ENVIRONMENTAL IMPACT ASSESSMENT REPORTenvironmentclearance.nic.in/writereaddata/EIA/31122014... · 2014-12-31 · ENVIRONMENTAL IMPACT ASSESSMENT REPORT Molasses based30KLPD Distillery

ENVIRONMENTAL IMPACT ASSESSMENT

REPORT

Molasses based30KLPD Distillery unit of

Udagiri Sugar and Power Limited

Village Bamni (Pare), Taluka Khanapur, District Sangli

Prepared By

VASANTDADA SUGAR INSTITUTE

Manjari (Bk), Pune, Maharashtra 412 307

Telephone: (020) 2690 2100, 2690 2343/7 Fax (020) 26902244

Web Site: www.vsisugar.com

*Accredited by QCI/NABET (Provisional) for EIA consultancy services and Recognized

R & D Center by Department of Scientific and Industrial Research DSIR), Ministry of Science and Technology,

Government of India and P.G. Center by ‘University of Pune’

October 2014

http://www.vsisugar.com/

EIA Report: New Molasses based Distillery project Udagiri Sugar & Power Ltd; Dist. Sangli, Maharashtra

i


ii


iii


iv

POINT WISE COMPLIANCE OF TERMS OF REFERENCE (TOR)

Sr.

No.

Terms of reference Compliance

1 Executive summary of the project Prepared and Bound

Separately and submitted

with EIA Report

2 Justification of the project Chapter I page No 2.1

3 Detailed break-up of the land area along with latest photograph

of the area

Chapter II page No 2.4

,Photographs after Chapter II

4 Present land use based on satellite imagery and details of land

availability for the project along with supporting document

Chapter-III

5 Details of site and information related to environmental setting

within 10 km radius of the project site

Chapter-III

6 Information regarding eco-sensitive areas such as national

park/wildlife sanctuary/ biosphere reserves within 10 km radius

of project area

Chapter-III

7 Total cost of the project along with total capital cost and

recurring cost/annum for environmental pollution

control measures

Chapter-II

Page No-

Chapter VI

Page no-

8 A copy of lease deed or allotment letter, if land is already

acquired

NA

Land is already available in

existing complex break up

for ;and utilization explained

in


v

Sr.

No.


Chapter II.

Page-2.3

9 List of existing distillery units in the study area along with their

capacity and sourcing of raw material

Chapter III

Table 3.18

10 Layout maps indicating existing unit as well as proposed unit

indicating storage area, plant area, greenbelt area, utilities etc

Chapter II

Page No 2.6

11 Details of proposed products along with manufacturing capacity Chapter –II

Page No, 2.4

12 Number of working days of the sugar unit, distillery unit and

CPP

Chapter -II

Page No, 2.4

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

materials including - If molasses based distillery, then give

source and quantity available for

molasses

Chapter -II

Page No, 2.14

14 Manufacturing process details of sugar, distillery and CPP along

with process flow chart

Chapter -II

Page No, 2.7

Page no- 2.22

Page no – 2.23

15 Sources and quantity of fuel (rice husk/bagasse/ coal etc.) for

the boiler. Measures to take care of SO2 emission. A copy of

Memorandum of Understanding (MoU) signed with the coal

suppliers should be Submitted.

Chapter II

Page no- 2.1, 2.24

Chapter IV


vi

Sr.

No.


Page No- 4.4, 4.4

Chapter VII

Page no- 7.3

16 Storage facility for raw materials, prepared alcohol, fuels and

fly ash

Chapter II

Page no-2.14

Chapter VIII

Page no- 8.6

Chapter VII

Page no-7.3

17 Action plan for ambient air quality parameters as per NAAQES

Standards for PM10, PM2.5, SO2 and NOX as per GSR 826(E)

dated 16th November, 2009

Chapter VII

Page No- 7.5,

18 One season site-specific micro-meteorological data using

temperature, relative humidity, hourly wind speed and

direction and rainfall and AAQ data (except monsoon) for

PM10, PM2.5, SO2, NOX , CO and HC (methane &non methane)

shall be collected. The monitoring stations should take into

account the pre-dominant wind direction, population zone and

sensitive receptors including reserved forests. Data for water

and noise monitoring should also be included

Chapter III

Page No-

19 Mathematical modeling for calculating the dispersion of air

pollutants and ground level concentration along with emissions

from the boiler’s stack

Chapter IV

Page No-


vii

Sr.

No.


20 An action plan to control and monitor secondary fugitive

emissions from all the sources

Chapter-VI

Page No,

21 An action plan prepared by SPCB to control and monitor

secondary fugitive emissions from all the sources

Chapter VI

22 Details of boiler and its capacity. Details of the use of steam

from the boiler

Chapter –II

Page No-

23 Ground water quality around proposed spent wash storage

lagoon and the project area

Chapter III

Page no-

24 Details of water requirement, water balance chart for existing

unit as well as proposed expansion (as applicable). Measures

for conservation water by recycling and reuse to minimize the

fresh water requirement

Chapter –II

Page No- 2.17

25 Source of water supply and permission of withdrawal of water

from Competent Authority

Chapter –II

Page No- 2.17

Photocopy of water

permission is in process copy

of application attached as an

annexure no-

26 Proposed effluent treatment system for grain/molasses based

distillery (spent wash and spent lees) along with utility

wastewater including CPP/Co-gen Unit (wherever applicable)

as well as domestic sewage and scheme for achieving zero

discharge. Details of treatment of effluent generation from

sugar unit

Chapter II

Page no -2.22 2.23, 2.24

27 Spent wash generation should not exceed 8 KL/KL of alcohol Chapter II


viii

Sr.

No.


production. Details of the spent wash treatment for molasses

based distillery based distillery

Page no-2.18

28 Capacity for spent wash holding tank and action plan to control

ground water pollution

Chapter II

Page no-2.31

Chapter VII

Page no- 7.7, 7.8, 7.9, 7.10

29 Layout for storage of bagasse/biomass/coal Chapter II

Page no-2.7

30 Capacity for spent wash holding tank and action plan to control

ground water pollution

Chapter II

Page no-2.31

Chapter VII

Page no- 7.7, 7.8, 7.9, 7.10

31 Dryer shall be installed to dry DWGS NA

32 Layout for storage of rice husk/biomass/coal Chapter II

Page no-2.7

33 Details of solid waste management including management of

boiler ash

Chapter II

Page no-, 2.24,

Chapter IV

Page no-4.12

Chapter VII

Page no- 7..4, 7.16,


ix

Sr.

No.


34 Risk assessment for storage and handling of alcohol and

mitigation measure due to fire and explosion and handling

areas

Chapter VIII

Page no- 8.6

35 Action plan for development of green belt over 33 % of the

total project area within plant premises with at least 10 meter

wide green belt on all sides along the periphery of the project

area, in downward direction, and along road sides etc

Chapter VII

Page no- 7.6

36 List of flora and fauna in the study area Chapter III

37 Noise levels monitoring at five locations within the study area Chapter III

38 Detailed Environment management Plan (EMP) with specific

reference to details of air pollution control system, water &

wastewater management, monitoring frequency, responsibility

and time bound implementation plan for mitigation measure

should be provided

Chapter VII

39 EMP should also include the concept of waste-minimization,

recycle/reuse/ recover techniques, Energy conservation, and

natural resource conservation.

Chapter VII

Page 7.19

40 Action plan for rainwater harvesting measures at plant site

should be included to harvest rainwater fromthe roof tops and

storm water drains to recharge the ground water

Chapter VII

Page no- 7.19

41 Details of occupational health surveillance programme Chapter VII

Page no-7.20

42 Details of socio-economic welfare activities Chapter X

Page no- 10.2


x

Sr.

No.


43 Transportation of raw materials and finished products for the

project (proposed/expansion) in respect of existing traffic, type

of vehicles, frequency of vehicles for transportation of

materials, additional traffic due to proposed project, parking

arrangement etc

Chapter IV

Page no- 4.5

Chapter VII

Page no- 7.5

44 Action plan for post-project environmental monitoring Chapter VII

Page no- 7.21

45 Corporate Environmental Responsibility

Chapter VII

Page no- 7.6

46 a) Does the company have a well laid down Environment Policy

approved by its Board of Directors? If so, it may be detailed in

the EIA report

NA

b) Does the Environmental Policy prescribe for standard

operating process/procedures to bring into focus any

infringement / deviation / violation of the environmental or

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

report.

NA

c) What is the hierarchical system or Administrative order of

the company to deal with the environmental

NA

d) Does the company have a system of reporting of non

compliance / violations of environmental norms to the Board of

Directors of the company and / or shareholders or stakeholders

at large? This reporting mechanism should be detailed in the

EIA report

NA

47 At least 5 % of the total cost of the project should be

earmarked towards the Enterprise Social Commitment based


xi

Sr.

No.


on Public Hearing issues and item-wise details along with time

bound action plan should be prepared and incorporated.

49 Total capital cost and recurring cost/annum for environmental

pollution control measures

Chapter II

Page no- 2.5, 2.20

Chapter VII

Page no- 7.27

50 Expansion/modernization proposals NA

New Project

i) Copy of all the Environmental Clearance(s) including

Amendments thereto obtained for the project from

MOEF/SEIAA shall be attached as an Annexure. A certified

copy of the latest Monitoring Report of the Regional Office

of the Ministry of Environment and Forests as per circular

dated 30th May, 2012 on the status of compliance of

conditions stipulated in all the existing environmental

clearances including Amendments should be provided. In

addition, status of compliance of Consent to Operate for the

ongoing I existing operation of the project from SPCB shall be

attached with the EIA-EMP report

NA

New Project

ii. In case the existing project has not obtained environmental

clearance, reasons for not taking EC under the provisions of

the EIA Notification 1994 and/or EIA Notification 2006 shall

be provided. Copies of Consent to Establish/No Objection

Certificate and Consent to Operate (in case of units

operating prior to EIA Notification 2006, CTE and CTO of FY

2005-2006) obtained from the SPCB shall be submitted.

Further, compliance report to the conditions of consents

NA

New Project


xii

Sr.

No.


from the SPCB shall be submitted

51 Any litigation pending against the project and / or any direction

/ order passed by any Court of Law against the project, if so,

details thereof

No any


i

CONTENT OF REPORT

CHAPTER PARTICULARS PAGE

NO

I INTRODUCTION

1.1 Purpose of the study and report 1.1

1.2 Rational of the study 1.1

1.3 Project proponent and Project 1.1

1.4 Project 1.2

1.5 Import ants of the project 1.2

1.5.1 Scenario for India 1.4

1.5.1.1 Industrial alcohol 1.4

1.5.1.2 Potable alcohol 1.5

1.5.1.3 Demand and supply gap 1.5

1.6 Structure of the report 1.6

II PROJECT DESCRIPTION

2.1 Introduction 2.1

2.2 Selection of site 2.1

2.3 Technology and process description 2.3

2.3.1 Continuous process 2.3

2.3.1.1 Propagation 2.5

2.3.1.2 Co2 Scrubber and recovery 2.5

2.3.1.3 Yeast recycling 2.5

2.3.1.4 Fermentation parameters (Typical) 2.6

2.3.2 Pressure vacuum distillation 2.6

2.3.2.1 Benefits of pressure vacuum distillation 2.7

2.3.2.2 Process of manufacture of extra neutral alcohol (ENA) 2.7

2.3.3 Product details 2.7

2.4 Resource/ Infrastructure requirement 2.8

2.4.1 Land 2.9

2.4.2 Raw material: Molasses 2.9

2.4.3 Steam 2.10

2.4.4 Water requirement 2.11


ii


NO

2.4.5 Power 2.13

2.4.6 Human resource 2.13

2.5 Effluent treatment 2.16

2.5.1 Spent wash 2.16

2.5.1.1 Primary treatment: Biomethanation 2.16

2.5.1.2 Microbiology and Biochemistry of Biomethanation process 2.17

2.5.1.3 Steps of reaction 2.17

2.5.1.4 Utilization of biogas 2.18

2.5.1.5 Biocomposting 2.18

2.5.1.5.1 Operational details 2.19

2.5.1.5.2 Windrow 2.19

2.5.1.5.3 Culture inoculation 2.19

2.5.1.5.4 Aeration 2.20

2.5.1.5.5 Effluent spraying 2.20

2.5.1.5.6 Merging of windrows 2.20

2.5.1.5.7 Curing in Heaps 2.20

2.5.1.6 Requirements for composting 2.22

2.5.1.6.1 Holding of spentwash 2.22

2.5.1.6.2 Compost site preparation 2.22

2.5.2 Treatment for spentlees and condensate from MEE 2.25

2.5.2.1 Pre-treatment 2.25

2.5.2.2 Secondary treatment 2.25

2.5.2.2.1 Anaerobic Filter 2.26

2.5.2.2.2 Biological (Aerobic) treatment 2.26

2.5.2.2.3 Secondary Clarifier 2.26

2.5.2.2.4 Disinfection 2.27

2.5.2.2.5 Sludge Disposal System 2.27

2.5.2.3 Tertiary treatment 2.27

2.5.3 Advantages of treatment scheme 2.27


iii


NO

2.6 Green belt development 2.28

III BASELINE ENVIRONMENTAL STATUS


3.2 Description of site and study area 3.3

3.3 Baseline environmental conditions 3.5

3.3.1 Climate and Rainfall 3.5

3.3.2 Temperature 3.6

3.3.3 Humidity 3.7

3.3.4 Cloudiness 3.7

3.3.5 Wind (Wind speed and Direction) 3.8

3.3.6 Special weather phenomena 3.8

3.3.7 Land Use patterns 3.9

3.3.7.1 Contour 3.13

3.3.8 Soil 3.13

3.3.9 Geology 3.14

3.3.9.1 Deccan Traps 3.15

3.3.9.2 Laterite 3.15

3.3.9.3 Alluvium 3.15

3.3.9.4 Lineaments 3.15

3.3.10 Geomorphology 3.16

3.3.10.1 Fluvial Origin 3.16

3.3.10.2 Structural Origin 3.16

3.3.11 Hydrology 3.17

3.3.11.1 Rivers and Dams 3.17

3.3.11.2 Baseline status for Water quality 3.19

3.3.12 Air environment 3.21

3.3.12.1 Methodology of monitoring 3.21

3.3.12.2 Observations 3.25

3.3.13 Noise environment 3.25

3.3.13.1 Method of Monitoring 3.26


iv


NO

3.3.13.2 Observations 3.27

3.3.14 Ecology and Biodiversity 3.28

3.3.14.1 Vegetation 3.28

3.3.14.2 Fauna 3.28

3.3.15 Socio-Economy 3.35

3.3.15.1 Demography (Census 2011) 3.35

3.3.15.2 Occupation Pattern 3.37

3.3.15.3 Agriculture and Cropping Pattern in the District 3.38

3.3.15.4 Power Station and Electricity Installations 3.39

3.3.15.5 Education Facilities 3.39

3.3.15.6 Medical Facilities 3.40

3.3.15.7 Industries 3.40

3.3.15.8 Transport Communication Network 3.42

3.3.15.9 Traffic Data 3.43

3.3.15.10 Banking Facilities 3.43

3.3.16 Seismic zone and other 3.43

IV POLLUTION SOURCES AND CHARACTERISTICS


4.2 Air pollution 4.2

4.2.1 Boiler emission 4.2

4.2.2 Ash generation estimates for the proposed project 4.3

4.2.3 Emissions of SO2 4.4

4.2.4 Other emissions from process 4.5

4.2.5 Pollution due to transportation activity 4.5

4.3 Noise environment 4.6

4.4 Effluent treatment 4.7

4.4.1 Spent less 4.9

4.4.2 Blow down water 4.10

4.4.3 Floor washing 4.10

4.5 Land/soil environment 4.10


v


NO

4.6 Solid waste sources 4.11

4.7 Hazardous waste 4.11

4.8 Biological aspects 4.11

4.9 Socio-economics 4.12

V ANALYSIS OF ALTERNATIVE TECHNOLOGY


5.2 Treatment and utilization options 5.1

5.2.1 Reboiler 5.2

5.2.2 Biomethanation 5.2

5.2.3 Reverse osmosis 5.3

5.2.4 Multiple effect evaporator 5.4

5.2.5 Mist evaporator 5.4

5.3 Treatment alternatives for condensate polishing unit (CPU) 5.6

5.3.1 Process description for membrane technology 5.6

5.3.2 Soil biotechnology process 5.6

5.4 Selection of alternative 5.7

VI ENVIRONMENTAL MANAGEMENT PLAN

6.1 Overview 6.1

6.2 EMP for construction phase 6.1

6.3 EMP for operation phase 6.10

6.3.1 Air environment management 6.10

6.3.2 Noise environment 6.10

6.3.3 Water environment 6.11

6.3.3.1 CREP guidelines for molasses based distillery 6.11

6.3.3.2

Spent lees and process condensate from ME Treatment unit 6.15

6.3.3.3 Important aspect 6.15

6.3.3.4

Operation and maintenance of other pollution control system 6.16

6.3.4 Land environment 6.16


vi


NO

6.3.4.1 Hazardous waste management 6.17

6.4 Green belt development 6.17

6.5

Concept of waste minimization, recycle/reuse/recover techniques, energy conservation, and natural resource conservation

6.20

6.6 Rain water harvesting 6.20

6.7 Safety, occupational health management 6.21

6.8 EMP for social environment 6.22

6.9 Environment monitoring program 6.22

6.9.1 Environment management cell 6.22

6.9.2 Water environment 6.23

6.9.3 Air environment 6.23

6.9.4 Other condition 6.23

6.9.5 Flow measurement 6.25

VII RISK ASSESSMENT AND RISK MANAGEMENT


7.2 The risk equation 7.1

7.3 Hazard identification 7.2

7.3.1 Mechanical hazard 7.2

7.3.1.1 Mechanical Injuries to Body parts 7.2

7.3.2 Electrical hazard 7.3

7.3.3 Thermal hazard 7.3

7.3.4 Hazard generated by noise 7.3

7.3.5 Hazard generated by vibration 7.4

7.3.6 Hazard generated by material /substances 7.4

7.3.7 Preliminary Hazard Analysis (PHA) 7.4

7.3.8 Qualitative Risk Assessment 7.4

7.4 Probable risk factor 7.7

7.4.1 Fire 7.7

7.6 Risk assessment: health 7.14


vii


NO

7.6.1 General assessment 7.14

7.6.2 Acute Health effect 7.15

7.6.3 Chronic Health effects 7.15

7.6.4 Recommended risk-reduction measures 7.16

7.6.5 Other methods to reduce exposure 7.17

7.7 Risk assessment: Environment 7.17


7.7.2 Acute ecological effect 7.18

7.7.3 Chronic ecological effect 7.18

7.7.4 Persistent in the environment 7.18

7.7.5 Bio-accumulation in aquatic organisms 7.18

7.7.6 Recommended risk – reduction measures 7.19

7.8 Risk assessment: Business 7.20


VIII DISASTER MANAGEMENT PLAN


8.2 Scope 8.1

8.3 Disaster management plan (DMP) Cycles 8.5

8.3.1 Pre Disaster situation 8.5

8.3.2 Response 8.7

8.3.2.1 Requirement for response phase 8.8

8.3.2.2 Situation identification/ assessment 8.9

8.4 Emergency management plan (on site) 8.10

8.4.1 Emergency organization structure 8.10

8.4.1.1 Designated persons functions 8.11

8.4.2 Shut downs in emergency 8.11

8.4.3 Personnel evacuation 8.12

8.4.4 Personnel accounting 8.12

8.4.5 Controlling disaster 8.12

8.4.6 Repairs and safety Implements 8.13


viii


NO

8.4.7 Medical treatment Arrangements 8.13

8.4.8 Training and rehearsals 8.13

8.4.9 Law and order 8.13

8.4.10 All clear signal 8.14

8.4.11 Special handling requirement 8.14

8.4.12 Equipment and facilities in emergency 8.14

8.4.12.1 Fire fighting Equipments 8.16

8.4.12.2 Emergency medical supplies 8.16

8.4.12.3 Training and drills 8.17

8.5 Off-site emergency management plan 8.17

8.5.1 Information to local authorities 8.17

IX PROJECT BENEFIT ANALYSIS

9.1 Project benefits: For the project proponent 9.1

9.2 Project benefits: For the local society 9.1

9.3 Benefits to country: Alcohol as a fuel 9.2

9.4 Environmental benefit analysis 9.3

X DISCLOSURE OF CONSULTANTS

10.1 Consultant 10.1

10.2 The Project Team OF EIA Study 10.2

LIST OF TABLES

TABLE NO. DESCRIPTION PAGE NO.

CHAPTER I

1.1 Consumption pattern of alcohol for the (Year 2013-14) 1.2

1.2 Total alcohol production of the world (Year 2009-2013) 1.4

1.3 Demand for alcohol in Maharashtra state 1.6

CHAPTER II

2.1 Silent features of the project 2.1


ix


2.2 Product and storage details 2.8

2.3 Project requirement 2.8

2.4 Land utilization details 2.9

2.5 Performance of the Mill for last two seasons 2.10

2.6 Projection on performance of the mill for next five years 2.10

2.7 Existing sugar mill boiler details 2.11

2.8 Water requirement (m3/day) 2.11

2.9 Electricity consumption 2.13

2.10 Estimated project cost 2.13

2.11 Capital investment on Environment Management 2.14

2.12 Schedule of approvals 2.15

2.13 Overview of environment management process 2.15

2.14 The composting techniques: Working Data 2.21

2.15 Mass balance (bio-compost) 2.21

2.16 General characteristics of bio-compost 2.21

2.17 CPU details 2.27

2.18 Details of Existing Green belt Around Industrial Complex 2.29

CHAPTER III

3.1 Classification of environment aspects 3.1

3.2 Environment setting of site and study zone in brief 3.2

3.3 Details of sampling locations 3.4

3.4 Rainfall data for Sangli District (mm) 3.6

3.5 Month wise Temperature and Humidity record for Sangli District 3.7

3.6 Mean Wind speed (km/hr) (Sangli District) 3.8

3.7 Special weather phenomena (Sangli District) 3.8

3.8 Land use/ land cover statistics of the 10 sq. km area 3.10

3.9 Results of soil analysis 3.14

3.9A Result of groundwater and surface water analysis 3.20

3.10 Ambient air monitoring observations 3.22

3.11 Noise monitoring Results(dB A) 3.27


x


3.12 List of Plant observed in study zone 3.29

3.13 Fauna: The animal life of study zone 3.32

3.14 Population details (for 10 Km. radius area and for the district) 3.35

3.15 Seasonal migration details 3.37

3.16 Cropping pattern observed for the Sangali disrict 3.38

3.17 Irrigation facilities 3.39

3.18 List of Sugar and distillery units in the Sangali district 3.41

3.19 The transport network summary 3.42

3.20 Traffic density on sugar factory approach road(avg. for peak hour) 3.43

CHAPTER IV

4.1 Analysis of Baggase 4.3

4.2 Model input data 4.5

4.3 Resultant concentrations due to incremental GLC`s 4.8

4.4 General noise levels 4.9

4.5 General characteristics of Raw Spentwash 4.11

4.6 Summary of impact assessment and environment management plan

proposed for the respective aspect

4.19

CHAPTER V

5.1 Merits and Demerits of each alternative 5.5

CHAPTER VI

6.1 Summary of EMP for: operation phase 6.3

6.2 Guidelines, formulated by Central Pollution Control Board (CPCB) new

Delhi, for Bio-Composting Plants

6.13

6.3 List of species recommended for greenbelt development 6.18

6.4 Flowering and foliage shrubs recommended for greenbelt 6.19

6.5 Human resources for environment management cell 6.22

6.6 Analysis of environmental parameters and its reporting schedule 6.24

6.7 Suggested schedule for maintenance of wastewater treatment unit 6.24

6.8 Format for water consumption reporting schedule 6.25

6.9 Format for Pollutant generation reporting schedule 6.26


xi


6.10 Format for pollutant disposal reporting schedule 6.26

6.11 Format for bio-composting unit reporting schedule 6.27

6.12 Estimated capital and recurring expenses for environmental management

programme

6.27

CHAPTER VII

7.1 Probability of occurrence of hazard 7.4

7.2 Severity-impact intensity 7.4

7.3 Risk assessment and mitigation measure 7.5

7.4 NFPA (National Fire Protection Association) Rating 7.7

7.5 Hazard warning information for ethyl alcohol 7.10

7.6 Summary of risk assessment and damage control 7.21

CHAPTER VIII

8.1 Various types of Hazards 8.2

8.2 The items recommended for emergency cupboard 8.15

8.3 List of emergency cupboard items 8.16

8.4 Emergency action code 8.18

CHAPTER IX

9.1 Staff requirement for the proposed distillery unit 9.1


xii

LIST OF FIGURES, IMAGES AND MAPS

NUMBER DESCRIPTION PAGE NO.

CHAPTER I

Figure 1.1 Site Location Map 1.3

CHAPTER II

Figure 2.1 Layout of sugar and distillery unit 2.3

Figure 2.2 Schematic of distillery process 2.5

Figure 2.3 Mass and water balance 2.12

Figure 2.4 Spentwash holding tank 2.23

Figure 2.5 Compost yard 2.23

Figure 2.6 Schematic for complete compost process 2.24

Figure 2.7 Process flow diagram for CPU 2.25

Figure 2.8 Schematic of green belt development 2.30

Figure 2.9 Decision making and its implementation hierarchy (from top to

bottom) and reporting hierarchy (from bottom to top) for

environmental conditions/compliances

2.31

CHAPTER III

Figure 3.1 Proposed project site 3.3

Figure 3.2 Satellite image of site and surrounding 3.4

Figure 3.3 Wind rose diagram 3.9

Figure 3.4 Land use/land cover map of 10 km radius study area 3.11

Figure 3.5 Contour map of 10 km radius study area 3.12

Figure 3.6 Types of soil observed in Sangli district 3.13

Figure 3.7 Geology of sangli district 3.16

Figure 3.8 Physiography of sangli district 3.17

Figure 3.9 Drainage pattern - sangli district 3.10

Figure 3.10 Drainage pattern for 10 km 3.19

Figure 3.11 Ambient air monitoring locations 3.21

Figure 3.12 Noise monitoring locations 3.26

Figure 3.13 Habitation map for 10km radius study zone 3.35


xiii

NUMBER DESCRIPTION PAGE NO.

Figure 3.14 Road and railway network map for study zone 3.44

Figure 3.15 Earthquake zones of Maharashtra 3.44

CHAPTER IV

Figure 4.1 Short term 24 hourly GLCs of particulate matter 4.7

Figure 4.2 Short term 24 hourly GLCs of So2 4.7

CHAPTER V

Figure 5.1 Treatment options for raw spentwash 5.1

Figure 5.2 Layout of SBT media 5.7

CHAPTER VI

Figure 6.1 Process flow diagram for CPU 6.15

Figure 6.2 Schematic of waste management 6.17

CHAPTER VIII

Figure 8.1 Probable cause of hazard 8.2

Figure 8.2 Schematic of disaster management process 8.4

Figure 8.3 Emergency organization structure 8.11

EIA Report: New Molasses based Distillery project

Udagiri Sugar & Power Ltd; Dist. Sangli, Maharashtra

LIST OF ABBREVIATIONS

Abbreviation Full Form

AA Absolute alcohol/ anhydrous alcohol

AP Air pollution

AQ Air quality

BOD Biological Oxygen Demand

COD Chemical Oxygen Demand

CPCB Central Pollution Control Board

CREP Corporate Responsibility For Environmental Protection

DG Diesel Generator

DO Dissolved Oxygen

EC Environmental Clearance

EIA Environmental Impact Assessment

EMP Environment Management Plan

ENA Extra Neutral Alcohol

EPA Environmental (Protection) Act

FAE Functional area expert

GLC Ground Level Concentration

SHE Safety, Health and Environment

HWMH Hazardous Waste (Management & Handling) Rules

ID Induced Draft

IMD Indian Meteorological Department

IMFL Indian Made Foreign Liquor

IS Indian Standard

KLD Kilo Liter Per Day

MINAS Minimal National Standards



Abbreviation Full Form

MOC Material of construction

MoEF Ministry Of Environment And Forests

MS Mild steel

MSDS Material Safety Datasheet

MTD Metric Ton Per Day

NAAQS National Ambient Air Quality Standard

OSHA Occupational Safety And Health Administration

PEL Permissible Exposure Limit

PM Particulate Matter

PPM Part per million

PPE Personal Protective Equipments

RM Raw material

RO Reverse Osmosis

RS Rectified Spirit

SPCB State Pollution Control Board

SPL Sound Pressure Level

SPM Suspended Particulate Matter

SS Suspended Solids

TCD Ton Crush per Day

TDS Total Dissolve Solid

TLV Threshold Limit Value

TPH Tons Per Hour

VSI Vasantdada Sugar Institute



LIST OF ANNEXURE

Number Description

I Site location map

II study zone of 10 km radius around proposed distillery site

III Layout of distillery with respect to sugar factory

IV NOC for proposed project by village gram-panchayat

V Factory registration certificate

VI water drawl permission of irrigation department to sugar factory

VII Consent to operate of existing sugar factory

VIII Approved terms of references

Chapter I



1-1

CHAPTER I

INTRODUCTION

1.1 PURPOSE OF THE STUDY AND REPORT

The prime objective of any EIA exercise is to identify and assess the impact of a project before its

implementation; so that necessary measures can be taken to prevent, control, mitigate or

minimize adverse impact in the planning stage itself. In view of this, the specific objectives of

this EIA study report are -

Understand the proposed activity thoroughly including allied activities

Understand the current environmental situation within 10km radius of the proposed

distillery site- by collection of baseline data on the environmental elements including air,

noise, water, land, ecology, geo and hydro-geology, climate and socio-economy.

Identify the probable sources of pollution that may arise from each stage of the project

processes

Assess the impact of the proposed activity on the surrounding environment

Prepare a comprehensive Environmental Management Plan (EMP) for the proposed

project and to ensure that the environmental quality of the surrounding region would be

preserved

To formulate a strategy for effective monitoring and identify any deviations in the

quality of environment after the project is in operation, which would help in evolving

measures to counter these

1.2 RATIONALE OF THE STUDY

According to the EIA notification (SO-1533) and its subsequent amendments, molasses based

distillery is placed under category ‘A’ and requires Environmental Clearance (EC) from the

Ministry of Environment, Forests and Climate Change (MoEFCC). Hence, the management of

Udagiri Sugar and Power Limited (USPL) has entrusted the job to Vasantdada Sugar Institute

(VSI), Manjari (Bk.), Pune.

1.3 PROJECT PROPONENT AND PROJECT

M/s. Udagiri Sugar and Power Ltd., (USPL) is one of the progressive sugar industries from south

Maharashtra. It is registered as a public limited company with registration number

U15424PN2010PLC136000 dated April 06, 2010 (factory license enclosed as annexure I). The

initial installed crushing capacity of the sugar factory was 2500 T.C.D. Its first crushing season

was in the year of 2012-13. Dr. Rahul Shivajirao Kadam is the chairman and chief promoter of

Chapter I



1-2

the project. After two successful seasons of the sugar mill, now the management is planning to

setup a molasses based distillery unit of 30KLPD.

1.4 PROJECT

Nature of the Project: New molasses based distillery

Size of the Project: 30 kilo litres per day (30KLPD)

Location of the Project: Within existing sugar factory at village Bamani (Pare),

Tal: Khanapur, Dist. Sangli, Maharashtra

Geographical Location 17°12'6.53"N and 74°35'40.43"E

Altitude 676 m above MSL

Nearest City/Town Vita town 10 km

Road Karad-Solapur state highway at 12km

National highway 4 at 50km

Railway Station Miraj about 85 km from the site

Air Port Karad about 50 km from the site

Chapter I



1-3

Figure 1.1: Site Location Map

Chapter I



1-4

1.5 IMPORTANCE OF THE PROJECT

The distillery industry today consists broadly of two parts; one, potable liquor and the industrial

alcohol including anhydrous ethanol for blending with petrol. The potable industry producing

Indian Made Foreign Liquor and Country Liquor has a steady but limited demand with a growth

rate of about 7-10 per cent per annum. Over the years the potable liquor industry has shown

remarkable results in the production of high quality spirits. Indian liquor industry is today

exporting a sizable quantity of Indian liquor products to other countries. The world alcohol

consumption pattern for different applications for the year 2013-14 is given in table 1.2.

Table 1.1: Consumption Pattern Of Alcohol For The Year 2013-14

Sr. No. Alcohol Consumption for (%)

1. Potable and Industrial 17.48

2. Fuel 82.52

The ethanol of commerce contains about five per cent water; hence, termed as "Hydrous

(water-containing) alcohol". If the last traces of water are removed, "Anhydrous alcohol" (water-

free or "absolute") is obtained, which is used to mix with petrol.

The world total ethanol production in the year 2011-12 was 102.58 Billion liters and major

consumption of alcohol was for fuel purpose. Many countries, including Brazil, USA, Canada,

Sweden and China have already started using anhydrous ethanol for blending with petrol. In

India, the Central Government has taken a policy decision to start using anhydrous alcohol (fuel

ethanol) for blending with petrol. Thus, it is expected that the demand of alcohol for fuel

purpose is going to increase in coming years.

Table 1.2: Total Alcohol Production Of World (Year 2009 To 2013)

Sr. No World Regions Years & Production in Million Liters

2013* 2012 2011 2010 2009

Total (for worlds

geographical regions)

103336 102589 102994 103838 90089

World’s top five alcohol producing countries

Chapter I



1-5

1 U.S.A. 50450 51800 54205 51538 42178

2 Brazil 25950 23540 22883 27963 26075

3 China 7900 8950 8600 8378 7317

4 India 2575 2342 2159 1850 1565

5 Canada 1950 1940 1670 1430 1370

* Projected production.

Source: - F. O. Licht’s World Ethanol and Bio-fuels Report, Vol. 11, No. 17, 07/05/2013.

1.5.1 Scenario for India

The Cabinet Committee on Economic Affairs (CCEA) of the Central Government has approved a

proposal for implementation of the ethanol blended petrol (EBP) programme in the country. As

a result, in January 2013 Petroleum Ministry floated a tender for supply of ethanol. As per the

tender ethanol requirement was 1404.10 million liters for 5 % blending for 20 States and 4 Union

territories and 315.20 million liters for Maharashtra for 10 % blending.

1.5.1.1 Industrial Alcohol

Ethyl alcohol is an important feedstock for the manufacture of chemicals. These

chemicals are primarily the basic carbon based products like Acetic Acid, Butanol,

Butadiene, Acetic Anhydride, Vinyl acetate, PVC etc. Figure 1.1 shows the different

important chemicals that could be made out of alcohol. The existing plants such as

synthetic rubber requiring large quantities of alcohol will grow to a larger capacity.

Acetic acid and Butanol needed in pharmaceuticals, paints and in other areas are

important industries as they are value added products.

The shortage of alcohol is widespread and it has hit most of the chemical, drugs and

other industries. The drug industry is also influenced by the scarcity of industrial

alcohol. Producers of insulin, antibiotics, tonics and several other essential bulk drugs

and finished formulations are unable to obtain their quota of industrial alcohol at

cheaper rate which is a vital raw material for them. Thus it follows that the supply of

industrial alcohol to chemical and drug units in the country will remain below normal for

some more time. In order to maintain proper rate of growth of industries, production of

alcohol must be increased.

1.5.1.2 Potable Alcohol

Chapter I



1-6

The use of alcohol for the purpose of potable liquor is as higher as its use for industrial

purposes. Alcohol is used for manufacture of country liquor consumed by common

masses. This is manufactured by diluting rectified spirit with water to different grades of

250 UP strength. Different varieties are produced by addition of flavors and are called

spiced liquors.

Good quality liquors are manufactured in a synthetic way to imitate Foreign Liquors like

Whisky, Brandy, Rum and Gin, which are called as Indian-Made-Foreign liquors (IMFL). It

requires alcohol of high purity. For this purpose, separate distillation plant to redistill

and purify Rectified Spirit is necessary. This alcohol is called as Extra-Neutral-Alcohol

(ENA). It is also useful for manufacture of cosmetics and perfumes. As a source of

income to the Government, the potable liquor units get an assured quota of alcohol.

1.5.1.3 Demand and Supply Gap

Based on information from various sources, it is anticipated that demand for alcohol in

the Maharashtra state, could be about 700-740million litres, as detailed in table 1.3.

Table 1.3: Demand for alcohol in the Maharashtra state

Industrial 200 - 240 million liters

Potable 150 –170 million liters

Fuel 330 million liters (For 10 % blending)

Total 700 – 740 million liters

During last few years, substantial quantity of alcohol (R.S., ENA and fuel ethanol) from

the country has been exported to mostly Africa and countries of South-East Asia. During

2013, about 230 million liters of alcohol was exported from India.

The demand of alcohol for industrial, potable & fuel alcohol in Maharashtra as well as in

whole country will increase significantly in coming years. The proposed 30 KLPD distillery

plant will contribute in fulfilling the alcohol and fuel ethanol requirement of

Maharashtra and neighboring deficit states.

Chapter I



1-7

In the present scenario, sugar industry is forced to explore the alternatives so as to

attain financial viability while producing sugar. Distillery is one such alternative, because

of the availability of molasses as a raw material, bagasse as a fuel, own power

generation ability and availability of the steam energy from own sugar factory.

Therefore, the management of the factory has planned to establish a 30KLPD molasses

based distillery within existing sugar factory premises.

1.6 STRUCTURE OF THE REPORT

The report comprises of 10 chapters, and the relevant supporting documents are in the

form of annexure. Executive Summary in English & Marathi is prepared and bound

separately.

Chapter I: Introduction

Chapter II: Project Description

Chapter III: Baseline Environment Study

Chapter IV: Environment Impact Assessment

Chapter V: Analysis of Alternative Technologies

Chapter VI: Environment Management Plan

Chapter VII: Risk Assessment and Risk Management

Chapter VIII: Disaster Management Plan

Chapter IX: Project Benefit Analysis

Chapter X: Disclosure of Consultants

Annexure

Chapter II


2- 1

CHAPTER II

PROJECT DESCRIPTION

2.1 INTRODUCTION

M/s. Udagiri Sugar and Power Ltd., (USPL) is one of the progressive sugar industries from south

Maharashtra. Its first crushing season was in the year 2012-13. The management of the sugar Mill is

planning to install a molasses based distillery unit to achieve effective utilization of available

resources such as molasses, bagasse, pressmud, land, boilers, and skilled manpower (partially), etc.

This chapter describes the material and resources requirements, manufacturing process as well as

preventive, control and mitigation measures on pollution aspect.

