C) SPECIFIC RAIN WATER HARVESTING DESIGN: 1. An alternate ...environmentclearance.nic.in/writereaddata/EIA/070920186RZ9WI91ei… · By artificial recharge slowly entire study block

M/s Shree Narmada Khand Udyog Sahakari Mandli Ltd., Dharikheda, Tal.- Rajpipla (Nandod), Dist.- Narmada, Gujarat

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C) SPECIFIC RAIN WATER HARVESTING DESIGN:

1. An alternate option 1 for rain water harvesting structure:

Figure4.11: Closed type recharge well

Recommendation for Narmada site: As per site condition, site situation, space availability, water availability closed type of rain water harvesting structure is recommended and modular type structure is recommended in green belt area and open area.


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Figure 4.12: Open type recharge well


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2. An alternate option 2 for storage pond:

Figure4.13: Pond design for storage and reuse Aerial view:

Cross-sectional view:

Dimension of pond:

1. Pond no. 1 (In front of TBM 2 on secutiry cabin) • Lenth x breadth x height = 56 m X 56 m X 5.80 m

= 18,188.80 m3

2. Pond no. 2: (Backside of TBM 2 on secutiry cabin) • Lenth x breadth x height = 65 m X 65 m X 5.80 m

= 24,505 m3

• Total pond storage = 42,693.80 m3 • Roof top area &Paved area will received 34373.26&7999.88 m3i.e., total rain water collected is

42,373.14m3which in turn will be stroredin pond.

Geomembrane sheet

coating as an

impervious layer

Geomembrane sheet

coating as an

impervious layer


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D) ADVANTAGES OF RAIN WATER HARVESTING STRUCTURES:

1. Rise in water table of the area i.e. development of water mount in the area. 2. Due to tube well or pond recharge there will be development of water mount in the whole area. 3. Qualitative & quantitative improvement in the existing tube wells. 4. Sudden changes in ground water conditions of the area. 5. Changes in hydrological parameters of the area. 6. Changes in aquifer saturation. 7. Increase storage capacity of aquifer system. 8. Whole aquifer system (confined and unconfined) will be highly saturated. 9. Yield and quality may improve up to 20% 10. Reduces odor and color including sulphide. 11. Reduces BOD, COD, level, hazardous chemical level etc. 12. Reduces turbidity and suspended solids. 13. Sudden changes in chemical composition of ground water where the artificial recharge is

implemented. 14. Reduces ammonia, nitrogen grease and fat level. 15. Prevent blockage and cleaning of pipeline. 16. Reduce sludge level. 17. Prevent blockage and cleaning of pipeline. 18. Reduces load and expense on treatment plants i.e. indirect increase the life of treatment plant. 19. Makes purification process easy. 20. Artificial recharge decreases our great national problem of water scarcity. 21. Increases soil moisture and fertility with results into increase in food production and cash crop

yield i.e. national economic growth. 22. There are remarkable changes in environmental conditions of the area. 23. Artificial recharge causes lot of changes in plant and vegetation growth i.e. the increase green

cover area/ green field area which is much helpful of all living organisms, insects, birds and animals.

24. Conservation of water by artificial recharge means increase the nature national resources, which is the best step in national growth.

25. In short it leads us all too healthy, wealthy and prosperous life and environments. 26. Miracle effect on plants, vegetation and green belt area. You will observe healthy green plants

with fast growth i.e. healthy environment. 27. It is a natural cycle to recharge the area during monsoon and get its advantage for the next season. 28. Recharge well / Production well is going to be compulsory as by laws in construction by town

planning department 29. Within 2 to 3 years (after execution of recharge project at site) successful production wells can be

constructed at site for domestic or drinking purpose. 30. Indirectly, it is a best social service given by your organization to the society. 31. Rain water (equivalent to DM water) harvesting is essential to flush leaky, unconfined & confined

aquifers so that entire study area/surrounding area will be automatically free from any sort of contamination or high concentration.


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E) ADDITIONAL BENEFITS BY IMPLEMENTATION OF RAIN WA TER HARVESTING PROJECT EXPECTED CHANGES IN GROUNDWATER CONDITIONS:

1. All aquifers (confined, unconfined, leaky, dry, saline) will be found saturated with qualitative and quantitative changes.

2. Sea water intrusion effect (if any) will be prolonged/ minimized. 3. Drastic changes in groundwater conditions of the block area like yield, hardness, Ph, chemical

composition etc. 4. Characteristics of soil cover will change from fertility point of view. 5. Groundwater flow pattern, direction, movement, rise in water level etc. changes will be observed. 6. Advantages of rain water harvesting structures (as mentioned above) can be measured in facts and

figures by periodical pre and post monsoon monitoring of the study area. 7. On the basis of periodical monitoring, a mathematical modelling of groundwater aquifer behaviour

can be established. 8. Dry zones, saline zones, unsaturated zones/ aquifers can be converted into fresh water productive

aquifers. 9. Over exploitation of groundwater aquifers can be balanced by induced recharge. 10. This is only conventional and economical method available to recharge different type of aquifer

system. Other methods are comparatively costly and less effective. 11. It is just like to add a zero TDS water in 1000 TDS glass of water. 12. On the bases of artificial recharge one can identify groundwater budget, safe withdrawal limits,

safe areas, over exploited areas etc. 13. Now a day’s all over country/ world there is a great shortage of drinking water and such multiple

projects (artificial recharge to groundwater aquifers) will bring miracle effect to the groundwater conditions of the case study area and will satisfy day by day our increasing industrial/ drinking water demands.

14. By artificial recharge slowly entire study block/ region will be converted into fresh water zone and in long run of time grey/ dark zones will be converted to safe/ white category for further exploitation and financial assistance to the needy farmers for irrigation purpose.

15. Restoration (surface/ sub surface) of water bodies for public use is the main objective for the groundwater development of the nation.

F) CONCLUSION AND RECOMMENDATION FOR DEVELOPMENT OF RECHARGE STRUCTURES 1. This is based on Geophysical survey /Ground water survey of the Area 2. Feasible depth varies from Min.100 mt to max.120mts. 3. 1st preference is given to 3rdlocationduly marked and located at the site. 4. Quality/ quantity of groundwater source is suitable for irrigation/ industrial use. 5. Drill cutting should be preserved at 20’ interval for pipe assembly as per recommendations. 6. Drilling, reaming, gravel packing, washing, back washing should be proper for best possible results. 7. Proper washing by clean water is recommended to break mud wall thickness. 8. Adequate capacity compressor unit is essential to develop the well. 9. Once the drilling work starts at site, work should be in continuous operation till completion

without long break. 10. Careful construction & development of well is essential for better possible results. 11. As per attached recommendation drilling/development of well is more important to get better

results.


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12. As per site condition, site situation, space availability, water availability closed type of rain water harvesting structure is recommended and modular type structure is recommended in green belt area and open area.

13. Roof top area and paved area rain water will be store and reuse by developing pond in the location as per recommendation.

14. Rainfall of this area falls under high intensity so natural recharge to groundwater aquifers may be considered very high.

15. Gravels/ pebbles (river bed deposits) are main formational saturated aquifers having high intake rate above 600 LPM which is considered for recharge calculation.

4.4.5 IMPACT ON NOISE ENVIRONMENT From noise point of view let us divide SNKUSML in four parts viz., (A) material unloading section, (B) manufacturing zone, (C) packing and loading sections and (D) waste treatment area. The four potentially noise generation stations are discussed. (A) From incoming material unloading and handling:

The molasses from the molasses storage tank will be brought in closed conduit & therefore there will not be significant noise pollution however in case factory brings molasses from outside, the internal road surface is kept reasonably smooth and non-undulating so as to avoid any noise generation and more so the spillages and fugitive emissions. 1. A large inventory of chemical is always a hanging sword on the engineers, whether it is hazardous

or non-hazardous material. SNKUSML therefore, made a policy of having a minimum storage capacity at hand so that inventory will be always limited.

2. The success of inventory control depends also on the Supplier-Industry relations. SNKUSML has kept it smooth and hence there is a free flow and availability of raw materials.

3. Major raw material molasses is brought in closed conduit in a very safe and environment friendly way of transportation. This is procured from own sugar factory or from vicinity.

4. The unloading of raw materials like DAP, Sulphuric acid, TRO (which is required daily in very less quantity) is one of the weaker links in the manufacturing/ production chain. As the prominent raw materials arrive in slow speed vehicles, the closed protected transfer is possible.

5. As a result of these precautions, there is neither a possibility of fugitive emission nor a possibility of noise during transfer or at storage.

This yard will be kept away from the road resulting in minimization of any propagation to the boundary. (B) Manufacturing area:

The manufacturing activity can be another source of noise generation. The generation is expected to be more, especially in such industries when there are a number of reaction vessels, transfer operations, open vessels, hammering or product cleaning, multiple pumps, ejectors, pulverizes, etc. This particular manufacturing activity involves only three steps simple unit operations and processes. By experience SNKUSML knows from where the noise problem may get generated. The causes are identified and so are the solutions. The foundation is strong by good civil engineering practices and offers no vibrations.

Table 4.19: Noise mitigation efforts

S.N. Source of noise Attenuation by 3 Generators & DG sets Fitted silencers and separate room provided

4 Steam for distillation & evaporation unit

Mild humming sound, but is not make-and-break type. This is inside the proposed distillery columns which is closed and jacketed by fiber wool all around (though basically foe thermal loss, also serves as barrier for noise, incidentally).

7 Aeration in CPU Most efficient Diffused aeration system has been provided 8 Yeast sludge& ETP sludge This machine is in open. However, smooth oiling, periodical


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composting overhauling, imported gears and level internal service roads are provided

9 Vibrations Proper sturdy foundation provided for all the machines and equipments

(C) Packing and loading sections

The finished goods will be stored under supervision: The alcohol (RS or FA)will be loaded in tankers by pump-pipe arrangement. Spring cushioning is provided below the floor of the truck to prevent noise, breakage, loss and spillage. (D) Waste treatment area For waste storage area noise mitigation efforts will be taken as shown in Table - 4.19.

Mitigation measures: The control measures as described above will give sufficient satisfaction, so as to make the consequent noise levels very low. There is no need of designing further mitigation measures beyond this. However, training will be given to the staff and workers to see that no noise-increasing activities are undertaken and also to report if they notice any abnormality high noises in any section or sub activity. A watch-dog committee (WDC) proposed under environment management plan (EMP) keeps a watch on its monthly round to judge this. Following measures are proposed for controlling noise level impacts on machinery operators and within core and buffer zone of SNKUSML. • In order to avoid noise during transport, the surface quality of internal roads is kept smooth in

engineering like manner. Loading will be done mechanically. • Development of greenery/barriers/landscaping of trees /bushes and shrubs. Trees of special

varieties with large number of small leaves are planned. • Reduce noise exposures to the operators of machinery by work scheduling and by providing ear

protective equipment. • Use rubber packing in the foundations of machineries to prevent noise transmission to the

surroundings

4.4.6 IMPACT ON SOIL ENVIRONMENT

The soil of the area may get affected due to dust emissions, if proper care is not taken.

i) Changes in soil texture due to settling of air borne dust. This will lead to change in porosity, permeability and other physical characteristics of the soil of the area. ii) Changes in soil chemistry due to addition of foreign material from polluted air and water due to unit activities in the area.

The soil characteristics in the study area are given in Chapter-3. It is seen that the soil quality is of moderate fertility. Waste water and solid waste if discharged without control on land are likely to affect soil quality. Industry will achieve ‘Zero Liquid Discharge’. Spent wash and solid waste are not discharged from the plant. Boiler ash contains soil nutrient such as potash and phosphate. Utilization of Boiler ash on agriculture land improves the soil quality. The solid wastes shall be segregated according to their properties, packed, transported and stored in a separate impervious storage area demarcated for them. They will then be disposed off according to the requirements of statutory authorities. Hence implementation of project will not have any major effect on the soil environment. Mitigation measures: 1. Efficient Air Pollution Control Equipment (APCE) like Multicyclone dust collector & Wet

scrubber has been installed to boilers. 2. Adequate stack height helps to control dust emissions. 3. A horticulturist has been engaged who ensures soil quality improvement in the plant area, by

adequate manuring and fertilizing. Therefore, no adverse impact on the soil quality of the area is


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anticipated. Maintenance of greenbelt/plantation in the plant area further helps in conserving soil and preventing soil erosion.

4.4.7 IMPACT ON BIOLOGICAL ENVIRONMENT

The study area is mainly agricultural land. There are no forests and no significant water bodies in the vicinity of the site except the river Narmada which is at 7.50 km north to the site. There are no National Parks and Protected Sanctuaries within the study area, no impact isanticipated on the same. No human habilitate with in 1 km from the site. For estimation the adverse impact of the proposed project on sensitive area, air quality modeling has done and Air quality modeling results shows that no adverse impact on sensitive area. There are no endangered flora and fauna species in the region. Vehicular movement during night will be restricted to avoid adverse consequence to birds and wide animals in the region. The project activities are restricted to the factory site except the transportation of raw material and products. There is no discharge of solid or liquid wastes to the environment. No impact of project on biological environment is expected. In spite of there being no impact, efforts will be made not only to maintain the ecological balance of the surroundings but also to improve upon the same. The attributes that are identified to describe ecology are animals, birds, fish, field crops, threatened species, natural vegetation etc. The study area does not have any identified endangered species, Forest, National Park, Sanctuaries and hence there is no question of any adverse impact on the same.

Mitigation Measures:

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

community service. 4. Cleaning of existing vegetation would be kept to minimum and shall be done only when absolutely

necessary. Even then cutting of big trees shall be avoided. 5. Plantation program shall be taken in all vacant lands including plantation in the proposed plant

premises, along the internal and external roads and also along the administrative buildings.

4.4.8 IMPACT ON SOCIO-ECONOMIC ENVIRONMENT

Establishment of project will enhance the transportation activity. This will create opportunities to the localites to start vehical garages. With development of the industry the roads and communicatiun facilities will be enhanced. The distillery will also create job oportunities to the local mass.

Presently the educational facilities in the study area are limited to primary and high school. With establishment of this industry the transportation, public mobility and job opportunity along with associated activities in the region may increase. These activities will improve economic condition of the local population. The presence of the industry will enhance commercial activities, which inturn will improve the economic conditions of the population. Service infrastructure like transportation, health care, education, communication facilities may improve considerably. The availability of power from the industry will help to reduce the power scarcity and frequent power failures in the region by stabilization of the power in the grid, which will improve power supply to irrigation pump sets and house hold requirements.

Positive Impacts-

1. Employment Employment opportunities will be created during planning and preparation, construction and operational phases of the proposed project.

2. Community Skills Development The employees will be benefited from the training programmes instituted by the company to enable the community labour force to work in the different areas of production.

3. Improved Standard of Living Employment opportunities created by the project will increase income and therefore improve the overall standards of living in the area.


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4. Community Organizational Capacity Development Through engagement of community members in development structures such as Community Development Committees, the community organizational capacity will be developed.

5. Economic Exposure and Development Implementation of the project will make financial institutions as well as related economic facilities, infrastructure and services available to the people. This will expose and introduce the local population to factors of economic development including the banking system, financial services, and credit and investment schemes. Adverse Impact-

1. Health Impacts The project has the potential for triggering health impacts through air pollutants from heavy vehicles, increased dust, creation of breeding grounds for diseasevectors, population influx which might introduce new diseases in the area, and inadequate sanitation facilities.

2. Livelihood change Due to the labour intensity of the manufacturing sector, the project will attract the more able-bodied persons from the community which in turn will lead to low labor availability in other sectors of the economy including agricultural, education and health skilled workers. Local employment opportunities will be created by the project. This impact will not be significant due to low level of education and skills in the area which will result in sourcing skilled workforce from outside the immediate area. But the magnitude of this impact will be high due to high number of dependents in a household. 4.4.9 IMPACT DUE TO SOLID AND HAZARDOUS WASTE GENER ATION Non Hazardous waste: No major impact during operation phase is anticipated due to solid waste.Negligibleamount of waste will get generated from proposed project.

Table 4.20: Detailsof Non Hazardous Solid Waste

Sr.No. Unit Waste & Quantity, TPD Treatment Disposal

1 Molasses based Distillery (45KLPD)

Yeast sludge 15 Compost Factory farm CPU Sludge 0.25 Compost Own garden Boiler Ash from existing sugar unit - As a soil conditioner to member farmers

2 Canteen 1.0 2.0

Compost Own Garden 3 Colony Compost Factory farm 4 Office Waste Papers 0.50 Sale Non – Hazardous 5 Packing section Waste papers 0.50 Sale Non – Hazardous The solid waste shown in the above table, will now serve as valuable material for the new product, bagasse as fuel, molasses as raw materials, press mud as valuable source of crop nutrients and acts as soil conditioner. Hazardous waste:

Hazardous solid waste is governed by hazardous waste (Management & Handling) Rules of 1989 as amended in 2000. The H.W. amendment is promulgated in 2000. It defines hazardous waste on a basis of different criteria. This is examined.


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The number of barrels containing Turkey Red Oil/Antifoam is only few, as the substance is not a raw material. It is merely an anti-foam agent. These are on returnable basis to suppliers. So, also can be said for the yeast supplement substances, like nutrients, which comes in bags only Mitigation Measures: Boiler ash and ETP sludge are the main solid wastes produced in the industry. The measures for control, storage, handling and disposal of these solid wastes are presented below.

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

2. Green belt of 6-10 m is maintained all around the bagasse yards. 3. Molasses will be stored in top covered M. S. tank. Dyke wall shall be constructed to hold the tank

contents in case of leakage. 4. ETP sludge and boiler ash would be supplied to the farmers for its use as soil conditioner in

cultivation of sugar cane and other corps. 5. Composting of press-mud is carried out scientifically and the quality of composted manure is

regularly checked. 6. Minimization at all levels need be attempted for discarded products, empty containers (which are

rare), packing surpluses, incoming raw material unloading spillages (which is rare) and fugitives. The factory has very little scrap materials. All these, however, be carefully stored on raised platform with dwarf toe walls all around, and a roof over-head. The contents should not be held in the premises for more than a fortnight.

7. These measures can easily be taken by SNKUSML because (1) they have no discards or off-specification products, and (2) the waste is fully recycled both in green stage and in dry stage.

4.4.10 IMPACT ON OCCUPATIONAL HEALTH

To find out the health status of workmen, company have developed a plan of annual health check-up of workmen including their general condition, routine examination of BP, Pulse, vision and other systems. Industry has appointed Safety officer & Medical officer. Regular health checkup of all employees is being done by the authorized medical officer. Mitigation Measures for Occupational Health Hazards 1. To detect the possible onset of an occupational disease regular monitoring of health status is

done/will be done. 2. Effectiveness of preventive and control measures will be ensured. 3. Adequate supply of potable drinking water is/will be provided from a fountain with an upward jet

or with a sanitary means of collecting the water for the purposes ofdrinking. 4. Pre-Employment Medical Examination is being/will be carried out for all new employees and

Contract labours. 5. Periodic medical hearing checks are/will be performed on workers exposed to high noise levels. 6. OHS orientation training is/will be provided to all new employees to ensure they are appraised of

the basic site rules of work at / on the site. 7. Contractors that have the technical capability to manage the occupational health and safety issues

of their employees are/will be hired. 8. Ambulance and fully fledged First aid treatment facilities are/will be provided with OHC. 9. Personnel Protective Equipment (PPE) are/will be provided to workers exposed to workplace

hazards. 4.4.11 ODOUR ENVIRONMENT

Odour is an undesired, unpleasant, irritating or harmful experience or a combination thereof. Odour pollution has been regarded among top environmental problems in certain situations. Odour is variously described as ‘unpleasant, disagreeable, pungent, characteristic, Odourless’ and yes even as ‘sweet or pleasing’. Odour is sensible only in terms of organoleptic test. The physiological and psychological effects of odour depend on the human exposure to the odour intensity and duration.


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It is our endeavor to have or low odour level within the factory work zone for the welfare of the workers and also at the four corners of the premises at the boundary wall and much beyond for the comfort of general public at large. Society will not certainly like any odour.

Table 4.21: Odour mitigation efforts

S.N. Probable source of odour Attenuation by 1 Stale press mud Consume quickly to compost yard

2 Fermentation Covered, CO2 captured and scrubbed and recovered. Avoids odour escape

3 Distillation column Now multi pressure- vacuum improved hardware.

4 Concentrated Spent wash storage Only 30 days storage, that too in the emergency for repairs/ maintenance of machinery.

5 Office, colony-guest house septic sludge Remove and compost it 6 Reusable CPU plant sludge Oxidize by bleaching powder or reagents

7 Moderately polluted stream effluent treatment No over detention. No anaerobic condition to set in

8 Moderately polluted spent lees effluent treated satisfactorily and recycled Apply it judiciously.

9 Press mud - Composting yard Fully aerobic by special turning machine, viable dedicated culture and fine spraying of water getting immediately absorbed.

4.4.12 WORK ENVIRONMENT

Dust free work environment will be maintained in view of worker safety, health and hygiene.

Table 4.22: Efforts taken for maintaining safe work environment

Sr. No. Source Attenuation 1 Generators Fitted enclosure and tall stack

2 Steam in For distillery & other processes

Heated material. The system is continuous and closed and jacketed by glass wool all around. These systems located in closed building.

3 Release of steam Only occasional and for a small duration of time. Line is not too long.

4 Aeration in ETP Diffused aeration systems are provided. Free board is adequate so that droplets are not spilling out.

5 Press mud composting

The aero tiller machine is in open. However, smooth oiling, periodical overhauling, imported gears and level internal service roads are provided to avoid Dust. The material gets heated quickly by microbial activity as soon as culture in inoculated say up to 65 C. but gets quickly utilized in pasteurization and moisture reduction.

6 Vibrations Proper sturdy foundation provided for all the machines and equipments to avoid fugitive escapes.

4.4.13 TRAFFIC DENSITY AND ITS IMPACT

The Plant of SNKUSML is well connected to SH - 64 (0.427 Km in North direction), NH –953 (12.50 km in SE direction). Nearest Railway Station is at Kumasgaon which is 2.21 km in NE direction from the plant site and Nearest Airport is at Vadodara which is 56.42 km in NNW direction from the plant site. Road facilities for the transportation of materials are already present near plant premises (as mentioned in the above paragraph). This is being used for inflow of raw material &finished product. Also, the existing road infrastructure is good enough to bear the increased traffic load. However, internal and nearby roads shall be maintained as and when needed to facilitate transportation.


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Existing Traffic Survey

Traffic survey has been conducted for 24 hours at Rajpipla - Ankleshwar Road which is approximately 0.427 Km in North direction from the plant site. The traffic survey monitoring was done in December, 2017 to predict the future traffic growth and the load on the plant road and surroundings due to the proposed plant capacity. Measurements of Traffic density were made continuously for 24 hours by visual observation and counting of vehicles under four categories, viz., heavy motor vehicles, two / four wheelers and others. Total numbers of vehicles per hour under the four categories were determined. The details of the traffic volume count have been provided in table given below.


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Table 4.23: Traffic Volume Count Survey (SH-64) Fast Vehicles Slow Vehicles

S. N.

Time Two wheelers Passenger Car/ Pickup van / Auto rickshaw

Car/ Van Buses Trucks Cycles Cycle Rickshaw

Up Down Up Down Up Down Up Down Up Down Up Down Up Down 1 10:00 to 11:00 am 8 10 2 1 3 2 2 1 1 - - 1 - - 2 11:00 to 12:00 noon 10 7 4 3 2 2 4 3 2 2 - - - - 3 12:00 to 1:00 pm 8 5 2 2 4 3 1 2 3 1 1 - - - 4 1:00 to 2:00 pm 7 9 5 2 2 1 1 - 2 2 - - - - 5 2:00 to 3:00 pm 5 6 4 3 4 2 2 3 1 2 - - - 6 3:00 to 4:00 pm 8 4 5 2 3 5 3 2 2 3 - 2 - - 7 4:00 to 5:00 pm 9 7 3 3 2 1 4 2 1 2 - - - - 8 5:00 to 6:00 pm 10 9 1 2 3 2 1 - - - 1 - - - 9 6:00 to 7:00 pm 7 8 3 1 2 1 1 2 1 - 1 - 10 7:00 to 8:00 pm 4 5 2 2 2 2 2 2 2 1 1 - - - 11 8:00 to 9:00 pm 9 4 3 3 1 3 - 1 - 1 - - - - 12 9:00 to 10:00 pm 6 2 2 1 2 2 1 - 1 2 - - - - 13 10:00 to 11:00 pm 3 2 1 2 1 3 2 1 - - - - - - 14 11:00 to 12:00 pm 1 2 3 1 2 1 1 2 - - - - - - 15 12:00 to 1:00 am 2 1 1 1 2 2 - - 2 - - - - 16 1:00 to 2:00 am - 1 - - 1 - - - - - - - - - 17 2:00 to 3:00 am 1 - - 1 - 1 - - 1 2 - - - - 18 3:00 to 4:00 am 3 2 2 1 2 1 - - - 1 - - - - 19 4:00 to 5:00 am 1 2 3 2 3 2 - 1 1 - - - - - 20 5:00 to 6:00 am 4 3 1 1 1 2 1 - 2 1 - - - - 21 6:00 to 7:00 am 2 4 4 1 2 1 2 2 2 2 - - - - 22 7:00 to 8:00 am 4 2 2 2 3 2 3 2 1 1 - - 1 - 23 8:00 to 9:00 am 6 5 4 5 2 4 1 2 1 2 - 2 - - 24 9:00 to 10:00 am 5 3 6 4 5 4 2 1 2 1 1 - - -

Grand total 124 104 62 46 54 51 33 28 25 27 6 7 - - Conclusion

From the study, it was observed that traffic movement at SH-64 road is Low. At present, the traffic load calculated is for 567 vehicles per day approximately. The study area is served by road transport. Most of the villages are connected by bus / other transport services. The above figures clearly show that mainly two wheelers run on SH-64 (40.21%) followed by four wheelers (18.51%) and heavy vehicles (19.92%). Barely, 21.34 % of the total traffic comprises of others, which includes three wheelers, passenger car, cycles etc


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Additional Traffic due to Proposed distillery Project

Both raw and finished materials will be transported by road. Due to proposed project, there will be additional trucks to the existing traffic volume. Adequate parking facilities will be provided to accommodate additional trucks within the plant premises. Additional Traffic during operation of the plant due to raw material and finished products transportation has been given in Table - 4.23 (A) and 4.23 (E)

Table 4.23 (A): Inward Traffic due to Cane Transportation for existing sugar factory during cane crushing season

Type of vehicle and Capacity Number of Trips / Day (approx.)

Truck -14T 152 Tractor- 10 T 143

Bullock Cart- 2 T 519 Total 814

Table 4.23 (B): Outward Traffic due to the Sugar Transportation from existing sugar factory

Type of vehicle and Capacity Number of Trips / Day (approx.)

Truck -14T 22 Tractor- 10 T 23

Total 45

Table 4.23 (C): Inward Traffic due to the Proposed Raw Material Transportation

Material Origin Type of vehicle and Capacity

Number of Trips / Annum (approx.)

Molasses – from outside sugar factory

Sitaram Sugars and Allied Industries Ltd, Ladhod, Badoli, Chota Udepur

Tanker – 20 T 592

Sulphuric acid Local vendor Tempo– 8 T 4 DAP for Distillery & biogas unit& Urea

Local vendor Tempo- 8T 4

Antifoam Local vendor Tempo – 8T 2 Lime for biogas Local vendor Tempo -8T 15 Culture for biocomposting

Local vendor Tempo- 8T 3

Total 2 Trips/day

Table 4.23 (D): Outward Traffic due to the Ethanol Transportation

Material Type of vehicle and Capacity Number of Tankers / day (approx.) Ethanol Tanker –20 - 25KL 2 Vehivles coming for cane supply will be returned with compost for farmer members.

Table 4.23 (E): Summary of Vehicle Transportation

Sr.No. Particulars No. of Trips/day 1 Inward Traffic due to Cane Transportation for existing sugar factory during

cane crushing season 814

2 Outward Traffic due to the Sugar Transportation from existing sugar factory 45 3 Inward Traffic due to the Proposed Raw Material Transportation 2 4 Outward Traffic due to the Ethanol Transportation 2


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Personnel During operation a maximum of about 83 persons (inclusive of employees and others) will be attending the industry. Maximum number of employees will be from nearby villages only. Quarters are also available for the employees. Traffic Projection and Impact due to Transportation Due to the proposed project, there will be addition of Heavy and Light motor vehicles in the existing traffic. The present road network is good enough to bear the increased traffic load. However, internal and nearby roads will be maintained as and when needed to facilitate transportation.Proper mitigation measures will be adopted by SNKUSML to minimize traffic flow to the best possible extent resulting in low level of dust, noise and gaseous emissions. Adequate space has been provided for parking. Anticipated Impacts 1. Increase in traffic density will lead to air pollution. 2. Movement of vehicles will cause noise pollution. 3. No direct impact is envisaged on the flora and fauna of the area. 4. Increased traffic may cause accidental incidences and public health problems. Mitigation Measures 1. Vehicles with PUC Certificate are/will be hired. 2. Vehicles are/will be covered with a tarpaulin and not over loaded. 3. Unnecessary blowing of horn is/will be avoided. 4. Roads are/will be maintained in good condition to reduce noise due to traffic. 5. Greenbelt of appropriate quality and width is/will be developed. 6. To avoid accidents, the speed of vehicles is/will be low near habitation areas. 4.4.14 GREEN BELT DEVELOPMENT Development of greenbelt in and around industrial activity is an effective was to check pollutants and their dispersion in to surrounding areas. The degree of pollution attenuation by a green belt depends on itsheight and width, foliage surface area, density, dry deposition, velocity of pollutants and the average wind speed through the green belt. The main objective of green belt around the factory is: 1. Mitigation of impacts due to fugitive emissions 2. Attenuation of noise levels 3. Ecological restoration 4. Improvement in aesthetic environment quality 5. Waste water reuse. 6. Soil erosion prevention Keeping in view of the soil and water quality available in and around the project site and the topography of land, following species are considered for green belt development. (Please refer attached landscape layout) Criteria for Selection of Species for Green belt 1. Rapid growth and evergreen type of species. 2. Tolerance to water stress and extreme climatic conditions. 3. Difference in height and growth habits 4. Aesthetic and pleasing appearance 5. Large bio-mass to provide fodder and fuel 6. Ability to efficiently fixing carbon and nitrogen. 7. Improving waste land 8. To suit specific climate and soil characteristics. 9. Sustainability with minimum maintenance.


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Plant species recommended by GPCB and as suited to the local environment will be used in green belt and greenery development. The width of green belts and type of plant species to be developed in the premise will include the following. GPCB has recommended more than 150 species which can be attempted in this subzone of the region. Selection is therefore based further on availability of species in the nearby nurseries. Biodiversity is also kept in view. Trees, shrubs, dwarf trees and vegetative cover/ lawn is proposed. For biodiversity we have made plantation Detailed description of Green belt development has been given in chapter No. 10 4.4.15. STORM WATER MANAGEMENT Large quantity of storm water is generated during rainy days. Total land area of the project is 43.7060 hectares, of which factory area is about 12.6015 hectares. Storm water gutters are designed based on contour data of the premise and rainfall data of the region. 4.5 IRREVERSIBLE AND IRRETRIEVABLE COMMITMENTS OF E NVIRONMENTAL COMPONENTS.

Assessment of environmental components is done.

Table 4.24: Potential Environmental Impacts

Sr.No. Component Discussion on potential Impact Whether is it relevant from point of irreversible/ irretrievable effect?

1 Land Area is compact & Limited. It is already an industrial one (NA). Thus there is no change in land-use pattern.

Not relevant

2 Water No encroachment on source of others. Not a process stoppage risk. Own efforts of recharging and reusing. Water use minimized. No harsh industrial Wastewater after treatment. Domestic effluent very low in quantity. No discharge to any surface water, or any percolation to groundwater.

Not relevant

Groundwater Available. In fact by rain harvesting, recharging will be done. Surface water available.

Not relevant. In fact improved.

3 Ambient Air Quality

Not likely to increase over routine. Satisfactory monitoring schedule. Fly ash arresters, MDC and wet scruber and stacks scientifically provided.

