GANGAMAI INDUSTRIES AND CONSTRUCTIONS LTD. (GIACL)environmentclearance.nic.in › writereaddata › EIA › 07012019... · 2019-01-07 · SRSL Shree Renuka Sugars Ltd. SS Suspended

ENVIRONMENTAL IMPACT ASSESSMENT (EIA) REPORT

FOR

EXPANSION OF MOLASSES DISTILLERY 30 KLPD TO 60 KLPD(INTEGRATED PROJECT COMPLEX OF 5500 TCD SUGAR FACTORY,

32 MW CO-GEN PLANT & 30 KLPD DISTILLERY)

GANGAMAI INDUSTRIES ANDCONSTRUCTIONS LTD. (GIACL)

BY

AT : NAJIK BABHULGAON, POST : RAKSHI,

TAL.: SHEVGAON, DIST.: AHMEDNAGAR (MS)

2018-2019

EQUINOX ENVIRONMENTS (I) PVT. LTD.,

PREPARED BY

ENVIRONMENTAL; CIVIL & CHEMICAL ENGINEERS, CONSULTANTS & ANALYSTS,

KOLHAPUR (MS)

E-mail: [email protected], [email protected]

An ISO 9001:2015 & QCI NABET ACCREDITED ORGANIZATION

P-25-GIACL-EXP-DISTILLERY-32018

GIACL

G IACL/Disti tterv I 2oL8-Ls I 5 o ITo,

The Member Secretary, (lndustry - ll)Expert Appraisal Committee (lndustry-ll),

Ministry of Environment, Forest and Climate Change (MoEFCC),

lndira Paryavaran Bhavan,

2nd floor, Vayu wing,Aliganj, Jorbagh Road,

New Delhi - 110003

Sub.: Grant of Environmental Clearance (EC) in respect of proposed expansion of molasses based

distillery from G0 KLpD to 150 KLPD (expansion by 90 KLPD) by - M/s. Gangamai lndustries

And Constructions Ltd. Najik Babulgaon, Post- Rakshi, Tal.: Shevgaon, Dist. Ahmednagar,

Maharashtra.

Ref.: t. your letter bearing No. F. No. J11011/97/2o78-l\ ll (l) dated 1,4.o4.2oL8.(Refer copy at

Enclosed - l)

2. Public Hearing Conducted on Dated 77.70.20L8

Dear Sir,

This has reference to the online application in Form-l format submitted to MoEFCC; New

Delhi for grant of ToRs. Same was w.r.t. our expansion of molasses based distillery from 60 KLPD to

150 KLPD (expansion by 90 KLPD) in existing premises of 5500 TCD sugar factory, 32 MW co-gen

plant and 60 KLpD molasses based distillery by M/s. Gangamai lndustries And Constructions Ltd.

Najik Babulgaon, Post- Rakshi, Tal.: Shevgaon, Dist. Ahmednagar, Maharashtra.

Subsequently, our application was granted standard ToR's on 14.O4.2OL8. Refer Enclosure - !

for the standard ToR's given by MoEFCC there under directions were given to conduct public

hearing. Thereafter, as per MoEFCC Notification No. S.O. 1533 (E) dated 14.09'2006 and

amendments thereto; public hearing was conducted on L7'1O'2OL8'

Accordingly, a final Environmental lmpact Assessment (ElA) report has been compiled by

incorporating the minutes of public hearing meeting and is being submitted herewith online' A hard

copy of the EIA report along with a CD containing soft copy of the same shall be submitted after

getting the acknowledgement of online submission.

Sir, you are requested please to consider our proposal at the earliest and accord an

Environmental Clearance (EC)to our proposed expansion project.

Please do the needful and oblige.

:Ti:-- Thanking you.

,#il&;,sl fl.ileglo la I

S\ot. rsrneln/F,,\h#/Encl.:. .As above

GiANGAMAInDusrRrff atgoTT5lrryrffiE.

Yours faithfully

,irh"fthedekarI@rti"t Financial officer)

Operations : Harinagar, Najik Babhulgaon, Post : Rakshi, Tq. Shevgaon, Dist. Ahmednagar (M.S.) - 414502, Telefax: +91 (02429) - 217251,Mob.: +91 - 9921994999, 9921995999, E-mail: [email protected], [email protected]

Corporate Office : 2* Floor, Tapadia Terraces, Adalat Road, Aurangabad431001. Tel.: +91 (240) 2333933, 2332572,F ax: +91'(240) 2333335, Email: [email protected]

ACKNOWLEDGEMENT I am extremely thankful to the management of Gangamai Industries And Constructions Ltd. (GIACL); Najik Babhulgaon, Tal.: Shevgaon, Dist.: Ahmednagar for entrusting assignments of the EIA studies and Environmental Clearance (EC) procurement in respect of proposed expansion project of molasses based distillery. It was indeed a great experience to have interactions, involvement and discussions with the management and technical experts of GIACL. Their knowledge and co-operation as well as support given during the draft EIA Report preparation impressed me a lot. Sharing of thoughts and planning with Mr. Ranjeet Mulye alias Bhaiyasaheb; Managing Director was always an interesting thing during the course of assignment. Thank you very much sir! Further the support and assistance from Mr. Vishnu S. Khedekar, Chief Financial Officer was of very much importance. Thanks for your co-operation sir! Prompt response as well as help from Mr. I. B. Inamdar, Distillery In-charge during providing certain information, documentation and data related to the production, processes and details of manufacturing is duly appreciated. Also, the co-operation of staff of GIACL Sugar Factory is duly acknowledged here. I must thank our Technical Directors and In-house Functional Area Experts (FAE) Prof. (Dr.) Jay Samant, Dr. Anuradha J. Samant, as well as our other Empanelled Functional Area ExpertsDr. J. B. Pishte, Mr. Vinod Sahasrabuddhe, Mr. J. M. Gadgil, Mr. B. S. Lole and Mr. Vinaykumar Kurakula for their able and timely contributions in the EIA studies and report preparation. Despite their busy schedules in the universities, colleges and own professions, they were always available, on time, for the necessary inputs; field visits and discussions. My staff of the EIA Study Cell here must receive a commendation and credit for all the in-house management and inputs during the monitoring, report preparation and presentations. The In-house experts of various functional areas have contributed their best. Last but not the least, the contributions from my non-technical staff members and laboratory team is also duly appreciated here.

DR. SANGRAM GHUGARE Chartered Engineer

Chairman & MD Equinox Environments (India) Pvt. Ltd. (EEIPL); Kolhapur

CAUTION

The information, data, figures, flow charts and drawings in respect of manufacturing processes, mass balance, chemical reactions, production layouts and instrumentation details included in this Environmental Impact Assessment (EIA) Report are the sole property of Gangamai Industries And Constructions Ltd. (GIACL); Najik Babhulgaon, Tal.: Shevgaon, Dist.: Ahmednagar. Some of the products, reactions and process methodologies may be patented.

The style and format of this Final EIA Report as well as the data, processing and presentations of various environmental features, environmental management planning; designs; drawings; plates; calculations, demonstrations on attributes towards pollution control and abatement aspects etc. are the intellectual property of M/s. Equinox Environments (India) Pvt. Ltd. (EEIPL); Kolhapur.

Under no circumstances, any part of this report may be used; reproduced; translated; recorded or copied in any form and manner except by the Govt. authorities requiring this report for taking decisions, based on details and information provided in same, during the Environmental Clearance procedure carried out as per EIA Notification No. S.O. 1533 (E) dated 14.09.2006 as amended from time to time.

Equinox Environments (India) Pvt. Ltd. (EEIPL); Kolhapur Environmental and Civil Engineers, Consultants& Analysts

ISO 9001 : 2008 & QCI-NABET accredited Organization

ABBREVIATIONS

AAQM Ambient Air Quality Monitoring ACF Activated Carbon Filter AP Air Pollution APC Air Pollution Control APHA American Public Health Association AQ Air Quality BDL Below Detectable Limit BIS Bureau of Indian Standards BOD Biochemical Oxygen Demand CE Critically Endangered CGWA Central Ground Water Authority CGWB Central Ground Water Board CMD Cubic Meter per Day CO Carbon Monoxide CO2 Carbon Dioxide COD Chemical Oxygen Demand CPCB Central Pollution Control Board CPU Condensate Polishing Unit CREP Corporate Responsibility For Environmental Protection CSR Corporate Social Responsibility CTE Consent to Establish CTO Consent to Operate CWC Central Water Commission dB (A) A- weighted Decibel DG Diesel Generator DIRD Directorate of Irrigation Research and Development DMP Disaster Management Plan DO Dissolved Oxygen DoE Department of Environment DVP Deccan Volcanic Province E East EAC Expert Appraisal Committee EB Ecology and Biodiversity EC Environmental Clearance EEIPL Equinox Environments (India) Pvt. Ltd. EIA Environmental Impact Assessment EMC Environment Management Cell EMP Environmental Management Plan EN Endangered ENA Extra Neutral Alcohol EPA Environmental Protection Act ESP Electrostatic Precipitator ETP Effluent Treatment Plant

http://www.bis.org.in/

FAE Functional Area Expert GEO Geology GIACL Gangamai Industries And Construction Ltd. GLC Ground Level Concentration GMPs Good Manufacturing Practices GPS Global Positioning System GSDA Ground Water Survey and Development Agency GW Ground Water Ha Hectare HDPE High-density polyethylene HG Hydrology, Ground Water and Water Conservation HSD High Speed Diesel IMD Indian Metrological Department IRS Indian Remote Sensing IS Indian Standards ISO International Organization for Standardization IUCN International Union for Conservation of Nature KL Kilo Liter KM Kilo Meter KLPD Kilo Liter per Day KVA Kilo Volt Ampere LC Land Cover LC Least Concern LU Land Use MoEFCC Ministry of Environment, Forests and Climate Change MOU Memorandum OF Understanding MPCB Maharashtra Pollution Control Board MSEB Maharashtra State Electricity Board MSIHC Manufacture Storage And Import of Hazardous Chemical MSL Mean Sea Level MT Metric Tone MW Mega Watt N North NAAQM National Ambient Air Quality Monitoring NAAQS National Ambient Air Quality Standards NABET National Accreditation Board for Education and Training NBSS National Bureau of Soil Survey NE North-East NFPA National Fire Protection Association NL Not listed NOx Oxides of Nitrogen NOC No Objection Certificate NT Near Threatened NTU Nephelometric Turbidity Units