2.2 SELECTION OF SITE

The selection of site was mainly based on the following factors.

a. The existing sugar mill site complies with the guidelines for site selection of an industry

prescribed by Ministry of Environment and Forest (MoEF); i.e. the site is at safe distance

from river, highway, railway, ecologically sensitive sites, forest reserves, etc.

b. Proximity of raw material i.e. molasses bagasse and pressmud (useful for composting

activity)

c. Availability of infrastructure/facilities from own sugar unit such as steam, and electricity

d. Adequate land is available with the Mill for proposed distillery and its ancillary units such as

spent wash storage tanks, compost yard, effluent treatment plant, etc.

e. Other infrastructure and facilities such as road, rail connectivity, communication and

transport facilities, education, health centers, banks, etc. are available and adequate to

cater the needs due to the proposed project

f. Availability of technically skilled human resource

g. Ease of control over both sugar as well as distillery unit by one management and sharing

common facilities like land, workshop etc.

Table 2.1: Salient features of the project

Project New Molasses Based Distillery Unit of 30 KLPD

Proponent Public Limited industry

Project Concept

a) Qualitative Standards of Product

Rectified Spirit (RS) IS Grade-I, 323 (1959)

Extra Neutral Alcohol (ENA)

Chapter II


2- 2

Anhydrous Alcohol (AA): IS: 321 (1964)

Head Spirit IS-Grade - II, 323 (1959)

b) Products, by products and Estimated Production

Rectified Spirit

Impure Spirit OR

28.5 KLPD

1.5 KLPD

Extra Neutral Alcohol (ENA)

Impure spirit OR

28.2 KLPD

1.8 KLPD

Anhydrous Alcohol 30.0 KLPD

Fusel oil 60 liters per day (0.060KLPD)

Biogas ~11,500-12,000m3/day

Bio-compost 8750 per annum

d) Annual Operational Days 270

e) Spent wash generation (after

evaporation @120m3/day)

32,400 m3/Annum

f) Annual Press mud

requirement

16,200 MT(Consumption ratio 1:2.0 (Pressmud to

Spentwash)) and 45 day cycle

c) Effluent Treatment System Biogas (bio-methanation) followed by multi effect

evaporation followed by Bio-composting

Requirement

a) Raw Material - Molasses 32,400 MT per annum: Source: own sugar mill

b) Steam Max. 121 MT/day; Source: own sugar mill boiler

c) Bagasse as a Fuel Max. 55 MT/day Source: own sugar mill

d) Water requirement 350 m3/day (after recycling) Source; Pare minor reservoir

e) Electricity Max. 432 kWhr : source: captive

f) Land Total = 10.7 acres

For distillery, bio-methanation &

Evaporation

2.5 acres

Bio-composting unit storage lagoon 5.6 acres

Chapter II


2- 3

For green belt development 2.6 acres

g) Employment opportunities for 77 persons

Financial Aspect

Total Project Cost Rs 3842.00 lakhs

Capital Expenses on Environment Management Rs 1167.00 Lakhs

Figure 2.1: Layout of Sugar and Distillery units 2.3 TECHNOLOGY AND PROCESS DESCRIPTION

Proposed distillery unit is designed for continuous fermentation process.

2.3.1 Continuous Process

In this process fermentation and distillation is coupled to get a continuous supply of fermented beer

for the distillation column. Yeast is recycled. The advantage of the process is highly active yeast cells

initiate the fermentation rapidly and the alcohol yield is also much higher compared to the batch

process.

Molasses is the chief raw material used for production of alcohol. Molasses contains about 50% total

sugars, of which 30 to 33% are cane sugar and the rest are reducing sugar. During the fermentation,

Proposed Distillery,

Evaporation, storage

biomethanation and

compost yard Site

Chapter II


2- 4

yeast strains of the species Saccharomyces cerevisiae, a microorganism belonging to class fungi

converts sugar present in the molasses such as sucrose or glucose into alcohol. Chemically this

transformation for sucrose to alcohol can be approximated by the equation.

Thus, 180g of sugars on reaction gives 92g of alcohol. Therefore, 1MT of sugar gives 511.1 kg of

alcohol. The specific gravity of alcohol is 0.7934 hence; 511.1 kg of alcohol is equivalent to

511.1/0.7934 = 644.19 liters. During fermentation other by-products like glycerin, succinic acids etc.

are also formed from sugars. Therefore, actually 94.5% total fermentable sugars are available for

alcohol conversion. Thus, one MT of fermentable sugar will give only 644 x 0.945 = 608.6 liters of

alcohol, under ideal condition theoretically. Normally, only 88 to 90% efficiencies are realized in

Continuous type plant. Molasses containing 47% fermentable sugars gave an alcoholic yield of 283

liters per MT. Molasses, diluted with water to a desired concentration is supplied continuously to the

fermenter. Additives like urea and de-foaming oil are also introduced in the fermenter as required.

There is an automatic foam level sensing and dosing system for de-foaming oil. Every kilogram of

alcohol generates, about 290 kilocalories of heat. This excess heat is removed by continuous

circulation of fermented wash through an external plate heat exchanger called the fermenter cooler.

The fermenter temperature is always maintained between 32-34oC, the range optimum for efficient

fermentation. The yeast for the fermentation is initially developed in the propagation section. Once

propagated, yeast recycling and continuous aeration of the fermenter maintain a viable cell

population of about 350 to 500 million cells/ml. Fluctuations in the yeast count of +/- 20% have little

effect on the overall fermenter productivity. Yeast cell vitality, which is usually above 70% in times of

stress drop to 50% without affecting the fermentation.

Invertase

I) C12H22O11 + H2 2C6H12O6

Cane Sugar Glucose + Fructose

II) C6H12O6 Zymase 2C2H5OH + 2 CO2

180 2 x 46 + 2 x 44

Glucose/Fructose Ethyl alcohol Carbon dioxide

Chapter II


2- 5

Figure 2.2: Schematic of distillery process

2.3.1.1 Propagation

The propagation section is a feeder unit to the fermenter. Yeast, either Saccharomyees cereviseae or

Schizosaccharomyees pombe (the choice being determined by other process parameters, mainly the

downstream effluent treatment system) is grown in three stages. The first two stages are designed

for aseptic growth. Propagation vessel III develops the inoculum using pasteurized molasses solution

as the medium. This vessel has a dual function. During propagation, it serves for inoculum build-up.

When the fermenter enters the continuous production mode, propagation vessel III is used as an

intermediate wash tank. Propagation is carried out only to start up the process initially or after very

long shutdowns during which the fermenter is emptied.

2.3.1.2 CO2 Scrubber and Recovery

The carbon dioxide produced during fermentation is scrubbed with water in packed-bed scrubber, to

recover alcohol. The water from the scrubber is returned to the fermenter. In some industries, carbon

dioxide is captured by, scrubbing the fermenter off gas. A part of the wash is drawn into a separate

vessel and is aerated there. This external aeration allows the recovery of carbon dioxide un-

contaminated with air.

2.3.1.3 Yeast Recycling

Chapter II


2- 6

The yeast in the fermenter wash is removed as 45 to 55% v/v slurry, and is returned to the fermenter.

This feature ensures that a high yeast cell concentration is achieved and maintained in the fermenter.

Mature active yeast will be recycled so as to reduce the excess consumption of sugar by growing

yeast. Thus, it make available for ethanol production and ensuring high process efficiency.

2.3.1.4 Fermentation Parameters (Typical)

The pH of the fermenter is maintained within 4.0 to 4.8 usually by addition of any acid. The alcohol

concentration is maintained between 7.0 to 8.5 % v/v, unless a highly concentrate effluent is to be

produced. Conversion of sugar to ethanol is instantaneous and the residual sugar concentration is

maintained below 0.2% w/w as glucose. This usually corresponds to a residual reducing substances

concentration of 2.0 to 2.5 % w/w in wash. Weak Wash /Spent wash Recycling (Optional - depends

upon yeast strain)

Recycling of weak wash helps to maintain the desired level of dissolved solids in the fermenter, so

that an adequately high osmotic pressure is achieved. Osmotic pressure and the concentration of

alcohol in the fermenter, together keep off infections and minimize sugar losses. Weak wash recycling

reduces the quantity of effluent spent wash and reduces the process water requirement of the plant.

2.3.2 Pressure Vacuum Distillation

Vacuum distillation system consists of three to four distillation columns namely –

Analyzer column – Operated under vacuum.

Pre rectifier column – Operated under vacuum

Rectifier cum Exhaust Column – Operated under pressure

Fusel oil concentration column may be added to improve quality of alcohol further.

Fermented wash is preheated in fermented wash pre-heater and fed at the top of the analyzer

column, analyzer column is fitted with thermosyphon reboiler. Top vapors of analyzer column are

sent to pre-rectifier column. Rest of the fermented wash flows down and is taken as spent wash from

analyzer column bottom. Pre-rectifier bottom liquid is preheated with spent-lees and fed to rectifier

cum exhaust column.

Low boiling impurities are concentrated in the pre-rectifier column. A top draw is taken out as

impure alcohol from the pre-rectifier column. The bottom of pre-rectifier column is sent to rectifier

feed tank. Rectifier exhaust is operated under pressure and heats analyzer column through reboiler.

Alcohol is enriched towards the top and is drawn out as Rectified spirit (RS). Fuel oil build-up is

avoided in the Rectifier column by withdrawing outside streams of fuel oil. These are sent to fuel oil

concentration column from where the fuel oil is sent to decanter for further separation. The fuel oil

wash water is recycled back to the column. A top draw is taken out as impure alcohol from the top of

fuel oil column & pre-rectifier column.

Chapter II


2- 7

2.3.2.1 Benefits of Pressure Vacuum Distillation

The technology advantages are as follows.

Since the analyzer column operates under vacuum, the formation of by-products such as

‘acetyl’ may minimize there by improvement in quality of alcohol.

Pre-rectification column ensure removal of unwanted substances and also reduces load of

lower boiling volatile compounds passing on to Rectifier cum exhaust column.

The chances of scaling due to invert solubility of certain precipitating inorganic salts are

minimized in vacuum distillation.

Vacuum distillation requires low steam consumption i.e. 2 Kg/lit. for Recited Spirit and around

3.2 Kg/lit. for export quality ENA.

2.3.2.2 Process of Manufacture of Extra Neutral Alcohol (ENA) and AA

Extra neutral alcohol is manufactured from rectified spirit. The impurities in rectified spirit are

reduced to considerable extent by properly diluting and redistilling the spirit. The impurities like

aldehydes, acids, esters, higher alcohol's are minimized by controlled condition and tapping

impurities at appropriate points during distillation.

The main stages in the manufacture of extra neutral alcohol are -dilution of rectified spirit with

filtered soft water in the ratio 1:3 to 1:4.The diluted spirit may be treated with potassium

permanganate. Separation of low boiling impurities takes place in purifying column, separation of

esters and other volatile impurities in Rectifying column and concentration of alcohol. Removal of

excess water takes place at exhaust column. Concentration of fuel oil & their removal takes place in

the fuel oil concentration column. Concentration of low boiling impurities & their removal takes place

in the head concentration column.

Fuel ethanol is an important product required by industry. As per IS specification it is nearly 100%

pure or water free alcohol. In order to extract water from alcohol it is necessary to use some

dehydrant or entrainer, which is capable of separating, water from alcohol. The various processes

used for dehydration of alcohol are as follows

I) Azeotropic Distillation

II) Molecular Sieve Dehydration (MSDH)

III) Pervaporation / Vapour permeation system.

From these, the USPL has planned to select molecular sieve dehydration (MSDH) technology.

2.3.3 Product detail

Production of rectified spirit (RS) conforming to Indian Standards 323/1959, Grade-I will be minimum

90 % of total and impure alcohol will be maximum 10%. For export purpose alcohol of 96 % v/v is

Chapter II


2- 8

required. During the process of distillation, a by-product known as fusel oil separates out. It is a

mixture of higher alcohols. The production of fusel oil is in the range of 0.2 – 0.3 % of alcohol

production depending upon quality of molasses and fermentation operations.

Table 2.2: Product and storage details

# Particulars Production

(KL/Day)

Receiver

capacity (m3)

Storage

capacity (m3)

Make

1.

Rectified Spirit 28.5 KLPD 60 x 3 600x1 MS

Impure Sprit OR 1.5 KLPD 10x3 600x1 MS

2. E.N.A. 28.2 KLPD 60x3 600x3 MS

Technical alcohol OR 1.8 KLPD 10x2 MS

3 Anhydrous alcohol 30.0 KLPD 60x3 600x2 MS

4. Fusel oil 60L per day 10x1 MS

2.4 RESOURCE/INFRASTRUCTURE REQUIREMENT Table 2.3: Project requirements

Sr.

No.

Particular Consumption/

Production (per day)

Remark

A. Raw Materials, Consumption

1. Molasses, MT 120 MT Basis 45 % of F.S.

Source: Attached Sugar Mill

upto 27,000 MT/annum; remaining from

the nearby sugar mills

B. Chemicals, Consumption

1. Nutrients (N,P) 15 kg Stored in Fermentation House

Source: Local Market at Vita,

Khanapur/Karad/Sangli

2. Turkey Red Oil

150 kg Source: Local Market

Local market at Vita, Khanapur/Karad/Sangli

C. Utilities, Consumption

1. Fuel: Bagasse

Biogas

Max. 55MT

~11,500m3/day

Source: Attached Sugar Mill

Source: spentwash from distillery

2. Water 350 m3 Source: Pare minor reservoir

Permission from concerned department is in

process

Chapter II


2- 9

2.4.1 Land

The proposed distillery unit will be within the existing sugar mill premises, which is located at village

Bamani (Pare), Khanapur tahsil of Sangli district. The sugar mill is having total 72 acres of land, out

of which approx 35 acres of land is utilized by sugar mill and its ancillary units. From the remaining

land 10.5 acres will be utilized for distillery, its ancillary units including greenbelt. Surplus land is kept

reserved for future developments.

Table 2.4: Land utilization details

Sr.

No

Particulars of land utilization

Area

(in Acres)

Area allocation for proposed Distillery

1 For distillery, Bio-methanation , Evaporation 2.5

2 Storage lagoon and Bio-compost yard 5.6

3 Green Belt 2.6

Total area for distillery unit 10.7

Total land available with the sugar mill 72.00

*Actual compost yard area may vary subject to type of machine to be used, the mentioned

figure indicates provisions

2.4.2 Raw material: Molasses

The total quantity of molasses required per annum is around 32,400 MT. While estimating the

requirement fermentable sugar of 45-47% was considered; this usually yields about 280L of spirit per

MT of molasses. The mill has estimated a molasses production of 27,000 MT for the season of 2014-

15 (refer table 2.5- These estimates are based on the cane development programme of the mill, sugar

mill modernization planned by the management to achieve higher efficiency and existing cane

availability. Remaining quantity of molasses of about 5,400 MT will be procured from nearby sugar

mills. There are 18 sugar mills in Sangli district, of which only 7-8 factories are having distilleries. In

the adjacent district Kolhapur, there are 22 factories of which 10-11 are having distilleries. This

indicates, the distillery could get the deficit molasses from the nearby sugar mills.

Storage: At present, the mill has one mild steel tank of 7,000 MT capacity. The mill has decided to

install one more MS tank of 10,000MT capacity. Thus, capacity of molasses storage will be 17,000MT.

3. Steam, MT Max. 121 MT/day Source: Attached Sugar Mill (during season)

4. Power Max. 432 kwhr Source: Attached Sugar Mill

Chapter II


2- 10

A two months stored molasses is ideal for fermentation. Molasses will be pumped through pipeline

from the sugar mill storage tank to the distillery day molasses tank. The molasses storage will be as

per the CPCB guidelines.

Table 2.5: Performance of the mill for last two seasons

Sr.

No.

Particulars Season 2012-13* 2013-14

1 Cane Crushed (Lac MT) 2.13 402,363

2 Sugar Produced (Lac Qtls.) 2.51 4.92

3 Recovery % Cane 11.81 12.23

4 Molasses Produced (MT) 10,670 17,905

5 Press-mud produced (MT) 7662 15,169

*first/trial season Table 2.6: Projections on performance of the mill for next five years

Sr.

No.

Particulars Seasons

2014-15 2015-16 2016-17 2017-18 2018-19

1 Cane to be Crushed (Lac MT)

6.00 6.00 6.00 6.00 6.00

2 Sugar to be Produced (Lac Qtls.)

7.20 7.20 7.20 7.20 7.20

3 Recovery % Cane 12.00 12.00 12.00 12.00 12.00

4 Molasses to be Produced (MT)

27,000 27,000 27000 27000 27000

5 Press-mud to be produced (MT)

24000 24000 24000 24000 24000

2.4.3 Steam

The steam requirement of the proposed distillery will vary from 5.5 to 6.5 MT/h depending on the

final product (for Multi-pressure option). This requirement will be fulfilled from sugar mill boiler. At

present the mill is having one Bagasse fired boiler of 75 TPH operated at 72.5kg/cm2 pressure and

515oC temp. Presently it consumes approx 30TPH of bagasse and supplies steam to cogeneration

unit. Exhaust low pressure steam from the turbine is used in sugar unit. Now, additionally it will be

used for distillery operations. The estimated fuel requirement for distillery is 2.29TPH, however, no

additional fuel will be required for the distillery during season. The same boiler will be operated at

lower capacity to fulfill the requirement of cogeneration and distillery unit during off-season of sugar

mill.

Chapter II


2- 11

Table 2.7: Existing sugar mill boiler details

Particular Specification

Boiler capacity 75 TPH

steam pressure and temperature 72.5 kg/cm2 / 515oC

Fuel type Bagasse - required @2.3TPH

Air pollution control equipment Electro Static Precipitator (ESP)

Boiler attached to Stack

Stack height and Diameter 72 m / 3. 0 m

Multi-Pressure Vacuum Distillation

a. F. Wash to rectified spirit (RS)-2.2 Kg/liter; F. Wash to ENA- 3.2 Kg/liter

b. MEE ~3.0MT/h

2.4.4 Water Requirement

Initial fresh water requirement will be 600m3 per day. This requirement will be minimized by re-

circulating 255 cum/day. This includes process condensate 180 m3/day and Spineless 75m3/day (refer

water balance figure 2.3). After recirculation of the treated water from condensate polishing unit net

water requirement will be 345 m3 per day. Source of water is Pare minor reservoir. Water drawl

permission issued by irrigation department, Government of Maharashtra is available with the Mill (for

the sugar unit). Permission for additional water drawl for distillery is under process. Existing water

storage tank of 10,000 m3 will be used by proposed distillery. Thus, sufficient quantity of water can

be made available to the distillery from the water reservoir.

Table 2.8: Water Requirement (in m3/day)

Particulars Intake Consumption And Losses

Generated Effluent

Recycle and Reuse

Daily Net requirement

Industrial Process

360.0 60.0 300.0 155.00 205.00

Cooling Purpose

225.00 125.00 100.00 100.00 125.00

Domestic 10.0 03.00 7.00 00 10.0

Other & Gardening

05.0 05.0 00.0 00.0 05.00

Total 600.00 193.00 407.00 255.00 345.00

Chapter II


2- 12

Figure 2.3: Mass and water balance

Over all loss 90m3/day by

evaporation etc.

Process Mass Balance for 30 KL Distillery

Molasses

75 m3

Fresh water 270 m3/day

for dilution & CO2

scrubber

Fermentation

Distillation

Bio-methanation

Multi effect

evaporation

Bio-composting

Steam 121MT Sugar

From Boiler

Fresh Soft water

90m3/day

Cooling

water

Press mud

Steam 121 MT

RS + Impure Spirit 30 KL

Spent lees 75 m3/day

Process

condensate

180 m3/day

Condensate polishing Unit

255 m3/day

This water recycles to Fermentation

and cooling tower makeup water

Spent wash 300 m3/day

Recycle as CT makeup

255 m3/day

CO228 m3

Yeast Sludge 2.0

m3/day

Concentrated Spent wash 120

m3/d@ 12-15% solid

BMSW 300 m3/day

Chapter II


2- 13

2.4.5 Power

Total power requirement for fermentation, distillation, ena section, cooling tower, storage and boiler

biomethanation, bio-composting, & plant yard lightning is 432.5KW/h. The sugar mill has bagasse

based cogeneration unit of 14 MW capacity. The mill has proposed to supply power to distillery unit

from the existing captive power unit.

Table 2.9: Electricity Consumption

2.3.8 Human Resource

The distillery will be under administrative control of ‘Vice President” of the sugar mill. The Manager of

distillery unit will be responsible for day to day operations of the distillery and effluent treatment

system. There will be independent staff for office work under the Distillery Manager for various

routine work. The proposed project will provide direct employment to about 77 persons, out of which

36 shall be technical personnel and rest shall be skilled & unskilled workers (Refer chapter IX, table

9.1 for details). Support from sugar mill personnel may be utilized by the distillery in case of

necessity. The installation of distillery within sugar mill premises is advantageous from the point of

security also.

Table 2.10: Estimated Project cost

Sr. No. Particulars Amount

(Rs. in Lakhs)

1. Land Development 28.00

2. Civil work and building 735.50

3. Plant and machinery 2654.03

4. Miscellaneous fixed assets for distillery and ETP 242.50

5. Preliminary, pre-operative and other expenses 117.96

6. Contingency @3% 54.01

7. Margin Money 10.00

TOTAL 3842.00

Section Operating (KW/h)

(At peak load)

Fermentation, Distillation, Cooling Tower, Storage 282.5

Absolute alcohol Plant 50

Bio-methanation, Bio-composting, & Plant Yard lightning 100

Total 432.5

Chapter II


2- 14

Table 2.11: Capital investment on environment management

Sr.

No.

Particulars Amount

(Rs. in Lakhs)

1. Spent wash cooling and holding tank 123.00

2. Compost yard with PCC top finish 195.00

3. Cil work at ETP (Foundation for evaporation,

biogas polishing unit )

100.00

4. Leachate management system 29.00

5. Laboratory shed and its glassware, equipments, etc. 10.00

6. Polishing units for condensate treatment 20.00

7. Biomethanation Unit 260.00

8. Stand alone evaporation 300.00

9. Spryaing pumps, Spent wash pumps and piping,

HDPE piping, internal site piping, valves and fittings

27.00

10. Biocomposting machinery, pipeline and other 68.00

11. DG set for ETP 10.00

12. Wire fencing around ETP 5.00

13. Electrification at ETP 10.00

14. Fire fighting equipments and other 5.00

15. Tree plantation and bore well for composting 5.00

TOTAL 1167.00

Chapter II


2- 15

Table 2.12: Recurring expenses

Table 2.13: Overview of environment management processes

Sr.

No

Waste product and source Treatment and disposal

1. Waste water

Spentwash Bio-methanation followed by stand alone evaporation

followed by bio-composting

Other effluent:

Process condensate, Blow down

from cooling tower, Pump

Sealing, floor washing and other

cleaning activities

Effluent will be sent to condensate polishing unit (CPU)

and reused as a cooling tower make-up

Sewage: Domestic wastewater As local acceptable practice, by septic tank and soak pit

system

2. Gaseous emission

Flue gasses from boilers

Due to burning of bagasse and

biogas

Existing sugar Mill boiler of 75TPH will be used

ESP is in place on existing boiler

The existing chimney of height 72m

Bagasse is carbon neutral fuel, contains sulfur in trace

amount

No loose bagasse, it will be in bar(block) form hence

fugitive dust will get controlled

Since, the distillery is proposed within sugar Mill

premises, hence handling and transportation of various

material will be nominal. It will help to control fugitive

dust.

Greenbelt of 33% of the plot area i.e. 2.6 acres

Bio-composting CH4; H2S Fully auto spraying and aerobic composting

Diesel generators It will be operational only when captive as well as grid

Recurring Expenses/annum

Salaries and wages @ 5% on capital investment 58.35

Operation and maintenance of all pollution control devices,

motors, pumps, pipelines, etc. 5% on capital investment

58.35

Fuel (composting activity) and Electricity (in case of diesel

generator operation)

1.26

TOTAL 117.96

Chapter II


2- 16

power supply failure, hence emissions anticipated to be

less frequent and minor

Fermentation unit: CO2 Fermenteres are covered, CO2 scrubbed in water

3 Solid waste

Boiler ash Bagasse ash contains soil nutrients such as potash and

phosphates. It will be mixed with bio-compost and sold

to farmers for use in agriculture lands.

Fermented sludge: Yeast sludge,

Polishing unit sludge

The sludge generated from fermentation unit 1-2

m3/day, biodigster sludge 5-7m3/day and Polishing unit

sludge 0.5-1m3/day contains organic nutrient and micro

elements.

It will be mixed with bio-compost.

2.5 EFFLUENT TREATMENT

2.5.1 Spentwash

2.5.1.1 Primary Treatment: Bio-methanation

In recent years, due to escalation of energy costs and environmental concerns there is an increase in

the installation of anaerobic treatment units for distillery-spent wash. The anaerobic method of

spentwash treatment offers number of significant advantages with some drawbacks over other

treatment methods.

Benefits Limitations

Production of methane as a fuel, it is renewable

source of energy and helps in reducing direct

emission of methane into atmosphere

It contains sulfur in minor quantity (less

than 2%), which causes damage to boiler;

act as a source for SOx emissions

Low production of waste biological solids Relatively long periods of time are required

to start up the process

Low nutrient and power requirement It is a pre-treatment method. Hence,

some of the parameters such as BOD,

COD, colour, TDS, etc. requires adequate

treatment for its safe disposal.

Very high loading rates can be achieved -----------

Active-anaerobic sludge can be preserved unified for

many months

-----------

Chapter II


2- 17

The biochemistry and microbiology of anaerobic processes is much more complicated than that of

aerobic ones. As a result many pathways are available for an anaerobic process. These pathways and

microorganisms responsible for the reactions are not known in great detail but during the last 10-15

years a broad outline of the processes have been established.

2.5.1.2 Microbiology & Biochemistry Of Biomethanation Process

Basically the anaerobic degradation is performed by two groups of bacteria.

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

(acetic acid & hydrogen)

1) Methane producing bacteria : Acetoacetic methane bacteria (acetophilic) Methane bacteria

(hydrogenophilic)

2.5.1.3 Steps of Reaction

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

regarded in a three-step process

Step I: Hydrolysis of suspended and soluble organic of high molecular weight

Step II: Degradation of small organic molecules to various volatile fatty acids, ultimately acetic

acid.

Step III: Production of methane, primarily from acetic acid, also from hydrogen and carbon

dioxide

Out of three steps, the second one is rather quick, while the two others are slow. This accounts for

many instability problems encountered in anaerobic processes. However, the anaerobic processes

are not more unstable than aerobic. One of the reasons why this is a rather rare view is that

engineering design practice for anaerobic processes through the years have been operating with

rather small safety factors and a very poor process control.

Hydrolysis of organic matter is a rather slow process brought about by extra cellular enzymes. Factors

like pH and cell residence time play an important role with respect to reaction rate.

During start-up of the anaerobic process the volatile acid concentration should be kept reasonably

low (1-1.5 Kg HAC/m3) and can be used to control the slow loading. The hydrogen partial pressure (or

redox potential) regulates the production of the various acids. For digesters, operating at very short

solids retention time the concentration of propionic acid and hydrogen is increased. This fits well into

the general picture, and can also explain the increased propionic acid concentrations under unsteady

state or varying load conditions. Propionic acid is an indicator of instability and has been generally

accepted as a process control parameter all though not used much in practice.

If, the acid production rate is high as compared to the methane production rate, which means that a

sudden increase in easily degradable (soluble) organic will result in increased acid production with

Chapter II


2- 18

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

generation step. Parallel to the acid production ammonia is released by the degradation of proteins

and amino acids. The ammonia concentrations thus established would generally not be of a

magnitude that will inhibit the anaerobic process but nitrogen rich wastes, treated in highly loaded

processes, ammonia inhibition could occur.

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

Methane is produced from acetic acid or from hydrogen and carbon dioxide. About one third of the

methane has its origin in molecular hydrogen. Small amounts of methane can be produced from

methane and formic acid, but these reactions have little practical importance. The bacteria producing

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

utilizing bacteria.

2.5.1.4 Utilization of Biogas

Biogas generated in the bio-methanation process will be utilized as a fuel for Mill boiler. Flare unit will

be installed as an alternative, in case of non-consumption of biogas in boiler. There are some

alternative available for the use of biogas. It can be upgraded /purified into methane and

compressed. This is used for higher commercial applications such as fuel for vehicles or for generation

of electricity. However, considering the investment and other economics, these options could be

useful in near future.

2.5.1.5 Bio-Composting

Bio-compost is prepared by mixing spentwash and pressmud (filter cake produced during sugar

manufacturing, having 50-70% moisture) in an optimum proportion of 3:1. The activity is carried out

with the help of excavator- cum –loader for mixing, turning, loading and unloading of compost

material. It is observed that in the first five days, fungal activity is predominant and in subsequent

days bacterial activity continues until stabilization of organic matter into humus is accomplished.

The composting site will accommodate the required number of windrows of filler material. The

windrow size (width & height) will depend upon the type of aeration mixing and turning machine as

well as area of yard to be used. The filler material will comprise of filter cake, screened/half

decomposed bagasse, bagacillo, boiler ash, sludge from biomethanation unit as well as ETP etc. The

windrows will be inoculated with certified microbial culture to enhance the composting process. The

filler material will be homogenised with mixing/turning and aeration machine. The machine traverse

windrows, thoroughly aerating and agitating the composting mixture and grinding shredding of lumps

to uniform size. Spent wash will be sprinkled on windrows in a controlled manner at specific intervals

so as to maintain the moisture content of windrows around 50 to 60 percent. The spraying of the

spent wash will be strictly controlled so as to avoid seepage problem and avoiding anaerobic

Chapter II


2- 19

condition. The windrows will reach a temperature of 65-70oC automatically and within a period of a

week followed by a turning. This will now require more spent wash for maintaining the moisture.

The composting cycle will be of minimum six weeks.

2.5.1.5.1 Operational Details

A composting cycle can be divided into two stages i.e. 40 days of windrow composting (Aerobic

process) and 4-5 days for curing in heaps. Thus, one cycle takes about 45 day’s period.

Compost process can be divided into the following stages –

Active Stage

It is a stage when the maturation is just initiated. During this period there is a rise in

temperature, which continues for first 10-15 days of process after formation of windrows and

spraying of inoculum.

Maturation Stage

This stage includes the greater part of maturation and extends to and beyond the period of

temperature decline. It consists of the 14 days when the temperature is maintained and the

next 10 days when the temperature starts to decline.

Ripening or Curing Stage

This stage allows compost to age for four weeks, until the moisture stabilizes at 30% to 35%.

2.5.1.5.2 Windrow

Recommended windrow Size = 3.0 x 1.5 m (Width x Height- subject to available area)

Distance between two windrows = 1m

Press-mud should be formed in windrow size of 3.0 x 1.5m. The windrows should be formed straight

and have correct size.

2.5.1.5.3 Culture Inoculation

After running the machine for a day, spray inoculum. Inoculum acts both as an odor reducing agent

and an activator to hasten the process of raising the temperature. Normally for every MT of press-

mud 0.5kg of inoculum is applied. It is diluted 100 times with effluent and sprayed on the windrows

spreading over 3 days for effective results (in the 3rd, 5th and 10th day) Immediately after the

application of inoculum, windrow should be aerated with mixing machine to spread the Inoculum

uniformly to all parts of windrow.

2.5.1.5.4 Aeration

Normally mixing machine is used for mixing up the windrow, loosen the same and create a situation

congenial for natural aeration. When the moisture content reduces below 50% an addition of effluent

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

Chapter II


2- 20

oxygen. Moisture content should be brought down to about 50% by giving proper aeration.

Microorganisms make use of nitrogen and carbon for their metabolic activities. The energy required

for this process is derived by aerobic decomposition.

Aeration is given to raise the compost temperature and establish aerobic condition. The temperature

should be 60-650C in the windrow. Continue spraying and aeration till the completion of composting

cycle.

2.5.1.5.5 Effluent Spraying

Spraying is done before aeration. The quantity of effluent applied is strictly controlled so that the

windrows always have moisture content, which is optimum for aerobic composting.

2.5.1.5.6 Merging of Windrows

Once the hard material or lumps is broken by the mixing machine and is loosened, it gets compacted

and the windrow height gets reduced due to proper degradation of organic matter with proper

aeration.

After about 15 days of initial composting the windrow height is likely to be reduced to about 0.5

meter. At this point it is required to merge 2 windrows into one and continue further processing.

2.5.1.5.7 Curing in Heaps

After completing the spraying, windrow is aerated for 2 or 3 days without spraying effluent. After

reducing the moisture to about 30% to 35% heap the compost in the corner to a height of about 2

meter to have anaerobic process for about 15 days and also to make the space free for fresh windrow

formation.

A distinctive black loamy, free flowing and ready to use compost, which has a pleasant earthy smell

and moisture content of 30-35 % is produced.

The salient features of Bio-compost process are:

1. Zero Pollution

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

3. High product value – quick payback

4. Product is usually dry, easy to handle, bagged and transport

Table 2.14: The Composting Technique: Working Data

Sugar Mill

1. Crushing rate (Capacity – 2500 TCH) Average rate 2,800

2. Projected Crushing rate @ 180 days /annum 5,04,000 MT

3. Annual Pressmud production @4% 20,160 MT

4. Moisture content of Pressmud 50 - 70 %

Chapter II


2- 21

Distillery

5. Capacity (liter /day) 30 KLPD

6. Days of operation 270

7. Spent wash production/annum 81,000 MT

8. Spent wash production after evaporation (@ 120 m3/day) /annum 32.400 MT

9. Ratio Press mud: Spentwash, (45 days cycle) 1:2.0

10. Pressmud requirement (in MT per annum) 16,200 MT

11. Culture Required prescribed proportion

Quantity required/year (270days)

1Kg/MT of

pressmud

16,200 Kg

Yard requirement 3.8 acres

Land provision for compost yard 5.5 acres

Table 2.15: Mass Balance (Bio-compost)

Sr. No. Description Solids

Content %

Quantity Total Solids

MT

1. Annual Raw Material

a) Press mud*

b) Spentwash

30

12

16,200 MT

32,400 MT

4,868

3,888

Total 8,748*

2. Annual Compost 65 8,748 MT**

Compost

Annual Compost Production: approx 8,748 MT

* *Assuming loss in weight as CO2 and moisture content of approx. 35 %

Table 2.16: General Characteristics of Bio-compost

Parameter Percentage

Organic Carbon 20 - 25%

Nitrogen 1.5 – 2%

Phosphorous 1.0 – 2%

Potassium 2 – 3.5%

C:N Ratio <17:1

2.5.1.6 Requirements for composting

The proposed molasses based distillery will produce average 300m3/day of spent wash for treatment.

The Mill has proposed to adopt bio-methanation followed by stand alone evaporation followed by

bio-composting process. It has allocated about 5.5 acres of storage lagoons and composting. These

Chapter II


2- 22

proposed lands develop as the guideline issued by the Central Pollution Control Board (CPCB) the

details are as follows.

2.5.1.6.1 Holding of Spentwash

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

impervious tank/lagoons. An impervious storage tank of 30 days and five day holding capacities will

be constructed to store spentwash prior to biocomposting treatment. Spentwash storage tanks will

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

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

of spent wash holding tank is given in fig. 2.4.

Spentwash lagoon of maximum 30 days capacity = 9000m3

Spentwash lagoon of 05 days capacity = 1500m3

2.5.1.6.2 Compost Site Preparation

The aerobic biocomposting process will be carried out wherein thermophilic activity of microorganism

will be involved for fast degradation of BOD and COD values in spent wash surface. The compost site

will be prepared as per the norms specified by Central Pollution Control Board (CPCB), New Delhi. The

details of which are furnished in the chapter Environment Management Plan.

A separate Environmental cell will be constituted and it will monitor this entire operation. Bore wells

will be set up towards the downstream side of the compost site to check the seepage; if any. The

results shall be recorded for the perusal of the regulatory authorities.

The schematic indicating the tentative layout for complete composting process including storage

tanks, windrows, and chamber is shown in Fig. 2.5.

Chapter II


2- 23

Figure 2.4: Spentwash Holding Tank

Figure 2.5: Compost yard

Chapter II


2- 24

Figure 2.6: The Schematic for Complete Compost Process

Chapter II


2- 25

2.5.2 Treatment for spentlees and condensate from MEE

FEED

PRE TREATMENT

SECONDARY

TREATMENT

TERTIARY

TREATMENT

Figure 2.7: Process Flow Diagram For CPU

2.5.2.1 Pre – Treatment

Equalization: To absorb variation in quantity and quality of condensate and to provide uniform flow

at the downstream treatment process, a collection or equalization tank is provided. This will avoid

shock loading and process upsets of the treatment plant.

Neutralization: Neutralization system is provided to neutralize the condensate using lime slurry

(10%)

2.5.2.2 Secondary Treatment

EQUALIZATION

NEUTRALIZATION

ANAEROBIC FILTER OR DIGESTER

AEROBIC TREATMENT

SECONDARY DIGESTER

TUBE SETTLER

SLUDGE DISPOSAL

SYSTEM

CLARIFICATION

SAND FILTER

ACTIVATED CHARCOAL TREATMENT

Chapter II


2- 26

2.5.2.2.1 Anaerobic Filter

The anaerobic filter, also known as fixed bed or fixed film reactor is used for the treatment of non-

settelable and dissolved solids by bringing them in close contact with a surplus of active bacterial

mass. This surplus together with “hungry” bacteria digests the dispersed or dissolved organic matter

within short retention times. Anaerobic filters are reactors consisting of supporting material layers.

On the surface of these material layers or bed, fixation of microorganism and the development of

biofilm take place. Anaerobic filters can be applied not only for treating concentrated wastewater but

also for those wastewaters that have low organic load (grey water). If they are preceded by a reactor

that retains settled solids, they will work better. It is suitable for all industrial wastewater which have

a lower content of suspended solids. The bacteria in the filter are immobile and generally attach

themselves to solid particles or to the reactor walls. Filter materials like rocks, cinder, plastic, or

gravel provide additional surface area for bacteria to settle. Thus, the fresh wastewater is forced to

come into contact with active bacteria intensively. The larger surface area for the bacterial growth

helps in the quick digestion of the wastes. A good filter material provides a surface area of 90 to 300

m2 per meter cube reactor volume. Biological oxygen demand up to 70% to 90 % is removed in a well

operated anaerobic filter.

Pre-treatment in settlers or septic tanks may be necessary to eliminate solids of larger size before

they are allowed to enter the filter. When the bacterial film becomes too thick it has to be removed.