Not relevant.

4 Soil MSW, Non Haz. and Haz Waste, attended. Soil is not spoilt. Landscaping is done. Organic solid waste is garden-composted. Inorganic segregated. Saleable to fixed authorized vendors. Remaining either for sanitary or secured landfill. No hospital to create bio-medical waste.

Not relevant. In fact improved.

5 Aesthetics Noise. No big machinery kept near boundary, shed at central part of plot, sturdy foundations, no vibrations. Greenery maintained. In closed, covered sheds, with cladding

Not relevant.

Odour. Various measures are taken to make ‘non-relevant’ --

Not relevant.


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1. Water use minimized. Wastewater minimum. 2. Lagoons are kept normally dry and are

relatively small. Only 30 days are permitted 3. Receives I- treatment in closed bio-digester

followed by concentration of spentwash 4. Secondary treatment is fully aerobic/ thermal 5. No evaporation solar ponds 6. No disposal on land with cess pools.

5 Community Acceptability. The economic situation is very harsh for the local neighbors. Very low livelihood. Lands only rain-fed. People are anxious to have at least some development.

Not relevant

It may thus be seen that the potential impact is neither Irreversible nor irretrievable to any degree of significance. It may be adverse on some consideration and even beneficial in some other. This is discussed in details later in this Chapter in ten levels of Hierarchy. 4.6ENVIRONMENTAL IMPACT MITIGATION MEASURES (BRIEF) Every human activity creates some side-effects. This can make significant adverse impact if left unattended. It is proposed to reduce the impact by prevention, abatement, and control and mitigation mechanism. Detailed analysis of Mitigation measures have been given in chapter 4. However brief summary is as follows-

Table 4.25: Environmental impacts Mitigation Measures in Brief

Sr.No. Facets of Environment

Mitigation & Impact Thereafter

(A) Construction Phase 1. Air 1. The approach roads will be paved or asphalted and regular

sprinkling of water on roads and construction site will be undertaken.

2. Regular PUC check will be undertaken. 3. All vehicles and construction equipment with internal combustion

engines being used will be maintained for effective combustion to reduce vehicular emissions.

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

5. Unleaded petrol blended with fuel ethanol will be used for vehicles in use.

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

7. Measures will be taken not to use asbestos in the construction work. 8. Development of sufficient vegetation will be considered.


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2. Water and Waste Water

1. Fresh water requirement will be minimized by using RMC 2. High pressure hoses will be used for cleaning and dust suppression

purpose. 3. Monsoon season would be avoided for the construction activity,

particularly the excavation work. 4. Wherever required check dams and dykes will be provided for

control of soil erosion. 5. Fast growing soil holding/binding vegetation e.g. grass will be

grown around the construction site before commencement of construction activity to reduce soil erosion and dust suppression.

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

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

8. Rain Water Harvesting will be done. 3. Noise 1. Mandatory use of personal protective equipment like ear plugs shall

be ensured to mitigate any significant impact of such equipment on personnel operating the machinery.

2. Long exposure to high noise levels shall be avoided by practicing proper shift arrangement for workers. Similarly, shift arrangements shall be made to avoid long exposure to hand-arm vibration and full body vibration.

3. Noise making construction activities shall be carried out during day time only.

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

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

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

4. Soil Construction wastes will be segregated as much as possible at site itself to increase the feasibility of recycling concrete and masonry as filling material and steel pieces as saleable scrap. Litter disposal and collection points will be established around the work sites. Empty packaging materials, drums, glass, tin, paper, plastic, pet bottles, wood, thermocol and other packaging materials, etc. will be disposed through recyclers. The construction spoils will be temporarily stored at designated dumpsite located inside the plant premises.

(B) Operation Phase 1. Air Air pollution will not take place because in the proposed project, there is no

provision of new boiler. Adequate stack height will be provided for proposed DG set of 600 KVA.

2. Fugitive Internal roads paved, leveled, no undulations, no sharp curves, slow speed. Tree plantation on surrounding available area.


1. Spentwash treatment will be as biomethanation followed by concentration of biomethanatedspentwash with integrated evaporation and standalone evaporation system to concentrate biomethanated spent wash (6% to 30%, i.e. from 482 TPD to 96 TPD) followed by aerobic composting system.The mother liquor left behind after distilling-off alcohol is called as spent wash.

(***Concentrated biomethanated spent wash will be generated at the rate of 2.13 KL/KL of alcohol which is very less than the prescribed standards i.e. 6-8 KL/KL.)

2. 78% of water will be recycled. Only 22 % of fresh water will be


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required. 3. Rain Water Harvesting will be done. 4. Continuous online monitoring system as per CPCB norms will be

installed for monitoring distillery waste water. 4. Solid Waste 100% collection every day. Segregated and treated/ disposed per SPCB

norms. 5. Odour Limited source of odour. Controlled by keeping closed regime during initial

treatment. Use of heat exchanger for cooling. Bio-digester is fully covered& aerobic composting technique will be used. The green belt around composting & other places will be emphasized.

6. Noise Smooth roads. Sturdy foundation. No Vibrations. Acoustic enclosures to existing sugar unit DG Set as per manufacturers’ design. Use as standby only. Trees are planted around. Side cladding. Large No. of tree barriers. Factory placed away from boundary. Acoustic enclosure will be provided to proposed DG set of 600 KVA for distillery project.

7. Socio-economic Employment generation, Community Skills Development, Improved Standard of Living, Community Organizational Capacity Development Economic Exposure and Development

4.7 ASSESSMENT OF SIGNIFICANCE OF IMPACTS

For such assessment of significance of Impacts, Magnitude and Importance of 100 impact potential considerations (Grouped in 11 categories A to K) are considered taking Guidance from Leopold Interaction Matrix , (Source: Handbook of EIA, Scientific Publishers (India), Jodhpur), and modified to suit the present purpose. The categories A to K are-

A. Modification of Regime B. Land Transformation and Construction C. Resource extraction D. Processing E. Land alteration F. Resource renewal G. Changes in Traffic H. Waste Replacement and Treatment I. Chemical Treatment J Accidents, and K. Others

The above eleven attributes are further subdivided for better analysis, totaling to 100 consideration aspects. For the scenario of this present proposal, this is worked out in details and presented below.

Table No. 4.26: Impact Attributes

Sr.No. Description Impact Potential Explanation Category A. Modification of Regime

a. Exotic fauna introduction

Nominal, nearly nil This is a compact area and is already permitted for industrial use.

b. Biological controls

Nil There is no discharge of untreated effluent or of watery sludge from the premises

c. Modification of habitat

Nil We have planted 10612 trees and plan for another 11431 trees. No release of liquid effluents, or any excessive air pollutants after ECE. So habitat will improve for avifauna.

d. Alteration of ground cover

Nominal, but beneficial

Barren area is now being converted to greenery. Previous rain run-off now collected and used for Groundwater recharge.

e. Alteration of groundwater hydrology

Nominal, but beneficial

We will draw groundwater at very less quantity. Rainwater harvesting will be done by the industry.


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f. Alteration of drainage

Nil This is a plain level land. The built-up area requirement is very small. The natural drain pattern is not disturbed.

g. River control and flow modification

Nil We do not release any wastewater into river. Hence no flow modification by us either.

h. Canalization Nil Neither the topography is disturbed for bringing water, or for sending wastewater, or for erecting buildings, or for constructing any new roads-culverts.

i. Irrigation Nil We do not release any raw wastewater on irrigated land or canal. Hence no irrigation effect by us either. We have developed our own greenery inside

j. Weather modification

Nominal, but adverse.

This activity is temperature oriented but only to limited heating to a level. This thermal activity is likely to modify the weather to a small extent. This will be in the work zone. As the shed is fully cladded and as the shed is centrally placed , the micro-climate of outside the premises however may not get significantly moderated.

k. Burning Nominal, but adverse.

Explained as above, and kept controlled.

l. Surface paving Nominal, but beneficial

Within the already industrial area. The footprint plinth is very limited. Paving is done to arrest any possibility of groundwater percolation/ pollution. Thus beneficial. With RWH, Rain runoff is not increasing.

Category B. Land Transformation and Construction Description Impact Potential Explanation

a. Urbanization Nil This is a reasonably small plot. This is located in a village background. The labour force is divided in shifts. As such the mofussil nature continues. Colony, guest house is small and self-contained.

b. Industrial sites and buildings

Nominal but marginally beneficial

This is an Agro-based industry. As such sheds with few warehouse and store will be needed. Other infrastructure like office, guesthouse, and time office can be common and small facility. Hence not a substantial impact. In fact, by our presence, safety, law & order, facilities and rise in land-prices will increase.

c. Airports Nil Once streamline with steady state production, only local traffic by surface will be undertaken. No air traffic.

d. Highways & Bridges

Nominal and adverse There will be nominal increase in traffic. However precautions taken for good wide roads, guarded junctions, parking and illumination.

e. Roads and trails Nominal and adverse There will be nominal increase in traffic. However precautions taken for good wide roads, guarded junctions, parking and illumination

f. Railroad Nominal nearly Nil Neither the raw materials, nor finished products, nor by-products, nor waste nor passenger traffic related to this activity go by rail, as they prefer road.

g. Cables and lifts Nil Neither the raw material, nor finished products, nor by-products, nor waste, nor passenger traffic related to this activity go by cables or lift.


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h. Transmission lines, pipelines and cowherds

Nil Neither the raw materials, nor finished products, nor by-products, nor waste, nor passenger traffic related to this activity go by or disturb or overload the transmission lines, pipelines or cowherds. GSEB (Govt.) has permitted use of their power transmission lines.

i. Barriers incl fencing

Nil Neither the raw materials, nor finished products, nor by-products, nor waste nor passenger traffic related to this activity go by or disturb or overload the barriers & fencing.

j. Channel dredging & straightening

Nil Neither the raw materials, nor finished products, nor by-products, nor waste, nor passenger traffic related to this activity use any channel hence neither dredging nor straightening involved.

k. Channel revetments

Nil Neither the raw materials, nor finished products, nor by-products, nor waste nor passenger traffic nor water supply related to this activity use any channel hence no channel revetments is involved.

l. Canals Nil Neither the raw materials, nor finished products, nor by-products, nor waste nor passenger traffic nor wastewater release related to this activity use canal and hence not involved.

m. Dams and impoundments

Nominal but beneficial

This is small activity with small area involved. There are small undulations and rain is medium. However it is decided to create some impoundment for water harvesting. This will recharge the groundwater hence beneficial.

n. Piers, seawalls, marinas & sea terminal

Nil This is located in landlocked area.

o. Offshore structures


p. Recreational structures


q. Blasting & drilling


r. Cut & fill Nominal and beneficial on 2

counts

This is small activity with small area involved in a plot. There are no undulations and site is plain. Care is taken to orient the buildings such as to balance the cutting and filling. No borrowing of material from outside needed. Some surplus cutting material of top soil will be used for greening landscaping as good soil not to be imported. Hence doubly beneficial.

s. Tunnels & underground structures

Nil There is neither a tunnel nor any underground structure involved

Category C. Resource extraction Description Impact Potential Explanation

a. Blasting & Drilling

Nil This is an Agro-based industry and not engaged in any activity like Blasting & Drilling (even during construction).


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b. Surface excavation

Nominal nearly Nil This is an Agro-based industry. As such sheds with few tanks and store will be needed. Other infrastructure like office, guesthouse, and time office can be common. Hence not a substantial impact. Nominal excavation to reach foundation will be made, but will be internal not sending any impact outside the premises. Hence nominal nearly nil.

c. Sub Surface excavation & retorting

Nil For foundation only surface excavation as covered above. No any other. Sub Surface excavation & retorting

d. Well dredging & fluid removal

Nil This is an Agro-based industry and not engaged in any activity like Well dredging & fluid removal

e. Dredging Nil This is an Agro-based industry and not engaged in any activity like Dredging

f. Clear cutting Nil This is an Agro-based industry and not engaged in any activity like Clear cutting. There is no much use of timber except door frames. No trees are coming in construction area. In fact about 16200 trees will be planted by SNKUSML.

g. Commercial fishing and hunting

Nil This is an Agro-based industry and not engaged in any activity like Commercial fishing and hunting

Category D. Processing Description Impact Potential Explanation

a. Farming Nil This is an Agro-based industry and not engaged in any activity like Farming of our own.

b. Ranching & Grazing

Nil This is an Agro-based industry and not engaged in any activity like ranching and grazing

c. Feedlots Nil This is an Agro-based industry and not engaged in any activity like feedlots

d. Dairying Nil This is an Agro-based industry and not engaged in any activity like feedlots.

e. Energy generation

Highly Beneficial This is an Agro-based industry and engaged in producing energy. This is much beneficial to the State.

f. Mineral processing

Nil This is an Agro-based industry and not engaged in any activity like mineral processing

g. Metallurgical industry

Nil This is an Agro-based industry and engaged in an activity like metallurgical industry

h. Chemical industry

Nominal nearly Nil This is an Agro-based industry and not engaged in any harsh chemicals, but kept in control.

i. Textile industry Nil This is an Agro-based industry and not engaged in any activity like textile industry

j. Auto and aircraft Nil This is an Agro-based industry and not engaged in any activity like auto and aircraft industry

k. Oil refinery Nil This is an Agro-based industry and not engaged in any activity like oil refinery

l. Food Significantly Beneficial

This is an Agro-based industry and engaged in activity useful in food, food processing. Care taken.

m. Lumbering Nil This is an Agro-based industry and not engaged in any activity like lumbering

n. Pulp and paper Nil This is an Agro-based industry and not engaged in any activity like pulping-papering.


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o. Product storage Nominal nearly Nil This is an Agro-based industry and product will be in good demand thus stored for short time. Full precautions taken as per factory Act. Hence no impact.

Category E. Land alteration Description Impact Potential Explanation

a. Erosion control & terracing

Marginal but beneficial

This is an Agro-based industry and not engaged in any activity that will create land erosion or there will be any need demanding controlling it. However for rainwater harvesting, industry have planned terracing contour bunding etc. which will benefit halting any erosion. There is no incremental rain runoff by our development.

b. Mine sealing and waste control

Nil This is an Agro-based industry and not engaged in any activity like mine or its waste

c. Strip mining rehabilitation

Nil This is an Agro-based industry and not engaged in any activity like mine or its rehabilitation, remediation

d. Landscaping Marginal but beneficial

This area under this unit and is already in the possession of industry. Thus there will be no change in land use pattern or on landscape. However, industry shall be growing additional trees and lawns, and landscape will be more aesthetically pleasant

e. Harbour dredging Nil This is a land-locked industry and not engaged in any activity like Harbouring or dredging

f. Marsh fill and drainage

Nil This is a land-locked industry in dry climate land with low to moderate rainfall. Thus marsh filing and drainage not involved.

Category F. Resource renewal Description Impact Potential Explanation

a. Reforestation Marginally beneficial This is a moderate sized area, and is already an industrial land. No forest is involved, nor even cutting or disturbing any trees or greenery. In fact we shall plant a commensurate number of trees and lawns.

b. Wildlife stocking & management

Marginally beneficial This is an area away from forests, and is already an industrial land. No forest is involved, nor any fauna met here. However, birds will be attracted to our greenery.

c. Groundwater recharge

Significant magnitude

Special efforts are taken for rain harvesting, hence significant magnitude

d. Fertilization application

Nominal nearly Nil This is an Agro-based unit with commensurate small gardening. Thus any fertilization application has no much potential.

e. Waste recycling significant and beneficial magnitude

The raw material itself is supplied by Own/ neighboring Sugar Mill. The waste generated by them is used to produce this product for reusing again. Industry’s own waste too is recycled by industry itself.

Category G. Changes in Traffic Description Impact Potential Explanation

a. Railway Nil Neither the raw materials, nor finished products, nor by-products, nor waste nor passenger traffic related to this activity give preference to road rather than rail.

b. Automobile Nominal but adverse Nominal increase in traffic will take place. However precautions taken for good wide roads, guarded junctions, parking and illumination


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c. Trucking Nominal but adverse Nominal increase in traffic will take place. However precautions taken for good wide roads, guarded junctions, parking and illumination

d. Shipping Nil Neither the raw materials, nor finished products, nor by-products, nor waste nor passenger traffic related to this activity go by shipping.

e. Aircraft Nil Once streamline with steady state production, only local traffic by surface will be undertaken. No air traffic.

f. River, Canal traffic

Nil Neither the raw materials, nor finished products, nor by-products, nor waste nor passenger traffic or wastewater release related to this activity use canal and hence not involved.

g. Pleasure Boating Nil This is located in landlocked area. h. Traits Nil This is located in plain land area. i. Cables and lifts Nil Neither the raw material, nor finished products, nor by-

products, nor waste nor passenger traffic related to this activity go cables or lifts.

j. Communication Nominal nearly nil The proposal is an Agro-based industry with local base. Its infrastructure is small for communication. Hence no new burden except nominal. In fact, we shall extend our facilities to the people as well.

k. Pipeline Nil Neither the raw materials, nor finished products, nor by-products, nor waste nor passenger traffic related to this activity go by or disturb or overload the existing pipelines.

Category H. Waste Replacement and Treatment Description Impact Potential Explanation

a. Ocean Dumping Nil This is a land-locked industry and not engaged in any activity like Ocean Dumping

b. Landfill Nominal nearly Nil Landfill in a small way only, because Solid Waste is nearly fully recycled.

c. Emplacement of tailings, spoils and overburden

Nil This is an Agro-based industry and not engaged in any activity like Emplacement of tailings, spoils and overburden

d. Underground storage

Nil This is an Agro-based industry and not engaged in any activity like Underground storage

e. Junk disposal Nominal nearly nil This is an Agro-based industry and nominally involved with ferrous scrap. If it occurs it is in small quantity and is recycled forthwith. This is only in initial construction phase.

f. Oil well flooding Nil This is an Agro-based industry and not engaged in any activity like Oil well flooding

g. Deep well emplacement

Nil This is an Agro-based industry and not engaged in any activity like Deep well emplacement

h. Cooling water discharge

Nil This is an Agro-based industry and though engaged in activity like Cooling water, zero liquid discharge will be achieved.

i. Municipal waste discharge including spray irrigation

Nil This is an Agro-based industry and not faced with high Municipal waste. Taken precautions. Locally absorbed.


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j. Liquid effluent discharge

Nil This is an Agro-based industry. Converts the liquid waste into usable farming water and power. Thus zero outside discharge and not engaged in any activity like Liquid effluent discharge.

k. Stabilization and oxidation pond

Nil There is no such Stabilization and oxidation pond.

l. Septic tank, commercial and domestic

Nil There is well designed septic tank with proper sub-soil irrigation.

m. Stack and exhaust emission

Nil No provision of new boiler as Steam & Power requirement will be met through existing Sugar Unit & captive power plant. Proper Air Pollution Control facilities have been provided for existing sugar unit boilers.

n. Spent lubricants Nominal but nearly nil

Spent lubricants will be collected. As the quantity is not significant, it will be used internally with SPCB consent.

Category I. Chemical Treatment Description Impact Potential Explanation

a. Fertilization Nil This is an Agro industry not engaged in any activity like using of harsh Fertilizer

b. Chemical deicing of highways

Nil This is an Agro industry and not engaged in any activity like using of Chemical deicing of highways. In any case this is not relevant to this part of the country.

c. Chemical stabilization of soil

Nil This is an Agro industry and not engaged in any activity like using of Chemical stabilization of soil.

d. Weed control Nil This is an Agro industry and not engaged in any activity like using of Weed control. Greening is only attendant activity.

e. Insect control (Pesticides)

Nil This is an Agro-based industry and not engaged in any activity like using of Insect control (Pesticides)

Category J. Accidents Description Impact Potential Explanation

a. Explosions Nil This is an Agro-based industry and not related to any potential explosion from distillery and co-gen unit

b. Spills and leaks Nil This is an Agro-based industry and not engaged in any handling of fluids and so not related to any uncontrolled spills.

c. Operational failure

Nil This is simple few step process. No operational failures are foreseen as to create any accidents. If at all it may give less production by lower efficiency.

Category K. Others Description Impact Potential Explanation

a. Fire Hazard Nil Raw material or finished goods can catch fire. Full precautions taken.

b. Public acceptability

Significant and beneficial

The economic situation is very harsh for the local neighbours. Very low livelihood. Nearby lands only rain-fed. People are anxious to have at least some development.

c. SPCB acceptability


The industry will be working with consent to operate and will obey all the conditions.


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Having done above exercise for a matrix with 100 considerations, marks are allotted depending on the hierarchy of impact potentiality. The hierarchy starts from “Totally Adverse irreversible” impact with minimum marks as 1 and ranging up to maximum of 10 for “High with beneficial magnitude and importance”, being –

Table 4.27: Yardstick for Mark – Giving Where the impact potential is this Allot marks Totally Adverse irreversible 1 Totally Adverse reversible 2 Nominal but adverse 3 Nominal, nearly nil 4 Nil 5 Nominal, but Marginally beneficial 6 Nominal, and beneficial 7 Nominal, and beneficial on two counts 8 Significant beneficial impact 9 High beneficial in magnitude and importance 10

The marks allotted to these 10 attributes for total 101 considerations are tabulated below –

Table 4.28: Impact Matrix S.No

. Attribute

Impact A B C D E F G H I J K Total

no. Marks

Per No.

Total

1 Adverse irreversible 0 0 0 0 0 0 0 0 0 0 0 0 1 0 2 Adverse reversible 0 0 0 0 0 0 0 0 0 0 0 1 2 2 3 Nominal but adverse 2 2 0 0 0 0 2 0 0 0 0 6 3 18 4 Nominal, nearly nil 1 1 1 2 0 1 1 4 0 0 0 10 4 40 5 Nil 5 13 6 11 4 0 8 10 5 3 1 66 5 330 6 Nominal, but marginally beneficial 1 1 0 0 2 2 0 0 0 0 0 6 6 36 7 Nominal but beneficial 3 1 0 0 0 0 0 0 0 0 0 4 7 28 8 Nominal, but beneficial on more counts 0 1 0 0 0 0 0 0 0 0 0 1 8 8 9 Significant beneficial impact 0 0 0 1 0 2 0 0 0 0 3 6 9 54 10 High beneficial magnitude & importance. 0 0 0 1 0 0 0 0 0 0 0 1 10 10 Items considered 12 19 7 15 6 5 11 14 5 3 4 101 526 Legend of attributes – A. Modification of Regime B. Land Transformation and Construction C. Resource extraction D. Processing E. Land alteration F. Resource renewal Changes in Traffic H. Waste Replacement and Treatment I. Chemical Treatment J. Accidents K. Others Thus, the marks obtained are 526. Acceptability of a Project or a decision of “No Project” depends on the marks obtained as –

d. Salability of product


The product Alcohol is a desirable substitute and a specialty chemical needed in many industries like pharmaceutical, food, petrol-substitute etc. and hence much in demand. This also means that there will not be any need of unnecessary undue long storage of these products in these premises. Early dispatch without storage is environmentally beneficial and less risky. The products are useful to the society. Power is transmitted to GSEB.


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Table 4.29: Yard-Stick for Ranking

Score 750 to 1000 = Environmental Acceptability is Very High Score 600 to 750 = Environmental Acceptability High Score 450 to 600 = Environmental Acceptability Moderate Score 300 to 450 = Environmental Acceptability Low Score Below 300 = Environmental Acceptability Very Low

4.8 SUMMARY AND CONCLUSION

The environmental impact evaluation of possible effects as a result of plant site activities and operation on various environmental parameters is primarily based on careful study of Unit operations, surrounding environment etc. The principles of minimization or off-setting mal-effects are based on the principle of prevention, abatement, treatment, reuse, and smooth disposal of wastes. The summary of anticipated adverse environmental impacts and mitigation measures are given in Table - 4.30.

Table 4.30: Minimization Efforts for Environmental Impacts

Sr.No. Regarding Measure/ effort Remark 1 Raw

Material Obtained clean Less loss, less load to environment.

Dependable source Continuity assured. No shock load to environment by make and break.

Inventory Only small as assured source. No fear of degrading. 2 Land Limited. Already industrial. No rehabilitation involved. No leveling necessary. No

prime agricultural land. Not used previously by general public. Already in possession.

3 Water Safe, reliable dependent source

No encroachment on source of others. Not process stoppage risk. Own efforts of recharging and reusing.

4 Groundwater Available. In fact by rain harvesting, recharging is made. Wells are existing and usable. No new tapping.

5 Air pollution No gas as raw material, no gas generated in process (except CO2, SPM)and

effluent treatment (except CH4)

No provision of new boiler. Not likely to increase over routine. Satisfactory monitoring schedule. Proper Air Pollution Control facilities have been provided for existing sugar unit boilers.

6 Wastewater Though of moderate BOD, both the Domestic&

Industrial effluents fully taken care of making zero

discharge outside

Water use minimized. Zero liquid discharge will be achieved. Domestic effluent reasonably low in quantity. No discharge to any surface water, or any percolation to groundwater.

7 Soil MSW, Haz Waste, attended. Soil is not spoilt. Landscaping is done. Organic solid waste is locally garden composted. Inorganic segregated. Saleable to fixed authorized vendors. Remaining either for sanitary or secured landfill. No hospital to create bio-medical waste.

8 Aesthetics Noise No big machinery kept near boundary, shed at central part of plot, sturdy foundations, no vibrations. Greenery maintained. In closed, covered sheds.

Odour Various measures are taken as – 1. Water use minimized. Wastewater minimum. 2. Lagoons are kept normally dry and are

relatively small.(only 30 days are permitted) 3. Receives I- treatment in closed bio-digester


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4. Secondary treatment is fully aerobic/ thermal. 5. No evaporation solar ponds 6. No disposal on land with cess pools.

9 Community Acceptability The economic situation is very harsh for the local neighbors. Very low livelihood. Lands only rain-fed. People are anxious to have at least some development. Assistance offered.

10 Track record Social work and Law-abiding Project proponents are keen on matters environmental and have well past record. They wish to continue the same. The society has respect for them.

With the mitigation measures proposed above with subsequent efforts of implementation, the potential impact (especially irreversible and irretrievable) should become very low / insignificant / nominal or none.


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CHAPTER – 5 ANALYSES OF ALTERNATIVES (TECHNOLOGY & SITE)

5.1 INTRODUCTION

It is necessary that one should try to find various alternatives and what is environmentally best be preferred. There can be many points for which alternatives must be found. This is attempted here, irrespective of whether scoping has asked so or not. This is done voluntarily and submitted herein below. As per EIA Notification dated 14th Sept., 2006 and its subsequent amendments; theChapter on “Analysis of Alternatives (Technology and Site)” is applicable only, if thesame is recommended at the Scoping stage.As per the ToR points issued by MoEFCC, New Delhi vide letter no. No.IA-J-11011/384/2017-IA-II (I) dated 26th October, 2017 for the proposed project; the Analysis ofAlternative Site is not required since, the proposed project will be done within the existing plant premises. 5.2 ALTERNATIVES

Any proposed human activity is never a simple straightforward matter. A number of decisions are required to be taken and for each step a number of alternatives are available. Selection is thus all the more critical in an industrial development where time, money, environment and natural resources are at stake.

This Industry decided to undertake an “Alternative Analysis (AA)” for this project. The various alternatives are (1) Product (2) Raw materials, (3) Technology, Engineering & Hardware, (4) Site, and (5) ‘No-Project’.

Highlights of the final selection can be summarized as: • The unit will be with latest technology including continuous fermentation and multi pressure vacuum

distillation system. • Large quantity of condensate water will be recovered from integrated-evaporators which will be utilized

in the plant itself for dilution molasses and make up of cooling water. • Spent wash is treated through biogas unit followed by evaporation cum composting. • The distillery will be with zero discharge of spent wash. • Sugar and co-gen units will support distillery for steam and power. 5.3 PRODUCTS

Proponents have opted to produce rectified spirit and Fuel Alcohol. This option is selected with some consideration. This comes from molasses which is otherwise a waste from our Narmada District sugar units and is an environment risk with high BOD of molasses (900000 mg/lit.) and auto-combustion nature. On the other hand, the product alcohol is useful in pharmaceutical, food and as petrol-substitute. It is in demand. This is evident from Indian manufacture statistics. There are more than 300 such distilleries in the country with a total installed capacity of 3500 million liters per annum. However, though such abundant licensed capacity the production is only about 1900-2000 million liters per annum. Department of Chemicals & Petrochemicals Government of India have kept an aim of at least 2710 million liters per annum. This shows how much the chemicals are in great demand both in India and abroad. Though the global recession has thrown that industry out of balance, in India the demand continues. This industry with wide support of research then decided to produce Fuel Alcohol. This has given a versatile look to this industry. Now we can cater to many fields which are as say acetic acid, acetaldehyde, acetic anhydride, VAM, Ethyl acetate, and many similar.

In case, the scoping exercise results in need for alternatives: • Description of each alternative • Summary of adverse impacts of each alternative • Mitigation measures proposed for each alternative and • Selection of alternative • Various alternatives for various considerations, Pros and Cons, Environmental Significance, ranking

and Selection or “No Project” Option •


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While producing alcohol in its fermentation step CO2 is liberated by microbiological activity. We have adopted a practice to scrub it in water. While producing alcohol in its distillation step liquid effluent spent wash is generated. This is a nuisance creating foul odour and large scale fish mortality. To avoid this, we are using this for biogas recovery and to get good quality bio- manure. 5.4 RAW MATERIAL ALTERNATIVE

The raw materials required are available with us and additional if needed are from assured vendors in this and adjoining district where much sugarcane based agro-industries are working. There is also good road connectivity. Some other helping substances also will be needed in minor quantities on occasions such as acid etc., as also lubricating oil. The choice of source, as mentioned above was adopted because there the materials are in purer forms. If raw material is purer and is in the desirable form, it avoids a probability of discards or non-specification outcome. It also obeys the mass balance more faithfully than when impurities are involved. No problem of any empty containers or bags is encountered. There is a possibility of selecting excellent molasses. 5.5 TECHNOLOGY ALTERNATIVES

The technology of making the products has been developed over the years, and refined indigenously in well equipped Research and Development Laboratories of Government and private Institutes and Private Vendors etc., in which devoted scientists, engineers, skilled and experienced staff is working, to find the best alternatives, addressing the above enquiries. 5.5.1 ENGINEERING & HARDWARE OPTIONS

The process development and engineering designing of this project has been done in such a way that the whole operation of manufacturing can be carried out in a controlled system with no or low gaseous emissions, effluents, and minimum waste generation. The material handling and transfer of raw materials are also carried out in controlled and supervised system. Thus, the technology is not only cost-effective but also environment friendly. Improvements I process are done by modernization such as Dehydration. There are many ways and environmentally the best one is selected. It is note- worthy that - • Rectified spirit feed is pretreated by product vapour. • Evaporator column gets energy from re boiler • Steam condensate is feed back to boiler • Twin adsorbents beds. One in dehydration mode, other is regeneration mode. • Switching of beds by Automation. The process development and engineering designing of this project has been done and the industry proposes to employ following specialty in their manufacturing - • The first peculiarity is this, that the Project Proponent has made adequate provision for pollution

control and greening drive in the outset itself. • The raw material is used immediately after procuring. This is transported and also transferred

without any chance of fugitives. This has become possible due to nearness of site to the raw materials fields and tar roads in the vicinity. The size is controllable.

• It is possible to select good and uncontaminated, materials answering particular specifications, as free from any foreign material including any undesired admixtures.

• Selection of correct quality raw material is possible because three inspections are done in time. • When the procurement is done, the quality also will be recorded, which keeps an eye on recovery,

resource conservation and waste minimization. This is prevention of pollution. 5.6 SITE ALTERNATIVES Alternative Site is not required since, the proposed project by SNKUSML at Village: Dharikheda, Tehsil: Rajpipla (Nandod), District: Narmada (Gujarat) will be done within the existing sugar plant premises by new machine installation.

The criteria kept for candidate sites included:


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• Nearness of raw materials • Purity of raw materials • Adequate transportation network • Ease of conveyance of raw materials • Desire of Government for industrialization in that area • Nearness of market • Dispatch facilities • Less Undulation of site • Steam, Power and water supply, without encroaching on need of others • Remoteness of target • Not Destroying prime agricultural lands • Maximizing infrastructure capacity utilization • No forest land is involved • No Revenue land is involved • No tribal land is involved • No R & R dis-satisfaction.

