ENVIRONMENTAL MANAGEMENT PLAN Under Para 7(ii) of EIA

NANGLAMAL SUGAR

COMPLEX

NANGLAMAL SUGAR COMPLEX

EXPANSION OF EXISTING DISTILLERY FROM 120.0 KLPD TO 150 KLPD (MOLASSES BASED DISTILLERY) ALONGWITH 8.0 MW POWER COGENERATION AT VILLAGE: NANGLAMAL, TEHSIL: SADAR, DISTRICT: MEERUT, STATE: UTTAR PRADESH OF M/s NANGLAMAL SUGAR COMPLEX (A UNIT OF MAWANA SUGAR LTD)

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ENVIRONMENTAL MANAGEMENT PLAN

Under Para 7(ii) of EIA Notification dated 14th

September, 2006 and subsequent amendments

For

Expansion of Molasses based distillery

From 120 KLPD to 150 KLPD along with co gen

power 8 MW

By

Modernization and efficiency improvement within

existing plant

At

Village-Nanglamal, Tehsil-Sadar,

District-Meerut, State-Uttar Pradesh

Applicant:

M/s. Nanglamal Sugar Complex Distillery Division (a Unit of Mawana Sugar Ltd)

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ENVIRONMENTAL MANAGEMENT PLAN 1.0 Introduction

Industrial development is associated with a few positive and negative impacts on the

environment. The negative impacts should not hinder industrial development but they should

be properly mitigated.

An environmental management plan (EMP) has been prepared for the expansion of existing

distillery to minimize negative impacts and is formed on the basis of prevailing

environmental conditions and likely impacts of this project on various environmental

parameters. This plan will also facilitate monitoring of environmental parameters.

Preparation of EMP is required for the formulation, implementation and monitoring of

environmental protection measure. EMP includes schemes for proper and scientific treatment

and disposal mechanism for air, liquid and solid hazardous pollutants. Apart from this, green

belt development, safety aspect of the workers, noise control, fire protection etc. are also

included in it. The various components of the EMP are outlined in subsequent sections.

1.2 Purpose of Environmental Management Plan

Various purposes of the environmental management plan are:

To treat and dispose off all the pollutants viz. air, liquid, gaseous and solid waste so as to

meet statutory requirements (Relevant Pollution Control Acts) with appropriate

technology. It will help to reduce the adverse effect on human being as well as on

environment due to the proposed activity.

To support and implement work to achieve environmental standards and to improve the

methods of environmental management.

To promote green-belt development.

To encourage good working conditions for employees.

To reduce fire and accident hazards.

Budgeting and allocation of funds for environment management system.

To adopt cleaner production technology and waste minimization program.

1.3 During Construction Phase

Environmental pollution during the expansion of existing distillery is inevitable during the

construction phase but impact would be insignificant. The project proponent should take

appropriate steps to control pollution during construction phase.

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1.4 During Construction Phase

Operation phase of any industry being longer in duration and because of its potential to

create continuous impacts is quite important from the impact point of view. Comprehensive

and effective EMP has to be prepared and implemented to safe-guard environmental

concerns during operation phase of any unit.

1.5 Air quality management

(A) Stack Emission Control

ESP (Electrostatic Precipitator) with stack of adequate height (75 m) is already

installed with the boiler (47 TPH) to control the particulate and gaseous emissions, as

per CPCB guidelines. No new boiler is proposed as the existing will cater to the

needs after expansion by modernization also.

All the Stack is having stack monitoring facility (SMF) consisting of sampling port-

hole, platform and access ladder. ESP limits the particulate emission from the stack

within the permissible limit 50 mg/Nm3.

CO2 generated during the fermentation process is being/will be recovered by CO2

Scrubbers and sold to beverage & packaging industry.

Stack height for D.G. set is being/will be maintained as per CPCB norms.

In order to carry out efficient dispersion of gaseous pollutants, desired velocity of

emission shall be ensured through proper functioning of FD/ID fans.

The company has established safe shutdown procedure during emergency like

APCD failure.

Online stack monitoring system is already installed with the existing stack.

Green belt development and Scientific Plantation in and around the plant at possible

sources of fugitive emissions to reduce dust and gaseous pollutants.