This may be done by back-flush of wastewater or by removing the filter mass for cleaning outside the

reactor. Nonetheless, the anaerobic filter is very reliable and robust. Anaerobic filters may be

operated as down flow or up flow systems. A combination of up-flow and down-flow chambers is also

possible.

2.5.2.2.2 Biological (Aerobic) Treatment

This is the main section of the plant where degradation of organic pollutants with the help of aerobic

micro-organism takes place.

In aeration tank activated biomass is developed in such a way that certain MLSS is maintained for

continuous condensate flow which comes to aeration basin. Condensate is degraded in given

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

The sludge, which is not required after recirculation, is passed to sludge drying bed

To maintain the aerobic condition in the bioreactor, air supply arrangement is provided by means of

aeration equipment which has high oxygen transfer efficiency.

2.5.2.2.3 Secondary Clarifier

Chapter II


2- 27

In secondary clarifier, condensate passed from aeration tank along with biomass (MLSS) gets settled

here. The settled biomass recycled back to aeration tank as per requirement and excess biomass

transfer to sludge drying bed.

2.5.2.2.4 Disinfection

Supernatant from Tube settler, flow by gravity to the chlorine contact tank. To disinfect the harmful

bacteria in the treated water as well as to remove the refractory organics from treated water, in this

tank hypo chlorite solution is dosed with the help of dosing system.

2.5.2.2.5 Sludge disposal system

Settled sludge from tube settler will be removed by pumping to the sludge drying bed.

2.5.2.3 Tertiary treatment:

Secondary treated water will be further passed through sand media filter followed by activated

carbon filter.

Filtered water will be collected in the Treated water Storage tank from where it will be for desired

non potable application. Backwashed water from filters will return back to equalization tank.

2.5.3 Advantages of treatment scheme

a. It will produce the treated water which can be recycled back, thus, very important to save

freshwater intake

b. It is based on biological principle hence no need use of any excessive

hazardous chemicals for the main degradation process

c. Due to efficient aeration system, electrical power requirement will be very low

d. Due to user friendly equipment, plant maintenance will be very less.

e. Due to inbuilt automation, plant machinery life is high & ensures trouble free operation

f. All process rotating electromechanical equipment is provided with standby equipment to

ensure the uninterrupted operation.

Table 2.17: CPU Details

Nature of waste water Process condensate & Spent lees

Flow up to 550 m3/day (maximum designed capacity)

Operating Period ~ 20 h/day

A] RAW CONDENSATE & LEES PARAMETER

pH 3-4

COD 6,000 mg/lit

BOD 3,000 mg/lit

TDS <1000 mg/lit

Chapter II


2- 28

Temperature 35-45 °C

B] TREATED WATER PARAMETER AT THE OUTLET OF CPU

DESCRIPTION PARAMETER

pH 6.5-7.5

COD 100 mg/lit

BOD 30 mg/lit

TDS <1000 mg/lit

2.6 GREEN-BELT DEVELOPMENT

Usually, a greenbelt is developed with an objective of attenuation or mitigation of pollution.

However, the importance of the greenbelt should not confined for pollution control because it offers

many other advantages such as -

Create an aesthetic

Helps to enhance bio-diversity to some extent and thus supports ecosystem

Controls temperature

Maintains micro-climatic conditions

Helps to hold water and restore ground water

Prevent soil erosion & surface run off

The sugar Mill has developed a greenbelt present around the fencing of the premises. It has also

developed greenbelt around guest house and small housing colony near the Mill. Details of existing

greenbelt are mentioned in table 2.18. In case of the proposed activity, greenbelt developed around

manufacturing unit will consist of tall and medium size trees. These trees will be developed in 2-3 raw

curtain, depending upon space availability. Ornamental shrubs, herbs including lawn will be

developed at selective locations.

Greenbelt will also be developed around the waste disposal areas, such as ETP, compost yard,

spentwash storage lagoon, etc. This will be mainly for beautification. Since, the soil around industry is

combination of clay and loam, water holding capacity of the same is around 50%, which is significant.

This factor is considered while estimating the water requirement, which is around 52m3per day.

Treated effluent from sugar Mill will be used for watering plants. While suggesting species for

greenbelt developments following factors are predominantly considered.

Climatic conditions such as rainfall, temperature, humidity, etc.

Soil conditions

Species endemic or native to the region

Chapter II


2- 29

Species supporting and enhancing biodiversity

Enhancing aesthetics of the site

Availability of species in the nearby nurseries

Schematic of greenbelt development for proposed unit is represented in Fig. 2.8.

Table 2.18: Details of existing greenbelt around Industrial Complex

Name of species Individual Location

Saptaparni (Alstonia scholaris) 70 boundary of the sugar unit, road side

Neem (Melia azadiracta) 70 Behind godown 1 and guest house

Kadamba 125 Behind switch yard, boundary of the sugar unit, road

side

Pipal (Ficus relegiosa) 50 Behind office and residential area

Peltoforum pterocarpum 50 along the boundary of cane receiving yard

Gulmohor (Delonix regiea) 100 Road side

Sita Ashok (Saraka indica) 75 Near office

Terminalia cattapa (Desi

Badam) 100 As an avenue tree

Karanj (Pongamia glabra) 125 Along the plot boundary

Amla 50 Near cane yard

Amaltas (Cassia fistula) 25 Behind guest house

Chinch (Tamarindous indicus) 25 Along the boundary near godown 2

Jamun (Sizygium cummini) 50 Along parking area and avenue tree

Wad (Ficus benghalensis) 20 Along plot boundary

Mango (Mangifera indica) 50 Near guest house, office

Raintree (Samania saman) 100 near reservoir

Apta (Bauhinia purpurea) 50 Near spray pond unit fencing

Coconut (Cocus nucifera) 105 Near godown 1 and long the road near godown

Lagerstroemia 30 Garden and Traffic island

Champa (Plumeria alba) 50 Near office area

Chapter II


2- 30

Bakul 50 Near office area

A) Sub Total 1300

B) Shrubs

Tecoma gaudichaudi 250 Near spray pond , switch yard

Tagar 300 Near godown 1 and long the road near godown

Lantana 500 Near godown 1 and long the road near godown

Pomegranate 100 cane receiving yard

Almanda 250 near office, guest house, along the road

Oleander 200 near office, guest house, along the road

Ixora coccinia 500 near office, guest house, along the road

Myana erectica 300 Near water treatment plant

sub total 2,400

Total 3,700

Fig.2.8: Schematic of Greenbelt Development

Chapter II


2- 31

Figure 2.9: Decision making and its implementation hierarchy (from top to bottom) and reporting hierarchy (from bottom to top) for environmental conditions/compliances

Chapter III


Udagiri Sugar & Power Ltd; Dist. Sangli Maharashtra

3.1

Chapter III

BASELINE ENVIRONMENTAL STATUS

3.1 INTRODUCTION

The baseline environmental conditions are established through field studies/monitoring (primary

data) and secondary data such as reports and survey records published by authentic agencies.

Considering the site at the centre, a 10km radius area was defined as a study zone. In the study

zone, primary and secondary data was collected. In addition, information on the location of

towns and cities, national parks, wildlife sanctuaries and ecologically sensitive areas, etc. was

collected. Guiding factors for the baseline study of the project are terms of references (ToR)

issued by Ministry of Environment and Forestry (MoEF) and the Environmental Impact

Assessment notification Sep. 2006. For the present study, the field monitoring was carried out in

summer season of 2014 i.e. March to May 2014. Data was sufficient to develop a clear

understanding of the nature and magnitude of potential impacts of the project. Generally, the

baseline environmental study is carried out by collecting data on attributes such as air, noise,

water, soil, flora, fauna and overall ecosystems. In addition, data for meteorology, topography

and drainage, hydrology, geology, socio-economy together form an appropriate baseline data. All

these elements together describe the prevailing conditions and facts about local environment.

This helps in understanding the environmental characteristics of the area and thus, assessing the

impact on existing environmental quality, on the basis of proposed developments being planned.

Table 3.1: Classification of environment aspects

Physical Environment • Climate and Meteorology

• Geology, hydrology and hydrogeology

• Air environment

• Noise environment,

• Water environment,

• Soil environment

Biological Environment Ecology: Existing Flora and Fauna in study area

Socio-economic • Demography

• Availability of infrastructure

• Economic profile

• Migration pattern

• Social Initiatives by the industry

Chapter III



3.2

Table 3.2: Environment setting of site and study zone in brief

Sr.

No

Particulars Description

1. Project site within existing sugar factory premises At Bamni (Pare),

Tal - Khanapur, Dist – Sangli, Maharashtra

2. Geographical coordinates Latitude: 17°12'6.53"N

Longitude: 74°35'40.43"E and

Elevation: 676m

3. Nearest villages East - Village Padali at 2km

South east - village Dhamni 1.5km

South – village Bamni 2.4km

South west (SW)- village Mangrul 3.5km

West – village Chinchani 2.2km

North village pare 2.3km

4. Climate and meteorology

a Temperature Annual Max Temp (Avg. summer months): 380C

Annual Min Temp (Avg. winter months) : 140C

b. Precipitation annual average for Khanapur Taluka 550 mm

c. Wind Predominant wind direction west, southwest

5 Land Within in existing sugar factory premises

6. Nearest town Vita town 10km towards north

7 Nearest Highway /Road NH4 ~50km, state highway ~12km

8. Airport Karad ~ 80 Km from the site

9. Nearest railway station 35 km away

10. Water body River Yerala at 6km towards west

11. Soil Type 3 Types; Light, medium and deep soil

12. Ecologically sensitive areas Sagareshwar wildlife sanctuary at 25.3km

13. Archaeologically important

places

None

14. Reserved/Protected forests

within 10 km radius

No

15. Nearest place of tourist/

Religious importance

Gorakhnath temple, Shirala 80km

Sambhu Appa Urus – Islampur 30km

16. Topography of proposed site Flat , barren land

17. Main Agricultural crop in the

District

Jawar, Bajra, Wheat, Groundnuts, , Sugarcane,

Turmeric, Grapes, Pomegranate

Chapter III



3.3

18. Major Industries of the district Sugar mills, cotton mill and engineering unit

3.2 DESCRIPTION OF SITE AND STUDY AREA

The proposed site is located in Khanapur tahsil, which is located towards north of Sangli

district. The site is 570m above mean sea level. It is within existing sugar factory premises. It is

on plane, flat terrain/ land with very gentle slope towards SE of the plot. Greenbelt developed by

the sugar factory, wild grasses and bushes are the only vegetation present on site and

surroundings. There is a water storage reservoir of the factory towards west of the proposed

distillery unit. Agricultural fields are towards east, west and north boundaries of the proposed

unit and sugar mill is towards the south. The adjacent villages to the site are mentioned in table

3.2 (point 3). There is a small hillock located towards east of the site (average height of 25-30m)

at a distance of 2.5km.

Figure 3.1: Proposed project site

Chapter III



3.4

Figure 3.2: Satellite image of the site and surrounding

Chapter III



3.5

3.3 BASELINE ENVIRONMENTAL CONDITIONS

Primary data collection was carried out in study area comprises of villages in 10 km radius

from the site

Table 3.3: Details of sampling location

Parameter Location

Ambient Air Factory premises, Mangrul, Bamni, Aalte, Padali, Dhamni, Hatnoi, Pare and

Narsewadi

Noise Factory premises, Pare, Padali, Narsewadi, Dhondewadi, Hatnoli, Bamni,

Mangrul, and Aalte

Water Aalte, Dhamni, Mangrul, Padali, Pare, Bamni, Narsewadi

Soil Mangrul, Aalte, Dhamni, Pare, Padali, Dhondewadi, Bamni, Narsewadi

3.3.1 Climate and Rainfall

Agro Climatic Zone (NARP): Western Maharashtra Scarcity Zone (MH-6); and Western

Maharashtra Plain Zone (MH-4).

Sangli has a semi-arid climate with three seasons, a hot, dry summer from the middle of February

to the middle of June, a monsoon from the middle of June to late October and a mild cool season

from early November to early February. The climate in the district is fairly tolerable throughout

the year. The climate gets hotter and drier towards the east and humidity goes on increasing

towards the west. The maximum temperature ranges between 31.5o C and 38.2oC, while the

minimum temperature ranges from 12.9oC to 22.7oC.

This district falls partly in Krishna basin and partly in Bhima basin. Consequently, it is divided into

different drainage systems. The whole district can be divided into three different parts on the

basis of topography, climatology and rainfall viz.

1. Western hilly area of Shirala tahsil with heavy rainfall.

2. The basin area of Krishna, Warna & Yerala rivers, comprising of tahsil Walwa, & western

part of Tasgaon and Miraj tahsils with medium rainfall.

3. Eastern drought prone area which comprises of eastern part of Miraj, and Tasgaon

tahsils, north-eastern part of Khanapur tahsil and whole of Atpadi, Kavathe Mahankal &

Jath tahsils.

Chapter III



3.6

The western part of Shirala tahsil gets heavy rainfall on an average over 1300 mm in a year.

The central and eastern parts receive annual rainfall about 900 mm in a year. The

northeastern portion receives the lowest rainfall in the district - only 300 mm in a year. Due

to this lowest rainfall, the tahsils of Atpadi, Jath, Kavathe Mahankal, Miraj (East), Tasgaon

(East) and Khanapur (East) are drought prone areas.

Table 3.4: Rainfall Data for Sangli district (mm)

YEARMONTH JAN FEB MAR APR MAY JUN JUL AUG SEPT OCT NOV DEC

2009 0.0 0.0 0.0 0.0 37.2 58.3 178.6 101.9 198.5 117.9 103.2 1.3

2010 0.1 0.0 0.0 17.0 2.5 186.1 179.7 145.5 151.8 79.7 56.2 2.4

2011 0.0 5.7 0.0 11.7 71.6 105.3 103.7 132.8 87.5 86.8 0.0 0.0

2012 0.0 0.0 0.0 18.3 5.7 49.6 103.0 68.9 70.4 145.1 9.4 0.0

2013 0.0 0.6 0.0 12.5 15.1 124.1 185.6 58.7 165.3 53.8 10.0 0.0

Rainfall Normal RF(mm) Normal

Rainy days

Normal

Onset

Normal Cessation

SW monsoon (June-

Sep)

473.5 35 2nd week of

June

1st Fortnight of

October

NE Monsoon(Oct-Dec) 137.6 8

Winter (Jan- Feb) 9.4 1

Summer (Mar-May) 71.9 5

Annual 692.4 49

(Source: Indian Meteorological Department)

3.3.2 Temperature

The cold weather starts by about the end of November and lasts till about the middle of February,

December being the coldest month. In this month the mean daily maximum temperature is

29.5oC while the daily minimum (mean) is 14.3oC. The minimum temperature may sometimes

go below 7oC. The period from about the middle of February to the end of May is one of

continuous increase of temperature. In May, the hottest month, the mean daily maximum

temperature is 37.5oC and the daily minimum (mean) is 22.7oC. The heat is intense and the

maximum temperature may sometimes go up to 42.0oC. Afternoon thundershowers bring

Chapter III



3.7

some relief from the heat on few days. The onset of the south-west monsoon by the first or

second week of June brings down the day temperatures appreciably, but night temperatures

continue to be nearly the same as in summer. During the south-west monsoon, the weather is

cool and pleasant. Sometimes the day temperatures are even less than in the cold season.

After the withdrawal of the south-west monsoon by the end of September, day temperatures

increase slightly. After about mid-November both day and night temperatures begin to drop.

Table 3.5: Month Wise Temperature And Humidity Record For Sangli District

Month maximum temperature (Mean

daily)

minimum temperature (Mean

Daily)

Relative Humidity (%)

— oC oC 0830h 1730h

January 30.5 14.1 62 35

February 32.8 15.2 56 31

March 36.1 18.5 54 27

April 37.9 21.5 64 30

May 37.5 22.7 73 40

June 31.5 22.3 82 66

July 27.9 21.7 86 79

August 28.2 21.2 87 76

September 29.2 20.2 86 68

October 31.0 20.1 74 51

November 30.1 17.3 65 45

December 29.5 14.3 61 37

Annual 31.9 19.1 71 49

*Hours in Indian Standard Time

3.3.3 Humidity

During south-west monsoon, the air is highly humid. In the post-monsoon, summer and cold

season the air is dry particularly in the afternoons.

3.3.4 Cloudiness

The cloudiness is recorded in Oktas i.e. in one-eighth of the sky covered. Skies are generally clear

or lightly clouded during the months November to March. Cloudiness begins to increase

progressively from April and afternoons are more clouded than the mornings. During the

monsoon, the skies are heavily clouded to overcast. But cloudiness decreases in the post-

monsoon period i.e. October and November.

Chapter III



3.8

3.3.5 Wind (Wind Speed and Direction)

Winds are light to moderate except in the south-west monsoon season when they are

stronger. In the south-west monsoon season, winds are from directions between south-west

and north-west, the westerlies being more frequent. In the post-monsoon season they are

predominantly from the north-east or east. Easterlies and south-easterlies are common in the

cold season. By February westerlies and north-westerlies appear and these predominate in

the summer.

The predominant wind direction observed during the study period was from Northeast and

southwest directions, with 8.1 %. Southeast directions follow this with 6.4%. Calm conditions

constituted about 33.7 % of the total time observed. A wind rose diagram giving the details of the

wind pattern for the study period at the site is given in fig. 3.3.

Table 3.6: Mean Wind Speed (km/hour) (Sangli district)

3.3.6 Special Weather Phenomena

Thunderstorms occur in the hot season and in the post- monsoon season. In the beginning

and end of the south-west monsoon season rainfall is often associated with thunder.

Table 3.7: Special Weather Phenomena (Sangli district)

Mean No. of days with

Jan. Feb. Mar. Apr. May June July Aug. Sep. Oct. Nov. Dec. Annu

al

Thunder 0.0 0.0 1.7 4.4 6.1 3.1 0.1 0.9 2.0 4.0 0.9 0.4 23.

6

Hail 0.0 0.0 0.1 0.1 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.2

Dust-Storm 0.1 0.0 0.1 0.2 0.4 0.2 0.0 0.0 0.0 0.0 0.0 0.0 1.0

Squall 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0

Fog 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0

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

7.4 7.7 8.9 10.6 14.2 16.3 18.0 15.4 12.2 8.4 8.5 8.4 11.3

Chapter III



3.9

Figure 3.3: Windrose Diagram

3.3.7 Land Use Patterns

Land cover is a fundamental parameter describing the Earth’s surface. Remote sensing, in

conjunction with geographic information systems, has been widely applied and been recognized

as a powerful and effective tool in analyzing land cover/use categories. The study area of

proposed molasses based distillery unit project of M/s Udagiri Sugar and Power Ltd. at Village

Bamani, Taluka Khanapur, District Sangli, Maharashtra is covered in survey of India Toposheet no.

47 K/11, and 47 K/12, and lies within latitudes of 17°12'11.05"N to 17°12'12.18"N and longitudes

of 74°35'41.07"E to 74°35'55.30"E.

Chapter III



3.10

Satellite imagery and software, used for the present land use study, is detailed as follows.

Satellite Data: LANDSAT_8, OLI_TIRS cloud free data has been used for Land use / land cover

analysis

Satellite Sensor: LANDSAT_8, OLI_TIRS

Path and Row: Path 146, Row 48

Spatial Resolution: 30 m

Date of Pass: 09 Feb 2014

PC based GIS and image-processing software was used for the purpose of image classification and

for delineating drainage and other features in the study area. Number of peripheral devices such

as scanner, plotter, printer etc. has also been interfaced with the system. Satellite data of Rabi

season was classified using supervised classification technique. Maximum likelihood algorithm

classifier was used for the analysis. The scenes were individually classified and then were

integrated to get a composite classified output where information from Rabi season is available.

A truth table was generated taking 0.95 as the conversion threshold. After aggregation, the final

classified output was converted in raster format. The image was then converted in raster format,

which is understood by GIS software. Eight landuse/ landcover classes were identified in ten sq.

km area around the Project Site. Area under each class has been calculated (Table 3.8).

Table 3.8: Landuse/ Landcover Statistics of the Ten square Km Area

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

1 Waterbody 73.62 0.23

2 Long Fallow 1822.5 5.78

3 Current Fallow 2970.99 9.43

4 Agriculture Land 5350.77 16.98

5 Vegetation 680.04 2.16

6 Open Scrub 13932.9 44.23

7 Built-up Land 816.39 2.59

8 Barren Land 5855.58 18.59

The above data shows that, the land use under open scrub category is highest i.e. 44.23%

followed by barren land of 18.59%. The proposed site is already acquired by the sugar mill and

hence, no change in landuse will take place due to the proposed project.

Chapter III



3.11

Figure 3.4: Land use/land cover map of 10km radius study area

Chapter III



3.12

Figure 3.5: Contour map of 10km radius study area

Chapter III



3.13

3.3.7.1 Contour

Contouring is the standard method of representing relief on topographic maps. Contour lines are

lines joining points of equal elevation on the surface of the ground. They can also be thought of

as the lines of intersection between a series of horizontal planes and the ground surface. For a

given map the vertical distance between adjacent contour lines or the contour interval is fixed

i.e.20m. By examining the horizontal distance between successive contours it is possible to

visually estimate the variation in slope of parts of the terrain. As the vertical distance between

contours is the same, the closer the contour lines are together the steeper the slope. The

maximum height of the terrain in given study area of10 sq.km is 890m at a distance of 10km

towards northeast of the site. It can be easily found that a range is passing from northern part to

southeastern part of the study area,

3.3.8 Soil

Soil formation in Sangli district has been predominantly influenced by the climate. Soil is different

in different parts of the district. The western zone, which receives very heavy rainfall, has lateritic

soils on up-ghats and reddish brown soil on hill slopes, the latter being developed on parent

material of trap rock. It is 7.37% of the total area of the district. The transition zone of Krishna

valley has deep black soils of alluvial origin. It is observed in central part i.e. Entire Walwa tahsil

and western part of Miraj and Tasgaon tahsils. It is 26.18% of the total area of the district. The

third is the eastern drier zone, which consists largely of regular black soils and poor shallow soils.

Saline-alkaline soils are met with in the low-lying patches in the areas of low rainfall. The soil is

faint gray accounting for 66.45% of the total area of the district. Land in the region is best

suitable for agriculture.

Chapter III



3.14

Figure 3.6: Types of Soil observed in Sangli district

Table3.9: Results of soil analysis

3.3.9 Geology

The basaltic lava flows belonging to the Deccan traps of upper cretaceous to Eocene age is the

only geological formation occurring in Sangli district. Isolated patches of laterite are occurring

along the eastern boundary. The Deccan traps are overlain by alluvial deposit at few places along

the Krishna and Warna river. The stratigraphical sequence of various geological formations

occurring in the district is given below.

Formation Age Lithology

Alluvium Recent Sand silt and clay

Laterite Pleistocene Laterites

Deccan Traps Eocene to Upper Cretaceous

Basaltic lava flows of amygdular and massive nature flows often separated by red bole.

The Deccan Traps are formed of effusive lava flows. These basaltic rocks are fine grained with

gray to black in colour. They overlie the rocks of granitic composition with extremely irregular

contact zones. They are formed of a number of lava flows towards the close of cretaceous.

Subsequent to the bagh and lamet beds a large part of the Indian peninsula and entire study

region was affected by an outburst of volcanic activity. It resulted in the eruption of lava flows

and associated pyroclastic materials. These, some hundreds of meters of horizontally bedded

sheets of basalt have resulted. The thickness of these beds decreases towards east. The beds

Parameter Mangrul Aalte Dhamni Padali Pare Dhonde-wadi

Site Narsewadi

pH 7.69 7.87 7.79 8..01 8.30 7.58 7.99 7.56

EC 0.875 0.509 0.975 1.042 0.436 0.362 0.419 0.272

Organic

carbon (%)

1.01 0.97 0.97 1.64 0.97 1.13 1.36 1.25

Moisture (%) 0.67 1.14 0.71 0.27 0.40 0.41 0.09 0.34

Available P2O5

kg/Ha in

6.13 4.26 3.61 4.01 4.34 2.76 2.12 4.89

Total Available

N kg/Ha

672 672 224 425.6 313.6 268.8 380.8 224.0

Available K2O

kg/Ha in

220 244.5 178.5 277.5 213 129.5 93.8 85.3

Chapter III



3.15

obliterated all the previously existing topographical details and it gave rise to an immense

volcanic plateau. Basalt and laterite are two main types of rocks in the study area. The individual

geological formations are described below in detail.

3.3.9.1 Deccan Traps

The Deccan Traps are formed by piling of basaltic lava flows over one another. The individual flow

has two distinct units. The upper layer generally consists of vesicular basalt. Vesicles are often

filled by secondary minerals like zeolites, quartz, and calcite and hence called as zeolitic traps.

The bottom layer consists of hard and compact massive basalt. The flows are usually separated

by thick red clay compact massive basalt or called as "Red Bole". The thickness of flow varies

from few meters to as much as 30 meters

3.3.9.2 Laterite

Laterite caps over plateau tops have been observe along the eastern border of the district. The

occurrence of laterite caps is of sporadic nature and does not have wide extension.

3.3.9.3 Alluvium

The river Krishna and Warna have deposited alluvium along the banks at few places. The alluvium

consists of clay, slit and sand. The alluvium occurs in small patches and does not have a

continuous stretch. It is underlain by the Deccan Traps. The thickness of alluvium is very

insignificant and ranges between 6 to 10 meters.

3.3.9.4 Lineaments

The presence of weaker zone i.e. fractures in the basaltic rock have been observed on the

satellite imagery in the form of lineaments. Most of the lineaments are trending in northwest-

southeast and northeast-southwest direction. The lineaments at places have controlled the

drainage's.

Chapter III



3.16

Figure 3.7: Geology of Sangli district

3.3.10 Geomorphology

The Sangli district is dominated by the trappean land forms. The trappean land forms of the

district have been divided in two groups depending upon origin of the land forms viz., the

structural land forms and denudational land forms. The structural land forms again have been

divided in two units depending upon the degree of dissections namely, 1) Highly dissected

plateau (HDP) and 2) Moderately dissected plateau (MDP). A very small area along the major

rivers shows the fluvial land forms. Various land forms have been identified and delineated by

studying the image characters, which are described below in detail.

3.3.10.1 Fluvial Origin

Valley Fill: A very small area along river Krishna and Warna is covered by alluvium which forms

the valley fill. The area has a gentle slope, thick soil cover as well as covered by sand, silt and clay.

The area forms the storage zone. Agriculture is the principal land use of the area.

3.3.10.2 Structural Origin

Highly Dissected Plateau (HDP): The district is located at the foothills of steep sloping western

ghat hill range. Therefore, major part of the district is exposed with hard and compact basaltic

flows which also has a moderate to steep slope. These areas have been classified as the highly

dissected plateau. The area has a very high drainage density and thin soil cover and therefore

Chapter III



3.17

forms the run-off zone. Major parts of Shirala, Khanapur, Tasgaon, Atpadi, Miraj, Kavthe-

Mahankal and Jath tahsils are occupied by the highly dissected plateau. The highly dissected

plateau units are dominated by the scrub lands.

Moderately Dissected Plateau (MDP): The low lying valley areas which has a moderate slope form

the moderately dissected plateau ( MDP). These plateau units are also covered by the basaltic

lava flows. The area has a moderate drainage density

Figure 3.8: Physiography of Sangli district

3.3.11 Hydrology

3.3.11.1 Rivers and dams

• Krishna with tributaries Warna and Yerla flows through the western part of the district.

• Warna flows from west to east along the southern boundary of the district and joins the

Krishna at Haripur near Sangli town.

• Yerla flows from north-west to south-east and after traversing the western parts of

Khanapur and Tasgaon tahsils joins Krishna near Brahmanal

• These rivers are the lifelines of the western half of the district and serve as source for

large irrigation schemes.

• Agrani, Man and Bor constitute the drainage system for the eastern part of the district.

The water resources from these rivers are limited and they remain dry for most part of

the year.

Chapter III



3.18

• There is only one major dam at Chandoli on the river Warna. Besides, there are two major lift

irrigation schemes on the Krishna River. There are five Medium Irrigation Projects, namely

Morna, Shindewadi, Bassappawadi, Doddanala and Sankh. There are 66 minor irrigation projects,

462 percolation tanks 353 masonry dams and 11 Kolhapur type weirs (Bandharas).

Figure 3.9: Drainage pattern – Sangli district

Drainage map of 10km radius study area shows highest order of drainage as 6th order. The study

area is under the confluence of Yerala river which is one of the tributory of Krushna River. Many

streams are contributing to the Yerala river from surrounding part of the study area. The pattern

of drainage for the study area is mixture of trellis and Sub-draindritic.

Chapter III



3.19

Figure 3.10: Drainage pattern for 10km

3.3.11.2 Baseline status for Water quality

Assessment of base line data on water environment includes

• Identification of surface water sources, ground water sources

• Collection of water sample

• Analyzing collected water samples for mainly physical and chemical parameters

Water samples (includes surface & ground water samples) were collected from ten location and

analyzed at laboratory of Department of Environmental Sciences of VSI. All the basic precaution

and care were taken during the sampling to avoid contamination. Collection and analysis of water

samples were carried out as per standard methods and a procedure prescribed by CPCB.

Relevant IS and APHA standard methods were used for the analysis.

Figure 3.8: Water Sampling Location details

Number Location Number Location

1 Dhamni -Well water 6 Padali – well water 2 Pare bore well water 7 Bamni – Tube well water 3 Mangrul well water 8 Pare – reservoir water 4 Padali bore well water 9 Narsewadi – tube well 5 Pari Bore well water 10 Bamni – well water

Chapter III



3.20

Table 3.9: Result of ground water and surface water analysis

Parameter Location IS 10500

1 2 3 4 5 6 7 8 9 10

pH

8.02 6.9 8.4 8.2 8.3 8.1 7.4 8.3 8.1 8.2 6.5 to 8.5

EC (m-S)

0.67 1.05 0.97 0.59 0.71 0.86 1.35 0.38 1.37 0.69

Total Hardness

176 204 210 54 184 282 270 65 198 168 200

Calcium Hardness

20.8 6.4 16.03 16.9 24.04 24.8 20.84 24.04 16.03 28.05

Magnesium Hardness

30.13 45.68 41.31 2.9 30.13 53 52.1 1.2 38.4 23.8

Chloride 90 79 148.9 47 97 102 145.9 29 191.9 99 200

Alkalinity 10 BDL 12.5 12.5 7.5 5 BDL 5 BDL 5 200

Sulphate

40.8 65.9 35.2 15.3 34.7 47.2 52 7.3 58.2 37.1 200

Phosphate BDL 0.05 BDL BDL BDL BDL BDL BDL BDL BDL

TDS 616 792 722 468 500 930 946 990 950 582 500

Methyl orange alkalinity

130 272.5 200 180 160 127.5 282.5 82.5 212.5 140

Residual chlorine

BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL

BOD 26 10 11 06 14 12 10 12 BDL BDL

COD 64 25.6 25.6 12.8 38.4 25.6 25.6 25.6 BDL BDL

Sodium 61.2 72.5 116.3 93.5 73.9 52.9 35.8 24.8 42.4 64.3

Potassium 23.2 11.8 23.1 22.3 23.6 8.6 16.3 16.9 24.7 22.1

Cu 0.005 0.009 0.002 0.002

BDL 0.001 BDL BDL 0.001 0.008 0.05

Zn 0.001 0.002 0.014 0.013

0.009 0.007 0.015 0.017 0.024 0.017 5

Mn 0.009 0.009 0.011 0.007

0.004 0.005 0.006 0.002 0.011 0.010 0.1

Fe BDL BDL BDL BDL BDL BDL BDL 0.020 BDL BDL 0.3

note – All parameters are in mg/lit. Except pH and EC

Water samples 7 and 10 were collected from sources close to the site. Water analysis table

reveals that the water is mild alkaline in nature at most of the places. As per IS 10500 for drinking

water, Total dissolved solids (TDS) was observed to be exceeding the standard limit of 500mg/L.

Hardness limit of 200mg/L was found to be exceeding at location Pare, Mangrul, Padali and

Chapter III



3.21

Dhamni. BOD/COD values were significant for well water collected from village Dhamni. Overall,

the water quality in 10km radius area was partly deteriorated but acceptable for domestic

activities.

3.3.12 Air environment

The ambient air quality status was monitored in the study area of the site. Baseline values of the

same were used to calculate incremental air pollution load with respect to monitored locations.

Thus, it helped in predicting the impacts due to the proposed activity on the air environment of

the study area.

3.3.12.1 Methodology of monitoring

The ambient air quality monitoring has been conducted during the months of March to May 2014

(summer season). Monitoring has been conducted twice a week, for 24 hours at one location.

The fine dust sampler of Polltech Make were used to collect air samples for PM10, Pm 2.5, SOx

and NOx. There were four stations installed in the factory premises and six stations were in the

surrounding villages, including prevailing upwind and downwind directions. The monitoring

locations are shown in figure 3.11.

Chapter III



3.22

Figure 3.11: Ambient air monitoring locations

Table 3.10: Ambient Air Monitoring Observations

Location: Village Pare (Rural residential area) NAAQS for PM10 (24h): 100 µg/m3

PM 2.5 (24h): = 60 µg/m3

SOx (24h): =80 µg/m3

NOx (24h): = 80 µg/m3

Direction from site - north; Distance 2.3km

Parameter 1 2 3 4 5 6 7 8 9 10 11 12 98th

percentile

PM10 62.5 58.1 52.9 55.1 60.6 57.1 60.7 61.5 59.1 57.8 56.2 57.2 62.28

PM2.5 14.3 16.3 12.6 13.7 17.0 18.7 19.3 18.1 16.3 15.5 15.4 15.3 19.17

NOx 8.40 7.80 7.20 6.60 6.40 6.90 7.40 8.10 7.90 8.00 8.20 7.80 8.36

SO2 5.9 6.2 6.9 7.2 7.1 7.5 7.3 6.9 7.4 7.1 6.8 7.3 7.48

Location Village Padali (Rural residential area)

NAAQS for PM10 (24h): 100 µg/m3

PM 2.5 (24h): = 60 µg/m3

SOx (24h): =80 µg/m3

NOx (24h): = 80 µg/m3

Direction from site: East Distance: 2km

Parameter 1 2 3 4 5 6 7 8 9 10 11 12 98th

percentile

PM10 80.2 78.3 72.4 75.9 80.2 75.5 76.0 76.8 79.9 85.2 80.7 77.5 84.21

PM2.5 23.4 24.6 26.2 25.7 20.1 19.9 23.9 28.1 27.6 28.9 30.7 26.4 30.30

NOx 9.65 8.90 8.70 9.40 10.7 11.4 9.9 10.8 10.5 9.90 11.2 10.7 11.36

SO2 5.3 5.7 6.0 7.2 6.9 7.1 7.4 6.8 7.5 7.8 8.2 8.5 8.43

Location: Village Narsewadi (Rural residential

area)


PM 2.5 (24h): = 60 µg/m3

SOx (24h): =80 µg/m3

NOx (24h): = 80 µg/m3

Direction from site: ENE Distance 4.7km

Parameter 1 2 3 4 5 6 7 8 9 10 11 12 98th

percentile

Chapter III



3.23

PM10 50.0 45.7 47.2 53.4 46.3 40.1 42.7 38.6 44.7 38.2 30.5 33.5 52.65

PM2.5 23.1 20.4 18.6 21.5 24.5 14.9 17.9 17.5 16.2 20.5 20.7 14.7 24.19

NOx 8.42 7.8 7.2 6.9 7.1 7.5 6.9 8.10 8.50 9.10 7.70 7.20 8.97

SO2 6.23 5.7 5.0 5.40 6.20 6.90 7.10 6.20 5.50 5.20 6.10 5.80 7.07

Location: Village Hatnoli (Rural residential area) NAAQS for PM10 (24h): 100 µg/m3

PM 2.5 (24h): = 60 µg/m3

SOx (24h): =80 µg/m3

NOx (24h): = 80 µg/m3

Direction from site: South Distance: 5km

Parameter 1 2 3 4 5 6 7 8 9 10 11 12 98th

percentile

PM10 37.5 40.4 32.2 25.7 30.1 26.7 18.1 22.6 31.5 32.4 34.7 30.8 39.76

PM2.5 16.6 15.5 18.4 11.7 21.1 22.7 14.7 12.1 11.3 17.8 14.9 15.0 22.35

NOx 8.06 8.10 7.70 8.20 9.10 9.60 8.30 9.10 9.70 8.90 7.80 8.70 9.68

SO2 6.27 7.50 8.20 8.40 7.90 7.70 6.70 7.80 8.80 9.10 8.00 7.10 9.03

Location: Village Bamni (Rural residential

area)


PM 2.5 (24h): = 60 µg/m3

SOx (24h): =80 µg/m3

NOx (24h): = 80 µg/m3

Direction from site - South Distance 2.4km

Parameter 1 2 3 4 5 6 7 8 9 10 11 12 98th

percentile

PM10 62.0 55.3 66.3 51.6 58.8 64.1 59.1 57.8 54.0 50.1 47.8 49.2 65.82

PM2.5 21.8 18.9 27.8 20.6 15.9 28.4 19.1 17.2 18.1 14.6 15.8 17.2 28.27

NOx 7.92 8.8 9.1 10.2 8.4 8.9 7.5 6.4 7.1 7.8 8.0 7.1 9.96

SO2 5.95 6.05 8.02 7.60 7.10 8.0 8.30 7.75 8.60 9.00 8.25 7.55 8.91

Location: Village Aalte (Rural residential area) NAAQS for PM10 (24h): 100 µg/m3

PM 2.5 (24h): = 60 µg/m3

SOx (24h): =80 µg/m3

NOx (24h): = 80 µg/m3

Direction from site; Southwest Distance: 7km

Parameter 1 2 3 4 5 6 7 8 9 10 11 12 98th

percentile

PM10 50.2 57.1 49.4 44.8 57.2 48.9 51.9 46.6 57.4 60.1 52.1 55.7 59.51

PM2.5 20.9 26.75 17.9 20.2 27.4 22.2 23.0 20.1 16.8 25.9 23.4 29.7 29.19

NOx 7.80 9.25 10.1 9.75 11.1 11.6 10.7 10.1 9.55 8.85 8.70 7.75 11.49

Chapter III



3.24

SO2 6.12 8.25 7.85 9.10 8.80 10.2 7.90 7.10 8.7 7.75 8.50 9.10 9.96

Location: Existing sugar mill premises - Main gate

(Industrial area)


PM 2.5 (24h): = 60 µg/m3

SOx (24h): =80 µg/m3

NOx (24h): = 80 µg/m3

Direction from site - south; Distance: 0.3km

Parameter 1 2 3 4 5 6 7 8 9 10 11 12 98th

percentile

PM10 86.5 80.7 84.9 79.1 85.5 81.6 74.1 66.7 59.7 63.3 50.7 55.9 86.28

PM2.5 36.4 29.7 38.1 33.8 31.5 30.7 28.4 35.1 29.4 30.8 22.5 24.7 37.73

NOx 8.50 10.25 9.55 11.7 10.5 12.2 11.1 11.8 8.9 7.75 8.10 6.90 12.11

SO2 6.35 8.75 9.25 8.5 10.2 10.9 8.9 9.5 8.8 7.9 6.7 7.10 10.75

Location: Existing sugar mill premises – Near

Laboratory

(Industrial area)


PM 2.5 (24h): = 60 µg/m3

SOx (24h): =80 µg/m3

NOx (24h): = 80 µg/m3

Direction from site – south west; Distance: ~1.0km

Parameter 1 2 3 4 5 6 7 8 9 10 11 12 98th

percentile

PM10 62.1 55.3 64.7 69.1 66.2 57.9 66.0 60.4 54.9 50.1 53.7 41.8 68.46

PM2.5 28.5 30.4 32.1 27.8 37.1 22.6 30.7 30.2 27.6 28.9 22.9 13.7 36

NOx 7.57 8.25 9.50 10.1 10.5 9.9 10.2 10.8 11.3 10.7 9.90 9.10 11.19

SO2 6.3 7.5 8.2 8.5 7.75 7.2 6.8 6.9 6.5 7.25 7.5 6.8 8.43

Location: Existing sugar mill premises – Guest

house

(Industrial area)


PM 2.5 (24h): = 60 µg/m3

SOx (24h): =80 µg/m3

NOx (24h): = 80 µg/m3

Direction from site - west; Distance: ~1.0km

Parameter 1 2 3 4 5 6 7 8 9 10 11 12 98th

percentile

PM10 50.2 54.2 49.5 59.1 60.8 51.3 49.5 57.8 48.7 51.5 45.3 39.7 60.43

PM2.5 23.4 18.8 17.3 19.4 27.1 21.4 20.9 18.8 15.5 22.1 16.2 18.7 26.29

NOx 9.16 8.20 8.55 9.15 9.90 10.5 9.75 9.25 10.1 10.3 9.1 8.7 10.46

SO2 6.75 7.5 7.8 8.2 7.85 7.25 6.85 7.9 7.2 7.0 6.8 5.7 8.13

Chapter III



3.25

Location: Existing sugar mill premises –

Administrative office

(Industrial area)


PM 2.5 (24h): = 60 µg/m3

SOx (24h): =80 µg/m3

NOx (24h): = 80 µg/m3

Direction from site - southwest Distance: 1.2km

Parameter 1 2 3 4 5 6 7 8 9 10 11 12 98th

percentile

PM10 37.5 44.6 36.2 41.7 40.4 45.8 39.8 32.1 30.0 28.7 27.5 36.9 45.54

PM2.5 17.5 18.7 14.8 18.9 19.3 22.1 16.5 17.5 15.0 14.5 12.0 14.4 21.48

NOx 10.25 10.7 11.4 10.4 10.8 11.2 10.5 9.9 10.7 9.90 9.50 9.25 11.36

SO2 7.60 8.2 8.5 7.85 8.1 8.5 8.9 8.1 7.75 7.8 7.25 7.5 8.81

Chapter III



3.26

3.3.12.2 Observations

The observations for PM 10, PM 2.5, SO2 and NO2 were well within new National Ambient Air Quality

(NAAQ) Standards (November 2009). Predominant wind direction during monitoring period was west,

southwest. Padali village at a distance of 2.km is in downwind direction and influenced by the sugar mill

air pollutants. Village Narsewadi is another residential area located towards east of the factory at a

distance of 4.5km. This is located on a small hillock of 17-20m in height. The concentrations of measured

parameters (i.e. PM, SOx, NOx) were significantly less compared to village Padali. There are two sugar

mills in 20km radious area of the factory; namely Yashwant Sahakari Sakhar Karkhana Limited towards

north west at approx 16km from the site and Tasgaon Sahakari Sakhar Karkhana Limited towards

southwest at 17km from the site. Cane transportation and crushing operations of these factories might

have some influence on ambient air quality of the study zone. The other influencing factors for ambient

air quality of study zone were agricultural activities in the surrounding area, domestic activities,

vehicular movements, etc.