On the four sides of this particular site we have only open fields. There is no habitation within one km. There is no sensitive establishment in the vicinity such as health resort, hospital, archaeological monuments, sanctuaries, etc. The normal wind direction is found to be favorable at this site. There are more no. of villages in the study zone and are examined. It is found that: 1. Majority of the villages are engaged in agriculture. 2. All these villages have road network connected. 3. None of these villages have fully satisfactory amenities like medical facilities. education,

employment, transportation, communication. They would like to have this through media of industry.

4. All are provided with drinking water from wells or Government Water Supply Schemes RWS. Hence TI does not encroach upon their supply.

5. The population is limited. With all this consideration, this site was ranked first and adopted. 5.7 NO PROJECT OPTION

No project option is considered mainly with respect to: 1. Utilization of natural resources 2. Environmental impacts, harmful or beneficial 3. Benefits of the industry to the society The project is proposed mainly for the purpose of best utilization of waste product such as molasses produced in the sugar industry to produce ethanol. This project will be environmental friendly. Ethanol is an essential product for use in beverages, as raw material for various organic products and as a liquid fuel for use in automobiles. Fuel alcohol (FA) is useful as a substitute to the petroleum source and basically an environmental friendly product. It is a major source of revenue to the government. The production of FA has a potential in saving foreign exchange and export earnings. Being an agro-based unit the distillery will help farmers to improve their economic conditions. The proposed project will not cause depletion of natural resources or the significant adverse impacts on environment. On the contrary, it will produce value added resources such as ethanol, agro-manure. Hence, “No Project Option” is not considered. 5.8 CONCLUSION

In any human activity there are always possibilities of finding various options. TI decided to examine and adopt one such option that will be both environment friendly and best suited for production. Various alternatives in terms of product, raw material selection, technology, engineering and equipment are considered. A final selection is thus arrived.


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CHAPTER 6 ENVIRONMENTAL MONITORING PROGRAMME

6.1 INTRODUCTION

Post Project Monitoring is an essential part to check the impact of project related activities. Hence, monitoring of various environmental parameters is being / will be carried out on a regular basis to ascertain the following:

•••• Status of Pollution within the plant site and in its vicinity •••• Generate data for predictive or corrective purpose in respect of pollution •••• Examine the efficiency of pollution control system adopted at the site •••• To assess environmental impacts

Monitoring is being / will be carried out at the site as per the norms of CPCB. Environmental Monitoring Programme is being / will be conducted for various environmental components as per the conditions stipulated in Environmental Clearance Letter issued by MoEFCC, New Delhi and Consent to Establish / Consent to Operate issued by GPCB. Six monthly compliance reports are being / will be submitted on regular basis to MoEFCC, New Delhi. Monthly compliance Report for conditions stipulated in CTO are being / will be submitted to GPCB on regular basis. Various environmental components and pollution sources, which are being / will be monitored under environmental monitoring programme are stack emission, ambient air quality, water quality and noise levels. Details of the Environmental Monitoring programme, which will be undertaken for various environmental components, are detailed below.

6.2 MONITORING PLAN

The environmental monitoring will be done to assess performance of pollution control equipment recommended for proposed project. The sampling and analysis of environmental attributes including monitoring locations point sites will be as per the guidelines of the Central Pollution Control Board. Environmental monitoring will be conducted on regular basis by SNKUSML to assess the pollution level in and around the project area. The attributes, which require regular monitoring, are specified underneath: 1] Air quality; 2] Water and wastewater quality; 3] Noise levels; 4] Soil quality; 5] Afforestation; and 6] Socio Economic aspects and community development

6.3 MONITORING POINTS / LOCATIONS, PARAMETERS AND F REQUENCY

The environmental monitoring points shall be decided considering the environmental impacts likely to occur due to the operation of proposed project as the main scope of monitoring program is to track, timelyand regularly, the change in environmental conditions and to take timely action for protection of environment. The monitoring points/location and components of significance shall be as per Table 6.1

Contents of this chapter are: Managerial & Technical aspects of monitoring the effectiveness of mitigation measures (incl. Measurement methodologies, frequency, location, data analysis, reporting schedules, emergency procedures, detailed budget & procurement schedules)


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Table 6.1: Post project environmental monitoring schedule

Sr. No.

Particulars Parameters Location Frequency

1 Flue gases from existing sugar unit stacks (As existing sugar factory boilers will be used for stream & power requirement)

PM10, PM2.5, SO2 and NOx

Stack monitoring of sugar mill boilers

Continuous Online Monitoring System will be installed

2 Ambient air quality

PM10, PM2.5, SO2 and NOx, CO.

• Check wind direction • Select two point in upwind

direction at 1200 from site • Take one point within site at

down wind direction from sugar mill boiler about 1 km distance

• Take one point within site at down wind direction from distillery boiler about 500 m distance

• Take two points beyond site in down wind direction about 2 km distance at 1200 from site opposite to points taken in upwind direction.

24 hrs sample, half yearly

3 Water (Ground Water and Surface Water)

As per drinking water standards

• Take one upstream and downstream sample of surface water. Minimum distance 500 m.

• Take ground water sample near spent wash storage tank frompiezometer /pilot bore wells. One point upstream at higher elevation from plant site.Also at lower contour point at 3 locations.

Quarterly

4 Soil organic & inorganic matter

• Near spent wash lagoon. • Near molasses tank. • Near Sugar mill ETP • Outside plant boundary at

lower contour

Pre & post monsoon

5 Spentwash from proposed Distillery plant.

pH, Temperature, EC, Turbidity, Total Dissolved Solids, Calcium, Magnesium, Total hardness, Total Alkalinity,Chlorides, Sulphates, Nitrates, DO, COD, BOD, oil and Grease, Metals expected in effluent

Spentwash at inlet & outlet of biogas

Daily. Continuous online monitoring of distillery wastewater.

6 Vapor Condensate at CPU Unit

pH, Temp.,conductivity, BOD, COD, TDS

At CPU inlet & outlet Daily

7 Compost parameters Temp. of windrow, At windrow & compost yard Daily


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at Compost yard Compost quality- C: N ratio, moisture, N, P, K

8 Noise level, work zone (hourly)

Equivalent noise level- dB (A)

• One location near turbine house. within 3 m

• One location in boiler house. One location near I.D. Fan.

• Especially monitor noise during soot blowing.

• Four locations around plant boundary(Fermentation, distillation, biogas and concentration).

Quarterly

9 Greenbelt Number of plantation (Units), Number of Survived plants/ trees, Number of poor plants/ Trees

Check plant growth and survival of plants

Ongoing- round the year

10 Environmental Audit

As per Direction of ISO 14001

- Once in a Year

11 Water utilization, m3/d

- For process, domestic, cooling and boiler

Daily

12 Power utilization - For air pollution control facility at boilers and for ETP (biogas, concentration, CPU and composting)

Daily

6.4 MONITORING METHODOLOGIES

Monitoring of environmental samples shall be done as per the guidelines provided by MoEF&CC / CPCB/ SPCB. The method followed shall be recommended / standard method approved / recommended by MoEF & CC / CPCB.

6.4.1 LABORATORY FACILITIES

Environment Laboratory is proposed with manpower and facilities for self monitoring of pollutants generated in the industry and also its effects on the receiving soil, water body and atmosphere. The list of laboratory facilities to be provided in the industry is given below. The laboratory is equipped with instruments and chemicals required for monitoring following pollution parameters 1. pH 2. Total hardness(TH) 3. BOD 4. COD 5. TDS 6. TSS 7. Oil & Grease

List of laboratory equipments proposed 1. pH Meter 2. Conductivity meter 3. TH analysis kit. 4. BOD and COD incubator 5. TDS meter 6. Oil & Grease separator 7. Reflux apparatus for BOD /COD Analysis 8. Flame Photometer Environment lab will be working in three shifts. Each shift is of 8 hrs. In off season, other work of maintenance of ETP, APC will be done along with paper work related to Gujarat pollution control board.


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6.4.2 OPERATION & MAINTENANCE OF POLLUTION CONTROL FACILITIES

Environmental Protection will be met only if the pollution control units work with capability. For this, performance efficiency of each unit of ETP and ECE (effluent treatment plant and emission control equipments) will be assessed. Help of laboratory is necessary to run a plant. CPCB has published many booklets related to various industries and have given certain monitoring schedule. Here is one example from book COINDS/9/1980-81.

Table 6.2: ETP/CPU Unit monitoring

Sr.No. Station Frequency Examine (*) 1 Screen Weekly SS 2 Oil-Grease Trap Weekly Oil & Grease 3 Equalization Tank Every day Flow

4 Aeration tank Daily DO, pH, MLSS

Every third day BOD, SS Fortnightly Microscopy

5 Settling unit Every third day MLVSS, SVI

Fortnightly Microscopy 6 After final treatment Daily pH, BOD, TDS

(*) Whatever applicable to our ETP units will be taken up with suitable frequency.

The ETPs and ECEs must be maintained properly and this too must be monitored. Instead of emergency maintenance, preventive maintenance is better. The modern concept is predictive maintenance. Suggested schedule is:

Table 6.3: ETP/CPU units Maintenance Monitoring

Sr.No. Part See (*) Frequency

1 Bearings See temperature Daily Change grease 2-monthly

2 Gland Change packing 2-monthly /as reqd 3 Indicators Pressure gauge, vacuum gauge calibration of 3-monthly 4 All type valves Change packing 6-monthly 5 Impellor Check all blades, sleeves, bearing, impel nut check Yearly, change if reqd 6 Electric motor Open side doors, blow dust, check air gap Monthly 7 Motor winding Blow off dust, test insulation 2- Yearly

8 All hand carts, wheel barrows

Grease wheels Monthly Change rubber tyres 6-monthly if reqd

9 Gear box Oil level Check every week, replenish 3-monthly

10 Scraper shoe Tighten nut bolts, change broken-bent members, change leather-rubber shoes 3-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

(*) Whatever applicable to our ETP units will be taken up with suitable frequency. The above table may be readjusted according to the catalogues of the suppliers. Reports of the findings will be useful for rectification internally. The same will be submitted in the format as may be asked by MoEF and SPCB with due frequency.

Six monthly watches will be kept as self-discipline on our working as post project environmental monitoring and the same will be duly submitted to MoEF, CPCB and GPCB.


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6.5 REPORTING AND DOCUMENTATION

The records of the monitoring program shall be kept on regular basis for all aspects of the monitoring. Separate records for water, wastewater, solid wastes, air emission, soil and manure / compost shall be prepared and preserved regularly. Immediately upon the completion of monitoring as per the planned schedule, report shall be prepared and necessary documents shall be forwarded to the concerned person. Methodology of monitoring (sampling and analysis) shall be prepared as separate documents as SOP (standard Operating Procedure) wherever required. The records showing results / outcome of the monitoring programs shall be prepared as per the requirement of the schedule mentioned above. Regularly, these documents and records shall be reviewed for necessary improvement of the monitoring plan / mitigation measures / environmental technologies as well as for necessary actions of Environmental Management Cell. 6.6 COMPLIANCES TO ENVIRONMENTAL STATUTES

1) This industry is law-abiding and the Environmental Statutes are proposed to be complied with letter and spirit.

2) Carrying out “Environmental Audit Statement” of various environmentalaspects 3) Review of the environmental policies with the help of experts and make the up-gradation /changes

accordingly. 4) Submission of the “Environmental Statement” to the State Pollution Control Board in Form V

under Rule 14 of the Environment (Protection) Second Amendment Rules 1992 of the Environment (Protection) Act, 1986.

5) Renewal of Consent to Operate under the Water and Air Acts. 6) Filing the Cess returns to the State PCB under the Water (Prevention and Control of Pollution)

Cess Act, 1977. 7) Renewal of the Hazardous Waste Authorization under sub-rule 3 of the Hazardous Waste

(Management and Handling) Rules, 1989. 6.7 STAKE-HOLDERS & STAKES Generally there can be many stake-holders to whom a project may either give comfort or may give nuisance. These issues are identified first and then discussed as –

Table 6.4: Environmental ramification points

Sr.No. Aspect needing monitoring Stake for

1 Water source encroachment Villages 2 Power load shedding Villages 3 Construction phase disturbances Villages & Government 4 Rehabilitation Not Applicable 5 Storm-water Villages & Government

6 Transparency All. Villagers, Our staff & Colony Residents, Government

Various departments with whom rapport will be kept are --

Table 6.5: Interface – This New Industry’s Administration

Deals with Sector of S.N. Dept. / Organization

Government

1 Forest Dept. 2 Cane commissioner 3 Excise Dept.

4 Safety Dept.


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5 Revenue Dept. 6 Urban Development Dept. 7 Town Planning Dept.

Semi-Government

8 Zillah Parishad 9 State Road Development Corporation 10 State Pollution Control Board 11 Gram Panchayats

Non-Government 12 Non-Government Organizations 13 Tribal & Local Community 14 Clients

6.8 SUCCESS INDICATORS

The success of the sincere and honest efforts put in, will be judged by various indicators, such as 1. No complaint from the villagers regarding transfer of lands. 2. No complaint from the customers regarding quality of product and delivery schedule. 3. No complaints from Government or Non Government Authorities and Public. 4. Statistics of Health, Safety and Environment maintained. 5. Other Promoters come to seek our advice. Demonstration to others for rainwater harvesting, environmental status report, environmental statements (annually). Water cess returns (monthly), groundwater recharging, sand-substitute ash, plastic-free packing, care for disabled etc. 6.9 BUDGET AND PROCUREMENT SCHEDULE

On regular basis, Environment Management Cell shall inspect the necessity and availability of the spares suitability of technology materials, services and maintenance status. The Cell shall make appropriate budget for the purpose. Regular record review for any change in financial requirement of environment management shall be done and appropriate budgetary provisions shall be made. Along with other budgets, Budget for environmental management shall be prepared and revised regularly as per requirement. The budget shall include provisions for:

• Environmental Monitoring Program • Operationand Maintenance of Environmental Technologies / Equipments • Laboratory works for Environmental management activities • Emergency Purchase of necessary material, equipments, tools, services • Annual Environmental Audit. • Preparing environment statement.

Budget for Post ProjectEnvironmentalMonitoring The total budgetfor post project monitoring is envisaged to be about Rs 141.10Lacs/Annum. Details are given in Table 6.6 & 6.7.

Table 6.6: Remuneration of technical staff for environment management

Sr. No. Description Nos. Salary Rs. (per month) 1 Environmental Manager 1 50,000 50,000 2 Safety Officer 1 30,000 30,000 3 Medical Surveillance Officer 1 40,000 40,000 4 MEE Operator 4 15,000 60,000 5 CPU Plant Operator 4 15,000 60,000 6 Biogas Plant Operator 4 15,000 60,000 7 Composting Unit Operator 4 15,000 60,000 8 Laboratory Incharge 1 25,000 25,000 9 Environmental Chemist 4 20,000 20,000 10 Laboratory Attendants 4 10,000 40,000 Total Monthly expenses 2,35,000 4,45,000 Total Yearly expenses 28,20,000 53,40,000


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Table 6.7: Post Project Environment monitoring budget

Sr. No. Description of Item Cost of Post project Environmental

Monitoring Rs Lacs / annum Existing Sugar Unit

1 Stacks Monitoring (total 3 in No.s) including proposed environmental monitoring system 11.00

2 O & M of Existing Air pollution control facilities 9.00

3 O & M of Existing Water pollution control measures& water analysis 10.50

Proposed Distillery Unit

4 O & M of Proposed Water pollution control measures& water analysis

34.10

6 Noise Abatement 0.10 7 Occupational Health 5.00 8 Safety Management fire fighting & safety aspects 5.00 9 Env. Laboratory, equipments & chemicals 7.50 10 Rain water harvesting 2.50 11 Green belt 3.00

12 Remuneration of technical staff for environment management

53.40

Total 141.1

6.10 CHAPTER CONCLUSION

It is proposed to frame an Environmental Monitoring programme both in Construction and Operational stages to monitor the effectiveness of the mitigation measures by judging the impact on environment. A separate budget is proposed for the same as also a dedicated Cell. A transparent approach will be kept with documentation and Reporting with statistical treatment to the data. Checklist of Statutory Obligations will be maintained and compliance with it will be monitored. The ultimate aim is that the Proponents and Public make a combined effort in the same direction of Sustainable Development.


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CHAPTER 7-ADDITIONAL STUDIES

7.1 PUBLIC HEARING AND CONSULTATION The project is establishment of New Molasses based distillery - 45 KLPD, At- Dharikheda, Post- Timbi, Rajpipla (Nandod) Taluka, Narmada District in Gujarat State. Public Hearing for proposed distillery was conducted on 20th July, 2018 at factory site. Details of the Public Hearing include:

• Public Hearing Proceedings • Public Hearing Notice published in Newspapers “Divya Bhaskar” dated 02.06.2018 and “Times of

India” dated 04.06.2018. • Photographs of Public Hearing. • Action Plan for the issues raised during Public Hearing.

Public Hearing Proceedings Public Hearing Proceedings (Gujarati and English translation) along with attendance sheet have been enclosed as Annexure 15 along with this Final EIA Report.

Contents of this chapter are: • Public Consultation • Risk Assessment


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Figure 7.1: Public Hearing Notice Published in Newspaper


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Figure 7.2 Photographs of Public Hearing


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Table 7.1: Action Plan for the issues raised during Public Hearing

Sr. No.

Name of the Person

Issues / Points raised

Reply to the Issues / points raised Action Plan

1 Shri. Bipinbhai Natvarbhai Patel, Vill. Umalla, Tal.- Jhagadiya, Dist.-Bharuch

He represented that; this plant should be established if there will be a benefit to the farmers by the distillery plant. It is my request to provide information regarding the special benefits to the farmers by this plant

Company’s representative replied that, molasses is our by-product. Ethanol and rectified spirit will be produced from molasses so has to have further value addition. This project will produce 45KLPD capacity ethanol. It will benefit to member farmers. Instead of selling molasses outside, this company will produce ethanol from molasses thereby there will be value addition. The previous ex-factory rate of ethanol was Rs. 40/- per litre. However as per the recent bio-fuel policy declared by central government, the rate of ethanol will be Rs. 43/- per litre. Even considering rate of ethanol as Rs. 40/- per litre and molasses production as 40,000 metric ton from 7.5 lakh ton cane crushing which will also increase further. In future thereby, the availability of the molasses will be of the order of 38,000 to 40,000 per metric ton, the profit will be in the range of Rs. 10 to 12 crores. Factory will be able to pay additional price in the range of Rs. 140 to Rs. 150 per metric ton of cane crushed to the member farmers.

Factory will be able to pay additional price in the range of Rs. 140 to Rs. 150 per metric ton of cane crushed to the farmers.

2 Shri. Anilkumar Manubhai Rohit, Vill.-Amletha, Tal.-Nandod, Dist.- Narmada

He represented that, for any project financial management is very important. In this project kindly let us know the finance raised for this project

Company’s representative replied that, factory has already prepared detailed project report. NCDC, Delhi has made appraisal of the project and sanctioned loan to the tune of Rs. 48 crores. If there is increase in the project cost, the government will assist by way of providing additional finance. As per the recent bio-ethanol policy of the central government, it will promote and provide financial assistance to the distillery and ethanol project. Since NCDC has sanctioned Rs. 48 crores, it may be sufficient for this project and there won’t be financial problem. Further to inform all that, this factory has received 5 to 6 awards.

NCDC has sanctioned Rs. 48 crores, it may be sufficient for this project and there won’t be financial problem.

3 Shri. He represented Company representative replied that, Compost will be


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Dineshbhai Desai, Vill.- Lachhrachh, Tal.- Nandod, Dist.- Narmada

that, earlier we were getting bio-compost from sugar unit. Now whether we will get compost? If we get, what quality? And what will be the price?

factory is still producing bio-compost, but in this distillery project, after bio-gas production, the residue emerged out will be further concentrated to minimize the volume which will be used for making bio-composting thereby achieving the Zero Liquid Discharge. It is our duty to protect environment, birda and animals. We are proud to inform all that, this is the first project in Gujarat state producing biogas from spent wash and further concentrating the bio-methanated effluent and making compost from it. It is rich in nitrogen, phosphorous and potash and organic in nature. It will be made by the factory to provide it at subsidize rate. On behalf of factory I assure that, it will be provided without taking any profit. Best quality compost will be provided to our cane growing farmers.

made by the factory to provide it at subsidize rate. It will be provided without taking any profit. Best quality compost will be provided to our cane growing farmers.

4 Shri. Ashokbhai Arvindbhai Patel, Vill.- Varkhadi, Tal.- Nandod, Dist.- Narmada

He made appeal that, this project should be executed at the earliest, thereby the farmers will get better price to their produce. i.e. sugar cane.

Company’s representative replied that, the main objective of the factory management is financial growth of the member farmers. Ours is the only factory in the Gujarat state producing sulfur free refined sugar which is innovative in its own way. This factory is operating as per the vision of the chairman and with the co-operation of the cane growers. Factory is going to work in such a way so that it will get financial gain. As informed earlier the cane growers will get additional cane price of the order of Rs. 150/- per metric ton cane supplied to factory. I again assure you all that, our cane growers will get additional cane price due to this project.

Additional cane prices will be provided.

5 Shri. Bhupendrasinh M. Vasava, Vill.- Virsinghpura, Tal.- Nandod, Dist.- Narmada

He represented that, he is a member of this organization with a code number 31041. The company is in operation since 1996. The company is doing good progress and it is the only facory in

Company representative replied that, company covers 102 acres of area. Company has got adequate land and all the resources like water, electricity etc. So there is no further acquisition of land. He welcomed the suggestions regarding the local employment and assured for the same. About 25 to 30 persons may get employment in this project.

About 25 to 30 persons may get employment in this project. Additional cane prices will be provided to farmers.


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Gujarat which manufactures sulfur free sugars. Two dams have been constructed in the district in which many tribals have lost their land and in his opinion in this factory also only tribals have lost their land. As presented today, there would be the development of surrounding villages and local employment because of this project so requested further efforts for giving employment to the locals and wish that, farmers would get good price for their produce.

6 Shri. Ashvinbhai Lallubhai Patel, Vill.- Pratapnagar, Tal.- Nandod, Dist.- Narmada

He represented that, there would be a great benefit to the members and farmers by their plant so it should be allowed. He also informed that, all the village sarpanchs and elders gathered here welcomed the new project.

Campany’s representative expressed thanks for this.

-


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7.2 RISK ASSESSMENT

An industry with its complex nature of activities involving various plant machineries, raw materials, products, operations, intermediates and environmental discharge has a number of associated hazards. A minor failure can lead to major failure resulting into a disaster causing heavy losses to life, property and environmental. Risk assessment studies are being conducted to ensure safety and reliability of any new plant, through a systematic and scientific methods to identify possible failures and prevent their occurrences before they actually cause disasters and production loss. 7.2.1 OBJECTIVES OF THE STUDY

The distillery involves storage and handling of large quantity of ethanol which is flammable and explosive under unfavorable situations. To ensure safe operation of the plant, it is proposed to carryout the Risk Analysis Study with the following objectives,

1. To identify the major hazards relating to fire, explosion and toxicity due to storage and handling of hazardous chemicals.

2. To visualize maximum credible accident scenarios 3. To analyze and quantify primary and secondary effects and damage potentials of the identified

maximum credible accident scenarios using standard procedure. 4. To study the nature of exposures, pathways and consequences of maximum credible accident

scenarios and characteristics of risk levels. 5. To provide guidelines for disaster management plan. Risk assessment studies have been carried out to assess the worst case scenarios of the plant operations to formulate an emergency management plan. 7.3 VARIOUS MATERIALS & PRODUCTS OF DISTILLERY a) Molasses b) Yeast c) Urea d) Defoaming Oil e) Ethyl Alcohol f) Fusel Oil Properties of the Material- a) Molasses-

Brown coloured, sweet smelling, semisolid with medium to very thick consistency viscous fluid, Corrosive nature with acidic pH. Can cause severe water pollution problem, if enters in to water body due to high content of oxygen demanding organic matter. Imparts colour and disagreeable odour to water supplies. If exposed through- Inhalation: No harmful effect Ingestion: Strong taste, no harmful effect Skin: No any action except physical discomfort Eyes: Irritation, wash with ample fresh water b) Yeast-

If exposed through- Inhalation: No harmful effect Ingestion: Undesirable taste, no any harmful effect Skin: No any action Eyes: No effect c) Urea-

If exposed through-


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Inhalation: Disagreeable odour, no any serious effect Ingestion: Strong taste, seek medical help immediately Skin: No effect Eyes: Irritation, wash with fresh water d) Defoaming Oil

If exposed through- Inhalation: No harmful effect Ingestion: No harmful effect Skin: No harmful effect Eyes: Irritation, wash with fresh water e) Ethyl Alcohol-

Flammable organic colorless chemical with pleasant odour. If exposed through- Inhalation: Pleasant smell with no serious effect. Ingestion: Extremely dangerous if ingested in a raw stage, seek medical advice immediately. Skin: Irritation, wash with water on contact. Eyes: Very serious effect, wash with ample fresh water and seek medical help immediately. f) Fusel Oil-

If exposed through- Inhalation: Very irritating smell with strong objectionable odour Ingestion: No harmful effect. Skin: No harmful effect, wash with ample fresh water Eyes: Irritation, wash with ample fresh water 7.4. HAZARD IDENTIFICATION

Safety Audit will be conducted by qualified technical personnel to study the installation and activities of the industry and to suggest measures to protect personnel and property against the risks. The areas of possible hazardous incident are given for follow up action:

1. Fire and explosion at alcohol storage tanks, distillery plant, bagasse storage yard, diesel storage tanks and bio-gas plant.

2. Fire in, alcohol storage tanks and diesel storage tanks. 3. Mishap due to biogas 4. Electric Short circuit and consequent fire accident. 5. Puncture of Boiler and boiler tubes. 6. Possibility of any gas leakage. 7. Bursting of pipeline joints. 8. Fall from high level structures

7.4.1 HAZARDS ASSOCIATED WITH DISTILLERY

Molasses Storage: The molasses is stored in bulk normally in the range of 5000-6000 tons capacity tank. Molasses is a thick and viscous fluid with the poor heat transfer capacity and hence to be circulated continuously to achieve the uniform the heat transfer. Such cooling is a high energy consuming activity. The leakage of material due to hole or overflow is difficult to contain as dyke bund is relatively small. It is very difficult to retrieve this spilled molasses. This leakage can cause environmental problems. It is observed that many times that the roofs of molasses tanks are corroded and hence there is possibility of person falling down into the tank if he climbs on it.


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Fermenter: If a person is required to work in the vicinity of these tanks, there is possibility of asphyxiation due to presence of higher concentration of CO2 and depletion of oxygen. The proper precaution should be taken before entering into this area of the Plant.

Distillation Column: Distillation column presents a hazard in that they contain large inventories of flammable boiling liquid, usually under multi-pressure and vacuum conditions. There is a no. of situations that may lead to loss of containment of this liquid. The condition of operation of the equipment associated with the distillation column, De-gasifier column, Stripper-Rectifier column, extractive column, refining column, particularly the re-boiler and bottom pumps are severe so that failure is more probable. The hazard in the distillation column can be limited by reduction in inventory. A distillation column has a large input of heat at the re-boiler and a large output at the condenser. If cooling at the condenser is lost, the column may suffer overpressure. It is necessary therefore, to protect against this by pressure relief devices. On the other hand, loss of steam at the re-boiler can cause under pressure in the column. On columns operating at or near atmospheric pressure inert gas injection is needed to provide protection against this. Another hazard is overpressure due to heat radiation from fire. Again, pressure relief devices are required to protect against this. A quiet different hazard in a distillation column is in the ingress of water. The rapid expansion of the water as it flashes to steam can create very damaging overpressure.

Alcohol storage: The distillation product i.e., alcohol is stored in the bulk storage tanks of about 500-700Kl each. A typical installation has 4 to 6 such tanks.

Safety precautions envisaged are: 1. It is observed that in many installations the tanks are kept too close to each other. The fire in one

tank can lead to fire in another tank. 2. The dyke volumes are too small to contain the leakage from tanks. 3. It is observed that the alcohol is stored in the closed shed (Excise department restrictions). This

hampers the ventilation around the tank and restricts the easy dispersion of the flammable vapors in the vicinity.

4. The vaporization of the alcohol from open tank can be reduced by the provision of sprinkler system. The vent losses can be reduced by providing the cooler at vent. The best practice is to provide scrubber at vent discharge to prevent any vapor going to atmosphere.

5. No source of ignition should be allowed within 15 m radius of the installation. 6. Provide flame arrestor to the vent to prevent the flash back into the tank from outside fires. Do not

allow source of ignition form vehicle exhaust. 7. Use spark arrestor to the loading/unloading truck and other vehicles to avoid the source of ignition

from vehicle exhaust. 8. No plastic material should be used in the plant as it can generate the static charge which in turn can

give the spark to initiate fire. It is observed at many places that the plastic buckets, stirrers, beakers are used during sampling and gauging processes. Even metal hardware is dangerous as it can generate spark on impact.

9. To separate and distinct earthing should be provided to every equipment, pipeline and storage tank. This earthing should be different from electrical installation earthing. It should be monitored regularly and records maintained.

10. All the equipment should be maintained in good order. The earthing measurement record of all equipment should be maintained to ensure the safety of plant at all times.

11. Alcohol should not be dropped from height into storage tank during transfer. Use dip pipe or divert flow to impinge on side wall.

7.5 HAZARD ANALYSIS

Preliminary Hazard analysis is used to identify typical and often relatively apparent risk sources and damage events in a system. A characteristic of Alcohol is a clear, colorless and flammable liquid. It has the


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boiling point of 780C, ignition point of 3630C and explosive limits of 3.3 % - 19.0 % by volume. It is listed as hazardous substance by NFPA, MSIHC Rules. It is important to control or eliminate all potential ignition sources in areas that might lead to ignition of vapor. The potential sources of ignition are: Open flames, Electrical wiring / devices, Smoking, Heat sources / hot surfaces, Welding and cutting, Friction, Sparks and Arcs, Static sparks, Gas Compression. Following are the precautions that will be taken to minimize the probability of ignition: • Electrical equipment and wiring should be suitable for the hazard. • If a heating operation is necessary, use only indirect heating methods. • Do not allow any open flames. • Provide grounding and bonding for all equipment handling using these liquids. • Maintenance program will be established to assure that all equipment and safety controls are

functioning satisfactorily.

7.5.1 Characteristics of Ethanol

Rectified spirit (RS), Absolute Alcohol is basically ethanol of different grades and have the same hazard characteristics. Hence, all these products are considered as ethanol in hazard analysis. Ethanol is a clear, colorless and flammable liquid. It has the boiling point of 780C, ignition point of 363oC and explosive limits of 3.3% - 19.0% by volume. It is listed as hazardous substance by ACGIH, DOT, NFPA and NIOSH and is regulated by OSHA. The characteristics of ethanol are given in following Table- 7.1.

Table 7.2: Characteristics of Ethanol Physical State Liquid Appearance Clear Color Colorless Physical Form Volatile Liquid Odour Alcohol Odour Taste Burning taste Molecular Weight 46.07 Molecular Formula C-H3-CH2-O-H Boiling Point 1720F (780C) Freezing point -1790F (-1170C) Flash Point 55 F(13 C) L. E. L. 3.3% at 60 °C (Lower Explosive Limit) U.E.L. 19 % at 60 °C (Upper Explosive Limit) Vapor Pressure 40 mm Hg @ 190C Vapor Density 1.59 Specific Gravity 0.789 Water Solubility Soluble Volatility 100 % Odour Threshold 5 – 10 ppm Viscosity 1.22 – 1.41 cp @ 200C Latent Heat 857.9 KJ/Kg Liquid specific Heat 2.85 KJ/Kg Cp/Cv 1.13 Heat combustion 269 x 10 2 KJ / kg

Solvent Solubility Benzene, ether, acetone, chloroform, methanol, organic solvents

Table 7.3: Hazard Rating of Alcohol is based on flammability, reactivity and toxicity as given in National Fire Protection Association codes 49 and 345 M as

Chemical NH (Health Factor) NF (Fire Factor) NR (Reactivity) Ethanol 2 3 0

(Least-0, Slight-1, Moderate-2, High-3, Extreme-4)


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Based on Manufacture, Storage and Import of Hazardous Chemical Rules, 1989 framed under Environment Protection rule 1986 we find applicability of GOI Rules 1989 to the notified threshold quantities, analysis of products and quantities of storage in the plant has been carried out & are given in following Table No. 7.3.

