Environmental Impact Assessment Reportenvironmentclearance.nic.in/writereaddata/EIA/23102015TDI7F8H7FULLEIA... · Environmental Impact Assessment Report Molasses Based 30 KLPD Distillery

Environmental Impact Assessment Report Molasses Based 30 KLPD Distillery of

Shree Rameshwar Sahakari Sakhar Karkhana

Limited

At village Raosahebnagar, Post Sipora Bazar, Taluka Bhokardan,

District Jalana ,Maharashtra

Prepared By

VASANTDADA SUGAR INSTITUTE

*

Manjari (Bk), Pune, Maharashtra 412 307

Telephone: (020) 26902100, 26902343/7/6 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

March 2013

http://www.vsisugar.com/

Shree Rameshwar SSKL, Dist. Jalana, Maharashtra

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 and project proponent 1.2

1.4 Project site 1.2

1.5 Import ants of the project 1.4

1.5.1 Project and it’s important to the country and region 1.5

1.6 Demand for alcohol 1.7

1.6.1 Industrial alcohol 1.7

1.6.2 Potable alcohol 1.7

1.6.3 Demand and supply gap 1.8

1.7 Structure of the report 1.8

II PROJECT DESCRIPTION

2.1 Introduction 2.1

2.2 Project justification 2.1

2.2.1 Location 2.2

2.3 Technology and process description 2.6

2.3.1 Continuous process 2.6

2.3.2 Pressure vacuum distillation 2.9

2.3.3 Product details 2.11

2.3.4 Raw material-molasses 2.13

2.3.5 Steam 2.15

2.3.6 Water requirement 2.16

2.3.7 Power 2.17

2.3.8 Human resources 2.18

2.4 Effluent treatment 2.21

2.4.1 Spentwash 2.21

2.5 Green belt development 2.33

III BASELINE ENVIRONMENTAL STUDY


3.2 Methodology of baseline study 3.1

3.3 Description of study area 3.4


ii

3.3.1 Geographical features surrounding the site 3.4

3.3.2 Land use pattern 3.4

3.4 Sampling / monitoring location 3.5

3.5 Baseline environmental condition 3.6

3.5.1 Climate and meteorology 3.6

3.5.2 Geology, hydrology and hydrogeology 3.8

3.5.3 Air environment 3.11

3.5.4 Noise environment 3.18

3.5.5 Water environment 3.21

3.5.6 Soil environment 3.24

3.5.7 Ecology 3.27

3.6 Social economic development 3.39

3.6.1 Introduction 3.39

3.6.2 Methodology 3.39

3.6.3 Sources of information 3.39

3.6.4 Social profile 3.39

3.6.5 Settlement pattern 3.40

3.6.6 Economic profile 3.43

3.6.7 Social initiatives by the industry 3.42

3.7 Other important aspects 3.42

3.7.1 Archeology, historical sits 3.45

3.7.2 Seismic zone 3.46

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


iii

4.5 Land/soil environment 4.10

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 ENVIRONMENTAL IMPACT ASSESSMENT


5.2 Impact assessment: construction phase 5.1

5.2.1 Land transformation 5.1

5.2.2 Air quality 5.2

5.2.3 Water 5.3

5.2.4 Ecology 5.4

5.2.5 Socio-economic aspect 5.4

5.3 Impact assessment: operational phase 5.4

5.3.1 Impact on air quality 5.4

5.3.2 Water environment: impact on water resources 5.8

5.3.3 Land environment: impact of effluent discharge 5.9

5.3.4 Solid waste 5.10


5.3.6 Ecology 5.11

5.3.7 Socio-economic environment 5.12

5.3.8 Impact on physiography and drainage 5.13

5.3.9 Other impact: traffic 5.13

5.4 Summary 5.14

VI ANALYSIS OF ALTERNATIVE TECHNOLOGY


6.2 Treatment and utilization options 6.2

6.2.1 Reboiler 6.2

6.2.2 Bio-methanation 6.3

6.2.3 Reverse osmosis 6.4

6.2.4 Multiple effect evaporator 6.5

6.2.5 Mist evaporator 6.5

6.3 Selection of alternative 6.7


iv

VII ENVIRONMENTAL MANAGEMENT PLAN

7.1 Overview 7.1

7.2 EMP for construction phase 7.1

7.3 EMP for operation phase 7.5

7.3.1 Air environment 7.5



7.3.4 Land environment 7.13

7.4 Green belt development 7.13

7.5 Rain water harvesting 7.16

7.6 Safety, occupational health management 7.17

7.8 Environment monitoring program 7.18

7.8.1 Environment management cell 7.19


VIII RISK ASSESSMENT AND RISK MANAGEMENT


8.2 The risk equation 8.2

8.3 Hazard identification 8.2

8.3.1 Mechanical hazard 8.2

8.3.2 Electrical hazard 8.3

8.3.3 Thermal hazard 8.3

8.3.4 Hazard generated by noise 8.3

8.3.5 Hazard generated by vibration 8.4

8.3.6 Hazard generated by material /substances 8.4

8.3.7 Preliminary Hazard Analysis (PHA) 8.4

8.4 Probable risk factor 8.4

8.4.1 Fire 8.4

8.5 Qualitative risk assessment 8.9

8.6 Risk assessment: health 8.16

8.6.1 General assessment 8.16

8.6.2 Acute ecological effect 8.17

8.6.3 Chronic ecological effects 8.17

8.6.4 Recommended risk-reduction measures 8.18

8.6.5 Other methods to reduce exposure 8.19

8.7 Risk assessment: environment 8.20


v


8.7.2 Acute ecological effect 8.20

8.7.3 Chronic ecological effect 8.20

8.7.4 Persistent in the environment 8.21

8.7.5 Bio-accumulation in aquatic organisms 8.21

8.7.6 Recommended risk – reduction measures 8.21

8.8 Risk assessment: business 8.22


IX DISASTER MANAGEMENT PLAN


9.2 Scope 9.1

9.3 Objectives of the disaster management plan (DMP) 9.2

9.4 Requirement for effective DMP 9.3

9.5 Identification / assessment of situation 9.5

9.5.1 Action plan 9.5

9.5.2 Emergency shutdown of various sections 9.7

9.5.3 Evacuation of personnel 9.8

9.5.4 Accounting of personnel 9.8

9.5.5 Controlling the disaster 9.8

9.5.6 Implements for repairs and safety gears 9.9

9.5.7 Arrangements for medical treatment 9.9

9.5.8 Training and rehearsals 9.9

9.5.9 Law and order 9.9

9.5.10 All clear signal 9.10

9.6 On-site emergency management plan 9.10

9.6.1 Plant emergency organization 9.10

9.6.2 Plant risk evaluation 9.11

9.6.3 Properties of the material 9.11

9.6.4 Special handling requirement 9.13

9.6.5 Fire fighting requirement 9.13

9.6.6 Area of risk evaluation 9.17

9.6.7 Notification procedures & communication systems 9.17

9.6.8 Emergency equipment and facilities 9.17

9.6.9 Training and drill 9.18


vi

9.7 Off-site emergency management plan 9.19

9.7.1 Information to local authorities 9.19

X PROJECT BENEFIT ANALYSIS

10.1 Project benefit 10.1

10.1.1 Alcohol as a fuel 10.1

10.2 Improvement in the social infrastructure 10.2

10.3 Environmental benefit analysis 10.3

10.3.1 Advantages 10.3

10.3.2 Benefits of wastewater (spentwash) treatment 10.3

10.4 Employment generation 10.3

XI DISCLOSURE OF CONSULTANTS

11.1 Consultant 11.1

11.2 The Project Team OF EIA Study 11.2

LIST OF TABLES

TABLE

NO.

DESCRIPTION PAGE

NO.

CHAPTER I

1.1 Capacities ff Some Ethanol Based Chemicals In India 1.5

1.2 The state wise number of distilleries in India with their annual

licensed and installed capacity

1.6

CHAPTER II

2.1 Land Utilization details 2.3

2.2 Silent features of the project 2.4

2.3 Project details 2.12

2.4 Schedule for approval and implementation of project 2.12

2.5 Raw materials 2.13

2.6 Performance of the factory for last five years 2.14

2.7 Projection on performance of the factory for next five year 2.14

2.8 List of molasses / press mud providing sugar factory 2.14

2.9 Boiler details 2.15

2.10 Water requirement (cum/day) 2.16

2.11 Electricity consumption 2.18

2.12 Estimated project cost 2.18


vii

2.13 Capital investment on Environment Management Plan 2.19

2.14 Overview of environment management process 2.19

2.15 The composting techniques 2.27

2.16 Mass balance (bio-compost) 2.27

2.17 General characteristics of bio-compost 2.28

2.18 Details of Existing Green belt Around Industrial Complex 2.34

2.19 List Of Species Recommended For Green-Belt Development 2.34

2.20 Flowering and foliage shrubs proposed for green belt 2.36

CHAPTER III

3.1 Classification of environment component in used in EIA 3.2

3.2 Environment settlings in brief 3.2

3.3 Land use details in Jalana district 3.4

3.4 Environment Monitoring Locations 3.5

3.5 Annual rainfall of Bhokardhan taluka 3.6

3.6 Salient features of ground water exploration of Bhokardhan 3.10

3.7 Baseline Air Quality: PM10 3.14

3.8 Baseline Air Quality: PM 2.5 3.15

3.9 Baseline Air Quality: SO2 3.16

3.10 Baseline Air Quality: NOx 3.17

3.11 Noise monitoring location 3.19

3.12 Noise Monitoring Results 3.20

3.13 Results of ground water and surface water analysis 3.23

3.14 Soil type 3.25

3.15 Results of soil analysis 3.26

3.16 List of plant observed in study zone 3.28

3.17 Fauna: of the region 3.37

3.18 Other faunal element 3.39

3.19 Demography 3.40

3.20 Demography of the Jalana district 3.40

3.21 District profile on infrastructure and various other

socioeconomic aspects

3.41

3.22 Irrigation facility in the district 3.44

CHAPTER IV

4.1 Summary of probable pollution sources and characteristics 4.1

4.2 Details of bagasse analysis 4.3


viii

4.3 General characteristics of raw spentwash 4.8

4.4 Quality and characteristics of process waste water 4.9

4.5 Characteristics of waste water from cooling tower and boiler

blow down

4.10

CHAPTER V

5.1 Model Input Data 5.5

5.2 Resultant concentrations due to incremental GLC's 5.6

5.3 Road connectivity status 5.14

5.4 Estimated incremental traffic 5.14

5.5 Summary of traffic flow in percentage, percent and future stage 5.11

5.6 Impact definition 5.15

5.7 Matrix environmental impact associated with proposed project 5.17

CHAPTER VI

6.1 Merits and demerits of each alternative 6.7

CHAPTER VII

7.1 Summary of emp for: operation phase 7.3

7.2 Guidelines, formulated by central pollution control board

(CPCB) new delhi, for bio-composting plants

7.8

7.3 Characteristics of untreated and treated composite effluent 7.11

7.4 List of species recommended for greenbelt development 7.15

7.5 Flowering and foliage shrubs recommended for greenbelt 7.16

7.6 Human resources for environment management cell 7.19

7.7 Analysis of environmental parameters and its reporting

schedule

7.20

7.8 Suggested schedule for maintenance of wastewater treatment

unit

7.20

7.9 Format for water consumption reporting schedule 7.21

7.10 Estimated capital and recurring expenses for environment

management program

7.22

CHAPTER VIII

8.1 NEPA (National Fire Protection Association) rating 8.5

8.2 Qualitative risk assessment 8.9

8.3 Severity – Impact Intensity 8.9

8.4 Hazard warning information for ethyl alcohol 8.12

8.5 Summary of risk assessment and damage control 8.24


ix

CHAPTER IX

9.1 Emergency Cupboard Items 9.17

9.2 Emergency Action Code 9.20

LIST OF FIGURES, IMAGES AND MAPS

NUMBER DESCRIPTION PAGE NO.

CHAPTER I

Figure 1.1 Site Location Map 1.3

Figure1.2 Chemicals Obtained from Alcohol 1.4

CHAPTER II

Figure 2.1 Location map 2.5

Figure 2.2 Factory layout 2.6

Figure 2.3 Schematic of manufacturing process of alcohol 2.8

Figure 2.4 Block diagram of distillery process 2.5

Figure 2.5 Process water balance 2.17

Figure 2.6 Block diagram of polishing unit: to treat spent lees

and miscellaneous streams

2.21

Figure 2.7 Holding tank details 2.29

Figure 2.8 Compost yard 2.30

Figure 2.5 The schematic for complete compost process 2.32

CHAPTER III

Image 3.1 Satellite imagery showing proposed project site and

surrounding land use pattern

3.5

Figure 3.1 Wind -rose diagram 3.8

Figure 3.2 Hydrological features of jalana district 3.10

Figure 3.3 Air monitoring locations 3.12

Figure 3.4 Noise monitoring locations 3.19

Figure 3.5 Water sampling locations 3.22

Figure 3.6 Soil map 3.24

Figure 3.7 Soil sampling location 3.25

Figure 3.8 Indian seismic zone map as per is:1893 (part 1)-

2002

3.46


x

CHAPTER V

Figure 5.1 Short term 24 hourly GLCs of SPM 5.7

Figure 5.2 Short term 24 hourly GLCs of So2 5.7

LIST OF PHOTOGRAPHS

NUMBER DESCRIPTION PAGE NO

CHAPTER II

1 Land for proposed distillery site and compost site 2.37

2 Existing sugar factory ETP and green Belt 2.38

LIST OF ABBREVIATIONS

Abbreviation Full Form

BOD Biological Oxygen Demand

BP Back Pressure

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

EHV Extra High Voltage

EPA Environmental Protection Act

GLC Ground Level Concentration

SHE Safety, Health and Environment


xi

Abbreviation Full Form

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

MoEF Ministry Of Environment And Forests

MSDS Material Safety Datasheet

MTD Metric Ton Per Day

OSHA Occupational Safety And Health Administration

PEL Permissible Exposure Limit

PPE Personal Protective Equipments

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


xii

LIST OF ANNEXURE

Number Description

I Site location

II 10 km study zone around proposed distillery site

III Layout of distillery

IV NOC for proposed project by village gram-panchayat

V 7/12 document of proposed site

VI Permission of irrigation department

VII Consent to operate of existing sugar factory

VIII Factory licen

IX Letter of intent from nearby sugar factories for the supply of molasses and pressmud

X 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 adverse

impact of a project before its implementation; so that necessary measures to

prevent, mitigate or minimize adverse impact can be planned early and cost-

effectively. In view of this, the specific objectives of this EIA study report are -

1. To review the current environmental status of the area within 10 K.M. radius

of the proposed distillery site- collection of baseline data on the

environmental elements including air, noise, water, land, ecological, hydro-

geological climate and socio-economic environments.

2. To study in-depth and understand know-how of the project and to identify

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

process.

3. To estimate the impact of the proposed activity on the surrounding

environment.

4. To 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.

5. To formulate a strategy for effective monitoring and identify any deviations

in the environmental quality after the project is in operation, which would

help in evolving measures to counter these.

1.2 RATIONALE OF THE STUDY

According to the notification SO-1533, issued by the Ministry of Environment

and Forests (MoEF), Government of India, in September 2006, the installation of

molasses based distillery is placed under category ‘A’ and requires

Environmental Clearance (EC) from MoEF. Hence for the preparation of EIA and

development of EMP, the management of Shre Rameshwar SSKL has entrusted

the job to Vasantdada Sugar Institute (VSI), Manjari (Bk.), Pune. VSI is a

renowned institute, providing research, technical, and consultancy services to

the sugar and distillery industries, since 1975.

Chapter I


1-2

Shree Rameshwar Sahakari Sakhar Karkhana Ltd., Bhokardan, is always

concerned about the environment. The industry is also determined to implement

the Environmental Management Plan (EMP) as suggested in the study. The

industry shall comply the norms and regulations stipulated by the Central &

State Pollution Control Board and Ministry of Environment and Forests (MoEF),

New Delhi.

1.3 PROJECT AND PROJECT PROPONENT

M/s. Shree Rameshwar Sahakari Sakhar Karkhana Limited (SRSSKL) is one

of the progressive cooperative sugar factories from north Maharashtra. It is

registered under the Government of Maharashtra Co-operative Societies Act as

JLA/JBD/PRG/(A)/S-54/1994 dated 18-4-1994. The initial installed crushing

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

year of 2001-02. The management of the sugar factory is intending to install a

molasses based distillery unit of 30KLPD.

The factory is always exploring different avenues to generate more revenue, for

the benefit and development of the Karkhana, its shareholder farmers and the

society as well. Therefore, the management has decided to establish a molasses

based distillery on latest technology from molasses.

1.4 PROJECT SITE

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 Raosaheb nagar,

Post Sipora Bazar, Taluka -Bhokardan, District -Jalna, Maharashtra

Geographical

Location

750 51’12.00’’ E and 200 15’18.68” N.

Altitude 581 m above MSL

Nearest City/Town Bhokardan town 9 Km

Road Bhokardan -Jaffarabad state highway No.178 just a 0.9km

Railway Station Jalna 45 km

Air Port Aurangabad 80 km

Chapter I


1-3

Figure 1.1: Site Location Map

Chapter I


1-4

1.5 IMPORTANCE OF THE PROJECT

Alcohol has assumed a very important place in the country’s economy. It is a

vital raw material for a number of chemicals (Refer figure 1.2 and table 1.1). It

has been a source of revenue by way of excise duty levied by the State

Government on alcoholic liquors. It has a potential as fuel in the form of power

alcohol for blending with petrol in the ratio of 20:80. Alcohol by fermentation

process has a great demand in countries like Japan, United States, Canada, Sri

Lanka etc. The synthetic alcohol produced by these countries from Naphtha or

petroleum crude is not useful for beverages. Large quantities of alcohol have

been exported out of country during last few years.

Figure 1.2: Chemicals Obtained from Alcohol

CRACKING

Oxidation Dehydrogenation

Vinyl

Acetate

Acetate

Esters

Acetic

Anhydrid

e

Vinyl

Acetate N-Butanol

Ethylene

Glycol Acetic Acid

Butyraldehyde Ethyl

Hexan

ol

Ethyl Alcohol Ethylene Butadiene

Vinyl

Chloride

Styrene Acetone

Fermentation &

Distillation

Acetaldehyde

Pyridine

Acetaldehyde

Ethylene

Oxide

Oxidation

dehydrogenation

Cracking

Vinyl

Acetate

Chapter I


1-5

Table 1.1: Capacities of Some Ethanol Based Chemicals In India

Sr.

No Product

Capacity

(TPA)

Sr.

No. Product Capacity (TPA)

1. Acetic acid 4,00,000 11 Ethyl Amines 10000

2. Acetaldehyde 2,40,000 12 Ethyl Acetate 90000

3. Acetic Anhydride 70,00 0 13 Ethyl Vanillin 500

4. Pentaerithritol 27,000 14 Di-ethyl Sulphate 5000

5. Glyoxal 8,000 15 DDT ( Pesticide) 9000

6. Mono Chloro Acetic

acid 30,000 16 2,4 D ( Pesticide) 1500

7. Vinyl Acetate

monomer 42,000 17 Crotonaldehyde 1000

8. Poly Vinyl Acetate 9,500 18 Acetanilide 19000

9. Poly Vinyl Alcohol

Ethyl/Butyl/2Ethyl 4000 19 Di-Ethyl Oxalate 10000

10 Hexyl

Acetate 50000 20

Pyridines/

Picolines 5000

(Source – World Ethanol 2002 Conference – UK)

1.5.1 Project and its importance to the country and region

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

to attain financial viability while producing sugar. Distillery is one of such

alternative, because of 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.

In India, alcohol produced is mainly of three types, rectified spirit (RS), extra

neutral alcohol (ENA) and Anhydrous alcohol (AA). Of these, RS is used for large

number of industrial, scientific, laboratory, medical and many other applications.

Thus demand for the same is immense and it is ever increasing. ENA is used for

making liquors and other alcoholic beverages. AA is a fuel alcohol; it is used for

blending with petrol in the ratio of maximum 26:7

Jalna district is one of the seventh districts of Aurangabad Administrative Region.

It has been declared as one of the backward districts of Maharashtra State.

Chapter I


1-6

Earlier, The geographical area of Jalna district comprises of 2.53% of the area of

Maharashtra State. The majority of its population is engaged in agricultural

occupations and there is little industrial development in the district. In order to

make rapid industrialisation possible and with a view to de-centralising the

location of industries, the Govt. has made available a number of special

concessions and incentives for the Jalna district.

Table 1.2: State wise numbers of Distilleries in India during 2008-09

Sr. No

.

State Number of Distilleries

Annual licensed Cap. (KL)

Annual installed cap. (KL)

Total Attached with sugar factories



1 A. P. 25 12 162,068 79,009 157032 84902 2 Assam 1 1 1620 1,620 1620 1620 3 Bihar 13 3 95,020 33,900 99425 33900 4 Daman, Diu 6 -- 20,600 -- 26100 --

5 Goa 1 -- 336 -- 336 -- 6 Gujarat 10 5 155,900 85,100 146800 76000 8 H.P, J & K 8 -- 54,910 -- 56025 -- 7 Haryana 6 1 62,125 9,100 62125 9100 9 Karnataka 30 6 350,264 88,369 338944 88369

10 Kerala 8 2 28,328 4,418 25230 5520 11 M.P. 21 1 641,226 7,500 788726 7500 12 Maharashtr

a 69 53 10,84,38

2 69,3745 1040642 673610

13 Nagaland 1 -- 1,350 -- 1350 -- 14 Orissa 8 3 26,277 13,720 25850 13720 15 Pondicherr

y 3 -- 11,350 -- 11872 --

16 Punjab 7 3 149,620 19,200 134422 19200 17 Rajasthan 6 2 40,400 10,400 34900 10400 18 Sikkim 1 -- 4,600 -- 6400 -- 19 Tamil Nadu 22 11 339,300 204,950 324605 196225 20 U.P. 49 26 11,09,34

2 649,910 956947 553010

21 Uttarakhand

2 1 18,800 15,000 18800 15000

22 West Bengal

6 -- 64,052 -- 21937 --

All India 303 130 44,21,870

19,15,941 42,80,088

1788076

Chapter I


1-7

(Source – Cooperative Sugar, June 2011, Vol. 42, No. 10, Page No. 92)

1.6 DEMAND FOR ALCOHOL

Ethyl alcohol is basically used for three purposes i.e. Industrial alcohol for

production of downstream chemicals, potable alcohol for manufacture of

alcoholic beverages, country liquor and IMFL, and fuel ethanol, or anhydrous

alcohol, for blending with petrol.

1.6.1 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 industries are important 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.

Table 1.1 presents the projected demand for alcohol for production of chemicals

in the country.

1.6.2 Potable Alcohol

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 U.P 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-

Chapter I


1-8

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.

1.6.3 Demand and Supply Gap

There are more than 300 distilleries in the country with a total installed capacity

of 4,200 million liters per annum. However, it is discouraging to note that in spite

of such abundant licensed and installed capacity alcohol production in the

country has been lagging behind and is varying only around 2,000 million liters

per annum. Thus, it is not with-standing the great demand for alcohol both for

chemical industry and for potable purpose, The target of alcohol demand as

projected in the perspective plan for Chemical Industry; Department of Chemical

& Petrochemicals, Government of India is >3,000 million liters per annum.

The finished products viz. Rectified Spirit, Extra Neutral Alcohol, and Anhydrous

Alcohol is having excellent export potential.

1.7 STRUCTURE OF THE REPORT

The report is comprised of 11 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: Pollution Sources and Characteristics

Chapter V: Environment Impact Assessment

Chapter VI: Analysis of Alternative Technologies

Chapter VII: Environment Management Plan

Chapter VIII: Risk Assessment and Risk Management

Chapter IX: Disaster Management Plan

Chapter X: Project Benefit Analysis

Chapter XI: Disclosure of Consultants

Annexure

Chapter II

Shree Rameshwar SSKL, Dist. Jalna, Maharashtra

2- 1

CHAPTER II

PROJECT DESCRIPTION

2.1 INTRODUCTION

India is one of the largest producers of alcohol in the world and there has been a steady

increase in its production over the last 15 years. According to fresh statistics there are

more than 300 distilleries in India, mostly concentrated in Maharashtra, Uttar Pradesh,

Andhra Pradesh, Karnataka, Tamil Nadu, Gujarat and Madhya Pradesh.

Maharashtra has total 192 sugar factories out of which 165 are in cooperative sector. In

the year 2008-09, sugarcane crushed in Maharashtra was 400 Lac MT and sugar

produced was 46.00 Lac MT at average recovery of 11.50%. The estimated molasses

production in Maharashtra in the year 2008-09 was about 16.00 Lac MT. About 143

factories were in operation during the year 2008-09.