TABLE – 1.0,

EXISTING STACK EMISSION DETAILS

Sr

No

Particular Details

1 Boiler Details 47 TPH Slop fired boiler

2 Fuel Used Conc. Spent wash & bagasse

3 Stack Height 75 m

4 Internal Diameter (Top) (m) 3.0 m

5. Exit gas velocity 9.0 m/s

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6. Flue gas temperature 134°C

7. Volumetric Flow ( Nm3/Hr ) 168195.90

( 46.72 Nm3/Sec)

8. Emission gm/sec

a. PM 2.24

b. SO2 6.88

c. NO2 3.02

B) Fugitive emission control

To control fugitive emissions following measures are being/ will be adopted.

Regular inspection of valves, inlet pipes, outlet pipes to prevent any kind of gaseous

leakage.

Ambient air quality is being/ will be regularly monitored, so as to keep a check on

the emissions of different pollutants.

Regular water sprinkling is being/will be carried out on roads and dust generating

areas.

Covered conveyor belts is being/will be used for raw material & fuel transportation.

Roads within the premises are concreted /paved to avoid vehicular emissions.

All transportation vehicles carry a valid PUC (Pollution under Control) Certificate.

Proper servicing & maintenance of vehicles is being/will be carried out.

Ambient air quality will be regularly monitored.

Green Belt around the periphery and within premises already exists and the same

will be maintained after proposed installation.

C) Odour Management

Adequate greenbelt all around the periphery of the plant.

Odourless technology of incineration is being used and bio - compost area is being

100 % covered.

Efficient CO2 scrubbing to avoid carryover of alcohol vapours & other fumes.

Regular steaming of all fermentation equipment.

Longer storages of any product/by-products will be avoided & use of efficient

biocides to control bacterial contamination.

Regular use of disinfectants in the drains to avoid generation of putrefying micro-

organisms.

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1.6 Noise Quality Management

Following precautionary measures is being / will be adopted to control the noise level:

Noise generating sources and their platforms is being / will be maintained properly to

minimize noise vibrations generated by them.

Personnel working near the noisy machines in different plant locations is being / will be

provided with well-designed ear muffs / plugs (effective noise reduction 20 -25 dB).

D.G sets are already provided with acoustic to control the noise level within the

prescribed limit.

Proper maintenance, oiling and greasing of machines at regular intervals is being/will be

done to reduce generation of noise.

Green belts developed and maintain to act as a noise barrier.

Noise barriers / shields in the form of walls, beams will be provided around the units

wherever found feasible

Training to personnel is being / will be imparted to generate awareness about effects of

noise and importance of using PPEs.

1.7 Water Quality Management

The project is being/will be based on “Zero Effluent Discharge”.

Spent wash generated from the analyser column during the operation, is being / will be

concentrated in Multi – Effect Evaporator (MEE). Concentrated Spent Wash is

being/will be incinerated as fuel in incineration boiler along with auxiliary fuel like

bagasse.

Spent lees, cooling tower, boiler blowdown is being/will be treated in CPU and recycled

within the process.

Process condensate from MEE will be treated and recycled back in the process.

Domestic waste water is being/will be disposed off in soak pit via septic tank.

Regular monitoring of water quality will be carried out

During molasses based operation after expansion, fresh water requirement will be

600 KLD. Water as a resource will be recycled at each possible step of the process to

achieve the maximum recycling and reducing the water consumption up to 4.0 – 5.0

KL/KL of Product, for this latest technology and methodology will be adopted to conserve

and reuse the resources.

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TABLE – 1.1,

Water requirement for proposed expansion of distillery

SL Particulars Fresh water requirement

(KLD) Remark

1

Industrial

requirement 580 (@ 3.86 KL/KL of

product) (Net fresh water requirement after recycling)

Maximum fresh water

requirement of water in day will be 600 KLD

(@ 4.0 KL/ KLD of product) during

operation phase. 3 Domestic water requirement

20.0 KLD

Table: 1.1 (A),

WATER CONSUMPTION DETAILS FOR 150 KLD DISTILLERY PLANT Propose Existing Water

Consumption

(KLD)

Water

Consumption after

expansion

(KLD)

Remark

INDUSTRIAL

Process 818 946 Additional water requirement will be cater

from treated water CPU. No additional water will be required.