Table 7.4: Threshold Quantity

Product Listed in Schedule

Total Quantity Threshold Quantity Applicable Rule Rules 5,7-9 & 13-15 Rule 10-12

Ethanol 1 (2) 3110 KL 1000 Ton 50000 Ton Rule 5, 7-9 and 13-15 Based on the above, it is noted that alcohol produced and stored in the plant attract the rules of GOI 1989.

Table 7.5: Degree of Hazard based on Fire explosion and Toxicity indices for the storages

Section Fire Explosion Toxicity Ethanol Intermediate Light

Table 7.6: Minimum preventive and protective measures are recommended

Features FE & I Rating Light Intermediate

Fire Proofing 2 3 Water Spray Directional 2 3 Curtain special instr. 1 2 Flow Control 2 4 Blow down-spill 1 3 Internal Explosion 2 3 Combustible gas Monitors 1 3 Remote Operation 1 2 Dyking 4 4 Blast and Barrier wall separation 1 3

(1= optional, 2= suggested, 3= recommended, and 4= required)

Maximum Credible Accident Analysis (MCA Analysis) is one of methodologies evolved to identify worst credible accident with maximum damage distance which is still believed to be probable. The probable fire hazard in the plant is in the area of ethanol and is due to storage and handling. It is proposed to store about 60 day’s production of the products within dyke of 30 m x 40 m. As a worst case, it is assumed that the entire contents are leaked out. In the event of spilling its contents through a small leakage or due to rupture of the pipeline connecting the tank and on ignition fire will eventually forming pool of fire. In order to assess the radiation levels, Heat Radiation model has been used the algorithm of the models is based on the formulae published in the yellow book by the TNO, Netherlands. Alcohol Storage is asDay receiver, IS Receiver, Fusel alcohol tank, RS & FA Bulk storage tanks, IS Bulk Storage and denatured Spirit storage, as totally 8 tanks with capacity of 3110 KL With a dyke area as 30 x 40 m., the results are computed for Pool Fire Scenarios and Distances and accordingly fire protection is designed. 7.5.2 SITE SPECIFIC CONSEQUENCES

In order to assess the site-specific consequences, information pertaining to the site such as nearest habitation, nearest industry etc was collected. The nearest village to the plant site is Dharikheda village with a population of about a 2351 located at distance of 1.07km from the plant site in the N direction. Consequences of Heat Radiation are also seen. As the project is located away from any human habitation and surrounded by dry lands with shrubs the offsite damage to the general public and property is negligible.


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7.6 HEAT RADIATION

As a worst case, it is assumed that the entire contents are leaked out & on ignition; fire will eventually form a pool of fire. The resultant radiation has to be assessed of the pool fire. The heat load on objects outside the burning pool of liquid can be calculated with the heat radiation model. This model uses an average radiation intensity which is dependent on the liquid. Account is also taken of the diameter to height ratio of the fire, which depends on the burning liquid. In addition, the heat load is also influences by the following factors: 7.6.1 Distance from the fire

The relative humidity of the air (water vapor has a relatively high heat absorbing capacity). Visualization and Simulation of Maximum Accidental Scenarios The worst-case scenario which is considered for MCA analysis is Pool fire due to failure of storage of ethanol storage tanks in the farm area. The proposed industry will provide 60 days storage of the final product within the plant premises. The following table provides the storage details of ethanol and Rectified spirit.

Table 7.7: Ethanol Storage Details

Sr.No. No. of bulk storage Tank Capacity ,m3 1. 8 3110

Fires affect surroundings primarily through radiated heat, which is emitted. If the level of heat radiation is sufficiently high, other objects, which are inflammable, can be ignited. In addition, any living organism may be burned by heat radiation. The damage caused by heat radiation can be calculated from the dose of radiation received, a measure of dose is the energy per unit area of surface exposed to radiation over the duration of exposure. 7.6.2 Effects of Pool Fire

Pool fire may result when bulk storage tanks will leak/burst, and the material released is ignited. As these tanks are provided with dyke walls to contain the leak and avoid spreading of flammable material, the pool fire will be confined to the dyke area only. However, the effects of radiation may be felt to larger area depending upon the size of the plant and quantity of material involved. Thermal radiation due to pool fire may cause various degrees of burns of human bodies. More ever, their effects on objects like piping, equipment are severe depending upon the intensity. The heat radiation intensities due to the pool fire of the above tank farms are computed using the pool fire model. The results obtained are presented in the following Table.

Table7.8: Pool Fire Scenarios and Radiation Distances

Ethanol Storage Tanks Farm Quantity of Storage :3110m3 Dyke area :30 m x 40 m

Damage Criteria Damage Distance (m) 100 % Lethality (35.5 kW/m2) 3.0 50% Lethality (25.0 kW/m2) 22.0 1 % Lethality (12.5 kW/m2) 48.0 First Degree burns ( 4.5 kW/m2) 128 Normal Intensity with no discomfort (1.6 kW/m2) 170

7.9 RISK ASSESSMENT FOR 45 KLPD MOLASSES BASED DISTILLERY UNIT

Storage details A) Receivers Sr. No. Particulars Working Capacity MOC Qty

1 Rectified spirit receivers 50 M3 MS 3 Nos. 2 Impure spirit receivers 10 M3 MS 3 Nos. 3 Absolute Alcohol Receivers 50M3 MS 3 Nos.


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B) Bulk Storage Tanks

Sr. No. Particulars Working Capacity MOC Qty 1 Rectified spirit(RS) storage tank 500 M3 MS 3 Nos. 2 Impure spirit storage tank 100 M3 MS 1 No. 3 Fusel oil storage tank 10 M3 MS 1 No. 4 Absolute Alcohol(FA) Storage Tank 500 M3 MS 3 Nos.

7.7.1 RS/FA LEAKAGE THROUGH CATASTROPHIC FAILURE (2 x 500 MT = 1000 MT):

PARAMETERS: Tank diameter : 8.5 m Tank height : 8.5 m Storage temperature : 30oC Pool area : 200 m3

OUTCOME: Flammable Vapor cloud

Particulars Weather Condition Stability Class D

Wind speed 3 m/sec Stability Class F

Wind speed 2 m/sec Downwind distance for LEL – 3.3%, m 12 15 Max. approximate evacuation Zone width, m 14 18 Containment arrival time at downwind distance for LEL, min.

2.1 6.5

Containment departure time at downwind distance for LEL, min

4.1 10.3

7.7.1.1RS/FA LEAK (1000MT):

RS/FA leakage through failure LEL : 3.3% Atmospheric Stability Class : D Wind velocity : 3 m/sec

Downwind distance(m) Ground levelConcentration (ppm) Initial evacuation Zon width(m) 05 1254440 12 08 560982 14 10 200424 16

Downwind distance(m) Containment Arrival Time (minutes) Containment Departure

Time (minutes) 05 0.2 4.3 08 0.3 5.4 10 0.5 6.6

7.7.1.2RS/FA LEAK (1000 MT):

RS/FA leakage through catastrophic failure LEL : 3.3% Atmospheric Stability Class : F Wind velocity : 2 m/sec

Downwind Distance(m)

GroundlevelConcentration (ppm) Initial EvacuationZone width (m)

04 1150000 08 06 959554 10 08 480850 12 10 180580 14


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Downwind distance (m)

Containment Arrival Time (minutes)

Containment Departure Time (minutes)

04 0.3 4.5 06 0.8 5.1 08 1.1 5.8 10 1.5 7.4

FIRE: For LEL 3.3 % hazardous distance Flash point : 13°C Vapor density : 1.59 Vapor pressure : 40mmHg @19°C Downwind : 12 m Zone width : 16 m

BLEVE: Fireball diameter : 12.5m Fireball height : 20.5m Fireball duration : 15.0 seconds Fatality zone : 15 m Injury zone radius : 18.5 m

7.7.1.3UNCONFINED VAPOR CLOUD EXPLOSION:

Range of injuries from flying glass / object (0.1 bars) : 10 – 15 m Nearly complete destruction of houses : 10 – 15 m 1 – 99 % fatality among exposed population (1.0 bar) : 10 – 15 m

7.7.1.4 DOMINO EFFECT:

In case of BLEVE and Unconfined Vapor Cloud Explosion (UVCE), it is observed that the structural damage distance is about 10 m. The inter distance of tanks is more than 3.5m (0.5d) which is adequate for preventing any domino effect. This may result into failure of neighboring tanks and subsequent release of larger quantity of RS, further cascading the severity of damage. 7.7.2 RS/FA LEAKAGE THROUGH 50mm PIPELINE FAILURE ( 2 x 500 = 1000MT):

PARAMETERS: Tank diameter: 8.5 m Tank height: 8.5 m Storage temperature: 30oC Pool area: 50 m3

Note: Line leakages are depending upon the tank head i.e. static pressure of material.

OUTCOME: FLAMMABLE VAPOR CLOUD

Particulars Weather Condition Stability Class D Wind speed 3m/sec

Stability Class F Wind speed 2m/sec

Downwind distance for LEL – 3.5% 05 08 Max. approximate evacuation zone width, (m) 07 10 Containment arrival time at downwind distance for LEL, minutes 0.7 2.8

Containment departure time at downwind distance for LEL, minutes 4.2 6.4

Table 7.9: Scenario descriptions and data for emergency planning

Chemical RS/FA(Denatured Spirit) Catastrophic 2”Leakage Road Tanker


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Quantity, MT Storage temperature, oC Max. Ambient temperature, oC Pool area, m3 VAPOR DISPERSION – D-3 LEL, % Downwind distance, (m) Max. evacuation zone width, (m) Containment arrival time, min Containment departure time, min VAPOR DISPERSION – F-2LEL, % Downwind distance, m Max. evacuation zone width, (m) Containment arrival time, min Containment departure time, min

VAPOR CLOUD FIRE HAZARDS Downwind hazardous distance, m(LFL) Max. downwind hazardous distance, (m)

VAPOR CLOUD EXPLOSION 3.4 bar overpressure radius, m

FIREBALL (BLEVE) Diameter of fireball, (m) Height of fireball, (m) Duration of fireball, seconds Thermal load radius, (m)

- injury 5 kW/m2 - fatality 10 kW/m2

1000 30 40 100 12.0 14 0.4 1.5 2.1 2.2 10 3

12.0 14.0

10

10 14 15

12 15

50mm line 30 40 100 12 14 6.4 1.57 5.2 2.2 12 2

14.0 15.0

10

10 14 10

12 15

20 30 40 50 10 12 8.0 1.5 10.0 2.2 16 2

16.0 18.0

15

10 14 10

12 15

7.8 ESTIMATION OF PLANT RISK ASSESSMENT AND PREVENT ION THEREOF IN DISTILLERY UNIT

From the above consequences analysis of the plant risk assessment and followed by the preventive measures along with credible losses are exercised as below:- 1. Manufacturing plants are installed at open and well-ventilated location. The total plant is observed

as “No Smoking” zone. 2. The present plant is capable to produce 45 KL of Ethanol from molasses. 3. Dry Chemical powder (DCP) type or suitable extinguishers of about 90 Kgs each, trolley mounted

to be kept in R.S. bulk storage tank area. 4. Spirit storage room to have one trolley- mounted DCP extinguisher for each receiver. 5. Distillation area to have one trolley mounted 90 Kgs DCP extinguishers at operating level. 6. 10 Kg DCP extinguishers to be placed one each at 100, 110, 115 and 120 M levels in distillation

area. 7. Carbon di oxide extinguishers to be placed near each electrical panel. 8. Even though the leakage through any leaky pipe line or total failure of process plant which spill

total reaction mass in to plant nearby atmosphere and immediately such reaction mass will be converted in to flammable vapor cloud. Then plant risk due to Vapor cloud should be manageable. Vapor cloud generation due to flammable material and as a result it will be travelled to 10 to 12 meters with respect to wind velocity to attend the lower explosive limit (LEL). These generated vapor cloud should be needed source of ignition to explode or initiate the fire.

9. The source of ignition in the event of vapor cloud as boiler house and utility plant are situated at a distance of 90 meters from the existing plant activity.

10. Risk of the plant will be minimized by curbing the vapor cloud by generating water mist by installed sprinkler system. RS/FA is highly soluble in the running water.


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11. Flammable vapor detection system will be commissioned at manufacturing plant and storage tank yards to alert to discontinue the boiler operation and take appropriate action to break electrical energy.

12. The electrical distribution system around the manufacturing plant will be installed as per the guidelines prescribed under Petroleum rules 2002 i.e. observing zone “1” area.

13. Earthing and bonding will be provided to each pipeline of flammable material. Earthing is also installed to all non current carrying metallic parts of structures.

14. Cathodic protection will be provided to eliminate the danger of sparking in a hazardous area. 15. Electrical installation, cable insulation and earthing grids will be certified periodically to avoid the

source of ignition at hazardous operation area. Cable insulation of cables will be checked periodically, in-house maintenance crew.

16. Finish material tanks and raw material tanks, both flammable chemicals, will be installed nearly 55 meter away from the existing boiler house. The distance between each tank is kept nearly 2 to 3 meters. Tank farm is provided with water sprinkler system to cool the adjacent tank in the event of any emergency.

17. Fire Hydrant system as per the norms prescribed under the Gujarat factory rules and stipulated code of practices alongwith proper distribution system and an alarm system is to be considered. The required static water storage capacity has to be created.

18. In the event of any emergency the thermal radiation to nearest flammable material tank will be minimized by localized water mist generating sprinkler system. The fire hydrant monitor will be utilized additionally to avoid heat radiation and dissolve the vapor cloud formation. This will monitor the Boiling Liquid Expanding Vapor Explosion criteria in the event of emergency.

7.9 RISK ASSESSMENT FOR BAGASSE

7.9.1 PHYSICAL AND CHEMICAL PROPERTIES

Appearance - STRAW LIKE SOLID Odour - ODOURLESS WHEN FRESH Flammability - COMBUSTIBLE

7.9.2 STABILITY AND REACTIVITY

• Chemical stability - Stable under recommended conditions of storage. • Conditions to avoid - Avoid heat, sparks, open flames and other ignition sources. • Material to avoid - Incompatible with oxidizing agents (e.g. hypochlorite) • Hazardous Decomposition Products - May evolve carbon oxides and hydrocarbons when heated

to decomposition. • Hazardous Reactions - Polymerization is not expected to occur. 7.9.3 TOXICOLOGICAL INFORMATION

• Health Hazard Summary - Low toxicity. Under normal conditions of use, adverse health effects are not anticipated. However, if dust is generated, over exposure may result in irritation of the eyes, nose, throat and skin.

• Eye - Low irritant. Contact with dust may result in slight eye irritation. • Inhalation - Low irritant. Over exposure to dust may result in irritation of the nose and throat, with

coughing. • Skin - Low irritant. Prolonged or repeated exposure to dust may result in irritation and dermatitis. • Ingestion - Ingestion is considered unlikely due to product form. • Toxicity data - No LD50 data available for this product. 7.9.4 ECOLOGICAL INFORMATION

• Toxicity - No information provided. • Persistence and degradability - No information provided. • Bioaccumulative potential - No information provided. • Mobility in soil - No information provided. • Other adverse effects - No information provided.


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7.9.5 DISPOSAL CONSIDERATIONS

• Waste disposal - Reuse where possible. No special precautions are required for this product. • Legislation - Dispose of in accordance with relevant local legislation. 7.9.6 REGULATORY INFORMATION

Poison schedule - A poison schedule number has not been allocated to this product using the criteria in the Standard for the Uniform Scheduling of Medicines and Poisons (SUSMP). Inventory Listing(s) AUSTRALIA: AICS (Australian In ventory of Chemical Substances). All components are listed on AICS, or are exempt. 7.9.7 FIRST AID MEASURES

• Eye - If in eyes, hold eyelids apart and flush continuously with running water. Continue flushing until advised to stop by a Poisons Information Centre, a doctor, or for at least 15 minutes.

• Inhalation - If inhaled, remove from contaminated area. Apply artificial respiration if not breathing.

• Skin - Exposure is considered unlikely. Skin irritation is not anticipated. • Ingestion - For advice, contact a Poison Information Centre on 13 11 26 (Australia Wide) or a

doctor (at once). Due to product form and application, ingestion is considered unlikely. • Advice to doctor - Treat symptomatically • Product Name: BAGASSE

7.9.8 FIRE FIGHTING MEASURES

• Flammability – Combustible, May evolve toxic gases (carbon oxides, hydrocarbons) when heated to decomposition. Finely divided dust may form explosive mixtures with air.

• Fire and explosion- Evacuate area and contact emergency services. Toxic gases may be evolved in a fire situation. Remain upwind and notify those downwind of hazard. Wear full protective equipment including Self Contained Breathing Apparatus (SCBA) when combating fire. Use water fog to cool intact containers and nearby storage areas.

• Extinguishing –Dry agent, carbon dioxide, foam or water fog. Prevent contamination of drains or waterways.

• Hazchem code –None Allocated

7.9.9 ACCIDENTAL RELEASE MEASURES

• Personal precautions - Wear Personal Protective Equipment (PPE) • Environmental precautions - Prevent product from entering drains and waterways. • Methods of cleaning up - Moisten with water to prevent a dust hazard and place in sealable

containers for disposal. 7.9.10 STORAGE AND HANDLING OF BAGASSE

• Storage - Store in a cool, dry, well ventilated area, removed from incompatible substances, heat or ignition sources and foodstuffs. Ensure containers are adequately labeled, protected from physical damage and sealed when not in use. Check regularly for damage to containers.

• Handling - Before use carefully read the product label. Use of safe work practices are recommended to avoid eye or skin contact and inhalation. Observe good personal hygiene, including washing hands before eating. Prohibit eating, drinking and smoking in contaminated areas.

7.9.11 EXPOSURE CONTROLS / PERSONAL PROTECTION

• Exposure standards - No exposure standard(s) allocated. • Biological limits - No biological limit allocated.


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• Engineering controls PPE - Avoid inhalation. Use in well ventilated areas. Maintain dust levels below the recommended exposure standard.

• Eye / Face - When using in large quantities or where heavy contamination is likely, wear dust-proof goggles.

• Hands - Wear PVC or rubber gloves. • Body - When using large quantities or where heavy contamination is likely, wear coveralls. • Respiratory - Where an inhalation risk exists, wear a Class P1 (Particulate) respirator. 7.9.12 NECESSARY PRECAUTIONS TO BE TAKEN WHILE STORING BAGASSE IN YARD • Avoid storage of bagasse below & near high voltage (H.T.) transmission lines • Avoid route of electric supply cables &cable trenches far away from stored bagasse or bagasse

heaps. • Always keep raw & useful material far away from storage of bagasse area • Installation of Fire Hydrant (self auto-mode fire fighting) system around the area of bagasse yard • Posting of proper supervision staff with necessary communication facility • Daily record of bagasse storage data, proper review taken by higher authority • Training of all the involved staff in normal & emergency operating system • Thus in this way doing proper planning & taking some necessary steps, also creating awareness among workers about sudden bagasse fire and emergency action plan will definitely avoid risks of heavy fire. In this way, we can save a valuable fuel & life of human being working near bagasse. Also it is quite suitable & self-dependent thing of installing self auto-mode fire fighting system which is having less cost than cost paid by fire incidents say up to Crores of rupees loss. Since, definitely erection cost of self auto-mode fire fighting system is less than to pay much more after happening of fire accident. 7.10 PROPOSED SAFETY SYSTEMS FOR DISTILLERY PROJECT

7.10.1 FIRE FIGHTING AND SAFETY

In view of the inflammable nature of the end product the plant incorporates suitable firefighting equipment and flameproof lighting and power control arrangements. Non-inflammable and flameproof motors are used wherever absolutely necessary. Water hydrants will be provided at all strategic points. A suitable Fire ring system as per the guidelines of TAC will be incorporated. Non-flameproof and flameproof area will be separated by minimum distance of 15 meters. 7.10.2 FIRE FIGHTING FACILITIES

Elaborate firefighting system will be made available in any corner of the plant. Fire detection is also envisaged. • Fire water storage tanks • Fire water pump house containing combination of diesel & electrically driven pumps • Hydrant system with piping, valves, instrumentation, hoses, nozzles etc • Foam injection system for fuel oil tanks of foam concentrate tanks, foam pumps, in- line inductors,

valves, piping & instrumentation • Automatic high velocity water spraying system consisting of detectors. Deluge valve projectors,

valves, piping & instrumentation • Automatic medium velocity water spraying system consisting of QB (Quartzoid Bulb). • Water curtain arrangement will be commissioned between each storage tank to avoid dissipation of

heat to nearby tank. • Linear heat sensing cable detectors, deluge valves, isolation valves, nozzles, piping &

instrumentation • Early warning fire detection & alarm system • Portable & mobile extinguishers of type –Pressurized water, CO2, foam, DCP (Dry Chemical

Powder) at strategic locations throughout the plant 7.10.3 FIRE PROTECTIVE APPLIANCES


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Two sets of fire safety appliances each consisting of following units are located at store and alcohol storage, respectively, such as Self - Content Breathing apparatus (SCBA), Air line respirator arrangement, Face masks & gas masks (2), Face shield (2), Helmet (6), Safety belts (2) and Safety ladder (1) 7.10.4 FIRE BRIGADE

Fire brigade facilities available at Rajpipla and Narmada shall be utilized whenever need arises. Contacts are already established. The fire hydrant & fire-fighting equipment are to be procured from the reputed manufactures and the work of installation will be entrusted to a recognized qualified agency. 7.10.5 GENERAL SAFETY PRECAUTIONS TO AVOID FIRE REL ATED RISK WHILE WORKING IN DISTILLERY UNIT

The main hazards associated with the distillery operations are fire and explosion due flammable nature of the alcohol. The alcohol has a very low flash point (12 deg Celsius). The low flash point of the alcohol presents the risk of fire and possible explosion. The flammable range is 3.3 to 19% v/v in air. The ignition energy required for the alcohol to start burning is of the order of 0.1 to 1 milli joule. The spark due to static charge or the spark developed during switching operation of the electricity can be the potential source of ignition in case of alcohol.

Following is the list of general safety precaution to be taken to avoid fire related risk

1. The working area should be classified as per the Hazardous Area Classification of IS 5572: Part I, the area classification is carried out depending upon the possibility of flammable material present in that area. The hazardous area classification defines the areas into divisions and groups. Depending upon this area classification the suitable electrical equipment needs to be selected.

2. Flameproof electrical equipment is special electrical equipment that are designed to protect against fire, explosion in the area where flammable material is present.

3. It is important to select this flameproof equipment as per the area classification code. This equipment should also meet the CMRI requirements and should be certified by the DGMS.

4. All the flameproof electrical equipment should be properly maintained. The manufacturer’s recommendation related to the installation and maintenance should be adhered to.

5. The proper maintenance of all equipment like columns, pumps, condensers, instruments, etc. should be carried out. There is a possibility of leakage through gaps, joints, pump glands, etc.

6. No ordinary wiring, fitting, plug points should be provided in the flameproof classified area. 7. Proper ventilation will be provided before a person enters an empty tank for spirit. 8. No hot work should be carried out in the plant area unless proper precautions are taken. 9. No work should be carried out without the work permit system. 10. All electrical equipment should be electrically earthed at 2 distinct locations. 11. All equipment, piping should be bonded and earthed effectively and it must be monitored

regularly. 12. The condenser vent should be provided with flame arrestor to prevent the flash back of fire in case

there is fire in the vicinity. Ideally this vent gas should be passed through water scrubber and should not be left in the open to prevent the flammable material spreading in the area.

13. The liquid and vapor flow velocities must be maintained at low level to reduce generation of static electricity.

7.11 SAFETY PRECAUTIONS FOR ELECTRICAL EQUIPMENT

1. All metal work of wiring system (other than current carrying parts) including cable armour, panel box, conduit products, trunking starters, motors etc to be earthed by connecting to the earth – continuity conductor.

2. All cables in the installation area to be properly supported, so that there shall be no appreciable mechanical strain on the cable terminations.

3. The colour code for flexible cords is Red for live or positive, Blue for neutral or negative and Green and yellow for earth. The colour code for cables specifies Red for a.c. single phase or D C


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positive, Red, Yellow, Blue respectively for 3 phase line wires and black for the neutral of a c single phase circuits. Connections must be made accordingly.

4. Electrical control panel, pump sets, starters and apparatus should always be installed where they can obtain adequate ventilation and clean dry air. If the air contains dust moisture or corrosive gases, the equipment should be appropriately protected or else supplied with pure air through special pipes or ducting.

5. The electrical machines to be erected on solid and vibration free foundations and should be anchored by means of foundation studs. The mounting should be periodically checked.

6. The electrical machines must always be carefully aligned. This is of special importance for direct coupled drives.

7. Any fuse in the circuit should be regarded as protecting the wiring against the effects of short circuits or earth faults only. They are not suitable for overload protection. Fuse ratings must be sufficient to carry the starting current which may be taken as 6 times the name plate current (3 phase) or 4 times the nameplate correct for single phase.

8. The overload current setting should be upto 80% to 90% of the nameplate current. The relay should never be set at more than the actual current drawn by the motor.

9. The overload relay operates on the phase currents in star-delta starters. It should be set at 0.6 times actual load current.

10. Electrical shocks can be easily received. These should be avoided. The risk is not always apparent. 11. Avoid working on live parts. Switch them off before starting work on them. Every electrical drive

should have separate isolation switch. 12. Insulate yourself against shock by using insulating material like rubber, wood, plastic, etc. before

starting the work on live mains. Your hands and feet must be dry. 13. Avoid taking up repairs/ maintenance at those places where inflammable production is going on.

Do not open live parts like starters, main switches, main lines and be sure that the circuit is dead before starting the work if it is unavoidable.

14. Never tamper with electric protectives or interlocking gearing unless you are specially authorized for them, taking all precautions. The advice is for your safety only.

15. Always maintain earth connections in satisfactory condition. Safety depends upon good earthing. Every equipment/ machine must be earther properly.

16. In case of fire on electrical installation, do not throw water on equipment. Water can cause very great and irreparable damage.

17. Do not use a fire extinguisher on electricity unless it is suitable for that purpose. In case of fire, disconnect the supply immediately.

18. Check the earth resistivity during dry season half yearly and maintain and compare the record with previous readings.

19. Water should be poured at regular intervals during dry seasons at the sub-station earthing pits. The location of the earthing pits is given in the site plan.

20. Flame proof electrical accessories must be kept free from moisture. 21. Door covers of flame proof starters, main switches, junction boxes, plugs should be tight enough

and well greased to avoid rusting. 22. Additional load should be connected to the existing installation until it has been checked that the

cables and allied equipment can take the additional electrical load. 23. Don’t allow temporary connection in production area.

***At existing sugar unit, Lightning arrestors have been provided on both boiler chimneys. 7.11.1 Fire Prevention for Electrical Equipment

Electrical fires are likely to be started if proper care of the electrical installation and circuits is not taken. Electric fire may occur under the following circumstances: a. When the circuits are overloaded i.e. heavy load like heaters, water coolers, air coolers and other

electric motors are used on a particular circuit. b. When the proper protective devices are not employed in the circuit for safety. c. When the installation of the wires is damaged and wires come in contact together. d. When the live parts come in contact with the earthed point in the electrical circuit.


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In case of short circuits and overloads, excessive current flows through the wires and if the fuse connected in the circuit is not of proper rating it will not melt. The insulation of wires will get heated up, get damaged and may catch fire. In case, when live parts come in contact with the metal parts and the circuit is not properly earthed or the fuse is not of proper rating, the parts will get heated, damaged and the insulation materials use in the circuit may catch fire.

These electric fires may result in loss of property and lives. Hence avoidance of electric fire is a must. The following precautions should be observed: 1. Whenever the protective devices used in the circuit are replaced, these must be of proper rating

according to the load in the circuit. 2. The earth connection must be checked frequently for soundness and resistance. 3. Overloading of a particular circuit should be avoided. 4. The wires used in the circuit must have sound insulation, which should be checked periodically

and a record maintained. 5. The joints should be mechanically sound. 6. The fitting of the electrical installation must be tight enough. 7. The electrical installation must be free from moisture effect.

1. Removal from contact:

Switch off the current at the incoming mains. If a person is still in contact with the apparatus that has given him electric shock, the helper should, if possible stand on an insulated object like rubber mat, a dry wooden bench or wooden chair. If available rubber gloves should be used by the helper while removing the victim. Pull him using a dry coat, dry rope, coconut matting or stick.

2. Preliminary steps:

Extinguish any spark if the patient’s clothes are smoldering. Ascertain if he is breathing and send for a doctor. If apparently not breathing proceed as follows: (a) If the patient is suffering from burns, he should be made to lie down in such a manner as to avoid

subjecting the burnt parts to pressure. Artificial respiration or mouth to mouth resuscitation should be carried out to revive the patient.

(b) Burns, if serious, should be reated with a proper oil dressing. Avoid exposing patients to cold. Administer no restorotatives until the doctor comes. Cold water may be given and smelling salts applied in moderation.

7.11.2 Instruction for treatment of persons suffering from electric shock

Under rule 44 of the Indian Electricity Rules 1956 as defined in clause (m) of section 2 of the Factories Act 1948, factory premises in which electricity is used and in such other areas where electricity is used, suitable boards shall be affixed in conspicuous places in every generation station and sub-station and in every factory giving instructions for treatment of electric shock. Every employee in this establishment is required to make him familiar with the instructions given below. They can be followed rapidly if you have studied and practiced them before hand. Note: The particulars of the following doctors of hospitals which are within easy reach of the works should be given on the boards

Name Civil Hospital, Professor Colony, Rajendra Nagar Society, Rajpipla, Gujarat Prathamik Arogya Kendra, Bharuch Road, Vaghpara Primary Health Centre, Taropa

7.12 DISASTER MANAGEMENT PLAN

7.12.1 INTRODUCTION

A major disaster in a work is the one, which has potential to cause serious injury or loss of life. It may cause extensive damage to property and serious disruption both inside and outside the works. A Disaster would normally require the assistance of outside emergency services to handle it effectively. Whatever are


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the causative factors, like plant failure; human error; earthquake; vehicle crash; sabotage etc, they will normally manifest in three basic forms viz, fire, explosion, and or toxic release.

7.12.2 SCOPE

Each industry is expected to take steps to assess, minimize and wherever feasible eliminate risks. However, accidents may still occur in spite of the measures taken by an industry. Therefore, disaster planning becomes a necessary element for mitigating the effects of a major accident/ disaster. Elimination will require prompt action by operating staff, the staff on various emergency teams and the outsiders when called. Often quick plant stoppage, isolation and pressure release from the affected equipment, operating emergency sprays etc. are called for Minimizing the effect on people can be achieved by prompt rescue, evacuation, rehabilitation and communication. In all 'these steps, SPEED IS THE ESSENCE. Thus, in any disaster the fire brigade should report in 2 minutes and fire fighting should start within 4 minutes. Disaster management planning is not a substitute for good operating/maintenance /design practices. It is an aspect of Safety Management. Every industry, as mentioned above, should minimize risks by adherence to safe practices and by meeting all legislation, Although On-site and Off-site Disaster Management planning is different. It should be consistent and should complement each other. On-site disaster management planning is the responsibility of Site Management (Occupier). The District Authorities and the Directorate of Industrial' Safety and Health have the responsibility for the Off-site Disaster Management Plan of the district. All companies will need to have a round- the-clock duty team to manage disasters. The duty team will include several functions and members depending on the size of the organization and would be headed by a technically qualified as well as a trained individual. 7.12.3 OBJECTIVES OF THE DISASTER MANAGEMENT PLAN Disaster occurring at any factory or installation may cause injuries or loss of life or damage to the property or disruption inside as well as outside the premises. The disaster could be a result of abnormal functioning within the facility or caused by third parties or by natural factors. If an emergency becomes uncontrollable and leads to damage to life and property in the industry and it's neighborhood, it may be defined as the disaster. The objectives of disaster management plan include the following-

1. Controlling the disaster, localizing the disaster and eliminating the hazard 2. Welfare of person managing the disaster. 3. Head count and rescue operations. 4. Treatment of injured. 5. Safeguarding others by timely evacuation. 6. Minimizing damage to property and environment. 7. Informing and assisting relatives. 8. Informing and collaborating with statutory authorities. 9. Informing the news media. 10. Preserving records and organizing investigations. 11. Ensuring safety of the works before personnel reenters and resume work. 12. Investigating and taking steps to prevent recurrence. 13. Resorting normalcy. 7.12.4 PRE-REQUISITES FOR A GOOD DISASTER MANAGEMENT PLAN

1. Management's commitment to safety. 2. Emergency organization. 3. A good PublicAddress System in the complex with one or two jeeps with PA System for use in

surrounding areas also. 4. "Duty Team" for silent-hour coverage, approved emergency control centers and assembly points. 5. Written guidelines for the duty team members. 6. List of key personnel, experts, doctors, village leaders, authorities with their locations and

telephone numbers (both office and residence). 7. Clear-cut definition of role of individuals.