https://en.wikipedia.org/wiki/High-density_polyethylene

http://www.mppcb.nic.in/MSIH.htm

NV Noise and Vibration O&M Operation and Maintenance OHC Occupational Health Center OHSAS Occupational Health and Safety Assessment Series. PAH Pulmonary Arterial Hypertension PH Public Hearing PHC Primary Health Center PLC Programmable Logic Controller PM Particulate Matter PP Project Proponent PSF Pressure Sand Filter QCI Quality Council of India RA Risk Assessment RO Reverse Osmosis RS Rectified spirit S South SCBA Self Contained Breathing Apparatus SC Soil conservation SDB Sludge Drying Bed SE Socio - Economic SEIAA State Environment Impact Assessment Authority SHE Safety and Health Environment SHW Solid and Hazardous Waste SO2 Sulphur Dioxide SPM Suspended Particulate Matter SRSL Shree Renuka Sugars Ltd. SS Suspended Solids STP Sewage Treatment Plant SW South -west SWD Side Water Depth TCD Tones Crushing Per Day TDS Total Dissolved Solids TLV Threshold Limit Value ToR Terms of References TPH Tones Per Hour TWA Time Weighted Average USEPA United States Environmental Protection Agency VU Vulnerable W West WP Water Pollution

CERTIFICATE

Declaration by Expert contributing to the EIA in respect of proposed expansion molasses based distillery from 60 KLPD to 150 KLPD (Expansion by 90 KLPD) in premises of existing 5500 TCD Sugar Factory, 32 MW Co-generation plant and 60 KLPD distillery of Gangamai Industries And Constructions Ltd. located at Najik Babhulgaon, Post Rakshi, Tal: Shevgaon, Dist. Ahmednagar.

We, hereby, certify that we were a part of the EIA team in the following capacities that developed the above EIA.

Project Number P-25-GIACL-EXP-DISTILLERY-32018 EIA Coordinators Name : Dr. Sangram Ghugare

: Ms. Sulakshna Ayarekar

Period of Involvement : March 2018 toDecember 2018 Contact Information : [email protected]

Functional Area Expert:

Sr. No.

Functional Area

Name of the expert/s

Involvement (Period & Task) Signature

1 WP Dr. Sangram Ghugare

March 2018 to June 2018 • Study of process and operations• Site visit and finalization of water

sampling locations• Preparation of water balance and

identification of wastewater generation.

• Evaluation of water pollution &control management

• Identification of impacts, suggestionand finalization of mitigationmeasures

• Study on Treatment of effluentsthrough existing ETP and to beupgraded under proposed expansionwas contemplated and designs weredone accordingly.

2 EB Prof. (Dr.) Jay Samant

Ms. Sulakshna Ayarekar

March 2018 – May 2018 • Selection of Site for conducting

ecological & wildlife surveys. • Interaction with Govt. offices and

agencies for certain secondary data and information pertaining to region specific issues

• Review of rules, legislation andcriteria towards knowing and

mailto:[email protected]

Sr. No.

Functional Area



Dr. Rohan Lad

understanding inclusion in the study region of any eco-sensitive zones, wild life sanctuary.

• Collection, compilation and presentation of the data as well as incorporation of same in to the Draft EIA report.

3 SE Dr. Anuradha Samant

Mr. Neeraj Powar

March 2018 – May 2018 • Collection of data on socio-economic

aspects in study area through surveys.• Public opinions and recording of

events for future industrialization inthe study area.

• Study of sociological aspects likehuman settlement, demographic andinfrastructural facilities available instudy area.

• Compilation of primary andsecondary data and its inclusion inEIA report.

4 AP Dr. Sangram Ghugare

Mr. Yuvraj Damugade

March 2018 to June 2018 • Involved in detailed study of mass

balance w.r.t. raw materials &products especially from view pointof process emissions.

• Site visit and finalization samplinglocations

• Identification of impact andsuggesting the mitigation measures.

5 AQ Mr. Yuvraj Damugade

Mr. Sangram Patil

March 2018 to June 2018 • Designing of Ambient AQM network

for use in prediction modeling andmicro metrological data development

• Development and application of airquality models in prediction ofpollutant dispersion,

• Plotting of isopleths of GLCs, Worstcase scenarios prediction w.r.t.source and receptors.

6 HG Dr. J.B. Pishte

Mr. Vaibhav Survase

March 2018 – May 2018 • Hydro geological studies, data

processing; analysis and evaluation,Ground water table measurement andmonitoring network methodologypreparation.

• Planning and scheduling ofgroundwater sampling stations in theregion.

• Study of geology & generalgeological configuration of the regionas well as sub-surface geology.

7 GEO

Sr. No.

Functional Area



• Determination of impact andsuggesting mitigation measures

8 SHW Dr. Sangram Ghugare

March 2018 – May 2018 • Detailed study of manufacturing

process and mass balance.• Solid wastes generation in different

steps of manufacturing was identifiedand their quantification done waschecked.

• Identification of various hazardouswastes generated throughmanufacturing process.

• Practices of storage and disposal ofHW its impact and mitigationmeasures.

9 RH Mr. Vinod Sahasrabuddhe

March 2018 – May 2018 • All the necessary literature for

processes storage of hazardouschemicals was studied before visit.

• Site visit and Verification ofadequacy of on-site emergencypreparedness plan for proposed unitwas done.

• Identification of probableemergencies and procedures forpreparedness for handling the samewas verified.

• Worst case analysis by usingALOHA, Ware house safetymeasures, suggestion of mitigationmeasures.

10 NV Mr. Vinay Kumar Kurakula

March 2018 – May 2018 • Verification of noise levels

Monitoring (both work zone andambient) in the industrial premisesand study region

• Finalization and verification ofsampling locations, ambient noisemonitoring stations and the datacollected.

• Land use land cover mappingusing NRSC Satellite image,

• Satellite image processing, Imageclassification, Technical analysisand study for setting up of facility,planning of storage facility.

11 LU

Sr. No.

Functional Area



12 SC Mr. B. S.Lole March 2018 – May 2018 • Involvement physical analysis &

characterization of the soils. • Identification of Impact and its

mitigation measures • Interpretation of soil analysis,

results and data including comparison of same with standard soil classification.

• Collection, study and evaluationof soil information from data obtained from secondary sources & its interpretation.

Declaration by the Head of the Accredited Consultant Organization/authorized person:

I, M/s. Equinox Environments (I) Pvt. Ltd. (EEIPL); Kolhapur, Environmental & Civil Engineers, Consultants and Analysts., hereby confirm that the above mentioned experts prepared the EIA w.r.t. expansion of molasses based distillery from 60 KLPD to 150 KLPD (Expansion by 90 KLPD) in premises of existing 60 KLPD distillery and 5500 TCD Sugar Factory and 32 MW Co-generation plant of Gangamai Industries And Constructions Ltd.(GIACL) Najik Babhulgaon, Post Rakshi, Tal: Shevgaon, Dist. Ahmednagar.

I also confirm that the consultant organization shall be fully accountable for any mis-leading information mentioned in this statement.

Signature:

Name: Dr. Sangram Ghugare

Designation: Chairman & MD

Name of the EIA Consultant Organization: M/s. Equinox Environments (I) Pvt. Ltd. (EEIPL); Kolhapur.

NABET Certificate No. & Issue Date: NABET/EIA/1518/SA 063 dated 01.06.2018

CONFIGURATION OF REPORT

Chapter 1 - Introduction

This chapter is an introductory chapter, presenting the background information of the project, its location, objective of project, scope of study and documentation and compliance of ToRs.

Chapter 2 - Project Description

This chapter deals with technology and process to be used for the proposed establishment of project. It also deals with the sources of pollution and mitigation measures under proposed activity.

Chapter 3 - Description of the Environment

In this chapter, study of various attributes of environment such as Air, Water, Noise, Soil, Land Use Pattern, Geology, Hydro-geology and Ecology is carried out so as to know existing environmental status. Also, present social status is discussed to know if there are any sensitive issues in the area.

Chapter 4 - Environmental Impacts and Mitigation Measures

This chapter presents the conclusion drawn by studying the impact considering both the pre - project and post project scenario. It describes the sum impact of the proposed project and mitigation measures for abatement of the pollution.

Chapter 5 - Analysis of Alternatives

Various alternatives in terms of site selection and technology to be used are discussed in this chapter and the environment friendly and best suited technology is selected for the proposed distillery project.

Chapter 6 - Environmental Monitoring Program

This chapter deals with the planning of Environmental Monitoring Program both during construction phase and operational phase to assess the performance of pollution control equipments to be installed.

Chapter 7 - Additional Studies

This chapter illustrates the possible risk area under the proposed distillery project and the safety and disaster management plan prepared to mitigate the same.

Chapter 8 - Project Benefits

This chapter describes the predictable benefits due to proposed distillery in existing sugar factory and co-gen plant.

Chapter 9 - Environmental Management Plan

This chapter deals with the protection and mitigation measures for abatement of pollution after execution of the project. It also deals with the roles and responsibilities of the environmental management cell for proper implementation of the Environmental Management Plan.

Chapter 10 - Summary and Conclusion

This chapter summarizes the conclusion of the Final EIA report.

Chapter 11 - Disclosure of Consultant Organization

In this chapter the name and brief resume of the consultant organization engaged in preparation of the Final EIA report is presented.