M/s. Shree Rameshwar Sahakari Sakhar Karkhana Limited (SRSSKL) is one of the

progressive cooperative sugar factories from north Maharashtra. The initial installed

crushing capacity of the sugar factory was 2500 TCD. Its first crushing season was in the

year of 2001-02. The management of the sugar factory is intent to install a molasses

based distillery unit of 30KLPD.

In distillery industry, presently continuous fermentation technology is preferred,

because of reduction in the spentwash generation per liter of alcohol production. The

overall process of manufacturing spirit (alcohol) is simple and takes place in two stages.

In first stage, molasses is fermented into alcohol, and in second stage it is separated by

distillation in a multistage distillation/pressure vacuum column, system. This chapter

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

mechanism of pollution control.

2.2 PROJECT JUSTIFICATION

In the present scenario sugar industry in Maharashtra is forced to explore the

alternatives so as to attain financial viability while producing sugar. Distillery is one of

such alternative, because of

availability of molasses which is a raw material for distillery

bagasse as a fuel,

own power generation ability (captive power)

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Availability of steam energy from own sugar unit

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

based distillery unit within existing sugar factory premises.

In India, alcohol produced is mainly of three types, rectified spirit (RS), extra neutral

alcohol (ENA) and Anhydrous alcohol (AA) Of these, RS is used for large number of

industrial, scientific, laboratory, medical and many other applications. Thus demand for

the same is immense and it is ever increasing. ENA is used for making liquors and other

alcoholic beverages. AA is a fuel alcohol; it is used for blending with petrol in the ratio of

maximum 26:7

2.2.1 Location

2.2.1.1 Selection of Site

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

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

composting activity)

b. The existing sugar factory site comply 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.

c. Adequate land is available with the factory for proposed distillery and its

ancillary units such as spent wash storage tanks, compost yard, effluent

treatment plant, etc.

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

electricity

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 development

f. Availability of technically skilled human resource

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

sharing common facilities like workshop etc.

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2.2.1.2 Specific location

The proposed distillery unit will be within the existing sugar factory premises, which is

located at Raosahebnagar, Post- Sipora Bazar, Tal – Bhokardan Dist-Jalna. Bhokardan

tahesil is located in the north of the Jalna district. The site is located ~1km off

Bhokardan-Jaffrabad state highway. Jalna is nearest railway station 45 km away and

Aurangabad is nearest air port ~85km from the site. Geographical location of the site is

750 51’12.00’’ E and 200 15’18.68” N. altitude 581 above MSL.

The sugar factory has total 165 acres of land out of which 18.5 acres will be utilized for

distillery, its ancillary units as well as greenbelt.

Table 2.1: Land utilization details

Sr.

No

Particulars of land utilization

Area

(in Acres)

A) Area utilized for sugar unit

1 Industrial Use 32.30

2 ETP 3.30

3 Cane yard 17.4

4 Existing Green belt ~ 17.5

5 Internal roads 3.6

Total area for sugar unit 92.63

B) Area allocation for proposed Distillery

1 For distillery, Bio-methanation , storage

lagoon 4

2 Bio-compost (including yard* + storage) 10

3 Green Belt 4.6

Total area for distillery unit 18.6

Total land available with the sugar

factory 165

Land utilized for sugar and distillery

units (A + B) 111.2

Land available with the factory for future

developments 53.87

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

mentioned figure indicates provisions

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Table 2.2: Salient feature of the project

Project New Molasses Based Distillery Unit of 30 KLPD

Proponent Co-operative Industry

Project Concept

a) Qualitative Standards of Product

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

Extra Neutral Alcohol (ENA) ISI Grade-I, 6613 (1972)

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

b) 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

Impure Spirit

27.05 KLPD

1.5 KLPD

c) Effluent Treatment System Biogas (biomethanation) followed by Bio-composting

d) Annual Operational Days 270

e) Spent wash generation (Annual) (@300m3/day)

81,000 m3

f) Annual Press mud requirement

32,400MT(Consumption ratio 1:2.5 (Pressmud to Spentwash)) and 45 day cycle

Infrastructure prostitute

a) Raw Material Molasses 30,000MT per annum

b) Steam requirement Max. 110MT/day

c) Bagasse (Fuel) Max. 48 MT/day

d) Water requirement 460m3/day (Joe medium scale irrigation project, permission for the same has been given by the Jalna Small Scale irrigation division Jalna)

e) Electricity Max. 725KW/hr

f) Land

165 acres of land available with sugar factory of which 18.6 acres will be used for distillery and ancillary units as well as greenbelt Distillery unit –five acres

For distillery, Bio-methanation, storage lagoon

4 acres

Bio-composting unit 10 acres

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Project New Molasses Based Distillery Unit of 30 KLPD

For green belt development 4.6 acres

g) Employment opportunities for 95 persons

Financial Aspect

Total Project Cost Rs 3852.5 lakhs

Capital Expenses on Environment Management Rs 963.00 Lakhs

Figure 2.1: Location map

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Figure 2.2: Factory layout 2.3 TECHNOLOGY AND PROCESS DESCRIPTION

In India, alcohol is generally manufactured by two processes

Batch process

Continuous process

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 initiates 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, yeast strains of the species Saccharomyces Cerevisiae, a

microorganism belonging to class fungi converts sugar present in the molasses such as

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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

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Figure 2.3: Schematic of manufacturing process of alcohol 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

inoculums using pasteurized molasses solution as the medium. This vessel has a dual

function. During propagation, it serves for inoculums 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-di-oxide 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 CO2 un-contaminated with air.

2.3.1.3 Yeast Recycling

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

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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 also 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). Fusel oil build-up is avoided in the Rectifier column by

withdrawing outside streams of fuel oil. These are sent to fuel oil concentration column

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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.

Figure 2.4: Block diagram of distillery process 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.

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2.3.2.2 Process of Manufacture of Extra Neutral Alcohol (ENA)

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.

The design of the re-distillation plant is made in such a way that the Extra Neutral

Alcohol quality and the production do not get disturbed due to varying quality of

rectified spirit. The plant may be preferably in copper. As the plant deals with the

rectified spirit, there is no risk of corrosion and the quality of spirit produced will be

superior.

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%. The impure

alcohol is also marketable as such in the form of ordinary denatured spirit. It can be

disposed off by blending it with Grade–I, Rectified Spirit in a proportion, which will give

Grade–II spirit. This can be sold as special denatured Industrial Alcohol. Consumes of

alcohol for potable purpose require pure Grade- I Rectified Spirit. For export purpose

alcohol of 96 % v/v is 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 2.3: Product details Sr. No. Particulars Production per (KL/Day)

1. Rectified Spirit 28.5 KLPD

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Impure Sprit OR 1.5 KLPD

2. E.N.A. 28.2 KLPD

Technical alcohol 1.8 KLPD

And Anhydrous alcohol 27.05 KLPD

Impure Spirit 1.5 KLPD

Table 2.4: Schedule for approval and implementation of project

Table 2.5: Raw material

Sr.

No.

Particulars Consumption/

Production (per

day)

Remarks

A. Raw Materials, Consumption

1. Molasses, MT 111MT Basis 47% of F.S.

Source: Attached Sugar Factory

B. Chemicals, Consumption

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

Source: Local Market at Sipora

bazar/ Bhokardan /Sillod

2. Turkey Red Oil 27kg Source: Local Market

Sr. No Project Activity Proposed time

1. Initial application submitted to MoEF for TOR

and resubmission in

Dec. 2011

March 2012

2. Environmental monitoring work Dec. 2011 to March 2012

3. Approval of TOR from MoEF New Delhi. 12 May 2012

4. Submission of Draft EIA and public hearing. Dec 2012

5. Submission EIA to MoEF New Delhi for

environmental clearance.

April 2013

6. Environmental clearance from MoEF New Delhi May 2013

7. Commencement project construction work.

Commencement of commissioning and trial

production.

June 2013

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(TRO))

Local market at Bhokardan /Sillod/

Jalna

C. Utilities, Consumption

1. Fuel: Bagasse Max. 48MT Source: Attached Sugar Factory

2. Water 460m3 Source: Joe medium scale reservoir

with permission from Irrigation Dept;

Govt of Maharashtra

3. Steam, MT 2.2 to 3.5 MT/hr

Max. 96 MT/day

Source: Attached Sugar Factory

(during season)

4. Power Max. 725KW/hr Source: Attached Sugar Factory

2.3.4 Raw material: Molasses

The total quantity of molasses required per annum is around 30,000 MT. While

estimating the requirement fermentable sugar of 47% was considered; this usually

yields about 280L of spirit per MT of molasses. The factory will have its own molasses to

the extent of 14,000–17,000 MT. Remaining quantity of molasses of about 13,000-16,000

MT will be procured from nearby sugar factories. The factory has received letter of intent

from five nearby sugar factories regarding the supply of molasses and pressmud. The

molasses storage will be as per the CPCB guidelines.

At present, the factory is having of three mild steel tanks for molasses storage. Each is

having capacity of 4,000 MT. The factory has decided to install one more MS tanks of

6,000MT capacity. Thus capacity of molasses storage will be 18,000MT.

Table 2.6: Performance of the factory for last five years

Sr. No.

Particulars Season

2006-07 2007-08 2008-09 2009-10 2010-11

1 Cane Crushed

( Lac MT)

4.46 2.99 0.51 1.80 3.21

2 Sugar production

(Lac Qtls.)

4.72 3.39 0.47 1.76 3.20

3 Recovery % Cane 10.58 11.35 09.35 09.75 09.97

4 Molasses Production

( MT)

19,695 13,148 2,315 8,294 14,735

5 Press-mud Production (MT)

14,600 9,720 1,755 6,600 9,900

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Table 2.7: Projections on performance of the factory for next five years

Table 2.8: List of molasses/pressmud providing sugar factories

# Name of Sugar Factory Distance

(km)

Capacity

(TCD)

Status about Distillery Set-up

(Yes/No)

1 Chhatrapati Sambhaji Raje Sakhar Udyog Ltd, Dist-Sambhajinagar(Aurangabad.)

110 2500 NO

2 Vaidyanath-Sant Eknath Sakhar Udyog Dist. Aurangabad

140 1250 NO

3 Mukteshwar Sugar Mills Ltd

Dist. Aurangabad

125 1250 NO

4 Jijamata Sugar Pvt. Ltd Dist. Buldhana 100 1250 NO

5 Sharangdhar Sugar Mills Ltd Dist. Buldhana

110 1250 NO

6. Shri Sant Eknath SSKL Dist. Auransabad

140 1250 NO

7. SiddheshwarS SK Ltd, (Sillod) Dist.

Aurangabad

30 2000 Yes

8. Deogiri SSK, Ltd. Dist. Auraneabad 63 2500 NO

9. Jalna SSKL, Dist. Jalna 50 1250 NO

10. SagarS . S.K. Ltd. GhansawangDi ist. Jalna

120 2500 NO

Five sugar factories have confirmed in writing about their interest for supply of molasses

and pressmud for the proposed distillery of Shree Rameshwar SSKL. Therefore, shortfall

# Particulars Season

2011-12 2012-13

2013-14

2014-15

2015-16

1 Cane to be Crushed

(Lac MT)

4.25 4.40 4.50 4.55 4.75

2 Sugar to be produced (Lac Qts.)

4.46 4.84 5.06 5.14 5.46

3 Recovery % Cane 10.50 11.00 11.25 11.30 11.50

4 Molasses to be produced(MT)

17000 17600 18000 18200 19000

5 Pressmud to be produced(MT)

17000 18000 18000 18200 19000

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of molasses and pressmud will be overcome through this purchase. Hence, the sugar

factory is assured of smooth operation of proposed unit at its full capacity.

2.3.5 Steam

The steam requirement of the proposed distillery depending on the final product will

vary between 2.2 to 3.2 MT/h steam (for Multi-pressure option). At present the factory

is having two boilers, with total steam generation capacity of 32 MT/h and having 32

kg/cm2 (g) pressures. The sugar factory has decided to install an independent boiler of

10MT/h (45kg/cm2 (g)) for distillery operations. If required, additional DM water plant

will also be installed for supplying soft water for distillery boiler. Necessary

arrangement for reducing the steam pressure & de-superheating

will be made. Multi-Pressure Vacuum Distillation

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

b. F. Wash to ENA- 3.2 Kg/liter

Table 2.9: Boiler details

2.3.6 Water Requirement

The fresh water requirement at the startup will be approx 750 m3/day, which will be

reduced to around 460 m3 per day by recycling 290 m3 of treated water. Source of water

is Joe medium scale irrigation project; permission for the same has been given by the

Jalna small scale irrigation division Jalna. Water storage facility is available with the

sugar factory. Existing water storage tank capacity is 9000m3. Thus, sufficient quantity of

water can be made available to the distillery from the water reservoir.

To achieve better efficiency and maintain the plant and machinery in good condition, it is

necessary to have proper water treatment system. By having proper water supply

system such as clear water pumps etc, the distillery can have good water supply

arrangement. The breakup of water requirement is given below.

Table 2.10: Water Requirement (in Cum/day)

Boiler number Steam Fuel

MT/h Kg/ cm2(g) Material MT/day

Existing two Boiler total capacity (during season)

32 32 Bagasse 300

Additional boiler (during off-season)

10 45 Bagasse 48

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Particulars Intake Consumption And Losses

Generated Effluent

Recycle and Reuse

Daily Net requirement

Industrial Process

330 00 300 30 300

Cooling tower

300 150 150 150 150

Boiler feed 115 00 05 110 05

Domestic 05 01 04 00 05

Other 00 00 00 00 00

Total 750 151 459 290 460

Figure 2.5: Process water balance

Molasses 77m3

Dilution Water 240m3

Steam 110MT

CO2 37m3

ENA + IS = 30 KL

Soft water 90m3

Spent wash 300m3 Polishing unit

Press mud

WATER BALANCE FOR PROCESS

CT blow down 150+ lees 30 m3

Steam loss 150m3

Cooling water 300m3/h

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2.3.7 Power

Total power requirement for Fermentation, Distillation, ENA section, Cooling Tower,

Storage and Boiler Biomethanation, Bio-composting, & Plant Yard lightning is 725KW/h.

The sugar factory is having one STG of 2.5MW capacity. The factory has proposed to

supply power to distillery unit from the existing STG

Table 2.11: Electricity Consumption

2.3.8 Human Resource

The distillery will be under administrative control of ‘Managing Director’ of the sugar

factory. 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 requirement of an employee will be about 95, out of which 55 will be skilled and 40

will be semi skilled or unskilled. Existing technical and non-technical staff of the sugar

factory could also provide services to the distillery in case of necessity. The installation

of distillery within sugar factory premises is advantageous from the point of security

also.

Table 2.12: Estimated Project cost

Sr. No. Particulars Amount

(Rs. in Lakhs)

1. Land Development 41.00

2. Civil work and building 563.60

3. Plant and machinery 2695.70

4. Miscellaneous fixed assets for distillery and ETP 387.50

5. Preliminary, pre-operative and other expenses 114.00

Section Operating (KW/h)

(At peak load)

Fermentation, Distillation, Cooling Tower, Storage 425

Absolute alcohol Plant 50

Boiler 150

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

100

Total 725

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Sr. No. Particulars Amount

(Rs. in Lakhs)

6. Machinery stores, spares 05.00

7. Contingency @3% 82.00

8. Margin Money 10.00

TOTAL 3898.80

Table 2.13: Capital investment on environment management

Sr.

No.

Particulars Amount

(Rs. in Lakhs)

1. Spent wash cooling and holding tank 85.00

2. Compost yard with PCC top finish 175.00

3. Leachate management system 15.00

4. Laboratory shed and its glassware, equipments, etc. 15.00

5. Polishing units for condensate treatment 100.00

6. Biomethanation Unit 360.00

7. Biocomposting machinery, pipeline and other 70.00

8. Fire fighting equipments and other 25.00

9. Tree plantation and bore well for composting 8.00

10. Wet Scrubber 110.00

TOTAL 963.00

Recurring Expenses/annum

1. Salaries and wages 09.00

2. Operation and maintenance of all pollution control

devices, motors, pumps, pipelines, etc.

3.50

3. Fuel (composting activity) and Electricity (in case of

diesel generator operation)

1.50

4. Fire protection, greenbelt, other waste management 2.00

5. Transportation 1.00

TOTAL 17.00

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Table 2.14: Overview of environment management processes

Sr.

No

Waste product and source Treatment and disposal

1. Waste water

Spentwash Biomethanation followed by bio-composting

Other effluent:

steam condensate, Blow

down from bowler, cooling

tower, Pump Sealing, floor

washing and other cleaning

activities

Effluent will sent to pH correction and polishing

unit and reused as a cooling tower make-up,

dilution water for molasses or gardening

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

Particulate emissions will be controlled by Wet

scrubber and then vented through a common

chimney of height 60m

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

factory 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. 6.5 acres

Biocomposting CH4; H2S Fully auto spraying and aerobic composting

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

grid 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.

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Fermented sludge: Yeast

sludge, Polishing unit sludge

The sludge from fermenter contains organic

nutrient and micro elements. It will be mixed with

bio-compost.

Figure 2.6: Block diagram of polishing unit: to treat spent lees and miscellaneous streams

2.4 EFFLUENT TREATMENT 2.4.1 Spentwash

2.4.1.1 Biomethanation

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.

Aeration unit

Sludge drying beds

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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.

2.4.1.2 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)

2.4.1.3 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.

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- 22

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 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

Chapter II


2- 23

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.

2.4.1.4 Utilization of Biogas

Biogas generated in the bio-methanation process will be utilized as a fuel for sugar

factory 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.

2.4.1.2 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.

2.4.1.2.1 Composting Process

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 condition. The

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

Chapter II


2- 24

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.

2.4.1.2.2 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%.

2.4.1.2.3 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.

2.4.1.2.4 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.

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2- 25

2.4.1.2.5 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 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.

2.4.1.2.6 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.

2.4.1.2.7 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.

2.4.1.2.8 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

Chapter II


2- 26

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 2.15: The Composting Technique: Working Data

Sugar Factory

1. Crushing rate (present – in MT crushed / day) 2,500

2. Projected Crushing rate (average) 425,000 MT

3. Annual Pressmud production @4% 17,000 MT

4. Moisture content of Pressmud 50 - 70 %

Distillery

5. Capacity (liter /day) 30 KLPD

6. Days of operation 270

7. Spent wash production/annum 81,000MT

8. Ratio Press mud: Spentwash, (45 days cycle) 1:2.5

9. Pressmud requirement (in MT per annum) 32,400

10. Culture Required prescribed proportion

Quantity required/year (270days)

1Kg/MT of pressmud

32,400 Kg

11. Yard area, Approx. 7.6 acres

Table 2. 16: Mass Balance (Bio-compost)

Sr.

No.

Description Solids

Content %

Quantity Total Solids

MT

1. Annual Raw Material

a) Press mud*

b) Spentwash

30

05

32,400 MT

81,000 MT

9,720

4,050

Total 1,13,400 13,770*

2. Annual Compost 65 8,950 MT**

Compost

Annual Compost Production: approx 8,950 MT

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

Chapter II


2- 27

Table 2.17: 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

2.4.1.3 Requirements for composting

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

for treatment. The factory has proposed to adopt biomethanation followed by Bio-

composting process. It has allocated about 18.5 acres of land. For distillery process units,

biomethanation, storage lagoons is up to four acres, for composting yard 8.4 acres and

greenbelt 6.1 acres. 2.4.1.3.1 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, pitched by stone/bricks with SRC

mortar and SRC plaster 50 mm thick to prevent leachate. The sectional view of

spentwash holding tank is given in fig. 2.4.

Chapter II


2-28

PITCHING 2.00 M

SLOPE 1:2 1 m

SLOPE 1:1.5

PITCHING WITH STONE

G.L. 23.00 CM THICK

3.00 M

1 M

MURUM 1 M

IMPERVIOUS SOIL SOIL

250 μ HDPE SHEET

Figure 2.7: Holding Tank Details

30 CM THICK IMPERVIOUS

SOIL COMPACTING AND

20 CM THICK HARD MURUM

AND

COMPACTING

PITCHING WITH

STONE

23 CM THICK

Chapter II


2-29

Figure 2.8: Compost Yard

Chapter II


2-30

2.4.4.2 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. 2.9.

2.4.4.3 Molasses Storage Tank

At present, the factory is having three mild steel (MS) tanks each of 4,000 MT capacity.

Thus, total molasses storage capacity 12,000 MT. The factory has proposed to install

one more tank of 6,000MT capacity.

Proper care should be taken by the sugar factory to cool down molasses before it goes

to molasses storage tank. The molasses storage tank should have a suitable pump for

recirculation of molasses. A two months stored molasses is ideal for fermentation. The

molasses can be pumped through pipeline, which can be laid down from the sugar

factory storage tank to the distillery day molasses tank.

Chapter II


2-31

Figure 2.9: The Schematic for Complete Compost Process

Chapter II


2-32

2.5 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 factory 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

factory. 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 74m3per day. Treated effluent from sugar factory 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

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. 2.10.

Chapter II


2-33

Table 2.18: Details of existing greenbelt around Industrial Complex

Name of species Individual Location

Mango (Mangifera indica) 1,000 Around fencing, near guest house and housing colony

Neem (Melia azadiracta) 1,000 Internal road side, around fencing

Tectona grandis (Sag) 1,000 other open areas, internal road side

Dalbargia sisso (Shisam) 1000 Around fencing as well as other open areas

Peltoforum pterocarpum 100 Garden areas, Along internal road side, around fencing, near housing colony

Gulmohor 1000 Garden areas, internal road side, around fencing, near housing colony

Polyalthia longifolia (Ashok) 1000 Around fencing, near guest house and housing colony

Terminalia cattapa (Desi Badam)

500 Around fencing, Along internal road side, near housing colony

Suru 500 Around fencing, near housing colony

Avala 3000 Around fencing as well as other open areas

Zyzyphous (ber) 3000 Around fencing as well as other open areas

Chinch 3000 Around fencing as well as other open areas

Jambhul 1000 Around fencing as well as other open areas

Nilgiri 500

Total 17600

Table 2.19: List of Species Recommended For Greenery 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 saman M 500-1000 mm Tolerant of CO2

Chapter II


2-34

S

No.

Name Size* Climatic

condition

(Rainfall)

Feature/remark

5. Anona squamosa T 250-500 mm Fly ash tolerant

6. Anthocephalus

kadamba

T 500-1000 mm Dust tolerant

7. Azadiracta indica T 500-1000 mm Fly ash tolerant ,Tolerant of

alkaline and Saline soil,

common in the area

8. Bauhinia purpurea T 500-1000 mm Dust tolerant, cultivated near

residential areas

9. Bauhinia variegata T/M 500-1000mm Soluble sodium 1.0 to 2.0

10. Butea monosperma T 500-1000 mm -

11. Cassia fistula M 500-1000 mm pH 7.5 to 8.4, cultivated near

residential areas

12. Cassia siamea M/T 500-1000 mm Soluble sodium 1.0 to 2.0,

cultivated near residential

areas

13. Casurina equisetifolia T 500-1000mm Tolerant of sandy soil

14. Cordia spp. M 500-1000mm Dust tolerant

15. Delonix regia T 250-500 mm Fly ash tolerant

16. Emblica officinalis M 500-1000 mm -

17. Erythrina indica T 500-1000 mm Tolerant of CO2

18. Eucalyptus species T 500-1000 mm Tolerant of sandy soil, SO2

19. Ficus bengalensis T 500-1000 mm Fluoride tolerant, common

20. Ficus glomerata T 500-1000 mm Tolerant of CO2 common

21. Ficus religiosa T 500-1000 mm Tolerant of CO2 common

22. Nerium odoratum S 500-1000 mm Tolerant of SO2 common

23. Tamarindus indica T 250-500 mm Tolerant of acidic soil

24. Terminalia arjuna T 500-1000mm Tolerant of alkaline/Saline soil

25. Derris indica M/T 500-1000mm Tolerant to air pollution,


26. Dalbargia sissoo Tolerant to air pollution,


Chapter II


2-35

Table 2.20: Flowering and foliage shrubs proposed for greenbelt

It is advised to the factory to initiate greeb belt development along with construction activity

so that plants specially trees will get establish and grow well by the time construction activity

will get over (Considering construction phase of 20-24 months)

# 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

11 Vinca rosea

12 Ratrani

13 Gardenia

14 Canna

16 Chrysanthemum

Chapter III


3-1

CHAPTER III

BASELINE ENVIRONMENTAL STUDY

3.1 Introduction

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. The major

purposes of describing the environmental settings of the study area are,

• To understand the environmental characteristics of the area

• To assess the existing environmental quality, and on the basis of which predict

the environmental impact of the proposed developments being planned

• To identify environmental or geographical factors that could preclude any future

developments

3.2 Methodology of baseline study

The guiding factors for the present baseline study are the general Terms of

references (ToR) issued by Ministry of Environment and Forestry (MoEF) and the

Environmental Impact Assessment notification Sep. 2006.