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8. Adequate means of communication with good back-up facility for telephone system. Also, alternative methods of communication like wireless, messengers etc. should be available

9. Training, Regular rehearsals including alarms at least once / quarter. 10. Fire and safety manuals (Both common and plant wise). 11. Operating and Maintenance Manuals. 12. Strong conviction that "the prevention is better than cure". Therefore, more emphasis should be

made to prevent disasters. 13. Warehouse safety manual. 14. Chemical Information Sheets (CIS) or Material Safety Data Sheets (MSDS) or Work Practice Data

Sheet (WPDS) for all the hazardous substances handled. 15. Transport emergency cards (Tremcards) for the products transported by road. 16. Disaster Management Plan (both On-site and Off-site) 17. Rehearsal of the disaster management plan and modifying/ updating same. 18. Division of each large factory into 'Safety Districts' for better safety. 19. Availability of emergency 'Install ligh t' (emergency light) to take care of power failures. 20. Mutual aid scheme, if feasible 21. Provision of antidotes, emergency medicines and beds in nearby hospitals 22. Liaison with outside agencies and civic and government authorities for mitigation of the effects of

a disaster. 23. Round- theclock availability of trained first-aid personnel. 24. Standby communication system in case the telephone system is affected. e.g. Walkie-talkie, radio

telephone, mobile phone etc. 25. Rehearsals of the disaster management plan (disaster control plan) and modifying / updating the

same, if necessary. The timing of events, communication failures etc. should be noted and analyzed for improvement. The plan may therefore, have to be regularly discussed and updated.

7.12.5 ELEMENTS AND ESSENTIALS OF DISASTER MANAGEMENT PLAN

1. Vulnerable areas of the plant where disasters are likely to originate should be identified and planned measures to deal with the same should be decided.

2. Organization, i.e. appointment of key personnel with their duties and responsibilities should be done. This should cover personnel by their designation and it should not only consider the normal working but shifts and holiday work.

3. Communication mechanism for raising the alarm as well as that for the interaction within and outside works should be provided.

4. Roles and responsibilities of other individuals, as mentioned below, need to be defined clearly. • .Fire fighting • Medical • Rescue • Engineering support

5. All others not taking part in emergency handling operations. 6. Location of emergency control center and assembly points should be precise and carefully planned. 7. Check -list for sequence of operations to be followed should be prepared. 7.12.6 IDENTIFICATION / ASSESSMENT OF SITUATION

It is essential that the situation is identified at the earliest possible time and judged correctly and if necessary, the emergency is to be declared. The Shift In-charge, who is at all times in the fermentation & distillation house, shall identify situation of the hazard or calamity and report immediately the same to Distillery Manager and shall also sound the alarm bell provided in each of the sections. Under this plan, the Managing Director takes charge of the situation. No sooner, he gets the information from Shift In-charge, he shall move to the place of hazard / calamity. He shall assess the situation and decide to declare emergency either in that particular section or the entire plant and sound alarm bells accordingly.


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If the emergency is to be declared only in one plant, the other plants will work. normally. He shall take immediate steps to control the situation. 7.12.6.1 ACTION PLAN:

He shall initiate all such actions that are essential at the distillation house / fermentation house / shop floor etc. which would include- Evacuation of all the personnel on the shop floor who are not required for controlling the situation or hazard. Immediate grasping of gravity of the problem / hazard and issue or giving of instructions to the concerned teams as laid down to act in a manner required to control the situation. In case of fire, the help of fire force should be immediately sought and put into action. Simultaneously, the workman trained in the fire fighting procedures shall be called to extinguish the fire.

Following teams of personnel are formed to tackle a situation when an emergency arises in distillery Unit –

TEAM -A:

The Safety Officer, Environmental Manager, Works Manager & Distillery Manager along with Shift Supervisor of the Distillation Section and other supervisory staff shall put off the fire or the hazard as the case may be. TEAM -B:

The Works Manager and Distillery Manager, Shift Operator of the Distillation Section, Medical Officer, the Excise Assistant in the office, Security Officer and Labour Welfare Officer shall be responsible for contacting the fire brigade personnel and arrange for medical assistance, if required.

TEAM -C:

The Maintenance In-charge and his colleagues shall form another team and take charge of the safety appliances, tools and implements required to control the situation. They will rush to the spot for taking further instructions from the declarer / controller of emergency.

TEAM -D:

The union office bearers shall form another team and should see that none of the workmen crowds around or nobody comes nearer to that place of emergency. This team would also ensure that all the available manual help required by the declarer / controller of emergency is provided to him.

TEAM -E:

The Security Department, the Time Keeper, and Labour Welfare Officer shall form another team. They shall be available at the office and contact the personnel at the head office for assistance to the declarer / controller of emergency. It shall be the responsibility of this team to refer, immediately, to the checklist of names, addresses, telephone numbers of the authorities such as Director, Joint Director of Industrial Safety and Health, Boiler Inspector of Factory, Commissioner of Police, Police Station, Fire Brigade, Company Hospital Doctors, Private Doctors and Directors of the Industry and contact for assistance, if required. At all times, one vehicle is made available at the gate of the factory for emergency. All the personnel required shall be brought to the factory in the personnel vehicles of the officers. The hooter siren, that is provided, shall be used when a total emergency is to be declared for the entire factory.


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Emergency Organization Structure for Distillery Unit:

EmergencyOrganizationFor Distillery

7.12.7EMERGENCY SHUT DOWN OF VARIOUS SECTIONS

Only hazardous that is expected in the Distillery is fire. The following steps may be followed Put off the main supply.

7.12.7.1 Distillation Section

Shut down the boiler section and control the steam supply/movements.

7.12.7.2 Control Room

The security office shall function as a control room as the same is ideally situated nearer to the main gate and away from the plant. Thus, there shall be no risk as regard to the vapour of any toxic substances affecting the security office. However, if there should be a situation where / when the entire premises have to be declared as emergency, the control room shall operate from the premises which are out side the main gate. Since the entire plant is provided with good quality electrical fittings, there should be no anxiety as regard to switching on or off the motors and no sparks will occur. However, the declarer / controller of emergency shall decide, depending on the situation, whether to use generator power or the GSEB Power. In case the entire lighting has to be switched off to meet such an eventuality, the stand by generators, provided near the office, shall be started and the floodlights shall be used to tackle the situation during the nighttime.

7.12.7.3 Evacuation of Personnel

When a major accident occurs and if there are cases of workmen or supervisory personnel fainting or losing consciousness or any other type of accident, it shall the responsibility of Team D to evacuate them and carry in the vehicles to the nearest dispensary after providing necessary first aid.

WORK INCIDENT CONTROLLER, M.D.

Communication Team (Telephone Operators/Security Inspector, Works Manager / Distillery Manager)

Advisory Team Senior Managers (Technical)

TEAM A Safety Officer, Environmental Manager, Shift Supervisor of each Section and other supervisory staff

TEAM B Distillery Manager, Shift Operator of the Distillation Section, Medical Officer, the Excise Assistant in the office, Security Officer and Labour Welfare Officer

TEAM C Maintenance In-charge and his colleagues

TEAM D Union office bearers

TEAM E Security Department, the Time Keeper, and Labour Welfare Officer


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There are well-planned roads in and around the plant in the factory premises and they should choose the safest and shortest route to come out from the plant. The selected route should be kept clear by Team E at all the times.

7.12.7.4 Accounting of Personnel

It shall be the responsibility or the Team E to immediately take stock of the personnel on duty and cross-check the personnel who have come out of the plant or have got stuck up. This team shall co-ordinate with Team D to ensure that all the personnel are accounted for. It is also essential for Team E to counter check the security if any visitor or transport workers have entered the plant and if so they should also be accounted. 7.12.7.5 Controlling the Disaster

The declarer / controller of Disaster shall take steps to train all the teams and shall draw up an "Action Plan" forthwith. The Managing Director is earmarked as "WORK INCIDENT CONTROLLER" and shall act as an in-charge at the site of the hazard to control entire operations.

7.12.7.6 Implements for Repairs and Safety Gears

The declarer / controller of disaster along with the work incident controller shall immediately prepare a list of safety gear, tools and other implements required to control the emergency situations in respect of- 1. Fire 2. Bursting of Boiler 3. Short Circuiting This list shall be submitted to the Managing Director for approval and the material should be brought immediately. Also, It shall be the responsibility of "Work Incident Controller" to ensure that a separate set of implements, safety gear and tools are placed in a cupboard easily accessible in the workshop/at the work place and these shall be used only when emergency is declared in the plant.

7.12.7.7 Arrangements for Medical Treatment:

Most of the workers are trained in first aid and fire fighting procedures. The office team shall co-ordinate with these workers, trained in the first aid, and shall get them ready with necessary first aid material so that the injured workers are attended for first aid immediately and then shifted to the nearest dispensary or treated in the factory dispensary as the case may be.

7.12.7.8 Training and Rehearsals:

It is essential for all the teams to act in unisom and with patience. They are required to be trained to obviate any confusion that might arise due to emergency. It is responsibility of the declarer / controller of emergency that the teams are given training in their respective areas at least once in two months. For fire fighting training, the Government Fire Force will give training and for first aid training. The Red Cross Association will train the personnel.

7.12.7.9 Law and Order:

The Police shall be informed, immediately, by the declarer / controller of emergency to ensure that law and order situation is kept under control. The Joint Director/ Assistant Director of Industrial Safety and Health, Pollution Control Board authorities shall also be informed. In case of casualties, information should be sent to the nearest relatives of the affected people. If information is to be given to public or press, the public relation manager of the industry is authorized to do the same.

7.12.7.10 All Clear Signal:

Once the disaster is controlled and the normalcy is restored completely and when the declarer / controller of disaster is of the opinion that there is no further hazard involved and the work can go on normally, he shall then declare all clear signal.


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All the workers in the plant shall be given proper training to use the signals both at the time of declaring the disaster and at the time of clearing the disaster. 7.13 ON-SITE EMERGENCY PLAN

7.13.1 PLANT EMERGENCY ORGANIZATION

1) Designated Persons In-Charge

a) Members of Team A- Safety Officer, Environmental Manager, Shift Supervisor of each Section and other supervisory staff

b) Members of Team B- Distillery Manager, Shift Operator of each Section, Medical Officer, the Excise Assistant in the office, Security Officer and Labour Welfare Officer

c) Members of Team C-Maintenance In-charge and his colleagues d) Members of Team D-Union office bearers e) Members of Team E-Security Department, the Time Keeper, and Labour Welfare Officer

2) Functions of Designated Persons

In addition to the specific responsibilities, assigned to various Team Members, mentioned earlier following are the general functions to be performed by the designated persons- a) To communicate & report the clear position of a Disaster to Key Persons of the Distillery. b) To communicate & co-operate with other departments / aspects like security, safety of victims etc. c) To minimize the extent of Disaster by taking all possible measures which, are in control. d) To minimize the exposure of Disaster to human beings. e) To save property and valuable things as far as possible. 7.13.2 NOTIFICATION PROCEDURES & COMMUNICATION SYST EMS

a) Communication Equipment like Telephone, Wireless System and PersonalMessaging would be employed.

b) The families of injured employees would be notified by Telephone, Personal Messaging and through Verbal Communication.

7.13.3 EMERGENCY EQUIPMENT AND FACILITIES

The following emergency equipment & facilities would be provided-

7.13.3.1 Emergency Cupboard:

An emergency cupboard will be available in all plant areas. This cupboard should contain certain number of various personal protective equipment (PPE) for use in case of disaster. These items kept in the cupboard should be used only during an emergency and not under normal working conditions. A printed or typed list of items available in the cupboard should be displayed on the cupboard. The key of emergency cupboard should be available with the Shift In-charge.

Table 7.10: Items may be kept in the Emergency cupboard

Sr.No. Item Quantity 1 Air line mask set 2 sets 2 Self-containing breathing apparatus 1 set 3 Safety belt with life time 1 set 4 PVC gloves 2 pairs 5 Leather gloves 2 pairs 6 Asbestos gloves 2 pairs 7 PVC Suit 2 pairs 8 Electrical shock proof rubber gloves 2 pairs 9 Flame proof battery /torch , lighting 2 pieces 10 Safety goggle 2 pieces 11 Face- shield 2 pieces


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12 Ear-muff, mask against dusts, aprons against chemical spillage 1 set 13 asbestos blanket 2 Nos. 14 Manila Rope 100 meter long bundle 1No 15 Emergency lighting facilities 2No 16 Safety helmet 2 Nos. 17 Safety items of shoes, gum shoes 2 Nos. 18 Stretchers and oxygen cylinder. 2 Nos. 19 Air life line for working in vessels and tanks. 1 set 20 First AID medical units 1 No.

This item should be examined once a week by the safety observer to ensure that all the items is available and that they are in good condition, Items, defective must be replaced immediately.

Requirement of Equipments and Other Materials- 1. Helmets for the Work Incident Controller and others. 2. Megaphone (workable hand-held PA system). 3. Walkie- Talkie/ mobile phones/ pagers. 4. Stock of fire fighting material. 5. Note books!/pads and pens/ pencils. 6. Sign boards. Assembly point -Emergency control center -Road closed 7.13.3.3 Emergency Medical Supplies:

Sufficient number of First Aid Boxes would be located at appropriate and easily accessible locations. The First Aid Box would contain Bum Relief Sprays and Ointments, Bandages, Antiseptic as well as Pain Relief Medicine. 7.13.3.4 Training and drills

A) Knowledge of Chemicals- Every worker, working in a particular section, would be given a thorough knowledge of all the chemicals involved/ handled in that section, their reactions as well as properties etc. Also they would be instructed regarding the chemical spillage and its waste disposal practices.

B) Location of Fire Fighting Equipment- Every worker would be given clear-cut information regarding the 'location of Fire Extinguishers, Fire Buckets and Water Points etc.

C) Use of Fire Fighting Equipment-

Every worker would be trained with respect to nature and utility of Fire Fighting Equipment, its type and class of fire for which it is to be used.

D) Use of Personal Protective Equipment (PPE) Every worker would be trained in using the PPE such as safety helmets, hand gloves, nose mask, goggles etc.

Operators and Chemist to be trained periodically by supplier of fire fighting equipment for use of this equipment, preferably by demonstration, arranged by the suppliers of the equipment.Fire alarm drills to be carried out periodically to assess the knowledge and reaction time of the personnel. During these drills, some of the fire fighting appliances should be used to test their efficiency. After use, the appliances should be refilled.

7.13.3.5 Arrangement for Fire Fighting

a. Fire Fighting Equipment:

The fire fighting equipment -viz. (1) Fire Buckets, (2) Fire Extinguisher Cylinder; CO2 Water Expelling type; Class-A, (3) Fire Extinguisher Cylinder; Dry Chemical Powder Type; Class-B & C, (4) Water


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Connections in sufficient numbers and a 200 Ft. Emergency Water Hose - would be provided at required places. Here, various vulnerable locations in the Distillery Unit, probable causes & chances of occurrence of fire, its Class etc. would be given in-depth consideration.

b. Fire Extinguishers

Table 7.11: Fire Extinguishers installed in the Existing sugar factory area

1 Security 3 no.s of Fire Extinguisher 2 Mill House 2 no. Fire Extinguishers

(Co2) & Carbon Tetra Chloride 3 Power House 2 no. Fire Extinguishers (Co2) & Carbon Tetra Chloride 4 Boilers 1 no. Fire Extinguishers

(Co2) & Carbon Tetra Chloride 5 Bagasse Yard Water spray guns & a Fire Extinguisher (Co2) 6 Sugar Godowns 10 nos. Fire Extinguishers

(Co2) & Carbon Tetra Chloride 7 Work Shop Fire Extinguishers(Co2) & Carbon Tetra Chloride 8 Stores 2 Fire Extinguishers(Co2) & Carbon Tetra Chloride 9 Diesel Pump 6 Fire Extinguishers (Co2) 10 General Office 2 Fire Extinguishers (Co2)

• Type – Dry Powder Type (stored pressure) fire extinguisher suitable for – Fire wood, cloth, Paper

oil, petrol, kerosene flammable material, gasses, electrically started fires-ISI3849 (ABC class of fire)

• Type – Carbon dioxide fire extinguisher suitable for – All flammable liquids, gasses, Live and Delicate machinery fix, Electrical and sophisticated electronics equipment fires IS2878 (BC class of fire)

• Type – Dry chemical Powder fire extinguisher suitable for – Fire of oils, solvents, gasses, paints varnish, electrical wiring, Live machinery fires, All flammable liquid and gas fires IS2171, ISI0658 (BC class of fire)

• Type- Mechanical foam fire extinguisher (AFFF) suitable for fire of petrol, oil paints, spirits, chemicals flammable liquids.

• Caution-Do not use on electrical fires IS10204 (AB class of fires)

• Type – Water CO2 fire extinguisher- Suitable for – fighting of fire of wood, Paper cotton, jute etc. • Caution-do not use on oil & electrical fires IS-940, (A) class of fire)

• HALON – 1211 – BCF Fire extinguisher. - Not recommended by Safety Factory Inspector as this is based on chloro-floro carbons or Ozone depleting gasses.

• Fire Protective System – Fixed supply of Carbon dioxide from the Tank, normally connected to fix piping system with nozzles arranged to discharge CO2 directly on the burning material, equipped with Fire Alarm, Fire hydrant fm 200/70 and extinguishing system H.V.W / M.V.W Spray system (LOCAL APPLICATION ONLY). System consists of Alarm Bell, Control panel, remote station, electric control needed for operating system, Pressure switch Heat detector, Heat collector, and conveyor rail, Drain Board with dip tank and discharge nozzles.

Automatic fire Sprinkler System (Water Hydrant) – Electro-magnetic dehydration system uses an electric fire detection system installed in the area as open sprinklers /spray nozzles upon sensing a hazard, the Electromagnetic valve opens deluging the entire protected area with water. This Valve is used in high hazard area, where an extremely quick response is required.

b. How system works

In the fire water pump house, the fire pump is working on the base of sensing line pressure & operates on auto mode due to falling of line pressure. The necessary communication required for this is carried out by


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using Walkie Talkie set. This is done by the concerned supervisor/ Shift- In- Charge to pump house operator.

Table 7.12: Fire hydrant System Pump details for existing sugar Unit

Name Pump Motor

Fire pump Head - 88 m, Discharge - 1250 lpm 40HP

7.14 OFF-SITE EMERGENCY PLAN:

Since the only hazard that is expected in the distillery industry is fire and is normally contained within the premises no OFF-SITE EMERGENCY PLAN is needed. However, in case the hazard spreads out-side the premises, Team E 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.

7.14.1 Information to Local Authorities

It shall be the responsibility of declarer / controller of emergency to inform the Local Panchayat Official regarding the likely hazards from the industry and the steps to be taken when there is an Off-Site Emergency. It is preferable that the Local Panchayat Officials are also trained, on simple protective methods, through demonstrations. 7.14.2 Emergency Action Code

Table 7.13: Emergency action code For Fire of Spillage of Hazardous Substances

Emergency Action code scale For Fire or Spillage 1: Jets 2: Fog 3: Foam 4: Dry Agent

Notes for guidance – FOG – In the absence of fog equipment a fine spray may be used. DRY AGENT – Water must not be allowed to come into contact with the substance at risk. V –Can be violently or even explosively reactive. FULL – Full body protective B Clothing with BA. BA – Breathing apparatus plus protective gloves DILUTE – May be washed to drain with large quantities of water. CONTAIN – Prevent, by any means available, the spillage from entering drains of water course.

P V FULL DILUTE

R S V BA

(S) BA FOR FIRE ONLY T BA

(T) BA FOR FIRE ONLY W V FULL

CONTAIN

X Y V BA

(Y) BA FOR FIRE ONLY Z BA

(Z) BA FOR FIRE ONLY E CONSIDER EVACUATION

SUBSTANCE UN NUMBER UN HAZARD CLASS EAC (HAZCHEM CODE) Petrol 1203 3 3(Y) E

Methyl Alcohol 1230 3,6.1 2 PE L.P.G. 1075 2,3 2 WE

Ethyl Alcohol 1170 3 2 (Y) E


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Table 7.14: Proforma information in connection with formulation of on site and offsite emergency plan

1. Name of the unit Shree Narmada Khand Udyog Sahakari Mandli Ltd .

2. Address of the unit. Village- Dharikheda, Post- Timbi, Tal.: Rajpipla(Nandod), Dist.: Narmada, Gujarat

3. Name, address and telephone no. of occupier

Managing Director, Shree Narmada Khand Udyog Sahakari Mandli Ltd, Mobile No. - +919428815719 Phone- 02640-249711/712

4. Maximum no. of persons working in Distillery Unit

Total- 83

5. Hazardous process and operations conducted in the premises

i. Fermentation, Distillation & Alcohol storage ii. Biogas Unit

iii. Steam boiler in sugar unit. iv. Steam turbine in sugar unit v. Bagasse yard where bagasse is stored as a fuel.

6. Possible hazard anticipated. i. Mishap in boiler unit. ii. General electrical hazards.

iii. General mechanical hazards in rotating parts in compressor belts, steam turbines etc.

iv. Storage of ethanol v. Biogas unit

7. Method used for identification of hazards (please identify the relevant ones)

Hazard, fault free analysis, safety audit, Experience of other industries.

8. Nature of identified hazards Fire, Explosion, Release of vapours. Release of gas.

9. Population in the nearby area 1 KM radius : Nil 3 KM radius : 8372 No. 5 KM radius : 11540 No.

10. Basis on which the population is arrived at

Based on Sensus – 2011 and by survey considering the population present in the individual localities and also the activities likely to exist in these areas.

11. List of adjacent factories In 10 Km radius, Nil

12. List of adjacent factories engaged in hazardous process and/or storing hazardous chemicals

Nil

13. Normal wind direction NE to SW

14. List of possible accidents, effects of which remain within the premises

i. Burning of pressure parts in steam boiler. ii. Mechanical contact injuries at rotating machineries

iii. Electrical hazards. 15. List of accidents, effects of

which will be felt outside the premises.

Nil

16. The number of people likely to be affected by each of the possible accidents.

Maximum of three to five persons are exposed to any of the above accidents.

17. Name in order of priority of the declarer of emergency

i. Managing Director or ii. Works Manager or

iii. Distillery Manager


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18. Mechanisms by which the declarer will come to know about the accident (Please identify appropriate one)

i. Phone ii. Messenger iii. The person to get in touch with the declarer iv. Shift incharge v. Manufacturing chemist

vi. Plant Operators vii. Maintenance engineer.

19. The person to get in touch with the declarer

Distillery Manager, Works Manager, Environmental Manager, Safety Officer, Security Officer and Labour Welfare Officer.

20. Identification of control room i. Office of Security Dept. ii. Time office.

21. Facilities available at the control room (Please Identify appropriate one)

Telephone Vehicle

22. Declaration of emergency Coded siren 23. Whether workers are trained to

recognize the emergency message

Yes, would be trained.

24. Whether emergency plant shut down procedure used have been generated

Yes, the procedure would be generated.

25. Whether evacuation paths have been identified (please identify appropriate ones)

Yes, the paths would be identified.

26. Whether independent power supply to evacuation paths provided (please identify appropriate once)

Yes, it would be provided

27. Arrangement made for guiding workers to the specified evacuation paths (please specify)

Yes, the arrangement would be provided.

28. Arrangement for accounting the personnel(please specify)

The emergency team under Works manager, Environmental Manager, Distillery Manager, Operators of various sections is identified as search team for injured person(s).

29. Give names of team identified as search team to look for injured workers.

The emergency team under Works Manager, Distillery Manager and Environmental Manager is identified as search team for injured person in Distillery Unit.

30. Specify various teams identified for controlling the emergency.

Five teamswill be identified underManaging Director (orWorks Manager/Environmental Manager/ Distillery manager).

31. Availability of implements for repair (Please give details)

i. Personal protective such as hand gloves, gum bottles, aprons, helmets, safety goggles, etc. for handling toxic and corrosive chemical.

ii. Fire extinguishing, including dry chemicals, foam type extinguishers, sand buckets, water hydrant lines are used for control of fire.

iii. Water showers and eye fountain. 32. Arrangement for treatment of

injured workers. i. In charge of control assume the responsibility of correct

handling and treat ability of injured. ii. Affected persons are removed to safe, well-ventilated place.

iii. If body parts are contacted with toxic or corrosive chemicals they are fluently washed with fresh water.

iv. The control team gives premedical aid/first aid. v. Arrangement is made for immediate shifting of injured


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person to the nearest well equippedhospital. vi. One of the persons from control team will accompany the

injured person to give necessary background of accident to the doctor and to attend the injured person.

33. Arrangement for training of personnel.

i. Necessary literature, leaflets, and information regarding the occupational hazards, safety management, handling of emergency would be maintained in the factory for reference to the factory personnel including management supervisors and workers including the control team.

ii. Factory management and supervisory staff would be sent in rotation to institutes engaged in occupational hazard, safety and loss prevention for training.

iii. Periodically at least once in 2 years safety experts from the brigade and loss prevention organization would be called to educate and train factory personnel.

iv. Training programmers for safety and loss prevention would be arranged within the factory at once in the year using resources locally available.

34. Rehearsal, their natures and frequencies.

Simulated accidental situations such as fire, leakage of corrosive or toxic gas or liquid, machinery failures would be created and these would be handled. Such programmers would be held at least twice in the year.

35. Details of hospital ambulance antidotes available at the factory and the hospitals.

i. The required anti-dotes would be kept in the factory and in the hospital.

ii. The information regarding the chemicals used and the type of risks involved in the factory is indicated to the Government hospital in Rajpipla in advance to obtain correct and prompt services in case of emergency.

iii. Preaid facilities would be maintained in control room and in the factory.

iv. Medical oxygen facility is kept in the factory. v. Arrangements shall be made with various ambulance

owners at Rajpipla to obtain their services in case of emergency.

vi. There are a few hospitals with round the clock casually services whose services will be availed by the factory.

36. Person from the police dept. to take charge in case of site emergency.

The off-site emergency is unlikely in distillery. However, the police station shall be kept informed to take measures in case of off-site emergency.

37. Whether police personnel have been informed of possible hazards.

The police personnel of Rajpipla shall be informed.

38. Whether the fire brigade has been informed of the nature of the chemicals and of fires likely to erupt.

The fire brigades of Rajpipla shall be informed of the possible fire hazards.

39. Have the fire brigade adequate facilities to control the fire.

The government fire brigade at Rajpipla and at sugar plant has the required facilities to control the fire.

40. Person identified to make statement to the press and informing the relatives of the affected people.

The Managing Director will be in charge.

41. Arrangements for giving information to local authority.

The Works Manager shall give written information to the local authorities.


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42. Indicate how the local public, likely to be affected, has been informed of the likely hazard.

Off site emergencies are not possible in sugar industries as well as in the Distillery and therefore the situation to neither inform the public does nor arise.

43. Whether police have been informed regarding the advice to be given to the public in case of accident.

Not applicable as there is no possibility of off-site emergency.

44. Indicate arrangements to inform Factory Inspector, State Pollution Control Board or their nominee.

Telephonic information followed by detailed letter/E mail to the local offices and the head offices.

45. Code for giving all clear signal Coded Siren.

Table 7.15: District Incident Response Structure – Key Officer

Task Force Task Force Operation

room/ Contact No. Task Force Leader Contact No.

Task Force Alternate Leader Contact No

Incident Commander DC - 02640-22161

Alternate incident Commander

RAC - 02640-22326 9978405188

Warning & Communications

RAC Office 2640-222326 Mo.9978405188

-

Law & Order Police Control Room DSP 02640-22217 9978405076

DY SP 02640-222218 9925940100

Search & Research Fire Brigade CR Chief Fire Officer 02640-222939

-

Logistics DDO Office DDO 02640-22420 M-9978406241

DYDDO

Damage Assessment Survey

RAS Office Addl. Collector 2640-222326 9978405188

-

Incident Commander- DC/DM a) Law & Order - DSP b) Operations Section- RAC c) Logistic Section- Fire Officer

7.15 CONCLUSION

As discussed in above sections, adequate risk mitigation measures for process areconsidered for to say that the proposed project is not likely to cause any significant riskto onsite, offsite & environment. In the event of disaster onsite, offsite and all theemergency planning procedures are to be followed so as to minimize the impact onworking personnel, plant surrounding and environment.


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CHAPTER 8-PROJECT BENEFITS

8.1 INTRODUCTION

The proposed distillery plant would bring forth many positive socio-economic improvements due to its varied production line comprising of:

The Company envisages manufacturing / producing the following:

• Rectified Spirit(RS) • Absolute Alcohol / Fuel Alcohol (FA) • Bio-compost • Biogas

Rectified Spirit Rectified spirit, also known as rectified alcohol, or ethyl alcohol of agricultural origin is highly concentrated ethanol which has been purified by means of repeated distillation, a process that is called rectification. It typically contains 95% alcohol by volume (190 US proof). The primary uses of rectified spirit include medicines, household cleaners, liquors and cocktails.Ethanol is an important industrial ingredient and has widespread use as a base chemical for other organic compounds. Ethanol is used in medical wipes and in most common antibacterial hand sanitizer gels at a concentration of about 62 % v/v as an antiseptic. Ethanol is miscible with water and is a good general purpose solvent.

Absolute Alcohol (FA) Absolute alcohol is a common name for the chemical compound ethanol. The largest single use of ethanol is as a motor fuel and fuel additive.

Bio-compost Bio-compost is used to improve the fertility of the land using biological wastes, hence the term bio-compost. Biological wastes do not contain any chemicals which are detrimental to the living soil. They are extremely beneficial in enriching the soil with those micro-organisms, which produce organic nutrients for the soil and help combat disease. Bio-compost is the material remaining after the anaerobic digestion of a biodegradable feedback. Bio compostis known to play a number of vital roles in soil fertility, crop productivity and production in agriculture as they are eco-friendly.

The main advantages of bio-compost are as follows: • Increase crop yield by 20-30% • Replace chemical Nitrogen and Phosphorous • Stimulate plant growth • Activate soil biologically • Restore natural fertility • Provide protection against drought and soil borne diseases

Biogas Biogas typically refers to a gas produced by the breakdown of organic matter in the absence of oxygen. It is a renuable energy source, like solar and wind energy. In present context, biogas is generated from spent wash. Biogas is energy rich and is well suited as a source of energy for generation of steam in the boiler. Importance of the Distillery project:

Contents of this chapter shall be:

• Improvements in the physical infrastructure • Improvements in the social infrastructure • Employment potential –skilled; semi-skilled and unskilled • Other tangible benefits


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• Requirement of Product (alcohol) in market • India Needs Alcohol for industrial, potable & fuel purpose • Saves Petrol (additives) • Foreign Exchange Saver-Earner

8.2 IMPROVEMENT IN THE PHYSICAL INFRASTRUCTURE

• The beneficial impact of proposed SNKUSML plant on the civic amenities will be substantial after the commencement of the project activities.