Chapter 1

INTRODUCTION

INTRODUCTION…1

1.1 INTRODUCTION

'Environmental Impact Assessment (EIA)' is process of evaluating likely environmental impacts, both positive and negative, of a new or expansion project by taking into account natural, social and economic aspects. It also comprises of suggesting possible mitigation measures, for the negative impacts, before implementation of the project. Main objectives of an EIA report are -

• To describe a pre-project baseline condition with respect to Environmental indicators. • To identify possible sources of pollution and their environmental impacts including

identifying risks associated with setting up of a new / expansion project and suggesting appropriate mitigation measures for alleviating adverse impacts to the extent possible.

• To suggest environmental / risk management plans for implementing the mitigation measures.

India is the largest producer of sugarcane and sugar, still sugar factories in India are facing problems. Sugar factories cannot survive in healthy condition on a single product i.e. sugar. Thus, it is essential to develop sugar factory into an affiliated complex so as to utilize the valuable by-products more profitably. Bio-mass is the most promising alternative fuel. Agro-waste and agro industrial products have today been recognized as ‘modern’ bio-mass material which can be converted directly into useful forms of energy. Bio-mass has the crucial advantage of being environment friendly. Bagasse is a captive bio-mass.and can be used as fuel for generation of steam used in sugar factories and power would be benefit both to nation and industry. Molasses is a very important by-product of the sugar industry. The profits earned by conversion of molasses into alcohol are much higher than that of sale of molasses alone. Moreover, there is a good demand for alcohol in the country as production and consumption of alcohol in India are quite balanced. Also, there is a good export potential, out of the country, for the alcohol. With a due consideration to all the above facts, the management of Gangamai Industries And Constructions Ltd. (GIACL) have decided to go for an expansion of its 60 KLPD molasses based distillery up to 150 KLPD..

1.2 THE PROJECT & PROPONENTS Project site of GIACL is located at Najik Babulgaon, Post- Rakshi, Tal.: Shevgaon, Dist. Ahmednagar, MS. Expansion existing 60 KLPD molasses based distillery up to 150 KLPD in existing premises of sugar factory (5,500 TCD) & co-generation plant (32 MW). This report has been prepared in overall context of EIA Notification dated 14th September 2006 and amendments thereto issued by Ministry of Environment, Forest and Climate Change (MoEFCC); New Delhi. As per said notification, project comes under Category A, listed under Item 5(g) i.e. Distillery. EIA report comprises of requisite information and details w.r.t. project as mentioned in Standard Terms of Reference (TORs) issued by MoEFCC vide letter No. J-11011/91/2018-IA II(I) dated 14.04.2018 to GIACL. Public hearing w.r.t. expansion of project was conducted on 17.10.2018 at Industrial site. Unit would be designed in a versatile fashion by adopting latest process techniques as well as with state-of-the art machinery. Investment of GIACL project is presented at table 1.1. Names and designation of GIACL promoters are given in table 1.2

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INTRODUCTION…1

Table 1.1 Project Investment Details

Sr. No. Industrial Unit Capital Investment (Rs. Cr.) Existing Expansion Total

1. Sugar Factory and Co-gen Plant 209.55 -- 209.55 2. Distillery 55.93 19.18 75.11

Total 284.66

Table 1.2 Promoters of GIACL

Sr. No. Name Designation 1. Shri Padmakar H. Mulay Chairman 2. Shri Ranjeet P. Mulay Managing Director 3. Shri Sameer P. Mulay Director 4. Shri Vishnu S. Khedekar Chief Financial Officer

1.3 THE PLACE Expansion project of existing distillery would be implemented by GIACL in the premises of sugar factory and co-gen plant on gat No.: 6, 222/3, 223, 224, 228/1, 228/2, 228/3, 233 & 234, Najik Babulgaon, Post: Rakshi, Tal.: Shevgaon, Dist.: Ahmednagar. Total land acquired by GIACL is 2,70,661 Sq. M. (27.06 Ha). Detailed section wise area break up is given at Table – 2.3 of Chapter 2. Grampanchayat of Najik Babhulgaon has issued a NOC for the proposed distillery expansion project. Same is attached at Certificate and other documents of this report. Following aspects have been taken in to consideration while planning proposed expansion project activities in the GIACL complex - Proximity to the raw material availability Adequate land for implementation of proposed projects. Convenient location on the south west (SW) side of Shevgaon city at a distance of about

7.19 Km. Moreover, the State Highway SH - 44 & SH - 148 is at distance of 2.60 Km & 1.63 Km respectively from the project site.

Existing convenient availability as well as ease towards supply of proposed utilities such as water, steam and electricity from existing and proposed setups for conducting various operations and processes.

2

INTRODUCTION…1

Figure 1.1 Location of Project Site

3

INTRODUCTION…1

Figure 1.2 Photographs of Existing

4

INTRODUCTION…1

1.4 IMPORTANCE TO COUNTRY & REGION Alcohol has assumed very important place in the Country’s economy. It is a vital raw material for a number of chemicals and also a renewable source of energy. It has been a source of a large amount of revenue by way of excise duty levied by the Govt. on alcoholic liquors. It has a potential as fuel in the form of power alcohol for blending with petrol. Also, the fermentation alcohol has great demand in countries like Japan, U.S.A., Canada, Sri Lanka etc., as the synthetic alcohol produced by these countries, from naphtha of petroleum crude, is not useful for beverages. India is the fourth largest producer of alcohol in the world and there has been a consistent increase in its production over the last 22 years or so. Demand for alcohol in the country is expected to go upto almost 6000 million liters by year 2020. Present average alcohol production from molasses in the country is around 2,500 million liters per annum (Reference Opportunities for Green Chemistry Initiatives, 2014). Considering the above facts, management of GIACL has decided to go for an expansion of existing 60 KLPD distillery to 150 KLPD i.e. expansion by 90 KLPD. Moreover, trend for use of alcohol as an alternative to the mineral fuel oils is being established as the oil and natural gas sources are depleting at faster rates. It could, therefore, be seen that demand for alcohol will be ever increasing. Ethyl alcohol is an important feedstock for the manufacture of number of chemicals. These chemicals are primarily basic carbon based products like Acetic Acid, Butanol, Butadiene, Acetic Anhydride, Vinyl Acetate, PVC etc. Acetic Acid & Butanol, are needed in pharmaceuticals, paints and in many other industries, are important value added products. Ethylene, Ethylene oxide and Mono-ethylene glycol are also produced via petrochemical route. However, due to the latest technological developments and taking in to account the ever-increasing cost of petrochemical raw materials, it is now possible as well as more economical to produce Ethylene oxide, Mono-ethylene glycol etc. starting from ethanol. Petrochemical route needs designing of plants in mega range. Alcohol has an advantage of setting up of plants in medium as well as mini range. Average capacities of Indian molasses based distilleries ranges between 30 to 60 KLPD. There are very few distilleries above 100 KLPD capacities and the largest distillery capacity in the country is 420 KLPD. Gap between availability of alcohol and its requirement by industries is increasing constantly. During last decade, number of alcohol-based industries have come up and existing ones have marginally increased their capacities. Raw material needs of these alcohol-based industries have to be met to facilitate maximum capacity utilization of units in order to meet domestic demands for end products. These units are starving for want of raw materials. Shortage is wide spread and has hit most of the chemical drug and allied industries. Producers of insulin, antibiotics, tonics and several other essential bulk drugs as well as finished formulations are unable to obtain their quota of industrial alcohol, which is a vital raw material for them. Denatured Spirits and Rectified Spirit are made unfit for drinking by addition of certain chemicals which have strong disagreeable odour and which cannot be easily separated from spirit. Denatured Spirits are taxed at nominal rates so that their use in industries becomes economical. Alcohol has great future as a renewable source of energy. Trend for use of alcohol as an alternative to mineral fuel oils is well established as oil and natural gas sources are depleting at faster rates. It could, therefore, be seen that demand for alcohol will be ever increasing and there would not be any problem of marketing alcohol, which would be produced by distillery. Manufacture of alcoholic beverages from the alcohol is also an

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INTRODUCTION…1

attractive diversification as there is a great demand for the beverages. Moreover, diversification by way of manufacturing alcohol based chemicals, such as acetic acid, acetic anhydride, ethyl acetate, ethyl benzene, vinyl acetate etc. would be a big boon to the distillery. 1.5 SCOPE OF THE STUDY 1.5.1 Details of Regulatory Scoping Carried out as per Terms of Reference GIACL submitted a duly filled in online Form – 1 application to the MoEFCC, New Delhi on 10th March 2018 for grant of TORs. Proposal was accepted by Member Secretary (MS) on 14th march 2018. Subsequently monitoring for primary data collection was carried out in months namely March – April – May 2018. Draft EIA report along with Executive summary was submitted to MPCB, Mumbai. Public Hearing (PH) was conducted on 17.10.2018. After incorporation of PH minutes this Final EIA report has been complied with the TORs issued by MoEFCC. Summarized details of same are provided in following table –

Table 1.3 Summary of Terms of Reference No List of TOR’s Compliance A. Standard ToR 1 Executive Summary Refer Chapter 10 Page 202 –

209 2 Introduction i. Details of the EIA Consultant including

NABET accreditation Refer Chapter 11, page 211

ii Information about the project proponent Refer Chapter 1, Table 1.2, Page 1

iii Importance and benefits of the project Refer Chapter 1, Section 1.4 Page 5-6.

3 Project Description i. Cost of project and time of completion. Capital cost of the project will

be Rs. 19.18 Cr. Refer Chapter 1, Table – 1.1, Page 2

ii Products with capacities for the proposed project.

Refer Chapter 2, Table 2.6 Page 22

iii If expansion project, details of existing products with capacities and whether adequate land is available for expansion, reference of earlier EC if any.

Refer Chapter 2, Table 2.6, Page 22 for details of existing products with capacities. Refer Chapter 2, table 2.3 page 18 for details of area statement. Refer Appendix B for earlier EC.

iv List of raw materials required and their source along with mode of transportation.