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. In addition, information on the location of

metropolitan cities, national parks, wildlife sanctuaries and ecologically sensitive

areas like tropical forests, important lakes, biosphere reserves, ecological resources,

archaeologically important sites/monuments, etc. within a 10 km. radius of the plant

is also furnished. For present study the field monitoring was carried out in Winter

season Dec 2011 to Feb 2012. Data was sufficient to develop a clear understanding

of the nature and magnitude of potential impacts of the project. The studies were

conducted by considering the following.

Chapter III


3-2

Table 3.1: Classification of environment component used in EIA

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 • Social profile,

• Settlement pattern

• Demography

• Availability of infrastructure

• Economic profile

• Social Initiatives by the industry

Table 3.2: Environment setting in brief

Sr. No Particulars Description

1. Project site At Raosahebnagar, Post- Sipora Bazar, Tal -

Bhokardan, Dist - Jalna in Maharashtra

2. Geographical

coordinates

Latitude: 200 15’18.68” N

Longitude: 750 51’12.00’’ E.

Elevation: 581.5m

3. Nearest villages East Mahora 7.5 km

South east – Assaye 3.5km

South Dautput 2.5km

WSW Babhulgaon 2.5km

West Bhokardan 09km

North west Viregaon 5km

North Nimbola 4km

North east - Sipora bazaar 1.5KM, Borgaon

2.5km

4. Climate and meteorology

Chapter III


3-3

5. Temperature Annual Max Temp (Avg.): 410C

Annual Min Temp (Avg.) : 200C

6. Precipitation annual average for Bhokardan Taluka 650 mm

7. Wind Predominant wind direction from East to west

8. Land Within in existing sugar factory premises

9. Nearest town Bhokardan town 9Km

10. Nearest Highway /Road ~ 1km off State highway -178

11. Airport Aurangabad ~ 80 Km from the site

12. Nearest railway station 45 km away

13. Water body • River Jui– 2.5 km north-east

• River Kelna – 5 km, south

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

15. Ecologically sensitive

areas (National

Parks/Wildlife

sanctuaries/bio-sphere

reserves)

There are no tropical forest, biosphere reserve,

national park, wildlife sanctuary, coral

formation, defense installations, recreational

sites, holiday resorts, pilgrimage site,

historically important structures, monuments,

etc. in 10 km radius study area

• Gautala sanctuary – 90 km, west

• Lonar sanctuary 100 km east

16. Archaeologically

important places

Ajanta caves - 45 km, south west

17. Reserved/Protected

forests within 10 km

radius

No

18. Nearest place of tourist/

Religious importance

Ajanta caves - 45 km, south-west

19. Topography of proposed

site

Flat surface

20. Main Agricultural crop in

the District

Jawar, Bajra, Wheat, Pulses, Groundnuts, Cotton,

Sugarcane

21. List of Industries Mini industrial area is proposed at Bhokardan

There are 24 large and medium scale industries

in Jalna district, out of which 3 are sugar

factories & Shree Rameshwar SSKL is one of

Chapter III


3-4

them

3.3 Description of study area

3.3.1 Geographical features of the site

The proposed cogeneration plant is located at Raosahebnagar, Post- Sipora Bazar, Tal

– Bhokardan, Dist – Jalna in Maharashtra.. The geographical coordinates of the site

are 200 15’18.68” N and 750 51’12.00’’E. The northwestern part of the district is

comprised of the eastern slopes of the Ajanta Plateau. The Satmala hill ranges (943 m

amsl) throws an offshoot in south-eastern direction through Jafrabad taluka which

forms the western edge of the Buldhana plateau. Eastern offshoot of the Ajanta or

Satmala hill ranges comprising flat topped hills form divides between Purna and

Girija rivers and between Girja and Dudhna rivers. The southeastern offshoot of

Ellora hills comprising a series of dissected flat topped hills reach upto Ambad town.

Apart from these, hilly regions are occurring in northern and western parts of

Jafrabad, Bhokardan and Ambad talukas. Most of the southern and central parts of

the district comprise undulating plains. Elevations of the plains from 450 to 600 m

amsl. Generally ground slope in the district is towards east and southeast. There are

34villages in the study area (10km radius) which indicates scattered settlements

over the study area.

3.3.2 Land use pattern It was observed from the satellite imagery that, the project surrounding land is

mainly used for agricultural purpose followed by waste uncultivable land. The most

significant part of the Jalna district is that about 85 % of the geographical area is

under agricultural use. Out of the total 761,200 Hectares of the geographical area,

651,553 hectare of land is under agricultural use.

The details of the land use in Jalna district are given in below tables.

Table 3.3: Land use details of Jalana district

Land use / cover Category Area (in Ha.) Geographical area (%)

Built up land 2,381 0.28

Agriculture land 6,51,553 85.56

Forest land 12,600 1.65

Waste land 80,035 10.51

Water bodies & River 6,371 0.85

Chapter III


3-5

Others 8,260 1.15

Image 3.1: Satellite image of the site and surrounding

3.4 Sampling/monitoring locations

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

km radius from the site

Table 3.4: Details of sampling location

Parameter Location

Ambient Air Factory main gate, Davatpur, Lingewadi, Borgaon, Asai, Bhaydi,

Kolegaon, Danapur, Talni, Virgaon, Kodali, Wadshed

Noise Housing colony of factory, Lingewadi, Borgaon

Water

Khodli, Jui Dam, Viregaon, Sipora Bazar, Borgaon, Asai, Davatpur

Kolegaon Bhaydi, Talni, Shiv Sable, Wadshed

Soil Factory site, Lingewadi, Davatpur, Boregaon, Asai, Bhyadi, Kolegaon ,

Talni, Virgaon, kodali, Wadshed

Chapter III


3-6

3.5 Baseline Environmental Conditions

3.5.1 Climate and Meteorology

The district has dry and tropical climate with very hot summer and mild winter with

humid SW monsoon season of moderate rainfall. The bulk of rainfall is received from

the southwest monsoon, between June to September. The average annual rainfall of

the Bhokardan ranges between 650 to 750 mm. The district often experiences

drought with rainfall recording as low as 400 to 450 mm. The rainy season is

followed by winter, which last up to February, during which the minimum

temperature ranges between 9 to 100 c and maximum temperature ranges between

30 & 310 C. The winter is followed by hot summer, which continues up to June. The

maximum day temperature ranges between 42 & 430C during summer.

3.5.1.1. Rainfall

The rainfall record shows that the district has two regions on the rainfall pattern. The

first comprises Bhokardan, Jafrabad and Jalna talukas with rainfall of about 700 mm

favorable for Khariff cropping. The second region comprises Ambad and Partur

talukas with rainfall of about 800 mm or more favorable for rabi cropping. Rainfall is

not uniform in all parts of the district as assured rainfall area are Jalna and Ambad

talukas and the area of moderate rainfall of 625 to 700mm is Bhokardan and Jafrabad

talukas. The average annual rainfall in the area is 725.80mm. About 83% of the

rainfall occurs during June to September and July is the rainiest month. The rainfall

for the period 1998-2007 of Bhokardhan taluka is given in Table 3.5.

Table 3.5: Annual Rainfall of Bhokardhan taluka (1998-2007) (in mm)

Year Rainfall(mm)

1998 889.5

1999 673.5

2000 436.2

2001 658.6

2002 646.0

2003 657.0

2004 541.5

2005 630.2

2006 988.0

2007 521.3

Chapter III


3-7

Year Rainfall(mm)

Average 664.18

3.5.1.2 Temperature

Temperature is observed to be increasing steadily after February. April and May are

generally the hottest months. During May and June nights are comparatively warmer

than in April. On individual days during the summer season the temperature rises to

41oC or even more. Temperature during rainy season ranges from 21°C to 30°C. In

winter season temperature fall appreciably and range from 10°C to 25°C. In nights

temperature range is 20°C to 25°C with privilege of cool breeze.

3.5.1.3 Humidity

The air is generally dry over the district except during the southwest monsoon when

the relative humidity is high. The summer months are the driest when the relative

humidity is generally between 20°C and 25% in the afternoon.

3.5.1.4 Cloudiness

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

mostly heavily clouded or overcast during the southwest monsoon period. But

cloudiness decreases in the post-monsoon period i.e. October and November. The sky

is generally clear or lightly clouded during the period from December to February.

Cloudiness increases from April onwards and generally it is cloudier in the late

afternoon/evening.

3.5.1.5 Wind Winds are generally light to moderate with increase in speed during the latter half of

the hot season and in monsoon season. The winds blow predominantly from

directions between west and north during the hot season. They are mostly from

directions between southwest and northwest during the southwest monsoon season

3.5.1.6 Micro-Meteorology

The meteorological data recorded during monitoring period was very useful for

proper interpretation of the baseline information as well as for inputs for predictive

modeling for air dispersion. Meteorological information was collected from

meteorological department. Various parameters were recorded during the study

Chapter III


3-8

period of Dec 2011 to Feb 2012. This was done to understand the wind pattern,

temperature variations, relative humidity etc.

3.5.1.7 Wind Speed and Wind Direction

The predominant wind direction observed during the study period was from east

direction, 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. 3.1.

Figure 3.1: Windrose Diagram 3.5.2 Geology, hydrology and hydrogeology

3.5.2.1 Geology

The entire district is occupied by basaltic lava flows of the Deccan traps of upper

cretaceous to Eocene age. The lava flows are piled over one another. The individual

flow thickness ranges between 20 to 30m The individual flow has two distinct units.

The upper part is vesicular in nature and vesicles are filled with secondary minerals

like zeolite and quartz (e.g. Moss Agate, Zebra Agate and Green Agate) which is often

called as zeolitic trap. The lower part of the lava flow forms the massive basalt, and

often called as massive trap. Alluvial deposits along the major rivers overlie the

Chapter III


3-9

Deccan traps. The alluvium consists of clay, silt and sand. The thickness ranges

between 10 to 20m. The alluvium forms a very fertile land.

3.5.2.2 Hydrology

The district is well drained by river systems, which are dendritic type and have

matured valleys. There are two main drainage systems viz; Godavari River and the

Purna and Dudhna rivers. The Godavari River forms the entire southern boundary of

the district in Ambad and Partur talukas. It is one of the most important river of

Deccan plateau and entire Jalna district falls in its great basin. The direct tributaries

of the river are Shivbhadra, Yellohadrs, Galhati and Musa rivers. All these tributaries

rise from the Ajanta and Ellora plateau and flow south and eastwards to join the

Godavari River. While most of the smaller streams dry up in summer, the major

rivers are perennial. Purna River rise from near Mehun about 8km NE of Satmala

hills and at a height of about 725m amsl. It is most important river after Godavari and

drains entire area of Jafrabad. Bhokardan and parts of Jalna talukas. Its tributaries

are Charna, Khelna, Jui, Dhamna, Anjan, Girja, Jivrakha and Dudhna rivers.

3.5.2.3 Hydro-Geology

Groundwater occurrence and movement in the area is influenced by its rock

formations. Groundwater potentially depends upon porosity and permeability (both

primary and secondary) of rock formations. Jalna district is underlain by basaltic lava

flows and alluvium only. Water bearing properties of these rocks are described

below and the map depicting hydrogeological features is shown as Figure 3.2

Chapter III


3-10

Figure 3.2: Hydrogeological feature of Jalana district

3.5.2.4 Ground water potential

Central Ground Water Board and Ground Water Survey and Development Agency

(GSDA) have jointly estimated the ground water resources of Jalna district based on

GEC-97 methodology. Ground water resources estimation was carried out for

8042.59 sq. km. area out of which 542.99 sq. km. is under command and 7499.60 sq.

km. is non-command. The aquifers in the district are poor to moderately yielding

having low storage capacity. Therefore, ground water development should be

permitted very carefully in difficult and scarcity areas only.

Table 3. 6: Salient features of ground water exploration of Bhokardhan

1. BW’s Drilled 5

2. Depth (m bgl) 200.20

3. SWL (m bgl) 50.00

4. Discharge (lps) 0.38

Chapter III


3-11

Ground Water Resources (March 2004)

Taluka Area Net Annual

Ground

water

Availability

(ham/y)

Existing

Gross

Groundwater

Draft for

Irrigation

(ham/y)

Existing Gross

Groundwater

Draft for

Domestic &

Industrial water

Supply (ham/y)

Existing

Gross

Groundwater

Draft for All

uses

(ham/y)

Allocation for

domestic &

industrial

requirement

supply upto nest

25 years (ham/y)

Net

Groundwater

Availability for

future irrigation

development

(ham/y)

Stage of

Groundwater

Development

(%)

Bhokardhan

C 1227.19

368.35 15.30 383.65 4.13 160.46 31.26

NC 13532.67

7800.11 68.94 7869.05 159.89 5919.65

58.15

Total

14516.78

8254.58 80.76 8335.34 165.87 6107.62

57.42

C- Command, NC- Non-Command

3.5.3 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.

3.5.3.1 Methodology of monitoring

The ambient air quality monitoring has been conducted during the months of Dec

2011 to Feb 2012 (winter season). Monitoring has been conducted twice a week

continuously for 24 hours during the study period

The high volume air samplers (HVS) have been used to monitor the environmental

parameters. Spectrophotometer has been used to analyze NOx and filter paper has

been used to collect the SPM (PM 10) and RSPM (PM 2.5).

Ambient air quality of the study area has been assessed through a network of twelve

ambient air quality stations keeping in view the wind pattern in the study area. The

monitoring locations are shown in figure 3.3. Other factors such as the influence of

Chapter III


3-12

the existing sources are predominant villages in the study area also have been

considered. The details of the sampling station are given in below mentioned table.

Figure 3.3: Ambient Air Monitoring Locations

Chapter III


3-13

# Site/Location Distance

(km)

Direction

1. Factory main Gate 0 -

2. Lingewadi 5 SW

3. Davatpur 3 SE

4. Borgaon 2.5 NE

5. Asai 4 E

6. Bhaydi 5 NW

7. Kolegaon 7 NE

8. Babhulgaon 2.5 WSW

9. Talni 8 NW

10. Viregaon 5 WNW

11. Kodoli 5 S

12. Wadshed 5 N

Chapter III


3-14

Table 3.7: Baseline air quality: PM10 (Avg. in µg/m3) Week Location

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

1 75 60 65 61 59 61 59 67 62 66 61 62

2 73 55 52 58 50 55 54 61 58 59 61 58

3 80 50 45 55 52 50 46 65 56 58 60 60

4 78 60 58 60 55 60 58 68 61 55 62 58

5 83 58 55 56 60 58 45 59 58 58 58 62

6 79 49 52 50 58 49 52 58 62 54 60 59

7 77 54 50 55 55 54 54 63 57 62 54 55

8 82 56 55 50 54 56 51 56 56 56 60 60

9 84 60 52 61 60 60 45 60 60 60 58 66

10 78 58 57 60 55 58 60 57 56 54 55 55

11 80 64 60 62 60 64 54 62 54 55 50 64

12 77 66 62 65 62 66 53 56 50 56 60 66

Avg. 78.8 57.5 55.2 57.7 56.7 57.6 52.6 61 57.5 57.7 58.2 60.4

STD 100 100 100 100 100 100 100 100 100 100 100 100

Chapter III


3-15

Table 3.8: Baseline air quality: PM2.5 (Avg. in µg/m3)

Week Location

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

1 45 26 31 38 33 44 28 34 30 27 22 24

2 43 22 28 32 30 29 37 28 25 25 24 30

3 38 20 25 39 25 24 29 35 22 24 25 26

4 42 25 30 34 31 28 25 30 17 26 29 31

5 41 23 32 30 33 27 30 29 20 31 32 27

6 35 26 25 32 35 21 26 32 25 34 30 25

7 37 31 24 31 33 26 23 35 30 32 32 29

8 39 27 32 35 28 29 26 39 24 38 28 25

9 40 25 27 33 32 26 24 37 27 30 24 32

10 39 33 30 29 29 24 25 30 29 32 32 28

11 42 28 25 32 36 25 23 32 23 35 34 25

12 36 34 29 28 30 30 29 33 28 27 25 24

Avg. 39.7 26.7 28.2 32.7 31.2 27.75 27.1 32.8 25 30.1 28.1 27.2

STD 60 60 60 60 60 60 60 60 60 60 60 60

Chapter III


3-16

Table 3.9: Baseline air quality: SO2 (Avg. in µg/m3)

Week Location

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

1 17 12 10 13 12 12 9 10 11 10 12 12

2 18 11 10 12 12 11 11 13 10 13 10 11

3 16 10 10 10 13 11 11 12 11 12 11 10

4 17 10 9 10 12 12 10 10 11 13 12 12

5 16 9 9 9 13 11 10 13 10 11 14 12

6 16 10 10 12 12 11 10 13 12 9 10 11

7 15 11 10 11 12 11 11 12 9 13 11 10

8 16 11 9 10 13 12 10 12 13 10 9 12

9 16 10 8 10 11 12 9 13 10 10 10 13

10 17 9 9 11 11 10 7 11 12 13 12 12

11 18 9 10 9 12 11 9 12 11 10 11 10

12 18 10 10 12 13 11 10 12 12 9 10 11

Avg. 16.67 10.17 09.50 10.75 12.17 11.25 9.75 11.92 11.00 11.08 11.00 11.33

STD 80 80 80 80 80 80 80 80 80 80 80 80

Chapter III


3-17

Table 3.10: Baseline air quality: NOx (Avg. in µg/m3)

Week Location

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

1 18 14 10 12 14 10 9 11 13 9 9 10 2 17 13 9 10 14 11 11 13 11 9 9 11

3 18 14 11 10 13 10 11 14 10 11 11 9

4 19 13 10 9 12 10 10 11 12 12 10 10

5 15 10 10 10 13 11 10 12 10 10 11 11

6 18 13 10 11 12 11 10 13 11 12 12 9

7 19 12 9 10 13 11 11 11 11 10 12 12

8 17 12 9 11 11 10 10 12 10 9 10 12

9 18 13 10 10 12 10 11 10 9 9 9 9

10 19 11 9 9 12 10 10 11 10 10 12 10

11 17 12 10 9 14 11 11 11 10 11 13 11

12 19 11 9 10 14 11 10 13 11 11 10 11

Avg. 17.83 12.33 9.67 10.08 12.83 10.50 10.33 11.83 10.67 10.25 10.67 10.42

STD 80 80 80 80 80 80 80 80 80 80 80 80

Chapter III


3-18

3.5.3.2 Ambient air quality observations

The maximum concentration of pollutants such as PM 10, PM 2.5 as well as SO2 and

NO2 were recorded at the factory site. However, the concentrations recorded at all

locations were well within new National Ambient Air Quality (NAAQ) Standards

(November 2009).

3.5.4 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. A total of ten noise sampling locations were

identified and are depicted in Fig. 3.3

Chapter III


3-19

Figure 3.4: Noise monitoring locations

Table 3.11Noise monitoring location

Location number Location

1. Factory guest house

2. Lingewadi

3. Davatpur

4. Asai

5 Kolegaon

6 Borgaon

7 Bhaydi

8 Bhokardan

9 Talni

10 Danapur

3.5.4 .1 Method of Monitoring

Chapter III


3-20

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 3.12

A reconnaissance survey was undertaken to identify the major noise generating

sources in the area. The noise from different sources have been identified which are

the 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

Leq = 10 Log L / T∑ (10Ln/10)

Where, L = Sound pressure level at function of time dB (A)

T = Time interval of observation

Noise levels during the night time generally drop, therefore to compute equivalent

noise levels for the night time, noise levels are increased by 10 dB (A) as the night

time high noise levels are judged more annoying compared to the day time.

Table 3.12: Noise monitoring results (dB A) Location Avg. level day

time

Avg. level

night time

Standard

Day

time

Night

time

Factory guest house

(Industrial area)

70 63 75 70

Lingewadi

(Rural residential area)

45 40 55 45

Davatpur(Rural residential

area)

49 41 55 45

Asai (Rural residential

area)

46 40 55 45

Kolegaon (Rural

residential area)

44 40 55 45

Chapter III


3-21

Borgaon (Rural residential

area)

47 41 55 45

Bhaydi (Rural residential

area)

54 45 55 45

Bhokardan market

(commercial area)

62 42 54 55

Talni(Rural residential

area)

50 41 55 45

Danapur (Rural residential

area)

47 40 55 45

3.5.5 Water Environment

Understanding the water quality is essential in preparing the EIA and identification

of critical issues with a view to suggest appropriate mitigation methods for

implementation.

The purpose of the study was

• To determine the water quality of the resources in the study area:

• To assess the potential impact on water quality due to the proposed activity in

the study area,

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

Twelve water samples (includes surface & ground water samples) from various

location of the study area were collected and analyzed.

All the basic precaution and care were taken during the sampling to avoid

contamination. Spot tests were done as per statutory requirements. 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.

3.5.5.1 Observations of surface and ground water sampling

The summary of results of the parameters analyzed is given in Table 3.13

Chapter III


3-22

Figure 3.5: Water Sampling Locations

1 Khodli, 7 Davatpur

2 Jui Dam 8 Kolegaon

3 Viregaon 9 Bhaydi

4 Sipora Bazar 10 Talni

5 Borgaon 11 Shiv Sable

6 Asai 12 Wadshed

Chapter III


3-23

Table 3.13: Result of ground water and surface water analysis

Parameters 1 2 3 4 5 6 7 8 9 10 11 12

pH

7.8 8.4 8.4 8.5 7.7 8.7 7.8 7.9 7.6 8.7 8.3 8.3

EC (m-S)

3.5 1.1 0.9 0.5 3.8 1.7 1.9 3.2 3.6 0.4 1.9 2.9

Total Hardness 650 374 320 136 650 370 660 670 700 160 400 424

Calcium Hardness

550 190 230 100 400 150 240 520 550 60 330 240

Magnesium Hardness

100 184 90 36 250 220 420 150 150 100 70 184

Chloride 312 224 240 180 232 150 340 230 380 32 260 336

Alkalinity 589.3 96.7 89.5 28.4 596.4 292.5 284 53.9 717.1 25.5 198.8 244.2

Sulphate

254 205 115 43 207 192 176 250 255 35 129 343

Phosphate 0.65 0.14 0.40 0.91 0.08 0.17 0.48 0.30 0.26 0.78 0.71 1.05

TDS 1500 770 630 350 1000 990 1100 1500 1200 280 950 1200

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

Chapter III


3-24

3.5.6 Soil Environment

The soils of the district are derived from the basaltic lava flows. Thickness of the soil

cover is less in northern and western region where ground elevations are higher.

Soils in central, southern and eastern regions of the district near the banks of

Godavari and Dudhna rivers are thicker. Profile description and analytical data of

some typical soils are as follows

a) Light soils occur along hills, rugged regions, plateau and elevated plains. These

soils are brown to grey in colour, less fertile as plant nutrients are less and range

in depth from 0-15 cm. They comprise grains of basalt, quartz and clays with

calcareous nodules and gravels.

b) Medium soils occur along undulating plains, depressions in hilly regions etc. These

are dark brown in colour and contain more plant nutrients. The soil range in

thickness from 15 to 40 cms and comprises clays with some silica and lie over

murum at 40 to 100 cm depth.

c) Deep soils occur along plains of lower elevation, depressions and along river

banks. These are dark black cotton soils, plastic, sticky, rich in plant nutrients and

are very fertile. The soils range in thickness from 50 to 200 cm and lie over murum

at 2 to 4 meters depth comprising clays, loam, lime etc.

Figure 3.6: Soil map

Chapter III


3-25

Table3.14: soil type

For study purpose, soil was collected at 7 locations in the study area as shown in Fig.

3.5. These areas are selected so as to cover different land-use-patterns; the results of

the soil sampling and analysis are given in Table 3.15

Figure 3.7: Soil Sample Location

1. Lingewadi 7. Kolegaon

2. Factory premises 8. Talni

3. Davatpur 9. Virgaon

4. Boregaon 10. Bhokargao

5. Asai 11. kodali

6. Bhyadi 12. Vadshied

Major Soils types Percent ( % ) of total geographical area

Daeep black soils 13.37

Medium deep soils 21.36

Shallow soils 65.27

Chapter III


3-26

Table3.15: Results of soil analysis

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

pH 8.71 8.56 8.60 8.60 8.60 8.58 8.39 8.76 8.76 8.42 8.42 8.54

EC 0.657 0.220 0.255 0.573 0.199 0.269 0.208 0.313 0.215 0.223 0.272 0.268

Texture

Light

brown

coarse

Light

brown

coarse

Brown,

mediu

m

coarse

Dark

brown,

fine

Brown,

coarse

Light

brown,

coarse

Light

brown,

coarse

Brown,

mediu

m

coarse

Light

brown

coarse

Light

brown,

coarse

Light

brown,

coarse

Brown,

coarse

Calcareous matter % 4 5 6 5 6 4 5 6 5 6 4 6

Available P2O5 kg/Ha

in 17cms plough

layer

19 17 25 24 22 20 15 16 16 17 20 15

Available N kg/Ha in

17cms plough layer 180 220 210 225 222 190 194 186 195 185 210 205

Available K2O kg/Ha

in 17cms plough

layer

280 215 250 268 275 280 276 282 288 295 269 300

Chapter III


3-27

3.5.7 Ecology

3.5.7.1 Flora: The plant life of the region

The wild vegetation in the study area consists of semi-aired with significant thorny

species. The climate of Marathwada region is generally hot and dry. It receives low

rainfall. Due to the lack of adequate rainfall, vegetation cover shows its diversified

nature. Mainly agricultural (cultivated) vegetation is dominant in the study zone. No

wildlife sanctuary or national park or biosphere reserve exists within the 10 km

radius area of the site. There are no ecologically sensitive sites or rare or endangered

floral or faunal species recorded in the 10 km radius zone.