• The basic requirement of the community needs will be strengthened by extending educational facilities, health care, building and strengthening of existing roads.

• The living standards of the nearby villages will be improved. • The construction of new roads and improvement in existing roads in the influential area will

enhance the transportation facilities. • With improved transportation facilities, there is always scope for development. 8.3 IMPROVEMENT IN THE SOCIAL INFRASTRUCTURE

• Generation of employment both direct & indirect. • Further development of small scale industries may be developed. • Increase revenue both to the State and Central Govt. by way of taxes • Overall growth of agriculture & allied businesses based on agriculture. • By the presence of this industry, local transporters will have business. • The villagers will have employment opportunity and livelihood and basic amenity support for

better future • Improvement in Water conservation/ water shed management and overall water management

system. • Improvement in health and family welfare. • Proposed disillery project will not disturb the existing pattern of demographic structure. No R & R

Plan is required as the industry will be located in land already procured. • Gram panchayet will get financial support from the unit and will be able to improve local

infrastructure. • This will further enhance with diversification and the panchayat will have a continued benefit of

taxes and cess • The development of basic amenities such as roads, transportation, electricity, proper sanitation,

educational facilities, medical facilities etc. will be developed. • Overall, the proposed project will change living standards of the people and improve the socio-

economic conditions of the area. • Fire fighting facilities will be now more easily available at doorstep of villagers. • Education level of local community is expected to rise due to flow of funds and avenues of

livelihood being available. • Improvement in primary health centers (PHC) will help in health status of residents in this area • Augmentation in the areas of medical facilities will occur. • The corporate social responsibilities (CSR) initiatives are focused on employees, the communities

around its facilities and the environment running these activities. • Providing vocational training to make them self-sufficient • Unit will actively support the efforts of primary education to the children’s of economically weaker

sections of the society. • On the environment front active drive of tree plantations across villages and training lectures in-

house undertaken 8.4 EMPLOYMENT POTENTIAL

The impact of the project on the economic aspects can be clearly observed. The SNKUSML project activities will provide employment to persons of different skills and trade. The local population will be given preference to the employment. The employment potential will ameliorate economic conditions of


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these families directly and provide employment to many other families indirectly who are involved in business and service-oriented activities. The employment of local people shall upgrade the prosperity of the area. This in turn will improve the socio-economic conditions of the area.

• During construction phase of the project, this project will provide temporary employment to both skilled and unskilled labors in nearby villages.

• During operational phase, considerable people will be benefitted by provision of services to the residents. Thus, the direct and indirect generation of employment by this project.

• The trend of out migration for employment will be reduced due to better economic opportunities available in the area.

About 40 people will be deployed temporarily during construction of the project and about 83 people will be employed during operational phase of the project. 8.5 IMPROVING THE ECONOMY OF FARMING COMMUNITY

• The farmers will be provided with good quality seeds, improved farm implements, credit facilities for adoption of micro-irrigation system, the advanced training to improve yield and recovery etc.

• The capacity building of farmers will help them to achieve the targeted potential yields of various crops including sugarcane which in turn minimizes the cost of production with more emphasis on maintaining fertility of soil too.

8.6 OTHER TANGIBLE BENEFITS

Both tangible and non-tangible benefits will result from this activity and many of thoseare described as above. • Groundwater levels increase by recharging by rainwater harvesting. • Aesthetics improvement by general greenery with emphasis on biodiversity • Developed economy strengthens demographic set up that will bring weightage to secure better

school-subsidy and health institute • Improved safety security in surrounding with better law and order. • Symbiosis and sustainable development will be the ultimate objectives of the proposed project.


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CHAPTER 9-ENVIRONMENTAL COST BENEFIT ANALYSIS

9.1 ENVIRONMENTAL COST BENEFIT ANALYSIS

The Need and benefits of the proposed molasses- based distillery unit are well established and they have proved to be economical attractive. Sugar industries are agro based and located in rural area and they have contributed significantly in socio-economic development of the rural region of the country. In proposed distillery project water conservation techniques will be adopted. Principle of reduce, reuse, recycle have been followed strictly & Zero Liquid Discharge will be achieved.

As per EIA Notification dated 14th Sept., 2006, and its subsequent amendments; theChapter on “Environmental Cost Benefit Analysis” is applicable only, if the same isrecommended at the Scoping stage.As per the ToR points issued by MoEFCC, New Delhi vide letter no.No.IA-J-11011/384/2017-IA-II (I) dated 26th October, 2017for the proposed project, the Environmental Cost-Benefit Analysis is not required.

9.2 CONCLUSION

Pollution control is nothing but internalizing external diseconomy. This is in line with Polluter to pay principle adopted by Supreme Court. This cost-benefit work, though not asked specifically in scoping, is discussed. Though this may look ideal on paper, it will not serve the purpose unless Environmental Management Plan is prepared and got approved. To support the Plan, administrative set up is necessary and the same is described.

The EIA has indicated as to what steps are designed in the working of new project. This, however, is required to be manned properly. Unless an EMP is prepared in advance, as like production campaign the environmental protection will not automatically happen. For such EMP, fixing of objectives is the first step and ensures its implementation is the last step. This is designed in this Chapter and we have a commitment from the higher management to stick to this design. This will meet the objectives of fulfilling the legal requirements and not causing any hardships to people, whether it is only formulation extension or a technical grade manufacture.


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CHAPTER 10-ENVIRONMENTAL MANAGEMENT PLAN

10.1 INTRODUCTION

The environmental management plan consists of the set of mitigation, management, monitoring and institutional measures to be taken during implementation and operation to eliminate adverse environmental impacts or reduce them to acceptable levels. The present environmental management plan addresses the components of environmental affected during construction of the plant and by the different activities forming part of themanufacturing processes. Based on the evaluation of impacts and baseline conditions, an EnvironmentalManagement Plan (EMP) has been delineated to mitigate the adverse impacts onenvironment of the area due to the Proposed Project.The EMP is herein outlined after taking into account the various Acts, Rules andRegulations / Standards concerned with the environmental management.

Aims of EMP

i. Defining the components of environmental management ii. Preparing an environmental hierarchy iii. Preparing a checklist for statutory compliance iv. Preparing environmental organization v. Preparing a schedule for monitoring and compliance vi. Establish a watchdog committee voluntarily with an ultimate aim to get ISO 14000 certification

vii. Overall conservation of environment. viii. Minimization of waste generation and pollution. ix. Judicious use of natural resources and water. x. Safety, welfare and good health of the work force and populace. xi. Ensure effective operation of all control measures.

xii. Vigilance against probable disasters and accidents. xiii. Monitoring of cumulative and longtime impacts. xiv. Ensure effective operation of all control measures.

Environmental Management Plan is detailed under the following heads: • Air Quality Management • Noise Management • Waste Water Management • Solid & Hazardous Waste Management • Energy Conservation • Greenbelt Development & Plantation Programme • Occupational Health & Safety Measures.

Standards operating procedures, formats will be developed and records will be maintained. Provision of internal audit will be made. Any NCs/Observation will be directly conveyed to Management and accordingly corrective and preventive action will be taken. 10.2 POLLUTION CONTROL SYSTEM

Detailed study of the pre-project commissioning environment and also the likely (and predicted) implications after the plant commissioning suggests that the following preventive/control measures are considered necessary to reduce the adverse impact to the utmost practicable limit.

Contents of this chapter shall be:

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


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10.2.1 Air Environment

i. Stack height is 46 mand 60 m for 35TPH(2 nos.)& 65 TPH boilers respectively for gaseous emission confirming to the CPCB norms. D. G. Sets, stack height of 4.0 m above the roof level have been maintained.

ii. Stack emission level from boiler is being kept within permissible limit by installation of Multicyclone Dust collector & water scrubber and stack emission monitoring is being done.

iii. Ambient air quality and stack emission is being regularly monitored and effective control exercised.

iv. In order to avoid fugitive emissions from different sources, boiler blowdown water is being sprayed on bagasse and ash to keep them in wet condition. Also the roads within the premises will be concreted to prevent dust emission.

v. The ambient air monitoring will be carried out regularly in the work zone and surrounding areas, to check that ambient air levels of the contaminants, are well below the stipulated norms.

vi. Green belt around the periphery and within premises will be developed which will help in attenuating the pollutants emitted by the plant.

Table 10.1: Arrangements made for Air Pollution prevention in existing sugar factory

Sr. No. StackAttached to StackHeight Air Pollution Control Equipment 1 Existing Boiler I-35 TPH 46 m Fly ash arrester & MDC (2Nos) 2 Existing Boiler II-35 TPH 3 Existing Boiler III-65 TPH 60m Wet Scrubber 4 Existing DG Set of320 KVA 4 m Adequate stack height

10.2.2 Action Plan to Control Fugitive Emission

Main source of fugitive emissions is transportation of men and material during operational phase of project. To control fugitive emissions following measures shall be adopted:

i. In order to avoid fugitive emissions from different sources spraying of water shall be used ii. The roads within the premises will be concreted / paved to avoid vehicular emissions iii. All transportation vehicles shall carry a valid PUC (Pollution under Control) Certificate. iv. Proper servicing and maintenance of vehicles will be carried out. v. Regular sweeping of all the roads and floors will be done.

vi. 33% of the total plant area will be developed as green area. Green belt act as surface for settling of dust particle and thus will reduce the particulate matter in air.

vii. Ambient air quality will be regularly monitored and effective control exercised, so as to keep emission within the limits.

Action Plan to Control Fugitive Emissions is given in Table 10.2 below

Table 10.2: Action Plan to Control Fugitive Emissions S. No. Emissions Sources Management measures

1 Fuel and ash transfer

• Bagasse shall be compressed and formed into bales before feeding in boiler bunker.

• Boiler bottom ash will be collected on belt conveyor submerged in boiler blowdown water

• Covered transfer point 2 Vehicular

emissions • Paved roads • Regular sweeping • Water sprinkling through mobile tankers


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10.2.3 Waste Water Environment

i. The proposed Molasses based distillery would be based on “Zero Liquid Discharge” (ZLD) ii. Spent wash will be concentrated in IMEE (Integrated Multiple Effect Evaporator), then the

semisolid waste from IMEE (Integrated Multiple Effect Evaporator) will be used for bio composting.

iii. Condensate will be treated in condensate polishing unit and will used as make-up water in cooling tower and molasses dilution.

iv. A duly lined concentrated spentwash lagoon of 30 days capacity shall be provided. v. Online effluent quality monitoring system has been installed for existing sugar unit ETP and

distillery unit and transmission of online data to State Pollution Control Board and CPCB is being done.

10.2.4 Solid Waste Environment

i. Boiler ash from existing sugar unit bagasse-based boiler will be given to member farmers for soil conditioning.

ii. The other solid wastes expected from the unit are containers, empty drums which are returned to the product seller or sold to authorize buyers after detoxification.

10.2.5 Noise Environment

Various components of industrial operations will cause some amount of noise, which will be controlled by proper maintenance and compact technology.

i. Time to time oiling and servicing of machineries will be done. ii. Acoustic enclosure for existing sugar unit D.G. sets has been provided. iii. Green belt development (plantation of dense trees across the boundary) will help in reducing noise

levels in the plant as a result of attenuation of noise generated due to plant operations, and transportation.

10.2.6 Odour Management

The main causes of odour at distilleries are as under: i. Bad management of fermentation house; ii. Long retention of fermented wash, iii. Unattended drains The remedial measures will be taken such as Better house-keeping by regular steaming of all fermentation equipments; Temperature will be kept under control during fermentation to avoid in-activation/killing of yeast; Staling of fermented wash would also be avoided.

10.2.7 Green Belt Development

Green belt planning will be done with ecological perspectives for distillery plant of SNKUSML. Recommendations given by expert committee on plantation requirements in the premises of the plant would be fully implemented. This will help in reducing the concentration of pollutants and will also be effective in attenuating noise levels. SNKUSML has social obligation to recreate the environmental status by providing thick green cover to suppress fugitive emission and provide aesthetic beauty. Trees form the important part of the biosphere in the Eco-system. It will be exercised as follows: i. Green belt development in and around the project site will help in to attenuate the pollution level. ii. Out of the total plant area 33% land will be utilized for green belt development and plantation will

be done as per Central Pollution Control Board (CPCB) Norms. iii. Native species will be given priority for Avenue plantation. iv. The periphery will be devoted to generation of green belt area.

10.2.7.1 Plantation Techniques

Green belt will be developed within the Plant premises covering a total area of about 33% of total Plant area. The plantation work for green belt development will be carried out as per CPCB guidelines, local species would be preferred.


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10.2.7.2 Aftercare and Monitoring

Investment on reclamation would be futile without adequate and timely aftercare. Aftercare includes weeding, soil working, mulching and fertilizing, and if possible, irrigation to promote better growth of the planted seedlings. The vegetated area would be protected from grazing of animals until the plants are above the level of damage. Wherever necessary, fencing would be erected on the boundaries of reclaimed areas. Monitoring of the programme is the only way to improve both the long-term and shortterm planning. It involves two important aspects, namely site investigation and record keeping. 10.2.7.3 Baseline data and Potential Impacts of the Study Area The flora and fauna of an area shows a certain affinity to the existing environmental setting. Due to the proposed facility, there could probably be a change in the environmental surroundings for a short duration due to the construction phase and for a long term due to the operation of the project activities. Thus, in order to predict the ecological impacts from the proposed project, it is necessary to detail the baseline data. The potential impacts on the ecology of the study area are discussed below: i. As no wastewater from the proposed project will be discharged outside the premises, there will be

no impact on the ecology of the study area due to wastewater arisen from the proposed project. ii. The flora and fauna of the area could be disturbed if the various air pollutants discharged from the

proposed facility would not be maintained within specified permissible limits. But project authority has already provided adequate stack height, etc. Thus, the potential impact of air emission can be rated as no impact.

iii. Moreover, the proposed green belt would help in reducing the adverse impacts further if any. iv. On the periphery of the plant a series of trees will also be planted. 10.2.7.4 Recommendation on Green Belt Development A green belt or tree plantation around the proposed plant shall help to arrest the effects of particulate matter and gaseous pollutants in the area besides playing a major role in environmental conservation efforts. Green belt development and plantation programme for the proposed project shall also be a part of the proposed plan. For effective control of air pollutants in and around the proposed industry, a suitable green belt will be developed by taking into consideration the following criteria. The green belt would; a. Mitigate gaseous emissions b. Have sufficient capability to arrest accidental release. c. Effective in wastewater reuse. d. Maintain the ecological balance. e. Control noise pollution to a considerable extent. f. Prevent soil erosion. g. Improve the aesthetics. Taking the above-mentioned criteria into consideration, the proposed green belt would be covering around 33% of the total area. The green belt would be consisting of shrubs, trees, avenue trees, revenue trees, crops and potted plants. All the species suggested are pollution tolerant, besides having an aesthetic appeal. All the species suggested are pollution tolerant, besides having an aesthetic appeal. SNKUSML has already planted 10612 No. of trees covering an area of about 7 Ha. In addition to existing trees, 11431 No. of extra trees will be planted which will cover an area of about 7.6 Ha.Greenbelt development plan and list of existing plant species planted are given in Table 10.3 and Table 10.4 respectively. Photographs of existing green belt area are given in Figure 10.1.


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Table 10.3: Greenbelt development plan

Sr. No. Year Greenbelt Area (Ha) Total Plants (@1500/Ha) 1 1st Year 1.7 2500 2 2nd Year 1.7 2500 3 3rd Year 2.143 3215 4 4th Year 2.144 3216 Total 7.6 11431

Total 10.4: List of trees planted in existing sugar factory area

Sr.No. Common Name Botanical Name Quantity

1 Neem Azadirachta indica 754 2 Asopalav Polyalthialonggifolia 428 3 Mango Mangifera indica 205 4 Gulmohar Delonixregia 72 5 DeshiBavel A. nilotica 134 6 Peepal Ficusreligoiosa 92 7 Garmado Cassia fistula Linn 34 8 Su Baved Leucaenaleucocephala 1560 9 Champa Michaliachampaca 8 10 Nilgiri Eucalyptus Globu 315 11 Saag Tectona grandis 1890 12 Jambul Syzygium cimini, 52 13 Gal board Elaeocarpus serratus 250 14 Aakada Calotropis gigantea 1250 15 Khakad Pistacia integerrima 900 16 Bor Ziziphusjujuba 2500 17 Amla Phyllanthusemblica 70 18 Guava Psidium guajava 84 19 Coconut Cocos nucifera 14

Total 10612


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Figure 10.1: Photographs of existing green belt development


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Proposed Plantation Species:

Bottle brush (Callistemon sp.), Kadamb (Neolamarckiacadamba), Semal/Kapok (Bombax ceiba), Jamun (Syzygium cumini), Basant Rani (Tabebuiarosea), Morpankhi (Thuja occidentalis), Safeda (Eucalyptus), Neem (Azadirachta indica), Kasood (Cassia siamea), Pine/Junglisaru (Casuarinaequisetifolia), Orchid tree (Bauhinia blakeana), Saptparni (Alstonia scholaris), Gulmohar(Delonix regia), Rain tree (Samanea saman), Shisham (Dalbergia sissoo), Bel (Aeglemarmelos), Arjun tree (Terminalia arjuna), Cassia fistula (Amaltas), Yellow Gulmohar(Peltophorum ferrugineum), Guh babool (Acaciafarnesiana), Kaner (Nerium indicum), Champa (Plumeria rubra), Holy basil (Ocimumtenuiflorum), Jarul (Lagerstroemia speciosa), Bougainvillea spectabilis, Lemon (Citruslemon), Sankuppi (Clerodendrum inerme), Lawn Plantation and Shrubbery etc.

Plant species for Odour management:

Holy basil (Ocimum tenuiflorum), Tulsi (Ocimum sanctum), Sankuppi (Clerodendruminerme), Jasmine tree (Plumeria alba), Jarul (Lagerstroemia speciosa), Gurhal (Hibiscusrosa sinensis), Bunchgrass (Vetiveria zizanioides), Neem (Azadirachta indica), Saptparni (Alstonia scholaris), Guh babool (Acacia farnesiana),Morpankhi (Thuja occidentalis), Bougainvillea (Bougainvillea spectabilis), Lemon (Citruslemon), Kaner (Nerium indicum), Mehndi (Lawsonia inermis), Champa (Plumeria rubra), etc.

Gaseous emission (SO2 & NOx) tolerant species:

White fig (Ficusinfectoria), Maulsari (Mimusops elengi), Kaner (Nerium indicum), Jarul (Lagerstroemiaspeciosa), Neem (Azadirachta indica), Bel (Aegle marmelos), Kasood (Cassia siamea), EarleafAcacia (Acacia aur iculiformis), Saptparni (Alstonia scholaris), Aldu (Ailanthus excelsa),Siris (Albizia lebbeck), Shisham (Dalbergia sissoo), Pipal (Ficus religiosa),. 10.3 STORM WATER MANAGEMENT

The water management system will be designed to minimize the potential for storm water contamination occurring at the site. This will be achieved by incorporating the following features into the storm water management system: • Run-off from upstream areas will be diverted around the plant site. • The quantity of contaminated run off generated will be minimized by diverting run-off from areas

external to the plant to storm water discharge points. • Hazardous material and fuel storage areas will be bunded and drains will be provided around these

facilities to prevent entering of runoff water. • Run-off from area external to process areas of the plant will be contained within a storage system. 10.4 OCCUPATIONAL HEALTH AND SAFETY

Production of ethanol involves storage handling and use of several chemicals. Some of these chemicals are toxic and hazardous in nature. Information about these chemicals is therefore important for the safety of the employees and the plant. Besides, the health status of the employees is also important which may be affected due to exposure to these chemicals. The exposures may be sudden and accidental or for a long period. In both of the cases there will be different health effects. Therefore safety measures dealing withthese chemicals are of vital importance and will be followed judiciously. 1. In order to ensure good health of workers, regular health check-up of the plant workers will be carried

out. 2. Occupational health surveillance programme will be taken as a regular exercise for all the

employeesand their records maintained. 3. Proper storage and handling precautions will be taken. The storage area will be cool, dry and well

ventilated away from any source of heat, flame or oxidizers. 4. Use of Personal Protective Equipment (PPEs) will be encouraged. Proper training on use of PPEs,

characteristics of the material handled and safety precautions to be adopted will be given to the workers.


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5. Fire safety measures will be incorporated within the factory premises. All the fire extinguishing media such as water, dry chemicals, CO2, sand, dolomite, etc. will be kept in vital locations.

6. Mock drills will be arranged for the worker to test the effectiveness of the training program from time to time and the way to react in case of emergency.

7. Safety precautions will be displayed in the premises on the banners, boards etc. 8. Both On-site and Off-site emergency preparedness plan will be drawn.

10.4.1 Likely hazards at site for- 1. Molasses Storage 2. Alcohol Storage 3. Fermenters 4. Distillation Column 5. Mechanical Equipments 6. Electrical system

10.4.2 Measures adopted -

In order to ensure good health of workers, regular health check-up of the plantworkers is and will be carried out.Industry has appointed authorized medical officer.

i. Occupational health surveillance programme will be upgraded to include newemployees and their records will be maintained.

ii. Proper storage and handling precautions are taken. The storage area is cool, dry andwell ventilated, away from any source of heat, flame or oxidizers.

iii. Use of Personnel Protective Equipment (PPEs) is being/will be encouraged. Propertraining on use of PPEs, characteristics of the material handled and safetyprecautions is being/ will be given to the workers.

iv. Fire safety measures are/will be incorporated within the factory premises. All the fireextinguishing media such as water, dry chemicals, CO2, etc. are kept at vital locations.

v. Mock drills are/will be arranged for the worker to test the effectiveness of thetraining program from time to time and the way to react in case of emergency.

vi. Safety precautions are/will be displayed in the premises on the banners, boards etc. vii. Both On-site & Off-site emergency preparedness plan is prepared & will be updated.

10.4.3 List of Personnel Protective Equipments (PPEs)

Goggles: The workers will be asked to use goggles who work on washing of bottles, filling, sealing of bottles cap for protection of their eyes in case bottles are broken.

Rubber Gumboots: These will be provided to person who handles sulphuric acid. Full suit having handgloves, goggles, helmet and aprons will be provided.

Face Shield Helmet: The person deputed for welding work will be provided with face shield helmet. 10.4.4 Medical Facilities

The Company has following medical facilities to handle any emergency: i. Fully Equipped OHC (Occupational Health Center) has been provided.

ii. Hospital with all major facilities is available at 15 km from the site with qualified doctors & Trained Staff.

iii. Efficient Health Monitoring: by Pre Employment, Periodic Medical Examination in a proper scheduled way

iv. Investigations like Pulmonary Function Test, Audiometry, ECG, Blood Tests, Blood & Urine Glucose Estimation, etc.

v. Emergency Preparedness: by Qualified, Trained Staff, Efficient Doctors, Availability of Antidotes and Emergency Care Medicines etc.


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vi. Trend Analysis: by scheduled periodical medical examination and day to day disease data studies, to understand the disease pattern of employees and matching the same with the external disease pattern.

vii. There is integrated system under EHS to understand the health behavior and plan and implement the plan accordingly.

10.4.5 Implementation of OHS standards as per OHSAS

The overall objective of the company is to provide a system that is capable of delivering healthy and safe workplace. Following measures have been adopted for implementation of OHS standards. i. Well-equipped Occupational Health Centre with adequate paramedical staff.

ii. Routine and special investigation related to occupational health. iii. Health surveillance and maintenance of Health record. iv. Rules and procedure for effective implementation of Safety Health & Environment policy and made

to know all employees. v. Round the clock Ambulance facility.

vi. Sufficient number of First aid boxes. vii. Implementation of OHSAS 18001 for Occupational Health and Safety Management System. viii. Implementation of ISO 14001 for Environment Management System. ix. Risk assessment of each and every activity. x. Implementation of OHS management system.

xi. Training, awareness program and work place talk.

In case of need, factory will be having dispensary to give effective medical facility to workers. In dispensary, sufficient stock of medicines will be available to provide to workers in case of any major emergent situation. Industry has already appointed Registered Medical Practitioner (Qualified Medical Officer) as Incharge of the Dispensary with a Qualified Compounder. A vehicle will be always available to shift the sick/injured person to District Hospital.

10.4.6 Occupational Health Centre (OHC)

The company’s is having an Occupational Health Centre within the premises. It comprises of one Medical Officer, one medical assistant and one ambulance with driver round theclock. The company conducts pre-employment medical examination to screen and segregate medically unfit/fit before recruitment, so as to provide healthy assets to the company. i. Proactively health monitoring of the employees working in hazardous departments is done through

periodical medical examination as per Factories Act, OHSAS-18001 & WCM systems. ii. A pool of First Aid trained employee is maintained to overcome an emergency situation. Training,

retraining and refresher training are given at regular intervals to these employees to keep them ready for any medical emergency.

iii. First aid treatment is given to the employees. OHC is equipped with Oxygenator, ECG machine, Nebulizer, pulse oxymeter, Defibrillator and Suction machine. • OHC is also equipped with one ambulance to meet the emergencies.

b. The Ambulance is equipped with stretcher and emergency medicines like IV fluid, injection; adrenaline, dopamine, atropine, dexona etc are kept in it. • First aid boxes are placed at prominent places for easy access.

List of equipment for Occupational Health Monitoring i. ECG

ii. Noise Monitoring device (dosimeter) iii. Spiro meter iv. Audiometric device v. Vision screener

10.4.7 Details of Occupational Health Programme

i. Company is using all required instruments to control the emissions to be well within prescribed limit. ii. Company is conducting yearly medical examinations for all workers and twice in a year for workmen

working in critical Area such as bagasse yard, ash handling section etc. iii. At the time of pre-placement, Company does number of tests compulsorily which includes BP, CBC,

RBS, Urine Routine, Blood Group, HIV, ECG, X - Ray Audio & Eye Checkup.


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Safety officer will co-ordinate and manage occupational health management. A medical facility with qualified doctor and clinical facilities will be created in the industry to meet the factory and residential colony requirement of the health services. At present, industry has appointed medical officer. Higher medical services shall be availed from the hospitals present in Rajpipla.

Health care aspects to be practiced in the industry are indicated below-

i. Health and safety related displays will be exhibited at strategic locations in the industry. ii. Workers will be educated and trained in occupational health safety. iii. Regular health check up of the workers will be carried out and health records of individual workers

will be maintained. iv. Spirometry, Pulseoxyeometry, X-rays and other routine and specific tests will be conducted and

submitted to authorities v. Utility rooms provided will be provided with facilities and properly maintained. vi. First aid facilities will be provided at different locations. Further first aiders will be trained.

vii. Housekeeping in the industry, sanitation in utility rooms, canteen, Rest rooms and other places will be given top priority.

During operation stage, dust, gas cutting, welding may cause hazards, micro-ambient conditions near border, platforms etc. Periodical examination of workers’ occupational health is necessary. 10.4.8 Details of Health Status

To find out the health status of our workmen we have developed a plan of annually periodical health check-up of all the workmen and twice a year health check-up of workmen working in Hazardous Area. Detail of health status is given as Annexure -14. Details Health evaluation has been given in table 10.5.

Table 10.5: Health Evaluation

Sr.No. Occupation Type of Evaluation Frequency Pre-placement & Thereafter

For Age <30 every (years)

For Age 30-40 every (Years)

For Age 41-50 every (years)

1. Cane crushing area Chest X-ray, Spirometry & vision testing

5 4 2

2. Sugar Process area & Co-generation Area

Chest X-ray, Spirometry & vision testing

5 4 2

3. Main Control Room Far & Near Vision, colour vision and hearing test

5 4 2

4. Ash & Bagasse handling area

Chest X-ray, Spirometry, vision & Hearing testing

5 4 2

5. Noise prone area Audiometry Annually Note: All workers engaged in material handling system will be regularly examined for lung diseases such as PFT (Pulmonary Function Test). Details regarding recently analyzed data of occupational health of workers & health status of workers with special reference to Occupational health is attached as Annexure -14.

10.4.9 Annual Health Examination

Annual health examination is being done to detect occupational and ageing effect. Result of annual health examination is as follows: 1. Annual health examination of all the workers is being done regularly. 2. All people are investigated and treated by outside specialist and follow up treatment is continued

from our OHC with the instruction of salt and fat restricted diet and on continued follow up. However, ECG and Pulse rate of most of the workers are found to be normal.

3. Health knowledge of workers is improved by health talk on various topics in relation to environment, hygiene, different disease and anatomy of body.


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A sample copy of annual health examination record of employee is enclosed as Annexure- 14 with this EIA Report.

10.4.10 Treatment of Workers affected by Accidental Spillage of Chemicals

Whenever any worker is affected by accidental spillage of chemicals, company criticallyexamines the affected person to provide appropriate treatment. If a person is affectedby gas exposure, the person is brought in open space, his eyes are washed with water, ifneeded, O2 is given and the person is referred to nearest hospital. All other cases aretreated according to symptoms and signs.

10.4.10 Safety Committee

A safety committee has been formed and manned by equal participation frommanagement and workers with the following functions: i. Accident prevention and control including ensuring the use of safety appliances.

ii. Publicity, propaganda, education and training. iii. Assisting and cooperating with the management in achieving the aims and objectives outlined in the

“Health and Safety Policy” of the occupier. iv. Carrying out health and safety surveys for identifying unsafe working condition/pract ices, which

causes accident. v. SNKUSML has well laid Environment, Occupational Health & Safety Policy

10.4.11 Expenditure on Occupational Health & Safety

Budget details for last four financial years are as given below:

Table 10.6: Expenditure for Occupational Health in Existing Sugar Unit (From 2014 to 2017)

Sr. No. List of items 2014-15 (In Lacs)

2015-16 (In Lacs)

2016-17 (In Lacs)

1 Running & Maintenance expenses (Oxygen Cylinder, Spirit, room maintenance)

2 4.00 5.00

2 Lifting Tools and Tackles 10 10.00 15.00 4 Pre-medical Checkup for Employees 2 2.00 2.00 5 Heat resistant suit 1 3.00 3.00 6 Safety Audit & Training 5 6.00 5.50 7 Welding Screen (With handle) 0.5 2.00 2.00 8 Safety Belt, Safety Shoes, Safety Goggles 4.5 5.50 6.00 9 Periodic health checkup 2 2.00 2.00 10 Miscellaneous 3 3.00 3.00 Total(In Lacs) 30.00 37.50 43.50

10.4.12Fund Allocation to Occupational Health and Safety

The proposed distillery unit will spend approximately Rs.30 Lacs every year for Occupational Health &Safety measures.

Table 10.7: Fund allocation for OHS Sr.No. Particulars Cost(Lacs) 2 Lifting Tools and Tackles 10.00 4 Pre-medical Checkup for Employees 1.00 5 Heat resistant suit 1.00 6 Safety Audit & Training 8.00 7 Welding Screen (With handle) 1.00 8 Safety Belt, Safety Shoes, Safety goggles 4.00 9 Periodic health checkup 2.00 10 Miscellaneous such as First aid box cost etc 3.00 Total Capital Expenditure 30.00


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10.5 VEHICULAR POLLUTION CONTROL AND ITS MANAGEMENT

Vehicle emissions are responsible for 70% of the country’s air pollution. Various laws inthis regard have been laid out by the government. Exhaust from vehicles has increasedeight-fold over levels of twenty years ago; industrial pollution has risen four times overthe same period. SNKUSML is/will take care of all the measures to take up the vehicular pollution control inaddition to the pollution from the plant processes. All the vehicles will be keptenvironmentally compliant. The details are as below:

VEHICULAR POLLUTION CONTROL MEASURES:

1. Inspection and maintenance (I&M) programme for vehicles

The first and foremost important step towards emission control for the large in-usefleet of vehicles is the formulation of an inspection and maintenance system. It ispossible to reduce 30-40% pollution loads generated by vehicles through properperiodical inspections and maintenance of vehicles. It includes testing of variouselements of safety, road worthiness and compliance to pollution norms, renewal ofpermits and registration.

2. Emission norms

Emission norms for all categories of petrol and diesel vehicles are being/will be followed. Bharat stage emission standards are emission standards instituted byGovernment of India to regulate the output of air pollutants from internalcombustion engine equipments, including motor vehicles. The standards and thetimeline for implementation are set by the Central Pollution Control Board under the MoEFCC.