Refer Chapter 2, Table 2.8, Page 23 for list of raw materials, Section 2.6.3, Page 20-21 for details of transportation.

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INTRODUCTION…1

No List of TOR’s Compliance v Other chemicals and materials required with

quantities and storage capacities Refer Chapter 2, Section 2.6.3, Page 23 for details of storage

vi Details of Emission, effluents, hazardous waste generation and their management.

Refer Chapter 2, Section 2.7.1 to Section 2.7.5, Page no. 35-50

vii Requirement of water, power, with source of supply, status of approval, water balance diagram, man-power requirement (regular and contract)

Refer Chapter 2, Table 2.20, 2.21 & 2.22 Page 36-37 for Water requirement of GIACL project. Refer Chapter 2, Table 2.18 Page 33 electricity requirement of industry. Refer Chapter 2, Table 2.1, Page 16 for details of man power requirement. Refer Appendix – D for water lifting permission

viii Process description along with major equipments and machineries, process flow sheet (quantities) from raw material to products to be provided

Refer Chapter 2, Section 2.6.4 for manufacturing process, Figure 2.2 & 2.3 for mass balance for distillery and figure-2.4 for sugar mass balance. Page 25 - 35

ix Hazard identification and details of proposed safety systems

Refer Chapter – 7, Section 7.2 to 7.6 Page no. 172-191

x Expansion/modernization proposals a. Copy of all the Environmental

Clearance(s) including Amendments thereto obtained for the project from MOEF/SEIAA shall be attached as an Annexure. A certified copy of the latest Monitoring Report of the Regional Office of the Ministry of Environment and Forests as per circular dated 30th May, 2012 on the status of compliance of conditions stipulated in all the existing environmental clearances including Amendments shall be provided. In addition, status of compliance of Consent to Operate for the ongoing/ existing operation of the project from SPCB shall be attached with the EIA-EMP report.

Refer Appendix - C for copy of existing Environmental Clearance (EC) order w.r.t. 60 KLPD distillery & 5500 TCD sugar factory, 32 MW c-gen plant by GiACL.

b. In case the existing project has not obtained environmental clearance, reasons for not taking EC under the provisions of the EIA Notification 1994 and/ or EIA Notification 2006 shall be provided. Copies of Consent to Establish/ No Objection Certificate and Consent to Operate (in case of units operating prior to EIA Notification 2006, CTE and CTO of FY 2005 - 2006)

NA

7

INTRODUCTION…1

No List of TOR’s Compliance obtained from the SPCB shall be submitted. Further, compliance report to the conditions of consents from the SPCB shall be submitted.

4 Site Details i. Location of the project site covering village,

Taluka/ Tehsil, District and State, Justification for selecting the site, whether other sites were considered.

Refer Chapter – 1 , Figure 1.1, Page 2

ii A toposheet of the study area of radius of 10km and site location on 1:50,000/1:25,000 scale on an A3/A2 sheet. (including all eco-sensitive areas and environmentally sensitive places)


iii Details w.r.t. option analysis for selection of site.

As the expansion of distillery will be done within the existing premises of GIACL. Industry has sufficient land for expansion and hence no any alternative sites were considered.

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

Co-ordinates (lat-long) of all corners - 19°22'55.19"N, 75°16'50.20"E 19°22'54.51"N, 75°17'08.36"E 19°22'42.14"N, 75°17'09.86"E 19°22'38.32"N, 75°16'56.97"E 19°22'41.97"N, 75°16'49.82"E 19°22'46.92"N, 75°16'48.82"E

v Google map-Earth downloaded of the project site.


vi Layout maps indicating existing unit as well as proposed unit indicating storage area, plant area, greenbelt area, utilities etc. If located within an Industrial area/Estate/Complex, layout of Industrial Area indicating location of unit within the Industrial area/Estate.

Refer Appendix – A

vii Photographs of the proposed and existing (if applicable) plant site. If existing, show photographs of plantation/ greenbelt, in particular.

Refer Appendix – A for plot layout, Chapter 1, Figure 1.2, Page 4 for existing photographs. Photographs of green belt are presented at appendix- G

viii Landuse break-up of total land of the project site (identified and acquired), government/private - agricultural, forest, wasteland, water bodies, settlements, etc shall be included. (not required for industrial area).

Refer Chapter – 3, Table 3.1, and Figure 3.5, Page no. 63 for landuse breakup of total land.

ix A list of major industries with name and type within study area (10 km radius) shall be incorporated. Land use details of the study area.

No any major industry are present in study area of GIACL.

8

INTRODUCTION…1

No List of TOR’s Compliance x Geological features and Geo-hydrological

status of the study area shall be included. Refer Chapter – 3, Section 3.5 Page 79-85

xi Details of Drainage of the project up to 5km radius of study area. If the site is within 1km radius of any major river, peak & lean season river discharge as well as flood occurrence frequency based on peak rainfall data of the past 30 years. Details of Flood Level of the project site & maximum Flood Level of the river shall also be provided. (mega green field projects)

Refer Chapter – 3, Section 3.5 Page 79-85 study of Drainage & Geomorphology. Drainage map.

xii Status of acquisition of land. If acquisition is not complete, stage of the acquisition process and expected time of complete possession of the land.

The land is already acquired by GIACL

xiii R & R details in respect of land in line with state Government policy

There will not be any R & R plan as expansion of GIACL will be carried out in its existing premises.

5 Forest and wildlife related issues (if applicable)

i Permission and approval for the use of forest land (forestry clearance), if any, and recommendations of the State Forest Department. (if applicable)

NA

ii Land use map based on High resolution satellite imagery (GPS) of the proposed site delineating the forestland (in case of projects involving forest land more than 40 ha)

NA

iii Status of Application submitted for obtaining the stage I forestry clearance along with latest status shall be submitted.

NA

iv Projects to be located within 10 km of the National Parks, Sanctuaries, Biosphere Reserves, Migratory Corridors of Wild Animals, the project proponent shall submit the map duly authenticated by Chief Wildlife Warden showing these features vis-à-vis the project location and the recommendations or comments of the Chief Wildlife Warden-thereon

NA

v Wildlife Conservation Plan duly authenticated by the Chief Wildlife Warden of the State Government for conservation of Schedule I fauna, if any exists in the study area

NA

vi Copy of application submitted for clearance under the Wildlife (Protection) Act, 1972, to the Standing Committee of the National Board for Wildlife

NA

9

INTRODUCTION…1

No List of TOR’s Compliance 6 Environmental Status i. Determination of atmospheric inversion level at

the project site and site-specific micrometeorological data using temperature, relative humidity, hourly wind speed and direction and rainfall.

By using meteorological data the wind rose have been plotted.

ii AAQ data (except monsoon) at 8 locations for PM10, PM2.5, SO2, NOx, CO and other parameters relevant to the project shall be collected. The monitoring stations shall be based CPCB guidelines and take into account the pre-dominant wind direction, population zone and sensitive receptors including reserved forests.

Refer Chapter – 3, Section 3.7 Table 3.11 Page no. 87-90 for AAQM data.

iii Raw data of all AAQ measurement for 12 weeks of all stations as per frequency given in the NAAQM Notification of Nov. 2009 along with - min., max., average and 98% values for each of the AAQ parameters from data of all AAQ stations should be provided as an annexure to the EIA Report.

Refer Chapter – 3, Section 3.7 Table 3.11 Page no. 87-90 for AAQM data.

iv Surface water quality of nearby River (100 M upstream and downstream of discharge point) and other surface drains at eight locations as per CPCB/ MoEF&CC guidelines.

Refer Chapter – 3, Section 3.8, Table 3.11 & 3.13, Page 89-91 for surface water analysis results.

v Whether the site falls near to polluted stretch of river identified by the CPCB/ MoEF&CC, if yes give details.

NA

vi Ground water monitoring at minimum at 8 locations shall be included.

Refer Chapter – 3, Section 3.9, Table 3.12 & 3.14, page 89-91 for ground water analysis results

vii Noise levels monitoring at 8 locations within the study area.

Refer Chapter – 3, Section 3.9, Table 3.21, page no 95-99 for noise level monitoring results

viii Soil Characteristic as per CPCB guidelines. Refer Chapter – 3, Section 3.4, Table 3.4 page 69-79 for soil analysis results

ix Traffic study of the area, type of vehicles, frequency of vehicles for transportation of materials, additional traffic due to proposed project, parking arrangement etc.

Refer Chapter – 2, Table 2.12 to 2.15, page 24-25 for transportation details.

x Detailed description of flora and fauna (terrestrial and aquatic) existing in the study area shall be given with special reference to rare, endemic and endangered species. If Schedule-I fauna are found within the study area, a Wildlife Conservation Plan shall be prepared and furnished.

Refer Chapter 3, section 3.11 page 103-110 for detailed study of Ecology. Photographs and list of Flora and Fauna observed in study area are appended at Appendix –H

10

INTRODUCTION…1

No List of TOR’s Compliance xi Socio-economic status of the study area. Refer Chapter – 3, section

3.10, page no. 100-102 for details of socio-economic profile of study area.

7 Impact and Environment Management Plan i. Assessment of ground level concentration of

pollutants from the stack emission based on site specific meteorological features. In case the project is located on a hilly terrain, the AQIP Modeling shall be done using inputs of the specific terrain characteristics for determining the potential impacts of the project on the AAQ. Cumulative impact of all sources of emissions (including transportation) on the AAQ of the area shall be assessed. Details of the model used and the input data used for modeling shall also be provided. The air quality contours shall be plotted on a location map showing the location of project site, habitation nearby, sensitive receptors, if any.