Chapter III


3-28

Table 3.16: List of plant observed in the study zone Location No. 1 = factory premises, 2 = Babhulgaon; 3 = Kedar Kheda, 4 = Danapur, 5 = Mohora , 6 Pimpalgaon Kad, 7 = Varud Kd; 8 =

Varanjala(Sable) 9 =; Nimbola; 10 = wadshed

NO. NAME OF PLANTS FAMILY HABIT VERNACULAR NAME

1 2 3 4 5 6 7 8 9 10

1. Abelmoschus ficulneus (L.)

Wt & Am

Malvaceae S Ran-bhendi - - - - + + - - - -

2. Acacia catechu Willd Mimosaceae T Khair + - - + + - - + + -

3. Acacia ferruginea Mimosaceae T Pandhara Khair + - - + + - - - - -

4. Acacia leucophloea (Roxb.) Willd

Mimosaceae T Hivar + + + + + + + + + +

5. Acacia nilotica (L.) Del. sub species indica

Mimosaceae T Babhul + + + + + + + + + +

6. Acacia nilotica sub species tomentosa

Mimosaceae T Ramkathi + - + + + - - - + +

7. Aegle marmelos (L.) Corr.Serr.

Rutaceae T Bel - + + - + - - - - -

8. Ageratum conyzoides Linn.

Asteraceae H Sahadevi + + + + + + + + + +

9. Ailanthus excelsa Simarubacea T Mharukh - - - - + - - - - -

10. Annona reticulate Annonaceae T Ramphal - - - - + - - + - +

11. Annona squamosa L. Annonaceae T Sitaphal + + - + + - + - - +

12. Aporosa lindleyana (Wt.) Bail

Euphorbiaceae T Salai - - - - - + + - - -

13. Argemone maxicana Linn. Papaveraceae H Piwala Dhotra + + + - - - - + - -

14. Azadirachta indica A. Juss Meliacea T Limb + + + - + + - + + -

15. Bambusa arundinacea (Retz.) Roxb.

Poaceae Bamboo

Kalak - - + + + - + - -

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

http://en.wikipedia.org/wiki/Jos%C3%A9_Correia_da_Serra

Chapter III


3-29


1 2 3 4 5 6 7 8 9 10

16. Bauhinia recemosa Lamk. Caesalpiniaceae T Apta + - - - + - + - - -

17. Begonia crenata Dryand. Begoniaceae H Ambati - - - + - + - - - -

18. Blumea lacera (Clarke) Hook. f.

Asteraceae H Bhamrut - - - - - - - + - -

19. Bombax ceiba L. Bombacaceae T Sawari, Sawar - - + - + - + - + -

20. Bougainvillea spectabilis Willd

Nyctaginaceae CS Bogan wel + - - + + - - + - -

21. Bridelia squamosa (Lamk.) Geh.

Euphorbiaceae T Asana - - - + + - - - - -

22. Butea monosperma (Lamk.) Jaub.

Fabaceae T Palas - - + - + - - - - -

23. Calatropis gigantea (L.) R. Br.

Asclepiadaceae S Ruhi + + + - + + - - + +

24. Calotropis procera (Ait) R. Br.

Asclepiadaceae S Mandar - - + + + - + + - +

25. Canna indica (L.) Cannaceae H Kardal - - - + + - - - - -

26. Carica papaya L. Carricaceae T Papaya - - - + + - - - + -

27. Casuarina equisetifolia (L.)

Casuarinaceae T Suru + - + + + - - - - +

28. Celosia argentea L. Amarantheceae H Kurdu + + + + + + - - + +

29. Citrus karna Raf. Rutaceae S Idlimbu - - + + + - + - + -

30. Citrus limetta Risso Rutaceae T Mosambi - - + + + - + - + +

31. Clematis heynei MA Rao Ranunculaceae C Morwel - - + + - - - + + +

32. Clerodendrum multiflorum (Burm. F.) O Kize

Verbenaceae S Takli - - - - + + - - + -

33. Colocasia esculenta (L) Araceae H Alu - + - - - + - - + +

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

Chapter III


3-30


1 2 3 4 5 6 7 8 9 10

Schott. 34. Cordia dichotoma Boraginacea T - - + - + - - - - +

35. Dalbergia sissoo Roxb Fabaceae T Shisav + - - - + - - - - -

36. Dalbergia Sissoo Roxb. Fabacea T Shisav + + - + - + + + - +

37. Dalbergia sympathetica Nimmo.

Fabaceae C Katyacha Vel - - + + - - - + - -

38. Delonix regia (Boj.) Raf. Caesalpiniaceae T Gulmohar + + - + + - + - + +

39. Derris indica (Lam.) Bennett.

Fabaceae T Karanj + + + + + + + + + +

40. Duranta rapens L. Verbenaceae H Dhuranda + - - + + - - - + +

41. Eclipta alba (L) Hassk Asteraceae H Maka - + + - + - - + + +

42. Emblic officinalis Euphorbiaceae T Avla - - - - + - - - - +

43. Eragrostis unioloides (Retz.) Nees

Poaceae H Chimniche Pohe + + + + + + + + + +

44. Erythrina indica L. Fabaceae T Pangara, Paranga - - - + + - - + - +

45. Eucalyptus tereticornis Sm.

Myrtaceae T Nilgiri + + + + + - - + + +

46. Euphorbia nerifolia L. Euphorbiaceae S Nivdunga - + + - + - + + - +

47. Feronia elephantum Rutacea T Kavath - + + - + + + - + +

48. Ficus benghalensis L. Moraceae T Wad + + + + + + + + + +

49. Ficus recemosa L. Moraceae T Umbar - - + - - + - - + -

50. Ficus religiosa L. Moraceae T Pimpal - + + - + - - - + -

51. Ipomoea carnea Jacq. Convolvulaceae C Besharam + + + + + + + + + +

52. Ixora coccinea L. Rubiaceae S Devhari + - - + - - - - + -

Chapter III


3-31


1 2 3 4 5 6 7 8 9 10

53. Jatropha curcas L. Euphorbiaceae S Mogli Erand + + - - + + + - +

54. Lantana camara Var. aculeata (L.) Mold.

Verbenaceae S Ghaneri, + + + + + + + - + +

55. Launaea procumbens (Roxb) Rammayya & Rajgopal

Asteracea H Pathri - + + - + + - + + +

56. Leonotis nepetifolia (L) R.Br.

Lamiaceae H Deepmal - - + + + - - + + +

57. Mangifera indica (L.) Anacardiaceae T Aamba + - + + + - + + + +

58. Melia azaderach (L.) Meliaceae T Bakan-limb + + + + + + + - + +

59. Moringa pterigosperma Gaert.

Moringaceae T Shevga - - + - + - + + + +

60. Musa superba Musaceae T Ran Kel - + - + + - + + + +

61. Nerium indicum Mill. Apocynaceae S Kanher + - + + + - + + + +

62. Nyctanthus arbor-tristis L. Oleaceae T Parijatak, Prajakta - + - + + - - + - +

63. Opuntia delenica Euphorbiaceae S Nivdung - - - - + - - + - -

64. Oxalis corniculata L. Oxalidaceae H + + - - - + - + - -

65. Oxyteranthera monostigma

Poaceae Bamboo

Bundhi - - - + - - + - - -

66. Peltophorum pterocarpum DC.

Caesalpiniaceae T Tamrashingi + - + + + - + + - +

67. Plumeraia alba Linn. Apocynaceae T Dev Chapha, Pandhara Chapha

- + - + + + + - + +

68. Plumeria rubra Linn. Apocynaceae T Son Chapha + - - + - + - - + +

69. Polyalthia longifolia Benth. & Hook. f.

Annonaceae T Ashoka + + + + + + + + + +

Chapter III


3-32


1 2 3 4 5 6 7 8 9 10

70. Prosopis cineraria Fabaceae T Vedi Babhul + + - + + + + - - +

71. Punica granatum (L.) Lythraceae T Dalimb - - - + + - + - + +

72. Sesbania bispinosa (Jacq.) Weight

Fabaceae H Dhencha - + - + + - + + + +

73. Smithea conferta J.E. Sm. Fabaceae H + + + + + + + + + +

74. Solanum virginianum (L.) Solanaceae H Bhui Ringani + - + + + - - + + +

75. Sterculia urens Sterculiaceae T Khavis - - - + + - - - + +

76. Syzygium cumini (L.) Skeels

Myrtaceae T Jambhul + - + + + + - + + +

77. Tabernaemontana citrifolia (L.)

Apocynaceae S Tagar - - + - + - + + + +

78. Tamarindus indica L Caesalpiniaceae T Chinch + + - + + - + + + -

79. Tectona grandis (L.) Verbenaceae T Saag - - - - + - - + - -

80. Terminalia catapa (L.) Combretaceae T Jangli Badam - + - - + - - + - -

81. Thespesia populnia (L.) Sol. ex Correa

Malvaceae T Ran Bhend - - + + - - + - + +

82. Tridax procumbens L. Asteraceae H Ekdandi + + + + + + + + + +

83. Triumfetta pentandra A. Tiliaceae H Chota-landga - + + + + + + + +

84. Urena lobata L. Malvaceae H + + + + + + + + + +

85. Vitex negundo L. Verbenaceae T Nigdi, Nirgudi - - - + - - - - + +

86. Xanthium strumarium L. Asteraceae H Dhatura + + + + + + +

87. Ziziphus jujuba Gaertn. Rhamnaceae T Bor + - + + - + + + + +

88. Zizyphus Mauritian Lamk. Rhamnaceae S Bor + + + + + - + - + +

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

Chapter III

Shree Rameshwar SSKL, Dist. Jalana, Maharashtra 3-33

C. Agricultural crops

S. No Common Name Botanical Name

Bajari Pennisetum typhoides

Chavali Vigna sinensis

Mirchi (Chilli) Capsicum annuum var. longum

Kapus (Cotton) Gossypium hirsutum

Erand Ricinus communis

Chana (Gram) Cicer arietinum

Shengdana (Groundnut) Arachis hypogaca

Hulaga Dholichos biflorus

Jawar Sorghum vulgare

Karadai Carthamus tinctorius

Karale Guizotia abyssinica

Maka Zea mays

Mug Phaseolus aureus

Oos (Sugarcane) Saccharum officinaraum

Til Sesamum indicum

Tomato Lycopersicon lycopersicum

Tur Cajanus cajan

Udid Phaseolus mungo

Watana Pisum sativum

Gahu (Wheat ) Triticum sativum

Table 3.17: Fauna: of the region

S. No Species Name Scientific Name

1 Pond Heron or Paddy Bird Ardeola grayii

2 Cattle Egret Bulbulcus ibis

3 Little Egret Egretta garzetta

4 Blackeared or Large Indian Kite Milvus lineatus

5 Ring Dove Streptopelia decaocto

6 Spotted Dove Streptopelia chinensis

7 Koel Eudynamys scolopacea

Chapter III


S. No Species Name Scientific Name

8 Crow Pheasant Centropus sinensis

9 Small or Common Blue Kingfisher Alcedo atthis

10 White Breasted kingfisher Halcyon snyrensis

11 Small Green Bee-eater Merops orientalis

12 Large Green Barbet Megalaima zeylancia

13 Small Green Barbet Megalaima viridis

14 Grey Shrike Lanius excubitor

15 Golden Oriole Oriolus oriolus

16 Black Drongo Dicrurus adsimilis

17 Common Myna Acridotheres tristis

18 Jungle Myna Acridotheres fuscus

19 House Crow Corvus splendens

20 Jungle Crow Corvus macrorhynchos

21 Redwhiskered Bulbul Pycnonotus jocosus

22 Redvented Bulbul Pycnonotus cafer

23 Spotted Babbler Pellorneum ruficeps

24 Magpie Robin Copsychus saularis

25 Indian Robin Saxicoloides fulicata

26 Blue Rock Thrush Monticola solitarius

27 Grey Wagtail Motacilla capsica

28 Purple Sunbird Nectarinia asiatica

29 House Sparrow Passer domesticus

Mammals

S No Species Name Scientific Name

1 Rabbit Oryctolagus cuniculus

Chapter III


S No Species Name Scientific Name

2 House rat Rattus rattus

3 Dog Canis familiaris

4 Mongoose Herpestes auro punctatus

5 Domestic cat Felis domesticus

6 Cow Bos indicus

7 Buffalo Bubulus bubales

8 Sheep Ovis

9 Squirrel Funanbulus pennanti

10 Goat Capra sp

11 Indian hare Lepus nigricollis

12 Common bat Scotophilus heathi

Table 3. 18: Other Faunal elements

S No Name Zoological name

1 Common bull frog Rana Tigrina

2 Cobra (King) Naja naja

3 Rattle snake Crotalus horoidus

Common Fish Sr. Family/ Species Local Name

Cyprinidae

1 Rasbora daniconious (Hamilton, 1822) Kanheri

2 Labeo rohita (Hamilton, 1822) Rohu

3 Catla catla (Hamilton, 1822) Catla

4 Ctenopharyngodon idella (Steindachner, 1866) Gawatya

5 Cirrhina mrigala (Hamilton, 1822) Mrigal

Saccobranchidae

6 Wallago attu (Schlegel, 1839) Lachi

Clariidae

7 Clarias batrachus (Linnaeus, 1758) Magur

Ophiocephalidae (Channidae)

8 Channa striatus (Bloch, 1793) Morrul

9 Channa marulius (Bloch, 1793) Murrel

Chapter III


10 Channa gachua (Bloch, 1793) Dheri Dhok

11 Channa punctatus (Bloch, 1793) Phool Dhok

3.8 SOCIO- ECONOMIC ENVIRONMENT

3.8.1 Introduction

Socio- economic status of the population is an indicator for the development of the

region. Developmental project of any magnitude will have a bearing on the living

conditions and on the economy of the region as a whole. Similarly, the proposed

industry will have its share of socio-economic influence in the study area. The section

delineates the overall appraisal of society relevant attributes. The data collection, for

evaluation of impact of industrialization on socio-economic aspects in the study area,

has been done through the analysis of secondary data available for study area.

3. 8.2 Methodology

The methodology adopted in assessment of socio-economic condition is as follows

• To evaluate the parameters defining socio-economic conditions of the

population.

• Analysis of the identified social attributes like population distribution, etc

• Availability of public utilities etc. through web site of Census of India

3. 8.3 Sources of information

As per the scope of this study, the information on socio-economic aspects has been

gathered and compiled from several secondary sources. These include Taluka Office,

official web site of the district, Agriculture Department, Irrigation Department, etc. The

demographic data has mainly been compiled from the web site of Census of India and

official web site of the district and taluka (http://jalna.nic.in)

3. 8.4 Social profile

Sociological aspects include human settlement, demographic and socio-economic

aspects and infrastructure facilities available in the study area. The economic aspects

include agriculture and occupational structure of workers.

3.8.5 Settlement pattern

The demographic details Jalana District are as follows.

Chapter III


Table 3.19: Demography

Population 2001 2011 Bhokardan(2001)

Total 16.12 Lac 19.58 Lac 16950

Men 8.26 10.15 53%

Women 7.86 9.43 47%

Density 209/km 255/km

Female/Male Ratio

952/1000 929/1000

Literacy 2001 2011 2001

Total 64.52 % 73.61% 62%

Male 79.17 85.25 70%

Female 49.25 61.28 54%

http://jalna.nic.in/html/atglance.html

Table 3.20: Demography of Jalana district

State Maharashtra

District Jalna

Population 256191

Female Population 124859

Male Population 131332

Literacy 63.6%

Literacy Male 79.78%

Literacy Female 46.77%

SC Population 11.48%

ST Population 3.83%

Sex Ratio 951

No. of Household 48097

Population under age-group 0-642403

Sex Ratio under age-group 0-6897

total Workers 118866

Non Workers 137325

http://jalna.nic.in/html/atglance.html

Chapter III


http://www.biondmaps.com:8070/mediawiki-1.16.0/index.php/Bhokardan_Tehsil Table 3.21: District Profile on infrastructure and various other socio-economic aspects

Animal Husbandry (Livestock Census 1997)

Livestock 1650,000

Co-operation 2001-2002

All types of co-operative Societies 4409

Primary Agriculture Co-operative Credit Societies 718

Number of member of Primary Agriculture Co-operative

Credit Societies 380,000

Irrigation (Irrigation projects completed by the end of June 2002 and command area)

Major Irrigation Project 3

Medium Irrigation Project 16

Minor Irrigation Project -

Industry (End of 2001)

Registered factories 112

Registered factories in working condition 110

Co-operative sugar factories 2001-2002 7

Production of Co-operative sugar factories (2002) 205,000 Mt. Tones

Cotton Mills 7

Electricity (31.3.2002)

Village electrified 1269

Pump sets energized 88 In Thousand

Public Health Service 2001-2002

Hospitals 11

Dispensaries 27

Primary Health Centers 47

Primary Health Units 2

http://www.biondmaps.com:8070/mediawiki-1.16.0/index.php/Bhokardan_Tehsil

Chapter III


Education 2001-2002

Primary Schools 2011

Number of student per teacher 40

Technical and Vocational Education (2001-2002)

Industrial Training Institutes 15

Government Industrial Training Institutes 10

Non-Government Industrial Training Institutes 5

Intake capacity of the Government and Non-Government

Industrial Training Institutes 1636

Degree level technical Institutes 0

Their intake capacity for the first year 0

Diploma level Technical Institutes 0

Their intake capacity for the first year 0

Vocational Education Institutes (Up to 31.3.2000) 54

Transport and Communication

(Up to 31st March, 2002)

Village linked with roads

Perennial 1145

Seasonal 45

Total Road length (surfaced) 9685 Km.

National Highways 79 Km.

State Highways 1267 Km.

Major District Roads 1627 Km.

Other District Roads 1589 Km.

Village Roads 5123 Km.

Integrated Rural Development Programme

Families below poverty line (Survey-1997-98) 0.95 In Lakh

Chapter III


Welfare Scheme 2001-2002

Adivasi Ashram Schools 2

Civil Supply

Fair Price Shops (2001-2002) 1975

Drinking Water: Drinking water supply through tap is made available by Maharashtra

Jeevan Pradhikaran to most of the villages. However, due to scarcity of rain, many of the

villages get water by tankers during summer.

3.8.6 Economic profile

• The Economy of the Jalna district is based on Agriculture and Agrio-

industries, as the 85 % of the geographical area is under agricultural use. Out of the

total 7, 61,200 Hectares of the geographical area, 6, 51,553 Hectare of land is under

agricultural use.

• As per the Directorate of Economics & Statistics, Govt. Of Maharashtra, The

Estimate Income of the Jalna district from 2004-05 to 2009-10 is as below.

Type Prices 2008-09 2009-10

District Income

(Rs.in lac)

Current 687450 802243

Const. 544995 584626

Per Capita Income (in Rs.) Current 38990 45021

• Agriculture: About 75 % area is under Kharif crops, which about 40 % of

lands are under rabbi crops. The Jawar, Wheat, are the major cereals grown in the

district. The area under cotton is also very entrancing. The area under double crops

is just 15 % while area under irrigation is only 7.8% which is far below the state

average.

Chapter III


Table 3.22: Irrigation Facility in the district

Sr.No Name of Project Irrigated

Land

Total Irrigated

Land

1 Large Project [Jaikwadi-1] 36,000

2 Medium Projects

i. Upper Dhudhna 3,401

ii. Dhamna 1,788

iii. Jui 2,163

iv. Kalyangirja 1,996

v. Jivrekha 1,299

vi. Pirkalyan 1,999

vii. Khelna 1,133

viii. Galhati 2,196 15,975

3 Minor Irrigation [Local & State-20] 9,650

4 Upsa Projects [20 nos] 1,544

5 Well 841 nos] 36,641

Total Irrigation capacity in Hectors 1,02,030

3.8.7 Social Initiatives by the Industry

The foremost objective of Rameshwar SSKL, is to serve as a centre for all round

development of cane growers, peasants and workers in villages of economically

backward of district.

In addition to industrial growth in the area, the factory also involved in several socio-

economic developmental activities to help member farmers and workers of factory

Factory has provided cane seed of improved varieties to cane growers

through the agricultural set up at concessional rate.

Factory has improved the internal roads in the area of operation.

Factory has been supplying bio-compost made from press mud and distillery

effluent to farmers at concessional rate.

Chapter III


Factory is regularly providing technical guidance for cane development

programme at farmer’s field.

Factory has provided canteen, sports club, reading room, library as welfare

activities.

Factory has established “Sakhar shala” for children of cane harvesting

workers.

Factory has provided hospital facility for the employees and cane growers in

the area of operation and Karkhana also conducting eye treatment cum

operation camp with the help of lion’s club of Phaltan.

Factory is arranging cultural programs and sports tournaments for

employees and cane growers of area of operation.

Factory has provided employees credit cooperative society.

From last two years, the factory has started providing Rs. 20,000 per acre as

loan without interest to the member farmers from Bank to promote cane

cultivation in the region. The interest burden on account of the loan is being

born by the factory

3.9 Other important aspects

3.9.1 Archeology, historical sites

Ajanta is world famous historical monument recognized by UNESCO located 45 km

from the site and 105kms from Aurangabad City of Maharashtra, India. There are no

tropical forest, biosphere reserve, national park, wildlife sanctuary, coral formation,

defense installations, recreational sites, holiday resorts, pilgrimage site, historically

important structures, monuments, etc. in 10 km study area.

3.7.2 Seismic zone

Chapter III


Figure 3.7: Seismic zone map: Maharashtra

With reference to the above seismic zone map, Jalana district is located in seismic zone

II, where the earthquake could be observed up to 5 Richter scale.

Chapter IV


CHAPTER IV

POLLUTION SOURCES AND CHARACTERISTICS

4.1 Introduction

This chapter illustrates the probable pollution sources and its characteristics due to the

proposed project with reference to the prominent environmental attribute. Usually

distilleries are well known for its highly polluted wastewater in the form of “spent

wash”. It is the major pollutant produced by the industry. It causes heavy pollution, in

the receiving water bodies as well as due to land application. Other pollution aspects

such as air, noise, etc. are comparatively less significant in case of the distilleries.

4.2 Air pollution

4.2.1 Boiler Emissions

In case of the proposed project, chief sources of gaseous emissions will be the flue gases

due to burning of fuel in the boiler and diesel generator. During crushing season the

sugar factory will be operating its existing boiler of 32 TPH capacity to produce steam,

This steam will be firstly supplied to steam turbine generator (STG) so as to produce

electricity and exhaust steam from the same will be used for sugar factory as well as

distillery operations. The factory has made a provision of 10 TPH boiler, which will be

used during off-seasonal operations of the distillery. Existing as well as proposed boilers

will be operated on bagasse (as a fuel). In addition, the distillery will be installing a bio-

methanation unit to produce biogas. This will also be used as fuel for boiler. Pollutants

likely to be generated due to this activity could be anticipated by analyzing the fuel.

Table 4.1: Details of Bagasse Analysis

* bagasse of ~50% moisture is used as fuel in sugar factories

Parameter Value

Sulphur (%) Trace (<0.01)

Nitrogen (%) Trace (<0.2)

Carbon (%) 44-46

Hydrogen (%) 5-6

Oxygen (%) 45-46

Ash contain (%) Max. 2.00

Calorific value* 2250 kcal/kg

Chapter IV


This analysis reveals that, probable pollutant due to burning of bagasse (as a fuel) will

be suspended particles in the form of ash. Emissions of SOx will be in traces since sulfur

content of bagasse itself in trace quantity.

Similarly, elemental Nitrogen is also present in traces to produce NOx/NO2. Moisture

content of bagasse (~50%) also helps in restricting the furnace temperature around

900-1,000degree C. This temperature is low enough to prevent formation of NOx from

the nitrogen present in the air supplied for combustion of bagasse. Thus, the emission of

particulate matter is anticipated as a major pollutant due to project process.

The sugar factory has a diesel generator of 320KVA as a backup arrangement. It is use

only when captive power generation is not in operation. During off-seasonal operation

of distillery the sugar factory has a planned to take power supply from state electricity

department and use DG as a backup. Thus emissions from DG due to burning of diesel

will be very minor and for short interval.