3.3.13 Noise environment

Noise in general, is sound which is composed of many frequency components of various loudness,

distributed over the audible frequency range or Noise can be defined as an unwanted sound. It

interferes with speech and hearing. If intense enough, it can damage hearing, or is otherwise annoying.

The definition of noise as unwanted sound implies that it has an adverse effect on human beings and

their environment. Noise can also disturb natural wildlife and ecological system.

The most common and universally accepted scale for noise measurement is the weighted scale which is

termed as dB. This is more suitable for audible range of 20- 20,000 Hz and has been designed to weigh

various components of noise according to the response of a human ear. The environmental impact

assessment of a noise from the industrial activity, vehicular traffic can be undertaken by taking into

consideration various factors like potential damage to hearing, physiological responses, annoyance and

general community responses which have several effects varying from rise Noise Induced Hearing Loss

(NIHL) etc.

Noise levels were measured using a sound level meter. Noise survey has been conducted in the study area

to assess the background noise levels in different zones viz. residential, and Industrial zones. Noise

samples were collected from four locations within factory premises and eight locations in the surrounding

study zone.

Chapter III



3.27

Figure 3.12: Noise monitoring locations

3.3.13.1 Method of Monitoring

Sound pressure level (SPL) measurements were undertaken at above locations, for a period of 10

seconds, at an interval of 30 minutes per hour for 24 hours. The day noise level has been monitored for

6 am to 10 pm and night levels during 10pm to 6am at all monitored locations. The results of the noise

monitoring at the places monitored are given in Table 3.11

A reconnaissance survey was undertaken to identify the major noise generating sources in the area. The

different sources of noise were identified - mainly from industrial activities, commercial activities at very

minor scale, traffic, etc. The noise monitoring has been conducted at all the identified location in the

study area during the study period. Measured noise levels, displayed, as a function of time, is useful for

describing the acoustical climate of the community. Noise levels recorded at each station with a time

interval of about 30 minutes are computed for equivalent noise levels. Equivalent noise level is a single

number descriptor for describing time varying noise levels. The equivalent noise level is defined

mathematically as

Chapter III



3.28

Leq = 10 Log L / T∑ (10Ln/10)

Where, L = Sound pressure level at function of time dB (A)

T = Time interval of observation

Table 3.11: Noise monitoring results (dB A)

Location Avg. level day time

Avg. level night time

Standard

Day time Night time

Factory main gate

(Industrial area)

61.9 54.7

75 70

Factory Laboratory

(Industrial area)

65.2 63.2

Factory ETP

(Industrial area)

54.2 52.2

Factory guest house

(Industrial area)

60.1 56.1

Padali

(rural residential area)

58.1 44.2 55 45

Pare

rural residential area)

55.8 42.1 55 45

Narsewadi


60.2 44.3 55 45

Dhondewadi


50.1 40.6 55 45

Hatnoli


52.3 40.4 55 45

Dhamni


53.2 41.8 55 45

Mangalur (at market -

commercial place)

54.2 43.5 65 55

Aalte (busy road) 55.3 42.2 55 45

Chapter III



3.29

3.3.13.2 Observations

Noise levels within factory premises were observed within national standards for industrial zone. Day

time noise levels were observed exceeding the standard (55dB(A) level at village Padali, Pare, and

Narsewadi mainly due to agricultural and domestic activities. At village Aalte the noise levels were

measured for the traffic, where average levels observed to be exceeded for day time.

3.3.14 Ecology And Biodiversity

The study area is having semi-arid climatic conditions, where grassland vegetation (ecosystems) with

sparse trees is very common. But, due to human development, it is largely converted into agricultural/

cultivated land. Aquatic ecosystems were observed in the form of small artificial tanks, ponds, etc.

Rivers flows only in rainy season. Sagareshwar wild life sanctuary, having area of 10.87 sq.km is the

nearest sanctuary to the site. It is located at approx 26km from the site towards southwest.

3.3.14.1 Vegetation

Vegetation in the surrounding 10km radius zone was predominantly cultivated one. The crops observed

in the study zone are enlisted in table 3.12 (B). In case of natural vegetation, the site is located in

Khanapur Taluka of the district, which is towards east. Theses Eastern Taluka of the district such as

Atpadi, Jath, Kavathe Mahankal, Miraj (East), Tasgaon (East) and Khanapur are low rainfall areas hence

drought prone. The study area of the project is also part of this low rainfall zone. Hence, the natural

vegetation observed in the study zone is matching with semi arid climate, grasses are dominant with

scrubby vegetation. Species such as Acacia, Tamarind, Neem, Kashid, Subabool, Gulmolhar, Anjan,

Nilgiri, Australian Acacia, Pangara, Chilar, Sisoo, Agave, Khair, Karnaj, Shiras, Char, Bahava, Dhavada,

were very commonly observed. Plantation of Gliricidia under social forestry was observed very

frequently. Some of these were grown naturally where as fewer introduced one. Generally, small hill

slopes are covered with grasses.

3.3.14.2 Fauna

There are no major wild fauna observed in the study zone. Amongst these wild hare, snakes, squirrels

and different types of birds, which commonly observed on Deccan plateau, were recorded from the

area.

No any red listed floral or faunal element was recorded from the study area.

Chapter III



3.30

Table 3.12: List of plant observed in the study zone

Location 1: Factory site and Bamni ; 2: Dhamni; 3: Padali; 4: Narsewadi; 5: Dhondewadi; 6: Hanoli;

7: Aalte; 8: Chinchani; 9: Mangril; 10: Pare

Botanical Name Common Name 1 2 3 4 5 6 7 8 9 10

1. Abrus percatorius Guni - - - + + - - - + -

2. Acacia catechu Khair + + - + + - - - -

3. Acacia Leucophloea Hivar + + + - + + + + + +

4. Acacia nilotica (L.) Del. Babhul + + + + + + + + + +

5. Adhatoda zeylanica

Medic.

Adulsa - + - + + + - - - -

6. Aegle marmelos Bel - - - + - + - - - +

7. Agave Americana Ghypat + + + - + - + + + +

8. Albizzia lebak Shirish + + + + - + + - +

9. Amaranthus spinosus + - + - - + + + + +

10. Annona squamosa Sitaphal + + + + - - + + - +

11. Apluda mutica + - + - + + - + + +

12. Azadiracta indica A. Juss Kadu Limb/

Neem

+ + + + + + + + + +

13. Bauhinia purpurea L. Kanchan + - + - + - - + + +

14. Bauthinia recemosa Apta + + + - - + + - + +

15. Bougainvillea spectabilis

Willd

Bogan Vel + - + + + - + + + +

16. Butea monosperma Palas - + + + + + - - - -

17. Calatropis procera Ruhi + + + + + + - + - +

18. Caparis zeylancia Waghoti - - + + + - + - + -

19. Cardiospermum Sp Kapalphadi - - - + - - - - + -

20. Cassia auriculata Taravad + - + - + + + + + +

21. Cassia fistula Bahava - + - + - + + + - -

22. Cassia siamea Kasid + + + - + + -

23. Chloris barbata + + + + + + + + + +

Chapter III



3.31


24. Cleome viscose Tinval - + + + - - + - + -

25. Cordia dichotoma Bhokar - - - - + - - - -

26. Cymbopogon sp - - + - - + - - - +

27. Cynodon dactylon Durva/ Harali + + + + + + + + + +

28. Cyperous rotundous wala - + - - - + + + + -

29. Dallbergia sisoo Shisam + - + - + + - + + +

30. Delonix regia (Hook.)

Refln.

Gulmohor + + + + + + + + + +

31. Dhatura metal Dhotra + + - + + + - + + +

32. Eclipta alba Maka + + + + + + - + - +

33. Eragrostis sp Chimniche pohe + + + + + + + + + +

34. Eragrostris uniloidis Chimniche pohe + + + + + + - - + -

35. Erythrina variegate L. Pangara + + + + + + + + + +

36. Eucalyptus Spp. Nilgiri + + - + - + - - - +

37. Euphorbia nerifolia L. Nivdunga + + + + + + - + + +

38. Euphorbia tirucalli Sher + - + - + + + - + +

39. Ficus benghalensis L. Wad + + + + + + + + + +

40. Ficus recemosa L. Umbar + + + + + + + + + +

41. Ficus religiosa L. Pimpal + + + + + + + + + +

42. Ficus retusa Nandruk + + + + - + - - - +

43. Gliricidia sepium Fabaceae + + + - + + - + + +

44. Grewia tilifolia Dhavda - + - + + + - - + +

45. Heteropogon species + - + - + - - - - -

46. Jatropha gossipifolia Moghli errand + + - + - - + + - -

47. Lantana camara Ghaneri + + + + + + + + + +

48. Legenaria vulgaris Dudhani - - + - + - + - - -

49. Leucaena Leucocephala Subabul + + + + + + + + + +

Chapter III



3.32


50. Mangifer indica Mango/ Amba + + + + + + + + - +

51. Moringa oleifera Shevaga + + + + + + + + + +

52. Musa paradiasiaca Kel + + + + + + + + + +

53. Nyctanthus arbor-tristis

L.

Parijatak,

Prajakta

+ + + + - + - + + +

54. Ocium basilicum Ran Tulas - + + + + - + - +

55. Parthenium

hysterophorus

Congress grass + + + + + + + + +

56. Phylanthus amarus - + - + + + - + - -

57. Pithecellobium dulce Vilayati Chinch + - - - + - + - + +

58. Polyalthia longifolia Ashok + + + + + + + + +

59. Pongamia Pinnata (L.)

Pierre

Karanj + + + + + + + + + +

60. Proscopis juliflora Vedi Babhul + + + + + + + + + +

61. Prosopis spicigera Shami + + - + + - - +

62. Rhus parviflora Amoni - - - + + - + - - -

63. Scoparia dulsis + + + - + - - - + +

64. Solanum nigrum Bhui ringni - + + + - + + - - +

65. Sporobolus indicus - + + - + - + - + -

66. Syzygium cumini (L.)

Skeels

Jambhul + - + - + - + - + +

67. Tamarindus indica Chinch + + + - + + + + +

68. Tectona grandis Sag - + - + - + - + - +

69. Tinospora cordifolia Gulvel - - - + + - + - - -

70. Tridax procubens Ekdandi / Tantani + + + + + + + + + +

71. Tridex procumbanse + + + + + + + + + +

72. Vitex negundo L. Nirgudi + + + + + + + + + +

73. Vitis spp Draksha - - + + + - - + - -

74. Urena lobata L. - + - + - - + + + +

75. Xanthium strumarium L. Dhotri + - + - + - - - + +

76. Ziziphus jujuba Gaertn. Bor - - + + - + - + - +

Chapter III



3.33


77. Zizyphus mauritiana

Lamk.

Bor + + + + + + + + + +

B) Agricultural crops

S. No Common Name Botanical Name

1) Bajari Pennisetum typhoides

2) Chilly Capsicum sps.

3) Groundnut Arachis hypogaca

4) Hulaga Dholichos biflorus

5) Jawar Sorghum vulgare

6) Karadai Carthamus tinctorius

7) Maka Zea mays

8) Sugarcane Saccharum officinaraum

9) Til Sesamum indicum

10) Tobacco Nicotiana tobacum

11) Tomato Lycopersicon lycopersicum

12) Wheat Triticum sativum

13) Grapes Vitis vinifera

14) Turmeric Curcuma longa

Table 3.13: Fauna: The animal life of Study Zone

S. No Species Name Scientific Name

1. Cattle Egret Bulbulcus ibis

2. Little Egret Egretta garzetta

3. Blackeared or Large Indian Kite Milvus lineatus

4. Ring Dove Streptopelia decaocto

5. Spotted Dove Streptopelia chinensis

6. Koel Eudynamys scolopacea

7. Crow Pheasant Centropus sinensis

8. Small or Common Blue Kingfisher Alcedo atthis

9. White Breasted kingfisher Halcyon snyrensis

10. Small Green Bee-eater Merops orientalis

11. Large Green Barbet Megalaima zeylancia

12. Small Green Barbet Megalaima viridis

Chapter III



3.34

13. Black Drongo Dicrurus adsimilis

14. Common Myna Acridotheres tristis

15. Jungle Myna Acridotheres fuscus

16. House Crow Corvus splendens

17. Jungle Crow Corvus macrorhynchos

18. Red whiskered Bulbul Pycnonotus jocosus

19. Red vented Bulbul Pycnonotus cafer

20. Spotted Babbler Pellorneum ruficeps

21. Magpie Robin Copsychus saularis

22. Indian Robin Saxicoloides fulicata

23. Grey Wagtail Motacilla capsica

24. Purple Sunbird Nectarinia asiatica

25. House Sparrow Passer domesticus

26. Rose ringed parakeet Psittacula Krameri

b) Mammals

S No Species Name Scientific Name

1. House rat Rattus rattus

2. Dog Canis familiaris

3. Mongoose Herpestes auro punctatus

4. Domestic cat Felis domesticus

5. Cow Bos indicus

6. Buffalo Bubulus bubales

7. Sheep Ovis

8. Squirrel Funanbulus pennanti

9. Goat Capra sp

10. Indian hare Lepus nigricollis

11. Common bat Scotophilus heathi

c) Fish

Scientific name Local name

Mastacembelus armatus (Lacep) Vam

Anguilla angiulla (Ham.) Aheer

Chapter III



3.35

Oxygaster clupeoids (BL.) Vadshi

Oxvgaster Phulo Alkut

Barilius evazardi (Day) Thorya

Perilampus atpar (Ham.) Sonukli

Danio aequipinnatus (Meolelland) Balloki.

Brachydanio rario (Ham.) Dandai, Dandali

Puntius kolus (Skyes) Kolshi

Puntius sarana (Ham.) Khavli

Labeo boggut (Sykes) Sandasi, Sandi

Labeo fimbriatus (Bl) Tambir

Lepidocephachthys thermatic (C. and V.) Mori

Nemachilichtys rupelli (Sykes) Chikli

d) Other Faunal elements

S No Name Zoological name

1 Common bull frog Rana Tigrina

2 Cobra (King) Naja naja

3 Rattle snake Crotalus horoidus

e) Livestock details

Livestock Male (‘000)

Female (‘000)

Total (‘000)

Local low yielding (non descriptive) cattle

79.5 66.5 146.0

crossbred cattle 41.7 35.9 77.6 Buffaloes - local low yielding – non descriptive

20.8 256.6 276.6

Goat 369.9 Sheep 207.0

commercial dairy farms 8.23

Poultry Number of farms 212

Birds (‘000) 2125

Chapter III



3.36

3.3.15 Socio-Economy

Figure 3.13: Habitation map for 10km radius study zone

It could be observed from habitation map (figure 3.13) that the habitation is sparsely dispersed in the 5-

7km radius area. The density observed to be more towards 10km boundary towards North, Northeast

and east of the site. There are 23 villages in the 10km radious area of which only eight villages are in

5km radius circle.

3.3.15.1 Demography (Census 2011)

Table 3.14: Population details (for 10km radius area and for the district)

Sr.

No.

Village name Male Female Total

Population

1 Alta 1029 1037 2,066

2 Limb 620 660 1,280

Chapter III



3.37

Sr.

No.

Village name Male Female Total

Population

3 Hathnoli 1060 1061 2,121

4 Dhamani 606 644 1,250

5 Padali 482 569 1,051

6 Dhondgewadi 225 255 480

7 Kachrewadi 332 342 674

8 Ped 2871 2719 5,590

9 Hathnur 2478 2383 4,861

10 Visapur 1752 1761 3,513

11 Vita 21607 20197 41,804

12 Borgaon 2560 2523 5,083

13 Chichni.2 2231 1843 4,074

14 Bamni 1069 1077 2,146

15 Khambale 1138 764 1,902

16 Kindarwadi 276 359 6,35

17 Karve 1128 1139 2,267

18 Kurli 988 1023 2,011

19 Renavi 1058 1177 2,235

20 Revangaon 553 646 1,199

21 Ghoti (kh) 574 670 1,244

22 Ghoti(bk) 869 862 1,731

23 Ghanwad 1428 1346 2,774

Total 46,934 45,057 91,991

Demography of the sangli district

Description Rural Urban

Population (%) 74.51 % 25.49 %

Total Population 2,102,786 719,357

Male Population 1,071,124 364,604

Female Population 1,031,662 354,753

Chapter III



3.38

Sex Ratio 963 973

Child Sex Ratio (0-6) 859 889

Child Population (0-6) 230,283 76,494

Male Child(0-6) 123,855 40,500

Female Child(0-6) 106,428 35,994

Child Percentage (0-6) 10.95 % 10.63 %

Male Child Percentage 11.56 % 11.11 %

Female Child Percentage 10.32 % 10.15 %

Literates 1,495,094 554,373

Male Literates 827,806 293,744

Female Literates 667,288 260,629

Average Literacy 79.84 % 86.24 %

Male Literacy 87.39 % 90.63 %

Female Literacy 72.12 % 81.76 %

Table 3.15: Seasonal Migration details

Purpose Area

(Talukas)

Period

(calendar months)

Estimated population

in Migration

Sugarcane

cutting and

transport

Sangli (Miraj)

Walwa (Walwa)

Islampur (Walwa)

Chikali (Shirala)

Nagewadi (Khanapur) Kavathe

Mahankal (Kavathe Mahankal)

Jath (Jath)

Atpadi (Atpadi)

Tasgaon (Tasgaon)

Nov. to May

Nov. to May

Nov. to May

Nov. to April

Nov. to April

Nov. to April

Nov. to April

Nov. to April

Nov. to June

15,851

11,730

21,490

5,630

6,060

4,436

2,020

3,800

6,000

Total Sangli District Nov. to June 77,017

3.3.15.2 Occupation Pattern

Agriculture is the main occupation of the people. The villages are well connected with the urban areas of

the district for their needs such as education, health, administrative, industrial produces, fertilizers and

Chapter III



3.39

pesticides and also as a market centers for the agricultural productions. Majority of farmers takes animal

husbandry as an occupation, supplementary to farming. Rearing goats and sheep, Poultry are other

important occupations observed in the district. The mining activity is also observed where resources are

available in the district for extraction of stones, grits and bauxite. The sand from river bed is also used

for construction. Some people are working in mining occupation. As Sangli district is endowed with

various river beds and many water storage tanks, dams, due to these resources some people are

working in fishing occupation.

The role of sugar factories through co-operative and private sector is much important in the

development of industrial sector. Additionally, separate industrial estates are developed at Miraj,

Kupwad, Palus, Vita, Jat and Kadegaon, through Maharashtra Industrial Development Corporation.

Besides those the dairy farms, chilling plants and hatcheries, spinning mills are also among growing

industries. These Industrial developments are providing secondary occupation to the locals.

3.3.15.3 Agriculture and Cropping Pattern in the District

Net cultivated area is 594,623 hectares, while double crops area is 59,743 hectares. Thus gross cropped

area is 654,366 Hectares . Net cropped area is 82% as compared to the total cultivable area. Major crops

include Paddy, Jowar, Bajra, Groundnut, Wheat, Gram, sugarcane, Soybean, Grapes, turmeric,

Pomegranate, and Ber.

Out of the net cultivable area, 46% is under Jowar and 16% under Bajra. Jowar (Kharif) is sown in Walwa,

Miraj, Tasgaon, tahsils while Jowar (Rabi) is taken in Miraj (east), Khanapur, Atpadi, Jath and Kavathe

Mahankal tahsils. Bajra is grown in Jath, Atpadi and Kavathe Mahankal tahsils. Paddy is taken in Shirala

and Walwa tahsils. Sugarcane is taken in all the tahsils where there is assured source of water. Grapes

are cultivated in Tasgaon, Khanapur and Kavathe Mahankal tahsils. Tasgaon grapes are famous in India

and the Middle East. Pomegranates and Ber are taken in Jath and Atpadi tahsils while Soyabean is

cultivated in Walwa, Miraj, Tasgaon and Khanapur Tahsils. These tahsils also have groundnut crop.

Table 3.16: Cropping pattern observed for the Sangli district

Crop Types Names Cropping Period in Months

Market (District State Export)

Major Crops (Irrigated)

1) Sugarcane 2) Grapes 3) Turmeric

12 & 18 months 12 months

Sugar factories in Sangli dist.

Chapter III



3.40

Major Crops (Non-irrigated)

1) Hy. Jowar 2) Bajra 3) Soybean 4) Groundnut

4 to 5 months

District / State

Major Cash crops 1) Sugarcane 2) Grapes 3) Ber 4) Pomegranate

12 months 12 months 12 months 6 months

Sugar factories Dist./ State, India, Foreign Dist./State State /India

Major Plantations Mango, Guava, Pomegranate, Coconut

12 months 6 months 6 months

District State, India

Table 3.17: Irrigation Facilities

Net irrigated area 174,000ha

Gross irrigated area 190,000ha

Rainfed area 421.6 ha

source of irrigation Number Area (000 ha) Percentage

canal - 45 25.9 tank 100 0.2 0.1 Open well 54,065 63.6 36.5 bore well 133 3.4 2.0 Lift irrigation schemes 680 40.0 23.0

micro-irrigation 10.0 5.7 Other sources 11.7 6.7 Total Irrigated area 174.00 100 Pumps 35,000 Tractors 4,000

3.3.15.4 Power Stations And Electricity Installations

In Sangli district, there is one Circle at Sangli and separate Divisions for rural and urban areas. Three

rural Divisions are located at Sangli, Islampur and Vita and one urban Division at Sangli. Besides, the Sub-

Divisions at Tahsils and Brach Offices at village levels are also functioning. There are 275 km of High

Tension Lines (220 & 110 KW), 5300 km of High Tension Lines (32 & 11 KV) and 11405 km of Medium

Tension Lines. There are 8 highest tension stations and 32 high and medium tension stations.

Power supply is given to all the villages and Harijan households (wastis). Sangli district ranks sixth in the

state in supply of power to agricultural pumps. A total of 508,361 thousand KW of power is being used

in the district, out of which 44% is for industry, 25% for Agriculture, 20% for domestic purposes, 5% for

trade and commerce and 2% for street lighting.

Chapter III



3.41

3.3.15.5 Education Facilities

Primary education facilities at mahapalika level and palika level are provided by themselves while at

gram-panchayat level such facilities are provided by Zilla Parishad. The zilla parishad also provides

secondary and higher secondary educational facilities in the district. There are 1824 Zilla Parishad –

Primary schools, 476 secondary schools, 117 junior and senior colleges, 11 D.Ed. / B.P. Ed, 1 law college,

2 medical colleges, 2 engineering colleges, 2 polytechnic colleges and 2 pharmacy colleges in the Sangli

district. The educational facilities are mainly concentrated at Sangli, Miraj, Islampur and Vita city/towns

of the district. Higher education, professional and technical educational facilities are provided by private

institutions too.

3.3.15.6 Medical Facilities

Sangli and Miraj are well known for availability of the best medical facilities. Well equipped medical

institutions including a medical college are located in and around these two cities. Miraj Mission

Hospital is the biggest medical centre where eminent medical surgeons and expert consultants render

medical services. People from other states in India as well as Arab Countries also come for receiving

medical treatment in this hospital.

3.3.15.7 Industries

Though Sangli district is not backward in industrial development, but it cannot be said to be advanced.

Some industries are concentrated at Sangli-Miraj urban area, Islampur, Palus, Kirloskarwadi, Chikhali,

Atpadi, Walwa, Kavathe Mahankal and Thurch Phata. In rest of the district there is no industrialization

The district is mainly recognized for sugar and cotton textile industries in the state. There are 15 co-

operative and 3 private sugar factories (refer table3.18) and 21 cotton industries in the District. one

engineering factory is located at Kirloskarwadi and one bulb factory at Nerle. The city Vita, Madhavnagar

area of Sangli is famous for power looms. There are six state industrial estates in the district situated at

Sangli, Miraj, Vita, Kavthe-Mahankal, Islampur and Kadegaon and four co-operative industrial estates

situated at Sangli, Miraj and Palus. There are 692 registered factories of which 594 are working. Capital

invested amounts to Rs.301 Crores and working capital amounts to Rs.146 Crores. There are 36,000

workers. There are near about 7032 registered small scale industries employing about 25,000 workers.

Small scale industries like handlooms, garments, waving rough blankets are also established. Miraj is

famous for string instrument “Sitar”. In addition, there are many other industries like diamond cuttings,

Chapter III



3.42

Silver and gold ornaments, pottery making, foot wares, cement and plastic pipes. Cottage industries are

making pickle, papad, etc. There are nine industrial training institutes in Sangli district. List of sugar

factories and distilleries of Sangli district

Table 3.18: List of sugar and distillery units in the Sangli district

# Sugar unit Crushing

capacity (TCD)

Distance

(km)

Distillery status

1. Manganga Sahakari Sakhar

Karkhana Limited

1250 75 Unit of 30KLPD Molasses source –

attached sugar unit

2. Hutatma Kisan Ahir Sahakari

Sakhar Karkhana Limited

3500 80 30KLPD proposed /under process

3. Mahankali Sahakari Sakhar

Karkhana Limited

1250 60 No distillery unit

4. Rajarambapu Patil Sahakari


4000 50 75KLPD unit – molasses sources –

own sugar unit

5. Vasantdada Shetkari Sahakari


7500 90 45KLPD unit - molasses sources –

own sugar unit

6. Vishwasrao Naik Sahakari


2500 80 30KLPD unit - molasses sources –

own sugar unit

7. Yashwant Sahakari Sakhar

Karkhana Limited - Khanapur


8. Tasgaon Sahakari Sakhar

Karkhana Limited


9. R.V. Daphale Sahakari Sakhar

Karkhana Limited


10. Sonhira Sahakari Sakhar

Karkhana Limited

2500 65 30 KLPD unit - molasses sources –

own sugar unit

11. Ninaidevi Sahakari Sakhar

Karkhana Limited


12. Cane Agro Energy (P) Ltd 2500 45 45KLPD unit - proposed

13. Kranti Sahakari Sakhar

Karkhana Limited

4000 30 -

Chapter III



3.43

# Sugar unit Crushing

capacity (TCD)

Distance

(km)

Distillery status

14. Mohanrao Shinde Sahakari



15. Sarvodaya Sahakari Sakhar

Karkhana Limited


16. Rajarambapu Sahakari Sakhar

Karkhana Limited -Wategaon


17. Sadguru Sri Sugar (P) Ltd 2500 50 No distillery unit

18. Udagiri Sugar and Power Ltd 2500 - 30KLPD unit - Proposed

3.3.15.8 Transport and Communication Network

The site is well connected by road as well as railway network. State highway 111 and 78 are the nearest

highways to the site, at a distance of approx 9km towards north and east respectively. Mumbai- Banlore

National highway 4 is approx 50km from the site. The district is connected with the rail, highway, roads

and state roads with remaining area of the state and the country. Road length in Sangli district is 8315

km of which 1015 km roads are in charge of PWD, 6850 km belong to Zilla Parishad and 450 km are in

Municipal council area. There is one National highway of 30 km, 111 km of major State Highways, 809km

State Highways, 1952 km Major district Roads, 2710 km Other District Roads and remaining are village

roads. State transport buses run on 1193 routes of 55.2 thousand km. Daily average buses on route are

734, carrying passengers average 3.04 lakhs per day. There is a separate Regional Transport Office in

Sangli.

The district is connected with Pune –Banglore rail line. There is total 173.70 Km. broad-gauge railway

track in the district.

Table 3.19: The transport network summary

Number of National Highways 1

Length (in Kms) of National Highways 29.75

State highways (in Kms) 920.20

ZP roads (in Kms) 6850

Number of bridges on rivers 20

Chapter III



3.44

Number of ST depots 9

Numbers of villages not accessible by ST 37 Wadies & Hamlets

Number of railway stations with mail / express halts 3

Number of railway bridges 15

Railway routes (in Km) 173.70

Number of unmanned railway crossings 34

Number of airports/air strips 1

The district is also well connected by telecommunication and postal facilities to the rest of the country.

The telecommunication facilities are mainly provided by BSNL as well as some private leading operators

like Airtel, Aircel , Docomo etc. There are is one post office for every two villages together there are 412

Post Offices.

3.3.15.9 Traffic data

Table 3.20: Traffic density on sugar factory approach road (average for peak hour)

# Vehicle No.

1 Trucks, tankers, etc. 7

2 tractors- trailor (mainly for cane transport) 11

3 bullock carts (mainly for cane transport) 30

4 pick-ups 2

5 4 wheelers 12

6 2 wheelers (Including bicycles) 42

Total 104

3.3.15.10 Banking facilities

Nationalized, cooperative as well as private banks are located at Vita, Tasgaon, Khanapur and other

major town/villages. These are located in 15km radius circle from the site. In addition local credit

societies, farmers cooperative societies exist which provides different services to the local population.

3.3.16 Seismic zone and other

From figure 3.15, it appears that, the proposed site is in Earthquake zone III. In this zone, the probable

earthquake intensity of 5-7 Richter scale could be observed.

Chapter III



3.45

Religious place/s: Revanath temple located in village Renavi is a famous religious place situated at ~9km

from the site, towards north.

No defense installations or recreational sites, historically or archeologically important/ notified sites,

ecologically sensitive sites, national parks, sanctuaries, biosphere reserves present in 10km radius study

area.

Figure 3.14: Road and railway network map for study zone

Chapter III



3.46

Figure 3.15: Earthquake zones of Maharashtra

Chapter IV

EIA Report: New Molasses based Distillery project Udagiri Sugar & Power Ltd; Dist. Sangli Maharashtra

4-47

CHAPTER IV

ENVIRONMENTAL IMPACT ASSESSMENT

4.1 INTRODUCTION

This chapter discusses anticipated environmental impacts based on the quantities and/or

characteristics of various pollutants/ causing factors likely to be generated from different

activities of the proposed project.

4.1.1 Facts and Considerations

The impact assessment is based on following facts and considerations

The sugar unit is already operational

Effective utilization of land, boiler, steam, fuel, molasses, pressmud will be

achieved by the proposed distillery unit

Saving of resources such as bagasse and water

Sufficient land is available with project proponent to accommodate the process

units pollution control units as well as for development of greenbelt; therefore no

alternative site search was undertaken

No rehabilitation/restoration issues involved with proposed site

Land is already used for industrial purpose and no new land use will be set due to

the project

The process is simple and straight

Technology for the process as well as for the pollution control/disposal are

available indigenously

Spent wash treatment and disposal through bio-methanation followed by multi-

effect evaporation followed by biocomposting methods. ZLD will be achieved

The factory is having adequate provision of funds for the project as well as

implementation of EMP

Management is keenly concerned about health, safety and environmental issues

and implement all schemes /measures necessary for it

Project proponents are local, understands the socio-economy of the region and

well aware of environmental concerns of the people

4.2 AIR ENVIRONMENT

4.2.1 Pollution sources

4.2.1.1 Construction activity: Various construction activities of the project such as

erecting various units, buildings, pollution control devices, internal road involve use of

Chapter IV


4-48

construction equipments, road rollers, water tankers etc. These activities are machinery

intensive and usually driven by diesel engines. Thus, it resulting in emission of gases,

generation of dust and noise

4.2.1.2 Transportation: These activities causes’ air pollution through vehicular exhaust

emissions, dust from roads and loading unloading of material, etc.

In present case, transportation of raw material will be minimal since major raw material such

as bagasse and molasses will be made available from the sugar factory.

Transportation of finished product i.e. RS/ENA or AA usually takes place in bulk. Considering

gross capacity of storage tanks (600m3x7) 4200m3, it will require about 280 tankers

(considering each tanker of 15m3 capacity). Considering the loading time, availability of

tankers at a time and other practical aspects, it is anticipated that 30-40 tankers will

commute daily from the site. This activity may takes place for two to three weeks. Hence,

this could cause increase in NOx, and particulate matter during the period (particular days)

of transportation. Vehicles of employees and visitors could be a regular source of emissions.

The project is going to provide employment to approx 70 persons, in addition there could be

some contractual or seasonal employees. The project is located in rural area, where people

prefer two wheelers (bicycles, motor cycles, scooters, etc) to commute. Hence, about 90-

95% of such vehicular emissions are anticipated from two wheelers (~50-60 in numbers) and

remaining 5-10% due to passenger cars and other types of vehicles (~5-7 in numbers).

Therefore, transportation activity of the proposed project is anticipated to cause minor

increase in vehicular emissions.

4.2.1.3 Preventive, control and mitigation measures

The dust generated during the construction activity could be suppressed by

Sprinkling of water on dust generating sources

Sprinkling of water while loading/unloading the dust generating material,

wherever feasible

To reduce air and noise emissions, instead of diesel operated, electrically

operated machinery (wherever feasible) to be used

Barricading the dust generating or high noise generating areas

Provision of asphalted roads inside the premises and for approach road upto

state highway

Provision of adequate parking for goods as well as staff vehicles

Engage authorized transport agency for goods transport on the term to use well

maintained vehicles for the activity

Chapter IV


4-49

While bulk transportation, check the time to fill a tanker and call those many

which could get filled in 2-4 hours, example if one tanker requires about 8-10

minutes than call 12 tankers at a time and call next 12 after one and half to two

hours; this will help to reduce the risks of traffic congestion and minor accidents,

waiting period for vehicles and over all air pollution.

Provide separate entrance and exit lanes/gates for goods as well as employees

vehicles

Strict prohibition on washing/ maintenance of vehicles on site or in parking area

All roads with street light and proper signage at strategic locations

Main gate/s with 24x7 security arrangements

4.2.1.4 Manufacturing process: The manufacturing process is likely to generate two forms

of air pollutants i) is due to burning of fuel to generate steam and ii) from fermentation

process

a. Emissions due to burning of fuel (Bagasse)

In the proposed project, bagasse will be used as a fuel, which is a byproduct of sugar unit.

Bagasse is an excellent source of renewable energy. Conventionally, coal or natural gas is

used as a fuel in many other industries. Both, coal as well as natural gas is a fossil fuels and

non-renewable energy source. Burning of fossil fuels is considered as a one of the prime

Green House Gas (GHG) emission source. Hence, use of renewable energy sources is

encouraged all over the world. Use of biomass energy is encouraged especially in power

generation sector, due to its carbon neutral characteristics. The flue gasses generated due to

it will emit ash, which is the main source of air pollution. The analysis of bagasse is given as

bellow.