3. Appropriate Fuel

Diesel with lower sulphur content is/will be used. Pre-mixed fuels (petrol and oil mixture) for use of two stroke vehicles.

4. Periodical Checking of Vehicles

Vehicles are/will be checked internally or outsourced for the safety check as per theguidelines and the below mentioned checklist. Corrective measures are taken for the‘Unfit vehicles’.

Table 10.8: Vehicle Check Sheet for Fitness Certificate

Sr.No. Particulars Checks 1 Tyres Cut, deformation, thread ease wear 2 Steering Gear backlash, kingpin, stub axle, steering freeplay 3 Engine Noise level 85 dB 4 Horn Electrical, bulb, pressure horn 5 Brake Total brake effort > 45%, stopping distance at 30 kmph< 13 mtrs,

parking brake, brake oil leakage 6 Lamps/signals Headlamps, parking, turn signal, top lights, reflectors 7 Embossing of chassis Chassis and engine no. identification plate, month and year of mfg. 8 Speedometer Functioning, Speed Governors 9 Painting As per Act and rules 10 Wiper Wiper fitment and functioning 11 Body Seating, mudguard, emergency gate, window size, glasses, floor, etc. 12 Electrical Insulations, switches, doom light, spark arrester 13 Finishing Riveting, welding, bonnet, crankcase cover, etc. 14 Road Test Clutch, transmission, axels and performance 15 Others As per specifications


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Management Measures

• Traffic is minimized inside and outside the premises and is allowed to move as per the traffic plan • Adequate inspection and maintenance facilit ies • Older vehicles are being/will be timely replaced • Check on adulteration of fuel • Proper traffic management system • Concretization of roads • Development of Green belt and plantation around roads and plant periphery as a mitigative

measure. • Awareness programmes in the plant and nearby villages. 10.6 CORPORATE ENVIRONMENTAL POLICY (CEP)

We at SNKUSML commit to improve our Environmental Management System and minimize the impact of our manufacturing activity on the environment, on continual basis. The company has a well laid down Environment Policy approved by its Board of Directors as follows: i. complying with applicable environmental laws and regulations,

ii. Establishing systems and processes which minimize /prevent pollution and foster conservation of resources.

iii. Improving efficiency of all the operations through our proactive efforts in environmental management and incorporating cleaner technologies in the projects.

iv. Establishing objectives and targets and the review of policy. v. Enhancing the skills and competence of our employees to ensure sound environmental

management. 10.6.1 ENVIRONMENT MANAGEMENT HIERARCHY

SNKUSML is aware that environmental management is not a job, which can be handled without a careful planning. The success lies if three components are simultaneously present viz. (1) management support, (2) efficiency of the environment management cell and (3) acceptability of resulting environmental quality, both by SPCB and by public. A structure of this plan and hierarchy of process flow for environmental management is prepared and enclosed as logics, which is self-explanatory. SNKUSML will adopt this structure and hierarchy, which is akin to principles and practice.


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Figure 10.2: Environment Management Hierarchy

Draft SNKUSML Policy on Environment

Expectation of nearby people

Final Policy and Design

Legal requirements of SPCB, MoEF

Schedule of Funds Input

Schedule of Technological input

Preparation of Implementation

Schedule Implementation

Part A: Fully Implemented

Part B: Difficulties Encountered

Monitoring Additional

inputs of Funds /Technology

Unsatisfactory results Satisfactory results

Review Continue


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Figure 10.3: Environmental Management: Table- Structure

10.6.2 ENVIRONMENTAL ORGANIZATION:

Environmental organization will have an environmental cell responsible for pollution control and also for self-examination through monitoring 10.6.2.1ENVIRONMENT MANAGEMENT CELL (EMC)

Monitoring and feedback becomes essential to ensure that the mitigation measures planned by way of environmental protection function efficiently during the entire period of SNKUSML operation. Hence an environmental management cell involving top Management may be considered. Special efforts, therefore, are required to be undertaken to select good officers and deploy them in a well-designed environment organization cell. Organizational set up of Environment Management Cell (EMC) has been indicated in Figure No. 10.4

Prevention Abatement In –plant

Control

Waste Minimization Internal Lab

Top Management

Environmental Management Plan

Operation

SPCB

3rdParty Lab

Disposal

Monitoring

Training

Public

Treatment

Operation

Documentation

Feedback

Attenuation

Awareness


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Managing Director

Sugar & Co-gen unit works manager

Medical SurveillanceOfficer(1 No.)

Environmental Manager(1No.)

Laboratory I/C(1 No.)

Biogas Plant Operators (4 Nos.)

Safety Officer(1 No.)

MEE Operators(4 Nos.)

Lab Attendants(4 Nos.)

Environmental Chemist (4 Nos.)

Distillery Manager

CPU Plant Operators(4 Nos.)

Composting PlantOperators (4 Nos.)

Existing Sugar & Co-gen Unit

Distillery Unit

Figure 10.4: Environment Management Cell

Environment Management Cell will perform the following functions.

• Monthly review of environmental problems and monitoring of installation /performance /maintenance of pollution control measures.

• Enforcement of latest rules and regulations under relevant Environmental Protection Acts. • Preparation of budgetary estimates to seek sanctions for new pollution control measures if required

and/or for up-gradation of existing ones based on new technologies. • Emergency planning EMC shall meet at least once a month and take stock of progress of work relating to decisions taken and targets set in the previous meeting. 10.6.4 CHECKLIST OF STATUTORY OBLIGATIONS:

There are a number of environmental statutes required to be attended to by the industries. SNKUSML has prepared a checklist of these obligations, which facilitates the obedience of the laws of land. These are advised to SNKUSML as follows: 1. The Consents, whether under the Water Act or under the Air Act, are normally issued for a fixed

validity period. Please check whether the Consent is valid. If the same is expiring, it is better to apply for a fresh renewal at least Sixty days prior to the expiry date.

2. The Consent normally describes the items of manufactured products with quantity. One should see that, the described framework is not overstepped. In case, there is any likely hood of such increase, it will be worthwhile to obtain permission for the same. At least a letter to that effect be posted to the relevant board officer.

3. The Consent lays down a condition as to the volume and rate of discharge of effluents both for domestic as well as the industrial activity. By daily and hourly checks at the measuring devices, this is ascertained. Please do not forget to immediately make a record in the daily log-book.

4. A condition laid down for the treatment and disposal is of extreme importance. For this purpose, ETP or ECE is provided by the industry. There should be a continuous performance evaluation of these gadgets, so as to always remain inside tolerance limits. In case, you are exceeding the limits


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in certain parameters it is better to bring it on your internal record. The exceedance is discussed with the consultant, your production group and well-meaning Board authorities to seek guidance. Perhaps solution may be found in any or all of the following steps: • Characterization of raw effluents/ emissions • Attempting in-plant controls • Operation, maintenance, repairs and replacement of the ETP, ECE • Retrofit equipment to the existing plant

5. Disposal is the last-ditch battle. Disposal, dispersion, dilution, diversion, therefore, has to be planned very methodically and operated efficiently. This is a place where more reliable staff is required to be deployed. Any untoward incidence be reported.

6. Please check that the storm water and effluents do not get mixed. Keep the terminal manhole clean and always hospitable to facilitate taking of sample by the Board officials. Also check that no effluent is admitted in the channel down-stream of the terminal manhole, which means all the effluent, finally should pass via the terminal manhole only.

7. Monitoring aspects are always very crucial. For operating the plant, certain parameters be constantly checked. However, it will be a good practice to check monthly all the parameters through standard and approved laboratories. The result so obtained is routinely informed to the board offices. In case there is a water body in the vicinity, it is advised to take periodically samples from it. This applies both to the surface water as well as ground water. The findings will either give you a confident satisfaction or may give you a timely warning for improvement in the treatment or more so in the disposal system.

8. Although the environmental audit statement is required to be submitted on annual basis, it is better to keep the board progressively informed every quarter about efforts of pollution control and environment protection.

9. The industry should device their own format for a daily logbook recording of the running of their ETP or ECE. If the format is found to be satisfactory by trial and error it is better to finalize it and get printed. A printed format shows your conscious efforts towards the goal of pollution control, whenever any inspection takes place.

10. Please open an inspection book and make it a point that the visiting inspector, irrespective of their grades, gives some remark in the inspection book. If the remarks are favorable it shows your diligence and gives you an encouragement. If some of the remarks are unsatisfactory, it at least gives you an early opportunity to improve. The remark, in any case, gives a framework for improvement. Do not take inspection visit as a burden and indeed take it an opportunity for improvement. The compliance of the unsatisfactory remarks is shown during next inspection. This is better way to brighten your image. This diligence becomes helpful to you even in the court case.

11. In case, there is an unfortunate accident, unforeseen act or event by which pollutants are excessively released into the environment, the same is brought immediately to the notice of the board and other concerned agencies. This will enable you to get experienced timely help from them. Your burden gets shared. Synergistic effects can be predicted by an overview.

12. In case, you feel aggrieved by any conditions imposed in the consent approach the board immediately for discussion, or thereafter prefer an appeal timely. Therefore, read the Consent carefully as soon as you receive the same.

13. The Water Cess Act, 1977, is applicable to certain specified industries. In case your industry is covered, the regular returns be submitted. Water meters be installed, whether the industry is covered or not under the Cess Act. Also check from time to time whether the class of your industry which may not be presently specified, has since got covered under the Cess Act.

14. The Cess amount be paid as per assessment orders and record maintained. 15. In case you feel aggrieved by excessive Cess assessment or non-sanction of rebate, the appeal be

preferred in time, that is within 30 days. And in case, you are late in doing this, at least submit with reasons for the delay.

16. The Government or Board while giving site clearance or Consent, normally puts a condition of plantation of trees. Otherwise also, planting trees within the compound gives a good demonstration of your plant performance. A better practice is to select about three varieties and density is about 1000 trees per acre of the 33% of the available open land total plot area. The species selected is tough and tolerant for your type of environment.


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17. An unsafe working and the environmental pollution generally goes hand-in-hand. Therefore, the obligations under the Factories Act be scrupulously followed and record maintained.

18. There are certain responsibilities regarding the hazardous waste. These can be summarized as follows: a. Identification of quantity, constituents and compatibility of hazardous waste, being

generated during the activity. b. Proper labeling and marking of containers, which are used for store, transport, or disposal

of hazardous waste? c. Use of appropriate containers for storage and transport d. Furnishing of information regarding the waste, its nature, its hazards, antidotes, and non-

compatibility etc. to the persons who either transport, treat, store or dispose -off the waste e. Use of authorized operator agency system to ensure the proper disposal of hazardous

wastes and to streamline the treatment and disposal f. Training of personnel for handling and proper storage of such categorized waste g. Identify a transporter specialized in such wastes, and the practice of hex plicate manifest

be followed h. Submission of reports to MOEF and SPCB i. To provide safety measures for handling of hazardous waste j. In case of an unforeseen act or event in transit occurs, the transporter should immediately

report to the nearest police station about k. The accident, and the clean-up measures l. He should also report to SPCB on the Form prescribed by the Hazardous Waste

(Management and Handling) Rules, 1989 and the Annexure-11 of the Guidelines issued by the Central Government

m. A container be opened for a short duration while receiving the hazardous material in it a while removing out from it, or otherwise it must always be kept closed in storage yard. • A container be opened or handled so carefully and slowly as not to rupture/ damage

the container • Always keep in spare some empty, clean and sturdy containers handy and immediately

available • Inspect the filled and stored containers every day and if any found in bad condition

transfer the contents to a good container immediately but carefully • Keep a daily record of your custody

n. Documentation is always a matter of evidential value. No job is complete unless paper work is complete. Occupier/ generator should carefully note this, and following be developed. • Gate-pass when waste leaves the factory by a transport towards the treatment facility.

Keep the receipts. • A receipt of material as signed by the facility Operator as a manifested color coded

copy be preserved for three years • Analyze the out-going waste and keep the results for three years from the date of

dispatch • Daily record of waste generation be maintained

i. Quantity and points of generation ii. Physical state and chemical constituents

iii. Hazardous waste category as per E.P Rules of 1989 iv. Hazardous waste class, as per Motor Vehicle Rules of 1989 v. Certify internally, the limit of 90 days and storage of ten tons

vi. Quarterly returns to State PCB , on prescribed format vii. Annual returns to State PCB, on Form 4

viii. Annual returns to State PCB, on Form 5 Under the Manufacture, Storage and Import of Hazardous Chemicals Rules, 1989, the immediate duties can be summarized as:

• To forecast the possible situations of major accidents


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• To design steps in advance to avoid accidents and its consequences including cascading effect

• To educate the related workers to stand to such occurrence

19. The occupier should not merely do the above job, but also make a show of his work. Occupier is best advised to inform the concerned authorities and agencies, as to his preparing documents like risk analysis, emergency plan, safety training, avoidance of major accidents, health plan, etc.

20. Under the Motor Vehicle Act, as amended in 1989, certain responsibilities are required to be fulfilled. The intending consignor is duty bound by Rule 131, to supply the transport owner full information about the dangerous and hazardous chemicals being transported to enable the owner and driver to: a. Comply the requirements on classification, labeling, preventive, precautions, updating

emergency information panel, and proper reporting to the police b. Be aware of the risks created to health and safety of persons and environment by the

dangerous and hazardous goods being transported. b. Under the Public Liability Insurance Act, 1991 the industrial manager is advised to check

some important activities, such as: c. Owner should take out one or more insurance policies d. He should take out such policies before he starts handling any hazardous substances. If he

has existing activities involving hazardous substances, he should take the cover early as the rule had become applicable from 1st April, 1992

e. The policies should always be kept renewed and alive f. The amount insured shall not be less than the paid capital. Check this from time to time by

taking a review of your position (but shall not exceed Rs. 50 Crores) g. General Insurance Corporation or similar agencies may be able to throw light, if

approached

10.6.5 ENVIRONMENTAL MONITORING SYSTEM

A judgment can become truncated if it is scientifically supported. This work is done by an appropriate monitoring which is a technique of drawing a sample and understanding from it the universe. The sampling station, the parameters and frequency is of extreme importance as also the careful analysis, reporting and interpretation. The schedule decided for a small activity like that of SNKUSML is as follows –

10.6.5.1 Schedule for Environmental Monitoring:

Table 10.9: Schedule for Environmental Monitoring

Sr. No.





Continuous Online Monitoring system will be installed.






• Take one point within site at



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down wind direction from distillery boiler about 500 m distance






Quarterly



lower contour

Pre & post monsoon


pH, Temperature, EC, Turbidity, Total Dissolved Solids, Calcium, Magnesium, Total hardness, Total Alkalinity,Chlorides, Sulphates, Nitrates, DO, COD, BOD, oil and Grease, Metals expected in effluent




pH, Temp., conductivity, BOD, COD, TDS


7 Compost parameters at Compost yard

Temp. of windrow, Compost quality- C: N ratio, moisture, N, P, K

At windrow & compost yard Daily






• Four locations around plant boundary (Fermentation, distillation, biogas and concentration).

Quarterly

9 Greenbelt Number of plantation (Units), Number of Survived plants/ trees, Number of poor plants/




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Trees 10 Environmental

Audit As per Direction of ISO 14001

- Once in a Year



Daily


Daily

10.6.5.2 Schedule for Environmental Compliances: There will be three facets to design and follow the schedules VIZ: A) for compliance of responsibilities, B) for day- to- day operation and management of ETP and ECE, and C) for routine environmental monitoring, to assess the impact and take timely warning. The schedule:

1) Daily Compliance: Take the meter reading- initial and final, for checking the water consumption. 1. Maintain the electricity consumption record for pollution control equipments. 2. Monitor ambient air twice per week as per notification of April 1996.

2) Monthly Compliance: 1. Monitor the influent & effluent of sugar & distillery & other units 2. Monitor the emission sources through the competent authority and submit the analysis reports to the

board. 3. Monitor ambient/ work zone noise levels & ensure conformance to standards.

3) Quarterly Compliance: 1. Monitor the leachate around periphery of spent wash storage tanks and composting yard. 2. Monitor the ambient air quality at upwind and downwind locations of the factory. 3. Review the water reuse performance.

4) Yearly Compliance: 1. Carry out the “Environmental Audit Statement” of various environmental aspects, review the

environmental policies with the help of experts and make the up gradation/changes accordingly. 2. Submit the “Environmental Statement” to the State Pollution Control Board in Form V under Rule 14

of the Environment (Protection) Act, 1986. 3. Review of Green belt development, Adoption of latest techniques &on line monitoring techniques may

be done 4. Renew the Consent to Operate under the Water and Air Acts. 5. File the Cess Returns to the State PCB under the Water (Prevention and Control of Pollution) Cess Act,

1977. 6. Renew the Hazardous Waste Authorization under sub-rule 3 of the Hazardous Waste (Management &

Handling) Rules, 1989.


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SNKUSML also undertakes to comply the conditions prescribed by the Consent. In this direction, the following discipline will be followed

Table 10.10: Responsibility distribution for compliance of Consent conditions of proposed distillery unit

S.N. Condition regarding Mode of Compliance Action by

1 Validity Period Keeping a watch, Application for renewal will be submitted in advance

MD, DM, ENV-M

2 Production Quantity Not to exceed the permitted quantity. Feed will be adjusted to recovery

MD, DM, ENV-M

3 Quantity of effluent To be measured daily and in-plant control. Not to exceed any time

DM, ENV-M

4 Quantity of sewage To be measured periodically. Not to exceed DM, ENV-M

5 Total water input To be measured daily. Not to exceed. Repair meters. Make break-up as per usages. Fill monthly Cess returns. Pay as per assessment.

DM, ENV-M

6 Quality of Effluents By running ETP in correct fashion, Monitor, correct.

DM, ENV-M, LAB- I, ENV- C

7 Disposal of treated effluent

Not over application. No Percolation, No spillages. Monitor

DM, ENV-M

8 Fuel Quantity Not to exceed permitted quantity DM, Env-M,Sugar

& Co-gen works manager

9 Emission System Control boiler dampers, ID/FD fans, Co2 % monitor

Sugar & Co-gen works manager, Env- M

10 Ambient air quality Keep monitoring Env-M

11 Noise Levels Check foundations for vibrations, Tree plantation

DM, Env-M

12 Solid wastes Quantity to be measured & record kept, bagasse to be baled, molasses not in open pits, press mud to be carted out every day

DM, Env-M,Sugar & Co-gen works manager,

13 Environ. Audit To be complied every year before 30th Sept. MD, Env-M

14 Inspections Inspection book to be opened. Instruction given by State PCB visiting Officer to be complied & reported.

DM, Env-M

Legends: MD- Managing Director, DM- Distillery Manager, ENV-M- Environmental Manager, LAB- I- Lab incharge, ENV- C- Environmental Chemist.

10.6.5.3 Watch-dog committee

A high power watch dog committee will be set up which will have a power of sudden spot inspection, checking of documents and listening of complaints if any. This committee will supervise over the monitoring and environmental management cell as may be necessary, generally over the following facets of works: 1. Permit management 2. Construction management 3. Treatment and emission management 4. Transport management 5. Disposal management 6. Monitoring 7. Documentation 8. Law enforcement


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Monitoring and reporting mechanism The Watch- Dog Committee will supervise and monitor the working of Environmental Management Cell and give its report to Board of Directors (BOD) every three months. Any Deviation/violation / adoption of latest techniques in respect of Environmental management will be brought to the notice of BOD. The remedial measures/actions will be proposed with justifications for thereof. The BOD will discuss the subject and approve the appropriate action. The Managing Director will implement the decision of BOD. 10.6.6 COST PROVISION FOR ENVIRONMENTAL MEASURES

It is proposed to invest about Rs 2250.25Lacs on pollution control, treatment & monitoring system for proposed distillery project. The break- up of the EMP budget is given in the following Table 10.11.

Table 10.11: EMP Budget

Sr. No.

Description of Item Cost,Rs Lacs Recurring Cost, Rs Lacs / annum

EMP-Existing Sugar Industry 1 Existing Stacks (total 3 in No.s)-

1. A common stack for 2 boilers having capacity 35 TPH each 2. Stack attached to a boiler of 65 TPH 3. Stack attached to DG set 4. Proposed Online Monitoring System for existing stacks

Cost already incurred=170 Proposed Cost for online Monitoring System= 20

11.00

2 Existing Air pollution control facilities- 1. Fly ash arrester & Multicyclone dust collector (2 in No.s) attached to Existing common stack (Boiler capacity - 35 TPH each) 2. Wet scrubber attached to Existing stack of Boiler having capacity 65 TPH

Cost already incurred=

300

09.00

3 Existing Water pollution control measures 1.Existing Effluent treatment plants (ETP) of Sugar Unit with Online Monitoring system 2. Sewage collection, treatment & disposal (Septic tank & Soak pit)

Cost already incurred=

350

10.50

EMP- Proposed Distillery Unit 4 Proposed Water pollution control measures

1. Proposed Effluent treatment plants (ETP) of Distillery Unit biogas, mee, composting & cpu 2. Continuous online monitoring system for distillery waste

water(including mass flow meters before & after concentration and camera system for 30 days SW storage tank and compost yard)

3. Sewage collection, treatment & disposal (STP)

1180 34.10

6 Noise Abatement 0.25 0.10 Occupational Health 30 5 5 Safety Management fire fighting & safety aspects 85 5 7 Env. Laboratory, equipments & chemicals 75 7.50 8 Rain water harvesting 20 2.50 9 Green belt 20 3 10 Remuneration of technical staff for environment

management - 53.40

Total 2250.25 141.1


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10.7 ENTERPRISE SOCIAL COMMITMENT (ESC) Projects will be implemented based on community priorities and with significant localcontributions. Important areas such as female literacy, vocational training, health carefacility, safe drinking water, Sanitation & hygiene etc., identified through socio-economic survey will be considered under ESC activities. This approach will strengthen the groups, empower the members and will develop a high sense of ownership.Adequate funds i.e. 3.0 % of the project cost will be earmarked towards the Enterprise Social Commitment. Detailed action plan of ESC for next 5 years along with the budgetary allocation is given below:


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Table10.12: Cost already incurred under ESC (From 2008 to 2017)

Sr. No

Particulars (Amount, Rs Lakh ) 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 Total

1) Sanitation facilities in surrounding villages

0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

3) Social Forestry 3.638 2.529 2.488 1.431 8.90 3.007 0.730 3.67 3.071 16.428 59.250 4) Organization of medical Camps

in surroundings 1.639 1.711 0.887 0.851 4.045 0.041 0.281 0.833 0.288 0.351 10.991

5) Training, awareness and skill development programmes

0.451 1.050 1.090 0.379 0.778 0.048 0.000 3.671 0.000 0.000 7.466

6) Women empowerment 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 1.00 0.00 1.00 9) Facilities of pesticides Manure to

farmer (cane seeds advance) 65.526 27.554 125.919 179.504 42.61749 8.933 4.549 2.89 0.00 0.05 457.594

Total 71.254 32.843 130.384 182.165 56.341 12.029 5.560 11.065 4.360 16.829 536.302


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Table 10.13: Proposed Cost to be incurred under ESC at the rate of 3% of the project cost (From 2018 to 2022)

Sr. No Sector Activity Amount (in Lacs) 2018 2019 2020 2021 2022 Total

Amount 1 Entry Point Village level meeting for repo building and initial discussion for thecommunity

development needs in villages 0.60 0.60 0.00 0.70 0.60 2.50

2 Activities Baseline / Household survey in 25 villages 0.25 0.00 0.00 0.00 0.00 0.25 3 Educational Merit Scholarship / Prize Distribution to Merit Holders in Govt.Schools. 0.50 0.60 0.50 0.40 0.00 2.00 4 Programmes Distribution of education materials to needy children & Balpraveshotsav 0.80 0.50 0.60 0.80 0.55 3.25 5 Sakhar School, Assistance in School 1.00 1.00 1.00 0.80 0.70 4.50 6 Providing Computers, Fan, Tube lights, etc, to Educational Centers 1.00 1.00 1.00 1.00 1.00 5.00 7 Organizing sports meet in nearby villages 0.40 0.35 0.30 0.20 0.00 1.25 8 Health and Mother and Child care program), Health & Sanitation Awareness Camp /

Trainings (IEC Programme) 0.25 0.25 0.25 0.25 0.25 1.25

Family 9 Welfare Community Health Camps 0.50 0.70 0.80 0.50 0.00 2.50

10 Programme Mega Eye Check-Up and Operation Camp 0.30 0.30 0.30 0.30 0.30 1.50 11 Treatment of BPL, Old age or needy patient 0.45 0.5 0.65 0.40 0.50 2.50 12 Support in Pulse Polio Camp 0.30 0.30 0.30 0.30 0.30 1.50 13 Ambulance Support to BPL/needy patients 0.40 0.60 0.65 0.55 0.30 2.50 14 Infrastructure Internal Village Road - C:C/ RCC Road/ Paver Block Development/ 15.00 15.00 15.00 15.00 10.00 70.00

Development Drainage System Development 16 Cattle development project 1.00 1.00 1.00 1.00 1.00 5.00 17 Development of the Drinking Water Facility 2.00 2.00 2.00 2.00 2.00 10.00 18 Installation of Non-Conventional energy system viz. Solar Light 1.00 1.00 1.00 1.00 1.00 5.00 19 Construction of Funeral Shed in the nearby villages 1.00 1.00 1.00 1.00 1.00 5.00 20 Sustainable Formation of Self Help Groups & capacity building of rural women and men 0.35 0.25 0.35 0.30 0.00 1.25 22 Programme Computer Literacy Training 1.00 1.00 1.00 1.00 1.00 5.00 23 Exposure visit to progressive farmers field 0.50 0.60 0.50 0.40 0.50 2.50 24 Promotion of Agricultural Equipment-Demonstration 0.35 0.35 0.00 0.40 0.40 1.50 25 Awareness on Construction of Rain Water Harvesting Structures / Roof top

water harvesting / Pond deepening etc 0.00 0.30 0.30 0.40 0.50 1.50

26 Social Issues Organizing community marriages, 2.00 2.00 2.00 2.00 2.00 10.00 Intervention awareness camps on social issues etc.

27 Organizing Sports tournaments 0.00 0.60 0.60 0.70 0.60 2.50 Total (In Lacs) 30.95 31.80 31.10 31.40 24.50 149.75


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10.8 OVERALL RECOMMENDATION AND IMPLEMENTATION SCHE DULE The mitigation measures suggested in earlier Chapters 4 are to be implemented so as to reduce the impact on the environment due to proposed project. The implementation of these recommendations could be done in phases so that, the most important mitigation measures would be implemented first and the mitigation measures, which are less important, could be implemented later. Along with the implementation of these mitigation measures, monitoring schedule and infrastructural requirements for environmental protection detailed in previous chapter are important for environmental control measures.

Implementation Schedule and Environmental Management Cell

Proposed plant will be completed within 12 months from the date of obtaining Environmental Clearance. Environment monitoring and implementation measures shall be supervised by environment management cell.

10.9 CHAPTER CONCLUSION:

Unless an EMP is prepared in advance, as like production campaign the environmental protection will not automatically happen. For such EMP, fixing of objectives is the first step and ensures its implementation is the last step. This is designed in this Chapter and we have a commitment from the higher management to strict to this design. This will meet the objectives of fulfilling the legal requirements and not causing any hardships to people, whether it is only formulation extension or a technical grade manufacture.


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CHAPTER 11- SUMMARY & CONCLUSION

11.1 INTRODUCTION M/s Shree Narmada Khand Udyog SahakariMandli Ltd. (SNKUSML), Dharikheda, Post- Timbi, Tal- Nandod, Dist- Narmada, Gujarat is registered under co-operative society’s act in the year 1989 to venture agro-based industrial and related activities. SNKUSML is aco-operative agro based sugar complex unit established in 1989 for manufacturing of a 2500 TCD sugar & 9 MW Captive power. The sugar unit generates large quantities Co-products viz. bagasse, molasses and press mud. To be economically and environmentally sustainable, it is necessary for SNKUSML to convert these co-products into high value-addedproducts. SNKUSML is having about 22000member farmers and the average area under cane sown every year is about 10000 Ha. For getting better cane price to member farmers, SNKUSML is therefore, proposing to establish 45 KLPD molasses based distillery at the existing sugar complex. As per the EIA notification 2006 & its subsequent amendments existing sugar project does not require Environmental Clearance. Existing sugar unit have obtained consent to operate from Gujarat Pollution Control Board (GPCB). 11.2 TYPE OF PROJECT The Notification No. S. O. 1533 promulgated on 14th September 2006 has categorized 45 KLPD molasses based distillery under Category–A Schedule 5 (g). MoEF, New Delhi has specified TOR dated 26th October 2017. Accordingly, the EIA studies were conducted and the present summary of EIA report is prepared for submission to authorities for due Public Consultation. 11.3 NEED OF THE PROJECT

• Requirement of Product (alcohol) in market • India Needs Alcohol for industrial, potable & fuel purpose • Saves Petrol (additives) • Foreign Exchange Saver-Earner

11.4 SITE SELECTION& JUSTIFICATION THEREOF Proposed molasses based 45 KLPD distillery project will be done on available open land within the existing sugar plant premises. As adequate land is available within existing sugar factory premises, no additional land will be acquired. Hence, no other alternative sites are examined. The site for the existing sugar plant was finalized considering the ideal location for the industries. The proposed distillery plant location is considered based on availability of molasses, steam, power and water from existing sugar unit and hence it is the best option as far as location is considered.


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11.5 BRIEF DESCRIPTION OF NATURE, SIZE, LOCATION OF THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY, REGION

Table 11.1: Summary of proposed 45 KLPD molasses based distillery project

Sr.No. Particulars Details 1 Nature & size of Project 45 KLPD molasses - based distillery unit at the existing

sugar and Captive power plant. 2 New/expansion/ modernization New 3 Number of working days of the

distillery unit per annum 270 days/Annum

4 Location of the proposed project site Plot No. Survey No. 141, 142, 143 (These survey No.s are in the

Gamkuva Village) Village& post At-Dharikheda, P.O.- Timbi Taluka Rajpipla(Nandod) District Narmada State Gujarat Latitude/Longitude Latitude - 21.8271740N;

Longitude: - 73.3880850E 5 Average altitude above mean MSL 70 M above MSL 6 Corner Co-ordinates of the sugar

plant complex Coordinates of the project site as follows A -21.829289N 73.382765E B - 21.829884N 73.388677E C - 21.825338N 73.390316E D - 21.822620N 73.385796E

7 Toposheet Number F43N5 8 Area/Site details 9 Total plot area of sugar complex Total plot area is 43.70 Ha.

Proposed new distillery plant will be installed within the existing sugar plant premises.

10 Green belt/plantation area (Ha) Total area proposed for green belt development/ plantation is 14 Ha (i.e. 33% of the total plant area)

Environmental setting details (with approximate aerial distance & direction from the plant site) 11 Nearest village Dharikheda -1.07 km NE

Gamkuva - 1.30 km SW 12 Nearest Town Rajpipla : 13 km NE 13 Nearest National highway/ State

highway Rajpipla - Ankaleshwar highway (SH 64) - 0.427 km from the site in North direction National Highway No. 953 – 12.50 Km in SE direction

14 Nearest Railway station Kumasgaon Railway Station – 2.21 Km in NE direction 15 Nearest airport Vadodara Airport – 56.42 Km in NNW direction 16 Nearest major city Rajpipla : 13 km NE 17 Nearest national parks, wildlife

sanctuaries, biosphere reserves within 10 km radius

Within 10 Km radius, No national parks, wildlife sanctuaries, biosphere reserves.

18 Reserve/ protected forests within 10 km radius

Forest NOC is obtained.Attached as Annexure - 7

19 Nearest water body within 10 km radius

River Narmada - 7.50 km in North direction

20 Seismic zone Zone III 21 Archeological site None within 10 km radius 22 Critically polluted area as per

CEPI/CPCB None within 15 km radius


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11.6 MAJOR REQUIREMENT FOR THE PROPOSED DISTILLERY PROJECT

11.6.1 RAW MATERIALS REQUIREMENT

Table 11.2: List of raw materials required and their source along with mode of transportation

11.6.2 STEAM REQUIREMENT

Steam requirement for fuel alcohol production & spentwash concentration is of 6.2 TPH which will be met from existing bagasse based boiler of sugar unit during season whereas during off season, one of the bagasse based boiler will be used to generate steam for the production of fuel ethanol. 11.6.3 POWER REQUIREMENT

Power requirement of 825 KWH will be met from existing captive power plant of 9 MW during season.

