof

area will be separated by minimum distance of 15 meters. Portable fire extinguishers will also

be provided in strategic locations viz., power house, control rooms, switch yard. SMSKL has fire-

fighting facility in the existing plant.

Figure 2.5: Existing Fire Fighting System

2.10 BAGASSEHANDLING SYSTEM

The bagasse generated is used as fuel in boiler. Hence, the bagasse will be supplied to boiler

from elevated carriers and belt conveyors. Provision will be made for conveying excess bagasse

(not used in the boiler) to a storage area by conveyor belt.

2.11 ASH HANDLING SYSTEM

Ash generation due to burning of bagasse will be around 21.82 TPD. Ash generated from

proposed project will be sold to the farmers to mix into soil as potash enriching material.

Alternatively, it may be sold to nearby brick manufacturers.

2.12 MANPOWER

Existing: permanent 129+ Seasonal 174 & daily wages 118 = 421

For Proposed expansion: 164 including permanent +Seasonal

Total = 511

Chapter II


2.13 ENVIRONMENTAL ASPECTS

Table 2.9: Overview of Environment management processes

Sr.

No

Waste product and source Treatment and disposal

1. Effluent/Wastewater

Spentwash

Condensate + Spentlees

Biomethanation followed by multi effect

evaporation followed by bio-composting

CPU

Sugar effluent

Sewage: Domestic wastewater

Sugar ETP: Existing ETP will be upgraded; CPU is

proposed to treat excess condensate of sugar unit

septic tank and soak pit system

2. Gaseous emission

Flue gasses from boilers

Due to burning of bagasse,

biogas

Particulate emissions will be controlled by Venturi

wet scrubber and then vented through a chimney of

height 65m

Bagasse as well as biogas are renewable energy

sources

Bagasse transfer will be through closed conveyers

hence fugitive dust will get controlled

Handling and transportation of various materials

will be minimal.

Greenbelt expansion by 2.5 acres

Bio-composting (CH4) Fully auto spraying and aerobic composting

Diesel generators It will be operational only when captive power

supply failure, hence emissions anticipated to be

less frequent and minor

Fermentation unit: (CO2) Fermenters will be covered, CO2 scrubbed in water

3. Solid waste

Boiler ash Bagasse ash contains soil nutrients such as potash

and phosphates. It will be mixed with bio-compost

and sold to farmers (for use in agriculture lands) or

to brick manufacturer.

Fermented sludge: Yeast

sludge, bio digester sludge

Sludge from ETP and CPU

The sludge from fermenter will be degradable,

containing organic nutrient and micro elements. It

will be mixed with bio-compost.

Chapter II


2.14 POLLUTION ASPECT

2.14.1 SUGAR UNIT

In sugar unit, wastewater discharges arise from number of sources. These include -

Effluent from water treatment plants

Effluent from milling house

Boiling house

Blow down from the fan less cooling tower

Blow down from boilers

Excess Condensate

Condenser Cooling water

Soda and Acid Wastes

Effluent from ion-exchange

Sulphur burner, lime house, Oliver filter, compressor section

Sewage

Effluent from water treatment plant: Hydrochloric acid and sodium hydroxide will be used as

regenerate in the proposed demineralizing water plant. The acid and alkali effluents generated

during the regeneration process of the ion-exchangers would be drained into an epoxy lined

underground neutralizing pit. Generally these effluents are self-neutralizing. However

provisions will be made such that the effluents will be neutralized by addition of either acid or

alkali to achieve the required pH of about 7.0. The effluent will then be pumped into the effluent

treatment ponds which form part of the sugar plant's effluent disposal system.

Chlorine in cooling water: In the auxiliary cooling water, residual chlorine of about 0.2 ppm.

This chlorine dosing is done mainly to prevent biological growth in the fan less cooling tower

system. This value would not result in any chemical pollution of water and also meets the

national standards for the liquid effluent.

Effluent from mill house: It consists of water used for cleaning the floor of mill house, which is

likely to get contaminated by spilled and splashed sugar juice. (This cleaning-up operation will,

incidentally prevent growth of bacteria on the juice covered floor).

Water used for cooling of mill bearings also forms part of the waste water from this source.

Basically, this water contains organic matter like sucrose, bagacillo, oil and grease from the

bearings fitted into the mills. BOD of this effluent is around 900 to 1,000 mg/L, oil and grease

around 150 to 200 mg/L, and COD around 2,500 mg/L. An estimated volume of effluent from

mill house is 300 - 350 m3/day

Wastewater from boiling house: The wastewater from boiling house results from leakages

through pumps, pipelines and the washings of various sections such as evaporators, juice

Chapter II


heaters, clarification, pans, crystallization and centrifugation etc. The cooling water from

various pumps also forms part of the wastewater. The BOD of this stream is about 800 to 1,000

mg/L and COD is about 2000 to 2500 mg/L. The estimated volume of effluent from this house is

140 -150m3/day

Boiler blow down: The salient characteristics of blow down water from the point of view of

pollution are, the pH, temperature of water and dissolved solids. The pH would be in the range

of 9.8 to 10.3 and the temperature of blow down water will be about 100oC. The water used in

boiler contains suspended solids, dissolved solids like Ca-salts, Mg-salts, Na-salts, Fe-salts etc.

These salts get concentrated after generation steam from the original water volume. These

solids have to be expelled from time to time to save the boiler being covered up by scales.

General characteristics observed for this wastewater are -

BOD - 60 to 70 mg/L

SS - 800 to 1500 mg/L

TDS - 1,500 to 3,500 mg/L

Temperature - 90 to 100oC

The quantity of blow down water will be about 2 TPH i.e. 48 TPD which is very small. It will be

treated before its reuse.

Excess Condensate -The excess condensate does not normally contain any pollutant and is

used as boiler feed water and for washing operations. Sometimes, it gets contaminated with

juice due to entrainment of carryover of solids with the vapours being condensed in which case

it goes into the waste water drain. The treatment required in this case is almost negligible and

it can be used in place of fresh water or it can be let out directly as irrigation water after cooling

it to ambient temperature. The estimated excess condensate available is approx. 1150 m3/day,

after recycle or reuse in the process.

As per the CPCB norms, it should be treated through Condensing Policing Unit. Hence, for

treating surplus condensate coming from the sugar plant new CPU unit is proposed. This will

have equalizing tank, anoxic tank, aeration tank, clarifier and media filter. Schematic of which is

given in figure 2.8.CPU will deliver industrial utilizable water such as sugar factory cleaning

washing, cooling water make up and distillery process etc. Therefore, the mill has a plan to use

excess condensate to a maximum extent. It will solve its disposal problem and most importantly

it will conserve the fresh water.

Spray pond over flow -The auxiliaries of the turbo generators like oil cooler and generator air

cooler use cooling water. In addition, the steam gets condensed in the condenser, which

requires large quantity of water. Spray type cooling, cools the water and the cooling water

consequently gets concentrated with the chemical in the water, this concentration is generally

limited by the raw water quality and by the blow-down of water concentration. This value

Chapter II


would not result in any pollution of water and also meets the national standards for the liquid

effluent. Expected quantity of spray pond over flow will be the 600 m3/day and its important

characteristics are given below. This water will be used for irrigation directly.

# Parameter Value

1. Quantity 600 m3/day

2. Total Dissolved Solids <2,000 ppm

3. pH 8-9

Floor washing

The quantity of floor washing assumed to be about 10 m3/day. It will be treated in ETP and

treated water will be sent for irrigation purpose.

The flowchart for generation of effluent from sugar unit is shown below (Fig2.6).

Figure 2.6: Flowchart of effluent generation and management from Sugar unit

Sugarcane

Mill House

Boiling House

Boiler Blowdown

Boiler/Furnac

e

Bagasse

Treated water will be used

for industrial cooling and/or

gardening/irrigation

purpose

ETP – Sugar Mill

Sluice water from the bottom ash handling

system, boiler, chemical cleaning water

Effluent

Cooling &

Neutralization

Reused mainly for

cooling purpose

Steam

Chapter II


Figure 2.7: Schematics of Effluent Treatment Plant

Sr. No. Name of tank Dimension ( L x W x H) in meter 1. Switch yard E.T.P. 10 x 5.8 x 2 2. Oil & Grease chamber 13.0 x 2.0 x 1.2 3. Equalization Tank 8.0 x 15.0 x 1.5 4. Balancing Tank 11.0 x 15.0 x 1.4 5. Neutralization tank 2.0 x 2.0 x 1.4 6. Primary Clarifier 6.0 x 6.0 x 2.5 7. Aeration Tank 11.0 x 8.0 x 3.5 8. Secondary Clarifier 8.0 x 2.5 9. Holding Tank 7.0 x 4.0 x 1.2

10. Multi Media Filter --------- 11. Storage Tank 15.0 x 12.0 x 2.5 12. Sludge Drying Beds 4.0 x 3.0 x 1.2 13. Air Blower Capacity 800 cum/Hrs. 14. Oil Skimmer 15. Sludge recirculation 16. Waste/ excess sludge to sludge beds

2.14.1.1 ETP

Effluent generated from sugar unit will be sent to ETP for treatment. The treated water will be

utilized for gardening/irrigation purpose. Hot water from various sources will be cooled in

cooling pond and recycled to respective activities after attaining ambient temperature.

3 4

5

6

7 8

9

12 11

10

1

2

13

Effluent from

sugar mill

Chapter II


Primary Treatment

i. Oil & Grease chamber

ii. Primary clarifier: To remove solids from effluent

iii. Equalization Tank: Hot process condensate and other wastewater stream from the

evaporation section are collected in a equalization tank where the stream are mixed

well.

iv. Neutralization Tank: The effluent is neutralized by using caustic solution. Depending

on caustic solution is dosed using a dosing system consisting of dosing tank and dosing

pumps. Dosing is controlled using pH sensor attached on downstream of the static

mixer.

2.14.1.2 Secondary Treatment

i. Activated Sludge Process (ASP): This is the main section where degradation of organic

pollutants with the help of aerobic micro-organism takes place. In aeration tank, activated

biomass is developed in such a way that certain MLSS is maintained for continuous

condensate flow which comes to aeration basin. Effluent is degraded in given retention

time and activated sludge is further passed to clarifier and recycled as per requirement.

The remaining sludge is passed to sludge drying bed. Air supply is provided by means of

aeration equipment which has high oxygen transfer efficiency.

ii. Secondary Clarifier: In secondary clarifier, effluent passed from aeration tank along with

biomass (MLSS) gets settled here. The settled biomass recycled back to aeration tank as

per requirement and excess biomass transfer to sludge drying bed.

iii. Sludge disposal system: Settled sludge from tube settler will be removed by pumping to

the sludge drying bed.

Chapter II


Figure 2.8: Layout for proposed condensate polishing unit (CPU) for sugar unit

2.14.2 DISTILLERY UNIT

Effluent Treatment

The raw spent wash generated in the distillery will be sent to biomethanation unit. After

treatment, this biomethanated spent wash will be concentrated through standalone multi-effect

evaporation system. The concentrated spent wash will be in the range of 1.6 – 1.7 liters per liter

of total alcohol produced. The dissolved solid content in concentrated spentwash will be 30%.

The concentrated spent wash will be treated through bio-composting. The spentwash

evaporation condensate, spent lees and other waste will be treated in Condensate Polishing Unit

(CPU) and treated water will be reused for distillery cooling tower make up or for fermentation

process and for greenbelt. In this way, Zero Liquid Discharge (ZLD) will be achieved as per CREP

norms prescribed by CPCB. The flowchart for spent wash treatment and disposal is shown in

Fig.2.9.

2.14.2.1 Primary Treatment for Spentwash

The general characteristics of raw spentwash are given in Table 2.10. The raw spentwash

coming from the multi-pressure distillation system at the rate of 8 liters per liter of alcohol

produced (i.e. approx440 m3/day at about 12% total solids) will be taken to the bio digester for

primary treatment. During the biomethanation process, the COD will be reduced by about 65%

and biogas will be produced at the rate of about 0.53 Nm3/Kg of COD consumed. Total volume of

biomethanated spentwash generated will be 440m3/day containing approximately, 5 to 6%

solids.

Chapter II


In recent years, due to escalation of energy costs and environmental concerns have increased

the interest in direct anaerobic treatment of distillery spentwash. The anaerobic method of

waste treatment offers a number of significant advantages with little serious or inseparable

drawbacks over other treatment methods. Anaerobic degradation is performed by two groups

of bacteria.

1. Acid producing bacteria: Acid forming bacteria (butyric & propionic acid) Acetogenic

bacteria (acetic acid & hydrogen)

2. Methane producing bacteria: Acetoacetic methane bacteria (acetophilic) Methane

bacteria (hydrogenophilic)

Steps of Reaction

The anaerobic metabolism of a complex substrate, including suspended organic matter, can be

regarded as a three-step process:

1. Hydrolysis of suspended organic and soluble organic of high molecular weight

2. Degradation of organic molecules to various volatile fatty acids, ultimately acetic acid

3. Production of methane, primarily from acetic acid, also from hydrogen and carbon dioxide

Amongst these three steps, the second one is fast, while the two others are slow. This accounts

for many instability problems encountered in anaerobic processes. Hydrolysis of organic

matter is a rather slow process carried out by extra cellular enzymes. Factors like pH and cell

residence time play an important role with respect to reaction rate. Lipids are hydrolyzed very

slowly, therefore the hydrolysis step might be overall rate limiting for wastes containing

considerable amount of lipids. The types of lipid apparently play a role, as the degradation of

non-polar lipids in anaerobic processes seems to be considerably slower than the degradation

of polar substances.

Acid production results in formation of acetic acid or in case of instability, the higher fatty acids

such as propionic, butyric, iso-butyric, valeric and iso-valeric acid. The acid production rate is

high as compared to the methane production rate, which means that a sudden increase in easily

degradable (soluble) organic will result in increased acid production with subsequent

accumulation of the acids. This might inhibit the next step of the process the methane step.

Methane production is a slow process, in general the rate-limiting step of anaerobic

degradation. Methane is produced from acetic acid or from hydrogen and carbon dioxide.

About one third of the methane has its origin in molecular hydrogen. The bacteria producing

methane from hydrogen and carbon dioxide are fast growing ones as compared with the acetic

acid utilizing bacteria. Environmental factors of primary importance to anaerobic processes are-

Chapter II


Temperature

Nutrients

Toxic substances

The loading rates permissible in an anaerobic waste treatment process are primarily dictated by

the sludge retention in the anaerobic reactor. The solution for the biomass retention problem

resulted in the development of different anaerobic processes.

Figure 2.9: Flowchart for spent wash treatment and disposal

Table 2.10: Important Characteristics of Raw Spentwash

Sr. No. Parameter Value

1. Colour Dark brown

2. pH 3.5 – 4.5

3. COD (mg/l) 1,00,000 – 1,40,000

4. BOD (mg/l) 40,000 – 60,000

5. Total Solids (mg/l) 1,10,000 – 1,25,000

6. Total Suspended Solids (mg/l) Below 5,000

7. Chlorides (mg/l) 7,000 – 10,000

Chapter II


2.14.2.2 Secondary Treatment for Spentwash - Multiple Effect Evaporation (MEE) system

Biomethanated spentwash of 440 m3/day containing about 5% total solids will be evaporated in

a standalone falling film multiple effect (five stage) evaporator (MEE) to 25% total solids

(approx. 88 m3/day). The evaporation condensate (approx. 352 m3/day) after treatment in CPU

will be reused for distillery cooling tower make up or for fermentation process (molasses

dilution as make-up water).

Figure 2.10: Multiple Effect Evaporation (MEE) System

2.14.2.3 Tertiary Effluent Treatment for Spentwash

Concentrated biomethanated spentwash (88m3/day) and press mud will be used for making

biocompost as a tertiary treatment to achieve “Zero Spentwash Discharge” as per CPCB norms.

Bio composting is a biological process in which organic matter is degraded under controlled

conditions. It involves microbial mineralization.

The mixing of spentwash and press-mud in 1:1 proportion (50-70 % moisture) will be carried

out in trenches with the help of homogenizing/aerotiller (Self propelling) machine for spraying,

mixing, turning, loading and unloading of compost material. Addition of decomposing

culture/cow dung will provide microbes required for bio-composting. It is observed that in the

first five days, fungal activity is predominant and in subsequent days bacterial activity continues

until stabilization of organic matter into humus is accomplished.

Existing five acres of land is allotted to composting and axillary activities. The process will use a

composting machine having automatic spentwash spraying system.

Chapter II


Figure 2.11: Aerotiller/ mixing machine for mixing up the windrow

A. Bio composting Process Operational details

A bio-composting cycle can be divided into two stages i.e. 50 days of windrow composting

(Aerobic process) and 5-10 days for curing in heaps (anaerobic process). The degradation

should get completed in 60 days. Bio composting process can be divided into the following

stages.

Active Stage: After formation of windrows and spraying of inoculums active stage

starts. During this stage rise in temperature takes place. This phase lasts for first 10-15

days.

Maturation Stage: Includes the greater part of maturation and extends to and beyond

the period of temperature decline, which consists of the next 14 days when the

temperature is maintained and the next 10 days when the temperature starts to

decline.

Ripening or Curing Stage: Allow the compost to age for 4 weeks, until the moisture

stabilizes at 30% to 35%.

a. Formation of windrows: Press-mud will be formed in windrow size of 3.5 x 1.5m.

The windrows will be straight having correct size.

Windrow Size – 3.5 m Width x 1.5 m Height

Distance between two windrows – 1m (by using self-propelling machine)

b. Inoculum application: Inoculum act as an odor reducing agent as well as an

activator to hasten the process of raising the temperature. Normally for every MT of

press mud 0.5 to 1.0 kg of inoculum is applied. It is diluted 100 times with effluent

and sprayed on the windrows spreading over 3 days for effective results (in the 3rd,

Chapter II


5th and 10thday) immediately after the application of inoculum, windrow should be

aerated with mixing machine to spread the inoculum uniformly to all parts of

windrow.

c. Aeration: Normally aerotiller/ mixing machine is used for mixing up the windrow,

loosen the same and create a situation congenial for natural aeration. When the

moisture content reduces below 40% an addition of effluent should restore it to

65%. If the press-mud is wet (more than 70% moisture) there is lower supply of

oxygen. Moisture content should be brought down to about 40 % by giving proper

aeration. Microorganisms make use of nitrogen and carbon for their metabolic

activities. The energy required for this process is derived by aerobic decomposition.

Aeration should be given to raise the biocompost temperature and establish an

aerobic condition. The temperature should be 60-650C in the windrow. Continue

spraying and aeration till the completion of bio composting cycle.

d. Effluent Spraying: Spraying is done either before aeration or during the mixing/

aeration process. The quantity of effluent to be applied should be strictly controlled

so that the windrows always have proper moisture content, which is optimum for

aerobic composting.

e. Merge Windrows: Proper degradation of organic matter of windrow reduces its

height; hence, after about 15 days of initial composting the windrow height is likely

to be reduced to about 0.5 meter. Therefore, it may be required to merge 2

windrows into one and continue further processing.

f. Compost Curing: After completion of spraying of spentwash, aerate the windrow

for 2 to 3 days. After reducing the moisture to about 30 % to 35 % heap the compost

in the corner to a height of about 2 meter to have anaerobic process for about 15

days and also to make the space free for fresh windrow formation. A distinctive

black loamy, free flowing and ready to pack compost, which has a pleasant earthy

smell and moisture content of 30-35%, should be produced.

B. Salient features of the process

Zero Pollution

No odour or fly nuisance. The finished product is entirely free from any

repulsive odour

Destruction of BOD of the effluent

High product value – quick payback

Dry product - easy to bag, handle and transport

Negligible power/energy requirement

Chapter II


Zero effluent discharge to inland or any of the watercourses

Biocompost is rich in micronutrients (with organic and inorganic)

Biocompost can be sold to farmers to recover the expenditure.

C. Compost Monitoring Parameters

The desired characteristics of compost are given in Table 2.11. The following parameters

should be monitored for compost.

a. pH: Biocompost microorganisms operate best under pH is in the range of 5.0 to 8.5.

During the initial stages of decomposition- organic acids are formed. The acidic

conditions are favorable for growth of fungi and breakdown of lignin and cellulose. As

composting proceeds, the organic acids gets neutralized, mature compost generally has

a pH in the range of 6 to 8.

b. Temperature: As organisms decompose waste, they generate heat. Decomposition is

most rapid when the temperature is between 60 –700C. Bio-compost pile temperature

depends on how the heat produced by microorganisms is offset by the heat lost through

evaporating the effluent. After an initial high temperature period, compost pile

temperatures will gradually drop. Turning the compost rejuvenates the oxygen supply

and exposes new surface to decomposition, causing temperature to rise. When the

temperature drops down below 400C, the composting process is nearly complete.

c. Moisture: Active microorganisms need a moist environment. Microorganisms can use

organic molecules only if they are dissolved in water. Ideally, composting materials

should have between 50 and 70 percent water. When conditions are too wet, water will

fill the pore space needed for air movement and anaerobic conditions can result. If

conditions are too dry, the decomposition rate will slow down.

d. Carbon to nitrogen (C: N) ratio: Microorganisms require a balance of carbon and

nitrogen for healthy cell growth. Initially, the press mud C:N ratio is 30:1. After

composting, C:N ratio break down to 14:1.

Table 2.11: Desired Characteristics of Bio-compost

Parameters Value

Organic carbon 20 -25 %

Nitrogen 1.5 – 2.5 %

Phosphorous 1.0 – 1.7%

Potassium 1.5 – 2.85 %

Organic matter 38 – 42 %

pH 6-8

Chapter II


Performance

1. Average Press mud to spentwash ratio: 1:1

2. Biocompost cycle duration: 60 days/ five cycles

3. Culture required for bio-composting: 1 Kg/MT (culture in solid form) or 250 ml /MT (Culture

in liquid form) of press mud

D. Material balance for bio composting

The bio-composting requirements are given in Table 2.12 and mass balance for biocompost is

given in Table 2.13.

Total concentrated spentwash generation = -23,760 m3per annum

Press mud required to achieve SW: Press Mud Cake (PMC) mixing ratio at 1:1 = -23,760MT

PMC production: 43,200 MT per annum

Table 2.12: Composting Requirements

Sugar Mill

1. Crushing rate (Capacity – -250TCH) Average rate 6000 TCD

2. Projected Crushing rate @ 180 days /annum 10,80,000

3. Annual Press mud production @4% 43,200

4. Moisture content of Press mud 70 %

Distillery

5. Capacity (liter/day) 55 KLPD

6. Days of operation 270

7. Spent wash production/annum

8. Spent wash production after evaporation (@ 88 m3/day)

/annum

23,760

9. Ratio Press mud: Spentwash, (60 days cycle) (w/v) 1:1

10. Press mud requirement (in MT per annum)

11. Culture Required prescribed proportion

Quantity required/year (270days)

1Kg/MT of press mud

23,760 Kg

12. Yard requirement (Maximum) 4.6 acres

13. Land provision for compost yard (including green belt) 7.65 acres

Chapter II


Table 2.13: Mass balance: Compost

Sr. No. Description Solids Content % Quantity MT Total Solids MT

1. Annual Raw Material

a) Press mud*

b) Spentwash

30

25

23760

23760

7128

5940

Total 47520 13060

2. Annual Compost considering 20% loss during process as a CO2 10446.5 MT along with

30-35% moisture

D. Operations & maintenance guidelines for bio-composting

a. Rainy season

It is not possible to run the aerobic bio-composting process for three months during rainy

season. The reasons for stoppage of process during rains are:

It is not possible to run the bio-composting machine during rainy season

Freshly sprayed spentwash that is yet to be decomposed may give some colored

leachate after rain and will contaminate the soil

Due to rain, the bio-composting material in windrows may have moisture content of

more than 70%, which can result in anaerobiosis

Heavy rains can wash off the press mud

b. Precautions to be taken before on set of rainy season

The bio composting area will be vacated before start of rain

As far as possible all, the compost on the site will be sold out before start of rain. The

compost, which remains unsold, will be bagged and kept in stores / godown.

After harvesting the last batch of compost a 2 cm surface layer of press mud over the

brick on edge layer will be scrapped and this scrapped material shall be kept covered for

blending with compost.

The windrow of fresh press-mud will be formed after cleaning the scrapped area after

rainy season.

c. Un-seasonal rains

Precaution to be taken if there is an un-seasonal rain during bio-composting cycle.

In order to avoid the leaching of spentwash, the windrows on the area will be covered

with polyethylene sheets/pullover cover

Stop spraying spent-wash, temporarily when it is raining. Spraying will be resumed

when the sky is clear once again.

Chapter II


The provision of the trenches towards slopping side will be made to collect the run off

from windrow area. This run off will be collected in leachate collection pit. If necessary,

it will be pumped back to 30 days storage lagoon.

The run off outside compost yard should be suitably diverted so that it does not enter

the compost yard

Holding Tank for Spentwash

Since the project is an expansion of existing 30 KLPD distillery unit, the mill has already

constructed three spentwash holding tanks i.e. for raw spentwash 1500 M3 capacity, for

anaerobically digested spentwash1500 M3 and after MEE 3000 M3 capacity, as per CREP

guidelines.

Spentwash will be transported through closed conduct, HDPE/RCC pipes and stored in

impervious tank/lagoons. An impervious storage tank of maximum 30 days and minimum 05

days holding capacities are constructed to store spentwash. Spentwash storage tanks are duly

lined with 200 mm thick black cotton soil (40%) + murum (60%), 250 micron HDPE sheet,

pitched by stone/bricks with SRC mortar and SRC plaster 50 mm thick to prevent leachate.

Figure 2.12: Sectional view of Spent wash storage lagoon

Chapter II


Figure 2.13: Existing Compost yard with leachate gutter

Figure 2.14: Sectional view of compost yard

Figure 2.15: Sectional view of Leachate Gutter

Chapter II


Fig.2.16: Existing HDPE pipelines for

carrying Spentwash

Fig. 2.17: Existing Spentwash storage lagoon

Process condensate treatment plant (Condensate polishing unit - CPU)

Condensate from MEE, spent lees and other low strength waste streams such as cleaning in

place will be sent to this unit where it will be treated in three stages namely – primary,

secondary and tertiary. The details are given below-

i) Spent lees : ~110 m3/d

ii) Evaporation plant process condensate : 352m3/d

iii) Other low strength effluent : 40-50 m3/d

Total : ~512 m3/d

Condensate from MEE plant cooled in cooling tank and introduced to enzymatic treatment. This

treated condensate is recycle back as a cooling tower make up water

2.14.3 Sewage

Estimated domestic effluent will be 43 m3/d, which will be treated separately in septic tank and

soak pit.

2.14.4 Air Emissions and control measures

The sources of air pollution are emissions due to combustion of fuel i.e. bagasse, biogas the

boiler furnace, fugitive dust due to handling of bagasse, processes such as fermentation, bio-

composting etc. Emissions from diesel generator and vehicles are anticipated as a minor source.

Bagasse contains traces of Sulphur and Nitrogen, hence generation of SO2 and NOX anticipated

being limited. Venturi wet scrubber is already installed as air pollution control equipment

(PCE), to arrest fly ash emissions. It is attached to existing boilers of 70 TPH and 32 TPH. It is

connected to a stack of 65m height with 2.9 m inner diameter. The same will be used even after

expansion, after modifying it suitably as per requirement. An independent 8 TPH biogas fired

boiler will be installed for distillery to meet off season steam requirement. Emission rate of PM

and SO2 from flue gases is provided in chapter IV, table 4.2 at dispersion modeling study.

Chapter II


Enhancement of greenbelt by 2.5 acres is an additional measures for control of air emissions.

Area provided for the parking of vehicles is adequate. There is separate parking area for

vehicles carrying goods, products and private vehicles.

In general, if bio composting is not done under aerobic conditions CO2 and CH4are likely to get

generated. But with proper handling and supervision these emissions are minimized, as the bio

composting process is carried out in fully aerobic condition. Hence, there is negligible emission

from bio composting process.

Figure 2.18: Existing Venturi Wet Scrubber With Chimney

2.14.5 Noise Control

Steam turbine generator will be a major noise source from the existing project. Apart from that,

noise is anticipated from boiler, cane crusher, mill house, pumps, motor drives, utilities,

transportation etc. The plant and equipment will be specified and designed with a view to

minimize noise pollution. The major noise producing equipment will be provided with

soundproof devices and silencers. DG set will be provided with acoustic enclosures. Ear Plugs

and ear muffs will be provided to the workers in utility section. Greenbelt will be developed.

Figure 2.19: DG set with acoustic enclosure

Chapter II


2.14.6 Solid waste generation and management: Sugar Unit

The proposed industrial activity could generate solid waste in the form of ETP sludge and boiler

ash. The quantity and disposal technique is given briefly in the following Table2.4

Table 2.14: Solid waste generation and disposal (Considering 180 days season)

# Waste Quantity (tons per season)

Treatment Disposal Remark

1. Sugar ETP Sludge 35 Disposal into land/soil

Sold to the member farmers/or used on own plot

Organic

2. Ash

3,927 Mixed with bio-compost Disposal into land/soil

Used as manure/soil enriching material

Inorganic

3 PMC 43,200 Composting Soil conditioner Organic

4. Oil & Grease 4-5 KL Remove by oil skimmer

Use for boiler -

Distillery Unit

The proposed industrial activity will generate solid waste in the form of fermentation sludge

which is biodegradable and boiler ash. The quantity and disposal technique is given briefly in

the following Table 2.15.