Table 4.1: Analysis of bagasse

Parameter Value (in %)

Carbon 40-45

Hydrogen 2-6

Oxygen 40-45

Nitrogen 0.15-0.20

Moisture 50%

Ash content 1.5 - 2.00%

Sulphur <0. 01

Calorific value 2,250 kcal/kg

Chapter IV


4-50

Bagasse analysis report shows that the elements such as nitrogen and sulfur are present in

trace quantities, i.e. less than 0%. Thus, the generation of sulfur-dioxide (SO2) and oxides of

nitrogen due to combustion of bagasse are anticipated to be very low.

The quantity of ash generated can be calculated as follows

Bagasse required to generate 121MT steam per day

(generally observed bagasse to steam ratio 1:2.2)

= 55 MT/day = 2.29TPH

Ash content = 2.00 %

Total Ash generated = 1.10MT/day

= 0.0458 MT/h = 45.80 Kg/h

For bagasse, fly ash generation is usually 40% of total ash generated. ESP is in place on

existing 75TPH boiler to control particulate matter from flue gases

Bottom ash = 27.48 Kg/h

Fly ash generation = 18.32 Kg/h

Fly ash controlled by ESP (considering 98% efficiency) = 17.953 Kg/h

Fly Ash emission = 0.3664Kg/h

= 0.102 g/sec

Apart from this, trifling fugitive dust emission due to opening and leaks in duct and

manholes and also from ash handling operation at unloading and transfer point are the

minor pollution sources

Sulphur Dioxide (SO2): Another source of air pollution could be the SO2 formed due to

burning of biogas in the sugar factory boiler. The H2S present in the biogas after burning will

release the sulphur that will react with the oxygen present in the air and form SO2 the

reaction will be as follows.

2H2S + 2O2 SO2 + 2H2O + S ------------------ (Equation 1)

2(2+32) + 2(16) (32+32) + 32 + 2(2+16)

68 + 64 64 + 32 + 36

Estimated Biogas production (Considering COD 125,000 mg/liters) = 12,180 m3/day

1.) General composition of biogas produced by using distillery molasses are

Methane (CH4) 64%

Carbon dioxide CO2 34%

Hydrogen sulfide (H2S)Max 02%

Chapter IV


4-51

Amount of H2S from 12,180m3 Biogas = 243.6 m3/day

(Considering the density of H2S =1.539kg/m3) = 374.90 kg

As per equation I – 68 gm of H2S combustion required 64gm of oxygen i.e. 94% of

total volume.

374.9 x 0.94 = 337.41 kg oxygen required

Since the amount of Oxygen required = amount of SO2 generated

Total SO2 produced = 337.41 kg/day

Thus, SO2 Emission will be 3.90g/second

There are mainly two opportunities for NOx formation.

1. Thermal NOx - The concentration of “thermal NOx” is controlled by the nitrogen and

oxygen molar concentrations and the temperature of combustion. Combustion at

temperatures well below 1,300(C (2,370(F) forms much smaller concentrations of

thermal NOx

2. Fuel NOx - Fuels that contain nitrogen (e.g., coal) create “fuel NOx” that results from

oxidation of the already-ionized nitrogen contained in the fuel.

Emissions of NOx from combustion of fuel are primarily in the form of NO. Theoretically,

Nitric oxide (NO) is generated to the limit of available oxygen (about 200,000 ppm) in air at

temperatures above 1,3000C (2,370(F). At temperatures below 760(C (1,400(F), NO is either

generated in much lower concentrations or not at all. In case of bagasse fired boilers, the

temperature encountered are around 850-10000C, mainly due to high moisture content of

bagasse (~50% moisture). This temperature is much lower for formation of NO, which is

usually formed above 1,3000C. However, as a worst case scenario it is assumed that the NO

formation may take place at 50% rate. Secondly, the bagasse analysis data shows that, the N

percentage is less than 0% which is in the range of 0.10 to 0.20%. Therefore, an average of

0.15% of N content is considered while calculating NO emissions in the present case. Thus,

the second probability of fuel NOx becomes insignificant.

4.2.2 Air Dispersion Modeling

Impact on ambient air quality of the study zone is envisaged due to emissions from the

existing boilers of 75 TPH capacity of sugar mill. This boiler is Bagasse fed, supplied @ ~30TPH.

Steam generated at 72.5kg/cm2 at 5150C is fed to steam turbine generator of 14mw capacity

and the exhaust steam at low pressure is used in sugar mill. The distillery unit is going to use

low pressure exhaust steam from the cogeneration unit of the sugar mill. No additional fuel

will be burnt for steam generation during sugar cane crushing season. Flue gases are

released through 72m tall stack after passing through ESP, which is >98% efficient to trap

Chapter IV


4-52

particulate matter. During the off-season, the fuel requirement for distillery unit will be only

2.3TPH, which is <10% of existing (30TPH). It indicates that, the present ambient air quality

of 10km radious area may not get affected. On this background, the baseline air quality data

presented in chapter III table 3.10, observed at all locations were within NAAQS. However,

to calculate incremental load for PM and SOx it is assumed that, there would be additional

bagasse to be burnt.

Prediction of impact on air environment has been carried out employing mathematical model

based on a steady state Gaussian plume dispersion model designed for multiple point sources

for short term. In the present case, Industrial Source Complex-Short Term [ISCST3] developed

by United States Environmental Protection Agency [USEPA] has been used for simulations from

point sources.

Table 4.2: Model Input Data

Parameters Unit Stack Attached to Boiler

75 TPH

Stack height m 72

Stack diameter at exit / top m 3.0

Stack exit gas velocity m/s 4.2

Stack gas temperature at exit Deg. C 160

Bagasse requirement TPH 2.3-2.5

Emission rate of SPM g/s 0.12g/s

Emission rate of SO2 g/s 3.90g/s

Ash content 2% and dust removal efficiency of ESP 98%

Main fuel: Bagasse;

Auxiliary fuel: biogas, (approx 12,000m3/day)

The quantity of ash generated can be calculated as follows

The simulation is made to evaluate PM and SO2 incremental short-term concentrations due

to operation of boiler for proposed activity. In the short-term simulations, the incremental

concentrations were estimated for 10 km radius. Modeling has been done considering

boilers as source and is centre of grid for prediction. Hourly meteorological data recorded at

site for summer season on wind speed, direction and temperature is used as input. For the

site-specific mixing heights CPCB document PROBES/88/2002-2003 is followed.

Chapter IV


4-53

-10000 -8000 -6000 -4000 -2000 0 2000 4000 6000 8000 10000-10000

-8000

-6000

-4000

-2000

0

2000

4000

6000

8000

10000

0.00

0.05

0.10

0.15

0.20

0.25

0.30

0.35

0.40

0.45

0.50

-10000 -8000 -6000 -4000 -2000 0 2000 4000 6000 8000 10000-10000

-8000

-6000

-4000

-2000

0

2000

4000

6000

8000

10000

0.00

0.00

0.01

0.01

0.02

0.03

0.03

0.04

0.04

Figure 4.1: Short Term 24 Hourly GLCs of Particulate matter

Figure 4.2: Short Term 24 Hourly GLCs of SO2

4.2.2.1 Prediction Site/stack

Site/Stack

Chapter IV


4-54

The predicted results with baseline concentrations are tabulated below in Table 4.3 while

incremental dispersion trend is shown as isopleths in Figure 4.1 & 4.2.

Table 4.3: Resultant Concentrations Due To Incremental GLC's

* The baseline concentration (98th percentile) recorded at village Padali at 2km East of the site

The resultant concentrations of SPM and SO2 after operation of Boilers are within the

prescribed National Ambient Air Quality Standards (NAAQS) for Residential & Rural Areas

4.2.3 Other sources of air pollution

Fugitive dust/particulate matter: Fugitive sources will be mainly, from vehicular movement

and bagasse storage. Bagasse will be transported to distillery through closed conveyers,

hence fugitive dust will be negligible.

Carbon dioxide generated from fermentation process, will be of biological origin, i.e.

liberated from an agro-based waste material. Hence, it is assumed to be neutral for GHG and

therefore a minor source. Along with carbon dioxide, methane will be produced from

biomethanation process of spentwash treatment. This methane (biogas) will be used as a

fuel for boiler in sugar unit.

Odour is anticipated mainly due to storage of spentwash and partly from composting activity

Preventive, control and mitigation measures

Use of Bagasse as a fuel

Round RCC stack with 72m height

ESP to control particulate matter

Green belt of 2.6 acres around the project area

Methane produced from biodigesters will be used as a fuel; flare unit is an alternate

arrangement when it will not be used as fuel

Fermentors will be closed and CO2 scrubbers for fermentation unit

Composting will be done aerobically using machines

Ash slurry as well as bottom ash will be used to mix in compost since bagasse ash is

rich in potash

4.2.4 Impact assessment

Scenario Incremental

Concentration,

g/m3

Baseline

Concentration*

g/m3

Resultant

Concentration,

g/m3

CPCB Limit for

Residential & Rural

Areas, g/m3

PM10 0.04 84.21 84.25 100

SO2 0.5 8.3 8.8 80

Chapter IV


4-55

The construction activity will be for short period; the negative impact will be mainly due to

particulate matter. It will be restricted to the site by adopting above mentioned mitigation

measures. Hence, the resultant impact due to construction is anticipated to be temporary

and minor negative.

Human health: particulate matter from various sources and activities of project may cause

related ailments to persons likely to get exposed, beyond the stipulated NAAQS

Air quality: Air dispersion modeling study shows that, there will be minor/negligible increase

in PM concentration by 0.04micro gram at village Padali located at ~2km towards east of the

site. The resultant ground level concentration (after adding incremental load) anticipated to

be within NAAQS. Minor negative impact is anticipated mainly due to stack gas emissions

and transportation activities of the proposed project;

Ecology and biodiversity: Minor negative impact is anticipated on avi-fauna due to stack gas

temperature (approx 80-90oC), and on flora/plants in close vicinity of the project due to dust

(particulate matter)

4.3 NOISE

The identified chief sources of noise in the proposed project are -

Boiler

Motors and pumps

Distillation

Transportation

Diesel generator (rarely used only in case of total power failure)

Table 4.4: General Noise levels

Source Noise Level at source (average in dB(A)

Boiler 83.0

Motors and pumps 75.2

distillation 72.5

Transportation 81.3

DG 75.0

Preventive, control and mitigation measures

Use motors, pumps and other machines which comply national/international

standards. Noise generating activities will be under roof

Preventive as well as regular maintenance

Chapter IV


4-56

Provision of personal protective equipments as per requirement

Rotation of duties at high noise generating areas

Leveled and wide internal roads

Adequate parking space


Health: adverse impact of mainly noise and to some extent vibrations is anticipated on

persons working in close areas of noise source. This impact would be in the form of health

hazards such as impact on hearing ability, irritation, blood pressure and other similar related

to high noise levels.

Ambient air quality: Minor negative impact, particularly at work places

Ecology and biodiversity: Minor negative impact of noise from transportation activity is

anticipated on particularly human beings and fauna, along the approach road (3km length)

that connects site with state high way.

4.4 WATER ENVIRONMENT

4.4.1 Waste water sources and characteristics: Following wastewater sources have been identified for the proposed project

Spent wash

Spent lees

Blow down from boiler/cooling tower

Wastewater from washing/cleaning

Condensate water

Sewage

4.4.1.1 Boiler blow down

The water used in boiler contains suspended solids, dissolved solids like Ca-salts, Mg-salts,

Na-salts, Fe-salts etc. These salts get concentrated after generation steam from the original

water volume. These solids have to be expelled from time to time to save the boiler being

covered up by scales.

This water has following characteristics.

BOD - 60 to 70 mg/L

SS - 800 to 1,500 mg/L

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

Temperature - 90 to 100oC

The estimated volume form boiler blow down is 2.5 - 3m3/day. It could be recycled after

cooling.

Chapter IV


4-57

4.4.1.2 Condensate of MEE

Condensate characteristics would be as follows.

pH 3-4

COD 6,000 mg/lit

BOD 3,000 mg/lit

TDS <1000 mg/lit

Temperature 35-45 °C

This water will be treated in condensate polishing unit. The estimated excess condensate is

255m3/day totally recycle or reuse after treatment.

4.4.1.3 Spentwash

Using a continuous fermentation technology spentwash generation is about 10-12 liters per

lit of alcohol. Due to technology advancement, this volume is also getting reduced to 8L/L of

alcohol. Spentwash is a major pollutant and cause of concern for molasses based distillery. It

is because, spentwash is having high temp, highly acidic nature, and dark brown in colour. It

also contains high percentage of dissolved organic & inorganic matter; hence its BOD and

COD are also considerably high. The general qualitative characteristics of spentwash are

highlighted below.

Table 4.5: General Characteristics of Raw Spentwash

# Parameter Continuous Fermentation

Process

Unit

1. Volume, Liters. per Liters of Alcohol 10 -11 ----

2. Colour Dark brown ----

3. pH 4.0-4.3 ------

4. COD 1,00,000-1,10,000 mg/L

5. BOD 55,000-65,000 mg/L

6. Solids - Total Solids

Total Volatile

Inorganic dissolved

1,30,000-1,60,000

60,000-75,000

35,000-45,000

mg/L

mg/L

mg/L

7. Chlorides 6,000-7,500 mg/L

8. Sulphates 4,500-8,500 mg/L

9. Total nitrogen 1,000-1,400 mg/L

Chapter IV


4-58

10 Potassium 10,000-14,000 mg/L

11 Phosphorus 300-500 mg/L

12 Sodium 1,400-1,500 mg/L

13 Calcium 4,500-6,000 mg/L

Spent wash could cause severe pollution of surface and ground water. It could act as a

fertilizer if applied in controlled manner under skilled supervision. But, often applied in

excess that contaminates soil and run off from such field contaminates nearby water bodies.

Therefore, storage and disposal of spentwash considered to be important processes from

environment management perception.

4.4.1.4 Floor Washing

Other wastewater originates from washing of the floor, fermentation, vats and other

equipment. The quantity of floor washing will be about 4m3/day and will be reused for

gardening activity, within factory premises.

4.4.1.5 Spentlees

It is also an important source of pollution. The acidic nature of the spent lees is main cause

of the pollution. It will have a pH in the range of 3 – 4. Quantity of spentlees expected from

the proposed distillery will be approx. 75m3/day. The spentlees will be sent to treatment

unit and reused in the distillery.

4.4.1.6 Sanitary wastewater

In the proposed project, sewage generation will be about 5-6m3/day. It will be disposed by

septic tank and soak pit system.

4.4.1.7 Thermal Pollution

The hot effluents are boiler blow down and cooling tower blow down. The hot water will of

about 45-500C temperature and the quantity will be of 40-45m3/day. This hot water will be

cooled down to normal temperature in cooling pond and then recycled. Hence, there will be

no thermal pollution of any surface water body around the project site.

4.4.2 Preventive, control and mitigation measures

Spentwash of 300 m3/day will first treated in biodigesters to produce biogas from this

organic rich wastewater followed by biodigestion spentwash will be sent to multi effect

evaporation unit to reduce its volume from 300m3 to 120m3

Chapter IV


4-59

Then it will be sent to biocomposting process where it will be mixed with pressmud (a solid

waste from sugar mill) to produce compost; thus achieving ‘zero liquid discharge’ for this

highly polluted entity.

Spentwash storage lagoons and the compost yard will be constructed as per CREP guidelines

(Refer figure 2.4,2.5 and 2.6 of chapter II and also discussed in chapter VI)

4.4.3 Reuse of water (after proper treatment)

Wastewater due to cleaning and washing, Spentlees and condensate water will be treated in

CPU. This unit will comprised of anaerobic followed by aerobic treatment (discussed in

chapter II – point 2.5.2); treated water of 350m3 per day will be used for dilution of

molasses, cooling tower make up, irrigation, or cleaning activities, etc.

Recycle of water: Blow down water from boiler and cooling tower will be cooled in ponds

and recycled then after

Conservation of water: Rain water harvesting to improve the ground water aquifer and

partly fulfill the requirement during startup


Water availability: No negative impact since, Irrigation Dept will provide the water allocated

for industrial activities only; reuse, recycle of water will save significant of freshwater intake

Water/aquatic environment: No negative impact on water environment as well as aquatic

ecosystems of the surrounding area due to achieving zero liquid discharge

Air environment: minor negative impact due to odour of spentwash and due to generation

of methane and CO2 from composting process

Soil Environment: Due to impervious lagoons and compost yard probability of soil pollution

due to percolation of spentwash is zero. Hence, no negative impact is anticipated; The

compost prepared from spentwash, pressmud and solid waste filler material will help to

recycle the soil nutrients, thus positive impact is anticipated

Ecology and biodiversity: No negative impact, composting process usually attracts avi fauna

due to availability of micro-organisms as a food

4.5 SOIL ENVIRONMENT

Soil is likely to get affected due to following.

a. During construction of various units, removal of top soil layer which is usually more

fertile

Chapter IV


4-60

b. Excavation activity – particularly for spentwash storage lagoons and compost yard

c. Construction of various permanent structures/roads at project site

d. Degradation of soil due to construction material (cement, concrete)

e. Disposal of untreated solid (ash, sludge, etc) and/or hazardous waste (spent oil, etc) in

soil


Top soil layer of 15-20cm to be kept separate and use for greenbelt

development

Disposal of excavated material safely for construction of spentwash storage

lagoons, compost yard, leveling of roads, etc.

4.5.2 Solid Waste Management

Wastes from a sugar industry include bagasse, molasses, press mud, boiler ash and sludge

from effluent treatment plant.

Waste Material Type Upshot

Ash 1.10MT/day Used as a filler material for bio-compost, final

disposal system for the spentwash i.e. distillery

effluent

Yeast Sludge,

sludge from CPU

and biodigesters

5-7 MT/day

(wet basis)

mixed with biocompost


4.5.3.1 Boiler Ash

Bagasse ash is usually non-hazardous, non-toxic in nature, it is rich in potash. Hence, there

are three alternatives for the disposal of it.

I. Mix it with bio-compost prepared at distillery unit (practiced for spentwash disposal

treatment) as a filler material.

II. Directly sold to farmer as it is as a potash enriching material

III. Sell it to bricks manufacturing unit in the nearby areas.

The factory is planning to use it in the composting process.

4.5.3.2 Sludge from CPU

This sludge is usually bio-degradable, organic and nearly neutral in nature. It doesn’t

contains any toxic or hazardous elements. Therefore, this could be safely disposed by

adding it to bio-compost.

Chapter IV


4-61

4.5.3.3 Hazardous Waste

The only hazardous waste likely to be generated in the project will be the scrap oil from DG

set. However, the DG set will be used only in case of total power failure i.e. captive as well as

Electricity board power supply failure. Thus, the quantity of used or scrap oil is assumed to

be very minor. This waste oil can be disposed off safely by giving it to authorized hazardous

waste oil dealer. Alternatively, it can be used as a fuel for the boiler along with Bagasse

during startup phase.

4.5.4 Impact Assessment

Soil environment: no negative impact of solid waste; The biocompost produced from

spentwash-pressmud and mixing of degradable solid waste will have positive impact on soil

since organic carbon and soil nutrients are likely get recycled by the process

Ecology and Biodiversity: No negative impact due to solid waste; enhancement in micro-flora

due to compost

Water environment: No negative impact due to solid waste

4.6 ECOLOGY AND BIODIVERSITY

Generally, an impact of industrial activity on ecology and biodiversity is observed due to

following major reasons.

Tree cutting/ removal of vegetation

Habitat destruction

Threat to rare, endangered flora and fauna

Disturbance to wild life

Pollution

In case of proposed project, no tree cutting or habitat destruction is involved. National parks

or sanctuaries or biosphere reserves are not observed in 10km as well as 25km radious of

the site. Rare, endangered species of plants or animals are not recorded from the region.

4.6.1 Preventive, control and mitigation measure

Greenbelt development

Zero Liquid discharge will be achieved

Safe disposal of solid waste

Adequate measures to prevent, control and mitigate air, noise pollution


Minor negative impact on flora in the close vicinity of the site, due to particulate matter and

avi fauna due to thermal pollution from flue gases; no negative impacts from other activities

Chapter IV


4-62

are anticipated; Increase in the greenbelt will help to maintain and enhance the biodiversity,

thus there could be a positive impact. Increase in soil micro flora due to compost could be

another positive impact.

4.7 SOCIO-ECONOMIC ENVIRONMENT

Impact causing

factor

situation for proposed project Control, preventive and

mitigation measure

Impact

Population flux Project will provide 77 new

employment opportunities

Local candidates will be

preferred

Housing colony could

accommodate such

minor increase

No negative

impact

pressure on

infrastructure

such as road,

power, water

captive power

water from Irrigation

Department

minor increase in vehicle

number

Adequate school, college,

medical facilities are available

Public transport,

telecommunication, banks and

other infrastructure already

exist and adequate to support

minor increase in population

Emphasis on water

conservation by

recycling and reuse

rain water harvesting

maintenance of internal

road and approach road

No negative

impact

Employment Direct employment to 69

people

Raw material molasses is

derived from sugar cane,

which is cultivated in

agricultural fields, hence

indirect employment to

farmers, laborers, cane

transporters, etc.

Local candidates will be

preferred

Housing colony already

exist

Positive impact


While analyzing the impact on of proposed project on socio-economy, following factors were

considered.

Baseline data showed that the agriculture is primary occupation of the people,

hence employment opportunities revolves around agriculture sector

Chapter IV


4-63

The project is an agro based industry and extension /vertical integration for sugar

unit

Project will promote efficient utilization of available resources such as molasses,

steam, bagasse, electricity, land and man power up to some extent

Production of alcohol will generate large amount of revenue by way of excise duties

Local administrative institutions will also benefitted by collecting taxes/cess, etc.

Fuel alcohol is very important for the country to save on import of crude oil as well

as foreign exchange, this would have many fold impact on national economy

The sugar factory already had initiated several programmes for the benefit of its

employees as well as local farmers

Therefore, a positive impact is anticipated on the regional economy due to the proposed

project. The project could also help in maintaining and developing the infrastructure

required by the society.

4.8 LAND USE, GEOLOGY AND HYDRO-GEOLOGY /DRAINAGE


LULC map suggest there is not much impact on LU because the land is coming under barren

class. Therefore, the impact on LU is positive i.e. barren is getting converted into future built

up class which is beneficial for local population.

If we consider drainage map of the study area then we can able to say there could be a

minor impact on drainage, as some first order streams are passing very narrowly along the

project boundary.

No impact is envisaged on geology and hydrogeology of the site due to the project.

4.8.2 Environment management plan

Not to damage the first order drainage steams passing through the project boundary.

Precautions need to be taken to preserve or maintain these streams in their natural form or

need to be considered while landscape development.

4.9 OTHER IMPACT: TRAFFIC

In the project, the transportation activity will take place mainly during the construction

phase. Considering the availability of roads railway station are given in following table which

Chapter IV


4-64

is getting converted into a four lane, the nominal increase in vehicles during construction

phase may not cause any traffic congestion. During operation phase, the transportation

activity will be in phases hence; the probability of traffic congestion would be very low.

Road The site is located 10 km off State Highway111 and 76

Pune –Bangalore NH-4 ~45-50km

Good network of road exist in the district

Peak flow traffic on approach Road is about 105 vehicles/hour

Summary of traffic flow in percentage, present and future stage

Two

Wheelers

Four

Wheeler

Lorry/Truck/

tanker

Tractor Carts

Added (in

Percentage)

80-82 8-10 5-7 2-3 0

Traffic management measures

Present road condition is good. Will be maintained. Road markings will be done.

Topography is level and rains are not problematic. Culverts will be maintained.

Village roads connecting are of good surface. Will be maintained.

Our approach road will be constructed wide with illumination at 30 m spacing.

All factory vehicles to have back red light/reflectors

All gates manned by trained security 24x7

Trees on sides

Chapter IV


4-65

Table 4.6: Summary of Impact Assessment and environment management plan proposed for the respective aspect

Environm

ental

Issue

Potential

factors/sour

ce

cause Potential Impact Preventive control and mitigation

measures

Probable Resultant

Impact

EMP

Air

Quality

particulate

matter (PM)

SOx and

NOx

burning of fuel,

handling

and/or

transportation

of material

Impact on human

health by PM 2.5

Impact on ecology

mainly due to PM,

SOx, NOx and

emission of heat

from flue gases

Electrostatic precipitator to control

PM from flue gases; resultant ground

level concentration at nearest

downwind will be

stack height 72 m ,

Use of renewable source s of energy

such as bagaase and biogas

Enhancement of existing greenbelt by

2600 trees

internal roads to make asphalting

adequate parking for all types of

vehicles

Levels of PM

2.5,PM10, SOx and

NOx anticipated to

be within NAAQS

Minor negative

impact on health of

workers and

disturbance to avi

fauna due to flue

gases

Regular health check

up of workers (twice a

year/season), air

quality monitoring

within the project

premises and upwind

and downwind

directions at village

Odour ,

methane

and CO2

spentwash and

molasses ,

composting

activity

odour nuisance

Green house gas

emission

Biogas as a primary treatment for

spentwash; it will utilized as a fuel,

provision of flare unit when biogas

not used as fuel (methane will not

Methane and CO2

likely to get

generated in traces

from composting

Proper maintenance

of biodigester and

skilled supervision on

composting process;

Chapter IV


4-66

Environm

ental

Issue

Potential

factors/sour

ce


measures

Probable Resultant

Impact

EMP

get released in an atmosphere)

Follow the guidelines of regulatory

authorities for storage, handling and

transportation of such material

Avoid anaerobic condition

development for composting

Green belt development

CO2 generated will be from non-fossil

source, hence considered as neutral

while considering GHG potential

and storage of

organic waste

storage and disposal

of spentwash as per

CREP guidelines only

Noise Operation

of

machinery,

equipments,

transportati

on

Noise

generated

during the

operation

of the

machinery

Impact on human

health,

disturbance to

fauna

High noise potential activities are not

involved during operation phase,

Noise increase at specific locations

only, most of the machinery will be

under roof


4500 trees

No negative impact

outside the

premises;

minor negative

impact inside the

premises on mainly

workers as well as

Provision of personal

protective

equipments for

workers at high noise

areas; monitor noise

levels at ambient as

well as work place

Chapter IV


4-67

Environm

ental

Issue

Potential

factors/sour

ce


measures

Probable Resultant

Impact

EMP



vehicles

partially on faunal

elements

areas;

During construction

phase restrict noise

generating activities

for day time only

Water

Quality

Spentwash,

spent lees,

condensate

and other

Wastewater

,

solid waste

Contamination

of surface &/or

ground water

Soil

Contamination

surface and ground

water pollution,

thermal pollution of

water bodies,

Spentwash disposal thorough

biomethanation followed by MEE


Spentlees and condensate water

recycled after treatment

treated water reused mainly for

cooling, gardening/irrigation

spent wash storage, handling,

compost yard as per CREP norms

No negative impact

on ground or

surface water,

minor

contamination of

soil while handling

near compost or

storage areas

Install piezometer/s

and bore well

towards downstream

of compost site

check the water

quality of bore well;

vigilance for

accidental spillage of

spentwash and for

damage to impervious

storage lagoon or

compost yard

Chapter IV


4-68

Environm

ental

Issue

Potential

factors/sour

ce


measures

Probable Resultant

Impact

EMP

Water

Resource

water

availability

Water

Consumption

by the project

Depletion of

available water

resource

Water conservation thro’ recycling

and reusing treated/condensate

water

Rain water harvesting

No negative impact

since water is

allocated for

industrial activity

only

Strictly implement

proposed

conservation practices

and encourage the

staff to save and

conserve water at all

possible extents

Soil and

land

change in

land use

solid waste,

effluent/wa

stewater

project

activities

change in land use,

soil pollution due to

solid waste or

effluent

probability of

alteration in of first

order draining along

the boundary

Proposed site is open, barren under

the possession of the sugar factory

Keep the natural drainages intact

Solid waste generated in the project

is biodegradable hence utilized in

composting process

Disposal of effluent as per the

regulatory authorities guidelines

Excavated soil to be stacked and

reused for gardening, greenbelt

No change in land

use pattern

No negative impact

on soil quality,

minor negative

impact due to

excavation of soil

for project activities

Solid waste disposal

activity

check the

characteristics of solid

waste and compost at

least twice a

season/year

Monitor the soil

quality where treated

water is used for

irrigation – twice a

season/year

Chapter IV


4-69

Environm

ental

Issue

Potential

factors/sour

ce


measures

Probable Resultant

Impact

EMP

activity, material other than soil to be

used for leveling and similar activities

(Composting) –

support micro flora,

insects, warms and

indirectly supports

the avi fauna feeds

on it – positive

impact on ecology

Micro nutrients will

get recycled due to

compost – positive

impact on soil

quality and ecology

Ecology project

activities

Cutting of trees

or destruction

of habitat

Impact due to

contamination

Destruction of

terrestrial and

aquatic flora or

fauna

project within the existing sugar

factory premises, and the land is

barren and open, flat land no tree

felling is required

wildlife sanctuary, national park not

No negative impact

on ecology and

biodiversity

Greenbelt helpful to

improve biodiversity

Prefer local species for

greenbelt

development, provide

funds and manpower

to maintain it

Chapter IV


4-70

Environm

ental

Issue

Potential

factors/sour

ce


measures

Probable Resultant

Impact

EMP

of water

bodies.

within 25km radius

Effluent/Wastewater recycled/reused

after proper treatment


‘Zero Liquid Discharge’ scheme

implemented

Monitor air, water soil

at site and

surrounding area at

pre-defined interval

Hazard

and Risk

Assessm

ent

Storage of

raw

material and

finished

product

fire damage to living as

well as non-living

things

Implementation of safety norms as

per the regulatory authorities

guidelines

Appointment of safety officer

Lightening arresting system

water hydrant, fire extinguishing

system and training to staff for its

operation also training for first aid

and safety

Negative impact

only in accidental

case

Training and mock

drills for safety

Policy under PLI act

1991

Risk assessment to be

done through

professional risk

assessors

Socio-

Economic

population

flux

Temporary and

permanent

pressure on social

infrastructure

Maximum local labour for

construction and local candidates for

Population flux

could be negligible,

Initiate and

implement social

Chapter IV


4-71

Environm

ental

Issue

Potential

factors/sour

ce


measures

Probable Resultant

Impact

EMP

Impacts workforce

associated with

the project

employment

Housing facility is available with sugar

mill to accommodate marginal

increase

hence no negative

impact anticipated

Beneficial impact

due to direct and

indirect

employment,

government and

local institutions

benefitted through

taxes, improvement

in infrastructure

such as

transportation,

education, medical

facilities, etc. due to

the project

developmental

activities as a part of

CSR

Chapter V


5- 1

CHAPTER V

ANALYSIS OF ALTERNATIVE TECHNOLOGY

5.1 INTRODUCTION

The technologies for the treatment and safe disposal of spentwash- most polluting element

from distilleries – are discussed in this chapter. Traditionally, the spent wash was used for

irrigation of crops and for composting with press mud from sugar mills as filler material. At

several places in the country, it used to be spread on land in an uncontrolled fashion

resulting in destruction of agricultural land and pollution of ground water. When it was not

possible to use it on land, it was often discharged in surface waters affecting the riparian

rights of other users of the water body.

The new recommendations of CPCB/MoEF imposed a restriction on such utilization, of

spentwash on agricultural land. Therefore, it has become necessary to look for technologies

to reduce the volume and concentrate the spentwash, so that it can be handled effectively

without damaging the environment.

6.2 TREATMENT AND UTILIZATION OPTIONS

Figure 5.1: Treatment Options for Raw Spent Wash

Spentwash

Biomethanation (for distilleries attached

to sugar mills)

Bio-composting

Concentration

Multiple effect

evaporation

Reverse

osmosis

Concentration

Mist

evaporatio

n

Concentration and Incineration

(stand alone distilleries)

Chapter V


5- 2

5.2.1 Reboiler

Reboilers are used in distilleries for concentrating raw spentwash and simultaneously

recovering heat and water. Depending upon the input spentwash quality and the reboiler

design, the spentwash volume can be reduced to 75 to 85% of its original volume. When the

spentwash is to be used for composting and the rate of production of spentwash is more

than 10 m3 per KL of alcohol production, in volume through heating and evaporation of

water in a reboiler results in a corresponding increase in the concentration of BOD, COD,

nitrogen and TDS. Further, the efficiency of conversion of organic matter (BOD) to biogas in

the biomethanation step may also decrease when a more concentrated spentwash is

treated.

At present there is no prescribed recommendation regarding the quality of spentwash to be

used for preparation of compost. In order to achieve 'Zero Liquid Discharge', many

distilleries are concentrating their spentwash using reverse osmosis (RO) process also. The

effect of such salt laden spentwash, which also would be containing a higher concentration

of organic matter, on the process of composting and the quality of compost, is not known.

5.2.2 Biomethanation

Biomethanation is now a well-established process. Many types of reactor systems are

commonly used, namely, up or down-flow fixed film reactor, up-flow partly fluidized bed

reactor, commonly known as up-flow anaerobic sludge blanket (UASB) reactor and

continuously stirred tank reactor. Each system may have different variations of reactor

configuration, effluent and sludge recirculation and mixing. One variation employs two-

stage decomposition in two slurry reactors in series.

The bio-methanation reactors when properly designed and operated are capable of treating

spentwash having BOD in the range of 40,000 - 50,000 mg/L with an efficiency of 90% thus

producing an effluent having a BOD in the range of 4,000 - 5,000 mg/L. There is also some

reduction in the TDS content of the spent wash. Sulphate is reduced to hydrogen sulphide,

which escapes with the biogas, and there is a corresponding increase in the carbonate

alkalinity. This in turn results in precipitation of some calcium. The TDS of the spent wash

may decrease to 15,000 - 25,000 mg/L. pH of spentwash, after bio-methanation increase up

to 7 or 8. Some reactor designs may require the raw spent wash to be diluted before it can

be treated. This is particularly when the distillery uses continuous fermentation process for

production of alcohol in which case the COD of raw spent wash may be in the range of

Chapter V


5- 3

100,000 to 120,000 mg/L. Central Pollution Control Board has recommended that the

dilution water should not be more than 30% of the original volume of the spent wash.

Depending upon the fuel, which the biogas replaces, (i.e. bagasse, coal or furnace oil) the

cost of the biomethanation reactor is recovered in 2 to 4 years

5.2.3 Reverse Osmosis (RO)

In the past reverse osmosis (RO) has been used commonly as the final step in tertiary

treatment of wastewaters to remove dissolved inorganic solids and some recalcitrant

compounds. It is used to recover good quality of water from grossly polluted wastes. This

has been made possible due to development of new membranes and the membrane module

configuration, which allows easy accessibility for cleaning and replacement of membranes.

In any RO system, the preliminary treatment of wastewater is extremely important.

Adjustment of pH and temperature of the waste, which is compatible with the material of

the membrane, increases the membrane life and prior removal of total suspended solids

(TSS) decreases the rate of membrane fouling. Further, the flux of the dissolved substances

in permeate is lower if it is removed before hand to the possible extent by conventional

methods. It also allows operation of the system at comparatively lower pressure, hence

results in savings in operational and maintenance costs. With a poor quality of the feed

water, the quality of the permeate may be maintained only at the expense of recovery.

Pre-treatment usually comprises pH correction, pressure sand filtration followed by

cartridge filtration. The effluent is then pressurized and passed through RO modules. The

vendor of the RO system usually supplies the pre-treatment units also.

Effluent permeate from the RO plants contains carbon dioxide and sulphides. Its quality

can be improved and stabilized by stripping with compressed air in a packed column to

increase the scope of its utilization. In case there is a premium on the recovery water, the

reject from the RO plant is further treated through a secondary RO system or nano-filtration,

which uses a more 'open textured' membrane. This step produces permeate having 22,000-

25,000 mg/L TDS, 3,500-4,500 mg/L COD and 1,000-1,200 mg/L BOD. The permeate

recovery is 11-14% of the first stage feed.

The operation of the RO plant requires skilled personnel. The spares for regular

maintenance may also not be available in the open market. The Membrane required to be

imported. The fouling could be a problem. Running of the plant therefore should be

entrusted to the supplier to ensure efficient and continuous operation.

Chapter V


5- 4

5.2.4 Multiple Effect Evaporators

Though evaporation is an established unit operation in chemical engineering practice, its use

for concentration of spentwash is recent. With improvements in design and materials and

the willingness of the alcohol industry to spend more on pollution control equipment, some

distilleries are in the process of installing evaporation and drying plants.

Biomethanated effluent can be input to the multiple effect evaporators. However, both

biomethanated and raw SW can be fed to the evaporators. Steam used in the evaporation

process and the evaporated water from the SW feed form the condensate or the recovered

water. The condensate has a slightly acidic pH and BOD and COD of about 10 and 100 mg/L,

respectively.

The biomethanated feed containing about 4-5% of solids is concentrated to 30-33% solids

content. The concentrated SW can be either used for the preparation of compost or further

dried in a spray dryer to yield a solid powder containing about 4-5% moisture. The calorific

value of the powder is 2500 kcal/kg and it can be burnt for production of steam. The ash

obtained from the combustion of the powder is saleable for its potash content. The dry

powder also has a market value of about Rs.750 / T, as a soil additive rich in organic matter

and potash. The concentrated spentwash after evaporation can also be used directly as an

auxiliary fuel along with other fuel for generation of steam.

From a 300m3/d plant treating biomethanated spentwash about 620 kg/hr effluent powder

is generated, which when burnt yields 127 kg/hr ash.

The ash contains about 21% potash. In case raw spentwash containing 10% solids is

concentrated the yield of effluent powder and ash is 1875 kg/hr and 394 kg/hr, respectively.

5.2.5 Mist Evaporator

As the name implies the mist evaporator creates a mist of small droplets by pumping

spentwash through small diameter nozzles placed around the periphery of a duct through

which air is blown. The unit is placed at the edge of a lagoon and the spentwash is pumped.

The resulting mist forms a trajectory reaching as high as 18 m and going up to 55 m in the

horizontal direction. The large surface area of the mist results in evaporation of water and a

concentrated SW falls back in the lagoon. The rate of evaporation depends on temperature,

humidity and wind speed.

Experience with the mist evaporator in the country is limited. It is in use only at one location

for a distillery of 30 KL/d capacities. The manufacturers of the evaporator claim that for the

Chapter V


5- 5

yearly average ambient conditions 2 units, each of 30 KW would be required to evaporate

300 m3/d of spentwash.