Refer Chapter4, section 4.3.1.1 for details of GLC. Refer GLC at Appendix - .Q

ii Water Quality modeling - in case of discharge in water body

As ZLD of effluent will done hence no any effluent will discharge in to nearby water body. Refer Chapter –2, Section 2.7.1.1 and 2.7.1.2, table 2.20 and table 2.21, page 36 respectively for treatment of effluent.

iii Impact of the transport of the raw materials and end products on the surrounding environment shall be assessed and provided. In this regard, options for transport of raw materials and finished products and wastes (large quantities) by rail/rail-cum road transport or conveyor cum- rail transport shall be examined.

Entire transportation of products and raw material shall be done by road. Refer Chapter 2 for transportation details.

iv A note on treatment of wastewater from different plant operations, extent recycled and reused for different purposes shall be included. Complete scheme of effluent treatment. Characteristics of untreated and treated effluent to meet the prescribed standards of discharge under E (P) Rules.

Refer Chapter –2, Section 2.7.1.1 and 2.7.1.2, table 2.22 and table 2.22, page 37 respectively for treatment of effluent.

v Details of stack emission and action plan for control of emissions to meet standards.

Refer Chapter – 2, Section 2.7.2, Table 2.33 & 2.34, Page 44-46 for details of stack.

vi Measures for fugitive emission control Refer Chapter – 2, Section 2.7.2 Page 46

vii Details of hazardous waste generation & their Refer Chapter – 2, Section

11

INTRODUCTION…1

No List of TOR’s Compliance storage, utilization & management. Copies of MOU regarding utilization of solid and hazardous waste in cement plant shall also be included. EMP shall include the concept of waste - minimization, recycle/reuse/recover techniques, Energy conservation, & natural resource conservation.

2.7.5 page 48 for hazardous waste generation, their disposal and storage.

viii Proper utilization of fly ash shall be ensured as per Fly Ash Notification, 2009. A detailed plan of action shall be provided.

Refer Chapter – 2, Table 2.37 page 48 for details of quantity of fly ash. Fly ash will be mixed with spentwash powder and sold as manure.

ix Action plan for the green belt development plan in 33 % area i.e. land with not less than 1,500 trees per ha. Giving details of species, width of plantation, planning schedule etc. shall be included. The green belt shall be around the project boundary and a scheme for greening of the roads used for the project shall also be incorporated.

Refer Chapter – 2, Section 2.8 page 54 and Appendix-G for green belt development plan.

x Action plan for rainwater harvesting measures at plant site shall be submitted to harvest rainwater from the roof tops and storm water drains to recharge the ground water and also to use for the various activities at the project site to conserve fresh water and reduce the water requirement from other sources.

Refer Chapter – 2, Section 2.9, page 54-55 for rainwater harvesting details.

xi Total capital cost and recurring cost/annum for environmental pollution control measures shall be included.

Refer Chapter – 2, section 2.7.8, Table 2.39 & 2.40, page 50-51

xii Action plan for post-project environmental monitoring shall be submitted.

Refer Chapter – 6, Table 6.8 page 169

xiii Onsite and Offsite Disaster (natural and Man-made) Preparedness and Emergency Management Plan including Risk Assessment and damage control. Disaster management plan should be linked with District Disaster Management Plan.

Refer Chapter – 7, page 172 – 191

8 Occupational health i Plan and fund allocation to ensure the

occupational health & safety of all contract and casual workers

Refer Chapter – 2, section 2.7.8, Table 2.39 & 2.40, page 50-51

ii Details of exposure specific health status evaluation of worker. If the workers' health is being evaluated by pre designed format, chest X-rays, Audiometry, Spirometry, Vision testing (Far & Near vision, colour vision and any other ocular defect) ECG, during pre placement and periodical examinations give the details of the


12

INTRODUCTION…1

No List of TOR’s Compliance same. Details regarding last month analyzed data of above mentioned parameters as per age, sex, duration of exposure and department wise.

iii Details of existing Occupational & Safety Hazards. What are the exposure levels of hazards and whether they are within Permissible Exposure level (PEL). If these are not within PEL, what measures the company has adopted to keep them within PEL so that health of the workers can be preserved,


iv Annual report of heath status of workers with special reference to Occupational Health and Safety.

NA

9 Corporate Environment Policy i Does the company have a well laid down

Environment Policy approved by its Board of Directors? If so, it may be detailed in the EIA report.

--

ii Does the Environment Policy prescribe for standard operating process /procedures to bring into focus any infringement /deviation/ violation of the environmental or forest norms/ conditions? If so, it may be detailed in EIA.

--

iii What is the hierarchical system or Administrative order of the company to deal with the environmental issues and for ensuring compliance with the environmental clearance conditions? Details of this system may be given.

Refer Chapter 9, figure 9.1, page 196

iv Does the company have system of reporting of non compliances / violations of environmental norms to the Board of Directors of the company and / or shareholders or stakeholders at large? This reporting mechanism shall be detailed in the EIA report

Refer Chapter 9, table 9.1, page 195 for Environmental Management Cell and their responsibilities.

10 Details regarding infrastructure facilities such as sanitation, fuel, restroom etc. to be provided to the labour force during construction as well as to the casual workers including truck drivers during operation phase.

Refer Chapter 4, Section 4.2,

11 Enterprise Social Commitment (ESC) i Adequate funds (at least 2.5 % of the project cost)

shall be earmarked towards the Enterprise Social Commitment based on Public Hearing issues and item-wise details along with time bound action plan shall be included. Socio-economic development activities need to be elaborated upon.

An amount of Rs. 50 Lakhs will be allocated for CER for next 3 years. Refer Chapter – 6, Table 6.4 & 6.6, page 166-167 for detailed CER

12 Any litigation pending against the project and/or any NA

13

INTRODUCTION…1

No List of TOR’s Compliance direction/order passed by any Court of Law against the project, if so, details thereof shall also be included. Has the unit received any notice under the Section 5 of Environment (Protection) Act, 1986 or relevant Sections of Air and Water Acts? If so, details thereof and compliance/ATR to the notice(s) and present status of the case.

13 A tabular chart with index for point wise compliance of above TOR.

Refer Chapter 1, Section 1.5, Table 1.3, Page 6-15

B. Specific ToRs 1 List of existing distillery units in the study area along

with their capacity and sourcing of raw material There is no any distillery present in study area of GIACL.

2 Number of working days of the distillery unit Working days of the distillery-300-330. Refer Chapter2, table 2.4, page no. 21

3 Details of raw materials such as molasses/ grains, their sources with availability

For molasses based distillery molasses is used as raw material. Same will be taken from own sugar factory of 5500 TCD. Refer chapter 2, table 2.8 & 2.9, page 23

4 Details of the use of steam from the boiler Steam required for expansion of distillery will be taken from existing 8 TPH biogas based distillery boiler. Also, a boiler of capacity 30 TPH from existing sugar factory will be renewed to 40 TPH. steam from same will be used in expansion of distillery. Refer chapter 2, section 2.7.2, table 2.33-2.34 page no. 44-45

5 Surface and Ground water quality around proposed spentwash store lagoon, and compost yard

Refer chapter 3, section 3.7, table 3.12 & 3.14, page no. 91-94

6 Plan to reduce spent wash generation within 6-8 KL/KL of alcohol production.

Conc. Spent wash generation at 2.9 KL/KL of alcohol. Refer chapter 2, section 2.7.1.1 & 2.7.1.2, table 2.22, page no. 37

7 Proposed effluent treatment system for molasses/ grain based distillery (spent wash, spentlees, condensate and utilities) as well as domestic sewage and scheme for achieving ZLD

chapter 2, section 2.7.1.1 & 2.7.1.2, table 2.22, page no. 37

8 Proposed action to restrict fresh water consumption within 10 KL/KL of alcohol production

Refer chapter 2, section 2.7.1, table 2.19, page no. 35-36.

9 Details about capacity of spentwash holding tank, material used, design consideration, No. of piezometers to be proposed around spent wash holding

Refer chapter 2, figure 2.9, page 40 for cross section of spent wash storage tank.

14

INTRODUCTION…1

No List of TOR’s Compliance tank.

2 piezomenters are already installed in GIACL complex. Photographs of same are presented at appendix - J

10 Action plan to control ground water pollution Refer chapter 4, section 4.3.3, 11 Details of solid waste management including

management of boiler ash, yeast etc. Details of incinerates spentwash ash generation and its disposal.

Refer chapter 2, section 2.7.4, table 2.33, page 47

12 Details of bio-composting yard (if applicable) Not applicable. Conc. spentwash will be subjected to ATFD and converted into powder spentwash. same will be used as manure in fields.

13 Action plan to control odour pollution Refer chapter 4, section 4.3.1. 14 Arrangement for installation of continuous online

monitoring system (24x7 monitoring device) GIACL has installed online monitoring system to its existing boiler stack. Same practices will be followed after expansion.

15

Chapter 2

PROJECT DESCRIPTION

PROJECT DESCRIPTION …2

2.1 TYPE OF PROJECT Proposed expansion of distillery project is being undertaken by GIACL in its existing premises. Existing capacity of sugar factory is 5500 TCD, co-gen plant of 32 MW and 60 KLPD molasses based distillery. Expansion of distillery will be carried out from 60 KLPD to 150 KLPD i.e. expansion by 90 KLPD. 2.2 NEED OF PROJECT As discussed in Chapter-1 production of alcohol is gaining more importance with regards to production, usage, easy availability of raw material (grains as maize, sugarcane molasses). With the increase in business it has a considerable share in national income. Alcohol industry is the second largest source of revenue of the state. Industry is probably only one in which the inputs are de-controlled, but selling prices are determined by local state levies and excise duties. Moreover, there is a good export potential, out of the country for the alcohol. Alcohol has number of applications - • Blending with petroleum fuels, in pharmaceutical industry for blending with medicines

and drugs, in manufacturing of chemicals. • Used in perfumes, cosmetics and vegetable essences. • In manufacture of IMFL & Country Liquors. Apart from this following are also the need of the projects - 2.2.1 Employment Generation Potential Activities in proposed expansion would improve the socio-economic status of people in the study area in terms of local labor employment and contract basis jobs. Proposed expansion activity might provide employment opportunities to the local populace, especially in business and other services. Following are the details of manpower under existing and expansion project.