Table 2.15: Solid waste generation and disposal

# Waste Quantity (MT/Annum)


1. Yeast Sludge 50 Composting Used as manure/soil enriching material

Organic

2. Boiler Ash (off season of sugar)

157 --- Sold to the brick manufacturing unit

Inorganic

3. Sludge from bio-digesters,

70-80 Mixed with bio-compost

4. Distillery CPU Sludge

20 Composting Used as manure/soil enriching material

Organic

5. Spent oil from DG set

0.1-0.2 KL - Spent oil will be burnt in boiler

-

2.14.7 Hazardous Waste

The only hazardous waste likely to be generated will be scrap oil from DG set, automobiles,

gears etc. Since the DG set will run only in case of failure of regular power supply. Thus, the

quantity of used or scrap oil will be low and has been assumed to be very minor. This will be

Chapter II


stored in leak proof drums in storage yard. This will be disposed off periodically by burning in

boiler furnace along with fuel.

2.15 GREENBELT DEVELOPMENT

The main objective of greenbelt development in and around the proposed unit will be to –

Mitigate impacts due to fugitive emissions

Create an aesthetic environment

Create a complex bio-diverse ecology

SMSKL has already developed an greenbelt which is spread over an area of approx. 12 acres.

The trees are planted in the periphery, along the internal roads and in the open areas between

various units of the industry. The mill has planted ornamental plants near the guest house, in

front of office and open areas. The details of tree species in the existing greenbelt are given in

Table 2.16.The layout of existing green belt in sugar and distillery unit is shown in Fig. 2.20 (A)

and (B) respectively. In the proposed activity, land allocated for greenbelt development is

approximately 2.5 acres. Greenbelt consisting of small and medium size trees and will be

planted around the waste disposal areas, such as ETP, compost yard, spentwash storage lagoon,

etc. Treated effluent from sugar mill/distillery will be used for gardening purpose. The list of

species recommended for proposed green belt development is given in Chapter IX.

Chapter II


Table 2.16: Existing greenbelt (Including trees along the road)

Plant # Plant # Plant # Plant #

Mangifera indica

(Mango)

1045

Cassia fistula (Bahava)

75 Terminalia

belerica (Hirda)

110 Thevatia

species (Bitti) 320

Tamarind (Chinch)

70

Bauhinia racemosa (Apta)

& B. Verigata (Kanchan)

135+

30

Millingtonia (Indian Cork

Tree) 145

Thespesia populnea

(Jungli Bhendi)

325

Aegle marmelos

(Bel) 25

Mimusopselengi(Bakul)

80 Nerium indicum (Kaner)

470 Pterocarpus

marsupium(Biwla tree)

40

Sapota species

(Chikku) 125

Delonix regia (Gulmohar)

235 Tekoma 120

Adonsonia digitata (Gorakh Chinch)

10

Syzygium cumini

(Jamun) 40 Subabhul 180

Christmas tree

5 Dalbergia

Sisso(Sisum) 270

Phyllanthus emblica (Amla)

80 Polyakthia

longifolia (Ashok) 106

0

Thespesia species (Ran

Kapasi) 20

Terminalia arjuna (Arjun)

40

Bottle brush 90 Plumeria alba

(Chafa) 350 Eucalyptus 130

Acacia nilotica

(Babhul) 570

Pongamiapinnata (Karanj)

190 Terminalia

chebula 35

Acacia species Ram khathi

Babhul 135

Ficus racemosa (Umbar)

82

Azadirachta indica (neem)

665 Ficus religiosa

(Pimpal) 75 Bottle Palm 185

Anthociphalous (Kadamb)

40

Jackranda (Nilmohor)

40 Acacia

leucocephala (Babhul)

260 Ficus panda 130 Albizia spp.

(Shiras) 40

Bamboo 360 Terminalia catapa 35 Jackfruit 10 Guava (Peru) 80 Anogeissus

latifolia (Dhawada)

235 Coconut 152

0

Nyctanthes arbor-tristis

Parijatak 25

Lagerstromia specioca (Taman)

20

Borassus flabellifer(To

ddy Palm) 80

Annona reticulate (Ram Phal)

50 Caesalpinnia (Shankasur)

350 Tectona grandis (Teak)

210

Phoenix Palm 350 Putranjiva roxburghai (Putranjiva)

70 Rubber tree 30 Moringa Species

35

Samania saman (Rain

tree) 115

Alstonia scholaris (Saptaparni)

65 Casuarina

equisetifolia(Suru)

260 Ficus

benghalensis (Banyan tree)

75

Total 351

0 Total

4255

Total 212

5 Total 2157

Grand Total 12,047

Chapter II


Figure 2.20: Existing Green belt

Chapter II


Fig. 2.20 (A): Layout of Existing Greenbelt (Sugar unit)

Chapter II


Fig. 2.20 (B):Layout of Existing Greenbelt (Distillery unit)

Chapter II


2.16 COST OF THE PROJECT

The total cost of proposed activity of sugar and distillery unit will be about Rs. 5,669.1lakhs out

of which investments of approx. Rs.404.00 lakhs will be for Environment management.

Estimated cost of the proposed activity including capital expenditure on environment

management is mentioned in Table 2.17.

Table 2.17: Proposed Project Cost Details

# Particulars Amount (Rs. in Lakhs)

A Sugar Unit

1. Plant and machinery 2076.80

2. Machinery foundation 153.4

3. EMP (sugar) 64.90

Total 2,295.1

B Distillery Unit

4. Molasses handling, fermentation and distillation

units,

1,115

5. MEE, WWTP section, Biomethanation section 975

6. Cooling tower, Air compressors, Pumps etc. 150

7. Storage and electrical work 670

8. WTP section 125

9. Environment Management Cost 339

Total 3,374

Total (A+B) 5,669.1

Table 2.18: Project Implementation Schedule

# Project Activity Proposed time

1. Application to MoEFCC New Delhi for TOR 8th Aug. 2017

2. Meeting with MoEFCC for award of TOR for undertaking detailed

EIA studies

NA (ToR granted

on 29th Sep. 2017)

3. Draft EIA report submission for public hearing May 2018

4. Conducting public hearing Aug 2018

5. Preparation of final EIA report Sep 2018

6. EC presentation at MoEFCC Nov. 2018

7. Environmental clearance for project Dec. 2018

8. Start date for commission of the project Jan. 2019

9. Completion of the project May- June 2019

Chapter III

EIA Report: Expansion of Sugar Mill from 2,500 to 6,000 TCD and Distillery from 30 to 55 KLPD M/s. Shreenath MhaskobaSakharKarkhana, Patethan, Pune 3-1

CHAPTER III

BASELINE ENVIRONMENTAL STUDY

3.1 INTRODUCTION

The baseline environmental and socio-economic study of the project and project area was done to -

Understand existing environmental characteristics of the area and the project need

Assess the existing environmental quality and on the basis of that identify the

environmental impacts of the proposed project/future developments.

Identify environmental or geographical factors that could preclude any future

development

3.2 METHODOLOGY OF BASELINE STUDY

The baseline study and primary data collection was primarily carried outin the 10 km radius of the

project during summer i.e. October 2017 to January 2018.

The data used categorized as

Primary data i.e. the data collected by conducting field monitoring, sampling and

survey. Parameters such as air, meteorology, noise, water, soil, land use, geology, socio-

economic & biological environment, mainly studied with the help of primary data.

The data related land use, meteorology, geology, hydrogeology and socio-economic

environment, etc. collected from authentic sources, such as Govt. Publications, official

websites of various government departments, etc.

The baseline study began with site visits and reconnaissance survey in the study area, during which

the locationsfor monitoring and collection of primary data we decided.

3.3 DESCRIPTION OF STUDY AREA

3.3.1 Description of Site and Surrounding Features

The project site is located near the existing sugar factory premises at village Patethan, Taluka

Daund of Pune district. The proposed site lies between following geographical coordinates: -

1) 18°36'18.74"N, 74°13'34.87"E.

2) 18°36'29.87"N, 74°13'40.25"E.

3) 18°36'26.31"N, 74°13'52.02"E.

4) 18°36'14.44"N, 74°13'52.69"E.

Chapter III


The proposed site is at elevation of 551m above the mean sea level. River Bhima is approx. 2.20 km

away from the project site.

Table 3.1: Important Features around the Project Site

# Important Geographical Features Direction Distance (km)

1. Nearest Water Bodies

River Bhima SE 2.20

River Mula-Mutha NW 6.0

2. Nearest National Park/ Sanctuary

Chandoli National Park SW 170

Mayureshwar wildlife sanctuary SE 32

3. Religiously Important places

Bhuleshwar S 20

4. Historic Monuments

Malthan-DadojiKondhdev Palace N 26

5. Nearest Settlements

Patethan NW 2.54

*Note: All distance are approximate aerial distances from the project site

Chapter III


Figure 3.1: Satellite image showing site and surrounding area

3.3.1.1 Access to the site

The site is well connected by road, railway as well as air network. It is approx.18 km away from

thestate highway no. 27 (Pune-Ahmednagar) and ~16 km away from the national highway no. 9.

Yavatrailway station (on Pune-Solapur route) is approx. 16 km from the project site. The

internationalAirport of Pune (approx. 45 km) is the nearest airport to the site.

Table 3.2: Summary of Environmental features of study area

# Facet In brief

1. General characteristics Mostly hot and dry

2. Rainfall An average annual rainfall of 400-600 mm

Most of the rains received from June to September months,

July being the month with highest rainfall

3. Temperature Average maximum temperature in summer is around 31.5°C

and average minimum temperature in winter is around 17.7°C.

4. Humidity Minimum 17% and maximum 74%

Chapter III


5. Wind The predominance wind is blowing from W and NW in

summer months, SW and W in monsoon whereas in winter

months from N

6. Land use Crop land 83.62 %, scrub land 6.76 %,barren rocky land

2.11%, Dense forest 2.0%, open forest 1.18% and others

7. Air Quality Complies NAAQ standards of Nov., 2009 at all monitored

locations

8. Noise Quality Complies the standards of CPCB

9. Ground water Quality As per Central Ground Water Board report 2014,

10. Soil Quality Black cotton soil

3.3.2 Land Use Pattern

Satellite remote sensing, in conjunction with geographic information systems, has been widely

applied and recognized as an effective tool in analyzing land cover/use categories. This study

evaluates qualitative and quantitative outcome of land cover/use distribution using remote sensing

data and GIS technologies.

3.3.2.1 Methodology

General Description of the Area

Geographically, the site is located between 19°34'10.74"N and 74°30'10.00"E. The 10 km radius

area around project site is having latitudes 10° 67’ 64.59’’ N to 10° 87’ 97.62’’N and longitudes 76°

41’ 60.29’’E to 76° 44’ 35.42’’E. The site area falls in the SOI Toposheet No. E43I2, E43I6

Remote sensing and Collateral data used

Remote Sensing Data-Following remote sensing satellite data were used in the study.

Satellite data: LANDSAT_147_46, cloud free data has been used for land use/land cover analysis

Satellite Sensor – LANDSAT_147_46,OLI_TIRS

Spatial Resolution – 30 m

Chapter III


Ancillary data

PC based GIS and image processing Arc GIS 10.4 ver. software are used for the purpose of image

classification and for delineating drainage and other features in the study area. Number of

peripheral devices such as scanner, plotter, printer etc. has also been interfaced with the system.

Objectives:

Delineation of Landuse/ Landcover categories on the 1:50000 scale for the whole study

area.

Generation of digital cartographic database using secondary data sources.

Collateral Data

Survey of India (SOI) Toposheet No. E43I2, E43I6 on 1:50000 scale were used to collect

topographic and location information. The toposheetwas used to prepare base map, identification

of sample areas and drainage maps and for planning the traverse route for ground truth collection.

Remote Sensing Data Interpretation

The methodology followed for the interpretation of the resourcesat data. Data was interpreted

using digital image interpretation technique by supervised classification using Arc GIS 10.4 ver.

The other ancillary data such as toposheet and other available information (reports, maps etc.)

were used for preparation of land use/ land cover map.

Geo-referencing of imagery with reference to SOI toposheet using Tie Point Editor of ILWIS

software

Demarcation of 10 km radius around the site area and drainage lines available on SOI

toposheet

Interpretation of false colour composite (FCC) using digital image interpretation technique

of land use/land cover to generate pre-field image interpreted base map.

For land use/land cover mapping, the boundaries of notified forests were digitized using

SOI toposheet. Satellite data were interpreted for various land use classes like notified

forest, agricultural land, wasteland, habitation and water bodies.

Field work was carried out for collection of ground truth from each image interpretation

unit viz. land use.

Chapter III


Correlation of image interpretation units with the ground truth observations

Random field checks to verify and validate the land use units and their boundaries.

Finalization of land use/land cover maps after field verification.

The final output of land use/land cover was prepared using Arc GIS 10.4 ver. Software.

Results

Topobase

Topobase is prepared on the base of toposheet no. E43I2, E43I6. First toposheetwas scanned and

georeferenced based on the four ground control points (GCP) and projected in UTM projection

system with datum WGS84. The 10 km radius area around the site was delineated and prepare base

map. Further base map boundary is used to extract information from the georeferenced toposheet.

3.3.2.2 Land use/ Land cover Classes Details

Land use is the man’s activities on and in relation to the land, while land covers describes the

natural vegetation, water bodies, rock/soil and artificial constructions covering land surface

(Burley, 1961). Land use/ land cover map is an indicator of ecological and overall socio-economic

status of the area. Land use is a product of interaction between a society’s cultural background skill

and its physical needs on the one hand, and the natural potential of the land on the other. Thus, the

land use data and its spatial distribution are very useful for analyzing and preparing the land use

plan of the area

Image characteristics of different land utilization types identified on Landsat data have been given

in table 3.3. Nine land use/land cover classes identified in total 10 km radius area around project

site. The land use/land cover classes identified are crop land, scrub land, barren rocky land, dense

forest, open forest, industrial area, lake/ponds, river/stream, and settlement. The land use/land

cover map of the operational area is shown in fig.1 and the area under different land utilization type

is given in table no. 3.3.

Table 3.3: Land use/Land cover statistics of the ten square km area

Sr. No. Class Name Area (Ha) Area (%)

1. Crop land 26270.97 83.62

2. Scrub land 2123.26 6.76

Chapter III


3. Barren rocky land 661.65 2.11

4. Dense forest 628.32 2.00

5. Open forest 369.7 1.18

6. Industrial area 3.83 0.01

7. Lake/ ponds 37.09 0.12

8. River/stream 1031.97 3.28

9. Settlement 288.73 0.92

Figure 3.2: Land use/land cover map of the study area

3.3.3 Climatic Conditions of Daundtaluka

The information presented below gives detailed historical monthly or yearly average weather

conditions along with exceptional weather occurrences.

3.3.3.1 Rainfall

The annual rainfall received during the southwest monsoon season i.e. from June toSeptember, July

being the month with highest rainfall. The average data for the last ten years given in the Table 3.4.

Chapter III


Table 3.4: Annual rainfall for Daundtaluka

Last ten year annual rainfall in mm

Year 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 Avg.

Annual rainfall

594 604 326 474 639 347 337 402 450 460 620 525

3.3.3.2 Temperature

The summer season from March to May is one with continuous increase in temperatures,

whichdecreases during monsoon, increases slightly during the post monsoon season and

againdecreases during the winter. The average maximum temperature is 31.5 °C and average

minimum temperature is 17.7 °C.

Temperature data for Pune District

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

Maximum temp °C

29.9 31.9 35.4 37.7 36.9 31.7 28.4 27.4 29.4 31.4 30.1 28.9 31.5

Minimum temp °C

11.0 12.1 15.8 19.9 22.4 22.9 22.2 21.6 20.8 18.5 14.4 11.5 17.7

3.3.3.3 Relative Humidity

The climate of the region is characterized by a dry summer. Humidity is usually high during

themonsoon months, decreasesgradually during the post monsoon months and for rest of the year,

the average relativehumidity ranges around minimum16% and maximum 74%.

3.3.3.4 Cloudiness

The skies are heavily clouded to overcast during the south-west monsoon season. In the rest of the

year skies are mostly clear or lightly clouded.

3.3.3.5 Winds

Winds are generally light to moderate with increase in speed during half of summer and in

monsoon season. The predominance is W and NW in summer months, SW and W in monsoon

whereas in winter months from N.

Chapter III


3.3.3.5.1 Wind Speed and Wind Direction

The windrose diagram was prepared from site meteorological data in order to assess the wind

pattern i.e. direction, speed and frequency. The windrose diagram for the proposed site shows

following features. The predominant wind direction during Post-monsoon season was from North

East to East. Calm conditions subsist for 33.61%. The analysis of the recorded site data revealed

that the prevailing wind velocity is between 0.50 – 2.10 m/s throughout the study period. A wind

rose diagram (Fig. 3.3) shows the wind pattern for the site and wind class frequency distribution is

shown in Fig. 3.4.

Figure 3.3: Wind Rose

Chapter III


Figure 3.4: Wind class frequency distribution

3.4 ENVIRONMENT MONITORING DATA ON SOIL, WATER, AIR AND NOISE ASPECTS

Figure 3.5: Monitoring Location Map

Chapter III


Table 3.5: Monitoring Locations

# Location Direction Distance (km) Parameters (Sample collected for)

1. Factory Site - - Air, Ground Water, Soil

2. Patethan NW 2.54 Air, Ground Water, Water (River Bhima

Surface), Soil

3. Devkarwadi SW 3.57 Air, Ground Water, Soil

4. Pilanwadi S 4.22 Air, Ground Water, Soil

5. Rahu SE 5.7 Air, Ground Water, Soil

6. Telewadi E 3.75 Air, Ground Water, Soil

7. Arangaon NW 5.63 Air

8. Takali-Bhima N 4.01 Air, Ground Water, Water (River Bhima

Surface), Soil

9. Vadgaon-Bande NE 4.24 Ground Water, Soil

10. Vitthalwadi NW 6.45 Water (River Bhima Surface)

11. Nhavi-Sandas NW 7.80 Water (River Bhima Surface)

12. Mirawadi SW 9.09 Water (River Mula Surface)

13. Dahitane SW 6.94 Water (River Mula Surface)

14. Walki NE 8.39 Water (River Mula Surface)

15. Rahu SE 5.69 Water (River Mula Surface)

3.4.1 Soil: General characteristics for the district

The soils of Punedistrict are lighter in the West than in the East and belong broadly to three

mainclasses, viz., black, red and brown. In some places one class of soil blends with another in

varyingproportions and is in turn modified by sand, gravel, lime salts and other ingredients. Kali or

Black soils are nearly black in colour and sometimes have a grayish or bluish tinge. It is commonly

found in layers several feet deep and occurs mostly in the Eastern portion of Khed, Shirur, Daund

and Purandhar Tahsils and the whole of Baramati and Indapur Tahsils. Black soils are richer than

either red or coarse grey soils and are particularly suited for rabi crops because of their quality

ofretaining moisture for a longer time and crumbling instead of becoming hard due to the sun.

Wheat, gram, rabi jowar and sugarcane are amongst the important crops grown in these soils.

Brown or copper coloured soils, commonly known as tambvat are found in the transition tractviz.,

the Eastern parts of Khed and Haveli Tahsils and the Western parts of Shirur, Daundand Purandhar

Chapter III


Tahsils. These soils are shallower and coarser than the black soils. They are often impaired by

mixture of gravel but when watered by frequent showers, are generally well suited for wheat and

kharif crops particularly jowar and bajra.

3.4.1.1 Soil characteristics

Soil is a dynamic natural body on the surface of the earth in which plants grow, composed of

mineral and organic materials and living forms. Soil is an essential component of the terrestrial

ecosystem. Soil also acts as a medium of transport of various dissolved materials to the underlying

ground water. Hence the impact of the proposed activities on soil needs to be understood for

proper mitigation measure whenever required.

Agriculture is the main occupation of the people in the study area. Hence it is necessary to identify

the impacts in the study area on the soil characteristics, which would affect the agricultural and a

forestation potential.

Ground truth collection and soil analysis

Using the available base map and land use land cover map, the area was traversed for identification

of present land use/land cover classes. To understand the soil variability based on land use map,

eleven locations were selected for soil sampling within the 10 km radius of the study area. Nearly

2.0 kg of representative soil samples collected from each location at a depth of 30 cm.

Soil analysis

The bulk soil samples collected during the field work were initially air dried in laboratory at room

temperature, ground using wooden mortar and pestle, screened through 2 mm sieve, properly

labeled and stored in cloth bags for laboratory analysis. Soils were analyzed for texture, pH and

electrical conductivity (1:2.5 H2O), organic carbon, calcium carbonate, available nitrogen,

phosphorus, potassium and DTPA extractable micronutrient like iron, manganese, zinc and copper

and heavy metals like chromium, cadmium, lead and nickel using standard methods.

The data pertaining to soil analysis have been presented in Table 3.6 and salient chemical

characteristics of the soils have been discussed below.

Chapter III


Table 3.6: Soil analysis results for samples collected from the study area

Ch

ara

cte

rist

ics

pH

EC

(M

illi

mh

os/

cm)

Mo

istu

re

(%)

Te

xtu

re

Org

an

ic

ma

tte

r (%

)

Org

an

ic

Ca

rbo

n (

%)

Av

ail

ab

le

Nit

rog

en

(K

g/

ha

)

Av

ail

ab

le

Ph

osp

ho

rou

s (P

2O

5)

(Kg

/h

a)

Av

ail

ab

le

Po

tass

ium

(K

g/

ha

)

Project Site

8.1 0.263 18.73 Clay 0.55 0.32 344.96 18.11 188

Pilanwadi 7.9 0.083 14.16 Clay 0.89 0.51 330.84 17.47 214

Takali-

Bhima

8.5 0.310 19.62 Silt 0.94 0.54 316.73 18.39 110

Patethan 8.2 0.293 17.95 Silt-clay

0.82 0.47 354.36 19.97 182

Devkarwad

i

8.8 0.343 16.82 Silt-loam

0.52 0.30 238.33 26.62 177

Wadgaon-

Bande

8.0 0.089 18.38 Clay 0.40 0.23 211.68 15.81 203

Telewadi 8.3 0.401 16.27 Sandy 0.67 0.39 227.36 22.46 223

Rahu 8.1 0.321 12.26 Clay-loamy

0.31 0.18 338.68 16.64 198

3.4.1.2 Observations

The pH indicates the potential of ionizable hydrogen ion and represents the degree of acidity or

alkalinity in soils. Based on pH (soil reaction), the soils are grouped as acidic, alkaline or neutral.

The pH of the soils ranged from 7.9 to 8.8 (moderately alkaline to alkaline). The electrical

conductivity is a measure of soluble salt concentration in the soils. The EC (< 0.40Milli mhos/cm) of

all the soils are within the acceptable limitand not of much consequence for growing a range of

crops.

Organic carbon is an indicator of organic fraction in soils formed from microbial decomposition of

organic residues. It acts as a major factor regulating the organic forms of nitrogen, phosphorus,

sulphur and trace elements in the soils. It also improves the soil structure, infiltration rate, nutrient

retention and reduces soil erosion. The organic carbon content in the soils varies from 0.18 to

0.54per cent.

Chapter III


3.4.2 Hydrology

The entire area of the district is underlain by the basaltic lava flows of upper Cretaceous to lower

Eocene age. The shallow alluvial formation of Recent age also occurs as narrow stretch along the

major rivers flowing in the area. A map depicting the drainage pattern of study area is shown in

Figure–3.6.

Figure 3.6: Drainage map of the study area

3.4.3 Physico-chemical characteristics of surface water

The surface water samples collected during summerseason and analyzed for Physico-chemical

characteristics and the corresponding results interpreted in Table 3.7. The same were compared

with drinking water standard IS 10500:2012.The Physico-chemical parameters of river Bhima and

river Mula-mutha showed moderate water quality in terms of Total suspended solids: 54-66 mg/l.

Chapter III


Table 3.7: Analysis report - Surface water sources from the study area

Characteristics

Unit

Vit

tha

lwa

di

(Bh

ima

Riv

er)

Nh

av

i-S

an

da

s

(Bh

ima

Riv

er)

Mir

a W

ad

i

(Mu

la R

ive

r)

Da

hit

an

e

(Mu

la R

ive

r)

Ta

ka

li-

Bh

ima

(Bh

ima

Riv

er)

Ra

hu

(Mu

la

Riv

er)

Wa

lki

(Mu

la R

ive

r)

Pa

teth

an

(Bh

ima

Riv

er)

DW

sta

nd

ard

–

IS 1

05

00

:20

12

pH -- 7.6 7.5 6.6 6.7 6.9 6.8 7.9 7.9 6.5 to 8.5

Conductivity at 25°C mmhos

/cm

0.485 0.611 0.883 0.695 0.673 0.541 0.46 0.46 --

Total Suspended Solids mg/l 58 62 58 54 64 58 56 66

Total Dissolved Solids mg/l 300 286 268 324 250 270 304 232 <500

Total Alkalinity mg/l 47.5 55 95 97.5 85 77.5 75 90 <200

Total Hardness as

CaCO3

mg/l 115 135 145 120 195 125 135 135 <200

Calcium as Ca2+ mg/l 23.04 18.03 30.06 38.07 38.07 27.05 27.05 42.08 <75

Magnesium as Mg2+ mg/l 13.97 21.87 17.01 13.97 21.87 13.97 16.40 7.29 <30

Chlorides as Cl mg/l 49.98 46.23 41.23 31.24 27.49 59.98 29.99 49.98 <200

Residual chlorine mg/l BDL BDL BDL BDL BDL BDL BDL BDL >0.20

Sodium mg/l 60 50 55 60 95 50 30 40 --

Potassium mg/l 2.0 1.0 1.0 1.0 2.5 3 02 03 --

Sulphate as SO4 mg/l 43.88 37.76 60.19 44.27 32.03 40.77 31.55 42.52 <250

Phosphate mg/l BDL BDL BDL BDL BDL BDL BDL BDL --

Chapter III


Silica mg/l BDL BDL BDL BDL BDL BDL 0.26 0.52 --

Dissolved Oxygen mg/l 4.6 4.7 4.0 4.1 3.8 3.6 3.7 3.9 --

Biochemical Oxygen

Demand at 27°C for 3

days

mg/l 6.76 6.2 6.76 7.59 6.76 6.2 8.33 6.2 --

Chemical Oxygen

Demand

mg/l 16 16 16 18 16 16 20 16 --

Heavy Metals

Iron mg/l BDL BDL BDL BDL BDL BDL BDL BDL <0.3

Manganese mg/l BDL BDL BDL BDL BDL BDL BDL BDL 0.1

Copper mg/l BDL BDL BDL BDL BDL BDL BDL BDL --

Cadmium mg/l BDL BDL BDL BDL BDL BDL BDL BDL 0.003

Chromium mg/l BDL BDL BDL BDL BDL BDL BDL BDL 0.05

Nickel mg/l BDL BDL BDL BDL BDL BDL BDL BDL 0.02

Lead mg/l BDL BDL BDL BDL BDL BDL BDL BDL 0.01

Zinc mg/l 0.126 0.111 BDL 0.226 0.221 BDL BDL BDL 5

Chapter III


Table 3.8: Analysis report - Groundwater sources from the study area

Characteristics

Unit Pil

an

wa

di

(We

ll w

ate

r)

Ta

ka

liB

him

a

(Bo

re W

ell

wa

ter)

Pa

teth

an

(B

ore

We

ll w

ate

r)

Va

dg

ao

nB

an

de

(We

ll w

ate

r)

Fa

cto

ry S

ite

(Bo

re W

ell

wa

ter)

De

ok

arw

ad

i

(Bo

re W

ell

wa

ter)

Ra

hu

(B

ore

We

ll w

ate

r)

Te

Le

wa

di(

Bo

re

We

ll w

ate

r)

DW

Sta

nd

ard

- I

S 1

05

00

:

20

12

pH -- 7.6 7.4 7.3 7.6 7.5 7.7 7.7 7.5 6.5 to 8.5

Conductivity mmhos

/cm

0.670 0.243 0.33 0.371 0.822 0.47 1.45 1.373 -

Chemical Oxygen

Demand

mg/l 12 16 12 16 24 16 12 16 -

Biochemical Oxygen

Demand

mg/l 5.4 6.76 5.1 5.63 8.9 6.2 5.4 6.2 -

Dissolved Oxygen mg/l 4.2 4.1 4.2 4.3 4.7 4.8 4.6 4.8 -

Total Solids mg/l 548 310 224 398 548 692 670 620 -

Total Dissolved

Solids

mg/l 292 202 148 318 472 520 438 472 <500

Total Suspended

Solids

mg/l 78 84 68 76 70 66 78 72 -

Total Hardness as

CaCO3

mg/l 140 135 110 205 205 145 115 130 <200

Calcium mg/l 35.07 30.06 26.05 50.1 30.06 36.07 62.12 26.05 75

Magnesium mg/l 12.75 14.58 10.93 12.15 24.3 13.36 4.86 15.79 30

Chlorides as Cl mg/l 44.98 34.98 31.24 6.24 29.99 24.99 39.98 34.98 <200

Chapter III


Characteristics

Unit Pil

an

wa

di

(We

ll w

ate

r)

Ta

ka

liB

him

a

(Bo

re W

ell

wa

ter)

Pa

teth

an

(B

ore

We

ll w

ate

r)

Va

dg

ao

nB

an

de

(We

ll w

ate

r)

Fa

cto

ry S

ite

(Bo

re W

ell

wa

ter)

De

ok

arw

ad

i

(Bo

re W

ell

wa

ter)

Ra

hu

(B

ore

We

ll w

ate

r)

Te

Le

wa

di(

Bo

re

We

ll w

ate

r)

DW

Sta

nd

ard

- I

S 1

05

00

:

20

12

Sulphate as SO4 mg/l 54.85 25.33 56.79 74.75 49.02 79.61 50 48.54 <250

Phosphate mg/l BDL BDL BDL BDL BDL BDL BDL BDL -

Total Alkalinity as

CaCO3

mg/l 75 20 50 75 70 85 95 60 <200

Silica mg/l BDL BDL BDL BDL BDL BDL BDL BDL -

Sodium mg/l 70 30 75 30 50 80 75 95 -

Potassium mg/l 0.3 2 1.0 0.5 0.5 1.0 2.0 1.0 -

Residual chlorine mg/l BDL BDL BDL BDL BDL BDL BDL BDL >0.20

Nitrates mg/l 2.6 BDL 2.44 1.71 2.01 2.65 2.56 2.59 <45

Copper mg/l BDL BDL BDL BDL BDL BDL BDL BDL -

Cadmium mg/l BDL BDL BDL BDL BDL BDL BDL BDL 0.003

Chromium mg/l BDL BDL BDL BDL BDL BDL BDL BDL 0.05

Nickel mg/l BDL BDL BDL BDL BDL BDL BDL BDL 0.02

Iron mg/l BDL BDL BDL BDL BDL BDL BDL BDL 0.3

Zinc mg/l BDL BDL BDL 0.121 0.105 BDL BDL BDL 5

Manganese mg/l BDL BDL BDL BDL BDL BDL BDL BDL 0.1

Lead mg/l BDL BDL BDL BDL BDL BDL BDL BDL 0.01

Chapter III


Buffering capacity in terms of alkalinity found to be in the range of 47.5-97.5 mg/l, whereas pH

was in the range of 6.6-7.9. Nutrient load in terms total phosphates found to be BDL. Levels of

DO and COD observed to be in the range of 3.6-4.7 mg/l and 16-20 mg/l respectively. Heavy

metals like nickel, cadmium, chromium, copper, lead, iron, manganese are found below

detectable limits and zinc found in the range of 0.111-0.226 mg/l.