The setting up of the unit is easy and requires minimal supervision and maintenance

compared to other concentration methods. However, it will operate with varying efficiency

during the year. In the rainy season or in humid weather, there will be little or no

evaporation and the spentwash will have to be stored. Since, the wind direction is likely to

change a number of times for short periods over a day, there is likelihood of the mist spray

falling outside the lagoon. A more definite comment can be made after the unit is operated

for more time and systematic data regarding the solids balance are available.

The concentrated or thickened spentwash will have to be properly disposed. At present,

composting seems to be a possible alternative.

Table 5.2: Merits and Demerits of Each Alternative

# Technology Merits Demerits

1. Concentration Reduction in volume. Energy generation

after combustion.

Start-up and restart-up is a problem. Scaling problem.

2. Biomethanation Energy generation. Increase in volume. Higher initial cost. It is a primary

treatment only.

3. Biocomposting

Zero pollution can be achieved.

Production of good quality manure.

Large area required Problem of smell Operation in rainy season not

possible.

Availability of filler material is a problem.

4. R.O. System Recovery of water Reduction in volume.

Higher initial and operational cost. Fouling problem. Membranes are not indigenously

available.

Chapter V


5- 6

5.3 Treatment alternatives for Condensate Polishing Unit(CPU)

Condensate polishing unit, treats condensate from process/MEE as well as spentlees and

other minor effluents. Following alternatives are available for CPU

i. Conventional aerobic treatment (Extended aeration)

ii. Conventional aerobic treatment followed by membrane technology

iii. Conventional anaerobic treatment followed by membrane technology

iv. RO – MBR Technology

v. Soil biotechnology

5.3.1 Process Description for membrane technology: The proposed system is based on cross-flow membrane filtration technique and is

designed for removal of organic acids from the spent wash distilled stream like evaporation

condensate of a distillery unit. The condensate treated by such system can be reused back in

to the alcohol manufacturing process as cooling water make-up thereby reducing the

requirement of fresh water as well as solving the waste disposal to a great extent. The

system is based on following principle operations.

i) Cooling & Neutralization

ii) Membrane filtration of the neutralized stream to remove volatile acids.

iii) Recycle of treated streams back to process.

System typically recovers 85 % of the condensate as clean reusable water and has about 15

% reject.

Note:-

a) The quantity of caustic solution required is depends on the characteristics of feed to the

membrane ETP.

b) Phosphoric acid is required for cleaning of the membranes; the frequency of cleaning

depends on the quality of input to the membranes and will establish during operation of

the plant.

5.3.2 Soil Biotechnology Process

Considering the initial capital investment and recurring cost for operation of the

scheme, Soil Bio-Technology appears to be most economical for treatment of process

condensate of distillation, evaporation, RO permeate etc.

The system is designed for treatment of evaporation process condensate or RO permeate

and spent lees of a distillery unit. The process condensate and spent lees treated by such

system can be reused back in to the distillery cooling tower as cooling water make-up

Chapter V


5- 7

thereby reducing the requirement of fresh water as well as solving the waste water disposal

to a great extent.

The technology is based on a bio-conversion process where fundamental reactions

of nature, namely respiration, photosynthesis & mineral weathering take place in a media

housing micro & macro organisms which bring about the desired purification. SBT is an

oxygen supplying biological engine and so the process can treat all types of water –

domestic, municipal & industrial. SBT is suitable for treating water with salinity <2500 mg/L.

When salinity levels exceed, reaction rates in the SBT system are lower and hence the

system design is adjusted suitably to achieve the purification desired. If salinity is very high,

an additional facility using RO technology can also be included. The facilities of a treatment

process for water & waste water consists of a raw water tank, bioreactor containment,

treated water tank and associated piping, pumps & electrical. The layout of media on the

bioreactor is shown in Fig 5.2.

Figure 5.2: Layout of SBT Media

5.4 SELECTION OF ALTERNATIVE

Considering all available technological options, the industry has planned to implement

biomethanation followed by multi effect evaporation followed by bio composting for the safe

treatment and disposal of spent wash. It is based on the volume of spentwash to be disposed,

availability of land, press mud for biocomposting and the cost involved for the technology.

In case of CPU the proponent has planned for conventional anaerobic followed by aerobic treatment

supported by tertiary treatment. Treated water will be recycled/ reused in the industry. The

proposed option will be able to achieve the aim of “zero liquid discharge”.

Chapter VI



6-1

CHAPTER VI

ENVIRONMENT MANAGEMENT PLAN

6.1 OVERVIEW

The Environmental Management Plan (EMP) is a site specific document for the project. It aims to

identify and address the requirements for successfully mitigating the probable adverse

environmental impacts of the project at various stages of project formulation and execution. It also

identifies the post project monitoring requirements needed for the successful implementation of the

suggested measures.

EMP is a framework to ensure that the project can be implemented in an environmentally

sustainable manner and where all concerned persons of the industry as well as contractors,

understand the potential environmental impact arising from the proposed project and take

appropriate actions to properly manage such impact.

The objectives of EMP

Overall conservation of environment and thereby promote sustainable development

Minimization of waste generation and thus pollution

Judicious use of natural resources and water

Safety, welfare and good health of work force and populace

Ensure effective and efficient operation of all control measures

Vigilance against probable disasters and accidents

Monitoring of cumulative and long time impacts

Ensure effective and efficient operation of all control measures

6.2 EMP FOR CONSTRUCTION PHASE

In case of the proposed project, construction activity involves installation of various units of

distillery such fermenters, distillation columns, storage tanks for raw material as well as finished

products, cooling towers, treatment units such as bio-digesters and development of compost yard,

etc.

Thus, the major activities involved for construction phase would be:

Preparation / processing of construction material

Loading / unloading of construction material

Excavation work as per requirement for installation of various structures

Transportation of the material and workers to & from the proposed project location

Installations of various units

Chapter VI



6-2

Disposal of the liquid and solid waste generated by the temporary work force employed

for construction

Site situation

Well developed asphalted road upto sugar mill and internal road in sugar mill are also

asphalted

On site housing/guest house facility for construction staff and workers

Nearest residential areas are at 2km towards east and 2.4km towards north of the site

Construction activity will be executed through authorized and qualified firms

Greenbelt developed by sugar mill is in place

Considering the various types of pollution associate with the construction activities, recommended

mitigation measures are as follows.

Fugitive dust emission can be controlled by water sprinkling on dust generative surfaces as well

as material such as soil, sand, etc. while loading/unloading

The upper soil layer up to 20-30cm is productive part of the landscape; hence, it should be

carefully removed and preserved for future use. If these soil piles are dry it needs to be covered

with tarpaulin or similar material. This soil could be reused for the development of greenbelt.

The excess of excavated soil could be used for greenbelt by adding adequate amount of manure,

organic fertilizers to it. The material like stones shall be used within the project site, mainly for

minor leveling activities/internal roads, etc

The runoff from the construction site will be controlled by ditches and shall not allowed to

percolate in the surrounding land

The contractor should employ maximum local labour. Thus, the local people will get an

employment opportunity. It will also help in reducing the problems associated with

accommodation/housing of the labour, thus it will help in reducing linked issues such as demand

for water, sanitation and hygiene at the labour colony, etc. However, he should provide the basic

sanitation facility at the work site by using septic tanks and soak pits.

The activities generating noise should be restricted to daytime only

Run-off of loose soil should be prevented by means of compacting the soil

Transport contractors should be instructed to maintain their vehicles properly so as to

minimize the exhaust emissions, reduce the noise and prevent the oil leakages from vehicles.

Chapter VI



6-3

Table 6.1: Summary of EMP for Operation Phase

Environm

ental

Issue

Potential

factors/sour

ce


measures

Probable Resultant

Impact

EMP

Air

Quality

particulate

matter (PM)

SOx and

NOx

burning of fuel,

handling

and/or

transportation

of material

Impact on human

health by PM 2.5 –

Respiratory, lung

diseases, allergic

ailments, burning of

eyes/skin, etc.

Impact on ecology

mainly due to PM,

SOx, NOx and

emission of heat

from flue gases – 1)

Due to PM -

reduction in

photosynthesis

leads to decrease in

the yield

Electrostatic precipitator to control

PM from flue gases; resultant ground

level concentration at nearest

downwind will be

stack height 72 m ,

Use of renewable source s of energy

such as bagaase and biogas


5500 trees



vehicles

Levels of PM

2.5,PM10, SOx and

NOx anticipated to

be within NAAQS

Minor negative

impact on health of

workers and

disturbance to avi

fauna due to flue

gases

Regular health check

up of workers (twice a

year/season), air

quality monitoring

within the project

premises and upwind

and downwind

directions at village

Chapter VI



6-4

Environm

ental

Issue

Potential

factors/sour

ce


measures

Probable Resultant

Impact

EMP

Odour,

methane

and CO2

spentwash and

molasses ,

composting

activity

odour nuisance

Green house gas

emission

Biogas as a primary treatment for

spentwash; it will utilized as a fuel,

provision of flare unit when biogas

not used as fuel (methane will not

get released in an atmosphere)

Follow the guidelines of regulatory

authorities for storage, handling and

transportation of such material

Avoid anaerobic condition

development for composting


CO2 generated will be from non-fossil

source, hence considered as neutral

while considering GHG potential

Methane and CO2

likely to get

generated in traces

from composting

and storage of

organic waste

Proper maintenance

of biodigester and

skilled supervision on

composting process;

storage and disposal

of spentwash as per

CREP guidelines only

Noise Operation

of

machinery,

equipments,

transportati

Noise

generated

during the

operation

of the

Impact on human

health – increase of

blood pressure,

effect on hearing

ability, irritation,

High noise potential activities are not

involved during operation phase,

Noise increase at specific locations

only, most of the machinery will be

under roof

No negative impact

outside the

premises;

minor negative

impact inside the

Provision of personal

protective

equipments for

workers at high noise

areas; monitor noise

Chapter VI



6-5

Environm

ental

Issue

Potential

factors/sour

ce


measures

Probable Resultant

Impact

EMP

on machinery and other noise

related/associated

ailment

disturbance to

fauna


4500 trees



vehicles

premises on mainly

workers as well as

partially on faunal

elements

levels at ambient as

well as work place

areas;

During construction

phase restrict noise

generating activities

for day time only

Water

Quality

Spentwash,

spent lees,

condensate

and other

Wastewater

,

solid waste

Contamination

of surface &/or

ground water

Soil

Contamination

surface and ground

water pollution,

thermal pollution of

water bodies –

depletion of DO and

thus death of

aquatic life

Spentwash disposal thorough

biomethanation followed by MEE


Spentlees and condensate water

recycled after treatment

treated water reused mainly for

cooling, gardening/irrigation

spent wash storage, handling,

compost yard as per CREP norms

No negative impact

on ground or

surface water,

minor

contamination of

soil while handling

near compost or

storage areas

Install piezometer/s

and bore well

towards downstream

of compost site

check the water

quality of bore well;

vigilance for

accidental spillage of

spentwash and for

damage to impervious

storage lagoon or

compost yard

Chapter VI



6-6

Environm

ental

Issue

Potential

factors/sour

ce


measures

Probable Resultant

Impact

EMP

Water

Resource

water

availability

Water

Consumption

by the project

Depletion of

available water

resource

Water conservation thro’ recycling

and reusing treated/condensate

water

Rain water harvesting

No negative impact

since water is

allocated for

industrial activity

only

Strictly implement

proposed

conservation practices

and encourage the

staff to save and

conserve water at all

possible extents

Soil and

land

change in

land use

solid waste,

effluent/wa

stewater

project

activities

change in land use,

soil pollution due to

solid waste or

effluent

Proposed site is open, barren under

the possession of the sugar factory

Solid waste generated in the project

is biodegradable hence utilized in

composting process

Disposal of effluent as per the

regulatory authorities guidelines

Excavated soil to be stacked and

reused for gardening, greenbelt

activity, material other than soil to be

used for leveling and similar activities

No change in land

use pattern

No negative impact

on soil quality,

minor negative

impact due to

excavation of soil

for project activities

Solid waste disposal

activity

(Composting) –

support micro flora,

check the

characteristics of solid

waste and compost at

least twice a

season/year

Monitor the soil

quality where treated

water is used for

irrigation – twice a

season/year

Chapter VI



6-7

Environm

ental

Issue

Potential

factors/sour

ce


measures

Probable Resultant

Impact

EMP

insects, warms and

indirectly supports

the avi fauna feeds

on it – positive

impact on ecology

Micro nutrients will

get recycled due to

compost – positive

impact on soil

quality and ecology

Ecology project

activities

Cutting of trees

or destruction

of habitat

Impact due to

contamination

of water

bodies.

Destruction of

terrestrial and

aquatic flora or

fauna

project within the existing sugar

factory premises, and the land is

barren and open, flat land no tree

felling is required

wildlife sanctuary, national park not

within 25km radius

Effluent/Wastewater recycled/reused

after proper treatment


No negative impact

on ecology and

biodiversity

Greenbelt helpful to

improve biodiversity

Prefer local species for

greenbelt

development, provide

funds and manpower

to maintain it

Monitor air, water soil

at site and

surrounding area at

pre-defined interval

Chapter VI



6-8

Environm

ental

Issue

Potential

factors/sour

ce


measures

Probable Resultant

Impact

EMP

‘Zero Liquid Discharge’ scheme

implemented

Hazard

and Risk

Assessm

ent

Storage of

raw

material and

finished

product

fire damage to living as

well as non-living

things

Implementation of safety norms as

per the regulatory authorities

guidelines

Appointment of safety officer


water hydrant, fire extinguishing

system and training to staff for its

operation also training for first aid

and safety

Negative impact

only in accidental

case

Training and mock

drills for safety

Policy under PLI act

1991

Risk assessment to be

done through

professional risk

assessors

Socio-

Economic

Impacts

population

flux

Temporary and

permanent

workforce

associated with

the project

pressure on social

infrastructure

Maximum local labour for

construction and local candidates for

employment

Housing facility is available with sugar

mill to accommodate marginal

increase

Population flux

could be negligible,

hence no negative

impact anticipated

Beneficial impact

due to direct and

indirect

employment,

Initiate and

implement social

developmental

activities as a part of

CSR

Chapter VI



6-9

Environm

ental

Issue

Potential

factors/sour

ce


measures

Probable Resultant

Impact

EMP

government and

local institutions

benefitted through

taxes, improvement

in infrastructure

such as

transportation,

education, medical

facilities, etc. due to

the project

Chapter VI



6-10

6.3 EMP: OPERATION PHASE

6.3.1 Air Environment Management

Air Emissions: As summarized in table 6.1, the sources of air pollution are emissions due to

combustion of fuel i.e. bagasse and biogas in the boiler furnace, fugitive dust due to handling of

bagasse, processes such as fermentation, bio-compost, etc. Emissions from diesel generator and

vehicles are anticipated as minor sources. Considering this following management plan is

proposed.

Existing electrostatic precipitator (ESP) as air pollution control equipment (PCE), to arrest

fly ash emissions

Criteria for the design of ESP - mainly based on the characteristics of fuel, its quantity,

generation of pollutant, estimated volume of flue gas, etc.

Flue gases will be released through existing stack of 72 meter height

Preventive maintenance and regular checking of ESP

Fermentor – covered; CO2 scrubber will be installed

Existing of ash and bagasse handling system will be utilize

Proper maintenance of internal roads; greenbelt development along the roads

Biogas produced from the biomethanation process will be utilized as a fuel. In a rare

case if it is unutilized, it will be burnt through flare unit; but in any circumstances it will

not be freely released in the atmosphere

Disposal of potash rich ash by mixing it with compost

Composting process will be carried out in aerobic conditions, by using modern

machines (Aero-tiller) for rotation operations/supply of oxygen

Development of lawn on open areas with plantation of ornamental shrubs/trees in

between so as to reduce the dust generation from open areas and improve aesthetics

Greenbelt of minimum three tiers in the periphery of the project and more in

thickness towards east and west of the site

Monitoring of stack emissions and ambient air quality at regular interval

Compliance of other regulatory norms such as health, safety, etc.

6.3.2 Noise Environment

In case of distilleries, the main processes are fermentation and distillation. In these processes,

there are no major noise sources involved. Hence, simple measures such, as maintenance of

machines, equipments & vehicles, needs to be implemented. Addition measures includes

The noise management practices could be in following sequences

Prevent generation of noise at source by good design and maintenance

Chapter VI



6-11

Minimise or contain noise at source by observing good operational techniques and

management practice

Use physical barriers or enclosures to prevent transmission to other media e.g. for

boiler, STG, DG room

Increase the distance between the source and receiver

Sympathetic timing and control for unavoidably noisy operations;

Job rotation for workers placed at high noise areas.

Personnel Protective Equipments will be procure to the workers

Greenbelt development with suitable species for noise attenuation

6.3.3 Water Environment

The Ministry of Environment and Forests (MoEF), has recommended a guideline through

Corporate Responsibility for Environment Protection (CREP), charter. According to these

guidelines, it is mandatory for the distillery to achieve ‘Zero Liquid Discharge’ (ZLD). The project

proponent has developed a plan to achieve ZLD and has made necessary financial provisions

towards the planned activities. Biomethanation followed by the evaporation (MEE) is the

treatment and quantitative reduction of distillery spentwash. Aerobic composting is the disposal

technology to dispose the 120 m3/day for concentrated spentwash

6.3.3.1 CREP guidelines for molasses based distilleries

The industry has opted for Bio-methanation as primary treatment followed by bio composting

for the safe disposal of spent wash. The guidelines recommended through CREP, which will be

implemented by the project proponent, are as follows.

Raw Spentwash Storage lagoon five day storage capacity 1500 m3

Spentwash storage lagoon of ≤30 days capacity 9000 m3

Both lagoons must be impervious, constructed leak-proof, lined with HDPE sheets and

protected by brick lining

The compost yard lined with HDPE sheets and protected with brick/ concrete/

Bituminous Macadam

Provisions for leachate collection gutter and sump well with mechanical provision for

leachat management

A) Land Preparation for Compost Yard

Basic

1. While designing and preparing compost yard, its foundation need to be constructed

with utmost care. Therefore, preparation of the ground & proper compaction plays very

important role in the development of compost yard.

Chapter VI



6-12

2. Therefore, it is to ensure that-

The land is leveled and compacted properly

Soft soil cushion is essential to lay a 250 micron thick HDPE sheet

Further, another layer of soft soil/soft sand needs to be provided over the 250

micron thick HDPE sheet before proceeding with the top finish

Provision of underground spentwash spraying network for auto spraying

Provision of leachate management system as per guidelines

There are few options for top finish of compost yard, they are -

Brick on-edge gaps filled with dry sand/soft local soil

Providing Plain Cement Concrete (PCC) 1:3:6 in bays & scaling the joints with

bitumen.

Bituminous asphalting

Providing and laying interlocking concrete paving blocks

The project proponent has opted an impervious compost yard lined with HDPE sheet

and top finish of PCC (1:3:6)

B) Operations & Maintenance Guidelines for Composting

i) Rainy Season

It is not possible to run the aerobic composting process at least for two-three months

during rainy season. The reasons are:

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

leachate after rain and will contaminate the soil

Due to rain, the composting material in windrows may have moisture content of 70%,

which can result in anaerobic

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

Heavy rains can wash off the press mud

Precautions to be taken before onset of rainy season

The composting area must be vacated before start of rains

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

The compost, which remains unsold, should be properly bagged and kept in

godown/covered area

After harvesting the last batch of compost a 2 cm layer of pressmud should be

scrapped over the surface layer of compost yard and this scrapped material shall be

kept covered for blending with compost. After cleaning the scrapped area, fresh

windrow of pressmud shall be formed only after rainy season.

Chapter VI



6-13

ii) Unseasonal Rains

Precaution to be taken, if there is unseasonal rain during composting cycle

In order to avoid the leaching of spentwash, which is yet to decompose all the

windrows on the yard should be covered with polyethylene sheets/pullover covers

Stop spraying spentwash, temporarily when it is raining. Spraying can be resumed

when the sky becomes clear.

The provision of the trenches towards slopping side should be made to collect the

runoff from windrow area. This runoff should be collected in leachate collection pit.

It should be pumped back to 5 days as well as 30 days storage lagoon.

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

enter the compost yard.

In order to achieve ‘Zero Liquid Discharge’ the industry will be adopting biomethnation followed

by multi effect evaporation follow by biocomposting process. Impervious lagoons will be

constructed for storage of spent wash and impervious compost yard (1:3:6 PCC) with HDPE

lining as per CREP norms.

Table 6.2: Guidelines, Formulated By Central Pollution Control Board (CPCB) New Delhi, For

Bio-Composting Plants

# Description Requirement as per

C.P.C.B. Norms

Actual Design and

Provisions

1. Working days of Distillery

(Rainy season shall be avoided and the

entire compost area shall be kept dry

before starting of the rainy period)

270 days

270 days

2. Spentwash storage tank capacity (duly

lined with 250 micron HDPE sheet and

pitched by stone/bricks with cement

mortar to prevent leachate).

5days of generation

&

30 days of generation

5 days

&

30 days

3. Pressmud: Spentwash ratio 1: 2.5-3.0 1:2

4. No. of days required to complete one

composting operation cycle

45days/60 days 45 days

5. Land required for compost plant

Construction of compost yard as under

(with arrangement of leachate collection

and surface runoff and its pumping to

holding lagoon and laying of pipe net

work for automatic spraying of

spentwash)

I) Compaction of soil

II) 5 cm sand cushion (top)

850 MT/acre/cycle 850 MT/acre/cycle

Chapter VI



6-14

III) 250 micron HDPE sheet

IV) 5cm sand cushion (bottom)

V) PCC top

In case the coefficient of permeability is

less than 10-8 cm/sec (as in black cotton

soil), 30 cm depth of impervious soil,

compacted with 30 cm depth of murum

at the top may also be used.

6. Maximum allowable cycle/annum 1) Five cycles in case of

45 days composting

period

2) Four Cycles in case of

60 days composting

period

Five Cycles

7. Pressmud storage on compost site

during monsoon season after taking due

care for protection by using HDPE sheets

etc.

Equivalent to one cycle NIL

8. Land required for storage of ready

compost.

It should be raised 12

inch above ground level

and quantity equivalent

to 33% of the total

compost should be

stored

Compliance as per

required norms

would be done

9. Compost quality specification Moisture: < 35%

Organic Carbon:20-25%

C:N ratio : <17:1

Nitrogen: 1.5-2%

Phosphorous:1.5-2%

Potassium: 2-3.5%

Total Volatile Solids: 50-

60% on dry wt. basis

Compliance as per

required norms

would be done

Chapter VI



6-15

6.3.3.2 Spent Lees and process condensate from ME Treatment Unit (Condensate Polishing

Unit)

FEED

PRE TREATMENT

SECONDARY

TREATMENT

TERTIARY

TREATMENT

Figure 6.1: Process Flow Diagram For CPU 6.3.3.3 Important aspect

a. Spentwash: Its transportation to the treatment site by laying suitable and protected

pipeline of HDPE or similar material

b. Electricity: Provision of diesel/electricity required for carrying the mixing turning

aeration machine is must at the composting site. Three phase, 440 V electricity cable is

to be provided and laid down by factory to the inlet of isolation switch of MCC.

c. Compost: Arrangement for transports of compost from composting site (compost pit/

windrows) will be performed by the sugar factory

d. Press-mud, boiler ash and sludge as a filler material in required quantity and proportion

will be made available by the sugar factory and it will be transported by them up to the

composting site

EQUALIZATION

NEUTRALIZATION

ANAEROBIC FILTER OR DIGESTER

AEROBIC TREATMENT

SECONDARY DIGESTER

TUBE SETTLER

SLUDGE DISPOSAL

SYSTEM

CLARIFICATION

SAND FILTER

ACTIVATED CHARCOAL TREATMENT

Chapter VI



6-16

e. Other Infrastructure: Tree plantation (As a greenbelt development) will be done by the

sugar factory

f. Water required for plantation / drinking etc. will be made available by the sugar factory

Precautionary Measures

Cooling ponds shall be constructed of masonary/brick work with impervious one using

PVC lining duly finished and sulphate resistant cement shall be used. Since the spent

wash is highly acidic in nature, the corrosive resistant epoxy coatings shall be made.

Storage tanks of 30 days and 5 days capacity shall be constructed by providing and

laying leak-proof tar-felt coating and waterproofing primer for joints

Surface windrows should be constructed as described earlier

Bore well towards the downstream of the compost site to check the ground water

quality regularly

Provision to cover the windrows with HDPE sheets, in case of rains

Provision of lined garland drains around the surface compost pits to collect run-off.

6.3.3.4 Operation and Maintenance of Other Pollution Control System

All the pollution control system such as, Bio-methanation, air pollution control (APC)

equipment and any other system provided by the industry should be operated and

maintained strictly as per the operational manual. The record related to this should be

maintained and kept ready for inspection.

The preventive maintenance of all the plant and machinery including civil/mechanical

structure shall be carried out as per the prescribed scheduled.

Housekeeping in and around plant/pollution control system should be maintained

properly.

6.3.4 Land Environment

As discussed in previous chapters, the major threat to land environment is due to percolation of

spentwash / untreated effluent into the soil or disposal of the same by land application etc.

Change in land topography due to installation of various distillery units is another permanent

impact.

Zero Liquid Discharge (ZLD) is aimed for the proposed project and the scheme

recommended for storage, disposal of spentwash and other effluent will comply

CREP guidelines; hence these measures will help to reduce the land pollution due to

spent wash and effluent

Generally, solid & hazardous waste becomes a cause of concern for land

environment; however, in proposed project, the solid waste such as sludge

Chapter VI



6-17

generated from polishing unit, fermentation, bio-digestion activity is degradable,

hence it will be mixed with bio-compost

Greenbelt development could help in improving aesthetics of the site

Bio-compost could help in improving soil fertility

Recycling of potash could be achieved through mixing of bagasse ash in bio-

compost

Figure 6.2: Schematic of waste management

6.3.4.1 Hazardous waste management

Spent oil from the gear boxes and automobile batteries will be disposed as per the Hazardous

waste (Management and handling) Amended Rules, 2003.

6.4 GREENBELT DEVELOPMENT

Development of greenbelt in and around an industrial complex is an effective way to attenuate

air pollution. The degree of pollution attenuation is depends upon height, width, foliage, surface

area of leaf and density of species, etc. The Major objectives of the proposed green belt

development will be –

Mitigate impact due to fugitive emissions

Create an aesthetic environment

Enhance the bio-diversity of the vicinity

Help to restore the ground water table

Prevent soil erosion and surface run-off

While planning and designing greenbelt, its various functions will be considered: They are-

Spatio-visual separation of larger parts of the premises

Chapter VI



6-18

Entrance and roadside greenery helps in separating the main industrial structures

Provision of greenery along all interior pedestrian network

Provision of (smaller) resting areas for the workforce during breaks (park benches, etc,)

Provision of reserve sites eventually becoming necessary at a later development stage. Selection of plant species will be based on their following characteristics

Fast growing

Thick canopy cover

Perennial and ever green

Large leaf area

Preferably Indigenous

Resistant to pollutants and should maintain ecological balance for soil and geo-

hydrological conditions of the region.

Trees interspacing tree density

per 100m2

Size/type Location

3 x 3m 25 Shrubs, small and

medium trees

Boundary of sugar and

cogeneration,

Garden/landscape areas

5 x 5m 09 medium to large size

trees

Boundary of plot area –

20-25m 04-05 Large size trees Road side large size trees

Since, the greenery development will be done as per the requirement i.e. type of activity

performed at a particular area/block/plot, thus the tree spacing will vary from plot to plot.

Therefore, approx. 5,500 plants (including trees and shrubs) are proposed for the greenbelt

development.

Table 6.3: List of Species Recommended For Greenbelt Development

* T=Tall, M=Medium, S=Size

S

No.

Name Size* Climatic condition

(Rainfall)

Feature/remark

1. Acacia nilotica sub species

indica and tomentosa

T 250-500 mm Dust tolerant, very common

in the region

2. Acacia leucophloea T 500-1000 mm Tolerant to air pollution, very

common in the region

3. Aegal marmalose M/T 500-1000 mm Tolerant to air pollution,


4. Albizia leabak M 500-1000 mm Tolerant of CO2

5. Anthocephalus kadamba T 500-1000 mm Dust tolerant

6. Azadiracta indica T 500-1000 mm Fly ash tolerant ,Tolerant of

alkaline and Saline soil,

Chapter VI



6-19

common in the area

7. Bauhinia purpurea T 500-1000 mm Dust tolerant, cultivated near

residential areas

8. Bauhinia variegata T/M 500-1000mm Soluble sodium 1.0 to 2.0

9. Butea monosperma T 500-1000 mm -

10. Cassia fistula M 500-1000 mm pH 7.5 to 8.4, cultivated near

residential areas

11. Cassia siamea M/T 500-1000 mm Soluble sodium 1.0 to 2.0,

cultivated near residential

areas

12. Casurina equisetifolia T 500-1000mm Tolerant of sandy soil

13. Cordia spp. M 500-1000mm Dust tolerant

14. Delonix regia T 250-500 mm Fly ash tolerant

15. Emblica officinalis M 500-1000 mm -

16. Erythrina indica T 500-1000 mm Tolerant of CO2

17. Eucalyptus species T 500-1000 mm Tolerant of sandy soil, SO2

18. Ficus benghalensis T 500-1000 mm Fluoride tolerant, common

19. Ficus glomerata T 500-1000 mm Tolerant of CO2 common

20. Ficus religiosa T 500-1000 mm Tolerant of CO2 common

21. Nerium odoratum S 500-1000 mm Tolerant of SO2 common

22. Tamarindus indica T 250-500 mm Tolerant of acidic soil

23. Terminalia arjuna T 500-1000mm Tolerant of alkaline/Saline

soil

24. Derris indica M/T 500-1000mm Tolerant to air pollution,


25. Dalbargia sissoo Tolerant to air pollution,


Table 6.4: Flowering and foliage shrubs recommended for greenbelt

# Flowering plant (Shrubs) # Foliage plant (Shrubs/Under tree)

1 Hibiscus 1 Duranta species

2 Shankasur (Ceasalpinia spp.) 2 Dracena

3 Ixora 3 Euphorbia pulcherima

4 Tagar 4 Muscanda

5 Cassia biflora 5 Maranta bicolor

6 Powder puff 6 Agave

7 Nerium 7 Palm spp.

8 Alamanda 8 Croton

9 Chitrak (Plumbago)

10 Hemalia petans

Chapter VI



6-20

6.5 CONCEPT OF WASTE-MINIMIZATION, RECYCLE/REUSE/ RECOVER TECHNIQUES, ENERGY

CONSERVATION, AND NATURAL RESOURCE CONSERVATION

Industries are going to burn the 11700 m3/day biogas in to the boiler which could save

bagasse to the tone of 22 MT per day

Recycle of 255 m3/day of treated water (spent lees and process condensate water) after

polishing treatment, for cooling tower make up. This practice reduces the fresh water

requirement

6.6 RAIN WATER HARVESTING

Rain water is one of the purest sources of water for improving the water table and water quality

in the sub-soil. Rain water which is otherwise wasted has to be recharged in to the soil. This can

be adopted eitherusing traditional way or by modern technologies. The various types of rain

harvesting schemes are, diverting rain water collection through proper channels to the nearest

pond or open wells and run off from built in areas mainly roofs are diverted to storm water

drains, which is again taken to the nearest lake / pond.

The other method of rain water harvesting is ground water recharging. In this option, the

recharging structures should be prepared in scientific way. Recharging pits of size approx. 2x2 m

and 3m depth need to be constructed and filled with pebbles/rubbles of sizes more than 2”. At

the center of this structure 6” or 8” pipe is driven to the depth of approx.10m, with perforation

of 1or2”. Such structures can be built at pre-defined places (minimum 4 or 5 places, depending

up on the site situation) so that maximum quantity of rain water within the premises of sugar

factory can be collected. The water diverted through channels, from roof tops and other means

can be collected in this recharge structure, which will definitely improve the water table as well

as quality of the water and feed water to the plant during drought season.

The industry has planned rainwater-harvesting project by harvesting rain water from roof top

areas of building and structures of sugar unit only. This selection was mainly considering

contamination as well as other feasibility factors. All the rain water is collected, filtered and

channelized to spray pond, where it is stored. The dimensions of spray pond are 30x30x3m, that

offers a volume of 2700 cu.m. for rain water storage.

11 Vinca rosea

12 Ratrani

13 Gardenia

14 Canna

16 Chrysanthemum

Chapter VI



6-21

Rain water harvesting calculations for the existing scheme are as follows.

DESCRIPTION OF

CATCHMENT

AREA

AREA AVG RAIN-

FALL PER

YEAR

RUN

OFF

WATER AVAIL-ABLE Per

annum

SQM M % CUM

Roof top area

(sugar unit only)

3690 0.55 70 2029

Storage tank details

DIMENSIONS AREA TOTAL VOLUME PROVIDED

L B H Cu.m. Cu.m.

30.00 30.00 3.00 2700.00 2700.00

This water will be used during start up of various units of sugar factory during crushing season.

6.7 SAFETY, OCCUPATIONAL HEALTH MANAGEMENT

In this project, aspects of Safety and Occupational Health are given with the due consideration,

over and above applicable legislations such as Factories Act 1948. Extra attention is paid to

provide measures for ensuring safety and health of workers as well as integrity of the unit.

Following applicable national or international standards shall be followed

Use of flameproof electrics equipments

Suitable operating procedures shall be adhered to ensure all Safety, Health and Environment

Provision of safety gears to workers

Workers working in high noise/ high risk areas must be rotated to other areas

Smoking and other igniting activities should be strictly prohibited in the distillery, biogas as

well as bio-compost area

In exceptional case, when biogas couldn’t be consumed as a fuel in the boiler then as a

safety measure a flare unit shall be installed

The plant and buildings meet the corresponding provisions of statutes regarding inter-

distances, exits, ventilation, illumination, etc. Fire fighting arrangements shall be provided as

per the required statutes as well as corresponding standards

Plan of evaluation of health of workers

By pre designed format during pre placement and periodical examinations.

Proper schedule will be devised and followed with help of occupational health experts

and doctors.

Chapter VI



6-22

Health effects of metals used and health hazard plans based on monthly correlation of

these metal related diseases and people affected.

Schedule of medical check-up during operational phase

Comprehensive Pre-employment medical checkup for all employees

General check up of all employees once every year

Medical examination of employees after retirement is recommended for a period of five

years

Local hospitals and Govt. health monitoring system will be engaged

Dispensary and ESI facility will be provided to all workers as applicable

All safety gears will be provided to workers and care will be taken by EMC that these are

used properly by them. All safety norms will be followed

6.8 MANAGEMENT PLAN FOR SOCIAL ENVIRONMENT/ENVIRONMENT RESPONSIBILITY OF

THE INDUSTRY

Comply the norms of regulatory authorities as applicable

Proper implementation of schemes for employees health, insurance, welfare, etc.

Prefer local candidates for direct employment opportunities

Provide employment to backward classes/communities as per the regulatory norms

Policy under PLI Act 1991 is mandatory

Promote water conservation measures such as drip irrigation while implementing cane

development

Maintain the road infrastructure

Help to strengthen the other infrastructures such as school, medical facilities, water,

sanitation, etc by paying taxes, cess etc on time to local and state government

Help to maintain and improve social harmony in the region

6.9 ENVIRONMENT MONITORING PROGRAMME

In order to maintain the environmental quality within the standards, regular monitoring network

to maintain, environmental quality will be implemented. The sugar factory is already having a

monitoring program for various attributes and also has a full-fledged laboratory and technical

manpower for the pollution matters. The same can be extended to the distillery and ETP since

the distillery is proposed to be within the sugar factory complex. The existing laboratory needs

to be upgraded so as to serve the proposed project requirement.

6.9.1 Environment Management Cell

It is recommended to constitute, a separate Environment Management Cell by including

following personnel of existing staff. It should be established to monitor and control the

Chapter VI



6-23

environmental quality in and around the industrial complex. Members of the Cell should be well

qualified and experienced in the concerned field.

Table 6.5: Human Resource for Environment Management Cell

Particular Number

General Manager/Production Manager One

Environmental officer/Manager One

Laboratory Chemist One

Environmental Chemist /biodigester supervisor One

Safety Officer One

Supporting Staff Two to five

6.9.2 Water Environment

Water samples from bore well/s located towards downstream of compost yard from

village Padali and Dhamni should be collected and analysed as mentioned frequency in

the table 6.6

The characteristics of inlet spentwash and biomethanated spentwash, should be

collected and analysed as mentioned frequency in the table 6.6

Water Cess should be submitted to Pollution Control Board as per the schedule

6.9.3 Air Environment

Stack monitoring to be done form NABL/MoEF approved laboratory as mentioned

frequency in the table 6.6

Ambient air sampling and monitoring at list three location at site, keeping monitoring

samplers at 120o as mentioned frequency in the table 6.6

In addition ambient air quality to be tested in upwind and down wind direction twice a

season (at village Padali, Mangrul)

Noise measurement at list five locations on site as mentioned frequency in the table 6.6

6.9.4 Other Condition

Environment Statement Reports also to be filed as per the schedule prescribed by

Pollution Control Board

Hazardous Management Returns be filed as per the schedule prescribed by Pollution

Control Board

Any other condition prescribed by the MoEF/SPCB to be complies and communicate to

concern authority

Chapter VI



6-24

Any amendment in to the rule /regulation/notification suggestion by the Government

authority to be comply

Some of the routine tests of wastewater such as pH, solids, temperature, etc. could be carried

out in the laboratory of sugar factory. However, for additional tests of water, wastewater, soil,

air etc. services of reputed laboratories approved by Ministry of Environment and Forest (MoEF),

New Delhi - under EPA 1986, could be hired.

Table 6.6: Analysis of environmental parameters and its reporting schedule

Sr. No. Particulars Parameter Frequency#

1 Stack Emissions SPM, SO2, NOx Monthly

2 Ambient Air Quality PM10, PM2.5, SO2, NOx Monthly

3 inlet and outlet of

polishing unit

pH, BOD, COD, SS, TDS, Oil & Grease etc. Monthly

4 Bore well /ground

water sample nearer to

compost yard

pH, COD, BOD, TSS, TDS and Total solids,

hardness, Chlorides, Sulphate,

Phosphates, and Calcium.

Quarterly

/monthly

5 Noise monitoring Noise Levels measurement at high noise

generating places as well as sensitive

receptors in the vicinity

Monthly

6 Analysis of ready bio-

compost

Moisture, Organic Carbon, and C:N ratio,

Nitrogen, Phosphorous, Potassium, etc.