Table 2.1 Details of manpower

Sr. No.

Unit Existing Expansion Unskilled Skilled Unskilled Skilled

1 Sugar 150 50 -- -- 2 Co-gen 45 16 -- -- 3 Distillery 25 5 20 30 Total 220 71 20 30 Total

Workers 291 50

341 2.2.2 Export Potential of the Products

There is a good demand for products from proposed manufacturing in India as well as abroad. Alcohol produced has a demand for blending in petrol after making anhydrous alcohol from the conventional rectified spirit. ENA is utilized for production of value added product, for the production of spirit such as whisky, rum, brandy, gin and vodka but also as a base for a wide range of flavored alcoholic beverages providing huge market opportunity. Moreover, the electricity produced from existing co-gen plant shall be taken to switch yard from where it would be used for industrial needs in industrial complex.

16


2.3 PROJECT LOCATION As described in earlier chapter, proposed distillery expansion project would be implemented in existing GIACL complex located at Najik Babulgaon in Shevgaon Taluka of Ahmednagar district of Maharashtra. Geographical location of the site is 19022’47.28’’N Latitude and 75017’00.72’’E Longitude. At the time of site selection for existing industry, certain vital aspects were looked in to by the project proponents. Same included - (1) Availability of all basic facilities like water, electricity, man power etc., (2) District had rail and road links to prominent marketplaces so that procurement of raw material as well as marketing of finished product was easier and economical, (3) Availability of good communication facilities, (4) No rehabilitation and resettlement required, (5) Boundary of Jaikwadi Bird Sanctuary is about 5.51 Km from industrial site. Refer Figure 2.2 for google image of study area within 10 Km radius of the GIACL plant.

Table 2.2 Salient Features of Project Site

No. Particulars Details 1. Name and address of the Industry

(Integrated Project Complex of Sugar Factory ,Co-gen and Molasses based Distillery)

Gangamai Industries And Constructions Ltd., (GIACL) Gat No.: 6, 222/3, 223, 224, 228/1, 228/2, 228/3, 233, 234 529 and 210/5, Najik Babulgaon, Post- Rakshi, Tal.: Shevgaon, Dist.: Ahmednagar, Maharashtra State.

2 Land acquired 3,30,611 Sq. M. (33.06 Ha) 3 Elevation 450 M above MSL 4 Nearest habitation Najik Babhulgaon (1.16 Km) 5 Nearest city Shevgaon (7.19 Km) 6 Nearest highway SH- 44 (2.60 Km )&SH-148 ( 1.63 Km) 7 Nearest railway station Ahmednagar (68 Km) 8 Nearest airport Aurangabad Airport (50 Km) 9 Nearest tourist place(s) Paithan (15 Km) 10 Defense installations Nil within 10 Km radius 11 Archaeological important Mahadev Mandir at Ghotan (2.5 Km) 12 Ecological sensitive zones 5.51 Km from Project Site 13 Reserved /Protected forest / National

Parks/ Wildlife Sanctuary etc. Nil within 10 Km radius

14 Nearest streams / Rivers / water bodies (from Project Site)

Godavari River (13 Km)

15 Distance from boundary of Jaikwadi Sanctuary as well as Eco-Sensitive Zone (ESZ).

Project site is located 5.51 Km from ESZ Sanctuary.ESZ for Jaykwadi bird sanctuary got finalized vide MoEFCC Notification No. SO-2202 E dated 12th July 2017. As per this notification, our project is not located within ESZ. We have obtained No Objection Certificate (NOC) from Deputy Conservator of Forests (DCF), Aurangabad regarding our project. Refer appendix – B for copy of NOC obtained from Forest Department, Aurangabad.

17


No. Particulars Details 16 Site Co-ordinates (all corners) 19°22'55.19"N, 75°16'50.20"E

19°22'54.51"N, 75°17'08.36"E 19°22'42.14"N, 75°17'09.86"E 19°22'38.32"N, 75°16'56.97"E 19°22'41.97"N, 75°16'49.82"E 19°22'46.92"N, 75°16'48.82"E

2.4 DETAILS OF LAND REQUIREMENT

Table 2.3 Details of Area Break Up

Sr. No.

Description Built Up Area Sq. M.

Open Space Sq. M.

Total Area Sq. M.

A Administration Block 1,040 7,216 8,256 B Residential Colony 2,860 10,935 13,795 C Sugar Factory & Co-gen 1 Cane Yard 5,600 15,600 21,200 2 Water Reservoir 6,800 --- 6,800 3 Mill, Boiling House & Store 15,000 --- 15,000 4 Boiler Clarification & Power House 8,700 --- 8,700 5 Bagasse Yard 23,000 --- 23,000 6 ETP & Spray Pond 12,600 8,165 20,765 7 Molasses Tank 5,245 --- 5,245 8 Sugar Godowns 15,300 --- 15,300 9 Switch Yard 4,800 --- 4,800 Total 97,045 23,765 1,20,810

D Distillery 1 Water Reservoir 195 --- --- 2 Cooling Tower with pump 180 --- --- 3 Fermentation 1138 --- --- 4 Distillation 320 --- --- 5 Receiving Section 384 --- --- 6 Bulk Storage section 1492 --- --- 7 Distillery Office 44 --- --- 8 Security Cabin 16 --- --- Total 3,769 4,469 8,238 Distillery open space to be kept open for movement of trucks

E Biogas 10,901 -- 10,901 F Compost Yard & 30 days Lagoon 34,625

44,775 79,400

45,526 90,301 G Area under Roads 29,261 --- 29,261 H Green Belt (23% of total plot area) -- -- 61,350 Total (A+B+C+D+E+F+G+H) 1,79,501 25,341 2,70,661 Additional land procure for

development of green belt 60,000

Green Belt Area Total - 1,01,818 Sq.M. [38% of industrial total plot area]

61,350 Sq. M. (23% of industrial total plot area) 40,468.5 Sq. M (15% of industrial total plot area)

18


Land acquired by GIACL for industrial purpose is 2,70,661 Sq. M. (27.06 Ha). Out of this 0.82 Ha area comes under distillery. While 12.08 Ha area comes under sugar factory &co-gen plant projects. Unit wise area break-up in the GIACL is as shown in following Table 2.3. Therein area allocation for various amenities and buildings has been presented. GIACL has procured additional land of 6 Ha for development of green belt. Out of this 6 ha an area of 4.07 ha is developed as green belt. Hence total green belt developed by GIACL is 38% of industrial total plot area. Master layout showing sugar factory, co-gen plant and distillery area of GIACL is attached at Appendix -A .

19


2.4.1. Site History

GIACL Is located in village Najik Babhulgaon, Tal.: Shevgaon, Dist.: Ahmednagar, Maharashtra State. 2500 TCD sugar factory and 12 MW co-gen plant of GIACL was established in year 2010. Before establishment of sugar factory on procured land by GIACL, entire land was barren. About 91% of people in study area were depend on agriculture as their main occupation. Source of irrigation is rainwater or bore wells. Only one crop was taken based on rain water availability. Crops like Jowar, Wheat, and Vegetables, some grew cotton as well. Entire district experiences moderate and severe drought conditions for more than 20% of the years and is categorized as “drought area”. Since year 2004 the agriculture practice was stopped due to inadequate rainfall and other allied reasons. Land was not cultivated for 4-5 years. In year 2010 GIACL purchased the land from farmer namely- Mr. Sakharam Tukaram Dhorkule, Mrs. Kausabai Tukaram Dhorkule, & Mr. Kakasaheb Aasaram, in installation manner. Construction of sugar factory was start in April 2010. First crushing of sugar factory was taken in year Nov. 2010. Further GIACL has planned to go for an expansion of sugar factory from 2500 TCD to 5500 TCD and co-gen plant from 12 MW to 32 MW. Department of Environment, Government of Maharashtra granted Environmental Clearance (EC) for 2500 TCD to 5500 TCD and co-gen plant from 12 MW to 32 MW in year 2015. 30 KLPD distillery was granted EC from MoEFCC in year 2014. GIACL again expands its 30 KLPD distillery up to 60 KLPDafter having EC from MoEFCC in year 2017.Refer appendix -C for EC letter & consents

Figure 2.1 Images Showing Site History

Image a: - Landuse Status of Existing Sugar Factory, Co-gen Plant and Distillery by GIACL – Year 2009

Image a: - Landuse Status of Existing Sugar Factory, Co-gen Plant and Distillery by GIACL – Year2018

20


2.5 PROJECT OPERATIONS, APPROVALS & IMPLEMENTATION Presently, in the integrated project complex of GIACL, following activities are in operation – 1. 5,500 TCD Sugar Factory 2. 32 MW Co-gen Plant 3. 60KLPD Distillery

Existing 60 KLPD distillery of GIACL has been granted EC by MoEFCC in year 2017 and subsequently Consent to Operate (CTO) form MPCB. Also, other units namely sugar factory and co-gen plant have been awarded EC by SEIAA of Maharashtra Govt. Copies of the EC for existing units and that of the MPCB Consents (both CTO &CTE) are enclosed at Appendix-C. Proposed distillery expansion project will be implemented only after obtaining requisite approvals, permissions, consents from MPCB etc. Project would be formulated in such a fashion and manner so that the utmost care of safety norms and environment protection measures shall be taken. A question was asked during public hearing that how many days this project will run and how many days the plant works in one year. Consultant replied to public that plant will be working 330 days in a year. The project will go on depends upon the demand as there is heavy demand of Ethanol, due increase in petrol prices Project details in respect of capital investment and days of operation w.r.t GIACL Sugar factory and distillery as well as co-generation plant are given in Table 2.4 and Table 2.5 respectively.

Table 2.4 Working Pattern

Sr. No.