3.4.3.1. Physico-chemical characteristics of Ground water

The sampling locations of 08 groundwater resources (from bore well) are studied during winter

season. The results obtained for physico-chemical, inorganic parameters, nutrient demand and

organic parameters, heavy metals, characteristics of groundwater samples collected are

presented in Table 3.8. In groundwater, total suspended solids were found to be in the range of

66-84 mg/l. The alkalinity as CaCO3, was found to be in the range of 20 - 95 mg/l which is lower

than the prescribed standard (IS: 10500-2012) limit whereas pH was in the range of 7.3-7.7.

Concentration of nitrate and sulphate were found to be in the range of BDL1.71-2.65 mg/l and

25.33-79.61 mg/l respectively.

3.4.4 Hydrogeology

The entire area of the district is underlain by the basaltic lava flows of upper Cretaceous to

lower Eocene age. The shallow alluvial formation of recent age also occurs as narrow stretch

along the major rivers in the area. A map depicting the hydrogeological features is shown in

Figure–3.7.

Hard Rock (Deccan Trap Basalt)

Basaltic lava flows occupies more than 95% of the area of the district. These flows are normally

horizontally disposed over a wide stretch and give rise to table land type of topography also

known a plateau. These flows occur in layered sequences ranging in thickness from 7 to 45 m

and represented by massive unit at the bottom and vesicular unit at the top of the flow. These

flows are separated from each other by marker bed known as ‘bole bed’.

The water bearing properties of these flows depend upon the intensity of weathering, fracturing

and jointing which provides availability of open space within therock for storage and movement

of ground water. The thickness of weathering in the district various widely up to 20 m bgl.

However, the weathered and fractured trap occurring in topographic lows forms the potential

aquifer in the district.

The ground water in the district occurs under phreatic, semi – confined and confined conditions.

Generally, the shallower zones down to the depth of 20 to 22 m bgl form the phreatic aquifer.

The water bearing zones occurring between the depth 20 and 40 m bgl when weathered or

having shear zones yield water under semi-confined condition. The deep confined aquifers

generally occur below the depth of 40 m bgl.

Chapter III


The vesicular unit of lava flow when exposed or lying just few meter below the surface forms a

potential aquifer in the district. However, the vesicular portion of different lava flows varies in

thickness from few m to 10 m and nature and density of vesicles, their distribution,

interconnection, weathering are the decisive factors for occurrence and movement of water in

these units. The massive portions of basaltic flows are normally devoid of water, but when it is

weathered, fractured and jointed forms potential aquifer. In Deccan Trap Basalt, the yield of the

dugwells in different formations ranges from 30 to 150 lpm/day depending upon the local

hydrogeological conditions. The yields of borewells also show wide variations and it ranges

from traces to 30.62 lps (Lavle) a seen from CGWB exploration data.

Soft Rock (Alluvium)

Alluvium occurs in small areas along banks and flood plains of major rivers like Bhima, Ghod,

Mula, Mutha and their tributaries. In alluvium the granular detrital material like sand and gravel

usually occurring as thin layer in the district yields water. But due to its limited extent the

ground water potential in this formation is negligible

Figure 3.7: Hydrogeology of Pune District

(Source: Ministry of Water Resources Central Ground Water Board, Ground Water Information Pune

District Maharashtra, 2009)

Chapter III


3.4.4.1 Major Ground Water Problems and Issues

About 50 % area of Pune district falls under Rain Shadow zone of Maharashtra state. Long term rain fall

data analysis reveals that eastern, southern, south-eastern, central and north-central part area of district

around Indapur, Baramati, Jejuri, Daund, Talegaon, Dhamdhare, Alandi, Shirur and Bhor are classified as

drought areas. Decadal pre-monsoon water level trend (2002-11) shows fall in water levels up to 0.56

m/year in 30% of the GWMW of the district, whereas in postmonsoon season fall is observed upto 0.27

m/year in 37% of GWMW. The stage of ground water development has reached up to 96.13% in two

talukas of the district namely Baramati and Purandhar and are categorized under “Semi-Critical”

category. In 17% water samples collected from CGWB Ground Water Monitoring Wells, excessive nitrate

content (> 45 mg/L) was recorded during year 2011.

(Source: Ministry of Water Resources Central Ground Water Board, Ground Water Information Pune

District Maharashtra, 2009)

3.4.5 Air Environment

The baseline ambient air quality data is given in table 3.9.

Table 3.9: Baseline Ambient Air Quality data

Sr. No.

Location Ambient Air Parameters

PM10 (µg/m3)

PM2.5

(µg/m3) SO2

(µg/m3) NOx

(µg/m3)

1. Factory Site

Minimum 40.17 19.67 15.19 20.01

Maximum 58.28 37.04 20.28 32.16

Average 50.60 28.85 18.59 27.07

98th Percentile 55.84 36.61 20.25 32.12

2. Patethan

Minimum 41.00 21.29 12.24 15.73

Maximum 53.23 32.69 18.93 31.03

Average 48.80 27.39 17.31 25.43

98th Percentile 53.02 32.57 18.91 30.91

3. Devkarwadi

Minimum 36.34 19.48 13.08 15.34

Maximum 52.45 32.66 19.35 30.06

Average 46.85 24.48 16.89 23.68

98th Percentile 52.42 32.24 19.14 29.93

4. Pilanwadi

Chapter III


Sr. No.

Location Ambient Air Parameters

PM10 (µg/m3)

PM2.5

(µg/m3) SO2

(µg/m3) NOx

(µg/m3)

Minimum 40.48 18.78 13.5 14.96

Maximum 54.81 29.51 18.93 28.77

Average 44.7 22.57 16.63 22.78

98th Percentile 53.73 29.45 18.77 28.3

5. Rahu

Minimum 39.92 18.47 12.66 15.15

Maximum 53.18 33.46 18.71 29.9

Average 46.75 24.74 16.48 23.8

98th Percentile 52.86 32.66 18.67 29.4

6. Telewadi

Minimum 35.47 18.8 12.5 16.66

Maximum 52.21 28.28 19.36 26.57

Average 44.57 22.27 17.09 22.74

98th Percentile 51.73 28.02 19.27 26.55

7. Arangaon

Minimum 36.78 18.88 11.79 15.65

Maximum 49.89 26.93 19.77 28.55

Average 44.89 22.34 16.82 22.28

98th Percentile 49.86 26.87 19.53 28.26

8. TakaliBhima

Minimum 34.63 20.02 13.3 17.38

Maximum 50.27 30.13 19.57 29.61

Average 44.75 23.68 17.18 23.82

98th Percentile 49.87 29.42 19.47 29.61

NAAQS (24 hour) 100 60 80 80

Chapter III


3.4.5.1 Observations

Particulate Matter

PM10

The average PM10 concentration varied in the range from 44.57 - 50.60µg/m3. The highest

concentration among the locations observed at Factory site and lowest at Telewadi among the

locations monitored which may be due to windblown dust, unpaved roads etc. The PM10 for all

locations were observed to be below stipulated standards for NAAQS (24 hourly PM10 = 100

µg/m3).

PM2.5

The average PM2.5 concentration varied in the range from 22.27 – 28.85 µg/m3. The highest

concentration among the locations observed at Factory site and lowest at Telewadi among the

locations monitored which may be due to windblown dust, unpaved roads etc. The PM2.5 for all

other locations were observed to be below stipulated standards for NAAQS (24 hourly PM2.5 =

60 µg/m3).

Gaseous Pollutant

The average concentration of SO2 ranged between 16.48 – 18.59 µg/m3 and the average

concentration of NOx ranged between 22.28 – 27.07µg/m3. The highest and lowest

concentration of SO2 observed at project site and Rahu respectively. The highest and lowest

concentration of NOx observed at project site and Arangaon respectively. The SO2 and NOx

concentrations for all other locations were observed to be below stipulated standards for

NAAQS (24 hourly SO2 and NOx= 80 µg/m3).

The 98th percentile values of 24 hourly concentrations of PM10, PM2.5, SO2 and NOx ranged from

55.84-49.86µg/m3, 26.87-36.61µg/m3, 18.67 -20.25µg/m3 and 26.55-32.12µg/m3 respectively.

3.4.6 Noise Environment

Noise, in general, is sound which is composed of many frequency components of various

loudness, which are distributed over the audible frequency range. The most common and

universally accepted scale is the weighted scale which is measured as decibel or dB. This is

more suitable for audible range of 20-20,000 Hz and has been designed to weigh various

components of noise according to the response of a human ear. The environmental impact

assessment of a noise from the industrial activity, vehicular traffic can be undertaken by taking

into consideration various factors like potential damage to hearing, physiological responses,

annoyance and general community responses which have several effects varying from rise

Noise Induced Hearing Loss (NIHL) etc. Noise survey had been conducted in the study area to

assess the background noise levels in different zones viz. Industrial, commercial and residential

zones. Noise levels were measured using a sound level meter. Eight locations were identified for

the monitoring of noise levels (Table 3.10).

Chapter III


3.4.6.1 Method of Monitoring

Sound pressure level (SPL) measurements were undertaken at all locations, with an interval of

10second over a periodicity of 15 minutes for 24 hours. As per the CPCB guidelines, 6 am to 10

pm considered as daytime and 10 pm to 6 am is considered as nighttime.

3.4.6.2 Parameters Measured

It was observed that both the day time and night time noise levels were observed within the

national standards limits. The results of the noise monitoring at the location monitored are

given in Table 3.10.

Table 3.10: Noise Monitoring Results in dB(A)

#. Location Avg. Leq in dB (A)

Day time

(6 am to 10 pm)

Night time (10 pm to 6 am)

Industrial Area

1. Factory site

(Industrial Area)

54.4 49

Residential area (Rural)

2. Patethan 47.4 41.6

3. Devkarwadi 51.7 40.2

4. Pilanwadi 49.6 39.1

5. Rahu 52.9 43.2

6. Telewadi 49.8 39.8

7. Arangaon 50.1 41.8

8. TakaliBhima 42.5 40.5

Noise Standard Limits

Area

Code

Category of Area / Zone Limits in dB(A) Leq

Day Time Night Time

A Industrial Area 75 70

B Commercial Area 65 55

C Residential Area 55 45

D Silence Area 50 40

As per The Noise Pollution (Regulation and Control) Rules, 2000

3.5 GEOGRAPHY AND GEOLOGY

3.5.1 Geography

The district of Pune, located in the state of Maharashtra, covers a total geographical area of

15.642 square kms. Being the second largest district in the state, it covers 5.10 percent of the

Chapter III


total geographical area of the state. The district is bordered by Ahmednagar district on the

north-east, Solapur district on the south-east, Satara district on south, Raigad district on the

west and Thane district on the north-west. The landscape of Pune district is distributed

triangularly in western Maharashtra at the foothills of the Sahyadri Mountains and is divided

into three parts: Ghatmatha, Maval and Desh.

3.5.2 Geology

Geologically, the entire District is consisted of Deccan traps. These volcanic lava flows arespread

out in the form of horizontal sheets or beds. However, laterite caps the summit of some of

thehills of high altitudes in the District. Laterite rock is ferruginous hard and massive and

generallyvaries in colour from dark red to yellowish and dark brown to dirty brown. A fresh cut

surface of thelaterite bed is usually soft but becomes very hard and tough on exposure to the

atmosphere.Trap rocks are generally barren of any economically useful and important minerals

but beinghard, dense and durable are most suitable for building purposes. These rocks are

generally used asroad metal, railway ballast and as an aggregate for concrete mixtures.Irregular

nodules of kankar and gypsum occur in the soil at a number of places especially in the

Eastern parts of the District. Kankar on burning yields good lime and is locally used for the

manufacture of lime for use in construction purposes.

3.5.2.1 Minerals

There are no major mineral deposits in the district. However, Sand, Murum, Stone and clay are

available in abundance, which can be suitably used for construction of roads and building.The

geological and mineral map of Maharashtra is given in Fig. 3.8.

Chapter III


(Source:http://www.portal.gsi.gov.in/gsiDoc/pub/MP30_GM_Maharashtra.pdf)

Figure 3.8: Geological and Mineral Map of Maharashtra

3.6 BIOLOGICAL ENVIRONMENT

3.6.1 Methodology

Ecological study of the area was comprised of conducting survey of the study area, noting

important ecosystems and habitat therein, diversity of floral and faunal elements by listing of

species and assessment of their existing baseline ecological condition.

http://www.portal.gsi.gov.in/gsiDoc/pub/MP30_GM_Maharashtra.pdf

Chapter III


Study area was comprised of 10 km radius considering proposed unit at the centre

Primary data was collected on floral aspects as well as on avifauna by visiting the study

area,

Data on different type of animals, including mammals, amphibians, reptiles, insects, etc,

have been obtained from secondary sources

Secondary data was collected from literature, forest department’s web sites and

discussion with local people/ NGO

3.6.2 Floral diversity of study area

Field survey was carried out during October 2017 to January 2018at and around 10 km area of

the site, data on floral distribution was collected mainly by field observation and collection of

specimens, interview with local people & literature available. Plants characters were noted in

the field. Collected plant specimens were identified with the help of keys to the families, genera

and species provided in the field guides and floras.

The project site is predominantly covered by cultivated species that includes large number of

mango (Mangiferaindica), coconut (Cocos nucifera), Gulmohar (Delonixregia), Amla, Banana,

Drum stick, etc. Acacia, neem, shirish, Palas, members of Ficusgrown naturally observed along the

road as well as in the open spaces and to some extent on the boundaries of farms. Wild shrubs

such as Lantana, Jatropha,Calatropis, Cassia, Ricinus, Salvadorawere observed. Within the

project site, there is no aquatic body.

3.6.3 Faunal diversity of study area

Survey was carried out at site & around 10 km area of the site, data on faunal distribution was

recorded mainly through information gathered from local people, literature available about the

area and from official sources such as forest department, district gazetteer, zoological survey of

India, etc.

Study of birds was conducted early in the morning when birds vocalize most, which in known as

the dawn chorus. It is time of maximum bird movement. Direct observation was carried out

with the help of binocular. Existences of birds are recorded by collecting their fallen feathers, by

listening/recording bird’s calls, by observing nest, etc. Field guides were used for identification

of birds. Common birds like little egret, common babbler, Indian myna, Indian robin, jungle

crow, purple sunbird, small green bee eater, house crow etc. were common and dominant. A

detailed list of the same is enclosed as annexure XII.

3.6.4 Observations within 10 km surrounding study area:

There are no threatened species of plants or animals reported from the said area. The area is

predominantly under agriculture. The species observed are matching to the habitat. Wildlife as

Chapter III


such is negligible and common to this region. River Mula and Bhima are two important aquatic

ecosystems of this area. However, the aquatic life is very minor (Due to constructions of dam in

the upper region, fresh water flow is very poor and mainly treated sewage from Pune and

adjoining sub-urban area is released into the same). Fishes are generally collected from artificial

ponds/lakes or imported from some other areas. Any national park or sanctuary is not situated

in 10 or 25 km radius of the project. Hence, ecology-biodiversity aspect is not very sensitive for

the said project.

3.7 SOCIO-ECONOMIC ENVIRONMENT

3.7.1 Introduction

In general, while studying development of any geographical area or regions, socio- economic

status of the population residing in that area, is considered as one of the prime indicators.

Developmental project of any magnitude will have some bearing on the living conditions and on

the economics of the local population. Similarly, the proposed unit will have its share of socio-

economic influence in the study area.

3.7.2 Methodology

Data collection on Demography of the area, infrastructure available, etc. through site visit, a

questionnaire, official web site of the district, district gazetteer, census of India and other

government offices.

3.7.3 Sources of Information

As per the scope of this study, the information on socio-economic aspects has been gathered and

compiled from several secondary sources. These include block office, Collectorate office,

Agriculture Department, Irrigation Department, Central/state Ground Water Board, Department

of Mines and Geology etc. The demographic data has mainly been compiled from the website of

Census of India 2011. The socio-economic details are briefly described in following sections.

3.7.4 Social Profile

Hinduism is the majority religion in Daund taluka with 82.22% followers. Islam (Muslim) is

second most popular religion with approximately 9.94% and Jain is 1.73 % presented in below

table

Table 3.11: Religious status of Daund taluka

# Hindu Muslim Jain

Daund (%) 82.22 9.94 1.73

(Source: Census Book, 2011)

Chapter III


3.7.4.1 Demography

Demography is the statistical study of populations, especially human beings. It encompasses the

study of size, structure and distribution of these populations and spatial or temporal changes in

them in response to birth, migration, ageingand death. Demographics are quantifiable

characteristics of a given population. The demographic details of Daund talukaand number and

percentage of SC, ST population is given in Table 3.12.

Table 3.12:Number and percentage of Scheduled Caste and Scheduled Tribe population in

Daund Taluka, 2011

# Total

population

Total Scheduled

Caste

population

Total

Scheduled

Tribe

population

Percentage of

Scheduled Caste

population to

total population

Percentage of

Scheduled Tribe

population to

total population

Total 331,046 45,819 8,434 13.84 2.54

Rural 324,183 42,226 8,059 13.02 2.48

Urban 6,863 3,593 375 52.35 5.46

Table 3.13: Sex ratio by sub district

# Total Urban Rural

Daund 939 933 971

The population with respect to Schedule caste and schedule tribes in Daund taluka is given

below-

Table 3.14: Demographic details with respect to SC and ST Population

# Total SC ST

Total 3,31,046 49,450 8,434

Male 1,71,166 23,259 4,306

Female 1,59,880 22,560 4,128

(Source: District Census Handbook, 2011)

3.7.4.2 Literacy Levels

Literacy is very important for overall development of the region. It improves the quality of

human resources. Literacy brings about fundamental changes in socio-economic development

of any area. The literacy rate was found to be 85.70% within 10km of study area. The literacy

details of villages in Daund tehsil is given below (Table 3.15).

Chapter III


Table 3.15:Number of literates and illiterates, literacy rate by sex in sub-Districts, 2011

# Number of literates and illiterates Gap in

Male

female

Literacy

rate

Number of literates Number of illiterates Literacy rate

Persons Male Female Persons Males Females Persons Males Females

Total 263,989 146,684 117,305 116,507 49,599 66,908 79.09 85.70 72.13 13.97

Rural 220,410 123,593 96,817 103,773 44,124 59,649 77.64 84.67 70.20 14.47

Urban 43,579 23091 20,488 12,734 5475 7259 87.32 91.66 82.89 8.77

(Source: District Census Handbook, 2011)

3.7.4.3 Occupation structure

Agriculture and related activities provide major employment opportunities for the locals.The

list of few industries in Daund taluka is given in Table 3.16.

Table 3.16: List of Industries& Sugar mill/ distilleries in the surrounding area

List of Industries Distance,

km

List of sugar mills/distilleries

With capacities

Distance,

km

Neosym Industries

Ltd

14.00 RaosahebPawarGhodganaga SSK

(2500TCD/30KLPD)

35

Mahesh Industries 14.50 Venkateshkrupa Sugar (2500TCD) 30

Auto Point

Industries

14.30 Anuraj Sugar (2500TCD) 30

Mutual Industries 14.50 Bhima Patas (5000TCD/45KLPD) 35

Praj Industries 15.50 Daund Sugar (3500TCD/90KLPD) 65

3.7.4.4 Settlement Details

There are few settlements in the 10km proximity of the site viz., Patethan, Takli-Bhima, Nhavi

Sandas, Rahu, Pimpalgaon, Khamgaon, Dahitane, Valaki, etc. and Daund tehsil has 23 villages

within 10 km study area.

3.7.4.5 Availability of Infrastructure

Availability of infrastructure and facilities denote the level of overall development in the study

area. The availability of facilities with regard to education, health, transport and

communication, water supply and availability of electricity are dealt with in the following.

Chapter III


Road and railway network

The site is well connected by road, railway as well as air network. It is approx.13.3 km away

from the state highway no. 27 and 13.27 km away from the national highway no. 9. Yavat

railway station is approx. 13 km from the project site. The international Airport of Pune

(approx. 35 km) is the nearest airport to the site.

Education facilities

The overall educational facilities available in Daundtaluka. Primary school, Degree colleges in

Daund taluka are available at a distance of approx. 07km from the factory site.

c. Health Services

Primary health centre (PHC) is available in village KoregaonBhivar and Shindewadi.Apart from

government medical facility, many dispensaries are available in nearby areas/villages.

d. Drinking Water Supply

Drinking water facility is available in almost all the villages in the study area. Groundwater

sources namely, well and hand pump are used as drinking water sources. This reduces water

borne diseases to certain extent but may cause problems if ground water quality degrades.

e. Crops

The district and this region is well known for vegetables such as tomato, brinjal and Ladies

finger. Amongst cereals wheat, gram, rabi, jowar and sugarcane are cultivated. Other crops

include cotton, Soybeans, Sunflower and Sesame.

g. Communication facilities

The district is also well connected by telecommunication and postal facilities to the rest of the

country. The telecommunication facilities are provided by private leading operators like Idea,

Airtel, Vodafone etc. There are various newspapers like Pudhari, Sakal, Loksatta, Maharashtra

times, Lokmat etc. getting circulated in the district, which includes national level, state level as

well as local level newspaper. Pune has efficient telecom and internet services. Aakashvani is

operating its transmission station from Pune. Doordarshan has a very widespread in the

district. Now a days, direct to home services of private operators are also becoming popular.

h. Post and Courier

Modernization has changed lifestyle of people and nowadays e-mails are preferred for

communication in the urban areas but importance of postal services cannot be neglected when

it comes to send letters, mails and parcels to the distant places.

Chapter III


i. Power Supply

Mahato (1982) has stated that, when the economic prosperity rises, the per capita electric

power consumption generally increases. Hence, progress of electricity can be a good indicator of

socio-economic development and they were by human resource development. Electricity is

available in all villages coming under study area.

j. Banking Services

Many of the leading banks such as Bank of Maharashtra, Kotak Mahindra, Dena Bank, and Co-

operative Banks are present in the study area. They are also providing ATM facilities.

3.7.5 Social activities initiated and implemented by SMSKL

Since its establishment the factory has shown concern about the social development of the

region. As a part of its social commitment, it has initiated and implemented many activities in

the region. Some of them are highlighted below

A. Cane Development Scheme:

Distribution of organic and chemical fertilizers for farmers in command area and

establishment of “ShrinathMhaskobaAgri Services” for guidance to the farmers

The soil testing laboratory has been set up for the farmers at factory premises, the

soil testing is provided free of charge. Ever year 4500 to 5000 samples were

analyzed

The independent sugarcane development department has been established in the

factory and it provides guidance to farmers about the sugarcane

Technical group is set up in Agricultural department to provide knowledge from

planting to Harvesting of sugarcane crop

Technical knowledge is being provided to farmers for implementation of 100% drip

irrigation into the farms

B. The factory operates a school i.e. “SakharShala” for cane harvesting labour during

crushing season. All expenses towards this activity is borne by the factory, including

fees, stationery, uniform, etc. It also provides mid-day meals to the students.

C. Establishment of “Shree JansevaPratishthanSanstha” at Shikrapur in 2014. Following

activities are implemented

“Late SambhajiraoKarpe” Ayurvedic Clinic

From the perspective of women empowerment, “Late KalavatiRaut” women training

center was established

Chapter III


Hostel facility for the economically backward people and cane harvesting farmers is

being running in the name of “Late Sambhaji Bhujbal”

D. Financial Assistance is provided by the factory to improve educational level of the Zila

Parishad schools in factory operation area. About 15 schools and 4500 students

benefitted by this.

E. Tree plantation is done by the mill every year, about 12,296 number of trees are planted

in the surrounding villages and 11,770 number of saplings are distributed among the

farmers at free of cost.

F. The factory is operating indigenous cattle rearing center at site for farmers to

understand the importance of indigenous cattle for agriculture

G. Health and medical checkup facilities for workers and their families

H. Construction of tar roads in the factory premises and surrounding villages by the factory

for better transportation

I. Participation in various schemes implemented by the central as well as state

government. Participated in “Jalyukta Shivar” scheme implemented by Maharashtra

government. Under this scheme, water conservation work has been done by the factroy

in Rahu, Kondhapuri and other surrounding villages. Four ponds have been constructed

having 7.5 Cr. Liters storage capacity and about 3500 farmers are benefitted by this

work. Total expenses for this work is about 7.63 Lakhs in year 2016-17

J. Under ‘Swach Bharat Abhiyan’, construction of toilets for cane harvesting labours and

for residential lobours

K. A clean campaign has been implemented by the factory on quarterly basis

3.8 OTHER ASPECTS

3.8.1 Traffic Details

The average traffic per day during season and off season is given in Table 3.17.

Table 3.17: Average Traffic per day

# Type of Vehicle During Season During Off- Season

1. HMV (Trucks, Tankers, Tractors 124 23

2. LMV (Car, Jeep) 04 01

3. Four wheelers 01 00

4. Two wheelers 325 25

Total 454 50

Chapter III


From Seismic Zone map (Fig. 3.9), it appears that, the proposed site is in earthquake zone III. In

this zone, the probable earthquake intensity of >5 Richter scale could be observed.

No defense installations or recreational sites, historically or archeologically important/ notified

sites, ecologically sensitive sites, national parks, sanctuaries, biosphere reserves present in

study area of 10km radius.

Figure 3.9: Seismic Zone Map of Maharashtra

Chapter IV


Chapter IV

ANTICIPATED ENVIRONMENTAL IMPACT

AND MITIGATION MEASURES

4.1 INTRODUCTION

It is a foregone conclusion that any industrial projects or developmental activity will have

positive and negative impacts. This project i.e. expansion of sugar and distillery unit is also

anticipated to have environmental and social impacts. This chapter focuses on identification of

these impacts to the maximum possible extent. These impacts are identified based on the

activities involved in the project, site specific physical as well as environmental conditions,

quantities and/or characteristics of various pollutants, factors responsible for the impact and

direct/secondary sources of impact. The project activities are divided into two parts viz.

construction phase including erection & commissioning; and operation phase i.e. actual

production. Impact assessment is done for both the phases.

4.2 CONSTRUCTION PHASE

Presently, the project has following infrastructure.

Existing sugar unit with cane yard, milling, boiling and processing units, boiler with

stack and wet scrubber, spray pond, bagasse yard, sugar godown, molasses storage

tanks, ETP, etc.

Distillery unit including fermentation, distillation, bio-digester, MEE, cooling towers,

compost yard, spentwash storage lagoons, ETP/CPU, storage tanks for raw material and

finished products

Existing greenbelt of approximately12 acres

Raw water reservoir, DM plant

Other – such as asphalted internal roads, firefighting system, captive power source

Since it is an expansion project, the major activities during the construction phase of the

project will be:

Installation of various machineries in the existing sugar and distillery unit

Enhancing capacities of units such as storage of raw material and finished products, ETP

and CPU, spent wash storage lagoons, etc. as per requirement

Preparation / processing of construction material

Loading / unloading of construction material

Transportation of material

To & fro transportation of workers

Disposal of the liquid and solid waste generated by the temporary work force employed

for the construction

Chapter IV


4.2.1 Land Transformation

The proposed project will be within the existing sugar complex. The land is under the

possession of the project proponent. The management has made provision of 7.5 acres of land

for the expansion of sugar and distillery units. Out of which, it is estimated that 20,000 sq.m

(5.0 acres) will be built-up area where expansion units, internal roads, and other setup will be

installed/developed. Since, the existing land (allocated for the said activity) is flat, barren and

therefore, construction will take place with just minor leveling activity. It is anticipated that

approximately 3,000 tons of top fertile soil layer (Considering 15 cm layer) will get removed

due to this construction. In addition, it will generate excavated material such as murum and

stones in moderate quantities. Following measures will be adopted to minimize the potential

impact.

Upper fertile layer of soil will be kept separately and reused for the development of

greenbelt, mainly along the boundary of the unit and in areas where soil strata is very

poor.

The excess of excavated soil, stones and other earth material will be used within the

project site, mainly for foundation of various structures and for expansion of internal

roads (As per requirement)

Construction waste, debris will be disposed off according to their characteristics;

recyclable material will be sold to recycling agents; in any case construction waste will

not be dumped outside the factory premises, particularly into any water body, wetland,

community land etc.

The runoff from the construction site will be controlled by ditches and will not allowed

to runoff into any water bodies or percolate in the surrounding soils

Due to minor construction and erection of structures, a permanent change will take place in the

topography of the respective areas. However, construction activity will be carried out in

planned manner and thus any negative impact on the site specific drainage (if any) will be

avoided.

4.2.2 Air Environment

Construction equipment such as RCC machines, cranes, road rollers, water tankers, etc will be

used for proposed construction work. These all produce noise and often generate dust. Thus,

noise and dust are anticipated as a major impact causing factors.