Boiler 110 110

Cooling 671 699

Washing 30 30

Gardening 15 15

Other 00 00

Total Industrial 1644 1800

DOMESTIC 20 20

Table: 1.1 (B),

EFFLUENT GENERATION DETAILS FOR 150 KLD DISTILLERY PLANT

Propose Existing Effluent

Generation (KLD)

Existing Effluent Generation

after expansion (KLD)

Process (Spent Wash) 960 1116

Process (Spent Lees) 144 180

Boiler 32 32

Cooling 110 110

Washing 30 30

Other 11 11

Total Industrial 1287 1479

DOMESTIC 12 12


EXPANSION OF EXISTING DISTILLERY FROM 120.0 KLPD TO 150 KLPD (MOLASSES BASED DISTILLERY) ALONGWITH 8.0 MW POWER COGENERATION AT VILLAGE: NAGLAMAL, TEHSIL: SADAR, DISTRICT: MEERUT, STATE: UTTAR PRADESH OF M/s NAGLAMAL SUGAR COMPLEX (A UNIT OF MAWANA SUGAR LTD)

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Fig : 1.1, Water Balance for 120 KLD based Operation

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Fig : 1.2, Water Balance for 150 KLD based Operation


EXPANSION OF EXISTING DISTILLERY FROM 120.0 KLPD TO 150 KLPD (MOLASSES BASED DISTILLERY) ALONGWITH 8.0 MW POWER COGENERATION AT VILLAGE: NAGLAMAL, TEHSIL: SADAR, DISTRICT: MEERUT, STATE: UTTAR PRADESH OF M/s NAGLAMAL SUGAR COMPLEX (A UNIT OF MAWANA SUGAR LTD)

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1.7.1 Spent Wash Treatment Scheme

The distillery is being /will be based on “ZERO EFFLUENT DISCHARGE”.

Spent wash generated is being/will be concentrated in Multi-effect evaporator and then

used as fuel in incineration boiler (For 25 Days) and for rest 5 – 6 days, spent wash

generated is being / will be concentrated in MEE then utilised in bio composting. Bio

composting is being / will be done in covered shed.

Spent wash treatment scheme – 1 (For 25

days)

Spent wash treatment scheme – 2

(For 6 days)

Spent wash generated from the analyzer

column during the operation, is being /

will be concentrated in Multi – Effect

Evaporator (MEE). Concentrated Spent

Wash is being/will be incinerated as fuel

in incineration boiler along with auxiliary

fuel like bagasse/Other biomass.

Spent wash generated is being / will

be concentrated in MEE and

Concentrated Spent Wash is

being/will be used in bio -

composting.

After proposed expansion and modification, same scheme will be adopted for 150

KLD distillery capacity.

a) Standalone Multi - effect Evaporation Section:

The spent wash coming from distillation section will be fed in to first calendric of

the evaporator section. There are six calendric installed as per design to concentrate

the dissolved solids. Suggested treatment scheme is a four FF + Finisher

Evaporation Plant for spent wash Evaporation. The following points elucidate the

basic working principle:

Shell & Tube type Evaporators with highly efficient liquid distributor working on

the principle of Falling Film Evaporation have been used, with Plate Type

Preheaters for preheating of FEED stream which serves the purpose of energy

conservation.

Analyser vapour is fed to the first effect evaporator shell side at the given pressure

and temperature as the heating medium.

The Feed from the Feed balance tank is taken to make the best heat recovery.

The Feed after getting heated to the predetermined temperature in preheater is fed

from the first effect evaporator which is Falling Film Evaporator -1

Vapours generated in 1st effect VLS (Vapour Liquid Separator) are used as heat

source in the 2nd effect and from 2nd to third and so on.

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The product at the desired concentration of TS is obtained at the outlet from the

final effect,

A Shell & tube type Multi-pass Surface condenser is employed for condensing the

shell side vapours.

The Pure and the process condensate are collected in receiving vessels.

Highly efficient operating pumps are provided for pumping the required fluid.

The operation of the plant is under vacuum. Vacuum is created with the help of a

water ring vacuum pump.