4.2.2 Ash generation estimates for the proposed project

Steam requirement = 110MT/day (max @4.5MT/h)

Bagasse Requirement = 48 MT/day

Ash content (max.) = 2.00 %.

Total Ash generated = 960 Kg /day (40 kg/h)

Out of this about 60% will be bottom ash while 40% will be fly ash, which will be

emitted through stack. However, by installing wet scrubber system before stack this fly

ash will be entrapped and collected at bottom as wet ash.

The quantities are

1. Bottom Ash = 24 Kg/h

2. Fly Ash = 16 Kg/h

3. Fly Ash collected = 15.68 Kg/h (Wet Scrubber Efficiency 98%)

4. Fly Ash emission = 0.32 Kg/h = 0.089 g/sec

Another source of particulate matter is fugitive emissions due to handling of ash and bagasse, its loading/unloading and transfer as well as opening and leaks in dust collection facility.

4.2.3 Estimation of SO2

Sulphur content of bagasse is in trace quantity. Hence, formation of sulphur dioxide

(SO2) due to burning of bagasse could be very negligible. However, the sulphur dioxide

could get generated due to combustion of biogas (produced from bio-methanation unit

Chapter IV


for the disposal of spentwash) could lead to generation of some amount of sulphur

dioxide.

2H2S + 3O2 2SO2 + 2H2O ------------------ (Equation 1)

2(2+32) + 3(16x2) 2(32+32) + 2(2+16)

68 + 96 128 + 36

Estimated Biogas production (Considering COD 120,000 mg/liters) = ~11,000 m3/day

1.) General composition of biogas produced by using distillery molasses are

Methane (CH4) 64-65%

Carbon dioxide CO2 34%

Hydrogen sulfide (H2S) max: 02%

Amount of H2S from 11,000 m3 Biogas = 220 m

3/day

(Considering the density of H2S =1.363 kg/m3) = 299.86

As per equation I - 68g of H2S combustion required 96g of oxygen i.e. 142% of total volume

299.86 x 1.42 = 318.26 kg oxygen required

Since the amount of Oxygen required = amount of SO2 generated

Total SO2 produced = 425.80 kg/day

Thus, SO2 Emission will be 4.93 g/s

The emission rates for SPM & SO2 were considered for determining the Ground Level

Concentration (GLC) using a mathematical model based software Aermod/ISCST 3

dispersion model. The details of dispersion modeling study are given in Chapter V i.e.

Environment Impact Assessment

4.2.4 Other emissions from process

Carbon Dioxide (CO2): The process of fermentation takes place by producing Carbon

dioxide (CO2) and energy. The gaseous CO2 generated in the fermenter carries traces of

alcohol vapors. Hence, CO2 gas along with vapors is scrubbed with water.

Sugar- and starch-based fermentation processes include a similar fermentation process

in which yeast is added to convert glucose, a six-carbon sugar, to ethanol and CO2. One

mole of glucose is converted into two moles of ethanol and two moles of CO2 through

the following chemical reaction:

C6H12O6 + yeast = 2 C2H5OH + 2 CO2

1 glucose + yeast = 2 ethanol + 2 carbon dioxide

Chapter IV


Since one pound = 453.6g and

One gallon (US) = 3.785L

Equation 4.2 can be written as CO2 emission = 22,613kg/30KL or 22.613MT/day

4.2.5 Pollution due to transportation activity In case of the proposed project transportation requirements are identified for following

Transportation of pressmud (filter cake) from sugar factory to the compost site,

travel distance of 1 to 1.5km. The pressmud is transported in lot/bulk at the

beginning of compost cycle. Each composting cycle is carried out for 45days.

Approx 7,000MT of pressmud will be transported in each lot. Tractor trolleys

and dumpers will be used for the transport. A tractor trolley could carry approx.

15MT of load at a time. Hence, this transport could be carried out in 2-3 days

with the help of 4-5 tractor trolleys or dumpers. Since pressmud contains approx

65% of moisture, it helps in reducing the generation of fugitive particulate

matter. End product of compost process is manure which also contains 35% of

moisture. It will be sold to nearby farmers. Thus, its transportation will be

minimal (maximum in 25-30km radius area). Considering this fugitive dust

pollution could be negligible.

Molasses will be transported through pipeline from storage tanks at sugar

factory to the distillery unit, hence vehicular pollution is not anticipated for this

transport. However, the factory needs to import approx 10,000 to 12,000MT

(@111MT/day = 77cum) of molasses for operating distillery for the period of

Chapter IV


270days a year. Molasses will be transported from nearby sugar factories which

are in the radius of 100-125km. Therefore, daily 6-7 tankers of 15,000L size

could able to transport the required molasses to the factory.

Usually rectified spirit or ENA is sold in bulk, hence the transportation of finished

product will take place at periodic interval only. The product will be transported

through tankers.

Considering the and type as well as number of vehicles estimated for transportation,

extent of transportation activities are of limited, It will be at intervals and for short

distances. Therefore, vehicular emissions considered as minor source of air pollution

during transportation activity.

4.3 Noise environment

The chief sources of noise in the project will be

Boiler and conveyers

Rotating machinery

Ash and bagasse handling system

Diesel generator is presumed to be minor source since it will be rarely used only

in case of total power failure

Noise levels observed in potentially high noise level work places

Source Noise Level dB(A)

Boiler* 80-83

Turbine* 98-100

Fermentation unit 63-65

Distillation unit 70-72

Composting machinery * 72-75

Note: levels at source

The sound level falls with increasing distance from the source. The principal reason is

the wave from spreading and for a point source the “inverse square law” applies —

doubling the distance from a point source produces a reduction in sound level of 6dB.

Most industrial sources will be point sources. However, if the source is a long one, such

as a conveyor

Chapter IV


or a line of roof fans, the line source reductions will apply. In these cases, sound is

dissipated over a cylinder, rather than a hemisphere. If the distance from the source

doubles, then the sound pressure halves, that is, 3dB per doubling of distance

Natural attenuation

Sound passes through the air as a pressure wave. In open space the amplitude of that

pressure wave will naturally reduce as it moves from source to receiver through three

principal mechanisms:

spherical spreading — the natural dilution of the sound energy as it is spread

over a widening area

absorption by the air

absorption by the ground

Artificial attenuation by

Structures

Barriers

Estimates for noise levels at the proposed site based on following situations

The proposed distillery will be using existing boilers and turbines of sugar

factory during the crushing season, hence existing levels in these two places

anticipated to remain unchanged

Ash and bagasse handling will be carried out at sugar factory site (during

crushing season) hence, it will not add to any additional noise at distillery site

Natural and artificial attenuation measures will help in controlling the noise

levels on site as well as off-site

Therefore, the noise levels due to proposed activity may cause minor negative

impact at some work place areas. However, overall noise levels in the project

boundary are anticipated to be within prescribed standards.

4.4 Effluent treatment

The main effluent sources in molasses based distilleries are as follows

Spentwash and spentlees from distillation unit

Effluent from water treatment plant

Blow down from the cooling tower

Steam generation blow down (Boiler blow down)

Cleaning in place

Chapter IV


Sewage

The industry proposed to adopt a continuous fermentation based technology for the

production of alcohol. The distinct advantages of this process are-

1. Spentwash produced per liter of alcohol is less compared to conventional

process. The quantity of Spentwash produced from the continuous fermentation

is around 9-10 liters per liter of alcohol produced.

2. The yeast is recycled to the process and the de-yeasted wash is distilled and

hence the spentwash does not contain any yeast.

4.4.1 Spentwash

Spentwash generation is estimated to be around 300m3/day from the process i.e. before

bimethanation. Spentwash is considered to be a major pollutant from distillery industry

because of its highly acidic nature, high temperature, unpleasant colour & odour, It also

contains high percentage of dissolved organic & inorganic matter; hence its BOD and

COD are also significantly high. The general qualitative characteristics of spentwash

(raw) are highlighted below.

Table 4.2: General Characteristics of Raw Spentwash

# Parameter Continuous Fermentation

Process

Unit

1. Volume, Liters/Liter of Alcohol 9-10 ----

2. Colour Dark brown -----

3. pH 4.0-4.3 ------

Temperature 0C

4. COD 1,10,000-1,30,000 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

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

10 Potassium 10,000-14,000 mg/L

11 Phosphorus 300-500 mg/L

12 Sodium 1,400-1,500 mg/L

Chapter IV


# Parameter Continuous Fermentation

Process

Unit

13 Calcium 4,500-6,000 mg/L

Spentwash is considered to be one of the difficult effluents to treat. Similarly its

handling, storage, transport, treatment and disposal are need to be carried out with

utmost care. It is mainly due to its abovementioned characteristics. Its high temperature

and pH imposes a need of safe handling and transportation. Presences of various salts

make its storage impervious. Its colouring compounds are the most difficult part to

degrade/treat and dispose. Considering pollution potential of spentwash, Central

Pollution Control Board (CPCB) has prescribed a guidelines for safe handling, treatment

and disposal of distillery effluent. These guidelines are well known as CREP guidelines

(i.e. Corporate Responsibility for Environment Protection). According to these

guidelines the distillery has to achieve ‘Zero Liquid Discharge’ (ZLD).

Table 4.3: Quantity and characteristics of process waste water

Sr no Sources Quantity Type of flow

1. Spentwash 300 Continues

2. Spent less 30 Continues

3. Boiler blow and cooling tower blow down 150 Intermediate

5. Floor washing and other 4 Intermediate

4.4.2 Spentlees

Spentlees is another important source of effluent. Compared to spentwash it could be

considered as mild to moderate in pollution characteristics. It could be treated easily

and economically using existing mechanical treatment options. Spentlees generation

varies with products (i.e. RS, ENA or AA). Some of the spentlees is usually recycled back

to process. Considering this spentlees generation estimates to around 30m3/day.

spentlees is acidic nature which is the main cause of a pollution. It will have a pH in the

range of 3 – 4. The spentlees will be properly treated and reused for cooling tower

makeup as well as gardening type of activities in the factory area only.

4.4.3 Blow down water

Blow down water will be from cooling tower and boiler. Usually the important polluting

factors of the blow down are pH, temperature and dissolved solids. The pH could be in

Chapter IV


rang of 8 -10.3 and temperature of blow-down water presumes to be about 1000C. The

quantity of blow-down water is minor and hence, it is proposed to put the blow-down

for cooling and leave it in the effluent pond.

Table 4.4: Characteristic of wastewater from cooling tower and boiler blow down

# Parameter Unit

1. Quantity 150 m3/day

2. Total Dissolved Solids 2,000 ppm (max)

3. pH 8-9

4.4.4 Floor Washing

Other wastes originate from washing of the floor, fermentation, vats and other

equipments. The quantity of floor washing is generally about 4-5 m3/day. Fermentor

wash water is usually recycled back to the fermentor itself. Other wash water is mild

polluted mainly by suspended particles (dust).

4.5 Land/soil environment

The potential sources of land or soil pollution could be the handling, storage,

transportation, and disposal of spentwash. As described earlier the spentwash could

cause an impact on soil due to percolation and leaching. Similarly, runoff from bio-

compost yard could lead to the formation of leachates and could pollute the soil.

Accidental spillages of spentwash could be one of the soil pollution source.

The project requires about 14 acres (four acres for distillery and 10 acres for

composting activity) area for various units including compost yard. This area will be

covered by various structures of distillery. Thus, assuming 56,0000 sq.m. of area will be

excavated at various depth for construction and top 30cm (0.30m) of soil layer as fertile

layer, 16,000sq.m. of soil will be available for greenbelt. about, 900 sq.m. of land will get

excavated for spentwash storage lagoon. This soil will be used for -

internal road development;

Parking area

Plinth work of office, distillation tower unit, storage area, etc.

Generally, industrial waste/ solid waste are considered to be one of the major sources of

soil pollution. However, this factor is insignificant in case of sugar and distilleries. It is

mainly due to the agro-based nature of raw material and fuel, which forms non–

Chapter IV


hazardous, decomposable waste. Hence, it could be used as soil enriching matter.

Therefore, the soil/land pollution due to solid waste is presumed to be insignificant in

this case.

4.6 Solid waste sources Ash generated from fuel, sludge generated from fermentation process as well as

biomethanation and ETP units will be the main sources of solid wastes. Unlike other

chemical distillations, there is no distillation residue in alcohol production. Estimated

ash generation from the distillery unit will be 40Kg/h or 960Kg/day. It will be in the

form of bottom as well as fly ash. Estimate for fermented sludge is of 5-6 m3/day and

sludge from Biogas unit is approx 8-10m3/day. These solid wastes are non-hazardous

and easily decomposable due to its organic nature. Hence, these could be used in the

compost process.

4.7 Hazardous waste

The only hazardous waste likely to be generated in this project is the scrap oil from DG.

This spent oil is produced from generator diesel engines. Since, the power source for the

proposed distillery is captive hence generators will be used only during emergency and

of failure of regular power supply. Therefore, spent oil generation is difficult to quantify

in volume however it is anticipated to be in very minor quantity. Another minor source

of hazardous waste could be the waste lubricating oil and grease generated from gears

and other equipments. Like spent oil, lubricating waste is also anticipated to be in minor

quantities. One of the easiest and safe way to dispose it, is to burn it in furnace along

with fuel. If the quantity of the waste is sizable enough, then it has to be sent to

hazardous waste disposal facilities.

4.8 Biological aspects

Generally, the industrial projects cause impact on surrounding eco-systems and

biological factors due to various activities, such as –

Habitat destruction due to change in the land use

Cutting of trees/grasses

Discharge of solid, liquid and gaseous pollutants into the environment

Activities such as transportation, blasting or similar that leads to generation of

noise and vibrations

Chapter IV


In case of the proposed project, land use change is insignificant since, the land is within

sugar factory premises. The land is barren, flat and covered by seasonal weeds and

grasses. Hence, habitat destruction or large scale tree cutting, etc. are insignificant

issues. The industrial activities, pollution aspects linked with it and transportation may

cause minor impact on biotic and abiotic factors in the immediate surroundings of the

site. However, considering the adequacy of environment management plan overall

impact on ecology and biodiversity of the region is anticipated to be negligible.

Nearest wildlife sanctuaries are more than 50km from the site. There are no endanger

tree/animal/bird/butterflies/ reptiles/ other etc species recorded in the study zone. The

site is not located in the corridors of any wildlife or in the routes of migratory birds.

4.9 Socio-economics

The project is going to generate around 100 direct employment and large number of

indirect employment. This requirement could be easily get fulfilled from local skilled

and semi-skilled youths, (technical education institutes are available in nearby areas).

Hence, probabilities of large scale migration of population to the surrounding areas are

assumed insignificant. Important infrastructures such as schools, colleges, roads,

medical facilities etc. are available in the region. There is no adverse impacts attribute to

physical displacement because of proposed factory. The project is proposed on open

land, under the possession of the proponents; hence, no rehabilitation is necessary.

Positive impact generate through direct and indirect employment generation and other

social initiative by sugar factory like providing guidance to farmers, good quality seed

material and fertilizers, other welfare programs. Thus, significant positive impact is

anticipated on the socio-economic environment by the project.

Table 4.5: Summary of probable pollution sources and characteristics

# Activity Probable Pollution

source/Impact on

environment

Comment/Remark

Project

Location

Impact on natural resources

present in the vicinity

Habitat destruction or

biodiversity loss

Site complies the MoEF guidelines

The project within the existing sugar

factory premises; land is flat, barren

and open; no tree felling is required

No rehabilitation/ restoration issues

Nearest protected areas are more

than 50km away

Chapter IV


Regular Operation

Gaseous

emissions

Boiler

Emission

Fermentation

Air

Particulate Matter (SPM)

Formation of SO2, NOx

H2S from Biogas

Carbon dioxide due to

fermentation process

Odour

Wet scrubber proposed as air

pollution control equipment

Stack height 60m

CO2 scrubber

Mechanical handling of bagasse and

ash

Bagasse contains traces of S & N,

hence generation of SOX and NOX

anticipated to be limited

Bagasse is a renewable sources of

energy & carbon neutral fuel

Greenbelt around factory

Storage,

handling of

material and

process

Water

Molasses storage

Spentwash: 300 m3/day

Spentlees:30 m3/day

Process condensate: 110 m3

Molasses storage in MS tanks

Biomethanation followed by bio-

composting for spentwash

Spentwash storage and compost

yard preparation as per CREP

guidelines

Polishing unit for spentlees, CIP and

blow down water

Recycling of process condensate

Recycling of treated water

Waste

generated

from process

Land

Boiler Ash total Ash 40

kg/h

Fermented sludge and

sludge from biodigestors

and ETP

Scrap oil from diesel

generator

Bagasse ash is non toxic, rich in

potash; hence mixed with bio-

compost

Sludge – Organic & biodegradable,

mixed with compost

Use of DG set in very limited due to

captive power, hence scrap oil

generation in negligible quantity,

safely disposed by burning it into

boiler

Process

operations

and

transportation

Noise

Boiler, STG, process

operations

Transportation

Artificial noise attenuation by

placing boilers, turbines, machine

under roof (covered)

No major transportation involved;

leveled roads, adequate parking

proximity of state highway

Chapter V


5-1

CHAPTER V

ENVIRONMENTAL IMPACT ASSESSMENT

5.1 Introduction

This chapter gives the details of the anticipated environmental impacts due to the

proposed project. “Environmental Impact’’ refers to the alteration of environmental

conditions or creation of a new set of environmental conditions, adverse or beneficial,

caused or induced by the action or set of actions under consideration.

5.2 Impact assessment: construction phase

The construction activity involves installation of various units of distillery such as

storage tanks for raw material as well as finished products, boilers, air pollution control

device, distillation towers,, treatment units such as bio-digesters and development of

compost yard, etc.

The major activities during the construction phase of the project will 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

Disposal of the liquid and solid waste generated by the temporary work force

employed for construction

5.2.1 Land Transformation

Shree Rameshwar SSK Ltd has made a provision of land within its existing sugar factory

premises. Therefore, the proposed land is already allocated for industrial use. Hence, change in

the land use may not be recorded in the present case. However, the proposed open, flat and

barren land will be utilized for the erection/installation of various units of distillery. The

proposed construction could take place by minor leveling activity. Hence, no major

transformation in the topography is anticipated due to the proposed project.

While undertaking the construction activities following impacts are anticipated

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5-2

Removal of upper layer of soil; usually this layer is fertile and considering soil formation

process, the fertile layer of soil is precious resource

Excavation is carried out so as to construct foundation and pillars. These activity

generates debris in the form of soil, stones, etc. If this waste material generates in

excessive amount, it disposal could cause some impact

Another probable impact could be due to runoff from the construction site. The runoff

may carry construction debris with it and leads to water and some extent soil pollution

Since, the selected site is open land, however, for the construction of approach road or

waste disposal site if and removal of bushes may be required. If required, such removal

may cause negligible impact

Control measures

The upper soil layer 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

The runoff from the construction site will be controlled by ditches and shall not allowed

to percolate in the surrounding land

Transplantation/re-plantation of trees/bushes, if required

Thus, overall the construction activity anticipated to cause minor negative impact on

land environment.

5.2.2 Air Quality

In case of the proposed project, construction of internal roads and various structures of

the proposed industrial unit are the main activity. It involves use/operation of various

construction machines and equipment. Hence, it could cause noise and dust generation.

Some emissions are also anticipated due to diesel operated machineries and from

vehicles.

Control measures

Barricading the dust generating or high noise generating areas

Chapter V


5-3

Sprinkling of water on roads under construction and other dust generating

sources

Sprinkling of water while loading/unloading the dust generating material

Storage of cement under roof in closed area

To reduce air and noise emissions, use electrically operated machinery (wherever

feasible), instead of diesel operated

The construction activity will be for short period; hence the negative impact will be

temporary. It could be further reduced by, adopting the mitigation measures mentioned

above.

5.2.3 Water

During the construction phase, surface water quality can deteriorate due to run-off of

loose exposed soil and sanitary wastes of labour force. Construction activity and the

labour colony requires considerable amount of water. Hence, the probable impact of

construction activity on water environment could be use of large volume of water for

construction, generation of wastewater and pollution due to it.

Control measures

Restrict excessive use of water by good supervision and thus minimize the wastage

of water

Proper precaution to prevent the runoff from construction site, restricting it from

mixing into the nearby surface or ground water resource

Employ local labours up to maximum extent, so as to minimize the sanitary waste

Allow construction workers to utilize toilet/wash room facilities available in sugar

factory premises

Total prohibition on dumping/throwing any solid waste from construction activity

into any of the water bodies

Thus, proper implementation of control measures could help to minimize the negative

impact of construction activity on water environment considerably.

5.2.4 Ecology

The proposed site is within industrial premises. It is flat, barren and doesn’t require any

tree cutting. Some wild bushy vegetation present close to the waste disposal site. The

Chapter V


5-4

vegetation is mainly species such as Ipomea, calotropis, etc. These species are observed

very frequently in the area. Hence, it may not cause loss of any floral species or loss of

habitat for the faunal species. No migratory route of terrestrial macro-fauna exists

around the project site. Hence, the anticipated impact on flora and fauna could be

insignificant.

5.2.5 Socio-Economic Aspects

The project is proposed on open land, which is under the possession of the proponents.

Hence, no rehabilitation is involved in the project.

The construction phase will generate different employment opportunities for the local

population. Installation of distillery and its ancillary units involves work related to civil

and mechanical aspects. Civil work will provide employment to labours, especially to

the illiterate/semi-literate, unskilled persons. Installation of mechanical units requires

skilled, trained, and qualified persons. Transportation of various construction material

and mechanical units of the distillery could provide employment to many locals. Thus,

minor positive impact is anticipated on the socio-economic environment by the project.

5.3 Impact assessment: operation phase

The industry proposes to manufacture Rectified Spirit/Extra Neutral Alcohol using

molasses from its own sugar factory. The potential impact of the activities and measures

to prevent, control & mitigate the potential adverse impacts on the environmental

attributes are discussed here.

5.3.1 Impact on Air Quality

Generally, in industries the major air pollution is due to burning of fuel. In distilleries

also fuel bagasse is burnt to produce steam from water. During sugar factory operation

period i.e. crushing season, this steam will be generated in sugar factory boilers. During

off-season an independent boiler of 10TPH will be employed for the said purpose.

Bagasse analysis data reveals that sulfur is present below detectable limits, hence

particulate matter is the only probable pollutant, due to burning of bagasse in the

boiler/furnace will get release along with flue gases through stack, which is 60m in

height in the present case. This stack height has been determined on the basis of CPCB

guidelines. Wet Scrubber is proposed as an air pollution control (APC) equipment.

Chapter V


5-5

Often, the dispersion of air pollutants and its resultant ground level concentration/s are

predicted using various mathematical models. In the present study, a software based

model used to perform the said task, and detail thereof are discussed here.

5.3.1.1 Dispersion Modeling Study In the present study, Industrial Source Complex-Short Term [ISCST3] software has

been used for dispersion modeling purpose. This software is based on steady state

gaussian plume dispersion, designed for multiple point sources for short term. It is

developed by United States Environmental Protection Agency [USEPA] has been used for

simulations from point sources.

Table 5.1: Model Input

Parameters Unit Stack Attached to Boiler

Stack height m 60

Stack diameter at exit / top m 4.0

Stack exit gas velocity m/s 5.4

Stack gas temperature at exit Deg. C 150

Bagasse requirement TPD 48

Emission rate of SPM g/s 0.09*

Emission rate of SO2 g/s 3.68#

* Ash content 2% and Wet scrubber efficiency 98%

# Sulphur content 0.05% Modeling has been done considering boilers as source at the center of grid for prediction.

Hourly meteorological data of winter season has been used as an input data. For the

site-specific mixing heights CPCB document PROBES/88/2002-2003 is followed.

The simulation is made to evaluate SPM and SO2 incremental short-term concentrations

due to proposed operation of boiler. In the short-term simulations, the incremental

concentrations were estimated to obtain an optimum description of variations in

concentrations within 10 km radius.

Chapter V


5-6

5.3.1.2 Prediction The predicted results with baseline concentrations are tabulated below in Table 5-2

while incremental dispersion trend is shown as isopleths in Figure 5-1 & 5-2.