Following measures are proposed to minimize/control dust

Barricading the dust generating or high noise generating areas

Sprinkling of water while loading/unloading the dust generating material

Sprinkling of water on open, dust generating plots

Storage of cement bags in covered area

Chapter IV


Use of electrically operated machinery instead of diesel operated wherever

feasible to reduce air and noise emissions,

Existing internal roads are asphalted, these roads will be extended as per

requirements. Thus, dust generation from roads due to vehicles will be negligible.

Some administrative controls, such as a) permitting only maintained machineries for

construction work b) developing code for the civil and engineering contractors to follow the

environment management plan c) work permit for noise producing activities only during day

time d) engaging authorized suppliers and contractors which follow the laws and rules related

to safety, health and environment e) allowing vehicles which are well maintained and having

valid PUC certificates

Considering overall volume of the construction activity, it will last for short period of about six

months. Dust (particulate matter) and noise are anticipated to cause negative impact

particularly near the construction areas and along the transportation route. There are no

residential areas or other sensitive receptors in 500 m radius of the proposed site. Moreover,

the area allocated for the proposed project is sizable and the construction work will take place

smoothly without any congestion.

The impact due to dust and noise will be temporary and localized. Further, it will be

reduced/controlled by adopting above mentioned mitigation measures. Thus, localized and

short term minor negative impact is anticipated on ambient air quality as well as noise due to

construction activity.

4.2.3 Water Environment

The sugar complex is having ample open space to accommodate construction labour. Good

quality drinking water facility is available at existing sugar as well as distillery unit. Similarly,

toilet blocks are also available at various locations in these units. The same will be used by the

construction labour and workers. Thus, one of major source of surface water contamination will

be eliminated due to availability of such infrastructure at site. Run-off from construction site is

generally acts as a major source of surface water pollution.

Mitigation Measures: Based on the infrastructure available and site specific situations

following measures are proposed.

Use fresh water with utmost care, use spray pond overflow and sugar ETP treated water

for construction and dust suppression activities. It will help to reduce freshwater

requirement

Minimize wastage of water. Usually, it becomes run-off

Proper precaution to prevent the runoff from construction site from mixing into the

nearby surface and/or ground water resource

Chapter IV


Allow and insist construction labour to use toilet blocks available in the existing factory

premises

Total prohibition on dumping/throwing any solid waste, excavated material from

construction activity into any of the nearby water bodies

By implementing these measures, it is anticipated that overall impact of construction activity on

water environment will be negligible and short term.

4.2.4 Ecology

As mentioned earlier, in the present expansion case, the machinery will be installed in the

existing industrial sheds, Therefore, actual construction activity will take place on site without

cutting of any tree. Thus, construction activity is anticipated to cause no negative impact in the

form of loss of existing space (habitat), permanently. Runoff from construction site will be

managed properly to prevent contamination of nearby surface and/or ground water resource.

Hence, probability of disturbance of surface aquatic ecosystem is anticipated only in accidental

case. Construction activity is anticipated to cause negative impact on soil micro-fauna.

Construction vehicles are anticipated to disturb fauna dwelling along the roads. It will cause

short term, localized negative impact.

4.2.5 Natural Resources

The proposed activity will require natural resources such as minerals e.g. metals, mainly steel

for construction and copper for distillation towers. Glass and aluminum will be required in

minor quantities. Lime-stone will be used indirectly, in the form of cement. Stones and soil

excavated during the construction will also be utilized within the premises for various activities

such as leveling, internal roads, etc.

4.2.6 Socio-Economic aspects

Since, the project doesn’t require any new land and purchase thereof. Therefore, there are no

rehabilitation and restoration issues involved in the project. In the present case, construction

activity will require limited unskilled and skilled workers. Workers employed will be mainly

from nearby areas only. Thus, it will generate employment opportunities to approx. 364 skilled

and unskilled persons. Additionally, activities such as transportation, fabrication, installation of

machinery, etc. are anticipated to provide employment to local contractors, as well as vendor,

material suppliers, etc. Therefore, positive impact anticipated on the socio-economic

environment during the construction phase of the project.

Chapter IV


4.3 OPERATION PHASE: AIR POLLUTION

4.3.1 Transportation

Transportation activities cause air pollution through vehicular exhaust, dust from roads,

loading-unloading of material, etc. In present case, raw material transport such as sugar cane is

done through bullock cart and tractors. Bagasse will be used as a fuel and will be from captive

(sugar mill) source. Molasses will be raw material for distillery and it will be made available

from the sugar mill. Other raw material such as urea, de-foaming chemicals, sulfur, etc. will be

purchased in bulk and thereby daily transportation will be avoided. Therefore, transportation of

raw material anticipated to have minor negative impact on air quality.

Transportation of finished products i.e. sugar as well as RS/ENA or AA usually takes place in

bulk. Considering the gross collective capacity of storage tanks (12 numbers) 6,000m3 it will

require about 400 tankers (considering each tanker of 15m3 capacity). In addition, the

pressmud will be transported in bulk through tractors and dumpers up to compost yard. Sugar

is also sold in auction at periodical interval. Therefore, transportation of the same will also be in

bulk (not on daily basis). Hence, this is anticipated to cause increase in particulate matter and

NOx, particularly during the period/days of transportation. Vehicles of employees and visitors

will be a regular source of emissions. The project is going to provide new employment to

approximately164 persons, in addition there will be some contractual or seasonal employees.

The project is located in rural area, where people prefer two wheelers (motor cycles, scooters,

etc) to commute. Hence, about 95% of such vehicular emissions are anticipated from two

wheelers (~350 per day) and remaining 5% due to passenger cars and other types of vehicles

(~4-5 per day).

Therefore, transportation activity of the proposed project is anticipated to cause increase in

vehicular emissions. The impact will be at periodic interval for short term and beyond 10 km

study zone.

4.3.1.1 Preventive, control and mitigation measures

Asphalted roads are provided inside the premises, which will be extended as per the

requirement (in proposed expansion)

Provision of adequate parking space for goods as well as staff vehicles

Engage authorized transport agency for goods transport on the term to use well

maintained vehicles for all transportation activities

While bulk transportation of raw material/finished product, manage the vehicles in

such a way that on-site waiting period for vehicles will be minimum. This will help

in reducing the risks of traffic congestion, minor accidents and overall air pollution.

Provision of separate entrance and exit lanes/gates for vehicles

Chapter IV


Strict prohibition on washing and maintenance of vehicles on site or in parking area

All roads with street light and proper signage at strategic locations

Main gate/s with 24x7 security arrangements

4.3.2 Manufacturing process

The manufacturing process is likely to generate two forms of air pollutants i) from burning of

fuel to generate steam and ii) from processes

4.3.2.1 Emissions due to burning of fuel

Bagasse will be the main fuel and biogas from primary treatment of distillery spentwash will be

theauxiliary fuel. Bagasse is a byproduct of sugar unit. Both bagasse as well as biogas are

renewable energy sources. Use of renewable energy sources over fossil fuels is encouraged all

over the world. Biomass energy is carbon neutral. The analysis of bagasse is given as bellow.

Table 4.1: General characteristics of bagasse

Parameter Value (in %)

Carbon 40-45

Hydrogen 2-6

Oxygen 40-45

Nitrogen 0.15-0.20

Moisture content 50%

Ash content 1.5 - 2.00%

Sulphur <0. 02

Calorific value 2,250 kcal/kg

Bagasse analysis report shows that the elements such as nitrogen and sulfur are present in trace

quantities. Thus, the generation of sulfur-dioxide (SO2) and oxides of nitrogen due to

combustion of bagasse are anticipated to be very low. Flue gasses generated due to burning of

bagasse will produce ash. Therefore, particulate matter is considered as the main source of air

pollution.

Estimated ash generation from the project is as follows.

Sugar cane crushing season 6,000 TCD

Bagasse required to generate 2400MT steam per day

(generally observed bagasse to steam ratio 1:2.2)

1091 TPD

Total Ash generated @2% 21.82 TPD

Chapter IV


In case of fuel bagasse, fly ash generation is usually 70% of total ash generated. Venturi

wet scrubber is installed to control fly ash, which will be entrapped and collected as

slurry.

Bottom ash 6.546 TPD

Fly ash generation 15.274 TPD

Fly ash controlled by wet scrubber @95 % 14.51 TPD

Fly Ash emission 0.763 TPD (8.83g/s)

Sulphur Dioxide (SO2): (Only bagasse used as fuel)

Bagasse required to generate 2400MT steam per day 1091TPD

Sulphur dioxide emissions

(Sulfur content in bagasse 0.02%)

0.4364 TPD (5.05g/s)

Apart from this, trifling fugitive dust emission due to opening and leaks in duct and

manholes and also from ash handling operation at unloading and transfer point are the

minor pollution sources.

Sulphur Dioxide (SO2): Another source of air pollution could be the SO2 formed due to burning

of biogas in the sugar factory boiler. The H2S present in the biogas will release the sulphur; that

will react with the oxygen present in the air to form SO2 the reaction will be as follows.

2H2S + 2O2 SO2 + 2H2O + S ------------------ (Equation 1)

2(2+32) + 2(16) (32+32) + 32 + 2(2+16)

68 + 64 64 + 32 + 36

Estimated Biogas production (Considering COD 1,20,000 mg/liters) = 11,700 m3/day

General composition of biogas produced from distillery spentwashis Methane (CH4)-

64%, Carbon dioxide CO2-34%, Hydrogen sulfide (H2S)Max- 02%

Amount of H2S from 18,190 m3 Biogas = 363.8 m3/day OR

(Considering the density of H2S =1.539kg/m3) = 559.9kg/day

As per equation I – 68 gm of H2S combustion required 64gm of oxygen i.e. 94% of total

volume.

559.9 x 0.94 = 526.3 kg oxygen required

Since the amount of Oxygen required = amount of SO2 generated

Total SO2produced = 526.3 kg/day = 21.92 Kg/h

Thus, SO2 Emission will be 6.09 g/seconds

Chapter IV


The quantity of ash generation, particulate matter and SO2 emission during off-season –

considering bagasse along with biogas (subsidiary) as a fuel.

Bagasse requirement for distillery to produce 8TPH steam 87.27 TPD

Bagasse saved during off season due to use of biogas

Biogas generation 18,190 m3 per day

1000m3 of biogas = 2.05MT of bagasse

37.3 TPD

Total bagasse required 50 TPD

Ash content @2% 1 TPD

Bottom ash 0.3 TPD

Fly ash generation 0.7 TPD

Fly ash controlled by wet scrubber (considering efficiency 95%) 0.665 TPD

Fly Ash emission 0.035 TPD (0.4g/s)

Sulphur Dioxide (SO2):

Bagasse required 50 TPD

Sulfur content in bagasse 0.02% 0.01 TPD

Sulphur dioxide emissions from burning of bagasse

Sulphur dioxide emissions from burning of biogas

Max. Total SO2 emissions

0.23 g/s

6.09 g/s

6.32 g/s

In case of NOx, there are mainly two opportunities for NOx formation. They are:

1. Thermal NOx - The concentration of “thermal NOx” is controlled by the nitrogen and

oxygen molar concentrations and the temperature of combustion. Combustion at

temperatures well below 1,300(C (2,370(F) forms much smaller concentrations of

thermal NOx

2. Fuel NOx - Fuels that contain nitrogen (e.g. coal) create “fuel NOx” that results from

oxidation of the already-ionized nitrogen contained in the fuel.

Theoretically, Nitric oxide (NO) is generated to the limit of available oxygen (about 200,000

ppm) in air at temperatures above 1,300°C (2,370°F). At temperatures below 760°C (1,400°F),

NO is either generated in much lower concentrations or not at all. In case of bagasse fired

boilers, the temperature usually observed is around 850-10000C, mainly due to high moisture

content of bagasse (~50% moisture). This temperature is much lower for formation of NO,

which is usually formed above 13000C. However, as a worst case scenario it is assumed that the

NO formation may take place at 50% rate. Secondly the bagasse analysis data shows that, the N

percentage is less than 0% which is in the range of 0.10 to 0.20%. Therefore, an average of

0.15% of N content is considered while calculating NO emissions in the present case. Thus, the

second probability of fuel NOx becomes insignificant.

Chapter IV


4.3.2.1.1 Dispersion modeling for air pollutants

The impact of proposed project on ambient air quality of the study zone was studied with the

help of simulation studies. This helped to understand probable incremental concentration of

particulate matter (PM10) and Sox generated from burning of bagasse and biogas. Presently the

sugar mill is operating two boilers (72 + 32 TPH) of total capacity of104TPHwith wet-scrubber

as air pollution control equipment and 65-mtr height stack. The same will be used for proposed

expansion. During cane crushing season, the distillery unit will use low pressure exhaust steam

from the captive steam turbine generator unit of the sugar mill. No additional fuel will be burnt

for steam generation during season. Flue gases will be released through stack of 65 m height.

Wet scrubber is installed on existing boilers, which is >96% efficient to trap particulate matter.

During off-season, the steam requirement (8TPH) will be fulfilled from existing 32TPH boiler.

Therefore, during cane crushing season emissions of pollutant will be almost same for

particulate matter, as in the existing situation. The baseline air quality data presented in chapter

III (Table 3.9) reveals that PM10 values observed at all locations were within NAAQS. However,

increase in SO2 emissions is anticipated due to use of biogas.

Prediction of impacts on air environment was carried out employing mathematical model -

AERMOD view dispersion model 9.2 software developed by Lakes Environment Software, Canada.

This model was used for simulations from point sources. Modeling has been done considering

boiler as source and it is at center of grid for prediction of pollutant. The micrometeorological

data collected from site during summer season, used as input data. For the site-specific mixing

heights, CPCB document PROBES/88/2002-2003 referred. The dispersion model input data is

given in table 4.2

Table 4.2: Dispersion Model Input Data

Parameters Unit Stack Attached to Boiler

Stack height m 65

Stack diameter at exit/top m 3

Stack exit gas velocity m/s 8

Stack gas temperature at exit Deg. C 140

Fuel (Bagasse) requirement TPH 45.45

Ash content of bagasse % 2

Emission rate of SPM* g/s 8.83

Emission rate of SO2# g/s 5.05

Emission rate of SO2## g/s 6.32

* After fly ash removal efficiency of pollution control equipment (wet-scrubber) 95%

# Sulphur, considered 0.02% in bagasse

## SO2 emissions from burning of biogas and bagasse during off-season

Chapter IV


Figure 4.1: Isopleths showing incremental ground level concentration of particulate matter

(Short Term 24 Hourly) during cane crushing season

Figure 4.2: Isopleths showing incremental ground level concentration of SO2 (Short Term

24 Hourly) during cane crushing season

Chapter IV


Figure 4.3: Isopleths showing incremental ground level concentration of SO2 (Short Term

24 Hourly) during off-season – bagasse + biogas as a fuel

4.3.2.2 Prediction

The predicted results with baseline concentrations are given below in Table 4.3 while

incremental dispersion trend is shown as isopleths in Figure 4.1, 4.2& 4.3.

Table 4.3: Resultant Concentrations Due To Incremental GLC's

Description Concentration µg/m3

PM SO2

Maximum rise in GLC During season 1.48 0.84

During off-season Minor 1.24

Direction of Occurrence and distance W (0.8 Km)* W (0.8 Km)*

Coordinates of maximum GLC 180 36’ 20”N

740 43’ 06” E

180 36’ 20”N

740 43’ 06” E

Baseline Concentration reported nearby GLC

(at 0.5 km NW)

53.02

(Patethan)

19.91

(Patethan)

Total Concentration (Post project scenario) 54.50 21.15

NAAQS PM10 100 80

*The distance is measured from stack to the receptor of maximum GLC

* The baseline concentration (98th percentile) recorded at station Patethan at 0.4 km, is the nearest to the incremental GLC site

Chapter IV


a. Observation

The results of mathematical modeling of air pollutant dispersion (for particulate matter and

SO2) indicate that incremental concentration at ground level of these pollutants will be within

the prescribed National Ambient Air Quality Standards (NAAQS) for residential & rural areas. Other

major observations of dispersion modeling study are as follows.

Maximum increase in the concentration of PM will be 1.48g/m3 and SOx by

1.24g/m3towards west at approx.0.8 km distance from stack; This area is

predominantly occupied by agricultural vegetation

Nearest residential area is village Patethan towards NW at ~2 km from site

From the results derived from the mathematical modeling study, it is observed that

resultant concentration of these air pollutants in downwind direction will be well within

the national ambient air quality standards prescribed by CPCB in Nov. 2009.

4.3.3 Other sources of air pollution

Processes: Fermentation process produces carbon dioxide (CO2). It is anticipated that, 42 TPD

of CO2 will get produced from the distillery unit (@ 55 KLPD capacity). This CO2, will be of

biological origin, i.e. liberated from an agro-based waste material. Hence, it is assumed to be

neutral for GHG and therefore a minor source. In addition to this, composting process for the

disposal of spentwash and ETP process will produce CO2 and methane. Therefore, these

processes will be carried out in aerobic conditions to maximum extent. This will help in

reducing generation of methane and CO2.

Biomethanation process of spent wash disposal will produce, methane along with carbon

dioxide. This methane (biogas) will used as a fuel for boiler. Sulphitation process generates

sulfur dioxide in minor quantities.

Fugitive dust/particulate matter: Fugitive sources will be mainly, from vehicular movement and

bagasse storage. Bagasse will be transported to boiler through closed conveyers, hence fugitive

dust will be negligible. Bagasse will be utilized immediately and thus minimum stock will be

maintained. Towards end of the crushing season, all bagasse will be properly bailed and

stacked.

Odor is anticipated mainly due to storage of spentwash and partly from composting activity

Preventive, control and mitigation measures

Use of bagasse and biogas as a fuel which is renewable energy sources

Increasing green belt by 2.5 acres around the process unit

Methane produced from biodigester will be used as a fuel; flare unit is an alternate

arrangement when it will not be used as a fuel; in any case, methane will not be released

directly into the atmosphere

Fermenters will be closed

Chapter IV


Composting will be done aerobically using turning machines

Ash slurry as well as bottom ash will be used to mix in compost since bagasse ash is rich

in potash or will sold to bricks manufacturer

4.3.4 Impact assessment

Air quality: Air dispersion modeling study shows that, there PM concentration will increase by

1.48g/m3 and SO2 concentration by 1.24g/m3 near the project site. The resultant ground

level concentration (after adding incremental load) anticipated to be within NAAQS. Minor

negative impact is anticipated due to stack gas emissions and transportation activities of the

proposed project.

Ecology and biodiversity: Minor negative impact is anticipated on avi-fauna due to stack gas

temperature (approx 90oC), and on flora/plants in close vicinity of the project due to dust

(particulate matter).

Human health: Probability of respiratory or similar disease due to proposed increase in air

pollutant is very rare, unless the person/s get exposed, beyond TLV.

Manmade environment: Dispersion modeling study indicates that pollutant levels will be within

NAAQS during operation phase of the project. Thus, impact on manmade environment is

presumed to be negligible.

4.3.5 Noise

The principle sources of noise are boiler, STG and machinery (mainly motors and pumps).

Additionally, handling of bagasse is also considered as a noise source. Noise generated in the

boiler and STG section will be localized & confined because it will be under shed/covered area.

Thus, generated noise will be localized. Control measures to maintain noise level within the

standard limit (of 75dB (A) for day time and 70 dB(A) for night time) are as follows.

The rotating equipment to be maintained by periodical oiling and/or greasing

Installing machines and equipment of standard make as well as using spare parts of

standard make (complying with IS or other international standard)

DG set from a manufacturer that meets CPCB’s criteria for noise

Developing greenbelt or barriers to reduce noise levels

The project involves transportation of raw material (sugar cane) finished products (Sugar and

alcohol) and to some extent press mud, which is likely to increase daily vehicle density by 30-

40% in the existing load. It was observed that, during peak period, the vehicle density on main

road i.e. is around 450 vehicles per day. This road connects to Pune- Hyderabad national

highway on one side and Pune-Aurangabad state highway on the other side. Therefore, this

minor increase will easily get accommodated. Thus, this additional load of transportation will

not cause any traffic congestion. Considering this, it is anticipated that the project will cause

Chapter IV


minor negative impact due to noise, particularly during bulk transportation of products along

the transport routes and in the work premises.

4.4 WATER ENVIRONMENT

4.4.1. Preventive, control and mitigation measures

Spentwash of 440 m3/day (8 L/L of alcohol) will first treated in bio-digester to produce biogas

from this organic rich wastewater followed by this it will be sent to multi effect evaporation unit

to reduce its volume from 440m3 to 88 m3. Then it will be sent to bio-composting process where

it will be mixed with pressmud (a solid waste from sugar mill) to produce compost; thus

achieving ‘zero liquid discharge’ for this highly polluted entity. Spentwash storage lagoons and

the compost yard will be constructed as per CREP guidelines (Refer figure 2.11 to 2.14 of

chapter II pp. 2.37 to 2.39)

CPU Treatment as per following: About 350 m3/ day of condensate will generated from MEE

unit. The condensate will be cooling through sprinkling in 150 M3 capacity tank. Followed by

enzymatic reaction. Treated condensate will be utilized for cooling tower makeup and molasses

dilution.

4.4.1.1 Reuse of water (after proper treatment)

Wastewater due to cleaning and washing, spentlees and condensate water will be treated in

CPU. This unit will comprised of cooling followed by enzymatic reaction. Treated water of 352

m3 per day will be used for dilution of molasses, cooling tower make up, irrigation, or cleaning

activities, etc.

4.4.1.2 Recycle of water: Blow down water from boiler and cooling tower will be cooled in

ponds and recycled thereafter.

4.4.1.3 Conservation of water: Rainwater harvesting practice is accepted by industry to

improve the ground water aquifer and partly fulfill the requirement during startup of industry.

4.4.2 Impact assessment

Water availability: Permission is available with the factory to draw water from Bhima river. This

water is reserved for industrial activities. Hence, no negative impact on demand of other users

in normal situation. Further, reuse and recycle of water will save significant amount of

freshwater intake.

Water/aquatic environment: No negative impact is envisaged on water environment as well as

aquatic ecosystems of the surrounding area due to achieving ‘zero liquid discharge’ for distillery

unit as well as for sugar unit (by use of ETP treated water for own agricultural plots and

gardening). Negative impact is envisaged in case of accidental leakages and spillages of

Chapter IV


spentwash. In such circumstances, severity of impact depends upon nature and magnitude of

the accident.

Air environment: minor negative impact due to odour of spentwash and due to generation of

methane and CO2 from composting process

Soil Environment: Due to impervious lagoon and compost yard, probability of soil

pollution/ground water contamination due to percolation of spentwash is negligible. Hence, no

negative impact is anticipated. The compost prepared from spentwash, pressmud and solid

waste filler material will help to recycle soil nutrients, thus positive impact is anticipated.

Sugar mill effluent will also be treated properly in ETP and reused mainly for irrigating own

agricultural plots and watering the greenbelt. All effluents will be transferred through proper

drainages or impervious pipelines. Therefore, probability of soil contamination due to

effluent/wastewater from the project is negligible.

Ecology and biodiversity: No negative impact is anticipated, composting process usually attracts

avi fauna due to availability of micro-organisms as a food, thus increase in bird diversity is

anticipated from composting process for spentwash disposal.

4.5 SOIL ENVIRONMENT

Table 4.4: Solid Waste and its Management

# Waste Quantity (tons per season)


1. Sugar ETP Sludge 35 Disposal into land/soil

Sold to the member farmers/or used on own plot

Organic

2. Ash

3,927 Mixed with bio-compost Disposal into land/soil

Used as manure/soil enriching material

Inorganic

3 PMC 43,200 Composting Soil conditioner Organic

4. Oil & Grease 4-5 KL Remove by oil skimmer

Use for boiler -

Distillery Unit

1. Yeast Sludge 50 Composting Used as manure/soil enriching material

Organic

2. Boiler Ash (off season of sugar)

157 --- Sold to the brick manufacturing unit

Inorganic

3. Sludge from bio-digestors,

70-80 Mixed with bio-compost

4. Distillery CPU 20 Composting Used as manure/soil Organic

Chapter IV


Sludge enriching material

5. Spent oil from DG set

0.1-0.2 KL - Spent oil will be burnt in boiler

-

4.5.1 Preventive, control and mitigation measures

Press mud cake (filter cake) generated in the sugar unit will be used in the composting process

of distillery, hence it is not considered as a waste but a by-product. Therefore, main solid waste

from the project will be ash generated due to burning of bagasse, sludge from fermentation unit,

biodigester, ETP/CPU. Of these material, ash from bagasse is usually rich in potash and hence, it

will be mixed with compost for disposal. Sludge generated from various above mentioned units

will be organic in nature and therefore, it will also mixed with compost for safe disposal.

Packaging material and similar type of waste will be given to recyclers, according to its nature.

Such material will not be burnt in open or disposed off anywhere on land.

4.5.1.1 Hazardous Waste

The only hazardous waste likely to be generated in the project will be the scrap oil from DG set.

However, the DG set will be used only in case of total power failure i.e. captive as well as failure

of power supply from Electricity board. Thus, the quantity of used or scrap oil is assumed to be

very minor. This waste oil can be disposed off safely by giving it to authorized hazardous waste

oil dealer. Alternatively, it can be used as a fuel for the boiler along with bagasse during startup

phase.

4.5.2 Impact Assessment

Soil Environment: no negative impact is envisaged on soil due to solid waste. Bio-compost

produced from spentwash-pressmud and mixing of degradable solid waste will have positive

impact on soil. Organic carbon and soil nutrients will get recycled by the process.

Ecology and Biodiversity:No negative impact envisaged due to safe disposal of solid waste;

enhancement in micro-flora due to compost is anticipated.

Water environment:No negative impact envisaged due to safe disposal of solid waste.

4.6 ECOLOGY AND BIODIVERSITY

Generally, an impact of industrial activity on ecology and biodiversity is observed due to

following major reasons.

Tree cutting/ removal of vegetation

Habitat destruction/disturbance

Disturbance to wild life and threat to rare, endangered flora and/or fauna

Pollution

Chapter IV


In case of proposed project, no tree cutting or habitat destruction is involved. There is no

national park or sanctuary or biosphere reserve in 10km as well as 25km radius of the site.

Rare, endangered species of plants or animals are not recorded from the region.

In the following part, likely impact or cause of impact is discussed considering the site specific

conditions and facts.

1. Impact on terrestrial ecosystem

a. Habitat alteration

Proposed project is dependent upon agriculture for raw material i.e. sugar cane. Molasses,

bagasse and pressmudare by-products of sugar mill which directly depends on cane availability.

With reference to Table 2.1 and 2.2 (Chapter II)it is observed that in normal rainfall situation,

adequate amount of cane is available to sugar mill. The management of SMSKL is encouraging

local farmers to increase yield and thus, achieve sustainable cane availability. Therefore, there is

no need of converting other land (pasture, grassland, fallow, etc.) into agricultural land. The

only possibility is that, the area under cane may get increased or decreased depending upon the

rainfall and water availability through irrigation schemes. Thus, issue of wild habitat alteration

is envisaged to be insignificant.

Proposed project involves installation of few types of machinery in sugar and distillery unit as

well as modify the ancillary setup as per the requirement. This will be done on an open land

available within the existing sugar factory premises. Thus, habitat alteration is also anticipated

to be negligible and its impact on the ecosystem at site and surrounding will be insignificant.

b. Habitat disturbance

i) Transportation- Wildlife as such is very limited and it comprised of common species which

are usually observed in the vicinity of residential area(Refer annexure for details of flora and

fauna). Traffic density in this area is also very limited.Thus, minor negative impact is envisaged

in the form of disturbance due to increase in the transportation (and noise associated with it).

This impact will be localized. It will be comparatively high during cane crushing season.

ii) Odour- Odour is anticipated mainly from spentwash storage. Spentwash is having sweet

odour, which is not obnoxious or repellent as such. This odour may be sensed in roughly 4-5 km

radius. Village and population density in this area is limited and hence, disturbance due to

odour is envisaged to be minor.

Preventive measure: Use only existing road network. Don’t construct any new road/s. This will

help in preventing ecological disturbances in the area.

Chapter IV


2. Impact on aquatic environment

a. Due to water drawl-SMSKL has permission of Irrigation Department to lift the water

from Bhima river.Due to recycling of water and use of ETP/CPU treated water, fresh water

requirement of the proposed project will be reduced to maximum possible extent. Thus, existing

permission is adequate to fulfill the requirements of proposed project. It will not draw any

additional fresh water from any other source/s. Therefore, negative impact on aquatic and

terrestrial fauna due to water drawal by the project is envisaged to be insignificant.

b. Due to discharge of pollutants-Generally, air, water pollutants and solid waste are the

major causes of ecosystem degradation and/or disturbance due to an industry. In case of air

pollution, fly ash gets released through stack gases is likely to get settled mainly in 2-3km radius

area and this may cause adverse impact on flora. In this case, the air dispersion modeling study

reveals that the ground level concentration of PM (during operation phase) in ambient air will

remain within the NAAQ standard limits(Refer fig. 4.1-4.3 and table 4.3).Dispersion modeling

study concludes that the maximum increase in particulate matter after proposed expansion will

be of 1.48µg/m3. This increase is very negligible. The factory maintains its air pollution control

system regularly. Therefore, there were no complaints from farmers of the neighboring areas

for falling of ash. Hence, this micro increase in the concentration of suspended particles is

envisaged to have no negative impact on the health of human, vegetation as well as animals.

In the existing distillery unit, spentwash - highly polluted wastewater - is treated by

biomethanation followed by multi-effect evaporation process and finally disposed-off through

composting process. Other wastewater from distillery such as spentlees and condensate are

treated in existing ETP/CPU. Treated water is reused in the process or cooling purpose to

maximum extent and remaining water is used for greenbelt. Treatment facility will be modified

suitably for the proposed expansion. Similarly, in case of sugar unit, effluent generated is mild in

nature as compared to distillery. This effluent is gets treated in the sugar ETP. Treated water as

well as spray pond overflow are used for irrigation purpose (own plots). Considering these

existing practices, wastewater will not be released into any of the ground or surface water

bodies. Hence, it is envisaged that, air and water pollutants from the proposed project will have

no negative impact on surrounding ecosystem.