The plant has high level of automation to get consistent output at required

concentration.

The system operates under vacuum. Water-ring vacuum pumps are used to

maintain a desired vacuum. Cooling water from cooling tower is used in the surface

condensers for condensing the vapours.

b) Incineration boiler: The concentrated spent wash along with bagasse/other is being

/ will be used as fuel. This fuel is burnt in Incineration boiler of 47 TPH to generate

high pressure steam.

c) Bio composting: Approx.: 20 Acre of Bio composting area is being covered and bio

composting is being / will be done as per CPCB standard.

1.7.2 Distillery Effluent Treatment Scheme - Process Condensate Treatment Plant

The Effluent treatment scheme is as mentioned below: -

A. Process Condensate Treatment and Recycling System:

Ultrafiltration (UF) System

The company is using membrane technology in the design of water & wastewater

recycling systems. This can be done with different membrane types and different

selectivity of membranes.

• Ultrafiltration removes the following RO fouling materials like:

• Particulate matter, suspended solids, bacteria and viruses.

• Colloidal materials (non-reactive silica, silt etc.)

• High molecular weight organic compounds

Ultra-filtration has evolved as a one-stop solution for most of the pre-treatment

requirement for Reverse Osmosis (RO). Pre-treatment with ultra-filtration prior to reverse

osmosis ensures consistent, cost effective RO performance, by producing water with silt

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density index (SDI) less than 5.0. The UF system prevents RO fouling caused by

particulate matter, colloids and microorganisms. This minimizes RO cleaning protocols

and reduces operating pressures and enhances membrane life.

The feed water is disinfected and suitably conditioned with coagulant prior to

entering the UF. The feed water is pumped to the UF units through feed strainers to

prevent the entry of large particulate matter into the membrane. The feed water enters the

UF module either from the side bottom or side top port. The suspended impurities are

retained inside the fibre lumen during filtration. The product water comes from the top

port and collected in the product water storage tank. Service cycle is followed by a

backwash after a set interval of time or based on the increased trans-membrane pressure.

During backwash, the UF product water is pumped in the membrane in the reverse

direction. The cleaning takes place through the fibre in outside to in configuration. The

backwash water enters from the permeate port, the waste is taken out either from the top

side or bottom side port. The service inlet and backwash outlet can be alternated from top

and bottom for uniform distribution and removal of suspended impurities along the

length of fibre. To check the integrity of fibres, transparent pieces shall be installed above

individual module. Oil and particulate free plant air at a pressure of 1 bar shall be

available to perform the air integrity test.

Clean in Place (CIP) may be required in case the membranes become heavily fouled due

to sudden off spec water quality or overdosing and carryover of coagulant. Provision

shall be made in the system to perform CIP. A common CIP system can be used for RO

and UF.

RO System

The permeate of ultra-filtration is stored in RO feed tank and SMBS is dozed in order to

Remove any residual free chlorine, as the free chlorine is Harmful for the membranes.

Special Anti-scalant are dosed to make sure that the Feed Water Scaling tendency on the

Membranes are controlled within the limits. The system comprises of dosing pump and

solution preparation tank.

The provided Micron Filter unit removes fine suspended solids, which have escaped from

upstream units. The unit can remove fine solids up to 5 µ, which if carried over can clog

the R.O. membrane. The unit is fitted with special type of cartridge, which is having

more dirt holding capacity compared to other standard type of cartridges. The cartridges

are fitted in SS housing. Utmost care has been taken for designing of RO unit. The

system has been designed for an over all of 65 – 70% recovery. The RO systems comprise

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of R.O. membranes housed in FRP Pressure tubes. Necessary instrumentation is

provided to monitor the operation of the system. Almost all components / equipment’s

of the R.O. Unit are pre-engineered, pre-wired, pre-tested and ready for use after giving

necessary interconnections. The RO block is totally skid mounted. The characteristics of

CPU at inlet and outlet are as mentioned below: -

Table 1.2, Characteristics of ETP inlet and outlet

Particulars CPU Inlet CPU Outlet Prescribed Standards for inland surface waters

pH 3.5 7.03 6.5-8.5

Total Suspended

Solids(mg/l)

Nil Nil 100

Total Dissolved

Solids (mg/l)