Table 5.2: Resultant Concentrations Due To Incremental GLC's

Particulate SPM SO2

Incremental concentration, towards Nearest Downwind Site* g/m3 0.06 0.35

Baseline concentration**, g/m3 61 11.9

Resultant concentration#, g/m3 61.06 12.25

CPCB Limit for residential & Rural Areas, g/m3 100 80

*Nearest Downwind site village Babhulgaon 2.5 km- towards WSW direction

**Baseline Concentration – average - at village Babhulgaon

# Resultant Concentration at nearest down wind direction

Chapter V


5-7

. -10000 -8000 -6000 -4000 -2000 0 2000 4000 6000 8000 10000-10000

-9000

-8000

-7000

-6000

-5000

-4000

-3000

-2000

-1000

0

1000

2000

3000

4000

5000

6000

7000

8000

9000

10000

0.01

0.01

0.02

0.02

0.02

0.03

0.03

0.03

0.03

0.04

0.04

0.04

0.05

0.05

0.05

0.05

0.06

Figure 5.1: Short Term 24 Hourly GLCs of SPM

-10000 -8000 -6000 -4000 -2000 0 2000 4000 6000 8000 10000-10000

-9000

-8000

-7000

-6000

-5000

-4000

-3000

-2000

-1000

0

1000

2000

3000

4000

5000

6000

7000

8000

9000

10000

0.10

0.12

0.14

0.16

0.18

0.20

0.22

0.24

0.26

0.28

0.30

0.32

0.34

Figure 5.2: Short Term 24 Hourly GLCs of SO2

BOILER

BOILER

Chapter V


5-8

5.3.1.3 Observations

Based on the input data such as met data, wind data, flue gas generation, velocity,

discharge, the mathematical model has determined the resultant ground level

concentrations of SPM and SO2. The result of the study shows that, during

operation phase of the proposed project, the ambient concentration of SPM and

SOx could increase by 0.06 & 0.35 micro grams respectively. However, the

incremental concentrations may negligibly affect the quality of ambient air in the

surrounding area.

During crushing season, the predominant wind direction was from E, ENE, NE

and ESE. There are sparsely placed villages towards predominant downwind

direction. There is no residential area (except small housing colony of the

factory) in 2.5km towards wsw of the site where dispersion could be maximum.

Composting activity is also planned away from settlement areas.

Thus, there could be a fractional increase in the concentrations of PM10 and SOx; but

this increase may not cause severe impact on environment as well as human health.

5.3.2 Water Environment - Impact on water resource

The proposed distillery will be using water from Jui medium scale water reservoir. The

factory has permission for the same. Thus, the project may not cause adverse impact on

other users. Similarly, the project may not be affecting any ground water resource.

Reducing fresh water consumption as well as reducing generation of wastewater is a

strategy of the factory. Thus, it is going to employ methods of recycle and reuse in the

proposed unit. Recycling of mild polluted stream without treatment or just cooling

treatment and moderately polluted streams by treating it properly could help in

achieving the expected results.

Impact due to Effluent Discharge

Highly polluted wastewater from the distillery is called spentwash. It is characterized by

highly colored appearance with acidic pH, high BOD, COD as well as solids etc. More

upon, the spentwash is hot with temperature of about 50oC when separate out from the

process. Since the waste contains high BOD, it putrefies rapidly giving rise to offensive

odors. The brown, colour is aesthetically objectionable and affects photosynthesis. Due

to these characteristics handling, storage and disposal of spentwash is carried out very

Chapter V


5-9

carefully, according to the guidelines of CPCB/MoEF. The proposed distillery has

determined to implement these guidelines, so as to achieve ‘Zero Liquid Discharge’.

Thus the management has decided to adopt bio-methanation followed by

biocomposting scheme for the safe disposal of spentwash. These processes are

discussed in details in chapter VII – Environment Management Plan.

Apart from spentwash, the molasses based distillery produces wastewater in the form

of spentlees, blowdown from cooling tower, as well as boiler and water from cleaning

activities. These wastewater streams will be properly treated so as to comply the

standard prescribed for use of the water for irrigation. It will be reused for greenbelt

development as well as for cooling tower makeup. The proposed project is in rural area.

Hence, as a local accepted practice, septic tank, soak pit systems are used for the

disposal of sewage. The same will be used for proposed distillery for the disposal of

sewage.

Proper implementation of the proposed measures will help to reduce the negative

impact of waste water on environment.

5.3.3 Land Environment: Impact of Effluent Discharge

The anticipated impact due to project activity on land environment could be because of

spentwash, if it is discharged on the land directly, it damages the soil by

Affecting the soil porosity and thus oxygen transfer, it leads to development of

anaerobic conditions

It could change soil micro-organism composition

Acidic nature of spenwash affects soil pH

Leachate formation

Degradation of organics in soil depletes nitrogen

These factors cause germination disorders in seeds that are planted. .

Other damages caused by effluent discharge on land/vegetation are:

Charring of vegetables and crops

Accumulation of salts

Increase in cropping period

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5-10

Increase in the electrical conductivity

The other waste material such as ash generated due to burning of bagasse, is rich in

potash. Hence, it could act as soil enriching matter. Similarly, the sludge generated from

various units such as fermentation, bio-digesters and wastewater treatment are organic

in nature, and they are usually mixed with bio-compost, before supplied to the soil.

Thus, spentwash is the factor which needs proper care so as to control impact on

land/soil environment. Method of storage and safe disposal of spentwash i.e.

biomethanation followed by biocomposting is discussed in detail in Chapter VII of the

report. Considering these measures, the overall impact on land environment is

envisaged to be minor negative.

5.3.4 Solid Waste

As discussed earlier, the solid waste sources such as ash and sludge could be mixed with

bio-compost. Thus, it is anticipated that the solid waste from the proposed project will

have minor negative impact on environmental due to odour and decomposition, but

positive impact on soil environment since the compost will enhance the quality of the

soil.

5.3.5 Noise Environment

For the proposed project, principle source of noise is boiler. Operations carried out in

the process contribute little to the noise levels. Since, during crushing season the boilers

of sugar factory will be used to supply the steam to the distillery. Hence, noise due to

boiler operation during off-season period is the only concern. Boiler/s in sugar factory

are placed under covered area, hence noise get confined to the place. In case of the

independent boiler for distillery, it will also be placed under covered area. Thus, noise

levels are anticipated to remain within prescribed limits at work place.

Transportation and handling of bagasse could also contribute to increase in noise levels.

However, in case of proposed industry the transportation movement could be very

marginal i.e. 30-35 four wheelers including heavy vehicles per day and around 100-120

two wheelers per day. Vehicular movement will be maximum during start and closing of

duty hours. These sources are line sources and noise generation is also for a short

Chapter V


5-11

period. Hence, impact of noise could be observed in parking areas during the shift

change periods for duration of 15-30 minutes.

Another potential impact of vehicles on noise could be due to traffic congestion. This

mainly happens when roads and parking areas are inadequate. However, for the

proposed project, well defined parking areas will be provided for administrative as well

as goods vehicles. Leveled tar roads of adequate width will be developed internally.

Speed limit of 20kmph will be maintained for all goods vehicles, inside the premises.

Internal roads will be illuminated at 30m distance and safety sign boards will be placed

at strategic locations. Honking will be strictly restricted inside the project premises.

Authorized transport services will be used for goods. Maintaining all the goods vehicles

in good condition will be one of the term of contract with such service provider. All

these measures could help in controlling the noise level below the prescribed standards,

hence, minor negative impact is anticipated due to noise on surrounding environment.

5.3.6 Ecology

The potential impact on flora, fauna, and thus on ecosystem is mainly due to the

pollutants. Amongst air pollutants SPM and SO2 levels are likely to increase. The results

predicted by mathematical modeling study shows that, there could be minor increase in

the ambient concentration of these gases. However, the resulting concentrations for

these gases may not exceed the limits prescribed for national ambient air quality

standards prescribed in Nov. 2009. The SPM concentration may cause negligible impact

on terrestrial flora.

Noise generated in the project could disturb some of the faunal elements such as birds.

This could be observed where noise levels are likely to be high. Noise levels at project

boundaries are anticipated to be within limit, since no high noise sources are involved

in the project. Hence, noise could cause minor impact on avi fauna, within premises.

Accidental discharge of spentwash and other wastewater from distillery directly into

nearby water bodies or on land could damage the aquatic or terrestrial eco-system.

Spentwash due to its dark colour, strong odour, high BOD/COD and acidic pH could

damage aquatic flora and fauna considerably. The spentwash handling/storage is also

need to be carried out carefully, otherwise it could affect ground water aquifer.

Chapter V


5-12

Therefore, Ministry of Environment and Forest (MoEF)/CPCB has prescribed CREP

(corporate Responsibility for Environment Protection) guidelines for storage and safe

disposal of distillery effluent. According to these guidelines it is mandatory for

distilleries to achieve ‘Zero Liquid Discharge’. Hence, the proposed distillery has

planned for Biomethanation followed by biocomposting process for the safe disposal of

spentwash. Implementation of CREP guidelines could reduce the threats to the

surrounding ecosystem considerably. Hence, minor negative impact is anticipated on

surrounding terrestrial as well as aquatic ecosystems mainly due to accidental spillages

and leakages.

Spentwash will be safely disposed through a process of biocomposting, where it will be

mixed with pressmud (filter cake generated from sugar industry). Solid waste material

such as ash, sludge generated from fermentor, biodigester and wastewater treatment

unit will be mixed with biocompost. Thus, compost enriched with nitrogen and potash

will be produced through this activity. This bio-compost will be sold to local farmers;

hence it will help in recycle of soil nutrients. Another benefit is it will reduce the usage

of synthetic fertilizers up to some extent. Thus, the negative impact due to use of such

synthetic fertilizers will get minimized. This bio-compost will help in re-establishing

and maintaining soil micro-flora. Thus, it will help in improving agro-ecosystem.

Therefore, bio-compost process for the disposal of spentwash could cause positive

impact.

5.3.7 Socio-Economic Environment

While analyzing the impact of proposed project on socio-economic environment,

following factors were considered.

Project is proposed in an area where employment is mainly from agriculture

sector and the district is economically weak, compared to other districts of the

state

Project is proposed by cooperative sugar factory and member farmer are share

holder of the factory, hence these cane cultivators will be benefited by the

project

Chapter V


5-13

The project could be vertical integration so as to utilize the 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

Proposed distillery will generate about 90-100 direct employment opportunities;

similarly it will stimulate large number of indirect employment opportunities

The sugar factory already had initiated several programmes for the benefit of its

share holder farmers, employees as well as for the society

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.

5.3.8 Impact on Physiography and Drainage

The land is already under the custody of sugar factory. Therefore there will not be any

additional land acquisition. The physiography of the soil will get altered by, the

installation of the project units.

The project will not be disturbing or changing or altering any natural drainage system.

Proper storm water drainage system will be developed at the site. Hence, the project

will not contribute for water logging or flooding in the rainy season.

Very minor negative impact is envisaged on change in physiography and negligible

impact on drainage of the region.

5.3.9 Other Impact: Traffic

The project is going to add approximately 30-35 four wheeler and about 100-120 two

wheeler per day. Considering the availability of 10m wide state highway close to the

site, this nominal increase may not cause any traffic congestion in the vicinity. Apart

from that, adequate Zilla Parishad road infrastructure is available in the area, due to

which the probability of traffic congestion becomes insignificant. Road Infrastructure:

The site is well connected with other areas, for easier transportation of finished goods

and in case of import of molasses and press mud.

Chapter V


5-14

Table 5.3: Road Connectivity Status

# Station Distance (km) Importance

1 Bhokardan 9 Nearest town

2 State Highway No. 178 1 Nearest Road

3 Jalna 45 Railway Station

4 Aurangabad 80 Air port

Traffic Movement –

This is a small unit occupying small area with only one raw material and one product.

Table 5.4: Estimated Incremental Traffic (per day)

# Vehicle carrying No./d PCU*

1. Alcohol tankers 2-3 10

2. 4 wheelers (staff and visitors) 15-20 15-20

3. 2 wheelers (staff and visitors) 100-120 25-30

Total 117-143 60

(*PCU= passenger car units)

* Peak flow traffic on approach Road is about 25Vehicles/hour.

Traffic management measures

Present condition of approach road is good. It will be maintained.

Topography is level and rains are not problematic, culverts will be maintained

Village roads connecting are of good surface, it will be maintained.

The internal roads will be constructed wide with illumination at 30 m spacing

All vehicles to have back red light

All gates manned by trained security 24x7

Trees on sides

5.4 Summary

The use of continuous fermentation technology for the alcohol production adopted by

the distillery not only improves the process, but also will help in minimizing the effluent

quantity. It also helps in the yeast recycling which reduces the generation of yeast

sludge.

Chapter V


5-15

Setting up of a distillery unit in a sugar complex will be an added advantage as the

distillery can utilize the by-products such as molasses, bagasse, pressmud of the sugar

unit. Also it shares resources such as land, steam & water up to some extent with sugar

factory.

Adverse environmental impact of the project could be prevented, controlled and/or

mitigated by proper implementation of Environmental Management Plan. Considering,

overall benefits of the project it could achieve environmental sustainability.

Table 5.6: Impact Definitions

Likelihood (L)

Code No.

1 Rare Event may occur but only under exceptional

circumstances.

2 Unlikely Event could occur at some time.

3 Possible Event should occur at some time.

4 Likely Event will probably occur in most circumstances.

5 Almost certain Event expected to occur in most circumstances.

Consequence (C)

1 Negligible No detectable effect on or off site

2 Minor Detectable effects with minimal impact on site

3 Moderate Effects on and off site requiring attention

4 Major Sizable effects warranting immediate attention

5 Critical Sizable effects with a large impact warranting immediate

attention

Impact Level (L+C)

2 - 4 Negligible

5 Minor

6 Moderate

6+ High (Key issues)

B Benefits resulting from the proposed modifications are identified with a

“B” and will be addressed further.

5-16

Table 5.7: Matrix environmental impacts associated with proposed project Environmenta

l

Issue

Activity/

Process

Environmental Impact L

(1-5)

C

(1-5)

I

(L-H)

Comment

Air Quality Burning of

bagasse and

biogas for

steam

generation

Emission of SPM, SOx, NOx

minor impact

Reduction in green house

gasses

4

1 5 Wet scrubber as pollution control equipment

Stack height 60m

Adequate greenery development

Bagasse and ash

handling

Fugitive dust 4

1 5 Ash and bagasse handling system

Adequate greenery development

Composting

activity

odour 4

1 5 residential area towards predominant

downwind direction of composting site are

considerably away

Mechanized handling so as to provide

adequate air and avoid anaerobic

conditions

Greenbelt development

Transportation Dust and smoke due to vehicle

movement and/or traffic

congestion

4

1 5 No need of raw material transportation

Finished product transportation will be

minor; separate provision of parking for

administrative and goods vehicles; well

maintained tar roads internally with

adequate illumination and safety sign

boards

5-17

Noise Plant and

machinery

operations

Noise generated during the

operations of the machinery

2 2 4 Minor increase in noise level

Therefore this issue is considered to be a

low environmental issue

Water Quality Wastewater Contamination of surface &/or

ground water

Soil Contamination

2 3 5 Wastewater from distillery will be treated

by biomethanation followed by bio-

composting

Spent lees and miscellaneous waste water

will be treated in polishing unit, treated

water will be recycled in to the distillery

cooling tower as a make up water.

Water

Resource

Consumption of

Water

Depletion of resource 2 2 4 Water conservation is aimed thro’

recycling and reusing of treated water for

cooling tower make-up requirement

Terrestrial

Flora and

Fauna

Cutting of trees

or destruction

of habitat

Destruction of flora or fauna 1 1 2 Since, the project will be commissioned in

the existing sugar factory premises, and

the land is barren and open, flat land no

tree felling is required

Aquatic Flora

and

Fauna

Wastewater Impact due to contamination of

water bodies.

2 2 4 ‘Zero Discharge’, therefore no wastewater

will be released into surrounding water

bodies

Hazard and

Risk

Assessment

Storage of raw

material and

finished

products of

Negative impact only in case of

accidents, leakages, etc.

2 3 5 Safety norms shall be strictly followed

5-18

distillery

Socio-

Economic

Impacts

Temporary and

Permanent

workforce

associated with

the project

Construction and operation

phase of this project will

require an additional

temporary and permanent

workforce as outlined in the

original development

application.

B Beneficial impact due to generation of

employment

Traffic and

Transportatio

n

Traffic

congestion

Impact of air quality and noise

level

3 1 4 Minor impact during construction phase

and negligible during the operation phase

Chapter VI


6-1

CHAPTER VI

ANALYSIS OF ALTERNATIVE TECHNOLOGY

6.1 INTRODUCTION

The charter on Corporate Responsibility for Environmental Protection (CREP) was

formulated to obtain commitment from major polluting industries for compliance with

the existing standards in a time bound manner. Further, it was envisaged that the

industries would take initiative to explore and adopt cleaner technologies and improve

management practices to reduce generation of pollutants.

The spent wash from sugarcane molasses based distilleries is among the most

polluting effluents. Distilleries using batch fermentation process generate 9-10

Liters spent wash per Liter alcohol production. It has a biochemical oxygen

demand (BOD) of 45,000 - 50,000mg/L, chemical oxygen demand (COD) 1,

10,000 - 1,30,000 mg/L and total inorganic dissolved solids (TDS) 30,000-40,000

mg/L. It is highly acidic, pH 3.5-4.5, odorous and has a persistent dark brown

colour. Often it is discharged without any heat recovery at 85 to 95°C.

Traditionally, the spent wash is used for irrigation of crops and for composting

with press mud from sugar mills, as filler material. At several places in the

country, it is spread on land in an uncontrolled fashion resulting in destruction of

agricultural land and pollution of ground water. When it is not possible to use it

on land, it is often discharged in surface waters affecting the riparian rights of

other users of the water body.

The new recommendations of CPCB/MoEF have 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 effective without damaging the environment.

6.2 Treatment And Utilization Options

There are various ways of utilizing and disposing the spent wash. These are as

follows.

Chapter VI


6-2

Treatment Options for Raw Spent Wash

6.2.1 Reboiler

Reboilers are in use 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 the 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. The volumetric

application rate of spentwash on land for irrigation is regulated by the loading

rates of these constituents. Therefore, in case the spentwash is also utilized for

irrigation, the extent of volume reduction should be decided keeping in view

their prescribed limits for irrigation. 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.

Spentwash

Biomethanation Bio-compost

Bio-

composting

Concentration

Multiple effect

evaporation

Reverse

osmosis

Concentration

Mist

evaporatio

n

Dilution Tertiary

treatment

Surface water

discharge

Irrigation

Chapter VI


6-3

At present there is no prescribed recommendation regarding the quality of

spentwash to be used for preparation of compost. In order to achieve 'Zero

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.

6.2.2 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 slurry 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 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

Chapter VI


6-4

6.2.3 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 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 a 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

Chapter VI


6-5

therefore should be entrusted to the supplier to ensure efficient and continuous

operation.

6.2.4 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 spent 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% 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 450m3/d plant treating biomethanated spentwash about 930 kg/hr

effluent powder is generated, which when burnt yields 190 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.

6.2.5 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

Chapter VI


6-6

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 yearly average ambient conditions 3 units, each of

30 KW would be required to evaporate 450 m3/d of spentwash. The three units

will require a 100 m x 100 m lagoon.

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 6.2: 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

Chapter VI


6-7

# Technology Merits Demerits

problem.

4. R.O. System Recovery of water

Reduction in volume.

Higher initial and operational cost

Fouling problem

Membranes are not indigenously

available

6.3 SELECTION OF ALTERNATIVE

Considering all available technological options, the industry has planned to implement

biomethanation followed by bio composting for the safe disposal of spent wash. It is

base on the volume of spentwash to be disposed, availability of land, press mud for

biocomposting and the cost involved for the technology.

The proposed option will be able to achieve the aim of “zero discharge” of effluent. The

Spentwash will be utilized for bio-compost using press mud cake (PMK) from sugar

factory.

Chapter VII


7-1

CHAPTER VII

ENVIRONMENT MANAGEMENT PLAN

7.1 OVERVIEW

The Environmental Management Plan (EMP) 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 framework is a site specific document for the project, to ensure that the

project can be implemented in an environmentally sustainable manner and

where all concerned persons of the industry as well as contractors, understand

the potential environmental impact arising from the proposed project and take

appropriate actions 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 operation of all control measures

Vigilance against probable disasters and accidents

Monitoring of cumulative and long time impacts

Ensure effective operation of all control measures

7.2 EMP FOR CONSTRUCTION PHASE

The construction activity involves installation of various units of distillery such

as storage tanks for raw material as well as finished products, boilers, air

pollution control device, distillation 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

Chapter VII


7-2

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

Disposal of the liquid and solid waste generated by the temporary

work force employed for construction

Considering the various types of pollution associate with the construction

activities, recommended mitigation measures are as follows.

Fugitive dust emission due to transportation activities 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 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 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

Chapter VII


7-3

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

Table 7.1: Summary of EMP for Operation Phase

Activity Impact factors Mitigation Measure Assessment

Steam

Generation

thro’ boiler

(emissions

from stack),

transportation,

process of

fermentation

Particulate Matter

(SPM)

Formation of SO2,

NOx

H2S from Biogas

Carbon dioxide due

to fermentation

process

Odour

Wet scrubber to

control ash emission

through stack

Stack height 60m

Proper ash and

bagasse handling

system

Development of

greenbelt

Use of biogas as fuel

Installation of CO2

scrubber

Mechanical handling

of bagasse and ash

Bagasse contains

traces of S & N, hence

generation of SOX and

NOX anticipated to be

limited

Bagasse is a

renewable sources of

energy & carbon

neutral fuel

Minor Negative

impact on air

quality and

ecology of

immediate site

surrounding

Process and

effluent

storage,

disposal

Effluent from

processes,

cleaning, blow

down water, &

condensate

Storage of

spentwash and its

disposal

Zero discharge will

be achieved by

Adopting

Biomethanation

followed by

biocomposting

Treating other

effluents in

polishing unit and

reusing the

treated water

Storage of

Minor negative

impact

anticipate

mainly due to

accidental

spillages or

leakages and

thereby

contamination

of water,

ground water

or soil

Chapter VII


7-4


spentwash and

construction of

compost yard will

be strictly as per

CREP guidelines

Treated water

will be reused for

process &/or

irrigation

Fresh water

requirement will

be reduced by

recycling of water

Bore well, in

downstream area

of bio-compost to

monitor ground

water quality

Use of biogas as

fuel

Provision of flare

unit Rain water

harvesting

Generation of

ash and solid

waste

Ash Utilized in the process

of bio-composting

Greenbelt

development

Minor negative

impact on air

quality

No negative

impact on soil

Fermented sludge

and sludge from

Bio-digesters

Utilized in the process

of bio-composting

Positive impact

on soil

Chapter VII


7-5


Transportation Vehicular

emissions,

emissions & noise

due to traffic

congestions

Regular maintenance

of factory vehicles

Separate provisions of

parking for goods and

other vehicles is

adequate

Leveled, illuminated

and well maintained

internal roads and

proximity of state

highway

Safety sign boards at

strategic locations

Provision of Adequate

personal protective

equipments

Transportation

requirement is

limited, hence it

will help to

control the

gaseous

pollutants and

maintain

ambient air

quality

Minor increase

in noise level

particularly at

work is

anticipated

7.3 EMP: OPERATION PHASE 7.3.1 Air Environment Management

Air Emissions: As discussed in previous chapter, 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 a

minor sources. Considering this following management plan is proposed.

Installation of Wet scrubber as air pollution control equipment (PCE), to

arrest fly ash emissions

Criteria for the design of wet scrubber will be 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 60 meter height

Preventive maintenance and regular checking of wet scrubber

Fermentor – covered; CO2 scrubber will be installed

Installation of ash and bagasse handling system

Proper maintenance of internal roads

Chapter VII


7-6

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 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

Monitoring of stack emissions and ambient air quality at regular interval

Compliance of other regulatory norms such as health, safety, etc.

7.3.2 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

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 of unavoidably noisy operations;

Job rotation for workers placed at high noise areas.

Greenbelt development with suitable species for noise attenuation

7.3.3 Water Environment

As understood in Chapter IV, that spentwash is a highly polluting element, which

is potentially a major threat to environment. Thus, it is imperative to manage it

properly. Considering the pollution potential of spentwash, the Ministry of

Chapter VII


7-7

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.

The other wastewater sources such as spent lees, steam condensate and blow-

down water will be treated by the way of pH correction, and passing it through

polishing unit, so as to use it for cooling tower make-up water, soft water for the

process, water for the gardening/irrigation activity. Steam condensate will be

recycled back as a boiler feed water. Thus, the industry is determined to put its

sincere efforts for the recycle/reuse of water.

7.3.3.1 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.

Spentwash storage lagoon of ≤30 days capacity

The lagoons must be impervious, constructed leak-proof, lined with

HDPE sheets and protected by brick lining

The compost yard lined with HDPE sheets and protected with brick/

concrete/ Bituminous Macadam

Provisions for leachate collection gutter and sump well

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.

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

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7-8

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 anaerobiosis

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

Heavy rains can wash off the press mud

Precautions to be taken before onset of rainy season

The composting area must be vacated before start of rains

As far as possible, all the compost on the site should be sold out before

start of rain. The compost, which remains unsold, should be properly

bagged and kept in godown/covered area

After harvesting the last batch of compost a 2 cm layer of pressmud

should be scrapped over the surface layer of compost yard and this

scrapped material shall be kept covered for blending with compost.