The wastewater generated will be treated and recycled/reused for greenbelt, which is

anticipated as positive impact for the conservation of resource as well as efficient utilization of

it. Solid waste generated in the project i.e. bagasse ash, sludge from ETP, fermentation unit and

biodigester are organic in nature and ash is rich in potash. It will be mixed with biocompost and

added to soil. Thus, nutrients will get recycled and soil enrichment will take place. This is

Chapter IV


anticipated as another positive impact on the land and surrounding eco-system. Large numbers

of microorganisms, worms and insects gets developed during composting process. These

elements attract birds and reptiles. Thus food chain/web gets strengthen due to the process,

which will be another positive impact.

The factory has developed greenbelt for existing unit and thus, biodiversity is established in the

premises. This greenbelt will be enhanced by 2.5 acres in proposed expansion project. Thus, it

will provide food and shelter to many faunal elements. It will also help in improving the

aesthetics. This is another positive impact anticipated due to the project.

3. Impact Due to Project Lighting

The project is expansion of existing sugar and distillery units. These units are operated under a

covered area similar to workshop. Therefore, lighting arrangements are simple and light

penetration is mainly confined to industrial premises. The road lights and lighting near

ancillary units is mainly to avoid accidents but it is normal and not glaring or intense. There are

plenty of open spaces and tree barriers in the surrounding. These precautions will help in

reducing adverse impact.

In the study area, wildlife is very limited. According to local villagers, there is no sighting of apex

carnivores such as leopard, hyena, fox, jackal, etc. Amongst herbivores domestic animals and

wild hares are common. Presence of deer and antelope family members is not reported in the

study zone. It is envisaged that the light arrangements of the proposed project will have minor

impact on the movements of nocturnal animals as well as on plants in the close vicinity of the

project.

Overall Preventive, control and mitigation measures

Greenbelt development

Adherence to zero liquid discharge and safe disposal of solid waste

Adequate measures to prevent, control and mitigate air, noise pollution

Impact Assessment

Minor negative impact is anticipated from following activities.

Due to particulate matter emissions from stack and vehicles, impact on flora in the close

vicinity of the site and along the transportation route

due to thermal pollution from flue gases, localized impact on avian fauna

Positive impact is anticipated from following activities.

Increase in the greenbelt - helpful to maintain and enhance the biodiversity

Composting process, for enhancing soil micro flora as well as supporting food chain

Chapter IV


4.7 IMPACT ON SOCIO-ECONOMIC ENVIRONMENT

The proposed project is going to be beneficial in following ways

The project is agro-based.Sugar cane is cultivated and supplied to the mill by approx.

3,500-4,000 farmers; these families will be directly benefitted due to the project.

These farmers will get more value per ton of cane, which is a direct monetary benefit.

Approximately1200-1500 laborers involved in cane cultivation, will be indirectly

benefitted through the project.

These farmers will receive the bio-compost produced in the distillery at concessional

rate.

The project is going to generate about 164 direct employments for skilled and semi-

skilled workforce available locally.

The proposed project will preferably employ local labor for various works during

construction as well as operational phase. It is expected that about 40-50 labour will

be get employment during construction phase and nearly 100 labour will get

contractual/seasonal employment in the sugar and distillery (after expansion) during

operational stages.

These employees as well as cane harvesting labour receive insurance cover for medi-

claim and accident

Thus, roughly 6,000 families will be directly benefited due to the proposed project

By utilizing the available resource i.e. land, water, molasses and bagasse, the sugar

factory will generate additional revenue.

Proposed project will help to improve financial stability for the factory, which will be a

‘win-win’ situation for both, local cane growers as well as the management

As a policy the factory will preferentially select local candidates for permanent

employment. Therefore, it is anticipated that number of persons likely to migrate to

this place will be very limited. Available infrastructure is adequate to accommodate

this minor increase in the population due to the project. Thus, it is presumed that local

existing infrastructure and natural resources won’t be under stress due to such

increase in population.

The factory has made adequate provision of land for the proposed project. The site is

within the existing factory premises, no rehabilitation or restoration issues involved.

Since establishment of the sugar mill and distillery, there is a tremendous

improvement in the socio-economic conditions of the locals. Major activities

implemented by factory are mentioned in chapter III. According to which the mill has

paid more attention on developmental activities that directly beneficial to all farmers

and sustainable agriculture in the area. The mill has shown equal seriousness in

Chapter IV


careful utilization of available water resource. All these activities indicates factory’s

commitment for social and economic sustainable development of the region.

Considering the long term benefits to the locals and no issues of rehabilitation or restoration

involved with the project, it is anticipated that project will have immense positive impact on

socio-economic environment of the region.

4.8 IMPACT ON PHYSIOGRAPHY, GEOLOGY AND HYDRO-GEOLOGY (DRAINAGE)

The land is already under the possession of the sugar mill. As mentioned earlier, no draining is

passing through existing or proposed site. Therefore, construction will take place without

disturbing or altering any natural drainage. Proper storm water drainage system is in place and

the same will be extended for the proposed expansion. Hence, the project will not contribute for

water logging or flooding in rainy season.

The project doesn’t involve any blasting or deep excavation work or mining of any minerals.

Therefore, it is envisaged to have practically no negative impact on geology of the region. Minor

negative impact is envisaged due to change in physiography of the site.

4.9 OTHER IMPACT: TRAFFIC

During operation phase, the transportation activity is likely to get increased. However,

availability of adequate and proper road infrastructure in the area, this increase is anticipated to

have any impact leading to long term traffic congestion. Details of peak hours traffic at project

site is explained in Table 3.21 of Chapter III.

4.10 SUMMARY

Minor negative impact on air environment and ecosystem of the surrounding region is

envisaged due to the proposed activity. Also, negligible impact on physiography of the site is

envisaged.

At the same time, the major positive impact of the project is generation of employment and

social development in this region. Ethanol (fuel alcohol) is important for nation to reduce

import of crude oil. Important negative as well as beneficial impacts of the project are

summarized in Table 4.5.

Chapter IV


Table 4.5: Summary of Impact Assessment and Environment management plan proposed for the respective aspect

Activity Aspect N/AB/E Impact Receptor Legislative concern (Y/N)

Concern of interested parties (Y/N)

Business opportunity (Y/N)

Significance Assessment

X Y Z F Total#

Burning of fuel – bagasse and biogas – for generate process steam

Air pollution: Contamination of ambient air due to emission of Particulate matter (PM), SOx and NOx through stack

Normal (in a situation when APC system works properly)

Levels of PM, SOx and NOx anticipated to increase marginally but will be within NAAQS – minor impact on workers health if continuously get exposed to PM

Workers, villagers, agricultural and wild vegetation, domestic and wild animals

Yes No No 2 2 4 5 80

Abnormal

Level of PM anticipated to be high – moderate impact on human health till the situation returns to normal; significant impact on plants; minor impact on terrestrial fauna

Workers, villagers, agricultural and wild vegetation, domestic and wild animals

Yes No No 4 4 2 3 96

Emergency

Level of PM anticipated to be

Workers, villagers,

Yes Yes No 5 5 2 2 100

Chapter IV






X Y Z F Total#

very high Significant impact on human health as well as plant (particularly crops)

agricultural and wild vegetation, domestic and wild animals

Handling of bagasseand ash

Air pollution: increase in particulate matter due to fugitive emissions

Normal Levels of PM anticipated to increase, mainly at workplace

Workers within premises

Yes No No 3 2 4 5 120

Vehicular emissions

Air pollution: Due to vehicular emissions mainly of Particulate matter (PM), NOx, HC

Normal Increase in air pollution due to increase in the vehicle number plying on the roads

Residents along the roads, workers within the factory premises, and vegetation along the road

Yes Yes Yes 3 5 4 4 240

Pollution due to odour

Odour of spentwash from storage lagoons

Normal Nuisance -mainly disturbance

workers within the factory premises, villagers and

Yes Yes No 3 4 4 5 240

Chapter IV






X Y Z F Total#

animals in the close vicinity

Operation of machineries and equipments for process

Noise and vibration: mainly noise generation due operationsof machinery

Normal Impact on health of workers due to continuous exposure to different levels of noise

Mainly workers of the factory

Yes No No 4 1 4 5 80

Transportation Noise and vibration– Mainly noise from vehicles

Normal Impact on health of workers and residents along the road due to exposure to noise

Mainly workers and the residents along the roads

Yes No No 3 5 4 4 240

Fresh water utilized for process

Fresh water availability for other users from the existing water source

Normal No impact envisaged as the water drawl will be from Bhima river- with permission

Villagers in the vicinity, domestic animals

Yes Yes No 2 5 3 3 90

Abnormal

Other users may get affected in water scarcity situation (drought condition)

Villagers in the vicinity and domestic animals

Yes Yes No 5 5 3 3 225

Wastewater/effluent generation

Water and soil

Normal No negative impact is

Waterbodies in the nearby

Yes Yes No 2 3 3 4 72

Chapter IV






X Y Z F Total#

from various project activities, its handling, treatment and disposal

pollution: Contamination of surface or ground water, Contamination of soil

envisaged on surrounding aquatic ecosystem and soil health; as measuresin practice and proposed are adequate

areas, residents, domestic and wild animals

Emergency

Probability of contamination will be and impact on aquatic and/or ground water and/or terrestrial ecosystem would depend upon the degree of contamination

Villagers in the vicinity, domestic animals, water bodies in the vicinity

Yes Yes No 5 5 3 2 150

Construction of various units

change in land use

Normal Change in topography of the site,

Vegetation existing on the site, birds and animals, villagers in the vicinity

No No No 4 1 5 5 100

Solid waste generation from process

Water and soil pollution:

Normal In normal situation, no negative impact is

Waterbodies and soil in the nearby areas,

Yes No Yes 2 3 3 5 90

Chapter IV






X Y Z F Total#

Contamination of surface water, Contamination of soil

envisaged on surrounding ecosystems; as measures practiced and proposed are adequate

residents, domestic and wild animals

Process and allied activities such as transportation, storage, treatment and disposal

Risk and Hazard

Emergency

Negative impact envisaged

Workers, villagers, vegetation at site and surroundings, wild fauna

Yes Yes No 5 3 2 3 60

Socio-economy

Normal Positive impact is envisaged due to employment generation, recycling of nutrients from waste

No Yes Yes 4 5 4 5 400

X= severity (very low (1), low (2), moderate (3), high (4), very high (5);

Y = area – coverage within premises (1), close vicinity outside premises (2), up to 3 from project boundary (3), 3-5km from project boundary (4),

and >5km from project boundary (5)

Chapter IV


Z = Duration (very short (1), short (2), medium(3), medium to long (4), prolong periods (5);

F = Frequency -remote(1), rare (2), intermittently (3), frequently (4), daily (5)

Highest score = 625; considerable impact score: >310 (considering 50% of highest score)

Chapter V

EIA Report: Expansion of Sugar Mill from 2,500 to 6,000 TCD and Distillery from 30 to 55 KLPD

M/s. Shreenath Mhaskoba Sakhar Karkhana, Patethan, Pune 5-1

Chapter V

ANALYSIS OF ALTERNATIVES

5.1 ALTERNATIVE SITE

The proposed project is expansion of sugar unit from 2,500 to 6,000 TCD and distillery unit from

30 to 55 KLPD. The mill already possesses adequate land i.e. 77 acres of which 7.5 acres is

allocated for the new set up as well as its ancillary units such as pollution control system,

greenbelt, etc. Considering this fact, the point of alternative site search becomes insignificant.

5.2 MANUFACTURING PROCESS

The process of manufacturing sugar from sugarcane and alcohol from molasses is almost a set

process; there are no major alternative technologies available at present in this sector. Hence

alternative technology for manufacturing is not discussed.

5.3 EFFLUENT TREATMENT TECHNOLOGIES

The main area where alternative technologies are available is the effluent treatment. Sugar and

allied distillery industry is an agro based industry that generate effluent (wastewater) loaded

with organic matter. If this effluent discharged in the environment without any treatment or

insufficient treatment, it causes soil pollution as well as ground/surface water pollution. Since

this is an expansion project, the existing effluent treatment plant for sugar effluent will be

upgraded to make it suitable for the additional effluent generation hence alternatives for sugar

effluent treatment are not necessary.

The distillery effluent is presently treated by biomethantion followed by evaporation followed

composting. It is planned to use the same technology for additional spentwash generated. The

distillery has compost yard of 5 acres which is sufficient to treat the effluent generated. Hence,

discussion of alternative in this case is also not necessary

Chapter VI



Chapter VI

ENVIRONMENTAL MONITORING PROGRAMME

6.1 INTRODUCTION

Environmental monitoring helps to create a baseline for the impact of industrial pollutants in

the air, land and water. Significant short and long-term impacts of industrial projects and the

effect they may have on a given area can be determined through regular sampling and analysis

of air, water & soil samples. Monitoring is important for the control of pollution since the

efficiency of control measure can only be determined by monitoring. The regular monitoring of

environmental parameters is essential to assess the status of environment during project

operations. Regular monitoring network will be implemented to maintain the environmental

quality within the standards. SMSKL already has a full-fledged laboratory and technical

manpower for this purpose. The same can be extended to the proposed expansion project since

all activities are within the existing premises.

6.2 ENVIRONMENT MANAGEMENT CELL

In order to maintain the environmental quality within the standards, regular monitoring of air,

water/wastewater, soil, noise etc. is essential. A separate Environment Management Cell

under the direct control of the Chairman and Managing Director will look after the effluent

treatment facility to monitor and control the environmental quality. The composition of the

environment management cell is given in Table 6.1. Members of the cell should be well

qualified and experienced in the concerned field. Presently, the environmental cell has 2

persons in the sugar mill and 2 persons in the distillery who look after the effluent treatment

plant/effluent treatment system and related issues. Some experienced people from the existing

staff as well as appointment of a few new people will be made to take care of the additional

burden expected due to the proposed expansion of both sugar and distillery units. Routine

tests of wastewater such as pH, solids, temperature, etc. will be carried out in the laboratory

of sugar mill. However, for additional tests of water, wastewater, soil, air etc. services of

MoEFCC approved or NABL accredited laboratories can be hired.

Chapter VI



Table 6.1: Composition of Environment Management Cell

Particular Number

Chairman/Managing Director One

Chief Executive Officer One

Environment Officer Two

Environment Chemist One

Monitoring Staff One

ETP/biogas Lab Chemist Two

ETP Operators Six

Safety Officer One

Supporting Staff Two

Figure 6.1: Schematics of Environment Management Cell

Chairman & Managing Director

Chief Executive Officer

Process Manager Distillery Manager Work Manager General Manager

Environment Officer

Environment Chemist Monitoring Staff

ETP Lab Chemist

ETP Operators

Chapter VI



6.2.1 Monitoring Plan

6.2.1.1 Water Environment

Water samples from bore well/s located towards downstream of compost yard should

be collected and analyzed periodically

Spentwash as well as compost samples should be analyzed periodically

Characteristics of inlet and outlet of ETP, should be collected and analyzed as mentioned

frequency in Table 6.2

Water Cess should be submitted to Pollution Control Board as per the schedule

Environment Statement Reports also to be filed as per the schedule prescribed by

Pollution Control Board

For some of the routine tests of wastewater such as pH, solids, temperature, etc. and for

additional tests of water, wastewater, soil, air etc. services of reputed laboratories

approved by NABL or MoEF&CC New Delhi - under EPA 1986, could be hired.

6.2.1.2 Air Environment

Stack monitoring, Ambient air monitoring to be done from NABL/MoEF&CC approved

laboratory as per CPCB guidelines

In addition, ambient air quality to be tested in upwind and down wind direction/near

max GLC once in a quarter

6.2.1.3 Noise Environment

Noise measurement should be done within factory premises and if required at location

such as nearby residential area, school, dispensary etc. as per the frequency mentioned

in Table 6.2

Noise should be monitored at free field at 10 m from the equipments whose noise level

are being determined

In case of noise levels causing disturbance to the sensitive receptors, control measures

should be followed as suggested in EMP

6.2.1.4 Soil Environment

Soil should be monitored at areas where treated water is used for irrigation as well as at

where compost applied for soil conditioning

Soil should be analyzed for parameters such as pH, alkalinity, organic carbon, available

N,P,K etc during the pre-monsoon and post monsoon season each as per standards for

agriculture

Control Measure: At location of increased pollution levels; source shall be identified and

shall be diverted from future disposal

Chapter VI



6.2.1.5 Other Conditions

Table 6.2: Analysis of environmental parameters and its reporting schedule

# Particulars Parameter Frequency#

1. Stack Emissions Particulate matter, SO2 Monthly

2. Ambient Air Quality PM10, PM2.5, SO2, NOx Monthly

3. Inlet and outlet of

polishing unit

pH, BOD, COD, SS, TDS, Oil &

Grease etc.

Monthly

4. Bore well /ground

water sample nearer to

compost yard

pH, COD, BOD, Total solids,

Chlorides, Sulphate, Phosphates,

and Calcium

Quarterly/Monthly

5. Noise monitoring Noise levels measurement at high

noise generating places as well as

sensitive receptors in the vicinity

Monthly

6. Analysis of ready bio-

compost

Moisture, Organic Carbon, and C:N

ratio, Nitrogen, Phosphorous,

Potassium, etc.

Each batch of compost

7. Occupational health Health and fitness checkup of

employees get exposed to various

hazards

All other staff (except above)

including contract and casual

labours

Quarterly

Once a year

# Follow the consent condition, if consent conditions are different from recommended frequency

Periodical analysis of raw and bio-methanated spentwash

Table 6.3: Suggested schedule for maintenance of wastewater treatment unit

# Part See (*) Frequency

1. Bearings See temperature Daily

Change grease Bi-monthly

2. Gland Change packing Bi-monthly/as required

3. Indicators Pressure gauge, vacuum gauge Tri-monthly

4. All type valves Change packing Six-monthly

5. Impellor Check all blades, sleeves,

bearing, impel nut check

Yearly, change if required

6. Electric motor Open side doors, blow dust,

check air gap

Monthly

7. Motor winding Blow off dust, test insulation Bi- Yearly

8. All hand carts, wheel

barrows

Grease wheels Monthly

Change rubber tyres Six-monthly if required

Chapter VI



9. Gear box Oil level Check every week,

replenish tri-monthly

10. Scraper shoe Tighten nut bolts, change

broken-bent members, change

leather-rubber shoes

Tri-monthly

11. Central turn table See oil level Weekly

Check chain of sprocket, steel

balls, gear

Yearly

12. Aerator See oil and grease Weekly

Painting-coating blades Yearly

(*)As applicable to the unit

6.2.3 Flow Measurement

Water required for process, boiler, cooling, molasses dilution cleaning and domestic purpose

needs to be measured by installing flow meter at source. Quantity of sugar effluents, spentwash,

minor or moderately polluted effluents generated also need to be measured with the help of V-

notch or flow meter.

Table 6.4a: Format for Water Consumption Reporting Schedule- Sugar mill

# Particulars m3/hr m3/D m3/A

1. Boiler makeup

2. Injection channel / spray pond makeup

3. All water cooling system makeup

4. Body cleaning

5. Floor washing

6. Laboratory use

7. Sanitary Requirement

8. Domestic Use for Colony

Total

9. Water consumption per ton of sugar production

10. Power consumption for water lifting, KWH

11. Expenses for

Electricity (Rs.)

Water Cess (Rs.)

Water Bills (Rs.)

13. Expenses on water per ton of sugar

Chapter VI



Table 6.4b: Format for Water Consumption Reporting Schedule- Distillery

# Particulars m3/hr m3/D m3/A

1. Dilution of Molasses

2. Distillation process, dilution for ENA

3. Cooling tower (CT) make-up for distillery

4. CT make-up for cooling spentwash for biogas plant

5. Boiler make-up

6. Floor washings sterilize

7. Sanitary Requirement

8. Domestic Use for Colony

Total

9. Water consumption per KL of alcohol production

10. Power consumption for water lifting, KWH

11. Expenses for

Electricity (Rs.)

Water Cess (Rs.)

Water Bills (Rs.)

13. Expenses on water per liter of alcohol

Table 6.5a: Format for Pollutant Generation Reporting Schedule- Sugar Mill

# Particulars Today (m3) To date (m3)

A. Liquid Waste

1. Effluent generation

2. Spray pond overflow

3. Process condensate

4. Any other

B. Solid Waste

5. Sludge from ETP

6. Ash

7. Any other

C. Hazardous Waste

8. Hazardous waste from process

9. Hazardous waste from ETP

10. Any other

Chapter VI



Table 6.5b: Format for Pollutant Generation Reporting Schedule- Distillery

# Particulars Today (m3) To date (m3)

A. Liquid Waste

1. Spentwash generation

2. Spent lees generation

3. Process condensate

4. Any other

B. Solid Waste

4. Bio-methanated sludge

5. Sludge from CPU

6. Ash

7. Any other

C. Hazardous Waste

8. Hazardous waste from process

9. Hazardous waste from ETP

10. Any other

Table 6.6a: Format for Pollutant Disposal Reporting Schedule- Sugar Mill

# Particulars Disposal method Today (m3) To date (m3)

A. Liquid Waste

1. Effluent

2. Spray pond overflow

3. Any other

B. Solid Waste

4. Sludge from ETP

5. Ash

C. Hazardous Waste

8. From process

9. From ETP

10. Any other

Chapter VI



Table 6.6b: Format for Pollutant Disposal Reporting Schedule

# Particulars Disposal method Today (m3) To date (m3)

A. Liquid Waste

1. Spentwash Disposal

2. Treated effluent from CPU

3. Any other

B. Solid Waste

4. Bio-methanated sludge

5. Sludge from CPU

6. Ash

7. Any other

C. Hazardous Waste

8. From process

9. From ETP

10. Any other

Table 6.7: Format for Biocompost Reporting Schedule

# Particulars Opening

balance

Received

today

Received to-

date

Consumption

/ Sale

Closing

balance

1. Spentwash

2. Press mud

3. Culture

4. Ash

5. Bio-sludge

6. Biocompost

7. Any other

Chapter VII


Chapter VII

ADDITIONAL STUDIES

(SAFETY, RISK, DISASTER MANAGEMENT& PUBLIC HEARING)

7.1 SAFETY

Definition: Safety is the state of being “safe”, the condition of being protected against physical,

social, spiritual, financial, or other types or consequences of failure, damage, error, accidents,

harm or any other event which could be considered non-desirable.

The factory is proposing the following safety policy, which indicates the sincere commitment of

the factory towards safety at work place.

We have an idea that human life is precious

We give priority to our production process as a safety, health and pollution free

environment

In our opinion, the accident is an avoidable event

We are always careful to avoid accidents

We are committed to covering the safety in the factory carefully

We have made adequate organization to carry out all the above responsibilities

7.1.1 Goals/Targets of Safety

Accident prevention

Accident control

Protection of human health/life

Protection of material and property

Protection of environment

All workmen as well as staff of the factory are committed to safe work environment and

hence they follow the basic principle of ‘safety first’.

The safety department of the factory is responsible for creating safe environment at workplace.

They are also responsible for creating and maintaining awareness on safety aspects at factory

premises. This is achieved by regular training programmes, display of posters and notices at

strategic locations, arranging documentary film shows related to safety, on job training, daily

safety round, recommendation for corrective action, etc. The Department has formulated safety

procedures and rules, depending upon the nature of work carried out at respective location.

Chapter VII


These procedures allow the safety personnel to periodically inspect equipments such as safety

guards, cranes, lifting tackles, etc. He also inspects the certificates of fitness of the equipment. In

addition to this, each year employees has been rewarded for best safety suggestion.

As a result of excellent housekeeping and safety practices, the factory could able to achieve, zero

fetal as well as near miss accidents for last five years and has not lost a single hour due to

accidents. However, the factory has well laid procedure for accidents, which is as follows.

7.1.2 Procedures in case of accident

According to the procedures, when an accident occurs at any place of the factory, respective

shift in-charge immediately fills the accident report form. In the next step, this form is sent

to respective Head of the Department who signs the form and submits it to Managing

Director (MD), who communicate it to the Government Authority/ies. MD also initiates the

process of investigation under the supervision of safety officer. Root cause of accident is

determined and suitable preventive/corrective action is drawn. MD approves the findings of

the investigations and corrective/preventive action plan is submitted to respective Head for

implementation.

Figure 7.1: Schematic of procedure in case of accident

Accident Shift in-charge

Head of the Department

Managing Director

Safety Officer

Government Authorities

Chapter VII


7.2 RISK ASSESSMENT AND RISK MANAGEMENT

Generally, risk associated with industrial processes can be defined as a measure of probability

of harmful event such as death, injury, loss, etc. arising from exposure to chemical or physical

agent may occur under the specific conditions of manufacture, use or disposal. Risk is a

mathematical product of hazard and exposure. This relationship can, be expressed in the

following simple formula.

Multiplying any number by zero results in a product of zero, which means that an extremely

hazardous substance can be present with little risk of adverse effect, if handled safely under

proper conditions then the ‘exposure’ component of the risk equation is driven towards zero.

Similarly, the hazard component can be reduced to zero even if there is a high probability of

exposure, by changing the process design, substituting less hazardous commodity, using a lesser

amount of a chemical, etc. and the recognition of vulnerability as a key element in the risk

equation has also been accompanied by a growing interest in linking the positive capacities of

people to cope, withstand and recover from the impact of hazards. It conveys a sense of the

potential for managerial and operational capabilities to reduce the extent of hazards and the

degree of vulnerability, which derives the total equation of risk towards zero.

Risk assessment is concerned with determining those factors which are especially dangerous

and determining the likelihood of unacceptable toxic exposure. Risk should be assessed against

defined limits of exposure, established on the basis of tests under appropriate conditions. Risk

Management – a decision - making process to select the optimal steps for reducing a risk to an

acceptable level. In the industrial context, it consists of 3 steps: risk assessment (evaluation),

emission and exposure control, and risk monitoring.

Risk = Hazard x Exposure x Vulnerability

Chapter VII


7.2.1 Hazard Identification

7.2.1.1 Broad Categories of Hazard

To help with the process of identifying hazards it is useful to categorize hazards in different

ways like by topic, for example:

a. Mechanical

b. Electrical

c. Thermal

d. Noise and vibration

e. Material/Substances

f. Fire and explosion

a. Mechanical Hazard

It mainly involves properties of machine parts or work pieces, such as:

a. Faulty design (Shape): It may cause injury to workman

b. Relative location: Confined location during repairs & maintenance

c. Mass and stability: May cause physical injury

d. Inadequacy of mechanical strength

e. Accumulation of energy inside the equipment: steam/ air /water pressure cause injury

to workman

f. During commissioning, operation and maintenance following hazards are anticipated.

Crushing hazard, shearing hazard, cutting or severing hazard, entangling hazard, friction

or abrasion hazard and high pressure fluid injection or ejection hazard.

b. Electrical Hazard

Probable incidences for electrical hazards, could be

a. Contact of persons with live parts (direct contact),

b. Contact of persons with parts which have become live under faulty conditions (indirect

contact)

c. Approach to live parts under high voltage

d. Electrostatic phenomena

e. Thermal radiation or other phenomena such as the projection of molten particles and

chemical

f. Effect of short circuits, overloads, etc identified during construction, production and

maintenance.

c. Thermal Hazard

Probable causes of thermal hazards are -

Chapter VII


a. Burns, scalds and other injuries by a possible contact of persons with objects or

materials with an extremely high or low temperature, by flames or explosions and also

by radiation of heat sources

b. Damage to health by hot or cold working environment

c. Thermodynamic hazard such as overpressure, under pressure, over-temperature,

under-temperature need to be avoided by providing system management

d. Hazard generated by noise & vibration

In the proposed project, probable source of noise are – boilers, steam turbine generators and

transportation of bagasse on conveyer belts, motors, loading of bagasse, etc. Usually prolong

exposure to high noise level, results into

1. hearing loss (deafness), other physiological disorder (e.g., loss of balance, loss of

awareness)

2. Interference with speech communication, acoustic signals, etc.

In the proposed project the hazard due to vibrations could be due to -

1. Use of hand-held machines resulting in a variety of neurological and vascular disorders

2. Whole body vibration, particularly when combined with poor postures

e. Hazards generated by materials/substances

1. Hazards from contact with or inhalation of harmful fluids such as: anti rusting

chemicals, cleaning agents/acids/organic solvents gases, superheated steam through

leaks and bagasse dusts

2. Fire or explosion hazard—dry bagasse

3. Biological or microbiological (viral or bacterial) hazards: -Workplace exposure to dusts

from the processing of bagasse can cause the chronic lung condition pulmonary fibrosis.

During work activities following hazards could occur -

i. Slips/falls on the floor level

ii. Fall of persons from height

iii. Fall of tools, materials, etc. from height

iv. Inadequate headroom

v. Hazards associated with manual lifting/handling of tools, material, etc

vi. Hazards from plant and machinery associated with assembly, commissioning,

operation, maintenance, modification, repair and dismantling

vii. Vehicle hazards, covering both on-site transport and off-site travel by road

viii. Fire and explosion

ix. Violence to staff

Chapter VII


x. Substances that may be inhaled

xi. Substances or agents that may damage the eye

xii. Substances that may cause harm by coming into contact with, or being absorbed

through the skin

xiii. Substances that may cause harm by being ingested (Entering the body via

mouth)

xiv. Harmful energies (for example, electricity, radiation, noise, vibration, etc.)

xv. Non-compliance of regulation

xvi. Inadequate thermal environment (for example too hot temperature)

xvii. Lighting levels

xviii. Inadequate guard rails or hand rails on stairs

xix. Subcontractors’ Activities

7.3 Probable Risk Factors (Associate with the Industry)

Following scenarios fall under maximum credible accident scenario

• Fire in fuel storage yard (bagasse yard)

• Fire and explosion at storage yard (molasses and alcohol storage tanks)

• Fire due to short circuits

• Injury to body and body parts (mechanical)

7.3.1 Fire in fuel storage yard

This is the most common accident known to occur in any plant, while storing and handling fuel.