Type Of Activity

Days of Operation Season Off- Season Total

1. Distillery 180 Days 150 Days 330 Days 2. Sugar Factory 180 Days --- 180 Days 3. Co-gen Plant 180 Days 52 Days 232 days

2.5.1. Approval and Implementation Schedule

Table 2.5 Project Implementation schedule

Sr. No Activity Implementation Schedule

1 Grant of EC February 2019 2 Construction and Erection of Machinery April 2019 3 Application for Consent to Operate from MPCB May 2019 4 Trials & Commissioning of Project June 2019

2.6 TECHNOLOGY &PROCESS DESCRIPTION 2.6.1 Products Main products to be manufactured under proposed distillery expansion project are Rectified Spirit, Ethanol and Extra Neutral Alcohol. Fusel Oil, Carbon dioxide (CO2) and spentwash dry powder are by-products generated from molasses based distillery.

21


A question was asked during public hearing regarding type of products will be manufactured under this project. Consultant replied that in expansion project industrial alcohol, Extra Neutral Ethanol are the products and Fusel Oil, Biogas Carbon Dioxide are byproducts. Details of products under existing and expansion distillery activities are given in table 2.6. GIACL also manufacture sugar to the tune of 18,150 MT/M and 32 MW Electricity. Products manufactured under sugar factory and co-gen plant are presented at table 2.7.

Table 2.6 Products under Distillery Industrial

Unit Product Quantity

Existing (60 KLPD)

Expansion (90 KLPD)

Total (150 KLPD)

Distillery Rectified Spirit 1800 KL/M 2700 KL/M 4500 KL/M Extra Neutral Alcohol 1800 KL/M 2700 KL/M 4500 KL/M Ethanol 1800 KL/M 2700 KL/M 4500 KL/M

By-product Fusel Oil 34 KL/Annum 47 KL/Annum 81KL/Annum CO2 gas 1380 MT/M 2036 MT/M 3416 MT/M Compost (from Spent wash treatment)

20935 MT/Annum

-- 20935 MT/Annum

Spentwash Dry Powder (99% Solids)

-- -- 3000 MT/M


-- -- 2190 MT/M

* Under existing scenario of 60 KLPD conc. spent wash was mix with Boiler ash and to form bio-compost to the tune of 16,700 MT/Season. After expansion all spentwash will be dried in ATFD and convert in powder.

Table 2.7 Products under Sugar Factory and Co-gen Plant

Industrial Unit Product Quantity (MT/M)

Sugar Factory (5500 TCD) White Sugar 18,150 By - product

Molasses 6,600 Bagasse 49,500 Press mud 6,600

Co- Generation (32 MW) Electricity 32 MW

2.6.2 Raw Materials for Integrated Project Basic raw materials required for distillery, sugar factory and co-gen Plant along with their quantities and sources are listed in table2.8 and 2.9 respectively-

22


Table 2.8 Raw Materials for Distillery

Industrial Unit

Raw material Quantity Source of Material Existing

(60 KLPD) Expansion (90 KLPD)

Total (150 KLPD)

Distillery Molasses 7,200

MT/M 10,800 MT/M

18,000 MT/M

Own Factory & outside factories

Urea 2,400 Kg/M 2,600 Kg/M 5,000 Kg/M Local Vendors DAP 2,400 Kg/M 2,600 Kg/M 5,000 Kg/M

Formalin 200 Lit/M 100 Lit/M 300 Lit/M Bleaching Powder 120 Kg/M 180 Kg/M 300 Kg/M Sulphuric Acid 6,000 Kg/M -- 6000 Kg/M Caustic Soda 400 Kg/M 1100 Kg/M 1500 Kg/M Yeast Culture Test tube

culture Test tube

culture Test tube

culture

Table 2.9 Raw Materials for Sugar Factory and Co-gen Plant

Industrial Unit Raw Material Quantity Source of Material Sugar Factory (5500 TCD)

Sugarcane 1,65,000 MT/M Nearby Farms Sulphur 99 MT/M

Supplied by outside parties

Lime 330 MT/M Oil & Grease 9.9 MT/M Phosphoric Acid 3.3 MT/M

Co- Generation (32 MW) Bagasse 49,500 MT/M Own Sugar Factory

2.6.3 Raw Material Availability for GIACL Complex

Table 2.10 Availability of Molasses for Distillery Operations (Existing & Proposed)

Sr. No. Description Quantity 1 Cane crushing capacity (TPD) 5500 2 No. of days of sugar factory operations 180 3 Cane crushing MT / Season 990000 4 Molasses quantity generated @ 4 % of cane 220 MT/day 5 Molasses quantity generated during season 39,600 MT 6 Distillery Capacity (KLPD) 150 7 Daily molasses required for distillery 600 MT/day 8 No. of days of Distillery operations 330 9 Total molasses required for distillery 198000 MT 10 No. of days on

Own molasses 66 Procured molasses 264 Total 330

23


Table 2.11 On Site Molasses Storage Details

No. Description Tank Details Dimensions Remark 1 Molasses Storage Tanks

(In Sugar Factory) Quantity: 2 Capacity: 10,000MT each

Diameter – 30 m Height -10 m

Existing Tanks

2 Molasses Storage Tanks (In Distillery)

Quantity: 2 Capacity: 7,000 MT

Diameter 25 m Height -10 m

Existing Tanks



Diameter –28 m Height -10 m

Expansion Tanks

2.6.4 Raw Material and Product Transportation Details Molasses as a raw material for distillery shall be made available from own sugar factory as well as nearby sugar factories from Ahmednagar, Nashik Pune, Aurangabad, Beed, Jalna, Parbhani & Hingoli Districts. Details of molasses transport are presented at table – 2.12 Sugarcane as raw material for sugar factory shall be made available from nearby farms in 50 Km area from the factory. During cultivation of sugarcane in farms, farmers inform the field man of Karkhana which are appointed region wise, regarding the start of cultivation. Lateron, the field man submits the information to Karkhana office. Accordingly, days of maturation of sugarcane cultivation is calculated and labours as well as vehicles are forwarded by kharkana to the farms for its harvesting. Further, this harvested cane is brought to Karkhana site and immediately consumed for processing within 24 hrs. The vehicles filled with cane wait in parking lot for their turn. Hence, no any bulk storage of sugarcane is done on site. Ample parking space is provided for the bullock carts, trucks and trolleys. Details of sugarcane transport are presented at table – 2.13

Table 2.12 Details of Raw Material - Molasses Transport to GIACL Distillery Sr. No.

Type of Vehicle

Avg. wt (MT)

Daily No. of Vehicles Quantity (MT/Day)

Source Existing Expansion

1. Trucks - Molasses

15 5 20 375 Sugar factories in Ahmednagar, Nashik Pune, Aurangabad, Beed, Jalna, Parbhani & Hingoli District.

Table 2.13 Details of Raw Material – Sugarcane Transport to GIACL Sugar Factory

Sr. No.

Type of Vehicle Avg. wt (MT)

Daily No. of Vehicles

Quantity (MT/Day)

Source

1. Bullock Carts - Sugar Cane 2.25 1,200 2,700 Nearby farm land 2. Tractor Trolleys- Sugar Cane 9.14 175 1,600

3. Trucks- Sugar Cane 16.00 75 1,200 Total 1,450 5,500

24


Table 2.14 Details of Product – Alcohol Transportation

Sr. No.

Type of Vehicle

Avg. Wt.

(MT)

Cap. of Vehicles

KL / Season No. of Vehicles throughout Season

Avg. Daily Vehicles

Existing Expansion Existing Expansion Existing Expansion 1. Tanker

Alcohol 16 20 KL 19800 29700 990 1485 3 5

Total 49,500 2,475 8 Final product sugar manufactured is initially stored in godowns. Later on, it sold in market through tenders. Sugar shall be sold as per the market demand throughout the year and before commencing the ensuing season. It’s very uncertain to predict daily traffic due to transport of sugar.

Table 2.15 Details of Product – Sugar Transportation Sr. No.

Type of Vehicle

Avg. wt Nos. Bags or KL / Season

Cap. of vehicles

no. of Vehicles throughout

season

Avg. no. daily

Vehicles 1. Trucks - Sugar 50Kg / Bag 21,78,000 200 Bags 10,890 52

Total 52 2.6.5 Manufacturing Process for Alcohol Molasses is the main raw material used for production of alcohol. Molasses is stored in mild steel storage tank. Proper care is taken to cool down molasses before it goes to molasses tanks. Then the molasses is pumped from the MS storage tanks to weighing scales. Here it is weighed on automatic weighing scales and then fed for further processing. Molasses contains about 40-50% of total sugars, out of which 30-33% are cane sugars and the rest are reducing sugars. Fermentation yeast strains convert sugar present in the molasses such as sucrose or glucose to alcohol. Sucrose is present as non-reducing fermentable sugar in all sugary raw material e.g. sugarcane and sugar beet juice, syrup and molasses. Before fermentation, yeast enzymatically converts sucrose in to glucose and fructose. Glucose and fructose are reducing monosaccharide and get converted in to ethanol and CO2 within yeast cell Conversion of glucose to ethanol takes place through a series of biochemical reactions called as Embden Mayer Hoff (EMP) pathway. Chemically, this transformation of sucrose to alcohol can be approximated by the following equation. I) C12H22O11 + H2O 2 C6H12O6 Cane Sugar Inversion Glucose II) C6H12O6 C2H5OH + 2 CO2 Glucose Fermentation Ethyl Alcohol Carbon dioxide 180 2 X 46 + 2 X 44 100 kg of sugar would theoretically yield 51.11 kg of ethanol and 48.89 kg CO2. Part of glucose is used for yeast growth and by-product formation.