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7-9

After cleaning the scrapped area, fresh windrow of pressmud shall be

formed only after rainy season.

ii) Unseasonal Rains

Precaution to be taken, if there is unseasonal rain during composting cycle

In order to avoid the leaching of spentwash, which is yet to decompose

all the 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 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 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 7.2: 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).

30 days of

generation

30 days

3. Pressmud: Spentwash ratio 1: 2.5-3.5 1:2.5

Chapter VII


7-10


per C.P.C.B. Norms

Actual Design

and

Provisions

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)

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.

850 MT/acre/cycle 850

MT/acre/cycle

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

Compliance as

per required

norms would

be done

Chapter VII


7-11


per C.P.C.B. Norms

Actual Design

and

Provisions

compost should be

stored

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

7.3.3.2 Spent Lees Treatment Unit (Polishing Unit)

The proposed system is designed for treatment of spent lees and other

minor effluent of proposed distillery. The treated water will be recycled to the

distillery cooling tower as make-up water thereby reducing the requirement of

fresh water as well as solving the wastewater disposal to some extent. The

system is based on following principle operations.

i) Cooling & Neutralization

ii) Recycle of treated streams back to Cooling tower make up

A) Description of Unit Operation and Process

i) Equalization Tank

Spent lees (30m3/day) from the distillation will be collected in a

equalization tank, where the stream will get mixed with other minor

effluents (cleaning, CT blowdown, etc)

iii) Effluent Cooler

Hot effluent from the equalization tank will be pumped using priming

pump via plate heat exchanger, where it will be cooled to ambient

temperature before entering to neutralization tank.

iii) pH Correction

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7-12

The cooled effluent will be then sent to a static mixer, where it will

neutralized using caustic solution. Caustic solution will be dosed using a

dosing system consisting of dosing tank and dosing pumps. Dosing will be

controlled by, using pH sensor installed on downstream of the static

mixer.

Neutralized effluent then sent to aeration tank provided to reduce BOD &

COD.

iv) Aeration Tank

The neutralized effluent will be treated in aeration tank to reduce BOD &

COD and to increase the dissolved oxygen.

v) Clarifier Treated effluent from aeration tank sent to the clarifier for removal of

suspended particle. The separated sludge will be utilized in composting

process.

vi) Holding Tank The clear treated water coming from clarifier will be stored in holding tank.

vii) Filter Media

Clear effluent from holding tank will be filtered through Sand filters or Activated

Carbon Filter (ACF) to minimize odour and suspended solids.

viii) Water Softener

The treated water from filtration unit will be passed through water softener, to

reduce the TDS. Thus, the clear treated water will be recycled to distillery

cooling tower as makeup water.

Table 7.3: Characteristics of Untreated & Treated Composite effluent

Sr.

No.

Parameters Composite Effluent

Untreated Treated

1. Quantity 185 m3/day 185 m3/day

2. Temperature 650C ambient

3. Chemical Oxygen Demand (COD) 2500 – 2700 mg/Lit < 250 mg/L

4. Biochemical Oxygen Demand 1200 - 1400 mg/lit. < 30 mg/L

Chapter VII


7-13

(BOD)

5. Total Dissolved Solids (TDS) 400 – 500 mg/lit. 5 mg/L

6. pH 6.2 – 6.5 6.9 – 7.2

7.3.3.3 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

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 five 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

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7-14

Provision of lined garland drains around the surface compost pits to

collect run-off.

7.3.3.4 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.

7.3.4 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 case the solid waste such as

sludge 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

7.4 GREENBELT DEVELOPMENT

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7-15

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

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 –

Chapter VII


7-16

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, >4,500 plants (including shrubs and trees) are

proposed for the greenbelt development.

Table 7.4: List of Species Recommended For Greenbelt Development * T=Tall, M=Medium, S=Size

S

No.

Name Size* Climatic

condition

(Rainfall)

Feature/remark

27. Acacia nilotica sub

species indica and

tomentosa

T 250-500 mm Dust tolerant, very


28. Acacia leucophloea T 500-1000

mm

Tolerant to air pollution,

very common in the

region

29. Aegal marmalose M/T 500-1000

mm

Tolerant to air pollution,


30. Albizia saman M 500-1000

mm

Tolerant of CO2

31. Anona squamosa T 250-500 mm Fly ash tolerant

32. Anthocephalus kadamba T 500-1000

mm

Dust tolerant

33. Azadiracta indica T 500-1000

mm

Fly ash tolerant

,Tolerant of alkaline and

Saline soil, common in

the area

34. Bauhinia purpurea T 500-1000

mm

Dust tolerant, cultivated

near residential areas

35. Bauhinia variegata T/M 500-1000mm Soluble sodium 1.0 to

2.0

36. Butea monosperma T 500-1000

mm

-

37. Cassia fistula M 500-1000

mm

pH 7.5 to 8.4, cultivated

near residential areas

38. Cassia siamea M/T 500-1000

mm

Soluble sodium 1.0 to

2.0, cultivated near

residential areas

Chapter VII


7-17

S

No.

Name Size* Climatic

condition

(Rainfall)

Feature/remark

39. Casurina equisetifolia T 500-1000mm Tolerant of sandy soil

40. Cordia spp. M 500-1000mm Dust tolerant

41. Delonix regia T 250-500 mm Fly ash tolerant

42. Emblica officinalis M 500-1000

mm

-

43. Erythrina indica T 500-1000

mm

Tolerant of CO2

44. Eucalyptus species T 500-1000

mm

Tolerant of sandy soil,

SO2

45. Ficus benghalensis T 500-1000

mm

Fluoride tolerant,

common

46. Ficus glomerata T 500-1000

mm

Tolerant of CO2 common

47. Ficus religiosa T 500-1000

mm

Tolerant of CO2 common

48. Nerium odoratum S 500-1000

mm

Tolerant of SO2 common

49. Tamarindus indica T 250-500 mm Tolerant of acidic soil

50. Terminalia arjuna T 500-1000mm Tolerant of

alkaline/Saline soil

51. Derris indica M/T 500-1000mm Tolerant to air pollution,


52. Dalbargia sissoo Tolerant to air pollution,


Chapter VII


7-18

Table 7.5: Flowering and foliage shrubs recommended for greenbelt

7.5 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 either using 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.

# 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

11 Vinca rosea

12 Ratrani 13 Gardenia

14 Canna 16 Chrysanthemum

Chapter VII


7-19

The industry has planned to implement the rainwater-harvesting project. It will

appoint a special consultant, under his guidance the project will be designed and

implemented.

7.6 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

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.

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

Chapter VII


7-20

General check up of all employees once every year

Medical examination of employees after retirement is recommended for a

period of 5 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

7.7 EMP FOR SOCIAL ENVIRONMENT

While offering the employment local candidates will be preferred, unless suitable

candidate is not available locally. The indirect employment opportunities will be

plenty and again it will support to the local economy. The industry will be using

infrastructure and resources with social responsibility and it will try to maintain

the same. The sugar factory has already taken several initiatives for the social

development of the region. It will continue its activities in the areas of health,

education, culture, and in addition it will take activities related to women and

child welfare. The industry shall ensure that farmers, workers and all the society

in general get benefit by the project.

7.8 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.

7.8.1 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 environmental quality in and around the industrial

complex. Members of the Cell should be well qualified and experienced in the

concerned field.

Table 7.6: Human Resource for Environment Management Cell

Chapter VII


7-21

General Manager/Production Manager One

Bio-compost/ETP I/c. One

Laboratory Chemist One

Environmental Chemist /biodigester

supervisor

One

Safety Officer One

Supporting Staff Two to five

7.8.2 WATER ENVIRONMENT

Water samples from bore well/s located towards downstream of

compost yard should be collected and analysed periodically

The characteristics of biomethanated spentwash, should be collected

and analysed periodically

Water Cess should be submitted to Pollution Control Board as per the

schedule

Environment Statement Reports also to be filed as per the schedule

prescribed by Pollution Control Board

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 7.7: Analysis of environmental parameters and its reporting

schedule

Sr. No. Particulars Parameter Frequency#

1 Stack Emissions SPM, SO2, NOx Monthly

2 Ambient Air Quality SPM (PM10), RSPM (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 pH, COD, BOD, Total solids, Quarterly

Chapter VII


7-22

water sample

nearer to compost

yard

Chlorides, Sulphate, Phosphates,

and Calcium.

/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 7.8: 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 calibration of

tri-monthly

4 All type valves Change packing six-monthly

5 Impellor Check all blades, sleeves,

bearing, impel nut check

Yearly, change if

required

6 Electric motor Open side doors, blow dust,

check air gap

Monthly

7 Motor winding Blow off dust, test bi- Yearly

Chapter VII


7-23

insulation

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

7.8.3 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 spent wash generated is also need to be measured with the help of V-

notch or flow meter.

Table 7.9: Format for Water Consumption Reporting Schedule

# Particulars m3/hr m3/D m3/A

1. Dilution of Molasses

2. Distillation process, dilution for ENA

3. Cooling tower (CT) make-up for distillery

4. CT make-up for cooling spentwash for biogas plant

5. Boiler make-up

6. Floor washings sterilize

7. Sanitary Requirement

8. Domestic Use for Colony

Total

Chapter VII


7-24

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 7.10: Estimated Capital & Recurring Expenses for Environmental

Management Program

Sr. No. Particulars Amount (Rs. in Lakhs)

11. Spent wash cooling and holding tank 85.00

12. Compost yard with PCC top finish 175.00

13. Leachate management system 15.00

14. Laboratory shed and its glassware, equipments, etc. 15.00

15. Polishing units for condensate treatment 100.00

16. Biomethanation Unit 360.00

17. Biocomposting machinery, pipeline and other 70.00

18. Fire fighting equipments and other 25.00

19. Tree plantation and bore well for composting 8.00

20. Wet Scrubber 110.00

TOTAL 963.00

Recurring Expenses/annum 6. Salaries and wages 09.00

7. Operation and maintenance of all pollution control

devices, motors, pumps, pipelines, etc.

3.50

8. Fuel (composting activity) and Electricity (in case of

diesel generator operation)

1.50

9. Contingency and miscellaneous 1.0

TOTAL 15.00

Chapter VIII


CHAPTER VIII

RISK ASSESSMENT AND MANAGEMENT

8.1 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.

The uses of simple presence in a chemical commodity in the work place or the

environment in general, present 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.

Chapter VIII


8.2 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.

Risk = Hazard x Exposure

Simple Math’s 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.

8.3 Hazard Identification

8.3.1 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

Chapter VIII


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

8.3.2 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

8.3.3 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

8.3.4 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)

2. Interference with speech communication, acoustic signals, etc.

8.3.5 Hazard generated by Vibration

In the proposed project the hazard due to vibrations could be due to -

Chapter VIII


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

8.3.6 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.

8.3.7 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.

8.4 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)

8.4.1 Fire: This is the most common accident known to occur in any plant, while

storing and handling fuel. Since such incident takes sufficient time to get widespread,

enough response time gets available for plant personnel to get away to safer distance.

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 8.1: NFPA (NATIONAL FIRE PROTECTION ASSOCIATION) RATING

Chemical NFPA Ratings

Health Hazard Fire Reactivity

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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

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

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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

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

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,

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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

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.

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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.

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.

Mechanical injury to body parts

In an 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

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.

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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.

8.5 Qualitative Risk Assessment

Table8.2: 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 8.3: Severity - Impact Intensity 1 Minor-Failure results in minor system damage but does not cause injury to

personnel, allow any kind of exposure to operational or service personnel or

allow any release of chemicals into the environment

2 Major-Failure results in a low level of exposure to personnel, or activates facility

alarm system.

3 Critical --Failure results in minor injury to personnel, 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

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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


Major

Proactive Maintenance/PPE

5. Working on height Impact /falling down


Critical Work permit system Life belts/Helmet

6. Water feeder pump failure

Occasional Once per 10 years

Critical Alarming/communication arrangements

Electrical Hazard 7. Contact of

persons with parts which have


Major PPE/PPA/Permits

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Sr. No Hazard Probability Severity Mitigation Measure

become live under faulty conditions (indirect contact)

8. Approach to live parts under high voltage


Catastrophic

Guards/ authorization Enter Restriction

9. Electrostatic phenomena

Remote Major Earthling, avoid Dust Explosion

10.

Thermal radiation or other Short circuits, overloads, etc.


Major PPE/Checking /Inspection

Thermal Hazard

11. Burns, scalds and other injuries by steam


Major Safe working distance/PPA/protective dress code

12.

Damage to health by hot working environment


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

Table 8.4: Hazard Warning Information for Ethyl Alcohol

SECTION I

PRODUCT NAME Ethyl Alcohol,

SYNONYMS Anhydrous Ethyl Alcohol, Dehydrated Alcohol

CHEMICAL FAMILY Alcohol

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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

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

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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 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)

HEALTH (0) FIRE (3) REACTIVITY (0)

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RATING

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 OSHA (29 CFR

1910.134).

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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

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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.

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).

8.6 RISK ASSESSMENT HEALTH

8.6.1 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.

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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.

8.6.2 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.

8.6.3 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

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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.

8.6.4 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 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.

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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

1. Liver function tests;

2. 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.

8.6.5 Other Methods to Reduce Exposure

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.

8.7 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

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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.

8.7.2 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 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.

8.7.3 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.

8.7.4 Persistence in the Environment

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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.

8.7.5 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.

8.7.6 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 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

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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.

8.8 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.

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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

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8-24

Table 8.5: 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.

Chapter VIII


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 in contact

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 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

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

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 3 6

Chapter VIII


2. Responsibility

Site Controller: Head- Electrical



Hazards and details

Persons at risk

Control measures Action taken in case of emergency

Risk

Likelihood

Severity Risk rating

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

Chapter VIII


3. Responsibility

Site Controller: Head- Laboratory



Hazards and details

Persons at risk

Control measures Action recommended in case of emergency

Risk Likelihood Severity Risk

rating 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

Immediately treat the persons as guided in the MSDS

Hospitalize the affected person if necessary

3 2 6

Chapter VIII


the situation in the event of occurrence

4. Responsibility

Site Controller: Manager- Services



Hazards and details

Persons at risk



rating L S RR=LxS

Cooling Tower- Burns from returning hot water

Persons working with cooling tower

All workers are not permitted 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

Chapter VIII


5. Responsibility

Site Controller: Manager



Hazards and details

Persons at risk



rating 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

2 2 4

6. Responsibility

Site Controller: Head- Production



Hazards and details

Persons at risk



rating

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

2 2 4

Chapter IX

Shree Rameshwar SSKL, Dist Jalna, Maharashtra

9-1

CHAPTER IX

DISASTER MANAGEMENT PLAN

9.1 Introduction

Disaster is a phenomenon that can cause damage to life, property and destroy the

economic, social and cultural life of people.

A disaster is a natural or man-made (or technological) hazard, hence can be placed

into two broad groups. In the first, disasters are resulting from natural phenomena

like earthquakes, volcanic eruptions, cyclones, tropical storms, floods, avalanche,

landslides etc. The second group includes disastrous events occasioned by man, or

by man’s impact upon the environment. Examples are industrial accidents,

radiation accidents, factory fires, explosions and escape of toxic gases or chemical

substances, river pollution, mining or other structural collapses, air, sea, rail and

road transport accidents and can reach catastrophic dimensions in terms of human

loss.

In contemporary academia, disasters are seen as the consequence of

inappropriately managed risk. These risks are the product of a combination of both

hazard/s and vulnerability.

9.2 SCOPE

The first step towards disaster management is to analyze the potential causes of

disaster and prepare a plan accordingly. The proposed project is located in Jalna

district of Maharashtra. The potential natural disasters were analysed as follows.

Earthquake According to the seismic zone map for Maharashtra (furnished in

chapter III – figure 3.7) Jalna district is in seismic zone II. It means

the district may observe an earthquake of low intensity of upto 5

Richter scale

Flood According to the agro-climatic zone map of Maharashtra, the

district is place in assured rainfall zone having 700 to 900 mm of

annual rain and 75% of rains received in all districts of the zone.

The annual average rainfall for the Bhokardan taluka is 635mm.

Purna is most important river after Godavari and drains entire

area of Jafrabad. Bhokardan and parts of Jalna talukas. Its

tributaries are Charna, Khelna, Jui, Dhamna, Anjan, Girja, Jivrakha

Chapter IX


9-2

and Dudhna rivers. Out of these river Jui and Kelna are safely

away from the site at 2.5 and 5km respectively. A medium scale

reservoir has been constructed on river Jui in the upstream area.

Hence, usually flow of water is observed only when the reservoir

is full. Considering the average rainfall quantum and presence of a

reservoir, the potential disaster of flood is remote. Secondly, the

site is safely away.

Other

disasters

Disasters such as landslide or volcanic eruptions etc were not

observed so far in the district. The district is situated in the centre

of the state and not surrounded by coastal area, sea shore thus;

the probabilities of cyclone or storms are also very minor.

9.3 OBJECTIVES OF THE DISASTER MANAGEMENT PLAN (DMP)

The Disaster Management Plan is aimed to ensure safety of life, protection of

environment, protection of installation, restoration of production and salvage

operations in this same order of priorities. In the present case also, the industry

has aimed to take necessary steps to asses, minimize and wherever feasible

eliminate risk of disaster (natural calamity) as well as accidents (man induced).

Objectives

While making DMP, shielding life of the person/s exposed to disaster situation

shall be the first priority; hence ensuring safety of all staff (worker, laborers –

even contractual/seasonal, admin and managerial) present at the factory

premises

In worst case, ensuring safety of life of people outside the factory premises

Preventing the losses of movable and immovable goods, data, records, etc at

maximum extent without compromising the safety of life

preventing damage to environment by taking appropriate speedy action

timely communicating the facts and figures related to disaster to the society,

through authentic sources so as to curb the rumors

Disaster may be a result of abnormal or failure of functioning of any unit/operating

system or caused by third parties or by natural factors. In case of any industry or

similar installations when an emergency situation becomes uncontrollable at any

Chapter IX


9-3

of the location and likely to get spread across larger area and sometimes in the

neighborhood it may be defined as the disaster. In disaster situation, alertness and

prompt action by operating staff, is very essential for the control/reduction or

elimination of probable associated risk.

In a situation of disaster, in any industry actions generally followed for the

control and elimination of risk are

Identifying the disastrous situation and its probable spread, impact

Quickly responding to the situation by shutting off the affected as well as probable

machines/units/plants, switch on the siren

Isolating the affected area so as to arrest the spread of disaster, thus controlling the

disaster, localizing it and eliminating the hazard

Evacuating the affected area and shifting the people to safe places

Commencing rescue operations and simultaneously taking head counts

Treatment such as first aid, hospitalization to injured

Minimizing damage to property and environment

Informing and assisting relatives

Achieving control on the situation

Informing and collaborating with statutory authorities as well as media

Preserving records, organizing investigations and taking steps to prevent

recurrence

Ensuring safety of the works before personnel re-enter and resume work

Resorting normalcy

Disaster management planning is not a substitute for good safety and operative/

maintenance/ design practice. It is one of the aspects of safety management. Every

industry, as mentioned above, should minimize risk by adherence to safe practice

and meeting all legislation.

Disaster management plans are prepared for onsite as well as off-site activities.

Hence, these should be consistent and should complement each other. On-site

disaster management planning is sole responsibility of site occupier. However, in

off- site disaster management the occupier shares the responsibility with district

authorities and the Directorate of Industrial Safety and Health of the district.

Chapter IX


9-4

9.4 REQUIREMENTS FOR EFFECTIVE DMP

The factory should design and implement safety, health and environment (SHE)

policy and show strong commitment of management towards the same

It should prepare framework, guideline to achieve the objectives of SHE policy

Well designed Disaster Management Plan (both On-site and Off-site)

The factory needs to have a disaster management team available round- the- clock

duty. The duty team will include several functions and members depending on size of

the organization and would be headed by a technically qualified as well as a trained

individual

A good Public Address (PA) System in the complex with one standby system to

be used on site or off-site during disaster

Emergency alarms, and approved emergency control centers and assembly

points, etc

List of key personnel, experts, doctors, local authorities/leaders with their

locations and telephone numbers (office, residence as well as mobile)

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

5. All others not taking 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 unit' 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 Management

Round- the- clock availability of trained first-aid personnel at site

Availability of emergency 'Install light' (emergency light) to take care of power

failures.

Provision of antidotes, emergency medicines and beds in nearby hospitals

Chapter IX


9-5

Liaison with outside agencies and civic and government authorities for

mitigation of effects of a disaster

Communication mechanism for raising the alarm as well as that for the

interaction within and outside works

Check -list for sequence of operations to be followed in a situation of disaster

Updating fire and safety manuals (common as well as plant/unit wise);

operation and maintenance manuals, warehouse safety manual

Since, ‘prevention is better than cure’, therefore, more emphasis should be on

preventive measures

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 (Tremcards) for the products transported by road

9.5 IDENTIFICATION/ASSESSMENT OF SITUATION

In a situation of disaster, it is essential to identify it at earliest and judge correctly

and if necessary, the emergency is to be declared.

The Shift In-charge, who is at all times in the fermentation & distillation house,

shall identify situation of the hazard or calamity and report immediately the same

to Distillery Manager and shall sound the emergency alarm provided in each of the

section.

Under this plan, the Distillery Manager or Managing Director should take charge of

the situation. No sooner, he gets the information from Shift In-charge, he shall

move to the place of hazard / calamity. He shall assess the situation and decide to

declare emergency either in that particular section or the entire plant and sound

alarm bells accordingly.

If the emergency is to be declared only in one plant, the other plants will work.

Normally, He shall take immediate steps to control the situation.

9.5.1 Action Plan

He shall initiate all such actions that are essential at the distillation house /

fermentation house / shop floor etc. which would include-

Evacuation of all the personnel on the shop floor who are not required for

controlling the situation, or hazard

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9-6

Immediate grasping of gravity of the problem / hazard and issue or giving of

instructions to the concerned teams as laid down to act in a manner required to

control the situation.

In case of fire, the help of fire force should be immediately sought and put into

action. Simultaneously, the workman trained in the fire fighting procedures

shall be called to extinguish the fire.

Following teams of personnel are to be formed to tackle an emergency situation.

TEAM -A

The Distillery In-charge along with Shift Supervisor of the Distillation Section and

other supervisory staff shall put off the fire or the hazard, as the case may be.

TEAM -B

The Shift Operator of the Distillation Section, the Distillery In-charge, the Excise

Assistant in the office, Security Officer and Labour Welfare Officer shall be

responsible for contacting the fire brigade personnel and arrange for medical

assistance, if required.

TEAM -C

The Maintenance In-charge and his colleagues shall form another team and take

charge of the safety appliances, tools and implements required to control the

situation. They will rush to the spot for taking further instructions from the

declarer / controller of emergency.

TEAM -D

The union office bearers shall form another team and should see that none of the

workmen crowds around or nobody comes nearer to that place of emergency. This

team would also ensure that all the available manual help required by the declarer /

controller of emergency is provided to him.

TEAM -E

The Security Department, the Time Keeper, and Labour Welfare Officer shall form

another team. They shall be available at the office and contact the personnel at the

head office for assistance to the declarer / controller of emergency. It shall be the

responsibility of this team to refer, immediately, to the checklist of names,

addresses, telephone numbers of the authorities such as Director, Joint Director of

Chapter IX


9-7

Industrial Safety and Health, Boiler Inspector of Factory, Commissioner of Police,

local Police Station, Fire Brigade, Company Hospital Doctors, Private Doctors and

Directors of the Industry and contact for assistance, if required.

At all times, one vehicle must be made available at the gate of the factory for

emergency. The hooter siren, that is provided, shall be used when a total

emergency is to be declared for the entire factory.

Figure 9.1: Emergency Organization Structure

9.5.2 Emergency Shut Down of Various Sections

Only hazardous that is expected in the Distillery is fire. The following steps may be

followed

Put off the main supply

Distillation Section

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

TEAM A

Shift In-

charge and

supervisor

WORK INCIDENT CONTROLLER

Communication Team

(Telephone Operators/

Security Inspector

Administration Manager/

Personal Manager)

Advisory Team

Senior Managers

(Technical)

TEAM B

Shift Operator

Security

Officer

Labour

Welfare

Officer

TEAM C

Maintenance

Officer and

technicians

TEAM D

Union

Office

Bearers

TEAM E

Security

Department

Time Keeper

Labour Welfare

Officer

Chapter IX


9-8

Control Room

The security office shall function as a control room as the same is ideally situated

nearer to the main gate and away from the plant. Thus, there shall be no risk as

regard to the vapour of any toxic substances affecting the security office. However,

if there should be a situation where / when the entire premises has to be declared

as emergency, the control room shall operate from the premises which is out side

the main gate.