Usually, such incident takes sufficient time to get widespread. Enough response time is available

for plant personnel to get away to safer distance. An elaborate fire hydrant network and

firefighting system comprising of trained crew and facilities will mitigate the risk of such

incidents. In addition, as per requirement fire alarm system and smoke detectors have been

installed (in the existing unit).

The storage area is most vulnerable for fire and includes storage tanks of alcohol and molasses.

This is the most common accident known to occur in any plant, while storing and handling fuel.

Since such incident takes sufficient time to spread, enough response time is available for plant

personnel to get away to safer distance. An elaborate fire hydrant network and firefighting

system including trained crew and facilities will be provided to mitigate the risk of such

incidents. In addition, as per requirement fire alarm system and smoke detectors will be

installed.

Chapter VII


Table 7.1NFPA (NATIONAL FIRE PROTECTION ASSOCIATION) Rating

Chemical NFPA Ratings

Health Hazard Fire Reactivity

Ethanol 2 3 0

(Least-0, Slight-1, Moderate-2, High-3, Extreme-4)

Gas holder

Pressure in gas holder should be always more than 100 mm.wg. If pressure falls below

the biogas blower should be switched off and isolating valve in flare line should be

closed.

Moisture eliminator is provided at inlet & outlet of gas holder. These should be drained

at least once in a day to drain the water.Drain valve should be operated such that it is

closed tightly before gas can escape.

In case of maintenance of gas holder, on roof top should be opened and gas holder

should be properly purged before starting maintenance. Gas mask should be used for

entering the gas holder.

Continuous water supply to gas holder should be maintain for providing water seal.

Gas Handling System

Gas Blower is provided with flame proof motor, cable connection should be maintained

accordingly

Safety valve on blower discharge side should be properly adjusted to provide desired

gas

Moisture is likely to collect in the gas pipe line to Boiler. Drain points should be provided

at interval and drained at least once in a day. Precaution should be taken while

operating drain valve so that gas does not escape while draining water

Flame arresters provided in the gas line should be cleaned periodically so that gas

pressure at boiler end is maintained

At the time of lighting the burner, if burner does not light up within 15 to 20 sec. close

the shut off valve in gas line, and purge the furnace before trying to light up burner again

Do not light up burner from hot brick work.

7.3.2 Mechanical injury to body parts

In a plant, there are several places where workers are likely to be involved with accidents

resulting in injury to body parts. The places are workshop, during mechanical repair work in

different units, during construction work, road accidents due to vehicular movement, etc.

Chapter VII


Workers exposed to mechanical accident-prone areas are using personal protective

equipment. The non-respiratory PPE includes tight rubber goggles, safety helmets,

welders hand shields and welding helmets, plastic face shields, ear plugs, ear muffs,

rubber aprons, rubber gloves, shoes with non-skid soles, gum boots, safety shoe with toe

protection. All safety and health codes prescribed by the BIS will be implemented.

Table 7.2: Hazardous areas in a molasses based distillery attached to sugar mill.

# Hazardous Area Likely Accident

1 Boiler Explosion

2 Turbine room Explosion

3 Electrical room Fire and electrocution

4 Bagasse yard Fire

5 Alcohol storage tank Fire

6 Biogas holding tank Fire

Figure 7.2: Bagasse yard with fire extinguishing system

7.3.3 Mitigation Measures for Fire Hazards

A. Storage

Alcohol (RS, ENA or AA) and molasses will be stored in leak-proof MS tanks, gauges

of MOC will be strictly as per IS or relevant standards

Storage area will be well ventilated with adequate spacing between units

Lightening arresting system

Provision of alcohol vapor condensation system

Chapter VII


Strictly declared ‘No Smoking Zone’ and prohibition of use of any ignitable material

(e.g. even cell phones, etc.)

Electrical fittings of good quality that comply national or international standards

B. Firefighting system

The mill management is vigilant on the issues of safety of workers and plant. It has planned

following firefighting system for the proposed distillery unit

a. Guidelines ofOISD-STD-117 will be implemented

b. Lightening arresting system for the plant as well as storage

c. Alcohol vapors condensing system for storage tanks

d. The fixed water spray system will be provided on all tanks; fire water flow rate will be

calculated at a rate of 25 lpm/m2 as per OISD-STD-117

e. Fire water system will be designed for a minimum residual pressure of 7 kg/cm2(g) at

hydraulically remotest point in the installation considering single largest risk scenario

f. Water for the firefighting will be stored in easily accessible surface or underground

tanks of RCC/steel with minimum four hours aggregate rated capacity of pumps.There

will be one or two standby diesel engine driven pumps of the same type, capacity &

head as the main pumps will be provided; Jockey pump (one in number -AC motor

driven) for maintaining pressure

g. Hydrant system covering the entire plant including all important auxiliaries and

buildings is proposed. The system will be complete with piping, valves

instrumentation, hoses, nozzles and hydrants, valves etc.

h. High velocity water spray system near storage tanks

i. Portable extinguisher such as pressurized water type, carbon dioxide type and foam

type will be located at strategic locations throughout the plant

j. The diesel engines will be quick starting type with the help of push buttons located on

or near the pumps or located at a remote location.

k. Portable foam and/or water-cum-foam monitors will be provided for suppression of

pool fire in tank farm area.

l. Fire water pumps & storage will be located at 30 m (minimum) away from equipment

or where hydrocarbons are handled or stored.

m. Fire water pumps will be exclusively used for firefighting purpose only

n. Fire water mains, hydrant & monitor stand posts, risers of water spray system will be

painted with “Fire Red” paint as per IS: 5.

Chapter VII


o. Hose boxes, water monitors and hydrant outlets will be painted with “Luminous

Yellow” paint as per IS: 5

p. Electric audible fire siren will be to the farthest distance in the installation and also in

the surrounding area up to 1 km from the periphery of the installation that will sound

differently with respect to shift alarm with continuous power supply

q. Communication system like Telephone, Public Address System, etc. to be provided in

non-hazardous areas of the installation

r. Concerned officer/employees will be trained to handle the firefighting system

7.3.4 Boiler Operations

1. Provision of adequate sets of Personnel protective equipment's

2. Pilot lights will be provided on electrical panel boards

3. Provision of hand operable firefighting cylinders at strategic locations

7.4 QUALITATIVE RISK ASSESSMENT

Table 7.3 Probability of occurrence of hazard

Probability Number Causes/ Incident

1 Very unlikely (e.g. once in 10 yrs)

2 Remote (e.g. once in 5 years)

3 Occasional (e.g. once in a year)

4 Probable (e.g. once in a month)

5 Frequent or more often

Table 7.4: Severity - Impact Intensity

1 Minor Failure results in minor system damage but does not cause injury to

personnel, allow any kind of exposure to operational or service personnel

or allow any release of chemicals into the environment

2 Major Failure results in a low level of exposure to personnel, or activates facility

alarm system

3 Critical Failure results in minor injury to personnel exposure to harmful chemicals

or radiation, or fire or a release of chemical to the environment

4 Catastrophic Failure results in major injury or death of personnel

Chapter VII


Calculation of Risk assessment and mitigation measures

Risk = Probability x severity

If, there is a probability number of any particular cause/incident is 1 and its severity is minor

then,

Risk involved in the hazard is 1x1 = 1

Whereas,

If, there is a probability number of any particular cause/incident is 5 and its severity is

catastrophic then, Risk involved in the hazard is 5x4 = 20

Thus, the Risk of those hazards scoring 20 are defined and considered as ‘Non-acceptable Risk’.

Mitigation measures or operational control procedures required for such hazards identified is

given below in Table 7.5.

Table 7.5: Mitigation measures for identified hazards

# Hazard Probability Severity Mitigation Measure

Mechanical Hazard

1. Physical injury to

hand/legs, body

parts

during process

Frequent

Once per month

or more often

Minor

Use PPE/PPA

2. Burst of molasses

tank

Remote

Catastrophic

Layers of Protection

area (LOPA)

3. Boiler Explosion Remote Catastrophic Layers of Protection

Chapter VII



area (LOPA)

4. Fingers nipping in

between moving

part. Eg. Belt

Probable

Once per year

Major

Fixed /Movable

Guards at probable

sites

5. Steam pipe leakages

Frequent

Once per month

or more often

Major

Proactive

Maintenance/PPE

6. Working on height

Impact /falling down

Probable

Once per year

Critical Work permit system

Life belts/Helmet

7. Water feeder pump

failure

Occasional

Once per 10

years

Critical

Alarming/communica

tion arrangements

Electrical Hazard

8. Contact of persons

with parts which

have become live

under faulty

conditions (indirect

contact)

Occasional

Once per 10

years

Major PPE/PPA/Permits

9. Approach to live

parts under high

voltage

Occasional

Once per 10

years

Catastrophic

Guards/

authorization

Enter Restriction

10. Electrostatic

phenomena

Remote

Major Earthling, avoid Dust

Explosion

11.

Thermal radiation or

other Short circuits,

overloads, etc.

Probable

Once per year

Major

PPE/Checking

/Inspection

Thermal Hazard

12.

Burns, scalds and

other injuries by

steam

Occasional

Once per 10

years

Major

Safe working

distance/PPA/protect

ive dress code

12.

Damage to health by

hot working

environment

Frequent

Once per month

or more often

Critical

Minimum exposure

Ventilation/Humidity

control

Hazard generated by Noise

13.

Belt movement,

Pump/Motor, Turbo

generator

Frequent Critical Confinement of

source,

Use Ear Muff/Plugs

Hazard generated by Vibration

Chapter VII



14.

Whole body

vibration, during

working on feeder

platform

Remote

Major

Engineering solutions

Number of Accidents *Reportable* under the Factories Act,

1948(Including accidents to workers employed by

Contractors, Vendors, Transporters and Visitors)

Assessment Period

2016 2015 2014

1 Fatal000 Nil Nil Nil

2 Total Permanent Disability 000 Nil Nil Nil

3 Non-Fatal (Excluding item #5.2) 000 Nil Nil Nil

4 Weighted Accident Frequency Rate (WAFR)

[{10(Item #5.1 + 5.2)+ Item #5.3}] × 108

= Number of Total man-hours worked (as in item #3.2C)000

Nil Nil Nil

Hazard Warning Information for Ethyl Alcohol

SECTION I

Product Name Ethyl Alcohol

Synonyms Anhydrous Ethyl Alcohol, Dehydrated Alcohol

Chemical Family Alcohol

Molecular Weight 46.07

Formula C2H5OH

Health Fire Reactive Other Degree of

Hazard

Colour Coding Other Codes

0 3 0 - 0 = Minimum

1 = Slight

2 = Moderate

3 = Serious

4 = severe

Health = Blue

Fire = Red

Reactivity =

Yellow

Other = White

Ox = Oxidizer

Acid = Acid

Alk = Alkaline

COR = Corrosive

W = No use water

Chapter VII


SECTION II – INGREDIENTS

Composition Cas Rn. Nominal

Wt/Wt%

PEL/TLV Hazard

Ethyl Alcohol 64-17-5 100.0 1000 ppm Flammable/Nervous

System Depressant

PEL = Personal Exposure Limit

TLV = Threshold Limit Value

7.5 MITIGATION

7.5.1 Basic Design of The Sugar Unit

While designing the plant, ensure maximum plant load factors. The plant cycle should be

optimized to give the best efficiency. The success of the sugar & cogeneration plant depends on

this "basic design". Plant layout is a part of the basic design and is very important from the point

of view of operability and maintainability of the plant.

The plant and equipment should be so laid out that there is optimum routing of piping, cables

and conveyors. New boilers will be designed as per IS standard. Pilot lights will be provided on

electrical panel boards. SMSKL will provide hand operable firefighting cylinder at strategic

location viz. power house, control panel room, PRDS section etc.

7.5.2 Steam Generating System

Some fine tuning is required in the areas of excess air control and un-burnt carbon loss control.

Feed water quality control is an area needing attention and this is separately dealt in the

detailed project report (technical report).

7.5.3 Turbo Generator System

Problems in maintaining the steam purity in the boilers affect the turbine with deposits on the

blades. The major contaminant is silica that gets carried over as vapor as the operating pressure

of the boiler increases.

There could be some problems of vibration and failure of bearings. These could be due to-initial

problems in the lube oil system, and these could be resolved by having proper pre-

commissioning checks. Another problem observed usually in some industries is of exhaust hood

spray falling on the blades and causing vibration. This is mainly due to a misdirected spray

nozzle in the exhaust hood. Proper designing will resolve such problems.

7.5.4 Bagasse Handling

During the cane crushing season, the plant receives bagasse directly from the mill, and the

surplus bagasse is taken to the yard. The bagasse thus saved will be used for the off-season

operation of the cogeneration plant, or could be used to run the cogeneration plant on the

Chapter VII


cleaning days or when the mill is not running due to some other reasons. Under such

circumstances, back feeding of the bagasse from the yard to the boiler has been provided.

7.5.5 Milling Section

Milling section, where the juice is extracted from the cane, is the most important section of

sugar mill. This is where the bagasse is prepared as a fuel, and the moisture in the bagasse

controlled to a value of around 50%. If there are problems with this section, the moisture

content in the bagasse could go high and the bagasse will not be prepared well for handling and

combustion. Other points related to milling section are the use of optimum imbibition’s and the

use of electric or hydraulic drives for the mills.

7.5.6 Controls & Instrumentation

Being the most important subject from the point of view of operation and maintenance of the

sugar &distillery plant, this subject deserves a lot of attention. Distributed Control System (DCS)

is the order of the day.

7.6 RISK MITIGATION MEASURES: FIRE HAZARD

In view of vulnerability to fire, effective measures have been considered to minimize fire hazard.

Fire protection is envisaged through hydrant and sprinkler system, designed as per the

recommendation of Tariff Advisory Committee of Insurance Association of India / Loss

Prevention Association of India. For detection and protection of the plant against fire hazard,

any one or a combination of the following systems will protect susceptible areas:

a. Hydrant system

b. High velocity spray system

c. Portable fire extinguishers

d. Fire alarm system

The existing firefighting system is as per National Code/standards (for Factories), the details of

which are as follows.

7.6.1 Fire Fighting System

While designing, the firefighting system, various vulnerable locations in the Unit, probable

causes & chances of occurrence of fire, its class etc. has been considered in-depth.

The sugar factory has developed an excellent set up for firefighting. It is having a dedicated fire

fighting vehicle and operating staff in all shifts.

7.6.1.1 Fire Extinguisher

7.6.1.2 Classification of Fire

Class (A): Fire involving combustible materials like wood, paper, cloth and bagasse etc.

Chapter VII


Class (B): Fire due to liquid materials like oil, diesel, petroleum products and all inflammables.

Class (C): Fires involving domestic and industrial gases like butane and propane etc.

Class (D): Metal fires, etc.

Class (E): Electrical fires due to short circuiting, etc.

The factory has installed fire extinguishers, in the entire premises. Each extinguisher is properly

numbered and placed at required location according to its type. These locations are painted

with yellow and white bands, for an easier identification. These extinguishers are checked

periodically and sent for refilling immediately after its expiry. In order to know which type of

cylinder to be used in respective fire, boards have been displayed at several locations in the

factory.

7.6.1.3 Use of Fire Fighting Equipment

Most of the workers have been trained with respect to nature and utility of firefighting

equipment, its type and class of fire for which it is to be used. They also perform mock drills to

handle disaster situation such as fire.

7.6.1.4 Fire Evacuation

The factory has provided multiple exits to main building for easy and fast evacuation in case of

emergency. These exists are properly displayed using glow signs. Fire doors have been provided

in the corridors of buildings. Contact numbers in case of emergency are displayed at various

locations. In case of fire, a control room has been provided at ground floor at safe locations.

Provision has been made for alternate power supply for pumps, lights and other emergency

machineries. As described earlier, a dedicated tank has been provided which is available around

the year. Fire alarm, fire extinguishers, hydrant and pumps are properly maintained. Pumps and

extinguishers are checked for desired pressure.

The entire factory premises have been declared as ‘No smoking zone’ and this is strictly

implemented. All lobbies, staircases and open spaces are kept free from scrapped material such

as packaging boxes, used files, waste papers, and broken furniture such as chairs, tables and

cupboards as well as similar fire catching material. Office buildings, work places, storage areas

as well as parking places have been designed thoughtfully, so as to use natural light and

ventilation to maximum extent. The factory follows best housekeeping practices to keep

workplace neat and clean.

7.6.1.5 Procedure For In Case Of Fire

In case of fire, an alarm is pressed that gives signal to all staff as well as workers. It is advised,

not to be panic in such situation and follow the procedure as laid down and for which they have

been trained. In brief, the procedure is as follows -

Chapter VII


All the machineries located near fire place are shut downed immediately including EOT cranes.

The workers are suggested to vacate the area immediately. While vacating the area, it is advised

to walk and not to run (specially using staircases) and not to push each other. Vacate the

premises through safe exits which are away from fire and assemble at the place defined as

‘assembly point’.

7.6.1.6 Ventilation

Proper ventilation must be provided both in sugar and distillery unit. Since, adequate natural

ventilation is available at site, the mechanical ventilation is presumed to be minor or less

significant. However, if mechanical exhaust ventilation needs to be provided, it should be to the

order of 1 cfm/sq.ft. or floor area (0.3 m3/min.m2) by fans of adequate capacity having their

suction intake located near floor level to ensure a sweep of air across the entire area.

7.6.1.7 First Aid

A first aid center with adequate facilities should be provided at the site. It should be maintained

round the clock by trained personnel.

Important standards to be followed are -

1. Fire Protection

IS 2189: Standard for automatic fire detection and alarm system

IS 2190: Code of practice for selection and maintenance of first aid fire extinguishers

IS 3844: Code of practice for installation and maintenance of internal fire hydrants

and hose reels

IS 6382: Carbon dioxide fire extinguishing system – fixed, design and installation

2. Occupational Health And Safety

IS 4489: Code of practice for occupational safety and health audit

3. Electrical Risk

Hazardous area classification based on IS 5572

Selection of electrical equipment for hazardous area based on IS 5571

Lightning protection system based on IS 2309

NFPA 70 B Recommended practice for electrical equipment maintenance

NFPA 70 E Standard for electrical safety in employee work places

4. Process Safety Management

Hazard and Operability studies (HAZOP)

Failure Tree Analysis (FTA)

Chapter VII


Event Tree Analysis (ETA)

Primary Hazard Analysis (PHA)

Risk Assessment with risk ranking technique

5. Electrical Risk Assessment

Review of Hazardous area classification

Lightning protection risk assessment

Identification and control of electro-static hazards

Review of electrical preventive maintenance system

Electrical risk assessment (Fire, shock, explosion) using semi-quantitative risk

ranking (SQRR) technique

6. Fire Risk Assessment

Identification and assessment of fire risks at receiving station/s, storage, transfer and

handling of materials such as raw material, fuel, finished products

Identification and control of ignition sources in areas where flammable materials are

stored/handled/transferred

Review of fire detection measures adopted in the plant and to suggest suitable

improvement measures

Review of various active (fire hydrant, sprinkler, portable fire extinguishers) and

passive fire protection requirements for all work places and suggest improvements as

necessary

Review of contractor safety awareness (firefighting, emergency communication,

knowledge of plant hazards and safety regulations) and to recommend suitable

improvement measures to enhance safety

Review of safety awareness and safety training requirements (training identification

and efficacy) of employees with respect to hazards

The consequences, likelihood and exposure of each hazard are arrived using a systematic

approach and will help to determine the relative importance of hazard and focus on significant

risks.

7.7 Other Measures

Other mitigation measures include:

Emergency shutdown system

Pumps of reliable quality will be installed

Lightening protecting system as per Indian Electricity Rules

Chapter VII


Power cables, control cables, instrumentation cable, thermocouple extension wire will

be complying IEEE fire tests as defined in IEEE 422

Keeping safe distance between fuel storage area and main unit

Corrosion protection methods for pipelines

All locations where the above pipelines are close to traffic movement, protection like

crash guards should be provided

7.8 SAFETY ORGANIZATION

The organizational set-up to carry out the declared policy for Health, Safety & Environment

matters and in particular, the arrangements which have been made to implement the policy will

be as follows: -

The overall responsibility for Health, Safety & Environment will be that of a "Occupier”

The Works Manager will have the overall responsibility for the operations in the factory.

All the Department Heads will be responsible for implementation of this policy in their

respective areas of the operations. They will be accountable for the safety performance

in their area and due weightage will be given to this performance in their career

planning appraisal.

Safety Department will plan and administer the Safety Programme and Activities and

assist and advice on implementation of the Programme. The implementation will be

through Line Management.

Maintenance Department will be responsible for maintenance of machines and

equipment, inspection and testing of various equipment, guards, operation and

Maintenance of Effluent Treatment Plant and Pollution Control Equipment as

prescribed. Proper record of these activities will be maintained. Proper intenance

schedule will be drawn and strictly followed.

All employees have the responsibility and obligation to co-operate with Supervisors and

Managers to achieve the Safe and Healthy Working Environment, and to follow all Safety

Rules, Procedures, Systems and Practices including use of Safety Equipment and to take

reasonable care for the Safety and Health of themselves and their colleagues. These have

been enumerated in the Safety Manual of the Company.

In order to ensure that all Safety Rules, Procedures, Systems and Practicesincluding use

of Safety Equipment are followed. Regular Safety Audits either internally or through

external experts will be carried out.

Chapter VII


Communication between Management and Employees will be provided throughSafety

Committees which will assist in propagating Safety and motivatingEmployees to achieve

the objectives set-out in the Safety Policy.

Chief Security Officer/Fire Officer will be responsible for Inspection, Testing

andMaintenance of all Fire Extinguishing Appliances and Fire Hydrant

installationincluding record of such maintenance and for dealing with any fire

emergencies.He will also be responsible for organizing Fire Drills and Emergency"

Drillsparticularly for Security Personnel and selected persons from

MaintenanceDepartment.

The Doctor will be responsible forOccupational Health & Medical Checksof Employees

and remedial measures, as required statutorily and maintain up-to-date health record of

such employees.

The Purchase Department will consider the safety aspect while purchasing

plantmachine, equipment, material, etc. They will obtain and provide to the user

plant,Material Safety Data Sheets while purchasing any chemicals. While

procuringmaterial handling equipment, the Purchase Department will ensure that the

necessary certificates regarding safe working load, etc, are made available.

The Contractors will be responsible for all safety measures related to their

work.Contracting Departments will ensure compliance and supervision. It will

beobligatory on all Contractors and Visitors to follow the existing Plant Safety

Rules,Procedures, Systemsand Practices. They must start their work only afterreceiving

proper instructions and permission.

7.9 ON - SITE EMERGENCY PLAN

7.9.1 Introduction

A major emergency in a work place is one, which has the potential to cause serious injury and or

loss of life. In addition it may cause extensive damage to property and environment. The rapid

growth in the use of hazardous chemicals in industry and trade has brought about a very

significant increase in the number of people, both workers and members of general public,

whose life could be endangered at any one time by an accident involving these chemicals. In

addition, it causes serious disruption of activities both inside and outside the works. It would

normally require the assistance of outside emergency services to handle it effectively. Although

emergency may be caused by a number of different factors like, earthquake, vehicles crash,

sabotage, it will normally be manifested itself in two basic forms, fire and explosions

Chapter VII


Scope

Prevention of accidents is possible to a large extent through good design, correct operation,

periodic maintenance and routine inspection. Achieving all these will reduce the risk of an

accident, but it will not eliminate it altogether absolute safety is not achievable, and an essential

part of major hazard control, is concerned with mitigating the effects of a major accident. An

important element of mitigation is emergency planning, i.e. recognizing that accidents are

possible, assessing the consequences of such accidents and deciding on the emergency

procedures, both onsite and off-site, that would need to be implemented in the event of an

emergency.

7.9.2 Objectives

The overall objectives of an emergency plan are to

(1) Locate the emergency, if possible and eliminate it.

(2) Minimize the effects of the accident on the people and property.

Elimination: It requires prompt action by operators / works, emergency staff, e.g. firefighting

equipment, emergency shut off valves, water sprays. Minimizing the effects may include rescue,

first aid, evacuation, rehabilitation and giving information promptly to people being nearby.

7.9.3 Identification And Assessment Of Hazards

• Fire & Explosion possibilities in Storage and Handling of fuel, Sugar Godown,

Molasses Tank, Bagasse yard and Sulphur Godown, and alcohol storage area

Statutory Requirement: Section 41-B (4) of the Factories Act 1948 stipulates that the occupier of

the Factory engaged in a hazardous process shall draw up an on—site emergency plan and

detailed disaster control measures for the factory and more known to the workers and the

general public in the vicinity. This includes the safe measures required to be taken in the event

of a major emergency taking place. Further an occupier of hazardous chemicals storage plant is

to prepare an emergency plan as per Rule 13 of the Manufacture, Storage and Import of

Hazardous Chemical Rules 1989. This plan shall incorporate the guidelines given by office of the

Chief Inspector of Factories, and to be revised every 6 months to keep it in the latest form.

7.9.4 Emergency Control Centre

Security Main Gate Office is chosen as the “EMERGENCY CONTROL CENTRE”. The emergency

control center is the place from where the operations related to emergency are coordinated.

The Emergency control center is suitably equipped to receive and transmit information and

Chapter VII


directions from the incident site and furnish useful data to other affected areas inside & outside

works. The center shall contain the following information and facilities.

1) An updated copy of the ON—SITE EMERGENCY PLAN which gives the following information.

Master plan of the works showing different locations, where hazardous materials are

stored/ processed.

Sources of Personal Protection Equipment, portable fire extinguishers, and other safety

material.

Fire fighting system and sources of water. Mutual Aid system with other industries.

Plan of the works with safe distance areas, escape routes, assembly points.

Vicinity Plan of the area in which the industry is located.

List of key personnel and their telephone numbers.

List of Government officials, other areas of help — their telephone numbers

2) Updated Nominal roll of the employees and other visitors

3) Communication facilities like phones, mobile phones, walkie-talkie sets etc.

4) Standby power arrangements like— Generator –sets

7.9.5 Responsibilities of Works Manager

1. Prepare on—site emergency plan and revise it from time to time (once in 6 months)

2. Conduct regular mock drills

3. Educate / train all the employees regarding on-site emergency plan

4. Submit copy of “on—site emergency plan” and mock drill to Chairman / District Disaster Plan,

Deputy Chief Inspector of factories Office.

5. Stock necessary PPE for firefighting.

6. Device data collection forms for collecting data during emergency.

7.9.6 Emergency Siren

An emergency siren of minimum 500 Meter Capacity is installed for the purpose of alarming

employees on emergency. It is located near the Security Main Gate or Emergency Control Room.

The “CHIEF INCIDENT CONTROLLER” will decide the operating controls at appropriate time.

The following information is given for the identification of various signals of the siren to the

employees.

Sr. No. Type of Siren Duration

1 Factory shift siren continuous for 30 seconds

2 In case of fire Special Hooter Siren

3 Emergency Siren for other Emergency Special Hooter Siren repeating TWICE

4 All Clear siren Continuous Siren for three minutes

Chapter VII


7.9.7 Wind Direction:

For the purpose of identifying the wind direction WINDSOCKS are installed at company. The

windsock is located on the roof of workshop. The WINDSOCKS bore distinct white & red stripes

to attract immediate attention.

All the employees and visitors are requested to note the wind direction at the time of major

incidents.

Recommended Practice During Emergencies

There is an Assembly point located at Security Main gate for the purpose of assembly of the

Non-Emergency employees and visitors in case of emergency. However, the KEY Emergency

personnel will give appropriate guidance as and when situation warrants.

7.9.8 Organization Chart for Dealing Emergencies

Note: Each team will have a list of emergency personnel for dealing with the Emergency in their

respective specialization

CHIEF INCIDENT CONTROLLER

Managing Director SITE INCIDENT CONTROLLER

Safety Officer

LIAISON TEAM

Manager Personnel SAFETY & ENGINEERING TEAM

Works Manager/Safety Officer

FIRST-AID TEAM

EXTERNAL COMMUNICATION

FIRE & SECURITY/TRANSPORT

Security Officer/Security Supervisors

FIRST INFORMER

Chapter VII


7.9.9 First Information

Any person, who notices an abnormality like fuming, fire in shall phone to the security / inform

the security guard. He shall give his identity in case he contacts the security Main gate directly.

7.9.10 Brief Responsibilities

7.9.10.1 Chief Incident Controller

Declares emergency

Rushes to emergency control centre

Controls emergency by coordinating with site-incident controller

Communicates to external agencies through liaison team

Declares lifting of emergency

7.9.10.2 Site Incident Controller

Receives a call from security supervisor

After a brief visit to incident site, decides and advises chief incident controller to declare

emergency.

Controls the emergency by coordinating various activities through his teams '

Advises to chief incident controller lifting of emergency

Reviews and prepares a detailed report on the incident and submits to “Chief Incident

Controller”

7.9.10.3 Safety And Engineering Team

Device methods to isolate emergency and movement of people.

Provide necessary safety data to site controller

Provide required PPE.

Provide time to time information to site incident controller

7.9.10.4 First-Aid Team

Provide First-and /medical care to persons injured inside factory

Keep a lust of people sent for outside treatment and other welfare measures undertaken

Maintain the list of people inside premises and sent out including visitors

Provide time to time information to site incident controller

7.9.10.5 Fire Team, Security Team

Control the emergency by firefighting.Give a call tomutual aid if required.