11.6.4 MANPOWER REQUIREMENT

Additional manpower needed to operate the proposed distillery plant will be 83. More than 85 % of the manpower requirement will be fulfilled by employing the local people. Man power requirement for construction work i.e. on contract basis will be about 40. Construction workers will reside in nearby villages. Residential facility will not be required for the construction personnel. Infrastructure facilities such as sanitation, restroom etc. will be provided to the labour force during construction as well as to the casual workers including truck drivers during operation phase. 11.6.5 WATER REQUIREMENT

The water used for the proposedunit is already available, assured and dependable. This is treated to a reasonable extent by us, and it has good characteristics. As it is earmarked for this industry, we are not encroaching on anybody else’s water source.

Material Quantity Source Transportation (A) Major Raw Material

Molasses 192 MT/D Own Sugar Factory Pipe line Molasses Required For 270 Days/A 51840 MT/A Molasses from own sugar mill 40000 MT/A Molasses from outside sugar mills 11840 MT/A Sitaram Sugars and Allied

Industries Ltd, Ladhod, Badoli, ChotaUdepur

Tanker

(B) Other chemicals and Nutrients Distillery Unit

Sulphuric acid 0.135 KL/D Local vendor Tempo DAP 0.045 MT/D Local vendor Tempo Urea 0.075 MT/D Local vendor Tempo Antifoam 0.050 MT/D Local vendor Tempo Biogas Unit DAP 0.005 MT/D Local vendor Tempo Lime 0.450 MT/D Local vendor Tempo Concentration of Biomethanized Spentwash Biomethanated Spentwash 482 MT/D From distillery HDPE pipe line Compost Unit Culture 25.92 MT/A Local vendor Tempo Press mud 25920 MT/A Own Sugar Factory Tractor trolley

(Internal shifting) Concentrated Biomethanated spentwash

25920 MT/A From evaporation unit HDPE Pipe line


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Water is used at various stations like heating, cooling, process, floor washing, vessel washing, laboratory, scrubbing etc.

Total water input = 1486 m3/day Recycling & Utilization streams = 1162 m3/day Make up fresh water requirement = 324 m3/day 78% of water will be recycled. Only 22 % of fresh water will be required. In future, once distillery is established, treated water from existing sugar unit ETP will be used for plantation. ***Water at the rate of 7.2 KL/KL of alcohol produc tion will be required which is below the standards prescribed by the MoEF (i.e. 10 KL/KL of alcohol) 11.6.5.1 Status of Approval for water For obtaining water permission for additional 324 KLD water requirement, application has been submitted to CGWA. 11.6.6 LANDREQUIREMENT

Total land available with SNKUSML is 43.7060 Ha, out of which 11.4817 Ha of land has been utilized for existing sugar unit & residential quarters. About 33% of the total land i.e. 14.6954 Ha will be developed as green belt. Therefore17.5289 Ha of land is available for proposed distillery project.


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11.7 PROCESS DESCRIPTION ALONG WITH MAJOR EQUIPMENTS AND MACHINERIES, PROCESS FLOW SHEET (QUANTATIVE) FROM RAW MATERIAL T O PRODUCTS

A) PROCESS DESCRIPTION FOR RECTIFIED SPIRIT (RS)

The process of converting molasses to RS can be divided into following sub sections: 1] Feed Preparation and weighing 2] Yeast Propagation and Fermentation 3] Multi-pressure Distillation

1] Feed preparation and weighing Molasses Stored in a storage tank is first weighed in a tank with load cells so that accurate quantity can be fed to the fermentation section. The weighed molasses then transferred from tank to the dilutor in fermentation section where it is diluted with water and fed to the Fermenter.

2] Yeast propagation and fermentation The Yeast from Slant is transferred to Shaker Flasks and grown to the required volume. This “genetically marked” yeast strain is then further propagated, under aseptic conditions, in yeast culture vessel. These vessels are equipped with eductors which are designed to achieve enhanced efficiencies through better sugar / yeast contact by shearing and mixing, efficient oxygen transfer etc The ready yeast “seed” is then transferred from culture vessel to fermenter. The molasses is diluted by process water. The glucose in the Feed media gets converted to ethanol, in each of the 4 Fermenters operating in Batch mode. A plate heat exchanger and a circulation pump are provided to each fermenter, which will continuously recirculate the Fermenting Wash through PHE for maintaining the Fermenters at 30 deg C. The nutrients, biocide, acid and anti-foam agents are fed to the fermenters as per process requirement. The CO2 liberated during fermentation is sent to CO2 Scrubber for recovery of ethanol otherwise being lost in vent. The Fermented Wash is then sent to the Clarification Tank equipped with Lamella Separator. The settled sludge is sent to Sludge Washing Tank for recovery of alcohol.

3] Multipressure distillation (RS) The fermented wash is fed to CO2 stripper column to remove CO2 gas present in wash. Alcohol is stripped off water in stripper column. The top vapors [alcohol + water] are fed to Calendria. Distillate from Calendria is fed to extraction column; The Make DM Water & Recycled Spent Lees from Second Rectifier is used as dilution water. In extraction column most of the high boiling impurities separate from ethanol in presence of water. The bottom ethanol water mixture is pre-heated before being fed to rectifier column. In rectifier column RS is taken out from top tray. The impure spirit from top of CO2 stripper column, rectifier column, fed to fusel oil column. The final impure spirit cut is taken out from the fusel oil column and partly alcohol is recycled to rectifier column. The alcohol containing fusel oil from rectifier column is fed to fusel oil column. Rectification column works under pressure. The CO2 stripper, stripping column, works under vacuum and fusel oil column works under atmospheric condition. The top vapours from rectifier column are condensed in Stripper Reboiler. The alcohol water vapours from stripping column are partly sent to CO2 stripper bottom for heating. The Rectifier column and fusel oil column gets heat from steam. The Distillation process is operated through PLC. B] PROCESS DESCRIPTION FOR FA (DEHYDRATION – RS TO FA) Fuel alcohol (FA) is obtained by using Molecular Sieve process. Rectified Spirit at Azeotropic concentration is pumped by Feed Pump. This pump takes care of the entire backpressure of the system. The pump is in Stainless Steel material of construction for wetted parts complete with flameproof motor and mechanical seal. The rectified spirit will first pass through feed Preheater, which will pass through vaporizer cum super heater which will convert the Rectified Spirit feed to superheated Alcohol vapour stream ready to feed to the Molecular Sieve bottles. The degree of superheat is control via a temperature control loop and the flow rate to the plant is control via flow control loop. The superheated vapours will pass through a Sieve bottle, which is already regenerated, and pressurize to working pressure via. a bleed flow from an operating sieve bottle. After the drying cycle the flow will be shifted to the next Sieve bottle,


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which is ready after duly regenerated and pressurize. This sequence minimizes the rate of rise and fall of pressure through the molecular sieve. Thus, minimizing the attrition of the sieve beds. The sieve column after completion of drying cycle is evacuated to remove the adsorb water through an evacuation system via a condenser. The mixture of Alcohol and water is preheat by Anhydrous Alcohol Vapour in Plate Heat Exchanger before being feed to Recovery Column, which enriches the stream back to Azeotropic composition. The bottom of recovery column get heat from partly by condensing Anhydrous Alcohol Vapour in Plate Heat Exchanger the Anhydrous Alcohol vapours condensed in product cooler. A flow indicator indicates the rate of Anhydrous Alcohol going to the Anhydrous Alcohol receivers.


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11.8 DESCRIPTION OF ENVIRONMENT

Baseline study of the study area was conducted during Winter Season (October, 2017to December, 2017).

Ambient air quality monitoring has been carried out at 8 stations inthe study area on 24 hourly bases. During study period predominant wind direction was from NE to SW. Ambient Air Quality Monitoring reveals that the concentrations of PM10 and PM2.5 for all the 8 AAQM stations were found between 40. 90 to 81.2 µg/m3 and 15.54 to 33.97 µg/m3. The concentrations of SO2 and NOx were found to be in range of 5.03 to 10.56 µg/m3 and 8.82 to 19.08 µg/m3 respectively. The concentration of CO is in range of 0.205to 0.55mg/m3. The resultant concentration of the parameters is well within the prescribed limits of GPCB & NAAQS. Prediction of impacts on air environment has been carried out by employing a mathematical model. In the present case, Industrial Source Complex Short-Term (ISCST3) dispersion model based on steady state Gaussian plume dispersion, designed for multiple point sources for short term has been used for predicting the ground level concentrations. Results of mathematical modelling reveals that the maximum incremental short term 24 hourly ground level concentrations for PM10, PM2.5, SO2 and NOx likely to be encountered during pre-monsoon season are 2.38 µg/m3, 1.44 µg/m3, 4.06 µg/m3 and 7.22 µg/m3 respectively occurring at a distance of about 2-km in the South West direction.

Noise level monitoring has been carried out at 8 stations inthe study area. Noise level varies from 36.4to 69.4 Leq dB (A) during day time and from 33.8 to 60.3Leq dB (A) during night time. From the above study, it can be concluded that the resultant noise levels in the study area are within the limits as prescribed by the Noise Pollution (Regulation and Control) Rules, 2000.

Surface water sampling has been carried out at 8 stations inthe study area. SNKUSML is going to achieve Zero liquid discharge in surface water for the proposed distillery project& hence there is no effect on the river water quality due to this industry.

Ground water sampling has been carried out at 8 stations inthe study area. Analysis results of ground water reveals that pH varies from 7.06 to 7.53, Total hardness varies from 260 to 596 mg/l, Total dissolved solids vary from 353 to 847 mg/l.

Soil samples collected from 8 identified locations indicate pH value ranges from 7.16 to 7.92, which shows that the soil is having near neutral pH. Organic Matter ranges from 0.89% to 4.79% in the soil samples. Total Kjeldahl Nitrogen is found to be in good amount as it ranges from 1207.29 mg/kg to 1637.72 mg/kg and Phosphorous i.e. from 27.79 mg/kg to 247.98 mg/kg, whereas the Potassium is found to be ranging from 40.84 mg/kg to 72.44 mg/kg. Soil of the area is found to be suitable for agricultural activities.

The study area is delineated in 10 km radius from the project site. The proposed project site is surrounded by agricultural land. There are no any national parks, wildlife sanctuaries, biosphere reserves or critically polluted areas in the 10 km radius from the proposed project site.No Archeological siteis present within the study area. No forest is located in the study area. No Schedule - I fauna was found during the field survey. There is intense anthropogenic pressure on flora, fauna and forest resources, which are observed to be dwindling. However, no rare, endangered & threatened plant species was observed in the study area. Population of study area is 54660. Scheduled Caste fraction of the population of the study area (10 km) is 916 (1.67%) and Scheduled Tribe 44206 (81%). Literacy rate of the area is 69.55 %. Population of the workers engaged in occupation is 49.00%. Of these 21301 (39 %)are main workers and 5496 (10%) are marginal workers. Remaining, 27863(51%) of the total population is considered as non-workers. The socio-economic analysis of the study area showsthat in terms of education could be improved as the literacy rate is quite low i.e. 69.55%. With a high dependency ratio, the overall socio-economic status of the target population could improve with increase in work participation rate. Hence, the long-term positive impacts on socio-economic conditions of the area are anticipated.


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11.9 ANTICIPATED ENVIRONMENTAL IMPACTS AND MITIGATI ON MEASURES

Anticipated environmental impacts due to the proposed project along with mitigation measures are given in Table below.

Table 11.3: Environmental impacts Mitigation Measures in Brief

Sr.No. Facets of Environment

Mitigation & Impact Thereafter

(A) Construction Phase 1. Air 1. The approach roads will be paved or asphalted and regular sprinkling

of water on roads and construction site will be undertaken. 2. Regular PUC check will be undertaken. 3. All vehicles and construction equipment with internal combustion

engines being used will be maintained for effective combustion to reduce vehicular emissions.

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

5. Unleaded petrol will be used for vehicles in use. 6. Recycled water will be sprayed through high pressure water hoses

during dust generating construction activities e.g. excavation, crushing, concrete mixing, material handling etc. for dust suppression.

7. Measures will be taken not to use asbestos in the construction work. 8. Development of sufficient vegetation


1. Fresh water requirement will be minimized by using RMC 2. High pressure hoses will be used for cleaning and dust suppression

purpose. 3. Monsoon season would be avoided for the construction activity,

particularly the excavation work. 4. Wherever required check dams and dykes will be provided for control

of soil erosion. 5. Fast growing soil holding/binding vegetation e.g. grass will be grown

around the construction site before commencement of construction activity to reduce soil erosion and dust suppression.

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

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

3. Noise 1. Mandatory use of personal protective equipment like ear plugs shall be ensured to mitigate any significant impact of such equipment on personnel operating the machinery.

2. Long exposure to high noise levels shall be avoided by practicing proper shift arrangement for workers. Similarly, shift arrangements shall be made to avoid long exposure to hand-arm vibration and full body vibration.

3. Noise making construction activities shall be carried out during day time only.

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

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

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

4. Soil Construction wastes will be segregated as much as possible at site itself to


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increase the feasibility of recycling concrete and masonry as filling material and steel pieces as saleable scrap. Litter disposal and collection points will be established around the work sites. Empty packaging materials, drums, glass, tin, paper, plastic, pet bottles, wood, thermocol and other packaging materials, etc. will be disposed through recyclers. The construction spoils will be temporarily stored at designated dumpsite located inside the plant premises.

(B) Operation Phase 1. Air Air pollution will not take place because of the proposed project as there is

no provision of new boiler. Adequate stack height will be provided for proposed boiler of 600 KVA.

2. Fugitive Internal roads paved, leveled, no undulations, no sharp curves, slow speed. Tree plantation on surrounding available area.


1. Spentwash treatment will be as biomethanation followed by concentration of biomethanatedspentwash with integrated evaporation and standalone evaporation system to concentrate biomethanated spent wash (6% to 30%, i.e. from 482 TPD to 96 TPD) followed by composting system.The mother liquor left behind after distilling-off alcohol is called as spent wash.

2. (***Concentrated spent wash will be generated at the rate of 2.13 KL/KL of alcohol which is very less than the prescribed standards i.e. 6-8 KL/KL.)

3. Continuous online monitoring system will be installed for monitoring distillery waste water.

4. 23. Rain Water Harvesting will be done. 4. Solid Waste 100% collection every day. Segregated and treated/ disposed per SPCB

norms. 5. Odour Limited source of odour. Controlled by keeping closed regime during initial

treatment. Use of heat exchanger for cooling. Bio-digester is fully covered. 6. Noise Smooth roads. Sturdy foundation. No Vibrations. Acoustic enclosures to

existing sugar unit DG Set as per manufacturers’ design. Use as standby only. Trees are planted around. Side cladding. Large No. of tree barriers. Factory placed away from boundary. Acoustic enclosure will be provided to proposed DG set of 600 KVA.

7. Socioeconomic Employment generation, Community Skills Development, Improved Standard of Living, Community Organizational Capacity Development Economic Exposure and Development


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11.10 ENVIRONMENTAL MONITORING PROGRAMME Details of the environmental monitoring schedule / frequency, which will be undertakenfor various environmental components, is given in Table 11.4.

Table 11.4: Post project monitoring schedule for proposed distillery project

Sr. No.





Continuous Online Monitoring System will be installed.






• Take one point within site at down wind direction from distillery boiler about 500 m distance







Quarterly



lower contour

Pre & post monsoon


pH, Temperature, EC, Turbidity, Total Dissolved Solids, Calcium, Magnesium, Total hardness, Total Alkalinity,Chlorides,




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Sulphates, Nitrates, DO, COD, BOD, oil and Grease, Metals expected in effluent


pH, Temp., conductivity, BOD, COD, TDS


7 Compost parameters at Compost yard

Temp. of windrow, Compost quality- C: N ratio, moisture, N, P, K

At windrow & compost yard Daily






• Four locations around plant boundary (Fermentation, distillation, biogas and concentration).

Quarterly

9 Greenbelt Number of plantation (Units), Number of Survived plants/ trees, Number of poor plants/ Trees



10 Environmental Audit

As per Direction of ISO 14001

- Once in a Year



Daily


Daily

11.11ADDITIONAL STUDIES Additional Studies conducted as per ToR Letter no. No.IA-J-11011/384/2017-IA-II (I) dated 26thOctober, 2017, issued by MoEFCC, New Delhi are Risk Assessment and Disaster Management Plan. Public Hearing is to be conducted for the project. RISK ASSESSMENT

An industry with its complex nature of activities involving various plant machineries, raw materials, products, operations, intermediates and environmental discharge has a number of associated hazards. A minor failure can lead to major failure resulting into a disaster causing heavy losses to life, property and environmental. Risk assessment studies are being conducted to ensure safety and reliability of any new plant, through a systematic and scientific methods to identify possible failures and prevent their occurrences before they actually cause disasters and production loss.

Objectives of the risk assessment study The distillery involves storage and handling of large quantity of ethanol which is flammable and explosive under unfavorable situations. To ensure safe operation of the plant, it is proposed to carryout the Risk Analysis Study with the following objectives, 1. To identify the major hazards relating to fire, explosion and toxicity due to storage and handling of

hazardous chemicals.


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2. To visualize maximum credible accident scenarios 3. To analyze and quantify primary and secondary effects and damage potentials of the identified

maximum credible accident scenarios using standard procedure. 4. To study the nature of exposures, pathways and consequences of maximum credible accident

scenarios and characteristics of risk levels. 5. To provide guidelines for disaster management plan. DISASTER MANAGEMENT PLAN

A major disaster in a work is the one, which has potential to cause serious injury or loss of life. It may cause extensive damage to property and serious disruption both inside and outside the works. A Disaster would normally require the assistance of outside emergency services to handle it effectively. Whatever are the causative factors, like plant failure; human error; earthquake; vehicle crash; sabotage etc, they will normally manifest in three basic forms viz, fire, explosion, and or toxic release.

The objectives of disaster management plan include the following-

9. Controlling the disaster, localizing the disaster and eliminating the hazard 10. Welfare of person managing the disaster. 11. Head count and rescue operations. 12. Treatment of injured. 13. Safeguarding others by timely evacuation. 14. Minimizing damage to property and environment. 15. Informing and assisting relatives.

ix. Informing and collaborating with statutory authorities. x. Informing the news media. xi. Preserving records and organizing investigations.

xii. Ensuring safety of the works before personnel re-enter and resume work. xiii. Investigating and taking steps to prevent recurrence. xiv. Resorting normalcy

11.12 PROJECT BENEFITS

Implementation of proposed project will result in: • Improvement in the physical infrastructure • Improvement in the social infrastructure • Improvement in employment potential • Improving the economy of farming community 11.13ENVIRONMENT MANAGEMENT PLAN

Environmental Management Plan is detailed under the following heads: • Air Quality Management • Noise Management • Waste Water Management • Solid & Hazardous Waste Management • Energy Conservation • Greenbelt Development & Plantation Programme • Occupational Health & Safety Measures. • Enterprise social commitment (ESC)- Industry will utilize 3% of its project cost for ESC.


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Table 11.5: Environmental Management Plan

Particulars Details Air Quality Management

Existing sugar unit stack details • Stack height is 46 m and 60 m for 35TPH (2 nos.) & 65 TPH boilers respectively

for gaseous emission confirming to the CPCB norms. D. G. Sets, stack height of 4.0 m

• Stack emission level from boiler is being kept within permissible limit by installation of Multicyclone Dust collector & wet scrubber and stack emission monitoring is being done.

Water Management • The proposed Molasses based distillery would be based on “Zero Liquid Discharge” (ZLD)

• Spent wash will be concentrated in IMEE (Integrated Multiple Effect Evaporator), then the semisolid waste from IMEE (Integrated Multiple Effect Evaporator) will be used for bio composting.

• Vapor Condensate will be treated in condensate polishing unit and will used as make-up water in cooling tower.

• A duly lined concentrated spentwash lagoon of 30 days capacity shall be provided.

• Online effluent quality monitoring system has been installed for existing sugar unit ETP and transmission of online data to State Pollution Control Board and CPCB is being done.

• Online effluent quality monitoring system is proposed for distillery unit with mass flow meters before and after concentration and camera system for 30 days SW storage tank and composting yard.

Noise Management • Time to time oiling and servicing of machineries will be done. • Acoustic enclosure for existing sugar unit D.G. sets has been provided. • Green belt development (plantation of dense trees across the boundary) will help

in reducing noise levels in the plant as a result of attenuation of noise generated due to plant operations, and transportation.

Solid & Hazardous Waste Management

• Boiler ash from existing bagasse based boiler of sugar unit will be given to member farmers for soil conditioning.

• The other solid wastes expected from the unit are containers, empty drums which are returned to the product seller or sold to authorize buyers after detoxification.

Green Belt Development / Plantation

SNKUSML has already planted 10612 No. of trees covering an area of about 7 Ha. In addition to existing trees, 11431 No. of extra trees will be planted which will cover an area of about 7.6 Ha. In total, more than 33% of the total land i.e. 14.6954 Ha will be developed as green belt.

11.14 CONCLUSION The proposed project will prove beneficial to the local people as more infrastructure development, improvement in education and health facilities, roads, availability of drinking water, etc. in near-by villages will be done. There will be no significant impact on the area, as adequate preventive measures arebeing/will be adopted to contain the various pollutants within permissible limits. Regularmonitoring of all the components of environment is being / will be done. Increased socialwelfare measures taken by the company will bring development in the near-by villages.Greenbelt development around the area is being /will be also taken up as an effective pollution mitigative technique, as well as to control the pollutants.


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CHAPTER 12- CONSULTANTS ENGAGED

12.1 INTRODUCTION

SGM Corporate Consultants Pvt. Ltd ( Now, M/s. SGM Enviro (I) Pvt. Ltd.) hereinafter called as SGM which is an ISO 9001:2008 certified company with QCI-NABET Accreditation of category ‘A’ for the various project sectors for obtaining Environmental Clearances from authorities like Ministry of Environment and Forests (MoEF), State level Environment Impact Assessment Authority [SEIAA] etc.

SGM is a core group of professionals, dedicated & committed to a singular goal – Various Services under One Roof. The innovative idea of SGM is to provide the professional expertise at all levels to all the customers of SGM. We at SGM believe in delivering quality work within the stipulated time frame, with perfect professional care. Our team contributes Technical, Managerial & Financial Experts in the respective fields. SGM has well qualified & professional persons; who are looking after their departments in successful manner & have experience in respective fields for last 20 years. Client Satisfaction is our main motto. Team Work gives sure success and this is what we aim for and achieves Client Satisfaction. Well defined working philosophy, is the backbone of SGM’s growth. 12.2 WORKING PHILOSOPHY:

• Services Identification of industrial pollution problems in air, water and solid disposal, the environmental concerns and providing precise solutions, forms the core of our activities.

• Quality Results oriented services intended to suit customer requirement. Getting clear documents that require no corrections and impose minimum conditions to be on right side of law

• Integrity Not letting down customer in the hour of crisis, clarifications and repeated explanations called upon authorities. Provide answers with patience.

• Customer satisfaction Strive consciously to exceed customer expectations.

• Self Reliance Practice self reliance in all the aspects of management skills, technical competence, and application of sophisticated tools in project execution and report presentation, to provide one stop

12.3FIRM'S EXPERIENCE

Since inception, SGM have successfully completed several diverse projects for different type of industries and are regarded as a leading environmental management firm. SGM has served as consultants to industries, institutions and government for projects executed in India. SGM have acquired firsthand experience for the environmental problems of diverse industrial units such as Distilleries, Sugar industry, Building & Construction projects, Thermal Power Plants, Synthetic Organic Chemical Industry, Metallurgical industries, Townships and Area development projects etc, for Government, Private and Co-operative organizations. An important aspect of SGMs’ capabilities is the multi-disciplinary expertise and approach. SGM employs about fifty qualified technical personnel from various disciplines and offers services that integrate different dimensions of environmental engineering & technology. Capabilities and services provided by SGM Resources include; 12.4 OUR SERVICES IN ENVIRONMENT MANAGEMENT

• Preparing Environment Impact Assessment (EIA)reports • Obtaining compliance certification to EC, preparing EC compliance and Six monthly compliance. • Selecting, Designing and executing Pollution Control Systems. • Obtaining Consent from State Pollution Control Board


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• Obtaining compliance to consent conditions • Preparation of Detailed Project Report (DPR) • Groundwater and Surface Water Investigations • Soil Analysis & Testing • Solid waste management (Industry and construction projects) • Operation and maintenance of Effluent Treatment Systems (Industry) • Social Impact Assessment (SIA) • Conducting Energy Audit • Conducting Environmental Audit • Preparing Environmental Statement reports 12.5 INFRASTRUCTURE

Over the years SGM has acquired an operational infrastructure which provides a strong base to the services rendered by the organization Outline of the infrastructure which is specifically developed to meet services oriented work is summarized below: 12.6 TECHNICAL EXPERTISE

SGM considers their employees as human resources as they are obviously at the heart of any successful organization. The organization has result-oriented, experienced people with adequate qualification. SGM employs and has associated technical people to suit services provided, apart from the administration, accounts and other support staff. 12.7 OFFICE

SGM has a comfortable, centrally located office at Saahil Apartments, 1102/A/4B,Model Colony Lakaki Road, Opp. Kirloskar Bunglow, Shivaji Nagar ,Pune -411016. The office is equipped with all modern amenities and gadgets to complete any design, drafting, and publishing work in-house. In addition the state-of-art communication system facilitates immediate contact, interactions and data communication either from field to office or with any client around the globe. 12.8 COMPUTER CENTER:

SGM Computer center attached with various gadgets can rapidly process and store data. Computer is equipped with latest and custom-built software for designing and detailing equipments, Process flow diagram, Layout, drawings etc. Word processors and printing devices ensure quality production of any document or report. Internet facility is provided to all of employees in order to let them upgrade their knowledge and self search answer to their queries. 12.9 REFERENCE LIBRARY:

SGM maintains a library consisting of reference books, journals, papers, articles, publishers, reports and other such comprehensive study material. Continuous up-gradation of knowledge in the chosen area of business is a regular activity and every employee is trained and encouraged to do so. Latest edition of Handbooks on environmental, chemical, civil, mechanical, electrical engineering have been made available. Additional reference books on legal, management, communication and computers are also available here. Copies of environment protection act, notifications issued by MoEF are carefully preserved and referred. In addition books on specialized knowledge of functional areas as specified by QCI / NABET for example Air pollution, water pollution, land use, ecology and biodiversity, solid waste management etc are provided.


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SGM Corporate Consultants Pvt. Ltd (Now, M/s. SGM Enviro (I) Pvt. Ltd.) is accredited by QCI-NABET as an Environmental Consultant.

Figure 12.1: Copy of Accreditation


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Functional area experts and assistance to FAE involved in the EIA study for “M/s Shree Narmada Khand Udyog Sahakari Mandli Ltd. At- Dharikheda, P/o – Timbi, Taluka – Rajpipla (Nandod), District – Narmada, Gujarat, India ” is as follows:

Table 12.1: List of Experts

Sr. No.

Name of Technical Staff Member(s)

Educational Qualification

Sectors Approved/ Functional Area Expert

Experience Remarks Signature

1. Prof. Baban B. Gunjal

M.Tech (Dairy & Food Engg.)

Sectors Approved 1)Sugar Industry (25) 2) Distilleries (22) 3)Thermal Power Plant (Co-gen) (4)

37 Years i)1977-1987 yrs. as a Teaching/Professor ii) 1987- 1992yrs. as a Process Engineer iii) 1992-2007yrs. as a head Env.Sci.& Alcohol Technology In SGM i)2008-Till date as a EIA Co-Ordinator in sectors (25), (22), (4)

2. Dr. Mrs. Rekha Thakre

M.Sc. Botany Ph.D. (Botany)

Sectors Approved 1) Mining of Mineral Including Opencast/Underground mining (1) 2)Thermal Power Plant (4) 3)Cements Plants (9) 4) Metallurgical Industries (8)

41 Yearsi) 1969 to 2006 yrs. In NEERI Scientist In SGM ii) 2010 to to till date as a EIA Coordinator in Sectors (1), (4), (9), (8) iii) FAE in 1)Ecology& Biodiversity (EB) 2) Soil conservation (SC)

3. Mr. Somnath V. Deshpande

B.E.(Chemical) PG Diploma Industrial Safety PG Diploma( Fire Safety)

Sectors Approved - Synthetic Organic Chemicals (21) Functional Area Expert in – 1)Risk assessment & hazard management (RH) 2. Solid Waste and Hazardous Waste Management (SWM) 3. Air Pollution Monitoring, Prevention & Control (AP)

47 Years i) 1971-2000 yrs. Safety officer in a E.H.S Dept. ii)2000-2010 yrs. HAZOP, EIA Proprietor in a E.H.S Dept. In SGM i) 2007-Till date as a EIA Co- ordinator in sector (21) ii) Functional Area Expert in RH, SWM, AP.


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4. Mr. R. C. Katdare M. Tech. (Environmental Engineering) Persuing Ph.D in Soil Erosion

Functional Area Expert in 1. Water Pollution Monitoring, Prevention and Control (WP) 2. Land Use (LU ) 3. Hydrology & Ground Water (HG)

36 Years i) 1979 to 2007 yrs. as assistant/ Deputy Engineer ii) 2007- 2012 as a Teaching in Engg. College In SGM i)Dec 2012- till date as an FAE in WP, LU, HG

5. Dr. Adam M. Shikalgar

M. Phil (Economics) Ph. D (Economics)

Functional Area Expert in Socio-Economics (SE) “Cat- B”

38 Years i) 1977 to 2010 yrs as a Professor in Economics Dept. In SGM i) 2010- Till date as an Functional Area Expert in SE “Cat- B”

6. Mr. Sourabh Singh Jaiswar (Empanelled Expert)

M. Tech. (Environmental Engineering)

Sectors Approved 1.Building & Large Construction Projects (38) Functional Area Expert in 1.Water Pollution Control (WP) 2. Noise (N) 3. Solid & Hazardous Waste Management (SWM)

8 Years i) 2006 – 2011 as a Env. Engineer & Sr. Manager in EIA & projects In SGM i) 2012-Till date in SGM as a EIA Coordinator in Sector (38) ii) FAE in WP, N, SWM

7. Ashwini B. Kolekar B.E. Environmental Functional Area Associatet in 1. Solid & Hazardous Waste

Management (SWM) 2. Air Pollution Monitoring, Prevention & Control (AP)

2.6 Years i) 2015-2016- as Functional area associate in AP & SHW In SGM i) 2016 to till date as Functional area associate in AP & SHW

8. Surekha B. Ugale M.Sc Env. Sci - 4 Years i) 2014-2017 as Team Member In SGM ii) 2017 to till date as Team Member


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12.10 COLLABORATION WITH LABORATORY: S G M Corporate Consultants Pvt. Ltd. is engaged with Environmental services as well as doing work of Environmental Clearance under various Environmental Laws, thereby requiring the laboratory for the purpose of EIA monitoring and analysis . S G M Corporate Consultants Pvt. Ltd. has done all the lab work through M/s. Green Cirle Inc, Vadodara which is the NABL & MoEF, Govt. of India approved laboratory. A copy of NABL accreditation of M/s. Green Cirle Inc, Vadodara is shown in figure 12.2. Green circle inc.has well equipped ‘Sampling & Testing Laboratory’ located in Vadodara, to fulfill requirements of various Industries in the field of Testing.The laboratory has an Experienced and Qualified team of technicians, with all relevant Testing with all sophisticated Instruments. The detailed scope of its services in the field of Testing is enclosed for your perusal. The Laboratory is Ministry of Environment & Forest (MOEF) recognized & NABL approved environmental laboratory which is Certified from ISO 9001:2008, ISO 14001:2004 & OHSAS 18001:2007.

Figure 12.2: copy of NABL accreditation of M/s. Green Cirle Inc, Vadodara

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