565 40.5 Not specified

BOD(mg/l) 1245 2.3 30

COD (mg/l) 2815 5.0 250

Table 1.3, Quantity of effluent generated & treatment capacity Quantity of effluent generated from distillery process and sent to CPU

Existing 120 KLD After expansion to 150 KLD

1328 KLPD

(736 KLD MEE condensate+ 32

KLD boiler blow down+ 110 KLD

CT blow down + floor washing -30

+ DM reject – 11 KLD)

1523 KLPD

(856 KLD MEE condensate+ 32

KLD boiler blow down+ 110 KLD

CT blow down + floor washing -30 +

DM reject – 11 KLD)

1.1 ENVIRONMENT MANAGEMENT PLAN

Particulars Details

Air Management ESP with stack height (75 m) is installed with the boiler (47

TPH) to control the particulate and gaseous emissions, as per

CPCB guidelines. No new boiler is proposed as the existing

will cater to the needs after expansion by modernization also.

CO2 generated during the fermentation process is being/ will

be recovered by CO2 Scrubbers and sold to beverage &

packaging industry.

Stack height for D.G. set is being/will be maintained as per

CPCB norms.

All the internal roads are already asphalted and swept

regularly to avoid vehicular emissions.

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Greenbelt has already been developed inside and at the

periphery of the plant premises.

Regular monitoring is being / will be done to ensure ambient

air quality standards.

Online Stack Monitoring System is already installed.

Water & waste

water Management

The project is being/will be based on “Zero Effluent

Discharge”.

Spent wash generated is being treated through two treatment

scheme. Details are as follows:

Spent wash treatment

scheme – 1 (For 25 days)

Spent wash treatment

scheme – 2 (For 6 days)

Spent wash generated from

the analyzer column during

the operation, is being / will

be concentrated in Multi –

Effect Evaporator (MEE).

Concentrated Spent Wash is

being/will be incinerated as

fuel in incineration boiler

along with auxiliary fuel like

bagasse/Other biomass.

Spent wash generated is

being / will be

concentrated in MEE and

Concentrated Spent Wash

is being/will be used in

bio - composting.

After proposed expansion and modification, same scheme

will be adopted for 150 KLD distillery capacity.

Spent lees, PR lees is being/will be recycled within process.

Cooling tower, boiler blowdown is being/will be treated in

CPU and recycled within the process.

Process condensate from MEE will be treated and recycled

back in the process.

Regular monitoring of water quality will be carried out.

Noise Management Personal Protective Equipment like earplugs and earmuffs is

being / will be provided to the workers exposed to high noise

level.

D.G. sets are being provided with acoustic enclosures to

control the noise level within the prescribed limits.

Proper maintenance, oiling and greasing of machines at

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regular intervals is being / will be done to reduce generation of

noise.

Greenbelt inside the plant premises and at the plant boundary

has been developed and the same will be maintained.

Regular monitoring of noise level is being / will be carried out

and corrective measures in concerned machinery are

being/will be adapted accordingly to the possible extent.

Solid & Hazardous

Waste Management

Concentrated spent wash is being/will be burnt in boiler along

with auxiliary fuel.

Fly ash generated from the boiler is being/will be converted

to granules and then is being / will be utilized as manure.

Used oil generated from the plant machinery/ gear boxes as

hazardous waste is being/will be sold out to the CPCB

authorized recycler.

Green Belt Development / Plantation

Out of the total plant area of 22.26 Ha, ~33% (i.e. 7.34

hectares) has already been developed under greenbelt &

plantation.

Greenbelt has been developed as per Central Pollution Control

Board (CPCB) guidelines.

Native plant species have already been planted in consultation

with local horticulturist.

Odor Management Adequate greenbelt all around the periphery of the plant and

in odor prone areas is already maintained.

Efficient CO2 scrubbing to avoid carryover of alcohol vapors &

other fumes.

Regular steaming of all fermentation equipment.

Longer storages of any product/by-products is being / will be

avoided & use of efficient biocides to control bacterial

contamination.

Regular use of disinfectants in the drains to avoid generation

of putrefying microorganisms.

Documents

ENVIRONMENTAL MANAGEMENT PLAN Under Para 7(ii) of EIA