Each batch of

compost

7 Occupational health health and fitness checkup of employees

get exposed to various hazards

All other staff (except above)

Quarterly

Twice a year

# if consent conditions are different than recommended frequency then follow the consent

conditions

Periodical Analysis of raw and biomethanated spent wash

Table 6.7: Suggested schedule for maintenance of wastewater treatment unit

# Part See (*) Frequency

1 Bearings See temperature Daily

Change grease bi-monthly

2 Gland Change packing bi-monthly/as required

3 Indicators Pressure gauge, vacuum gauge tri-monthly

Chapter VI



6-25

calibration of

4 All type valves Change packing six-monthly

5 Impellor Check all blades, sleeves, bearing,

impel nut check

Yearly, change if required

6 Electric motor Open side doors, blow dust, check air

gap

Monthly

7 Motor winding Blow off dust, test insulation bi- Yearly

8 All hand carts,

wheel barrows

Grease wheels Monthly

Change rubber tyres six-monthly if reqd

9 Gear box Oil level Check every week,

replenish tri-monthly

10 Scraper shoe Tighten nut bolts, change broken-

bent members, change leather-

rubber shoes

tri-monthly

11 Central turn table See oil level Weekly

Check chain of sprocket, steel balls,

gear

Yearly

12 Aerator See oil and grease Weekly

Painting-coating blades Yearly

(*)As applicable to the unit

6.9.5 Flow Measurement

Water required for distillery process, boiler, cooling, cleaning and domestic purpose needs to be

measured by installing flow meter at source. Quantity of minor, moderate and highly polluted

effluent generated is also need to be measured with the help of flow meter.

Table 6.8: Format for Water Consumption Reporting Schedule

Chapter VI



6-26

# Particulars m3/h m3/D m3/A

1. Dilution of Molasses

2. Distillation process, dilution for ENA

3. Cooling tower (CT) make-up for distillery

4. CT make-up for cooling spentwash for biogas plant

5. Boiler make-up

6. Floor washings sterilize

7. Sanitary Requirement

8. Domestic Use for Colony

Total

9. Water consumption per KL of alcohol production

10. Power consumption for water lifting, KWH

11. Expenses for

Electricity (Rs.)

Water Cess (Rs.)

Water Bills (Rs.)

12. Total Expenses (Rs.)

13. Expenses on water per liter of alcohol

Table 6.9: Format for Pollutant Generation Reporting Schedule

# Particulars Today m3 To date m3

A Liquid

1. Spentwash generation

2. Spent lees generation

3. Process condensate

4. Any other

B. Solid waste

5. Biomethaned Sludge

6. Bio-sludge from CPU

7. Ash

8 Any other

C Hazardous waste

9 Hazardous waste from process

10 Hazardous waste from ETP

Chapter VI



6-27

11 Any other

Table 6.10: Format for Pollutant Disposal Reporting Schedule

# Particulars Disposal method Today m3 To date m3

A Liquid

1. Spentwash Disposal

2. Treated effluent from CPU

3. Any other

B. Solid waste

4. Biomethaned Sludge

# Particulars Disposal method Today m3 To date m3

5. Bio-sludge from CPU

6. Ash

7 Any other

C Hazardous waste

8 From process

9 From ETP

11 Any other

Table 6.11: Format for Biocompost unit Reporting Schedule

# Particulars Opening

Balance

Today

received

To date

received

Consumption

/sell

Closing balance

1. Spentwash

2. Press mud

3. Culture

4. Ash received

5 Bio-sludge

6 Biocompost

7 Any other

Table 6.12: Estimated Capital & Recurring Expenses for Environmental Management Program

Sr.

No.

Particulars Amount

(Rs. in Lakhs)

16. Spent wash cooling and holding tank 123.00

Chapter VI



6-28

17. Compost yard with PCC top finish 195.00

18. Cil work at ETP (Foundation for evaporation,

biogas polishing unit )

100.00

19. Leachate management system 29.00

20. Laboratory shed and its glassware, equipments, etc. 10.00

21. Polishing units for condensate treatment 20.00

22. Biomethanation Unit 260.00

23. Stand alone evaporation 300.00

24. Spryaing pumps, Spent wash pumps and piping,

HDPE piping, internal site piping, valves and fittings

27.00

25. Biocomposting machinery, pipeline and other 68.00

26. DG set for ETP 10.00

27. Wire fencing around ETP 5.00

28. Electrification at ETP 10.00

29. Fire fighting equipments and other 5.00

30. Tree plantation and bore well for composting 5.00

TOTAL 1167.00

Recurring Expenses/annum

1. Salaries and wages @ 5% on capital investment 58.35

2. Operation and maintenance of all pollution control devices,

motors, pumps, pipelines, etc. 5% on capital investment

58.35

3. Fuel (composting activity) and Electricity (in case of diesel

generator operation)

1.26

TOTAL 117.96

Chapter VII


7-1

CHAPTER VII

RISK ASSESSMENT AND MANAGEMENT

7.1 INTRODUCTION

Risk associated with the use of hazardous chemicals can be assessed and managed in terms of their

effect on human health, environmental health, and business operations, in general. When discussing

a particular chemical substance, each of these categories should be examined to ensure a

comprehensive understanding of a total risk and to provide the basis for an acceptable risk

management programme.

Presence of a chemical commodity in the work place or the environment in general, generates some

level of risk. Assessing the nature or severity of this risk is dependent upon a number of factors, all of

which focus on one common element: exposure. In assessing a risk a questions of exposures must

consistently be asked. Are personnel being exposed? Is there an exposure to the environment? What

is the risk to continue success in business operations if there is an exposure to personnel and/or the

environment? Therefore, risk assessment, which is the basis for risk management, is partially

contingent upon an understanding of term ‘Exposure’.

However, an exposure to chemical doesn’t always mean that the results will be detrimental. If such

exposure occurs (i.e. those with no detrimental or adverse effect to human health, the environment

or business operation) then additional question must be asked – what is the nature of the risk

associated with such exposure? Are these exposures hazardous or toxic? Hence, it is not always

enough to have experienced an exposure to a chemical to accurately assess the risk posed by such.

One must determine (assess) if the exposure was also hazardous before the level or nature of risk

can be properly identified. In other words, the specific hazardous of an exposure that present risk to

a person and/ or the environment must be examined. It becomes clear that the risk assessor or risk

manager must understand the principals of hazard, exposure, and risk.

7.2 THE RISK EQUATION

Risk is the probability that the hazard will occur (i.e. that an adverse effect or/event will

result from a given set of exposure condition). Since the risk is typically expressed as a mathematical

probability, the range of risk can be stated as zero (having no possibility of adverse effect or event).

One (having a certainty that an adverse effect or event will result) having established this, it is

important to note that risk is the mathematical product of hazard and exposure. This relationship

can, be expressed in the following simple formula.

Chapter VII


7-2

Risk = Hazard x Exposure

Simple Mathematics tells us that, multiplying any number by zero forces a product of zero.

Therefore, the above equation means that an extremely hazardous substance can be present with

little risk of adverse effect if it is handled with safe and proper conditions (i.e. when the exposure

component of the risk equation is driven towards zero). Similarly, risk can be reduced towards zero

by driving the hazard component of the equation towards zero (e.g. changing the process design,

substituting less hazardous commodity, using a lesser amount of a chemical, etc.), even if there is

still a high probability of exposure. Of course, the ultimate risk management solution would be

driving both the exposure and the hazard components of the equation to as low probability as

possible. Such measures would virtually guarantee a low or no risk scenario; however, in the real

world of everybody, operations, it is not always practical, feasible, or possible to reduce the

elements of risk to zero level or probability. For this reason, risk assessment and risk management

have become extremely vital element to successful business operations in recent years. More

importantly, the proper assessment and management of risks, which may be pose by the use,

transport, storage, or disposal of hazardous chemical can be laterally save lives, prevent illness and

injury and preserve the precious environmental resources.

7.3 HAZARD IDENTIFICATION

7.3.1 Mechanical Hazard

It mainly involves properties of machine parts or work pieces, such as:

a. Shape: It may cause injury to workman

b. Relative location: Confined location during repairs & maintenance

c. Mass and stability: May cause physical Injury

d. Inadequacy of mechanical strength

e. Accumulation of energy inside the equipment: steam/ air /water pressure cause injury to

workman

f. During commissioning, Operation and Maintenance of plant Crushing hazard, shearing

hazard, Cutting or severing hazard, Friction or abrasion hazard and High pressure fluid

injection or ejection hazard can not ruled out

7.3.1.1 Mechanical injury to body parts

g. In industry, there are several places where workers are likely to be involved with accidents

resulting in injury to body parts. The places are workshop, during mechanical repair work in

different units, during construction work, road accidents due to vehicular movement, etc

Chapter VII


7-3

h. Workers exposed to mechanical accident-prone areas will be given personal protective

equipment. The non-respiratory PPE includes tight rubber goggles, safety helmets, welders

hand shields and welding helmets, plastic face shields, ear plugs, ear muffs, rubber aprons,

rubber gloves, shoes with non-skid soles, gum boots, safety shoe with toe protection.

i. All safety and health codes prescribed by the BIS will be implemented. Fire hydrants will be

located at all convenient and strategic points along the major drains and checked for water

availability on regular basis. Fire extinguishing equipment, sand buckets, water sprinklers,

and water hoses will be provided at all convenient point. Fire, heat, smoke, and hydrocarbon

detection alarms will be installed.

7.3.2 Electrical Hazard

Probable incidences for electrical hazards, could be

a. Contact of persons with live parts (direct contact),

b. Contact of persons with parts which have become live under faulty conditions (indirect

contact),

c. Approach to live parts under high voltage,

d. Electrostatic phenomena,

e. Thermal radiation or other phenomena such as the projection of any particles and

chemical;

f. Effect of short circuits, overloads, etc identified during construction, production and

maintenance

7.3.3 Thermal Hazard

Probable causes of thermal hazards could be -

a. Burns, scalds and other injuries by a possible contact of persons with objects or materials

with an extreme high or low temperature, by flames or explosions and also by radiation of

heat sources

b. Damage to health by hot or cold working environment

c. Thermodynamic Hazard such as over/under pressure, over/under-temperature need to be

avoided by providing system management

7.3.4 Hazard generated by noise

In the proposed project probable source of noise are – boiler, motors and pumps,

etc. Usually prolong exposure to high noise level, results into

1. hearing loss (deafness), other physiological disorder (e.g., loss of balance, loss of

awareness)

Chapter VII


7-4

2. Interference with speech communication, acoustic signals, etc.

7.3.5 Hazard generated by Vibration

In the proposed project the hazard due to vibrations could be due to -

1. Use of hand-held machines resulting in a variety of neurological and vascular disorders

2. Whole body vibration, particularly when combined with poor postures

7.3.6 Hazards generated by materials/substances

1. Hazards from contact with or inhalation of harmful fluids such as: Anti rusting chemicals,

Cleaning agents/acids/organic solvents gases, Superheated steam through leaks, bagasse

dust, etc.

2. Fire hazard — dry bagasse, alcohol and molasses storage area, furnace

3. Biological or microbiological (viral or bacterial) hazards:-Workplace exposure to dusts from

the processing of bagasse can cause the chronic lung condition pulmonary fibrosis.

7.3.7 Preliminary Hazard Analysis (PHA)

Preliminary hazard analysis (PHA) is a semi-quantitative analysis that is performed to identify all

potential hazards and accidental events that may lead to an accident, rank the identified accidental

events according to their severity, and identify required hazard controls and follow-up actions. This

tool analysis is based on applying prior experience or knowledge of hazard to identify future hazards,

hazardous situation. This can be used for product, process and facility design. This can be used in

early development of a project where there is little information in detail is available.

7.3.8 Qualitative Risk Assessment

Table 7.1: Probability of occurrence of hazard

Probability No Causes/ Incident

1 Very unlikely Once per 1000 years or more seldom

2 Remote Once per 100 years

3 Occasional Once per 10 years

4 Probable Once per year

5 Frequent Once per month or more often

Table 7.2: Severity - Impact Intensity

1 Minor-Failure results in minor system damage but does not cause injury to personnel, allow

any kind of exposure to operational or service personnel or allow any release of chemicals

into the environment

Chapter VII


7-5

2 Major-Failure results in a low level of exposure to personnel, or activates facility alarm

system.

3 Critical --Failure results in minor injury to personnel, personnel exposure to harmful

chemicals or radiation, fire or release of chemical to the environment

4 Catastrophic Failure results in major injury or death of personnel

Table 7.3 Risk assessment and mitigation measures

Sr.

No Hazard Probability Severity Mitigation Measure

Mechanical Hazard

1. Physical injury to

hand/legs

during process

Frequent Once

per month or

more often

Minor

Use PPE/PPA

2. Boiler Explosion

Remote

Catastrophic

Layers of Protection

area(LOPA)

3. Fingers nipping in

between moving part. E

g Belt

Probable Once

per year

Major

Fixed /Movable Guards at

probable sites

4. Steam pipe leakages

Frequent Once

per month or

more often

Major

Proactive Maintenance/PPE

5. Working on height

Impact /falling down

Probable Once

per year Critical

Work permit system

Life belts/Helmet

Chapter VII


7-6

Sr.

No Hazard Probability Severity Mitigation Measure

6. Water feeder pump

failure

Occasional

Once per 10

years

Critical Alarming/communication

arrangements

Electrical Hazard

7. Contact of persons with

parts which have

become live under faulty

conditions (indirect

contact)

Occasional

Once per 10

years

Major PPE/PPA/Permits

8. Approach to live parts

under high voltage

Occasional

Once per 10

years

Catastrophic

Guards/ authorization

Enter Restriction

9. Electrostatic phenomena Remote Major

Earthling, avoid Dust

Explosion

10.

Thermal radiation or

other

Short circuits, overloads,

etc.

Probable Once

per year Major PPE/Checking /Inspection

Thermal Hazard

11. Burns, scalds and other

injuries by steam

Occasional

Once per 10

years

Major

Safe working

distance/PPA/protective

dress code

12. Damage to health by hot

working environment

Frequent Once

per month or

more often

Critical Minimum exposure

Ventilation /Humidity control

Hazard generated by Noise

13. Belt movement.

Pump/Motor

Turbo generator

Frequent

Critical

Confinement of source

Use Ear Muff/Plugs

Hazard generated by Vibration

14. Whole body vibration,

during working on

feeder platform

Remote Major Engineering solutions

*Severity - Minor, Major, Critical, Catastrophic

Chapter VII


7-7

7.4 PROBABLE RISK FACTORS

Following scenarios feel under Maximum Credible Accident Scenario

• Fire in fuel yard (bagasse yard) or storage yard (molasses and alcohol storage tanks)

• Fire due to short circuits

• Injury to body and body parts (mechanical)

7.4.1 Fire: This is the most common accident known to occur in any plant, while storing and

handling fuel. Since, such incident takes short time to get widespread. Quick response is required to

evacuate the plant personnel. An elaborate fire hydrant network and fire fighting system comprising

of trained crew and facilities will mitigate the risk of such incidents. In addition, as per requirement

fire alarm system and smoke detectors will be installed.

Table 7.4: NFPA (NATIONAL FIRE PROTECTION ASSOCIATION) RATING

Chemical NFPA Ratings

Health Hazard Fire Reactivity

Ethanol 0 3 0

NFPA Classifications

Health Hazard Definition

4 Materials which on very short exposure could cause death or major residual

injury even though prompt medical treatment were given

3 Materials which on short exposure could cause serious temporary or residual

injury even though prompt medical treatment were given

2 Materials which on intense or continued exposure could cause temporary

incapacitation or possible residual injury unless prompt medical treatment is

given

1 Materials which on exposure would cause irritation but only minor residual

injury even if no treatment is given

0 Materials which on exposure under fire conditions would offer no hazard

beyond that of ordinary combustible material

Flammability Definition

Chapter VII


7-8

4 Materials which will rapidly or completely vaporise at atmospheric pressure

and normal ambient temperature, or which are readily dispersed in air and

which will burn readily

3 Liquids and solids that can be ignited under almost all ambient temperature

conditions.

2 Materials that must be moderately heated or exposed to relatively high

ambient temperatures before ignition can occur

1 Materials that must be preheated before ignition can occur

0 Materials that will not burn

Reactivity Definition

4 Materials which in themselves are readily capable of detonation or of explosive

decomposition or reaction at normal temperatures and pressures

3 Materials which in themselves are capable of detonation or explosive reaction

bur require a strong initiating source or which must be heated under

confinement before initiation or which must be heated under confinement

before initiation or which react explosively with water.

2 Materials which in themselves are normally unstable and readily undergo

violent chemical change but do not detonate. Also materials which may react

violently with water or which may form potentially explosive mixtures with

water

1 Materials which in themselves are normally stable, but which can become

unstable at elevated temperatures and pressures or which may react with

water with some release of energy but not violently

0 Materials which in themselves are normally stable, even under fire exposure

conditions, and which are not reactive with water

MITIGATION MEASURES FOR FIRE HAZARDS

A. Storage

Alcohol (RS, ENA or AA) and molasses will be stored in leak-proof MS tanks, gauges of

MOC will be strictly as per IS or relevant standards;

Storage area will be well ventilated with adequate spacing between units

Provision of alcohol vapor condensation system

Chapter VII


7-9

Strictly declare as ‘No Smoking Zone’ and prohibiting use of any ignitable material (e.g.

even cell phones, etc.)

Use Electrical fittings of good quality that comply national or international standards

Mandatory to transport vehicle to use flame proof silencer


Product and storage details

# Particulars Production

(KL/Day)

Receiver

capacity (m3)

Storage

capacity (m3)

Make

1.

Rectified Spirit 28.5 KLPD 60 x 3 600x1 MS

Impure Sprit 1.5 KLPD 10x3 600x1 MS

2. ENA 28.2 KLPD 60x3 600x3 MS

Technical alcohol 1.8 KLPD 10x2 MS

3 Anhydrous alcohol 30.0 KLPD 60x3 600x2 MS

4. Fusel oil 60L per day 10x1 MS

B. Provisions of Fire fighting System will be as follows

a. Guidelines of OISD-STD-117 will be implemented

b. The fixed water spray system will be provided on all tanks, fire water flow rate will be

calculated at a rate of 20.4 lpm/m2 as per OISD-STD-117

c. Fire water system will be designed for a minimum residual pressure of 7 kg/cm2(g) at

hydraulically remotest point in the installation considering single largest risk scenario

d. Water for the fire fighting will be stored in easily accessible surface or underground

tanks of RCC/steel with minimum four hours aggregate rated capacity of pumps. There

will be one or two standby diesel engine driven pumps of the same type, capacity &

head as the main pumps will be provided; Jackey pump (one in number -AC motor

driven) for maintaining pressure

e. Hydrant system covering the entire plant including all important auxiliaries and buildings

is proposed. The system will be complete with piping, valves instrumentation, hoses,

nozzles and hydrants, valves etc.

f. High velocity water spray system near storage tanks

g. Portable extinguisher such as pressurized water type, carbon dioxide type and foam type

will be located at strategic locations throughout the plant

Chapter VII


7-10

h. The diesel engines will be quick starting type with the help of push buttons located on or

near the pumps or located at a remote location.

i. Portable foam and/or water-cum-foam monitors will be provided for suppression of

pool fire in tank farm area.

j. Fire water pumps & storage will be located at 30 m (minimum) away from equipment or

where hydrocarbons are handled or stored.

k. Fire water pumps will be exclusively used for firefighting purpose only

l. Fire water mains, hydrant & monitor stand posts, risers of water spray system will be

painted with “Fire Red” paint as per IS: 5.

m. Hose boxes, water monitors and hydrant outlets will be painted with “Luminous Yellow”

paint as per IS: 5

n. Electric audible fire siren will be to the farthest distance in the installation and also in

the surrounding area up to 1 km from the periphery of the installation which wills

different sound with respect to shift alarm with continuous power supply

o. Communication system like Telephone, Public Address System, etc. should be provided

in non-hazardous areas of the installation

C. Boiler Operations

1. Provision of adequate sets of Personnel protective equipment's

2. Pilot lights will be provided on electrical panel boards

3. Provision of hand operable fire fighting cylinders at strategic locations

D. Fire Fighting Strategy

1. In case of small fire the fire can be extinguished with the help of DCP followed by

water to prevent re-ignition.

2. If it is a major fire, cordon the area and restrict entry of any unauthorized personnel

3. Keep a safe distance if there is any possibility of explosion

4. In the event of any threat to the neighbouring residents, besides alerting those on the

incident ensure that necessary precautions have been taken by them with the help of Civil

Administration Authorities.

5. Mutual aid to be activated and district authorities shall be contacted for activating off site

emergency preparedness.

6. Proper safety equipment should be used & back up of fire fighting/rescuing team to be

provided.

7. Keep constant vigil on that particular spot and as well as on the neighbouring area.

Chapter VII


7-11

8. Avoid directing heavy streams of water on the roof to avoid water stagnation.

9. Follow the instruction of Man-In-Charge during the entire fire fighting exercise.

10. Cooling water streams should be applied to the top of tank (excluding floating roof tank) so

that the run-off down the sides of the tank will reduce the heat input to the tank.

11. Water must be applied on tank appurtenances, un-insulated supports and any porting of the

tank shell above the liquid level where there is direct flame contact.

12. If the flames from vents are discharging onto the top of the shell of the tank, water must be

directed on that area to keep it cool.

13. Cooling of tanks usually in needless unless there is direct flame contact or sufficient radiant

heat to scorch the paint.

14. As a rule, ground fires around the tanks must be controlled or extinguished before

attempting to extinguish the fire in the tank.

Table 7.5: Hazard Warning Information for Ethyl Alcohol

SECTION I

PRODUCT NAME Ethyl Alcohol,

SYNONYMS Anhydrous Ethyl Alcohol, Dehydrated Alcohol

CHEMICAL FAMILY Alcohol

MOLECULAR WEIGHT 46.07

FORMULA C2H5OH

Health Fire Reactive Other Degree of Hazard

Colour Coding Other Codes

0 3 0 - 0 = Minimum

1 = Slight

2 = Moderate

3 = Serious

4 = severe

Health = Blue

Fire = Red

Reactivity = Yellow

Other = White

Ox = Oxidiser

Acid = Acid

Alk = Alkaline

COR = Corrosive

W = No use water

SECTION II – INGREDIENTS

COMPOSITION CAS RN. NOMINAL WT/WT%

PEL/TLV HAZARD

Ethyl Alcohol 64-17-5 100.0 1000 ppm Flammable/Nervous System Depressant

PEL = Personal Exposure Limit

TLV = Threshold Limit Value

SECTION III – HEALTH INFORMATION

Chapter VII


7-12

INHALATION Exposure to over 1000 ppm may cause headache, drowsiness, and lassitude, loss of appetite, and inability to concentrate. Irritation of the throat.

INGESTION Can cause depression of central nervous system, nausea, vomiting, and diarrhea.

EYE CONTACT Liquid or vapor may cause irritation.

SKIN CONTACT May cause irritation and de-fatting of skin on prolonged contact

SECTION IV – OCCUPATIONAL EXPOSURE LIMITS

PEL (OSHA Permissible Exposure Limit): Mixture

See Section II

TLV (ACGIH Threshold Limit Value): Mixture

See Section II

SECTION V – EMERGENCY FIRST AID PROCEDURE

FOR OVEREXPOSURE BY

SWALLOWING

If victim is conscious and able to swallow, have victim drink water

or milk to dilute. Never give anything by mouth if victim is

unconscious or having convulsions. CALL A PHYSICIAN OR CHEM-

TREC (POISON CONTROL) IMMEDIATELY. Induce vomiting only if

advised by physician (Poison Control)

INHALATION Immediately remove victim to fresh air. If victim has stopped

breathing, give artificial respiration, preferably mouth-to-mouth.

GET MEDICAL ATTENTION IMMEDIATELY

CONTACT WITH

EYES OR SKIN

Immediately flush affected area with plenty of cool water. Eyes

should be flushed for at least 15 minutes. Remove and wash

contaminated clothing before reuse. GET MEDICAL ATTENTION

IMMEDIATELY

SECTION VI – PHYSICAL DATA

BOILING POINT 173° F (78 0C)

MELTING POINT -173° F (-114 0C)

VAPOR PRESSURE 44.6 mm Hg @ 68° F (20 0C)

SPECIFIC GRAVITY 0.7940 @ 60°/60° F

VAPOR DENSITY (AIR = 1) 1.59

SOLUBILITY IN WATER Complete in water, chloroform, acetone, ether, benzene and methanol

APPEARANCE AND COLOR Clear and colorless, volatile liquid with a weak, vinous, alcohol

Chapter VII


7-13

odour and bitter taste. Odour threshold = 84 ppm

SECTION VII – FIRE AND EXPLOSIVE HAZARDS

FLASH POINT 56° F ASTM D-56 (Tag Closed Cup)

AUTO-IGNITION TEMPERATURE 685° F

FLAMMABLE LIMITS IN AIR, % BY VOLUME

LOWER: 3.3 UPPER: 19

NFPA (National Fire Protection Association) RATING

HEALTH (0) FIRE (3) REACTIVITY (0)

FIRE FIGHTING PROCEDURES (Note: Individuals should perform only those fire-fighting

procedures for which they have been trained.) Use dry

chemical, “alcohol” foam, or carbon dioxide; water may be

ineffective, but water should be used to keep fire-exposed

containers cool. If a leak or spill has not ignited, use water

spray to disperse the vapors and to protect men attempting

to stop a leak. Water spray may be used to flush spills away

from exposures and to dilute spills to nonflammable

mixtures.

Firefighters should wear self-contained breathing

apparatuses in the positive pressure mode with a full-face

piece when there is a possibility of exposure to smoke,

fumes, or hazardous decomposition products.

SECTION VIII – REACTIVITY

STABILITY Generally stable.

HAZARDOUS POLYMERIZATION Not likely.

CONDITIONS & MATERIALS TO AVOID

Contact with acetyl chloride and a wide range of oxidizing

agents may react violently.

SECTION IX – EMPLOYEE PROTECTION

CONTROL MEASURES Handle in the presence of adequate ventilation.

RESPIRATORY PROTECTION Where exposure is likely to exceed acceptable criteria, use

NIOSH/MSHA approved respiratory protection equipment.

Respirators should be selected based on the form and

concentration of contaminant in air and in accordance with

Chapter VII


7-14

OSHA (29 CFR 1910.134).

PROTECTIVE CLOTHING Wear gloves and protective clothing, which are impervious to

the product for the duration of the anticipated exposure if

there is potential for prolonged or repeated skin contact.

EYE PROTECTION Wear safety glasses meeting the specifications of ANSI

Standard Z87.1 where no contact with the eye is anticipated.

Chemical safety goggles meeting the specifications of ANSI

Standard Z87.1 should be worn whenever there is the

possibility of splashing or other contact with the eyes.

SECTION X – ENVIRONMENTAL PROTECTION

ENVIRONMENTAL PRECAUTIONS Avoid uncontrolled releases of this material.

Where spills are possible, a comprehensive spill response

plan should be developed and implemented.

SPILL OR LEAK PROCEDURES Wear appropriate respiratory protection and protective

clothing as described in Section IX. Contain spilled material.

Transfer to secure containers. Where necessary, collect using

absorbent media. In the event of an uncontrolled release of

this material, the user should determine if the release is

reportable under applicable laws and regulations.

WASTE DISPOSAL All recovered material should be packaged, labeled,

transported, and disposed off, or reclaimed in conformance

with applicable laws and regulations and in conformance

with good engineering practices.

SECTION XI HANDLING AND STORAGE

Precautions

Keep locked up. Keep away from heat. Keep away from sources of ignition. Ground all equipment

containing material. Do not ingest. Do not breathe gas/fumes/ vapor/spray. Wear suitable protective

clothing. In case of insufficient ventilation, wear suitable respiratory equipment. If ingested, seek

medical advice immediately and show the container or the label. Avoid contact with skin and eyes.

Keep away from incompatibles such as oxidizing agents, acids, alkalis, and moisture.

Chapter VII


7-15

Storage

Store in a segregated and approved area. Keep container in a cool, well-ventilated area. Keep

container tightly closed and sealed until ready for use. Avoid all possible sources of ignition (spark or

flame). Do not store above 23°C (73.4°F).

7.6 RISK ASSESSMENT: HEALTH

7.6.1 General Assessment

The toxicity of ethyl alcohol is much lower in comparison to methanol or propanol. Ethyl alcohol is

primarily toxic to humans by ingestion. While inhalation of its vapors can produce some toxic effects,

its ability to enhance the effects of other chemicals poses a greater health risk for inhalation. Skin

contact can cause topical damage and absorption is, therefore, not likely. It should be noted that

most manufacturers of ethyl alcohol for use in industrial applications would normally mix it with a

denaturant (a substance added to make it un desirable to drink). These include gasoline, acetone,

formaldehyde, or methyl alcohol. Therefore, industrial exposures resulting from ingestion are very

unlikely.

Inhalation can cause irritation of the eyes, nose, throat, upper respiratory tract, and associated

mucosa. There may be headache, nervousness, tremors, dizziness, tearing, fatigue, nausea,

somnolence, and narcosis with stupor and loss of consciousness. There are no reports of cirrhosis

occurring as a result of inhalation exposures. However, chronic exposure to ethyl alcohol vapors

caused brain damage in mice. Vapor exposure can also increase the toxic effects of other chemicals

being inhaled. Also, the toxicity of ethyl alcohol is enhanced with the presence of compounds such

as barbiturates, carbon monoxide, and methyl mercury.

Liquid contact with the eyes causes immediate burning and stinging with lachrymator and reflex

closure of the lids. There may be injury to the corn epithelium and possible hyperemia (excessive

blood) the conjunctiva. Skin contact results in drying cracking, which can lead to secondary

infections dermatitis.

Ingestion of ethyl alcohol is not likely to occur in the industrial environment. However, if it does,

symptoms can include sleep disorders, hallucinations, distorted perceptions, ataxia, motor function

changes, convulsions and tremors, coma, headaches, pulmonary changes, alteration of gastric

secretions, menstrual cycle changes, glandular changes, nausea or vomiting, and decrease in body

temperature.

Chapter VII


7-16

7.6.2 Acute Health Effects

The following acute (short-term) health effects occur immediately or shortly after exposure to

alcohol.

Skin Causes dryness and cracking leading to dermatitis and possible

infection.

Eye Severe irritation with burning and possible damage to the cornea and

conjunctiva.

Lung Irritation of the eyes, nose, throat, and respiratory tract.

Central Nervous

System (CNS)

High concentrations can cause depression the CNS with symptoms of

sleepiness and I of concentration.

7.6.3 Chronic Health Effects

The following chronic (long-term) health effects occur at some time after exposure to ethyl alcohol

can last for months or even years:

Cancer Hazards: Ethyl alcohol is known to cause liver cancer in humans, primarily due to

ingestion. Industrial exposures through ingestion are not likely but are

certainly possible.

Reproduction: According to the references, ethyl alcohol can affect human reproduction

by ingestion. It causes changes in the female fertility index. Effects on

newborns include changes in the apgar score, neonatal measures or

effects, and drug dependence.

Other Chronic Effects: Very high or prolonged exposure may result in mucous membrane

irritation, headache, and depression of the CNS with symptoms of

somnolence and lack of concentration. Prolonged skin contact can cause

dermatitis.

7.6.4 Recommended Risk-Reduction Measures

Even though ethyl alcohol is a known carcinogen, this effect is primarily the result of ingesting large

amounts of alcoholic beverages. Industrial exposures by this route are not likely to occur. The best

risk reduction measure is to use a less toxic chemical as a substitute for an ethyl alcohol. However,

based upon the fact that ethyl alcohol is one of the most widely used industrial solvents, substitution

is usually not an alternative. Therefore, engineering controls are the most effective methods of

Chapter VII


7-17

reducing exposures. The best protection is to enclose operations' and/or provide local exhaust

ventilation at the site of chemical release. While not always operationally feasible, isolating

operations can also reduce exposure risk.

Using respiratory protection is less effective than the controls mentioned above, but is still advisable

whenever working with or around ethyl alcohol. For concentrations over the Permissible Exposure

Limit (PEL i.e. 1000 ppm), an air-purifying respirator with an organic vapor cartridge will suffice. For

higher exposures, a supplied-air respirator with full face piece operated in positive pressure mode,

or a self-contained breathing apparatus (SCBA) with full face piece and operated in pressure demand

mode are the recommended respiratory protection methods of choice. If a full face piece is not

available, then chemical goggles should be worn to protect the eyes. Whenever a chemical splash

hazard exists, a face shield and a protective apron should be worn. To prevent hand and skin

exposures, impervious gloves should be used.

Administrative controls should also be in place to minimize the potential for human exposures.

These may include written procedures or policies, which specify the methods and techniques that

will be practiced whenever personnel are to work with ethyl alcohol.

All personnel should receive training on- the use, hazards, protective measures, emergency actions,

and other precautions per 29 CFR 1910.1200 (Hazard Communication), prior to the first assignment

in an area where ethyl alcohol is used or stored. If symptoms develop or overexposure is suspected,

the following medical tests are recommended

a. Liver function tests;

b. Skin testing with dilutes ethyl alcohol to help diagnose allergy (performed by a

qualified allergist).

Any medical evaluation should include a careful history of past and present symptoms with an

examination. Medical tests that look for existing damage are not a substitute for controlling

exposures. Also, since consuming large quantities of alcoholic beverages can lead to liver dysfunction

and even cancer, persons with alcohol addiction who arc exposed to ethyl alcohol on the job may

develop symptoms much quicker and with greater intensity than those who do not drink under

identical exposure conditions. Prudent risk management requires careful consideration of all

possible factors that may be causing the appearance of exposure symptoms.

7.6.5 Other Methods to Reduce Exposure

Chapter VII


7-18

1. Where possible, enclose operations and use local exhaust ventilation at the site of

chemical release. If local exhaust ventilation or enclosure is not used, respiratory

protection should be mandatory.

2. Always ensure that proper protective clothing is worn when using chemical

substances.

3. Wash thoroughly immediately after exposure to ethyl alcohol and at the end of the

work shift or before eating, drinking, or smoking.

4. Hazard warning information should be posted in the work area. In addition, as part

of an on-going education and training program, all information on the health and

safety hazards of ethyl alcohol should be communicated to all potentially exposed

workers.

7.7 RISK ASSESSMENT: ENVIRONMENT


The environment is at risk of exposure during transportation, storage, disposal, or

destruction of ethyl alcohol. In almost every scenario, the threat of environmental exposure is

contingent upon the proper handling of the chemical substance. Accidental spills, large or small, can

result in fire, explosion, and possible contamination of the surrounding environmental mediums

(water, soil, and air).

Ethyl alcohol is considered a class IB flammable liquid (according to OSHA 29 CFR 1910.106). Its low

flash point and relatively low boiling point present a serious fire and explosion hazard concern. Also,

because it is incompatible with a number of common materials, especially strong oxidizers and many

metal nitrates, contact can result in violent and explosive reactions. It can form explosive mixtures in

air and can ignite on contact with heat, fire, or sparks. It will react and then explode in contact with

acetic anhydride + sodium hydrogen sulfate. It also reacts violently with acetyl bromide (evolves

hydrogen bromide). These characteristics require special consideration during any emergency

situation involving a leak or spill of ethyl alcohol.

Ethyl alcohol can enter the environment through unchecked industrial discharges into effluents and

through spills.

7.7.2 Acute Ecological Effects

Acute (short-term) toxic effects may include the death of animals, birds, or fish, and death or low

growth rate in plants. Acute effects are seen 2 to 4 days after animals or plants are exposed to ethyl

Chapter VII


7-19

alcohol. This chemical has moderate acute toxicity to aquatic life. Insufficient data are available to

evaluate or predict the short-term effects of ethyl alcohol to plants, birds, or terrestrial animals.

7.7.3 Chronic Ecological Effects

Chronic toxic effects may include shortened life span, reproductive problems, lower fertility, and

changes in appearance or behavior in exposed animals. These effects can be seen long after first

exposure(s) to toxic chemicals. Ethyl alcohol has moderate chronic toxicity to aquatic life. Insufficient

data are available to evaluate or predict the long-term effects of ethyl alcohol to plants, birds, or

land animals.

Water Solubility: Ethyl alcohol is highly soluble in water. Concentrations of 1000 milligrams and more

can be expected to mix with a liter of water.

7.7.4 Persistence in the Environment

Ethyl alcohol is slightly persistent in water, with a half- life of between 2 to 20 days. The half-Life of a

pollutant is the amount of time it takes for one-half of the chemical to be degraded. About 90% of

ethyl alcohol will eventually end up in the air; the remainder will end up in water.

7.7.5 Bioaccumulation in Aquatic Organisms

Some substances increase in concentration, or bioaccumulate, in living organisms as they breathe

contaminated air, drink contaminated water, or eat contaminated food. These chemicals can

become concentrated in the tissues and internal organs of animals as well as humans. The

concentration of ethyl alcohol found in fish tissues is expected to be about the same as the average

concentration of ethyl alcohol in water from which the fish was taken.

7.7.6 Recommended Risk-Reduction Measures

Proper training of all transporters will reduce the likelihood of a mishap or accident resulting

in a leak or spill to the environment. The correct labeling while transportation on all transporting

vehicles should be enable emergency responders to react properly and quickly to any disaster

thereby reducing the potential risk to the environment and to personnel.

Storage of ethyl alcohol should be segregated from incompatible chemicals to minimize the risk of

cross contamination or contact. Buildings designated for storage should be equipped with

appropriate fire protection systems (alarms, sprinklers, emergency lighting, portable extinguishers).

Equipment should be designed to meet explosion-proof standards.

If a spill or leak to the environment has occurred, fire department, emergency response, and/or

hazardous materials spill personnel should be notified immediately. Cleanup should be attempted

Chapter VII


7-20

only by those trained in proper spill containment procedures. Contaminated soils should be removed

for incineration and replaced with clean soil. If ethyl alcohol should contact the water table, aquifer,

or navigable waterway, time is: of the essence. It is highly soluble in water and, therefore, total

containment and remediation may not be entirely possible. When such spills occur, the local and/or

state emergency response authorities must be notified. A comprehensive emergency response of

disaster preparedness/recovery plan should be in place prior to any operations involving the use,

transportation, storage, or disposal of ethyl alcohol. If ethyl alcohol is spilled or leaked, the following

specific steps are recommended:

a. Restrict persons not wearing protective clothing from area of spill or leak until cleanup is

complete and area can be opened for normal work.

b. Ventilate area and remove ignition sources.

c. Absorb liquids in vermiculite, dry sand, earth, or a similar material and deposit in sealed

containers. Use non-sparking tools.

d. It may be necessary to dispose of ethyl alcohol as a hazardous waste. The state PCB should

be contacted for specific recommendations.