Move people to safe areas specified by safety andengineering teams

Control the movement o‘ traffic at Gate

Provide time to tame information to siteincident controller

Chapter VII


7.9.10.6 Liaison Team

Provide important information to external agencies

(Government Officials Press and Public) Take necessary guidelines from Chief Incident

Controller

7.10 RESPONSIBILITY IN DETAILS

7.10.1 Chief Incident Controller

He will decide and declare emergency on the advice of ‘Site Incident Controller’.

He will advise to raise the emergency Siren to draw the attention of employees and

contract workmen to follow emergency regulations

He will rush to emergency control center. (SECURITY MAINGATE)

He will decide calling off emergency on the advice of ‘siteincident controller’.

He will instruct to raise all clear siren to mark calling offemergency.

He will give guidelines to liaison team on sharing information togovernment officials**,

press and general public.

He will have Time to Time interaction with site incident controller on dealing of

emergency.

He will call a meeting of the Site incident controller andemergency teams to discuss and

decide steps to restore normal working in the area of incident. He will also discuss on

theincident report and decide remedies to be implemented to avoid its recurrence.

Instructions given by Site incident controller and respective teams.

**District collector, deputy. Directors of factories, Municipal commissioner, Police

commissioner, chief Officer Fire brigade.

7.10.2 Site Incident Controller

On receipt of information from security office, he will rush to the site of incident /

accident.

After assessing the situation, he will advice ‘Chief Incident Controller’ to declare

emergency.

Coordinate the activities of various teams.

Give time to time feedback to ‘Chief Incident Controller’.

Formulate systems to collect data during emergency.

Isolate and take non-emergency employees to assembly point (safe location) through

security team.

Cordon off the area through security team.

Regulate the traffic in main gate through security team.

Chapter VII


Keep the escape routes clear through security team.

Fight and control the emergency through fire team.

Discuss and decide measures to control / isolate appliances and power through safety

and engineering teams.

Review at regular intervals on the availability of required PPE, Medicine and water for

firefighting.

Record the directions given in specified formats.

Collect filled in formats from respective teams, prepare a detailed ‘incident report’ and

submit the report to Chief incident controller.

To draw plans and assist Chief incident controller to restore normal working conditions.

7.10.3 Safety Team & Engineering Team

Act as per the directive of ‘site controller’.

Check direction of wind and decide assembly points for non-emergency employees.

Check availability of water, fire extinguishers and make arrangements for replenishing

theme.

Discuss and execute isolation of equipment for localizing emergency i.e. combustibles

storage locations.

Shift/cordon off flammable materials from the danger zone.

Put off power supply wherever not required.

Provide necessary personal Protective equipment like firefighting suits, gas masks, hand

gloves, helmets, etc.

Keep a list of essential staff needed during emergency.

Record the activities in a specified format

7.10.4 Fire Team & Security Team

Inform site incident controller the incident and call him to site ofIncident

Act as per the directive of Site incident controller.

Rush fire—fighting team to site of incident and start fire-fightingoperation.

Rush security team to cordon off the incident site.

Move nonessential employees to assembly point.

Regulate the traffic at gates.

Keep the escape routes and roads free from obstruction.

Make transport facilities for transporting nonessential employees.

Keep list of essential staff needed during emergency

Chapter VII


7.10.5 First-Aid Team

• Keep a detailed list of employees and contract workmen present in the premises for the

day. Make arrangements for head count.

• Offer first aid facilities to the injured and send to assembly point.

• Recommend hospital treatment to the injured and inform the hospital authorities in

advance.

• Keep enough stock of medical equipment, drugs, and antidotes.

• Give information to the families of the injured.

• Make ambulance facilities for the injured persons and transport facilities to non—

emergency persons.

• Inform government authorities and fulfill statutory regulations.

• Record the activities in a specified format.

• Act as per the instructions of site incident controller.

• Keep a list of essential staff required to assist during emergency.

7.10.6 Responsibility Of Non-Emergency Employees And Visitors

• On hearing the emergency siren stop the work, put off the equipment wait for the

instruction of shop in charge / supervisor

• Leave calmly to the specified assembly point.

• Don't block the emergency escape routes.

• Don't spread rumors/ unnecessary information to public.

7.10.7 Key Emergency Personnel: Respective group leaders of the teams in the ON—SITE

EMERGENCY organization chart.

7.11 OFF - SITE EMERGENCY PLAN

Since the only hazard that expected in the distillery is fire and normally contained within the

premises. In rare case if the fire hazard spreads out-side the premises respective group leaders

shall communicate to the District Magistrate, Commissioner of the Police, Control Room and

inform the situation as Off- Site Emergency. It shall be the responsibility of the Police Personnel

to look after the law and order, traffic control, evacuation of workers and other personnel. They

should also advise, through public address system, the localities that are likely to get affected

and the steps to be taken.

Chapter VII


Emergency Response Flow Chart

Major Spills

Yes

Major Spill Occurs

Initiate emergency

response action

Notify area

supervisor

Notify emergency

Coordinator

Notify employees

Evacuate hazard

area

Obtain emergency

medical assistance

Summon On-Site

Emergency Team

Can On-Site

Emergency Team

contain emergency

Summon off site

assistance

Notify appropriate

agencies

Verify identity of spilled material

Use appropriate

personal protective &

emergency equipment

Contain Spills

Determine quantity &

notify appropriate

agencies

Transfer to recovery

containers

Decontaminate spill

area

Label, store, dispose

of containers

Signal end of

emergency

Restock emergency

suppliers

Follow-up

notifications

Assess incident/

revise plans

No

Flammable

Remove sources

of ignition and

incompatibles

Corrosive

Use appropriate

personal protective &

emergency equipment

Contain Spills

Neutralize with

appropriate agent

Chapter VII


Emergency Response Flow Chart

Major Fire

Fire Occurs Is there

large quantities of materials, or

difficulty in containment, or

a threat to the environment or

panic among employees

Evacuate Area

Shut Down Equipment

Are people injured?

Summon On-site Response Team

Can On-site response team contain fire?

Use correct protective equipment

Remove ignitable substance and those

could cause heat-induces explosion

Initiate fire fighting

Containerizes fire debris

Label, store, dispose of containers

File written report with appropriate

agencies

Assess incident and revise contingency

plan

Contact medical personnel

Summon off-site assistance

Minor fire

Flowchart

Was hazardous substance

involved?

Risk of fire spreading to

areas where hazardous

materials are located

Risk of generating toxic

fumes/or contaminated

runoff?

Hazardous material

response not required

Yes

No

No

No

No

No

Chapter VII


Emergency Guidelines for teams

Emergency

Welfare Team Rescue/ evacuation team Engineering team Security fire team

Accompany injured to medical centre Establish communication with chief

coordinator emergency coordinators

Take instruction from chief controller Assist the site controller in carrying

out his duties

Assist the liaison /medical officer in

his duties

Cordon of the area with the help of

security team

Ensure safety of the remaining part

of the plant

Provide security coverage and

cordon off the emergency area

Continues communication with

emergency coordinators

Start search/ rescue operation Plant shut down on advice from the

emergency coordinators

Control and prevent the fire from

spreading

Give appropriate first-aid Ensure use of necessary personal

protective for search operation

Undertake any repair work on an

emergency basis

Identify fire and use appropriate fire

extinguisher

Inform hospital in advance so that

they are prepared

Ensure that emergency does not

escalate

Arrange to carry out civil work in the

course of emergency operation Transfer material to safer place

Direct injured to hospital Arrange to supply water under maximum

pressure for fire/emergency Arrange transport for victims

Miscellaneous duties regarding mechanical/

electrical/ electronic assistance

Direct the fire and rescue team

Chapter VII


EMERGENCY GUIDE

EMERGENCY

Confirm the message

No Emergency

Chief Controller / Dy. Chief

Controller

Proceed to emergency control

center & remain there

Coordinate and communicate from

emergency control center

Chief Coordinator

Coordinate all the team actives under

instruction from chief controller

Evaluate safety and health hazard

Coordinate transport services

Liaison officer

Undertake instructions from

Chief Controller

Direct injured to hospitals

Arrange for hospital

accommodations, canteen etc.

Liaison with press, Govt. agencies,

neighboring factories

Disclose all necessary information

so as to avoid rumors & confusion

Arrange for safe and temporary

shelter in consultation with site

Controller & liaison officer

Emergency Coordinators Site controller

Message to chief Controller/ Dy.

Chief Controller

Confirm the message

Undertake all rescue operation

under instructions from Chief

Controller

Arrange assistance from production

& maintenance in the course of

emergency operation

Inform medical center

Miscellaneous duties regarding

mechanical/ electrical/ electronic

assistance

Coordinate with security personnel

&maintains law and order

Regulate & restrict entry & exit of persons

Take all possible steps to control

emergency

Call local brigade in consultation with chief

controller

Take command of fire/ security team &

arrange to supply water under maximum

pressure for fire/ emergency operation

Chapter VII


PUBLIC HEARING

7.12 PUBLIC HEARING MINUTES

Chapter VII


Chapter VII


Point-wise reply to the queries of Public hearing

1) Queries raised by The Convener of Public hearing

a. Disposal of catalyst from distillery material is not mentioned

Reply: In the molasses based distilleries catalysts are not used for distillation

process. Therefore, there will not be any issue of disposal of such catalyst.

b. Piezometric well under CREP guidelines is not mentioned

Reply: Photographs of Piezometric well and monitoring report of ground water

near to the compost site is enclosed as annexure XV to this report

c. GSDA guidelines are not mentioned if the project proponent is using bore

well water;

The project is not using any ground water resource. Hence, these guidelines are

not applicable in the present project.

d. To install Continuous Online Monitoring System period is not mentioned

which is indispensable to project proponent;

Photographs of the same are enclosed as annexure XVI to this report

Online Monitoring System Details for Sugar Unit

Sr.No Particulars Parameters Vender Name Online monitoring started

1. Online multi parameter Analyser

pH, BOD,COD, TSS

M/s. Forbes Marshall Pvt, Ltd, Plot No. B-85, Phase-II, Chakan Industrial Area, Village Savardari-Chakan, Taluka- Khed, Pune

Season 2016-17

2. Dust Monitor Particulate Matter

3 Electromagnetic flow meter

Flow M/s. Krohne Marshall Pvt, Ltd, A-34/35, MIDC Industrial Estate H-Block, pimpri, Pune

Season 2016-17

Online Monitoring System Details for Distillery Unit

Sr.No Particulars Parameters Vender Name Online monitoring started

1. Online electromagnetic flow meter

Effluent outlet flow measurement

M/s. Krohne Marshall Pvt, Ltd, A-34/35, MIDC Industrial Estate H-Block, pimpri, Pune

Season 2016-17

3 Online web camera

Compost yard observation

M/s. Forbes Marshall Pvt, Ltd, Plot No. B-85, Phase-II, Chakan Industrial Area, Village Savardari-Chakan, Taluka- Khed, Pune

Season 2016-17

Chapter VII


2. Queries raised by Chairman of the Public Hearing Committee and Honorable ADM,

Shri Vijaysinh Deshmukh

1. As per the analytical studies of the soil of the area, it is observed that carbon

quantity is very meager. Hence quantity of organic carbon should be increased;

Reply: The factory has taken following measures to improve soil organic carbon

It is supplying press mud, Bio-earth compost on subsidized rate to farmers

also implementing sugarcane trash mulching program after harvesting cane

at farmers field

Under green manure program supplying seeds of sun hemp & Dhencha which

are helpful for increasing organic matter

The Management assures that it will continues its efforts as well as add new

programmes to increase soil organic carbon.

2. The pH of the soil is 8.8, which is at the higher side. This is due to excess use of

chemical fertilizers. It affects eco-system as well as our body system. As per the

report, it is concluded that the soil of Punjab is totally spoiled due to excess use of

fertilizers, hence there is rise of cancer patients of all age groups in Punjab. The

awareness program for the same should be carried in the local area.

Reply: The factory has established soil testing lab. It is recommending fertilizer as per

soil testing report, which will helpful for maintaining soil pH.

As suggested by Honorable ADM, we have made provision for such awareness

programme. It is mentioned in table 9.7 under point D Education – please refer chapter

IX, page 9-17 & 9-18 of EIA report.

3. The objections raised during the meeting should be solved immediately. The issue

of release of Soot/carbon particles in the environment should be solved

immediately;

Reply: Existing wet scrubber are suitable for our present crushing, It is also suitable for

proposed expanded capacity of 6000 TCD.

However, we have contacted to our wet scrubber supplier for its design suitability or

required any modification of it.

4. From the CER (Corporate Environment Responsibility) Fund, previously which is

used to be called as CSR (Corporate Social Responsibility) Fund, green belt should

Chapter VII


be developed in the area. It is appealed to the project proponent to extend the

financial aid to the nearby villages for the construction and maintenance of

Jalyukta Shivar;

Reply: As suggested by Honorable ADM, we have made provision for this activity under

watershed development programme of CSR. Please refer chapter IX, table 9.7 page 9-17

& 9-18 of EIA report for details of fund provision.

5. It is observed during the presentation that the bagasse remains in large quantity.

It should be used for co-generation project.

Reply: We are installing another turbine for running co-generation in off season. Saved

bagasse will be utilized for this project. The work is already started.

6. The local farmers should be made aware to use organic fertilizers for production

of sugarcane.

Reply: Cane development department of the factory is regularly providing guidance for

use of organic & bio-fertilizers for improving soil fertility & soil health.

Chapter VII


Chapter VII


Reply to the above letters is as follows.

We have received a letter through an email from Mr. H. Madhubabu, President (REEHAS, Rural

Environment Education and Health Awareness Society) on July 29, 2018. We appreciate his

observation and suggestion. In response to the same, this point-wise response is prepared.

1. The Proponent of M/s Shreenath Mhaskoba Sakhar Karkhana Ltd proposed to Expansion of

Sugar Unit & Distillery Unit as mentioned above

Reply: Yes, Noted

2. The Environment consultant Vasantdada Sugar Institute of this project study area covered

10 k.m radius around the proposed Project area, they studied locations of air ambient

quality , noise levels recorded , water samples collected, soil samples also collected these all

are in norms of CPCB. This is satisfactory.

Reply: Monitoring results given in Chapter-III of EIA reports. Thanking you for your perusal of

monitoring results and comment of satisfaction.

3. The consultant, please take health states of village people in 10 km radius around is must,

why because it is very useful in future.

Reply: Provision is made in the CER/CSR budget for medical camp in the project area.

4. Please take Crop production details from near Agriculture lands also.

Reply: Major crops of the area, is given in Chapter-III. Regarding crop production i.e. yield data

is collected by Government authority. It is not possible to collect the primary data on yield in

three months monitoring period. Also, it is not included in the monitoring guidelines or terms of

reference.

5. For operation of the project water requirement is 520 m3/Day It is taking from Bhima river

, in summer season chance to down fall water level so please arrange rain water harvesting

system.

Reply: Factory has already made facility for rainwater harvesting. This will be improved,

budgetary allocation for the same is made under EMP. Details are given in Chapter- IX of EIA

report. Factory will recycle the water to fullest extent and also use treated water to reduce fresh

water requirement.

6. Please utilize waste water to plantation, sprinkling on roads. It controls Dust Pollution when

your vehicles transport time

Reply: This suggestion is already in practice.

7. Your taking 14.5 Acres (33%) plantation for Green belt is good, it is CPCB norms, but I am

requesting to increase if any possible.

Chapter VII


Reply: The factory is already maintaining 12.5 acres of greenbelt. This will be enhanced in the

proposed project. We have noted your suggestion and we will try to implement.

8. You take avenue plantation to near villages, road side, it is useful to save environment.

Plant fruit baring and medicinal value trees.

Reply: Such activities are already in practice. In addition, financial provision for the same is

made in CER plan, that assures its implementation in future also.

9. Please give employment opportunities to local people first. And conduct skilled programs

for local youth like ITI, Diploma. They will get job opportunities other industries also

Reply: As a policy, the management of the factory has always given preference to the local

youth for permanent as well as contractual employment. The same policy will be continued

even after expansion.

10. Give medical facilities to near villages, Conduct Medical Camps Regularly.

Reply: Budgetary provision for these activities is already made in CER/CSR budget. Please refer

chapter-IX of EIA report.

11. Give drinking water facility to near villages.

Reply: Budgetary provision for such activities is already made in CER/CSR budget. Please refer

chapter-IX of EIA report

12. Give good education to near village children.

Reply: The factory is working on these lines for last several years. It has undertaken many

activities for education of children of harvesting labour, employees as well as children from

nearby areas. In continuation with the same, budgetary provision for such activities is already

made in CER/CSR budget. Please refer chapter-IX of EIA report

13. Develop all main roads and street roads of near villages.

Reply: Noted. The factory supports such type of developmental activities.

14. The project will contribute additional revenue to the State & Central Govt.

Reply: Thanking you for the keen perusal and remark

15. For using of CSR budget please form a Co-ordination committee with village people, Govt.

officials and company people, and find necessary works for villages not target oriented

works.

Reply: Thanking you for your suggestion. It is noted.

Once again, we thank Mr. H. Madhubabu, President (REEHAS, Rural Environment Education and

Health Awareness Society) for his suggestions and support to this project.

Chapter VII


We have received a letter through an email from Mr. S. Venkateshwarlu, Chief Functionary

(NEETHA Swachanda Seva Society, Environmental management Development Organization) on

August 2nd, 2018. We appreciate his observation and suggestion. In response to the same, this

point-wise reply is prepared.

1. To take up plantation in the surrounding villages with variety of trees, species and herbal,

fruit bearing types and to develop avenue plantation


made in CER/CSR plan, which assures its implementation in future also.

2. Greenbelt will be developed within the premises of the project.

Reply: The factory is already maintaining 12.5 acres of greenbelt. This will be enhanced in the

proposed project. We have noted your suggestion and we will try to implement.

3. To take Water sprinkling to reduce the PM emission level.


4. To take CPCB & CREP guidelines will be followed.

Reply: Factory is following CPCB & CREP guideline. Implementation of the same e.g. impervious

lagoons for spent wash storage, impervious compost yard, etc. are discussed in chapter II of

the EIA report.

5. To incorporate public health status and ground water status of the area.

Reply: Provision is made in the CER/CSR budget for medical camp in the project area. Ground

water monitoring results and status given in Chapter-III of EIA reports.

6. To providing the nearby villages in the employment.




7. To take CSR Activities will be carried out in the local area which will improve the social-

economic status of the local people.


8. Welcome to the proposed project to issue environmental clearance (EC) by MOEF&CC.

Reply: Thanking You

Once again, we thank Mr. S. Venkateshwarlu, Chief Functionary (NEETHA Swachanda Seva

Society, Environmental management Development Organization) for his suggestions and

support to this project. We have received a letter through an email from Mr. Vootkuri S. Reddy,

President (Dharithri Paryavarana Parirakshana Samstha) on July 07, 2018. We appreciate his

observation and suggestion. In response to the same, this point-wise response is prepared.

Chapter VII


1. You consultancy have already conducted baseline survey of air, water, land it is very good. My

request is please collect the data of the health status of the people, Data of Crop production

status and ground water availability status within 10Kms radius. It is very useful in future

and utilize as a parameter to take precautionary affective measure to maintain ecological

balance.

Reply: Monitoring results given in Chapter-III of EIA reports. Thanking you for your perusal of

monitoring results and comment of satisfaction. For health status of the people, provision is

made in the CER/CSR budget for medical camp in the project area. Major crops of the area, is

given in Chapter-III. Regarding crop production i.e. yield data is collected by Government

authority. It is not possible to collect the primary data on yield in three months monitoring

period. Also, it is not included in the monitoring guidelines or terms of reference. Ground

water monitoring results and status given in Chapter-III of EIA report.

2. My request and suggestion you take up industry proposed expansion of sugar unit form 2500

TCD to 6000 TCD and Molasses based distillery unit from 30 KLPD to 55 KLPD. Whatever you

draw river water. The water is not flowing throughout the year. The excess water flowing is

rain season only. It is beneficial to construct storage tanks for collecting overflowing water in

rainy season.

Reply: Factory has developed facility for rainwater harvesting. This will be improved,

budgetary allocation for the same is made under EMP. Details are given in Chapter- IX of EIA

report. Factory will recycle the water to fullest extent and also use treated water to reduce

fresh water requirement. Factory is storing the harvested rain water, in the ground reservoir

(after filtration and required precautions).

3. My request and suggestion to you to take up proposed industry of land, whatever you draw

water it is a limited natural resources. But the water is not sufficiently available throughout

the year it is a limited sources. The excess water is available in rainy season only. My

suggestion is please make special efforts to collect rain water to store construct storage tanks

for storage rain water. It is very useful to use the rainy water in non rainy days to your

industry. It is very beneficial to maintain ecological balance.

Reply: Factory has made facility for rainwater harvesting. This will be improved, budgetary

allocation for the same is made under EMP. Details are given in Chapter- IX of EIA report.

Factory will recycle the water to fullest extent and also use treated water to reduce fresh

water requirement. Factory is storing the harvested rain water, in the ground reservoir (after

filtration and required precautions).

Chapter VII


4. Please take up village plantation in nearby villages and also avenue plantation for internal

roads on which roads your vehicles transport the materials to control dust pollution. My

request is you should give priority to fruit baring plants and medicinal value plants instead of

normal plants it is useful to control dust pollution and available fruits in nearby villages.


made in CER plan, that assures its implementation in future also.

5. Please give priorities to local educated unemployed youth for employment in your industry.




6. My humble request is to promote skill development training to unemployed youth to better

skills useful to get employment chances in your industry remaining youth to get jobs in other

places. Countries like Japan and Korea 95% of youth they got skill development in India only

5 to 6 percent youth skilled persons.

Reply: The factory has made provision in CER/CSR budget for training of factory workers as

well as farmers. Please refer chapter IX, table 9.7 for the details.

7. My request is to form co-ordination committees with you company officials, Govt. officials and

PCB officials and villages to take up plan of action of CSR budget it is very useful and

meaningful to take up demand oriented works. This is very essential to village development.

Please discourage target oriented works. With this activity a great credibility comes to you.

Reply: Thanking you for your suggestion. As mentioned in chapter III of EIA report, the factory

is always undertaking the activities which are of local relevance and useful to local residents.

Thus, now as well as in near future the factory will implement social activities which are

beneficial to locals.

8. My suggestion please include promote the farmers planting of sugar cane to cutting it will

take 15 months approximately. The water used by farmers is 3 Crore liters in a crop year,

please encourage the farmers to minimum utilization of water either by drip irrigation or by

sprinkler so that, it will promote the farmers growing sugar cane in only one crore liters. To

take the better environment.

Reply: The factory is already working in this direction and supporting farmers who are willing

to install drip.

Once again, we thank Mr. Vootkuri S. Reddy, President (Dharithri Paryavarana Parirakshana

Samstha) for his suggestions and support to this project.

Chapter VIII



Chapter VIII

PROJECT BENEFIT ANALYSIS

8.1 PROJECT BENEFITS: FOR THE PROJECT PROPONENT

Sensible utilization of available resources such as land, boiler (steam), bagasse, molasses

and human resources

Cheap labour pool, since employment in rural area is agro-based and seasonal

The products have continuous market demand

Markets are located within state as well as at national/international levels and there is

very good connectivity of road, rail & air to the site

Generation of value added product from sugar mill by-product/waste

Similarly, spent wash (highly polluted wastewater) generated in the unit will get

converted into a good quality manure by mixing it with pressmud

Overall improving profitability of the business and ensuring long term sustenance in the

scenario of volatile sugar prices through byproduct generation

Ease to control both the units

8.2 PROJECT BENEFITS: FOR THE LOCAL SOCIETY

Sugarcane grower farmers and workers will be benefited, since distillery is an ancillary

unit of sugar mill

Generation of additional 364 direct employment

Indirect employment in various forms e.g. transportation, refreshment stalls,

workshops, daily commodity shops, etc. People will be benefitted by these services

Improvement will take place in infrastructures such as schools, medical facilities,

transportation, etc.

Revenue for the local authorities as well as state government

The benefits of following activities initiated by sugar mill will be continued.

Implementing various labour welfare activities such as health checkup camps, rewards,

celebration of various festivals, providing housing facility etc.

Providing cane seed of improved varieties to cane growers at concessional rate

Encouraging the farmers for lift/drip irrigation schemes, soil testing and other improved

farm management practices

Operating “Sakhar shala” for the children of cane harvesting workers

Chapter VIII



8.3 BENEFITS TO COUNTRY: ALCOHOL AS A FUEL

Ethanol is mainly produced from sugarcane molasses. Sugarcane is a renewable source of

energy. Sugarcane cultivation is an efficient method of converting ‘solar energy’ into ‘stored

energy’. Thus, use of ethanol as oxygenating agent or fuel-extender helps reduce the usage and

dependence on fossil fuels.

Ethanol is made from renewable sources of energy i.e. based on agricultural products. Thus, it is

not a depleting resource like petrol. Use of ethanol is also carbon neutral as compared to use of

fossil fuels.

Blending of petrol using ethanol even at 5% directly saves that much petrol. This quantity is

huge at national level. This helps to save valuable foreign exchange and strengthen the

economy. This could also help in controlling/regulating the prices of petrol in the market, since

ethanol is cheaper compared to petrol. Overall, it could have manifold effect on economy.

8.4 ENVIRONMENTAL BENEFIT ANALYSIS

Agro based industry and raw material is renewable

No rehabilitation, restoration issues involved

Saving on transportation of raw material and filler materials, as well as fuel cost

Exhaust steam from captive power/cogeneration unit will be used for distillery

operations, hence it will save energy (fuel) as well as water

Captive power – generated on renewable energy

Disposal of molasses, press mud and ash will get solved due to the proposed unit

Generation of energy (biogas) from wastewater i.e. spentwash; thereby, direct emission

of methane will be avoided. Methane is a greenhouse gas having 23-time higher global

warming potential than carbon dioxide

Recycling of soil nutrients by bio-compost; thus, increasing soil fertility

Recycling/reuse of treated water will save fresh water intake

Solid waste generated from sugar factory like press mud, ash and ETP sludge can be

converted to bio-manure

No wildlife sanctuary, national park within 10km radius of study area; no disturbance to

wildlife

Overall, pollution control at all possible extent, enhancing the environmental benefits

Thus, project is anticipated to be beneficial for sustainable development of the region.

Chapter IX


Chapter IX

ENVIRONMENTAL MANAGEMENT PLAN

9.1 OVERVIEW

The Environmental Management Plan (EMP) is developed for preventing, controlling, and/or

mitigating the likely adverse/negative environmental impacts of the project on surrounding

environment. EMP framework is a site specific document for the project, to ensure that the

project can be implemented in an environmentally sustainable manner and where all concerned

persons of the industry as well as contractors, understand the potential environmental impact

arising from the proposed project and take appropriate actions for proper management.

9.1.1 Objectives of EMP

Minimization of waste generation and pollution

Judicious use of available resources

Safety, welfare and good health of the work force and populace

Ensure effective operation of all control measures

Vigilance against probable accidents and disasters

Monitoring of cumulative and longtime impacts

Ensure effective operation of all control measures

Overall conservation of natural resources and environment

9.2 EMP FOR CONSTRUCTION PHASE

The project activity comprises of expansion of existing sugar and distillery units. As the

construction activity will take place in already developed industrial premises, many issues such

as water supply for drinking and domestic activities, sanitation facilities for labour at site,

electricity availability, safety and health facilities for labour, etc. become less significant. Labour

from neighboring areas is easily available. All these aspects were considered while anticipating

environmental impacts of construction phase. The construction activity involves installation of

various units of sugar and distillery such as storage tanks for raw material as well as finished

products, distillation towers, installation of mill, sugar godown, enhancement of spray pond and

compost yard, etc. Thus, the major activities involved for construction phase are

Loading / unloading of construction material

Excavation work (as per requirement) for the various buildings and structures

Transportation of the material and workers to & from the project location

Chapter IX


Modernization of existing various machineries/units

Disposal of the liquid and solid waste generated by the temporary work force

employed for construction

Considering the types of activities associated with the project and sources of pollution,

following mitigation measures are recommended.

Fugitive dust emission due to transportation activities as well as loading/unloading of

material will be controlled by water sprinkling on dust generative sources

The activities generating noise to be carried out within daytime only and prohibit all

such activities for night time

Run-off of loose soil to be prevented by means of compacting the soil

Transport contractors must be instructed to maintain their vehicles properly, so as to

minimize the exhaust emissions, reduce the noise and prevent the oil leakages from

vehicles

Labourers to be advised to use toilet blocks available in the existing mill premises

Solid waste material to be segregated properly and its further treatment/disposal to be

carried out according to the nature of the waste, under the supervision and guidance of

environment officer/chemist available in the existing sugar unit

Greenbelt enhancement/developmental activities to commence in the surrounding

zone of the construction site

9.3 EMP: OPERATION PHASE

Table 9.1: Environment management plan: operation phase

Aspect Impact causing factor Control/Mitigation Measures

AIR ENVIRONMENT

Air Environment

Particulate Matter (PM)

Formation of SO2, NOx

H2S from Biogas

Carbon dioxide due to

fermentation, Odour

due to composting

process

• Existing Stack 65 m height is adequate

• Wet scrubber to control ash emission through

stack

• Existing Greenbelt 12 acre and proposed 2.5

acre Total 14.5acres

Covered fermenters

Bagasse contains traces of S & N, hence

generation of SO2 and NOX anticipated to be

limited

Chapter IX



Proper ash and bagasse handling system

Use of biogas as fuel

Provision of flare unit

Aerobic composting by using aero-tiller

machines

Storage of spentwash as per CREP guidelines

Fugitive dust from

Handling and transport

of bagasse and ash;

dust generated from

roads, etc.

Mechanized system for handling of bagasse as

well as ash

Asphalted internal roads,

Adequate parking places for goods and private

vehicles

WATER ENVIRONMENT

Water

Environment

Major source – effluent

from milling section,

boiling house,

centrifugal house,

boiler blow down,

cleaning & condensate.