Since the entire plant is provided with good quality electrical fittings, there should

be no anxiety as regard to switching on or off the motors and no sparks will occur.

However, the declarer / controller of emergency shall decide, depending on the

situation, whether to use generator power or the MSEB Power.

In case the entire lighting has to be switched off to meet such an eventuality, the

stand by generators, provided near the office, shall be started and the floodlights

shall be used to tackle the situation during the nighttime.

9.5.3 Evacuation of Personnel

When a major accident occurs and if there are cases of workmen or supervisory

personnel fainting or losing consciousness or any other type of accident, it shall the

responsibility of Team D to evacuate them and carry in the vehicles to the nearest

dispensary after providing necessary first aid.

There are well-planned roads in and around the plant in the factory premises and

they should choose the safest and shortest route to come out from the plant. The

selected route should be kept clear by Team E at all the times.

9.5.4 Accounting of Personnel

It shall be the responsibility or the Team E to immediately take stock of the

personnel on duty and crosscheck the personnel who have come out of the plant or

have got stuck up. This team shall co-ordinate with Team D to ensure that all the

personnel are accounted for. It is also essential for Team E to counter check the

security if any visitor or transport workers have entered the plant and if so they

should also be accounted.

9.5.5 Controlling the Disaster

The declarer / controller of Disaster shall take steps to train all the teams and shall

draw up an "Action Plan" forthwith. The Distillery In-charge is earmarked as "Work

Chapter IX


9-9

Incident Controller" and shall act as an in-charge at the site of the hazard to control

entire operations.

9.5.6 Implements for Repairs and Safety Gears

The declarer / controller of disaster along with the work incident controller shall

immediately prepare a list of safety gear, tools and other implements required to

control the emergency situations in respect of-

1. Fire

2. Bursting of Boiler

3. Short Circuiting

This list shall be submitted to the Managing Director for approval and the

material should be brought immediately.

Also, It shall be the responsibility of "Work Incident Controller" to ensure that a

separate set of implements, safety gear and tools are placed in a cupboard easily

accessible in the workshop /at the work place and these shall be used only when

emergency is declared in the plant.

9.5.7 Arrangements for Medical Treatment

Most of the workers are trained in first aid and fire fighting procedures. The office

team shall co-ordinate with these workers, trained in the first aid, and shall get

them ready with necessary first aid material so that the injured workers are

attended for first aid immediately and then shifted to the nearest dispensary or

treated in the factory dispensary as the case may be.

9.5.8 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 fire fighting training, the Government Fire Force will give training and for first

aid training. The Red Cross Association will train the personnel.

9.5.9 Law and Order

The Police shall be informed immediately by the declarer/controller of emergency

to ensure that law and order situation is kept under control.

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9-10

The Joint Director/ Assistant Director of Industrial Safety and Health and Pollution

Control Board authorities shall also be informed.

In case of casualties, information should be sent to the nearest relatives of the

affected people.

If information is to be given to public or press, the public relation manager of the

industry is authorized to do the same.

9.5.10 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.

9.6 ON-SITE EMERGENCY MANAGEMENT PLAN

9.6.1 Plant Emergency Organization

1) Designated Persons In-Charge

a) Members of Team A- Distillery In-Charge, Shift Supervisor & Other

Supervisory Staff

b) Members of Team B- Shift Operator, Distillery In-Charge, Excise Assistant,

Security Officer, Labour Welfare Officer

c) Members of Team C- Maintenance In-Charge and his Colleagues

d) Members of Team D- Union Office Bearers

e) Members of Team E- Security Department, Time Keeper and

Labour Welfare Officer

2) Functions of Designated Persons

In addition to the specific responsibilities, assigned to various Team Members,

mentioned earlier following are the general functions to be performed by the

designated persons-

a) To communicate & report the clear position of a Disaster to Key Persons of

the Distillery.

b) To communicate & co-operate with other departments / aspects like

security, safety of victims etc.

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9-11

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.

9.6.2 Plant Risk Evaluation

Distilleries are frequently located in remote areas where public fire

protection is either inadequate or unavailable. Hence, adoption of proper

fire prevention measures and up-to-date maintenance of fire fighting

facilities assume vital importance. Since, Alcohol/Ethanol production units

have been classified, as high hazard occupancy therefore proper firefighting

equipment must be installed in adequate numbers throughout the entire

facility.

Potential Inflammable Raw Materials and Products

Molasses

Fusel Oil

Ethyl Alcohol

Yeast

Urea

Defoaming Oil

9.6.3 Properties of the Material

9.6.3.1 Molasses

Brown colored, sweet smelling, semisolid with medium to very thick consistency

viscous fluid, Corrosive nature with acidic pH. Can cause severe water pollution

problem, if enters in to water body due to high content of oxygen demanding organic

matter. Imparts colour and disagreeable odour, to water.

If exposed through

Inhalation: No harmful effect

Ingestion: Strong taste, no harmful effect

Skin: No any action except physical discomfort

Eyes: Irritation, wash with ample fresh water

9.6.3.2 Yeast

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9-12

If exposed through


Ingestion: Undesirable taste, no any harmful effect

Skin: No any action

Eyes: No effect

9.6.3.3 Urea If exposed through

Inhalation: Disagreeable odour, no any serious effect

Ingestion: Strong taste, seek medical help immediately

Skin: No effect

Eyes: Irritation, wash with fresh water

9.6.3.4 Defoaming Oil

If exposed through-


Ingestion: No harmful effect

Skin: No harmful effect

Eyes: Irritation, wash with fresh water

9.6.3.5 Ethyl Alcohol

Flammable organic colorless chemical with pleasant odour

1, Molecular Weight - 46.1

2. Boiling point - 78 °C

3. L. E. L - 3.3% at 60 °C (Lower Explosive Limit)

4. U. E. L - 19 % at 60 °C (Upper Explosive Limit)

5. Flash point - 55 ° F (13°C)

6. Freezing point - -130 ° C

7. Density - 789 kg/m3

8. Latent heat - 857.9 KJ/kg

9. Liquid specific heat- 2.85 KJ/kg

10. Cp/Cv - 1.13

11. Gas Viscosity - 0.1 x 10-4 N-m/ sec2

12. Gas specific Heat - 343 KJ/Kg

13. Heat Combustion - 269 x 10 2 KJ / kg

If exposed through

Chapter IX


9-13

Inhalation: Pleasant smell with no serious effect.

Ingestion: Extremely dangerous if, ingested in a raw stage, seek medical advice

immediately

Skin: Irritation, wash with water on contact.

Eyes: Very serious effect, wash with ample fresh water and seek medical

help immediately.

9.6.3.6 Fusel Oil

If exposed through Inhalation: Very irritating smell with strong objectionable odour

Ingestion: No harmful effect.

Skin: No harmful effect, wash with ample fresh water

Eyes: Irritation, wash with ample fresh water

9.6.4 Special Handling Requirement

a. During handling of the above materials equipment such as- electrical motor-

pumps, mechanical mixers, automatic weighing arrangement, automatic dosing

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 are provided with adequate operation and safety tools

/equipment.

c. Sufficiently trained and qualified workers are employed in all sections of the

Distillery.

9.6.5 Fire Fighting Requirements

The fire fighting equipments will be comprised of (1) Fire Buckets, (2) Fire

Extinguisher Cylinder; CO2 type; Dry Chemical Powder Type; Class-B & C, (3) Water

hydrants - Emergency Water Hose – would be provided at required places, 4)

water sprinklers 5) ventilation system 6) Smoke Detection system 7) Fire Alarms

Here, various vulnerable locations in the Distillery Unit, probable causes & chances

of occurrence of fire, its Class etc. would be given in-depth consideration.

9.6.5.1 Fire Extinguisher: Extinguishers that can be used on such fire are Foam,

DCP and CO2 type.

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9-14

9.6.5.2 Hydrants: In a distillery, hydrants play the dual role of providing water for

extinguishing tank fires as well as protection against fire exposure of other

equipment in the vicinity. There shall be provision for adequate numbers of

hydrants to protect the entire manufacturing and spirit handling facilities. It will be

placed at storage of final products (RS, ENA and Ethanol), at the fermentation and

distillation section and at biomethanation unit. In addition to hydrants pump of

suitable capacity with flameproof motor and head of 40 meter shall be provided.

Galvanized pipe of 2.5 inch diameter having adequate pressure, shall be provided

9.6.5.3 Automatic Sprinklers: The distillation plant as well as the spirit

storage area shall be protected by open head deluge system. Because of the height

of the distillation plant, sprinklers must also be provided at each floor. All sprinkler

system must be equipped with water flow alarms connected to a central board.

9.6.5.4 Ventilation: Proper ventilation must be provided both in the

distillation plant and in the spirit storage tank area to prevent accumulation of

alcohol vapours in the air. Since, the adequate natural ventilation is available at the

site, the mechanical ventilation is presumed to be insignificant.

However if mechanical exhaust ventilation needs to be provided, it should be to the

order of 1cfm/sq.ft. or floor area, (0.3m3/min.-m2) by fans of adequate capacity

having their suction intake located near floor level to ensure a sweep of a air across

the entire area.

Vapour density of alcohol vapour is 1.59; alcohol vapours, being heavier than air,

tend to settle at ground level, hence either low-level ventilation arrangement (in

case of natural ventilation) or downdraft mechanical ventilation should be resorted

too. An approved, portable, flammable vapour indicator should be used to check

for the presence of alcohol vapours in and around the distillation plant and spirit

storage tank area at regular intervals. Any process plant must be well designed and

provided with adequate protection systems. But safety is ensured when

appropriate training of personnel and proper maintenance of plant facilities are

simultaneously undertaken.

9.6.5.5 Knowledge of Chemicals: Material Safety Data sheet (MSDS) will be

procured or developed for the chemicals and made available to the employees. So,

every worker, working in a particular section, will be acquainted with all the

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9-15

chemicals involved/ handled in the section, their reactions as well as properties

etc.

Also, they will be instructed regarding the chemical spillage and its waste disposal

practices.

9.6.5.6 Alcohol Truck Filling: Truck filling area shall be protected by a complete

deluge system/ water sprinkling system. The fire fighting system will be designed

as per the guidelines prescribed by the respective authority.

9.6.5.7 Use of Fire Fighting Equipment: Every worker will 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.

9.6.5.8 Classification of Fire

Class (A): Fire involving combustible materials like wood, paper, cloth and bagasse

etc.

Class (B): Fire due to liquid materials like oil, diesel, petroleum products and all

inflammables.

Class (C): Fires involving domestic and industrial gases like butane and propane

etc.

Class (D): Metal fires, etc.

Class (E): Electrical fires due to short circuiting, etc.

Every worker shall be given clear-cut information regarding the location of Fire

Extinguishers, Fire Buckets, water Points etc.

Use of Personal Protective Equipment (PPE):

Every worker would be trained and made it mandatory to use the PPE such as

safety helmets, hand gloves, nose mask, goggles etc.

Inspection

Fire alarm panel (electrical) will cover the entire plant. The inspection group

Karkhana, will periodically inspect fire extinguishers in fire stations and machines

and other places. The groups will display emergency telephone number boards at

vital points. The group will regularly carry out general inspection for fire.

9.6.5.9 Procedure for Extinguishing Fire

The following steps will be taken during a fire accident in the system:

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9-16

As soon as the message is received about fire, one of the systems will be diverted to

the place of the fire accident along with a staff member. Simultaneously plant fire

station will be informed by phone / mobile for fire brigades and fire stations of

nearby area. In the meanwhile, the pipe system will be operated to obtain

maximum pressure on output. In case cables are within the reach of fire, power

supply will be tripped and the cables shifted.

First Aid

A first aid center with adequate facilities shall be provided. It shall be maintained

round the clock by a trained personnel.

Safety

The safety wing led by a Safety Manager will meet the requirement of emergencies

round the clock. The required safety appliances shall be distributed at different

locations of the plant to meet any eventualities. Poster/placards reflecting safety

awareness will be placed at different locations in the plant area.

Evacuation Procedure

As the major hazard is only due to fire, which has more or less localized impact no

mass evacuation, procedures are required. Evacuation would involve only the

people working very close to the fire area.

Emergency Control Center

Provision is made to establish an Emergency Control Center (ECC) from which

emergency operations are directed and coordinated. This center is activated as

soon as on–site emergency is declared.

The ECC consists of one room, located in an area that offers minimal risk being

directly exposed to possible accidents.

During an emergency, the Emergency Management Staff, including the site

controller will gather in the ECC. Therefore, the ECC is equipped with adequate

communication systems in the form of telephones and other equipments to allow

unhampered organisations and other nearby facility personnel.

Storage Facility (Tanks)

Spirit storage tanks in the open with brick wall height 1.5 M and above brick wall

chain link fencing 1.5 M. Internal & external plaster with paint. Gate lock

arrangement will be at place for storage section.

Chapter IX


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The inter spacing between two tanks will be as per the safety guidelines. There will

be lightening arresting system, flame-arresting system at the top of the tanks. In

addition to this, there will be condensing system to condense alcoholic vapors.

Since the storage tanks are proposed in the open area, there will be sufficient

natural ventilation available. The karkhana will take care of all safety guidelines

and measures, to minimize the fire hazard at all sub-units of the distillery.

9.6.6 Area Risk Evaluation

a) Contacts at Other Sites- The Sugar Factory Unit

b) Nearby Residence and Population Center- The villages located nearby the

Distillery and cogeneration unit

c) Established Procedures for Notification to Other Sites-

Personal Messaging would do through Telephone, Mobile phone and

Wireless System and notification to other sites

9.6.7 Notification Procedures & Communication Systems:

a) Communication Equipment likes Telephone, Mobile phone, Wireless System

and Personal Messaging would be employed.

b) The families of injured employees would be notified by Telephone, Personal

Messaging and through Verbal Communication.

9.6.8 Emergency Equipment and Facilities

The following emergency equipment & facilities would be provided-

9.6.8.1 Emergency Cupboard

An emergency cupboard will be available in all plant areas. This cupboard should

contain certain number of various personal protective equipment (PPE) for use in

case of disaster. These items kept in the cupboard should be used only during an

emergency and not under normal working conditions.

A printed or typed list of items available in the cupboard should be displayed on

the cupboard. The key of emergency cupboard should be available with the Shift

In-charge.

Table 9.1: List of Emergency Cupboard Items

# Item Quantity

1 Air line mask set 2 sets

2 Self-containing breathing apparatus 1 set

Chapter IX


9-18

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 Flextra 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 weeks by the safety observer to ensure

that all the items are available and that they are in good condition, Items, defective

must be replaced immediately.

Requirement of Equipments and Other Materials

1. Helmets for the Work Incident Controller and others.

2. Megaphone (workable hand-held PA system).

3. Walkie- Talkie/ mobile phones / pagers.

4. Stock of fire fighting material.

5. Note books /pads and pens/ pencils.

6. Sign boards.

Assembly point

Emergency control center

Road closed

9.6.8.2 Emergency Medical Supplies

Sufficient number of First Aid Boxes would be located at appropriate and easily

accessible locations. The First Aid Box would contain Bum Relief Sprays and

Ointments, Bandages, Antiseptic as well as Pain Relief Medicine.

9.6.9 Training and Drills

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9.6.9.1 Location of Fire Fighting Equipment

Every worker would be given clear-cut information regarding the 'location of Fire

Extinguishers, Fire Buckets, Water Points etc.

9.6.9.2 Use of Fire Fighting Equipment

Every worker would be trained with respect to nature and utility of Fire Fighting

Equipment, its type and class of fire for which it is to be used.

9.6.9.3 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.

9.7 OFF-SITE EMERGENCY MANAGEMENT PLAN

Since the only hazard that is expected in the distillery industry is fire and is normally

contained within the premises no Off-Site Emergency Plan is needed. However, in case

the hazard spreads out-side the premises Team E shall communicate to the District

Magistrate, Commissioner of the Police, Control Room and inform the situation as Off-

Site Emergency.

It shall be the responsibility of the Police Personnel to look after the law and order,

traffic control, evacuation of workers and other personnel.

They should also advise, through public address system, the localities that are

likely to get affected and the steps to be taken.

9.7.1 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 will also trained, on simple protective methods, through

demonstrations.

Chapter IX


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Table 9.2: Emergency Action Code

For Fire of Spillage of Hazardous Substances

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

Notes for guidance – FOG – In the absence of fog equipment a fine spray may be used. DRY AGENT – Water must not be allowed to come into contact with the substance at risk. V –Can be violently or even explosively reactive. FULL – Full body protective 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 water body

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 X


10-1

CHAPTER X

PROJECT BENEFIT ANALYSIS

10.1 Project Benefits

The sugar industry occupies a place of pride in rural economy. Most of the sugar

industries are located in rural areas providing employment to rural masses. The

molasses is used mainly for production of ethyl alcohol. The demand of alcohol for

industrial, potable & fuel alcohol in Maharashtra as well as in whole country will

increase significantly in coming years. Alcohol has assumed very important place

in the country’s economy. It is vital raw material for a number of chemicals. It has

been a source of large amount of revenue by way of Excise Duty levied by State

Government on Alcoholic liquors. It has a potentiality as fuel in the form of power

alcohol for blending with petrol in the ratio of maximum 26:74.

10.1.1 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 in India, as this is the

most major cause of environmental 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

Chapter X


10-2

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.

The proposed 30 KLPD anhydrous alcohol plant will contribute in fulfilling the

ethanol requirement of Maharashtra and neighboring deficit states. Recently

declared price of ethanol of Rs. 27/L. will help the sugar factory to pay attractive

cane price to the member farmers. This proposal is targeted at enhancing benefits

to the sugarcane farmers. The industry is established in the remote region of the

state. The industry helps to develop road and transportation facilities in the

region. The industry on expansion will provide direct and indirect employment

local rural persons. Both sugar unit and distillery units are complimentary to each

other in the development of the industrial activity in the region. This may develop

growth of agriculture and industrial activities in the region increasing the socio-

economic status of the farmers.

10.2 IMPROVEMENT IN THE SOCIAL INFRASTRUCTURE

Shree Rameshwar Sahakari Sakhar Karkhana Ltd., is a Co-Operative sugar factory.

The sugar factory has already initiated several activities for the development of the

region. Some of the prime activities are as follows.

Factory has provided cane seed of improved varieties to cane growers

through the agricultural set up at concessional rate

Factory has improved the internal roads in the area of operation

Factory is regularly providing technical guidance for cane development

programme at farmer’s field.

Factory has provided facilities such as housing, canteen, and other

welfare activities for its workers/share holders

Chapter X


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Factory has established “Sakhar shala” for children of cane harvesting

workers.

Factory is arranging cultural programs and sports tournaments for

employees and cane growers of area of operation.

Thus, the sugar factory will pass on the benefits due to the distillery to its

shareholder farmers and to the entire society of the region.

10.3 ENVIRONMENTAL BENEFIT ANALYSIS

10.3.1 Advantages

Raw material i.e. molasses and bagasse is readily available from the sugar

factory

Hence, saving of raw material transportation cost and fuel,

Problem of molasses and bagasse disposal issues will get solved

Generation of energy (Biogas) from wastewater i.e. spentwash

Utilization of Biogas and thus saving more bagasse for off-season that will

be utilized for cogeneration activity

10.3.2 Benefits of Wastewater (spentwash) Treatment

Factory has decided to install bio-methanation followed by Bio-composting

treatment System for spentwash treatment that has following advantages:

1. Bio-gas generated from bio-methanation unit could be used for Boiler as a

fuel and save bagasse consumption

2. Production of good quality bio-compost (organic manure)

3. Increase in fertility of soil (Physical and biological)

4. Achieve zero discharge in inland /surface water

10.4 EMPLOYMENT GENERATION

A. General Staff Requirement for Distillery Unit

Sr. No. Employment Description Requirement

1. Distillery Manager 0 1

2. Shift Chemist 3+1

3. Assistant Engineer (Elect./Mechanical) 01

4. Lab. Chemist 3+1

5. Fermentation Operator 3+1

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10-4

6. Fermentation Attendant 3+1

7. Distillation Operator 3+1

8. Wireman /Electrician. (For distillery & ETP) 02

9. Fitter 02

10. Warehouse Attendant 02

11. Laboratory Attendant 01

12. Unskilled Workers 05

B) Staff For Bio-composting Process , Biodigester

1. ETP -In charge 01

2. Chemist/ biodigester supervisor 01

3. Lab. Attendant 01

4. Aerotiller/Excavator Operator 02

5. Pay Loader Operator 02

6. Spraying Supervisor 02

7. Spraying Workers (Unskilled) 08

8. Trimming Staff (Unskilled) 16

C) Administrative Staff

1. Accountant 01

2. Clerk 02

3. Watchmen 3+1

Supporting Staff 2-5

D. Safety Officer 01

Addition to this the project will generate many indirect employment opportunities

to the local people.

Chapter XI


11-1

CHAPTER XI

DISCLOSURE OF CONSULTANT

11.1 CONSULTANT

Vasantdada Sugar Institute (VSI) Manjari (Bk), Pune 412 307 Maharashtra

Phone: (020) 2690 2100, 2690 2343/7/6 Fax: (020) 2690 2244

Web Site: www.vsisugar.com E-mail: [email protected]

National Accreditation Board for Education and Training (NABET) which works

under the Quality Council of India (QCI) has accorded provisional accreditation to the

Institute for the EIA consultancy services. VSI is accredited for sugar (category B),

distillery (category A) and thermal power project (category B).

The Institute is a recognized Research and Development center by Department of

Scientific and Industrial Research (DSIR), Ministry of Science and Technology,

Government of India.

The Department of Environmental Sciences of VSI is Post Graduate (PG) and Doctoral

course center (i.e. MSc & PhD), affiliated with ‘University of Pune’.

The activities of the Department are represented in the following chart.

Vasantdada Sugar Institute

Department of Environmental Sciences

Teaching and Training

Research and Development

Extension and Consultancy Services

http://www.vsisugar.com/

mailto:[email protected]

Chapter XI


11-2

11.2 The project team of EIA study

Name Designation Role / Expertise

Dr. DS

Nimbalkar

Scientist and Head

Department of

Environmental Sciences,

VSI

EIA coordinator

FAE: Water Pollution, Solid waste and

noise

Collection and interpretation of data and

impact assessment, formulation of EMP,

for expert areas of water pollution, noise

and solid waste management; overall

coordination of project

S.C. Deshmukh

Director General

Vasantdada Sugar Institute, Manjari (Br.)

FAE: Socio Economic

Guidance for data collection and analysis; impact assessment, formulation of EMP

A.B.

Deshmane

Scientific Officer,

Department of


VSI

FAE: Ecology and Biodiversity

Data interpretation and impact

assessment, formulation of EMP for the

expert area of ecology and biodiversity;

Assistance in coordinating all project

activities

E.P. Alhat Project Assistant

Department of


VSI

FAE: Water Pollution, Solid waste

Data interpretation, impact assessment

and formulation of EMP for the areas of

water pollution, noise, solid waste;

Assistance in coordinating

environmental monitoring and analysis

activities

S.V. Patil Head and Technical

Advisor Department of

Alcohol Technology, VSI

FAE: Water pollution and risk

management

Impact assessment and design of EMP

for water pollution and preparation of

risk management plan

Chapter XI


11-3

R.A.

Chandgude

Technical Advisor

Department of Sugar

Engineering, VSI

Air pollution prediction and control

Formulation of EMP for the same

Dr. Pravin

Saptarshi

Adjunct Professor

Department of

Environmental Science,

VSI

Interpretation and formulation of

Socioeconomic Environment

DB Phonde Department of Soil

Sciences, VSI

Expert in soil and soil conservation, Role

in impact prediction, preparation of EMP

Dr. DC

Meshram

Department of Geology,

University of Pune

Empanelled expert

FAE: Geology and soil

Swapnil

Awghade

Land use

Empanelled expert

Interpretation of land use data and local

topographical information, impact

M.G. Patil Head of Civil Engineering

Department, VSI

Land use studies, impact assessment and

formulation of EMP for the same

H.S. Kolte Project Assistant;

Dept of Env Sci., VSI Monitoring of air, water, soil, noise and

analysis; data collection for ecology and

biodiversity, involved in report writing

and preparation of presentations

V.P. Patil Research Assistant

Dept of Env Sci., VSI Monitoring of air, water, soil, noise and

analysis, involved in report writing and

preparation of presentations

Anand More Project Assistant

Dept of Env Sci., VSI Analysis of environmental samples and

Report preparation, involved in report

writing and preparation of presentations

KJ Divekar Project Assistant

Dept of Env Sci., VSI Analysis of environmental samples and

report preparation


1

Existing sugar factory ETP Green belt view in existing sugar factory

Green belt view in existing sugar factory


2

Photographs showing proposed distillery and compost site

Documents

Environmental Impact Assessment Reportenvironmentclearance.nic.in/writereaddata/EIA/23102015TDI7F8H7FULLEIA... · Environmental Impact Assessment Report Molasses Based 30 KLPD Distillery