Chapter VII


7-21

7.8 RISK ASSESSMENT: BUSINESS


Accidents or mishaps involving ethyl alcohol can present a moderate threat to business operations.

The loss or damage of equipment or facilities can significantly affect fiscal viability. Lawsuits that

may result from personnel injury/death, public exposures, and/or environmental contamination will

also require a serious expenditure of resources. Media attention surrounding an injury, death, or

environmental damage can also result in a loss of profits and loss of current as well as future

business.

Recommended Risk-Reduction Measures

Company attorneys, safety and health professionals, and environmental specialists should be

involved in the development of any procedures or policies intended to manage the use of chemicals

in the workplace. A company official should be pre-designated as a public relations officer with

specific training in dealing with the press. Corporate plans and policies should be developed,

approved, and implemented long before any need for such arises.

Safety Provisions Proposed: Others

1. Frequent checking of pipelines and storage units will be done.

2. Prohibiting welding or similar maintenance activities near combustible material storage

3. Pumps of reliable quality will be installed.

4. Lightening protecting system as per Indian electricity rules

5. keep safe distance between fuel storage area and main unit

6. Corrosion protection methods for pipelines

7. All locations where the above ground pipelines are close to traffic movement, protection like

crash guards will be provided

8. ‘Flame arresters' will be provided in gas lines to protect the digester from back fire from the

flame and / or the boiler burner.

9. Over / under pressure release device will be provided on biogas digester for its safety from over

pressure / vacuum.

10. Transfer of alcohol only mechanically

Chapter VII

7-22

Table 7.6: Summary of risk assessment and damage control

High risk equals 16 to 25

High Risks activities should cease immediately until further control measures to mitigate the risk are introduced

Medium risk equals 9 to 15

Medium Risks should only be tolerated for the short-term and then only whilst further control measures to

mitigate the risk are being planned and introduced, within a defined time period.

Note: Medium risks can be an organizations greatest risk, its achilles heel, this due to the fact that they can be

tolerated in the short-term.

Low risk equals 1 to 8

Low Risks are largely acceptable, subject to reviews periodically, or after significant change etc.

General Risk Assessment

1. Responsibility Site Controller: Head- Production

Incident Controller: Shift- In charge

Emergency Coordinators: Departmental Heads

Hazards and details

Persons at risk

Control measures Action recommended in case of emergency

Risk

Likelihood Severity Risk rating

L S RR=LxS

Furnace/boiler- Fire hazard caused by fuels/ ignitable substances

Persons working near the furnace area- Burns may be possible if directly come

Emergency alarm to be put on to signal the emergency

Emergency kit will be kept ready near the plant

Fire fighting equipments power/ foam type

Switch off the system.

Fire extinguishers are to be used immediately

Water hose to be operated to set out the fire depending on the situation

2 4 8

Chapter VII



7-23

in contact extinguishers on vehicles and mounted on walls will be kept readily available

Provision of water hose

Strictly ‘No smoking zone’ and prohibition of ignitable activities

Plant workers will be trained to fight fire

Outside fire brigade is to be called if the fire cannot be extinguished immediately

Inform the occupier/ manager and activate the onsite emergency plan

Immediate first aid to victims and sent to hospital for treatment

2. Responsibility Site Controller: Head- Electrical Incident Controller: Shift- In charge Emergency Coordinators: Departmental Heads

Hazards and details

Persons at risk Control measures Action taken in case of emergency

Risk


L S RR=LxS

Electrical Transformer- Electrical shock and fire

Person near the transformer

Shock proof insulated PCC platform

Cut off power supply.

Treat the injured for electrical shock

If fire is caused, immediately fight fire with available resources, summoning outside help if necessary

2 3 6

3. Responsibility Site Controller: Head- Laboratory

Chapter VII



7-24

Incident Controller: Shift- In charge Emergency Coordinators: Departmental Heads

Hazards and details

Persons at risk

Control measures Action recommended in case of emergency

Risk


L S RR=LxS

Lab chemicals- in case of bottle breakage, causes burns and damage to respiratory systems due to inhalation.

Persons working in the lab

Proper care should be taken while handling the chemicals.

First aid box should be available at site with all required medicines and devices

Fire fighting equipments like fire extinguishers, sand buckets should be always available

Instruction boards to be displayed for knowledge of other workers to care of the situation in the event of occurrence

Immediately treat the persons as guided in the MSDS

Hospitalize the affected person if necessary

3 2 6

4. Responsibility Site Controller: Manager- Services Incident Controller: Shift- In charge Emergency Coordinators: Departmental Heads

Hazards and Persons at risk Control measures Action taken in case of Risk

Chapter VII



7-25

details emergency Likelihood Severity Risk rating

L S RR=LxS

Cooling Tower- Burns from returning hot water

Persons working with cooling tower

Issue work permits to work near the tank and hot water line. Railing is to be provided all around the tank

Always precautionary measures should be taken and adopted

Victims are first aided by trained persons and then referred to doctor/ hospital

If any worker get injured/hurt, then immediate first aid should be provided to him and he should be referred to the hospital/ doctor for further treatment

2 3 6

5. Responsibility

Site Controller: Manager Incident Controller: Shift- In charge Emergency Coordinators: Departmental Heads

6. Responsibility Site Controller: Head- Production Incident Controller: Shift- In charge

Emergency Coordinators: Departmental Heads

Hazards and details


Risk


L S RR=LxS

Water tank- Drowning of personnel

Persons near the water tank

Water tank will be fenced/ covered The tank will not be permitted for domestic utility

Drowned person should immediately be given first aid

1 3 3

Chapter VII



7-26

Hazards and details


Risk


L S RR= LxS

Control rooms- electrical shocks

Persons working in the control room

Earth leakage circuit breaker installed.

Main supply will be immediately shut off

1 4 4

Chapter VIII



8-1

CHAPTER VIII

DISASTER MANAGEMENT PLAN

8.1 INTRODUCTION

According to the UN International Strategy for Disaster Reduction, (UNISDR) “A Disaster is

a sudden, calamitous event that causes serious disruption of the functioning of a community

or a society involving widespread human material economic or environmental losses and

impacts which exceeds the ability of the affected community or society to cope using its own

resources.”

Disaster Management is – "it is action taken to prevent Hazard converting into Disaster". A

major disaster in a work is 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

work. Normally, assistance of outside emergency services is required to handle disaster

situation effectively. Whatever are the causative factor like plan failure, human error,

earthquake, lightning, vehicle crash sabotage etc. they will normally manifest in three basic

forms viz. fire, explosion and/or toxic release.

Pre-disaster planning is crucial for ensuring an efficient response at the time of a disaster. A

well-planned and well-rehearsed response system can deal with the exigencies of calamities

and also put up a resilient coping mechanism. Optimal utilization of scarce resources for

rescue, relief and rehabilitation during times of crisis is possible only with detailed planning

and preparation. Keeping in view these factors, preparation of Disaster Management Plans

(DMP) is imperative.

8.2 SCOPE

Disaster: A serious disruption of the functioning of a society, causing widespread human,

material or environmental losses which exceed the ability of the affected community to cope

up by using its own resources.

Hazard: Hazard is an event or occurrence that has potential for causing injury or loss of life

or damage to property or the environment. Following factors are considered to identify

Hazard -

Physiology of the Hazard or and its peculiar characteristics.

Impact & probability of occurrence

The elements by affecting, Life / Property or environment, likely to get affected

Chapter VIII



8-2

High power committee on Disaster Management, Government of India has identified 32

types of hazards in India depending on area, probable damage, repentance of occurrence

and impact on Life, Property and environment etc.

Figure 8.1: Probable causes of hazard

Categorization of Hazards

Natural Man Made

Drought Air, Rail & Road Accidents

Flood Industrial Accidents

Cyclones Civil Commotions

Land Slides Terrorism

Cloud Bursts

Earthquakes

Table 8.1: Various types of hazards

Geological Hazards 1. Earthquake 2. Landslide

Chapter VIII



8-3

3. Tsunami 4. Dam burst

5. Volcanic eruption 6. Mine Fire

Water & Climatic Hazards 1. Tropical Cyclone 2. Cloudburst

3. Tornado and

Hurricane

4. Landslide

5. Floods 6. Heat & Cold wave

7. Drought 8. Snow Avalanche

9. Hailstorm 10. Sea erosion

Environmental Hazards 1. Environmental

pollutions

2. Desertification

3. Deforestation 4. Pest Infection

Biological 1. Human / Animal

Epidemics

2. Food poisoning

3. Pest attacks 4. Weapons of Mass

Destruction

Accidents related 1. Forest fires 2. Air, Road & Rail

accidents

3. Urban Fires 4. Festival related

Disasters

5. Mine Flooding 6. Electrical Disasters &

Fires

7. Oil Spills 8. Boat Capsizing

9. Major Building

collapses

10. Village fires

11. Serial Bomb Blasts

Chapter VIII



8-4

The geographic region of the proposed project may face probable hazards such as

earthquake, drought, thunder storms, accidents and environmental hazard such as pollution,

etc. So considering these probabilities, the disaster management plan is being

recommended.

Figure 8.2: Schematic of Disaster Management Process

Chapter VIII



8-5

8.3 DISASTER MANAGEMENT PLAN (DMP) CYCLES

Disaster management is a methodology to understand and face disaster and take

appropriate measures to minimize the losses of life, property and environment. This can be

represented in 3 sections namely – Pre disaster phase, During disaster and Post situations.

Pre disaster activities

1. Policy development and local level disaster organization formation

2. Vulnerability and capacity assessment

3. Prevention and mitigation

4. Preparedness, planning and training

Emergency activities

1. Warning (beginning before the actual event)

2. Evacuation, search and rescue

3. Emergency assistance (relief) – food, water, shelter, medical aid

Post disaster activities

1. Repair and restoration of life lines (power, telecommunications, water transportation)

2. Reconstruction and rehabilitation

8.3.1 Pre-disaster situation

Preventive measures

Earth quick resistant construction as per National Building code and considering the

factory is located in seismic zone III.

Analyze soil type before construction and do not build structures on soft soil. To

accommodate on weak soils adopt safety measures in design.

Follow Indian Standard Code for construction of buildings

Enforcement of building code in the byelaws

Land use control and restriction on density and heights of buildings

Strengthening of important buildings, which need to be functional after a disaster.

Upgrade level of safety of buildings.

Reduce possible damages from secondary effects. e.g., identify potential sites and restrict

construction in those areas.

In earthquake prone areas insurance should be obtained for buildings under

construction and those in use. Insurance policies for natural disasters is mandetory

and priced specifically on available scientific data of hazards in the region.

Chapter VIII



8-6

Preparation of disaster related literature in local languages with dos and don'ts for

construction.

Getting communities involved in the process of disaster mitigation through

education and awareness.

Networking of local NGOs working in the area of disaster management.

Preparedness is a process that enables the authority to respond rapidly to disaster situation.

It helps to cope-up with the situation effectively so that the extent of damage due to

disaster or emergency situation could be kept at minimum level. Preparedness includes the

formulation of plans at various levels, to be executed in pre disaster phase as well as, during

disaster and post disaster situation. These plans can be prepared by each of the department.

Factors, such as early warning systems, preparation of role and responsibilities of various

stake holders, conducting training, mock drills at various are included in this phase. In this

phase, capacity building, preventive measures, mitigation activities take front seat. This is

the time before disaster. With the past lessons learnt, and in anticipation of likely

occurrence of disaster, many activities could be carried-out to reduce the impact, and

spreading of Hazard. Therefore, disaster planning becomes a necessary element for

mitigating the effects of a major accident/ disaster.

In the preparedness phase, emergency managers develop plans of action carefully to

manage and counter probable risks and take action to build the necessary capabilities

needed to implement such plans. Common preparedness measures include:

Communication plans with easily understandable terminology and methods

Proper maintenance and training of emergency services, including mass human

resources such as community emergency response teams

Development and exercise of emergency population warning methods combined

with emergency shelters and evacuation plans.

For evacuation, a disaster supplies kit may be prepared and for sheltering purposes a

stockpile of supplies may be created. The preparation of a survival kit such as a "72-

hour kit", is often advocated by authorities. These kits may include food, medicine,

flashlights, candles and money. Also, putting valuable items in safe area is also

recommended

Stockpiling, inventory, streamline foods supplies, and maintain other disaster

supplies and equipment

Chapter VIII



8-7

Develop organizations of trained volunteers among civilian populations. Professional

emergency workers are rapidly overwhelmed in mass emergencies so trained,

organized, responsible volunteers are extremely valuable

It is realized that investment on Preparedness, Prevention and Mitigation is more cost-

effective compared to expenditure on relief and rehabilitation. The basic characteristic of

disaster management is ‘proactive’ prevention, preparedness and mitigation rather than the

prevalent ‘re-active’ relief and rehabilitation approach. Management of risks as a prelude to

crisis management has now gradually gained importance.

Disaster management planning is not a substitute for good operative/maintenance/ design

practice. It is an aspect of safety management. Every industry, as mentioned above, should

minimize risk by adherence to safe practice and meeting all legislation.

On-site disaster management planning is responsibility of project management (i.e.

occupier). The district authorities and the Directorate of Industrial Safety and Health have

the responsibilities for off- site Disaster management plan of the district.

The proposed distillery unit needs to have a round-the-clock team to manage disaster. The

team shall include several members. Their functions depend on size of the organization and

it shall be headed by a technically qualified as well as a trained individual.

8.3.2 Response

The response phase includes the mobilization of the necessary emergency services and first

responders in the disaster area. This is likely to include a first wave of core emergency

services, such as firefighters, police and ambulance crews. In some instances, it is termed

Disaster Relief Operation (DRO) and can be a follow-up to a Non-combatant evacuation

operation (NEO). They may be supported by a number of secondary emergency services,

such as specialist rescue teams.

A well rehearsed emergency plan developed as part of the preparedness phase enables

efficient coordination of rescue. Where required, search and rescue efforts commence at an

early stage. In this particular section the response plan is discussed in details.

The response plan of Disaster Management Plan is crucial and it includes the following

Controlling the disaster, localizing the disaster and eliminating the hazard, if any

Minimizing damage to property and environment

Safeguarding others by timely evacuation

Welfare of person managing the disaster

Head count and rescue operations

Chapter VIII



8-8

Treatment of injured

Informing and assisting relatives

Informing and collaborating with statutory authorities

Informing the media

Preserving records and organizing investigations

Ensuring safety of the works before personnel re-enter and resume work

Investigating and taking necessary steps

Resorting normalcy

8.3.2.1 Requirements for Response Phase

Well designed Disaster Management Plan (both On-site and Off-site)

Strong commitment of Management towards safety

A good Public Address (PA) System in the complex with one or two jeeps with PA system

for use in surrounding areas also.

Emergency alarms, and approved emergency control centers and assembly points.

List of key personnel, experts, doctors, village leaders, authorities with their locations

and telephone numbers (office, residence as well as cell/mobile phones)

Written guidelines for the duty team members and well-defined roles of individuals

mainly for following sections/activities

1. Fire fighting

2. Medical

3. Rescue

4. Engineering support

Others not needed to take part in emergency handling operations.

Standby communication system in case the telephone system is affected. e.g. Walkie-

talkie, radio telephone, mobile phone etc.

Division of each factory into 'Safety units' for better safety. 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 by the Management.

Availability of emergency 'Install light' (emergency light) to take care of power failures.

Mutual aid scheme, if feasible.

Provision of antidotes, emergency medicines and beds in nearby hospitals

Chapter VIII



8-9

Liaison with outside agencies and civic and government authorities for mitigation of

effects of a disaster.

Round- the- clock availability of trained first-aid personnel at site and volunteers in the

nearby areas

Vulnerable areas of the plant where disasters are likely to originate should be identified

and plan measures to deal with the same

Communication mechanism for raising the alarm as well as that for the interaction

within and outside works should be provided.

Check -list for sequence of operations to be followed should be prepared.

Updating Fire and safety manuals (Both common and plant wise); Operating and

Maintenance Manuals, Warehouse safety manual.

Strong conviction that "the prevention is better than cure". Therefore, more

emphasis should be made to prevent disaster

Chemical Information Sheets (CIS) or Material Safety Data Sheets (MSDS) or Work

Practice Data Sheet (WPDS) for all the hazardous substances handled.

Transport emergency cards (Trem-cards) for the products transported by road.

8.3.2.2 Situation identification/assessment

In the situation of disaster, (natural or human induced) it is essential to judge the situation

timely and correctly. If it is identified as disaster, the emergency is to be declared at the

earliest possible. The shift In-charge, who is available in the unit all times, shall identify

situation of the hazard or calamity and report immediately the same to the Management.

The emergency may be declaired in entire unit or part of it, depending upon the

situation/nature of disaster. Accordingly shift in-charge shall also sound the alarm bell to be

provided in each of the section.

Under such situation, the shift in-charge or higher authority such as General

Manager/Managing Director shall take charge of the situation. He shall initiate all such

actions that are essential at each of the sub-unit; 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.

Chapter VIII



8-10

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.

8.4 EMERGENCY MANAGEMENT PLAN (ON-SITE)

8.4.1 Emergency Organization Structure

Team A: The Shift In-charge along with supervisor of the unit or other supervisory staff shall

put off the fire or the hazard as the case may be.

Team B: The Shift Operator / In-charge and/or supervisor 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 staff/team 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 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 any other appropriate contact for assistance. At all

times, one vehicle should be made available at the gate of the factory for the rescue and

transportation of personnel. The hooter siren, that is provided, shall be used when a total

emergency is to be declared for the entire factory.

Chapter VIII



8-11

Figure 8.3: Emergency Organization Structure

8.4.1.1 Designated persons functions

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

Industry

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

8.4.2 Shut downs in emergency

The probability of fire hazard is presumed to be maximum, in case of proposed unit. The

following steps may be followed in such cases.

Team A

Shift In-

charge and

supervisor

WORK INCIDENT CONTROLLER

Communication Team

(Telephone Operators/

Security Inspector

Administration Manager/

Personal Manager)

Advisory Team

Senior Manager/s

(Technical)

Team B

Shift Operator

Security Officer

labour welfare

officer

Team C

Maintenanc

e officer

and

technicians

Team D

Union office

bearers

Team E

Security

department

time keeper

labour welfare

officer

Chapter VIII



8-12

Put off the main supply

Boiler section

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

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 fire

affecting the security office. However, if there should be a situation where / when the entire

premises has to be declared as emergency, the control room will operate from the premises,

which is outside the main gate. The declarer/ controller of emergency shall decide,

depending on the situation, whether to use generator power or State Electricity Board

Power.

In case the entire lighting has to be switched off to meet such an eventuality, the stand by

battery operated system need to be provided near the office. It shall be used as per the

need and the floodlights shall be used to tackle the situation during the nighttime.

8.4.3 Personnel evacuation

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 to take them to the nearest dispensary after providing

necessary first aid.

There are well-planned roads in and around the plant and within the factory premises and

they should choose the safest and shortest route to come out from the unit. The selected

route should be kept clear by Team E at all the times.

8.4.4 Personnel accounting

It shall be the responsibility or the Team E to immediately take stock of the personnel on

duty and take a head count. 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 inside the plant and if so they should also be

accounted.

8.4.5 Controlling disaster

The declarer / controller of Disaster shall take steps to train all the teams and shall draw up

an "Action Plan" forthwith.

Chapter VIII



8-13

The Shift In-charge shall be designated as "Work Incident Controller" and he shall act as an

in-charge at the site of the disaster to control entire operations.

8.4.6 Repairs and safety implements

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-

Fire

Bursting of Boiler

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.

8.4.7 Medical treatment arrangements

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.

8.4.8 Training and Rehearsals

It is essential for all the teams to act in uniform 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 firefighting training, the Government Fire Force will give training and for first aid

training. The Red Cross Association will train the personnel for first aid procedures.

8.4.9 Law and order

The declarer / controller of emergency shall inform Police immediately to ensure that law

and order situation will be kept under control. The Joint Director/Assistant Director of

Chapter VIII



8-14

Industrial Safety and Health as well as Pollution Control Board authorities shall also need to

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.

8.4.10 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.

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.

8.4.11 Special handling requirement

a. During handling of the above materials equipment such as- electrical motor-

pumps, mechanical mixers, automatic weighing arrangement, pressure release and

safety accessories on steam generating, handling as well as conveyance systems,

heat exchangers, condensers and cooling as well as chilling machinery, temperature

and pressure gauges are used.

b. The concerned workers shall be provided with adequate operation and safety

tools/equipment.

c. Sufficiently trained and qualified workers shall be employed in all sections

Risk evaluation area

a) Contacts at Other Sites- The Sugar Factory Unit

b) Nearby Residence and Population Center- Villages located nearby the unit

Notification Procedures & Communication Systems

Communication Equipment like Telephone, Wireless System and Personal Messaging

would be employed.

The families of injured employees would be notified by Telephone, Personal

Messaging and through Verbal Communication.

8.4.12 Equipment and facilities in emergency

An emergency cupboard shall be made available in plant area. This cupboard should contain

certain number of 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.

Chapter VIII



8-15

A printed or typed list of items available in the cupboard should be displayed on the front of

cupboard. The key of emergency cupboard should be available with the Shift In-charge.

Table 8.2: The Items Recommended for 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 Flextra or asbestos gloves 2 pairs

7 PVC Suit 2 pairs

8 Electrical rubber gloves 2 pairs

9 Safety touch 2 pieces

10 Safety goggle 2 pieces

11 Face- shield 2 pieces

12 Ear-muff 1 set

13 Flexure or asbestos blanket 2 Nos.

14 Manila Rope 100 meter long bundle 1No

15 Resuscitator 1No

16 Safety helmet 2 Nos.

This item should be examined once in week by safety observer to ensure that all the items

are available and that they are in good condition, Items, defective must be replaced

immediately.

Important requirements

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 such as -

Assembly point

Emergency exit door/Stair case

Fire alarms

Chapter VIII



8-16

Fire extinguishers

Water hydrants

Emergency control center

Road closed

8.4.12.1 Firefighting equipment

The firefighting 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 Connections in sufficient numbers and a 200 Ft. Emergency Water Hose would

be provided at required places. Here, various vulnerable locations in the Unit, probable

causes & chances of occurrence of fire, its Class, etc. would be given in-depth consideration.

Table 8.3: List of Emergency Cupboard Items

# Item

1 Air line mask set

2 Self-containing breathing apparatus

3 Safety belt with life time

4 PVC gloves

5 Leather gloves

6 Flextra or asbestos gloves and blanket

7 PVC Suit

8 Electrical rubber gloves

9 Safety torch

10 Safety goggle

11 Face- shield

12 Ear-muff

13 Manila Rope 100 meter long bundle

14 Resuscitator

15 Safety helmets

8.4.12.2 Emergency medical supplies

Sufficient number of First Aid Boxes would be located at appropriate and easily accessible

locations. The First Aid Box would contain Burn Relief Sprays and Ointments, Bandages,

Antiseptic as well as Pain Relief Medicine.

8.4.12.3 Training and Drills

Chapter VIII



8-17

Knowledge of Probable Inflammable Spots

Every worker, working in a particular section, should be given a thorough knowledge of that

section. So as to control the spread of accidental fires

Location of Fire Fighting Equipment

Every worker should be given clear-cut information regarding the 'location of Fire

Extinguishers, Fire Buckets, Water Points, etc.

Use of Fire Fighting Equipment

Every worker should 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.

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.

8.5 OFF-SITE EMERGENCY MANAGEMENT PLAN

Since the only hazard that expected in the cogeneration is fire and normally contained

within the premises. Hence, no specific Off-site emergency plan is required in this case.

However, in rare case if the fire 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.

8.5.1 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.

Table 8.4: Emergency Action Code For Fire of Spillage of Hazardous Substances

Chapter VIII



8-18

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

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 into waterbody

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

Ammonia 1005 2,3,6.1 2 PE

Kerosene 1223 3 3 (Y)

Ethyl Alcohol 1170 3 2 (Y) E

Chapter IX



9-1

CHAPTER IX

PROJECT BENEFIT ANALYSIS

9.1 PROJECT BENEFITS: FOR THE PROJECT PROPONENT

Sensible utilization of available resources such as land, boiler (steam), Bagasse,

molasses, and partially the human resources

Cheap labour pool, since employment in rural area is agro-based and seasonal

The products are have continuous market demand

Markets are located within state as well as at national/international levels and there is

very good connectivity of road, rail & air to the site

Law and order point of view the site is peaceful and people are law abiding

Overall, excellent environment to carryout and expand the business

Generation of value added product from sugar mill by-product/waste

Similarly spent wash (highly polluted wastewater) generated in the unit will get

converted into a good quality manure by mixing it with pressmud (filter cake generated

in sugar mill)

Overall improving profitability of the business and ensuring long term sustenance

Ease to control both the units

9.2 PROJECT BENEFITS: FOR THE LOCAL SOCIETY

Generation of direct employment

Indirect employment in various forms e.g. transportation, refreshment stalls, workshops,

daily commodity shops, etc. People in the vicinity could utilize some of these services.

Help to improve infrastructures such as schools, medical facilities, transportation, etc.

Revenue for the local authorities as well as state government

Sugar cane grower farmers and labours may get benefitted, since distillery is an ancillary

unit of sugar mill

The benefits of following activities initiated by sugar mill will be continued.

Providing cane seed of improved varieties to cane growers at concessional rate

Factory has improved the internal roads in the area of operation

Providing technical guidance for cane development at farmer’s field

Operating “Sakhar shala” for the children of cane harvesting workers

Chapter IX



9-2

Table 9.1: Staff requirement for the proposed distillery unit

Sr. No. Designation No. of Posts

A) Staff for Distillery Unit

1 Distillery Manager 01

2 Shift Chemists 3+1

3 Microbiologist 01

4 Maintenance Engineer

(Elect./Mech.)

01

5 Instrumentation Engineer 01

6 Lab. Chemists 3+1

7 Fermentation Operators 3+1

8 Fermentation Attendants 3+1

9 Distillation Operators 3+1

10 Wireman /Electrician.

(For distillery & ETP)

01

11 Fitter 01

12 Warehouse Attendants 02

13 Laboratory Attendant 01

14 Attendants 3+1

15 Chemist 04

16 Workers/helpers 08

D) STAFF ENGAGED IN EVAPORATION PLANT

17 Plant Operation 04

18 Worker 04

E) STAFF ENGAGED IN BIOCOMPOST

19 ETP Incharge 1

20 Laboratory Chemist 1

21 Lab. Attendant 1

22 Aerotliier & Robot skid operators 2

23 Pay load operators 2

24 Spraying supervisors 2

25 Workers/Helpers 12

Chapter IX



9-3

F) CLERICAL STAFF

26 Ware House Incharge 01

27 Clerk/Typist 01

28 Office Boy 01

Total 77

9.3 BENEFITS TO COUNTRY: ALCOHOL AS A FUEL

Ethanol is mainly produced from sugarcane molasses. Sugarcane is a renewable source of

energy. Sugarcane cultivation is an efficient method of converting ‘solar energy’ into ‘stored

energy’. Thus, use of ethanol as oxygenating agent or fuel-extender would conserve fossil fuels

and would reduce dependence on fossil fuels.

Addition of fuel-ethanol to petrol has several advantages, especially in a country like India. Use

of ethanol in place of tetraethyl lead or MTBE will prevent dangerous and poisonous emissions

containing lead or MTBE from petrol. It will not require any catalytic converter for the vehicles.

Use of ethanol in petrol reduces emission of carbon monoxide. This will reduce pollution, since

this is a major cause of vehicular pollution in India. Ethanol is made from renewable sources of

energy i.e. based on agricultural products. Thus, it is not a depleting resource like petrol.

Use of ethanol helps in maintaining the ‘carbon cycle’ of nature. Carbon dioxide in the

atmosphere is converted by agricultural crops like sugarcane or corn into carbonaceous

materials like sugar and starch using solar energy. This sugar or starch can be converted into

ethanol. This ethanol is used in vehicles to produce energy along with petrol. This combustion

in internal combustion engines converts ethanol into carbon dioxide. This carbon dioxide can

again be converted into sugar or starch. Thus, the ‘carbon cycle’ of nature continues.

This ‘carbon cycle’ uses solar energy, which otherwise would have been wasted.

Use of fossil fuels alone to generate energy only increases content of carbon dioxide in the

atmosphere, disturbing the natural balance. Sustaining the ‘carbon cycle’ reduces the

‘greenhouse effect.’ Use of ethanol, which is mostly a ‘home grown’ product reduces

dependence on the politically sensitive Middle – East region. India has vast agricultural waste

resources like sugarcane molasses to gainfully convert into ethanol.

Blending of petrol using ethanol even at 5% directly saves that much petrol. Thus, we could

reduce import of crude oil by 5%. This quantity is huge at national level. Hence, we could able to

save valuable foreign exchange and strengthen our economy. This could also help in

controlling/regulating the prices of petrol in the market, since ethanol is cheaper compared to

petrol. Overall, it could have manifold effect on economy.

Chapter IX



9-4

9.4 ENVIRONMENTAL BENEFIT ANALYSIS

Raw material i.e. molasses and bagasse is readily available from the sugar factory

Solid filler materials like press mud to dispose the highly concentrated spentwash

is readily available within sugar factory

Hence, saving of raw material as well as filler materials transportation cost and

fuel,

Disposal of molasses, press mud and ash will get solved due to the proposed unit

Generation of energy (Biogas) from wastewater i.e. spentwash; thus, direct

emission of methane will get avoided. Methane is a green house gas having 23

time higher global warming potential than carbon dioxide

Utilization of Biogas as a fuel for boiler and thus saving more bagasse for off-

season that will be utilized for cogeneration activity

Recycling of soil nutrients by bio-compost; thus, Increasing soil fertility

Recycling/reuse of treated water will save fresh water intake

Exhaust steam from cogeneration unit will be used for distillery operations,

hence it will save energy (fuel) as well as water

Sugar factory solid waste like press mud, ash and waste sludge from ETP can

covert in to the bio-manure

.

Chapter X



10-1

CHAPTER X

DISCLOSURE OF CONSULTANT

10.1 CONSULTANT

Vasantdada Sugar Institute

Manjari (Bk), Pune 412 307 Maharashtra

Phone: (020) 26902100, 26902343/7/6 Fax: (020) 26902244

The Institute has received provisional accreditation from Quality Council of India (QCI)/National

Accreditation Board for Education and Training (NABET) for EIA consultancy services. It is also a

recognized Research and Development center of Department of Scientific and Industrial Research

(DSIR), Ministry of Science and Technology, Government of India.

The EIA report has been prepared by, the Department of Environmental Sciences of VSI, which is

affiliated with ‘University of Pune’, as Post Graduate and Doctoral course center (i.e. MSc & PhD)

in the said subject.

The activities of the Department are represented in the following chart.

Chart 10.1: Activities of Department of Environmental Sciences


Department of Environmental Sciences

Teaching and Training Research and Development

Extension and Consultancy Services

Chapter X



10-2

10.2 The project team of EIA study

Expert/Team

Member

Designation Role / Expertise

Dr. Deepali

Nimbalkar

Senior Scientist and Head

Department of

Environmental Sciences, VSI

EIA coordinator

FAE: WP, SHW, NV and AP

Collection and interpretation of data;

impact evaluation/assessment; formulation

of EMP,; and overall coordination of project

Shivajirao

Deshmukh

Director General


FAE: Socio-Economics

Guidance for data collection and

analysis; impact assessment;

formulation of EMP;

Dr. Sanjay V Patil Head and Technical Advisor

Department of Alcohol

Technology, VSI

FAE: WP and RH

Preparation of Detailed Project Report for

distillery including effluent treatment; risk

analysis and management

Amol B.

Deshmane

Scientist

Department of


FAE: EB and SC

Data and sample collection; interpretation;

impact assessment, formulation of EMP;

Assistance in coordinating all project

activities

Eknath P. Alhat Project Assistant Department

of Environmental Sciences,

VSI

FAE: AP, WP, SHW and NV

Data collection, interpretation; impact

assessment and formulation of EMP;

Assistance in coordinating environmental

monitoring activities

DB Phonde and Scientist and Head, Soil

sciences section

FAE: SC

Guidance for sample collection;

Chapter X



10-3

Expert/Team

Member

Designation Role / Expertise

Dr. Preeti

Deshmukh

Scientist, Soil Sciences

section

interpretation; impact assessment,

formulation of EMP

Rajendra A

Chandgude

Technical Advisor

Department of Sugar

Engineering, VSI

FAE: Air pollution and NV

Air pollution prediction and control

Formulation of EMP for the same area

Dr. Nitin

Karmalkar

(Empanelled)

Professor and Head,

Department of Geology,

University of Pune

FAE: Geology and Hydro-geology

Data collection and interpretation on

Geological and hydro-geological aspects,

impact assessment, and preparation of EMP

Swapnil

Awghade

(Empanelled)

and Dr. Preeti

Deshmukh

C-DAC, Pune

Scientist, Soil science section,

VSI

FAE: Land use (LU)

Interpretation of land use data and local

topographical information, impact

assessment and formulation of EMP for the

same

Vivekanand P.

Patil

Senior Research Fellow

Department of


VP Patil -FAE for: AP, AQ, SHW, and WP

AB More for AP, AQ, SHW, and HG

NABL Accredited laboratory of Department of Environmental Sciences of VSI was used for the

analysis of environmental samples. The members involved in monitoring and analysis activities

are

1. Hemangi Nalavade (Dept of Env Sci)

2. Anand More (Dept of Env Sci)

3. Kalyani Gore (Dept of Env Sci)

4. Rahul Pawar (Dept of Env Sci)

5. Yogesh Katkar (Dept of Env Sci)

6. Prakash Jadhav (Dept of Env Sci)

7. Shreekant Takle (Dept of Alcohol Technology)























05/12/2014

To,

The Sub-Regional Officer,

Maharashtra Pollution Control Board

Sangli

Subject: Response to the Suggestions, queries, comments received during public hearing

procedure of proposed distillery project of M/s. Udagiri Sugar and Power Limited

Dear Sir,

This has reference to the suggestions, comments, queries; complaints received from your office,

during the public hearing procedure of proposed distillery project of M/s. Udagiri Sugar and

Power Limited, A/p. Bamni (Pare), Taluka Kahanpur, District Sangli, Maharashtra. Please find

herewith a point wise response to all these, as an attachment herewith.

Please accept the document and process the case.

Thanking you,

Yours faithfully,

For Udagrir Sugar and Power Limited

Mr. N.S. Kadam

Vice President



Point wise response to the queries, suggestions received for the new molasses based distillery

project of M/s. Udagiri Sugar and Power Limited, located at Bamni (Pare), Taluka Khanapur,

district Sangli

1. Suggestion received from Sunanda Reddy Vootkuri through Email

[email protected]

Address: V. Sunanda Reddy, H.No. 6-7-414, Shivaji Nagar, Nalgonda Telangana

Phone: 09848179729 and 08985929148

Point wise response to her suggestions/comments/queries

i. In EIA report, environmental consultancy has covered the baseline data on air, land and

water but not the health status of people and status of crop production

Response: The baseline data is collected as per the standard guidelines of Ministry of

Environment, Forests and Climate Change and in accordance with Terms of Reference

ii. Industry has allocated only 2.5 acres of land for plantation which does not satisfy the

required condition of allotting 33% of total land so as to maintain ecological balance

Response: Project will be developed in 8.1 acres of land and 33% of which is allocated

for greenbelt development

iii. Plantation in the industry does not contain fruit bearing plants and the plants that has

medicinal values

Response: In the proposed project non-edible fruit trees will be preferred, these plants

will not be used for any medicinal activities.

iv. Industry water requirement is 13 crore litres per annum but the storage capacity of

industry is only 1 crore litre which is not sufficient. At least 6crore litres of storage

capacity is required

Response: The estimated water requirement for the proposed industry would be 9.5

crore litres (270 operation days per annum). Since, the industry is having permission

from government authorities to draw water from the canal hence, the reservoir capacity

of the industry is not a significant issue.

v. A coordination committee has to be formed to monitor and spend the CSR budget which

should include villagers, industry staff and government officials.

Response: The industry has a plan to constitute environmental monitoring cell, which is

described in chapter VI of the report.

vi. The industry should consider the local youth in providing employment

Response: The industry is going to prefer local candidates based on their skills and

qualifications

vii. Industry has to take up avenue plantation in nearby roads.

Response: The industry has recorded the suggestion and it will take appropriate action

according to the situation

viii. Industry should also take up village plantation which includes contain fruit bearing

plants and medicinal valued plants

Response: The industry has recorded the suggestion and it will take appropriate action

according to the situation

ix. Industry has to create health awareness among the people by organizing health camps

mailto:[email protected]



Response: The industry is already organizing health check up for its employees of sugar,

cogeneration unit and their family members.

2) Complaint by Mr. Tanaji Yadav, A/p Bamni, Tal. Khanapur, Sangli

Regarding fly ash and dust falling on the roof and creating pollution

Response: The industry has installed and it is operating electro-static precipitator, an

advance air pollution control equipment to control fly ash. It is using covered conveyer

belt for the transport of bagasse, has developed good greenbelt to arrest fugitive dust.

3) Mr. Anandrao Bajarang Shelke and others, A/p Bamni, Tal. Khanapur, Sangli

Regarding storage of molasses in temporary lagoons and thereby water/ ground water

pollution

Response: The sugar unit is using mild steel storage tanks of 7000m3 capacity for molasses.

Since molasses is a valuable by product of sugar mill. In the proposed distillery, it will be utilized

as a raw material. There will be an additional storage tank of 10,000m3 for the proposed project.

Therefore, there is no any situation to store it in kucha lagoon or releasing it.

4) Mr. Baban Dnyanu Shelke A/p Bamni, Tal. Khanapur, Sangli

Regarding storage of molasses in temporary lagoons and thereby, probability of ground water

pollution

Response: As mentioned earlier the sugar unit is storing its molasses in MS tanks only as it is a

valuable by-product. It will be utilized as a raw material for the proposed unit. There will be an

additional storage tank of 10,000m3 for the proposed project. Hence, there won’t be any

probability of such pollution.

Documents

ENVIRONMENTAL IMPACT ASSESSMENT REPORTenvironmentclearance.nic.in/writereaddata/EIA/31122014... · 2014-12-31 · ENVIRONMENTAL IMPACT ASSESSMENT REPORT Molasses based30KLPD Distillery