Storage of spentwash,

its treatment and

disposal

Existing sugar ETP will be upgraded to treat

effluent of600m3/day from proposed units

(after expansion)

Currently, spray pond over flow is collected

separately and sent for irrigation after

proper treatment. Same will be followed after

expansion (quantity 600 m3/day)

ETP treated water will be reused for

greenbelt/irrigation (within the premises)

Process condensate from sugar unit will be

recycled (partially); reducing the fresh water

requirement considerably

Rain water harvesting

Bio-methanation as primary treatment for

spentwash

Multi Effect Evaporation (MEE)-secondary

treatment to reduce spentwash volume

Concentrated spentwash will be mixed with

Chapter IX



press mud cake to produce bio-compost

Spentlees, condensate of MEE and other

effluents will be treated in condensate

polishing unit and reused for distillery

activities

All effluent will be properly treated and

utilized/disposed within the premises

Storage of spentwash in 30 days and five day

impervious lagoons as per CREP guidelines

Enhancement of existing impervious

compost yard with leachate collection

drainage and other facilities - strictly as per

CREP guidelines

Fresh water requirement will be reduced by

recycling of water, using rain water during

startup period

Bore well, in downstream area of bio-

compost to monitor ground water quality

SOLID WASTE

Boiler

Ash Bagasse ash is rich in potash, thus used to enrich

the soil or sold for bricks manufacturing Provision

of greenbelt for natural control

ETP (Sugar unit) Sludge Organic and degradable hence, mixed with bio

compost Fermentation Sludge

Bio digester Sludge

NOISE

Process

machineries

Mainly Boiler, STG,

pumps and motors

Noise sources/ noise generating activities will be

under roof/in covered area

Regular maintenance of machinery

Provisions of personal protective equipment

Job rotation at high noise work places

Regular health check up

Walls and trees will help to attenuate noise

Chapter IX



Greenbelt development

Transportation Regular maintenance of vehicles

Well maintained internal roads and adequate

parking will reduce traffic congestion and noise

due to it

Ecology and

Biodiversity

Air, water, soil and

noise pollution

Tree cutting failing,

disturbance to wildlife

due to project

Adequate preventive, control and mitigation

measures for air, water and soil pollutants

No tree cutting failing involved since project

is on flat, barren land

No wildlife sanctuary, national park or

biosphere reserve within 10km radius, site is

not in migratory route of any wildlife, no rare

and endangered species of plants/animals

reported from the region

Development of greenbelt will help to

enhance the biodiversity and may provide

habitat to many species

Socio-economic

Environment

Rehabilitation and

Restoration (RR),

pressure on available

manmade

infrastructure/resource

due to population flux

No rehabilitation and restoration issue

involved since site is already under the

possession of project proponent

Local candidates will be preferred for

employment. Skilled work force is available

at nearby towns and cities

Safety and

Occupational

health

Accidents, improper

work practices

Safety officer and safety committee will be

formulated

Provision of adequate safety gears

Other safety measures as per the norms

Insurance policy for workers

Regular health check-up

Risk and disaster

management

Fire, accidents,

earthquake, etc.

The entire premises is no smoking zone

Lightening arresting system will be in place

Ethanol vapor condensing system will be

installed at storage area

Chapter IX



Proper storage of molasses, ethanol, bagasse

Firefighting system as per OISD guidelines

Earthquake resistant construction

9.3.1 Air environment

Measures in addition to above are as follows.

Greenbelt of minimum three tiers in the periphery of the project

While improving the greenbelt local/native species will be preferred in addition to the

species helpful in controlling pollution. It will help in attenuating dust and to some

extent SO2 pollution

Development of lawn on open areas with plantation of ornamental shrubs/trees in

between so as to reduce the dust generation from open areas and improve aesthetics

Preventive maintenance and regular checking of pollution control devices

Continuous emission monitoring system for stack

Monitoring of ambient air quality at regular interval within & outside the project

premises

Proper maintenance of internal roads

Compliance of other regulatory norms such as health, safety, etc.

All these measures will help in reducing and/or mitigating the potential negative impact of the

proposed activity on surrounding environment.

9.3.1.1 Other emissions

From Diesel Generator (DG): DGs are usually used as a backup provision for power. However,

in proposed project, the captive power will be available for season. Hence, operation of DG will

be very limited. Thus, emissions from DG sets assumed to be less significant. Stack height of DG

set- as per the guidelines of CPCB. However, DG sets need to be maintained regularly.

9.3.2 Noise environment

The noise management practices will be in following sequence

Prevent generation of noise at source by good design and maintenance of equipment

Minimize or contain noise at source by observing good operational techniques and

management practice

Use physical barriers or enclosures to prevent transmission to other media e.g. for

boiler, STG, DG room

Chapter IX


Increase the distance between the source and receptor

Sympathetic timing and control of unavoidably noisy operations

Job rotation for workers placed at high noise areas

Greenbelt development with suitable species for noise attenuation

9.3.3 Water environment

Figure 9.1: Schematic of water management

ETP of existing sugar unit is already described in chapter II with schematic (Refer Figure

2.7page 2-27 of Chapter II). This ETP will be modified suitably to treat effluent of 600 m3 per

day. Presently the mill is segregating the mildly polluted streams such as spray pond overflow

and excess condensate. It is sent for irrigation.

For molasses based distilleries, spentwash is a highly polluting element, which is potentially the

major threat to environment. Thus, it is imperative to manage it properly. Considering the

pollution potential of spentwash, the Ministry of Environment Forest& Climate Change

(MoEF&CC), has recommended a guideline through Corporate Responsibility for Environment

Protection (CREP), charter in 2003. According to these guidelines, it is mandatory for the

distillery to achieve ‘Zero Liquid Discharge’ (ZLD). The project proponent has developed

following scheme to achieve ZLD and has made necessary financial provisions towards the

planned activities.

For spentwash, bio-methanation as primary treatment to convert organic matter

into biogas – an energy source

In the secondary treatment stage, biomethanated spentwash will be sent to Multi-

Effect Evaporation (MEE) unit to reduce its volume from 440 to 88cu.m.

Reducing fresh water intake by

Efficient use of water/steam

Recycling of non or less

polluted streams

Recycling of cendensate

Waste generation

Minimized to all possible

extent

Proper treatment to all

effluent streams

Reusing treated water

Rain water harvesting

From roof top areas

Mainly by recharge sump

wells

Chapter IX


Following evaporation, concentrated spentwash will be mixed with press mud

cake (PMC - generated in the sugar mill) to produce bio-compost

Spentlees, condensate of MEE and other effluents will be treated in condensate

polishing unit (CPU); treated water will be reused for other activities of distillery

Steam condensate will be recycled back as a boiler feed water. Thus, the industry is

determined to put all its efforts for the recycle/reuse of water.

9.3.3.1 CREP guidelines for molasses based distilleries

The industry has opted for bio-methanation as primary treatment followed by bio-composting

for the safe disposal of spentwash. The guidelines recommended through CREP, which will be

implemented by the project proponent, are as follows-

Spentwash storage lagoon not >30 days’ capacity

The lagoons must be impervious, constructed leak-proof, lined with HDPE sheets and

protected by brick lining

The compost yard lined with HDPE sheets and protected with

brick/concrete/Bituminous Macadam

Provisions for leachate collection i.e. gutter and sump well

A) Land Preparation for Compost Yard

1. While designing and preparing compost yard, its foundation need to be constructed

with utmost care. Therefore, preparation of the ground & proper compaction plays very

important role in the development of compost yard.

2. Therefore, it needs to be ensured that-

The land is leveled and compacted properly

Soft soil cushion is essential to lay a 250 micron thick HDPE sheet

Further, another layer of soft soil/sand needs to be provided over the 250 micron

thick HDPE sheet before proceeding with the top finish

Provision of underground spentwash spraying network for auto spraying

Provision of leachate management system as per guidelines

There are few options for top finish of compost yard, they are -

Brick on-edge gaps filled with dry sand/soft local soil

Providing Plain Cement Concrete (PCC) 1:3:6 in bays & scaling the joints with

bitumen

Bituminous asphalting

Providing and laying interlocking concrete paving blocks

B) Operations & maintenance guidelines for composting

Chapter IX


i) Rainy season

It is not possible to run the aerobic composting process in rainy season. The reasons are:

Freshly sprayed spent wash that is yet to be decomposed may give some colored

leachate after rain and will contaminate the soil

Due to rain, the composting material in windrows may have moisture content of

70%, which can result in anaerobiosis

It is not possible to run the composting machine during rainy season

Heavy rains can wash off the press mud

Precautions to be taken before onset of rainy season

The composting area must be vacated before start of rains

As far as possible, all the compost on the site should be sold out before start of

rain. The compost, which remains unsold, should be properly bagged and kept in

godown/covered area

After harvesting the last batch of compost, a 2 cm layer of press mud should be

scrapped over the surface layer of compost yard and this scrapped material shall

be kept covered for blending with compost. After cleaning the scrapped area,

fresh windrow of press mud shall be formed only after rainy season.

ii) Unseasonal rains

Precaution to be taken, if there is unseasonal rain during composting cycle

In order to avoid the leaching of spentwash, which is yet to decompose all the

windrow on the yard should be covered with polyethylene sheets/pullover

covers

Stop spraying spentwash, temporarily when it is raining. Spraying can be

resumed when the sky becomes clear.

The provision of the trenches towards slopping side should be made to collect

the runoff from windrow area. This runoff should be collected in leachate

collection pit. It should be pumped back to 30 days storage lagoon.

The run off of outside compost yard should be suitably diverted so that it does

not enter the compost yard.

In order to achieve ‘Zero Liquid Discharge’ the industry will be adopting biomethanation

followed by MEE followed by Biocomposting process. Impervious lagoons will be constructed

for storage of spentwash and impervious compost yard (1:3:6 PCC) with HDPE lining as per

CREP norms.

Chapter IX


9.3.3.2 Rainwater harvesting

The industry has implemented the rainwater-harvesting project. Presently, it is harvesting

water mainly from roof top areas of mill shed, building. The rooftop area available for rain water

harvesting is 10,190sq.m. (sugar unit 8,910 sq.m and distillery unit 1,280 sq.m) All water is

collected and channelized to sump wells

Table 9.2: Details of rainwater harvesting and storage

DESCRIPTION OF

CATCHMENT AREA

AREA AVG RAIN-

FALL PER

YEAR

RUN

OFF

WATER AVAILABLE

(Per annum)

m2 m % CUM

Roof top area

(available building

and structures)

10,190 0.6 70 4280

Figure 9.2: Rain Water harvesting and storm water drainage Layout

9.3.4 Land environment

Effluent will be properly treated in ETP and treated water will be reused/recycled. Thus, the

probability of soil pollution in the surrounding area (outside the premises), is very remote. In

addition, effluent will be transported to ETP through well-constructed drainages/pipe system

which will prevent its percolation into the soil and mixing it with ground water. Thus, the soil

pollution shall be effectively prevented and controlled by the provision of ETP.

RWH Sump Well:

RWH Drain Line:

Chapter IX


Solid wastes from the proposed unit will be boiler ash and sludge from effluent treatment plant.

Table 9.3: Management of solid waste

Waste Material Nature Upshot

Ash(from bagasse) Solid Mixed with bio-compost which will be mixed into soil

Sludge from ETP Dry-

solid

Mixed with bio-compost which will be mixed into soil

Yeast Sludge Organic Mixed with bio-compost which will be mixed into soil

Sludge from Distillery

Polishing unit

Organic Mixed with bio-compost which will be mixed into soil

Figure9.3: Schematic of waste management

9.3.4.1 Hazardous waste management

Spent oil from the gear boxes and automobile batteries will be disposed as per the Hazardous

and Other Waste (Management and Transboundary Movement)Rules, 2016.

9.4 GREENBELT DEVELOPMENT

In the existing scenario, the mill has developed greenbelt on 32 acres of the land and 3 acres of

land is proposed for greenbelt development which is 33% of the industrial plot area.

Table 9.4: Tree plantation details

Tree

interspacing

Tree density

per 100m2

Size/type Location

3 x 3m 25 Shrubs and small trees Boundary of sugar and cogeneration,

Added

to soil

Bottom ash from furnace

Sludge

fly ash

Chapter IX


Garden/landscape areas

5 x 5m 09 medium to large size

trees

Boundary of plot area

10 x 10m 04 Large size trees Mainly along road side and on the

periphery of the unit

It is advised to undertake plantation during monsoon of 2018, by planting tree along the

boundary of the unit. The tree species must be healthy, preferably of few months old, so as to

improve its survival probabilities. Provide fencing to all the plants, which are vulnerable to stray

animals. It is also advised to plant ornamental trees, flowering plants, shrubs in the premises of

respective production, waste treatment units, once the major construction work of respective

site gets over. Table 9.5 and 9.6 give the list of recommended plant species for greenbelt.

Table9.5: List of recommended species for greenbelt

* T=Tall, M=Medium, S=Small

Name Size* Climate(Rainfall) Feature/remark

1. Aegalmarmalose(Bel) M/T 500-1000 mm Tolerant to air pollution,

common in the region

2. Albiziasaman (Shirish) M 500-1000 mm Tolerant of CO2

3. Anthocephaluskadamba

(Kadamba)

T 500-1000 mm Dust tolerant

4. Azadiractaindica (Neem) T 500-1000 mm Fly ash tolerant ,Tolerant of

alkaline and Saline soil,

common in the area

5. Bauhinia purpurea

(kanchan)

T 500-1000 mm Dust tolerant, cultivated near

residential areas

6. Butea

monosperma(Palas)

T 500-1000 mm -

7. Cassia fistula (Bahava) M 500-1000 mm pH 7.5 to 8.4, cultivated near

residential areas

8. Cordia spp.(Bhokar) M 500-1000mm Dust tolerant

9. Erythrinaindica

(Pangara)

T 500-1000 mm Tolerant of CO2

10. Ficusbengalensis(Wad) T 500-1000 mm Fluoride tolerant, common

Chapter IX


Name Size* Climate(Rainfall) Feature/remark

11. Ficusglomerata (Umber) T 500-1000 mm Tolerant of CO2 common

12. Ficusreligiosa (Pimpal) T 500-1000 mm Tolerant of CO2 common

13. Neriumodoratum(Kaner) S 500-1000 mm Tolerant of SO2 common

14. Tamarindusindica

(Chinch)

T 250-500 mm Tolerant of acidic soil

15. Eucalyptus species T 500-1000mm Tolerant of alkaline/Saline soil

16. Derris indica(Karanj) M/T 500-1000mm Tolerant to air pollution,

common in the region

Table 9.6: Flowering and foliage shrubs proposed for greenbelt

# Flowering plant (Shrubs) # Foliage plant (Shrubs/Under tree)

1 Hibiscus 1 Duranta species

2 Shankasur (Ceasalpinia spp.) 2 Dracena

3 Ixora 3 Euphorbia pulcherima

4 Tagar 4 Muscanda

5 Cassia biflora 5 Maranta bicolor

6 Powder puff 6 Agave

7 Alamanda 7 Palm spp.

8 Hemaliapetans 8 Croton

9 Chitrak (Plumbago)

10 Gardenia lucida

Chapter IX


Figure 9.4: Schematic of Greenbelt Development

9.5 SAFETY, OCCUPATIONAL HEALTH MANAGEMENT

Health and safety are important aspects of an organization’s smooth and effective functioning.

Good health and safety performance ensures an accident-free industrial environment.

Occupational health and safety is a cross-disciplinary area concerned with protecting the safety,

health and welfare of people engaged in work or employment. The goal of all occupational

health and safety programs is to foster a safe work environment. In this project, aspects of

Safety and Occupational Health are given with the due consideration, over and above applicable

legislations such as Factories Act 1948. Extra attention will be paid to provide measures for

ensuring safety and health of workers and as well integrity of plant. This will be done by

applying following national or international standards.

Use of flameproof electrics

Suitable operating procedures shall be adhered for overall safety and health

DG sets of appropriate ratings and as per the CPCB guidelines will be provided to ensure the

uninterrupted supply of power and thus for safety of plants and workers

Smoking and igniting activities are strictly prohibited in the entire unit

Chapter IX


Existing Firefighting system should be modified suitably so as to make it suitable for

proposed project (as per the statutory guidelines)

Regular medical checkup of workers, contractual workers and employees

Group insurance and medical insurance facilities provided in the existing setup should be

extended after proposed expansion.

Following standards will be adopted/implemented for the safety of plant, machinery as well

as human resources

IS :11592 Code of practice for selection and design of conveyors

IS:1891 Specification for rubber conveyor

IS:4776 Specification for troughed belt conveyors

IS :7155 Code of practice for conveyor safety

IS :8466 Bagasse carrier chains

IS :8531 Specification for pulleys for belt conveyors

IS : 8598 Specification for idlers for belt conveyors

IS 800 Code of practice for General Construction in Steel

IS 1893 Criteria for Earthquake Resistance, Design of Structures

IS: 325 Three phase induction motors

IS 7403 Code of practice for selection of Worm & helical gear box

IS:1554 P V C insulated (heavy duty) electric cables

IS:2705 Current transformers

IS:3043 Code of practice of Earthing

IS :8623 Low voltages switch gear & control gear

Facilities provided by the Management to workers and employees at existing unit

Separate parking facility for private vehicles (non-goods)

Drinking water facility

Canteen

Toilet and bathrooms

Firefighting system (vehicle)

Ambulance

First aid facility

Safety gears and PPE

Chapter IX


The abovementioned facilities will be made available to workers, as well as to the visitors and

transporters.

Plan of evaluation of health of workers

The mill is monitoring the health of its worker before placement and periodically

examines during the employment

Proper schedule is in place which will be modified suitably if required and followed with

help of occupational health experts and doctors

Health effects of various activities and health hazard, if any observed will be recorded

and discussed with the health experts for corrective and preventive actions need to be

taken by the industry

Schedule of medical check-up during operational phase

Comprehensive pre-employment medical checkup for all employees

General checkup of all employees (including contractual employees and casual labour)

once every year (the industry is doing it for existing unit)

Local hospitals and Govt. health monitoring system will be engaged

Dispensary and ESI facility will be provided to all workers as applicable

9.6 EMP FOR SOCIAL ENVIRONMENT

Many of the social activities initiated and implemented bythe mill has been described in chapter

III.In addition to that, the existing sugar unit is providing large number of seasonal

employment(>5000 families will be engaged in cane harvesting) to labour mainly from drought

prone areas of Marathwada region of Maharashtra. The mill operates a primary school for the

children of cane harvesters. It also provides educational aid such as books, stationery, etc. to

these students.Many of the social activities initiated and implemented by the factory have been

described earlier. The management is committed to continue these activities. In addition,

following plan is advised.

Provision of insurance coverage to cane harvesting labour as well as seasonal and daily

wage labour for medical and accidental cause

Provision of insurance as well as medicines for animals involved in cane transportation

Undertake activities for safe drinking water in nearby schools and educational

institutions

Provision of drinking water, electricity and basic sanitation for harvesting labour and

transporters

Financial assistant to nearby government schools

Chapter IX


The mill operatesindigenous cattle rearing center at site for farmers tounderstand the

importance of indigenous cattle for agriculture and they are also given cows free of cost

as per the demand of the farmers

Health Camp for farmers, workers and theirfamily members every year

School bus Facility for farmer & EmployeesChildren

Participation in “Jalyukt Shivar” Schemes of Maharashtra Govt.

Some of the social activities and budgetary allocation for the same are highlighted in the

following table.

Table 9.7: Financial provision for ESC (CSR) and CER activities planned for next five years

CSR activity head Year TOTAL

1st 2nd 3rd 4th 5th

Budgetary provision (Rs. in lakhs)

A. Drinking Water

Provision of drinking water to harvesting

labours and transporters

0.5 0.5 0.75 0.75 1.00 2.75

Watershed Management Work (Jalyukt Shivar)

Construction of water storage tanks/repair or

maintenance

11 11 12 12 15 61

Sub-Total for A 10.5 10.5 12.75 12.75 16.0 63.75

B. Health facilities

Health check-up of workers and their family

members and farmers

2 2 2.5 2.5 3 12

Organizing medical camps 1 1 1.5 1.5 2 07

Medical aid to needy people, etc. 5 5 5 5 5 25

Sub-Total for B 8 8 9 9 10 44

C. Education

Training to staff 1.5 1.5 2 2 3 10

Awareness programme for farmers 1 1 1.5 1.5 2 07

Training to local farmers 2 2 2.5 2.5 3 12

Educational facilities for orphans, children of

labours and women through NGO – Jan Seva

Prathisthan – supported by the factory

12 12 13 13 14 64

Educational aid to local schools, colleges, etc 2 2 3 3 3 13

Chapter IX


CSR activity head Year TOTAL

1st 2nd 3rd 4th 5th

Budgetary provision (Rs. in lakhs)

School ‘Sakhar Shala’ for children of cane

harvesting labour including midday meals

2 2 3 3 3 13

Sub-Total for C 20.5 20.5 25 25 28 119

D. Livestock care: Maintaining ‘Go-shala’

and providing related facilities for local

farmers

02 02 03 03 04 14

E. Tree plantation in neighboring villages 05 05 06 06 07 29

F. Other activities for maintaining social,

cultural and religious harmony

02 02 03 03 04 14

TOTAL BUDGETARY ALLOCATION FOR NEXT FIVE YEARS 283.75

9.7 ENVIRONMENTAL MONITORING PROGRAMME

In order to maintain the environmental quality within the standards, regular monitoring

network to maintain environmental quality will be implemented. Details of the environmental

monitoring programme have already been given in Chapter VI.

9.8 BUDGETARY ALLOCATION AND DECISION MAKING

Environmental management and monitoring require resources and support from the

management. To ensure smooth functioning of the EMP, budgetary provision should be made

for capital as well as recurring expenditure. The budgetary allocations for environmental

management are given in table 9.8 and table 9.9. The decision making and reporting hierarchy

also plays an important role and its details are given in figure 9.5.

Table 9.8: Budgetary allocations for environment management (Sugar Unit)

Sr.

No.

Particular Recurring cost

(Rs. In Lakhs )

Capital Cost (Rs. in

lakhs)

1 Air pollution control equipment

(venturi wet-scrubber)

6.00 --

2. Noise pollution control 0.10 0.10

3. Greenbelt 8.00 7.00

4. Occupational health, training and

community development

19.50 32.50

Chapter IX


Sr.

No.


(Rs. In Lakhs )


lakhs)

5. Fire protection 1.50 2.00

6. Water pollution control and ETP 7.75 11.80

7. Environmental monitoring system 4.50 4.50

8 Rain water harvesting and storm water

management

0.40 7.00

Total 47.75 64.90

Table 9.9: Budgetary allocations for environment management (Distillery Unit)

Sr.

No.


(Rs. In Lakhs )


lakhs)

1 Solid waste

management/Composting

30.00 60.00

2. Noise pollution control 0.10 1.00

3. Greenbelt 8.00 7.00

4. Occupational health, training and

community development

15.50 16.50

5. Fire protection 1.40 1.50

6. Water pollution control 100.00 250.00

7. Environmental monitoring system 01.00 01.00

8 Rain water harvesting and storm

water management

0.30 2.00

Total 156.30 339.00

Chapter IX


Figure 9.5: Decision making and its implementation hierarchy (from top to bottom) and

reporting hierarchy (from bottom to top) for environmental conditions/compliances

Chairman and Managing Director

Process Manager

Environmental Officer

Env Chemist and Monitoring Staff

ETP Lab chemist and ETP

Operators

Distillery Manager

Works Manager General Manger

Chief Executive Officer

Chapter X


Chapter X

SUMMARY AND CONCLUSION

M/s. Shreenath Mhaskoba Sakhar Karkhana Ltd., (SKL) at village Patethan, Tal-Daund Dist-

Pune has proposed an expansion of sugar unit from 2,500 to 6,000 TCD and molasses based

distillery from 30 to 55 KLPD. Baseline environmental quality data was collected for winter season

during October 2017 to January 2018. Identification and prediction of significant environmental

impacts due to proposed activity has been given in details (Chapter IV).

10.1. SALIENT FEATURES OF THE PROJECT

The salient features of the proposed project are given in Table 10.1

Table 10.1: Salient features of Proposed Project

1. Project Proposed expansion of sugar unit from 2,500 to 6,000 TCD and

molasses based distillery from 30 to 55 KLPD

2. Land Total land available with the factory = 77 acres

Of which ~50 to 55 acres is allocated/reserved for industrial activities

Land allocated for proposed Sugar unit ~1.50 acres

distillery unit ~6.00 acre (Considering all the requirements)

3. Green belt Existing 12 acres green belt will be increased by 2.5 acre

4. Operation Days Sugar: Average 180 days and Maximum 220 days

Distillery: Maximum 270 days

5. Total Water

Requirement

Sugar unit

Total 103 m3/day = 60 m3/day for process and 43 m3/day for

domestic activities

25 m3/day during off-season (for domestic purpose)

Distillery unit

417 m3/day

10 m3/day during off-season

6. Water Source Bhima river reservoir – with permission from Irrigation Dept.

7. Effluent

Treatment System

Sugar unit

Effluent will be sent to ETP and utilized for gardening/irrigation after

treatment

Distillery unit

Spentwash will be treated through Biomethanation followed by

multi-effect evaporation (MEE) followed by bio-composting. Zero

liquid discharge will be achieved.

Spentlees, cleaning water and condensate will be treated in

Condensate Polishing Unit (CPU)

Chapter X


8. Air Pollution

Control device for

flue gases

Existing Venturi Wet Scrubber will be used as air pollution control

device

9. Power and its

Source

During Season

Sugar+ Distillery = 6.5 MW

Source: Captive

During off-Season

Distillery + misc. for sugar = 1.5 MW

Source: Captive or State Electricity Board

10. Fuel Bagasse: ~1091 TPD (45.45 TPH)

Source: Own sugar factory

11. Steam Maximum 100 TPH

12. Manpower Total: 711 (Existing 347 + Proposed 364)

13. Total Project Cost Rs. 5,669.1 (Sugar unit Rs. 2295.1 + Distillery Rs. 3374)

14. Capital expenses

for Environment

management

Rs. 403.90 lakhs(Sugar unit Rs. 64.9 + Distillery Rs. 339)

10.2 CONCLUSION

During environmental impact assessment study, the potential environmental, social and economic

impacts of the above project have been assessed and given in EIA report. The proposed expansion

of sugar and distillery unit will have certain levels of marginal impacts on the local environment. It

has been endeavored to minimize the negative impacts by addressing them through environmental

management plan. Necessary control measures have been suggested to meet with the norms and

safeguard the environment. This expansion project will definitely improve the physical and social

infrastructure of the surrounding area. Adequate financial provision is made by management of

SMSKL for EMP and CSR activities (i.e. for upliftment of the local people). The proposed expansion

project will contribute to economic growth and helps in generating Government revenue.

Chapter XI



Chapter XI

DISCLOSURE OF CONSULTANT

11.1 CONSULTANT


Manjari (Bk), Pune – 412307, Maharashtra

Phone: (020) 26902100, 26902343/7/6

Fax: (020) 26902244

The Institute has received accreditation from Quality Council of India (QCI)/National Accreditation

Board for Education and Training (NABET) for EIA consultancy services. It is also a recognized

Research and Development center of Department of Scientific and Industrial Research (DSIR),

Ministry of Science and Technology, Government of India.

The EIA report has been prepared by, the Department of Environmental Sciences of VSI, which is

affiliated with ‘Savitribai Phule Pune University ’, as Post Graduate and Doctoral course center (i.e.

M.Sc. & Ph.D) in the said subject.

The activities of the department are represented in the following chart.

Figure 11.1: Activities of Department of Environmental Sciences


Department of Environmental Sciences

Teaching and Training Research and Development

Extension and Consultancy Services

Chapter XI



11.2 The project team of EIA study

Expert Designation Role / Expertise

Dr. Deepali

Nimbalkar

Senior Scientist and Head

Department of

Environmental Sciences,

VSI

EIA coordinator and FAE: ISW, SHW, N

Overall coordination of project; impact

evaluation/assessment; formulation of EMP,

and preparation of EIA report

Mr. Shivajirao

Deshmukh

Director General


FAE: SE

Guidance for data collection and analysis;

impact assessment; formulation of EMP

Dr. Sanjay V Patil Head and Technical Advisor

Department of Alcohol

Technology, VSI

FAE: RH

Risk analysis and management , impact

assessment and formulation of EMP

Dr. Amol B

Deshmane

Scientist

Department of


VSI

FAE: EB

Data and sample collection; interpretation;

impact assessment, formulation of EMP;

Assistance to EC in coordinating all project

activities, Preparation of EIA report

Dr. Eknath P

Alhat

Scientific Officer

Department of


VSI

FAE: WP

Study of project processes and sources of

wastewater generation, data interpretation,

assistance in coordinating environmental

monitoring

Dr. D B Phonde Senior Scientist and Head,

Soil Sciences section, VSI

FAE: SC

Guidance for sample collection;

interpretation; impact assessment,

formulation of EMP

Dr. Preeti

Deshmukh

Scientist,

Soil Sciences section, VSI

Dr. Nitin

Karmalkar

(Empanelled)

Vice Chancellor, Savitribai

Phule Pune University

FAE: Geology and Hydro-geology

Data interpretation , impact assessment, and

preparation of EMP

Chapter XI



Dr. Preeti

Deshmukh

Scientist,

Soil Science section, VSI

FAE: LU

Interpretation of land use data and local

topographical information, impact

assessment and formulation of EMP for the

same

Mr. Vivek P. Patil Research Assistant (EIA) Department of Environmental Sciences, VSI

FAE : AP, AQ

Monitoring of air, Interpretation of

monitoring results, AQ modeling, impact

assessment and formulation of EMP

Ms. Sharada

Rajiwade

Research Assistant Department of Environmental Sciences, VSI

AFAE : WP

Study of project processes and sources of

wastewater; data interpretation

ToR Compliance - Environmental Clearance

Documents

Transcript of ToR Compliance - Environmental Clearance