25


In the production of ethyl alcohol from molasses, two major steps are involved. 1) Fermentation of Molasses with the help of yeast strains of the species Saccharomyces

cerevisiae (belonging to fungi class) to produce 6% to 8% alcohol in the fermented wash; and

2) Distillation of the fermented wash for recovery and concentration of alcohol. 2.6.5.1 Fermentation Process Normally, molasses is made up of water or moisture and solids. Solids are further categorized as organic and inorganic. Organic solids can be classified as fermentable sugars, non-fermentable sugars, volatile acids, nitrogenous matter, caramel, gum and waxes as well as other concentrated components which had been added during sugar processing like polyelectrolyte’s, biocides etc. Volatile acid content has profound effect on yeast performance. Term volatile acids present in molasses are acetic acid, propionic acid, butyric acid, valeric acid and isovaleric acid. Volatile acidity is expressed in terms of acetic acid. Acetic acid affects cell multiplication. As ethanol fermentation is growth-associated product, due to less growth of yeast, alcohol formation rate is decreased. This affects fermentation efficiency and capacity. Butyric acid is more potent to yeast than acetic acid for the same concentration. Saccharomyces is versatile in nature and most preferred yeast to carry out fermentation at industrial scale because of its fast growing and fast fermenting characteristics. Raw material is diluted to appropriate sugar concentration. Yeast is inoculated and fermentation is carried out at optimum temperature, pH, aeration, agitation and supplementary nutrients. Fermentation section is based on HIFERM-FERMENTATION continuous / semi continuous fermentation process. In existing 60 KLPD distillery; four fermentor systems are present. After expansion of distillery GIACL will installed additional 2 new fermenters. Individual fermenter is equipped with molasses dilution system, aeration for mixing in fermenter, safety system etc. Process utilizes special culture yeast fast fermenting property. In continuous mode of operation, molasses and process water are added proportionately to maintain desired alcohol concentration in individual fermenter. Fermented wash from last fermenter is passed to Clarified wash tank through Wash settling tank from which it is fed to distillation. In semi continuous mode of operation, molasses and process water are added along with yeast to maintain desired alcohol concentration in individual fermenter. After reaction completion, individual fermenter is harvested. Dedicated molasses weighing system is provided to determine molasses consumption. In spent wash recycle section, spent wash cooler and distribution system is provided. A part of spent wash from distillation section is cooled and recycled to fermentation and used as diluent by replacing process water. CO2 scrubber recovers alcohol from carbon dioxide. Alcohol scrubbed water from scrubber is further sent to clarified wash tank. Air is sparged in yeast culture vessels, activation Vessel and fermenter. Systems for dosing nutrients, sulfuric acid and de foaming agent are provided with appropriate tanks and pumps.

26


2.6.5.2 Distillation Operation

Multi-pressure distillation system is designed to produce RS, ENA and Ethanol from fermented wash. Mainly, following columns play important role in the distillation operation. (1) CO2 stripper, (2) Stripping, (3) Pre-rectifier column,(4) Extraction, (5) Rectification, (6) Refining, (7) Fusel oil concentration, (8) Evaporator column

Fusel oil column concentrates the heads and fusel oil and recovers alcohol. In CO2 column non-condensable gasses remove from the top. Plant is operated from control room through PLC system.CO2 stripper, extraction and refining columns workat pressure below atmospheric whereas the rectifier and fusel oil columns work above atm. pressure.Rectifier column, fusel column & pre-rectifier columns are indirectly heated by steam. Pressurized vapours from the top of rectifier column supply thermal energy to the re-boiler of stripper column.Top vapours of pre-rectifier column supply the thermal energy to the re-boiler of extraction column and also to the re boiler of the refining column.Stripper column top and middle vapours supply direct heat to CO2 column. 1. CO2 Stripper Column

Fermented wash after clarification and yeast separation is pumped to the column through the Beer heater & plate heat exchanger by adjusting wash flow through flow meter. Fermented wash fed to the top of column and the vapours coming from the stripper column heat the wash.Hot wash is fed to stripper column. Non condensable gasses escapes from top of the column and condensed in condenser.Condensate get recycled back to the column. Non condensable gasses are connected to vacuum pump. 2. Stripper Column

Hot fermented wash from CO2 column is fed to stripper column. Spent wash at the bottom of the column is circulated by axial flow pump and passed through re-boiler and is taken out from bottom by pump.Heat recovered from outgoing spentwash through is used to heat incoming fermented wash.Alcohol vapors coming out from top of this column and fed to the pre-rectifier column under ENA mode. Otherwise, they are fed to the extraction column for operations under RS mode through pump. Spent lees from the bottom of the column are free from alcohol and are used for heating by passing through. Bottom liquid is pumped and partly fed to extraction column.

3. Pre Rectifier Column

Steam flow control valve is adjusted to get required reflux and temperature to the column. Subsequently, the bottom level of column is checked and adjusted up to 50% and thereafter the level control valve is set on auto mode. Also, the level of reflux tank is checked. During the operation, the concentration of reflux, product and fusel oil draw is checked periodically.Then the RS draw valve is gradually opened. 4. Extraction Column

Column is designed to separate all low boiling impurities; aldehydes, esters and sulfur compounds from the feed alcohol. Addition of process water or spent less or chemicals

27


dosing increases volatility of low boiling compound with respect to ethanol in solution containing of water. In this process the impurities of ethanol water mixture get removed at the bottom of the column. Then the impurities go on the top portion of the column.The dilution water/spent lees get heated by passing through PHEs. Top vapour from the column is condensed in main condenser and vent condenser and reflux is sent to the column through glass tube rotameter. Partly the fusel oil and other impurities are fed to FOC and the vent is connected to vacuum system.Bottom liquid containing alcohol water mixture is fed to rectifier column. 5. Rectifier Column

Rectification column is provided to accommodate alcohol.It takes some time to build up the required alcohol profile in the column. Here, it is extremely essential to observe the temperature difference of alcohol draw plate and fusel oil draw plate which are required to be near the designed temperature. From this column, the alcohol is fed to refining column by opening the product control valve.

6. Refining Column

Refining column is mainly designed for polishing the product by removing traces of volatile impurities and maintaining aroma and flavors to meet the premium quality norms.Pure alcohol is removed from bottom of column & after cooling it is pumped to ENA day storage section. 7. Fusel Oil Column

Impurities from rectifier column &pre-rectifier column are concentrated in this column.Concentrated heads are taken out from top of column. Spent lees from bottom of column are passed through PHEtorecover the heat. Concentrated fusel oil is drawn from middle portion of the column and sent for decantation. Subsequently, the fuseloil is sent to FO storage tank. 8. Fusel Oil Decanter Fusel oil comes from fusel oil column, cooled in cooler and fed to fusel oil decanter. In decanter, fusel oil is washed to remove traces of alcohol by adding process water. The fusel oil layer is taken out as by-product and the bottom liquid is recycled back to fusel oil column for further recovery. 2.6.5.3 Technology used by GIACL for conversion of liquid Spentwash into Spentwash

Powder Spentwash generated from 150 KLPD molasses based distillery will be first subjected to bio-methanation followed by concentration in MEE. Bio-methanated and MEE concentrated spentwash then subjected to Agitator Thin Film Dryer (ATFD). Under MEE three force circulation evaporation bodies will be installed. Two in operation and one in standby mode. Followed by four no. of ATFD; three in operation and one in standby mode.In Force circulation evaporators solids raised from 30% to 55% fade to three ATFD in series which ejaculate 95-99% solid spentwash powder. Spentwash powder is potash rich and contains 28% Potash. Spentwash powder with 95% solids will be mixed with boiler ash and sold as

28


manureduring crushing season; to the cane grower farmers command area of industry.During non crushing season GIACL will form spentwash powder of 99% solids. Same will be bagged and sold out. At present GIACL had 60 KLPD molasses based distillery on site. 60 KLPD plant comprising of two plants of identical capacities i.e. 30 KLPD each. First 30 KLPD distillery was commissioned in year2014 and another 30 KLPD was commissioned in Dec. 2017. After getting EC for 150 KLPD distillery, GIACL will scrap its exiting 30 KLPD distillery which was established in year 2014 and at same place GIACL will installed a new modernized plant of 120 KLPD. 2.6.5.4 Various Manufacturing Configurations 1. Wash to ENA Manufacturing Mode Fermented Wash -- CO2Stripper -- Stripper Column -- Pre Rectifier Column -- Extraction Column -- Fusel Oil Column -- Rectifier Column-- Refining Column

2. Wash to RS Mode

Fermented Wash -- CO2 Stripper -- Stripper Column -- Extraction Column -- Fusel Oil Column -- Rectifier Column

3. Wash to Ethanol Mode Fermented Wash -- CO2 Stripper -- Stripper Column -- Extraction Column -- Fusel Oil Column -- Rectifier Column 2.6.5.5 Alcohol Storage Details

Table 2.16 Existing Alcohol Storage Arrangements at GIACL Site

Sr. No

Description Details of tanks Remark Existing Under Expansion

Details Dimensions Details Dimensions 1. RS Receiver Quantity: 3 No.

Capacity: 130 M3, Material: M.S.

Diameter – 4.5 m Height -7.0 m

-- -- Site Fabricated

2. ENA Receiver

Quantity: 2 No. Capacity: 130 M3, Material: M.S.



3. Ethanol/ AA Receiver




4. Impure Spirit Receiver


Diameter –2.1 Height -3.0 m


5. Denatured Spirit Storage Tank


Diameter – 3.0 m Height -4.27

-- -- Site

Fabricated

29


Sr. No

Description Details of tanks Remark Existing Under Expansion

Details Dimensions Details Dimensions 6. RS Bulk

Storage Tank

Quantity: 2 No. Capacity:1000M3, each Material: M.S.

Diameter –11.0 m Height -11.5 m

-- -- Site

Fabricated

7. ENA Bulk Storage Tank

Quantity: 1 No. Capacity: 750M3/Hr, Material: M.S.

Diameter – 9.14 Height -11.6 m

-- -- Site

Fabricated

8. Ethanol/AA Bulk Storage Tank

Quantity: 3 No. Capacity: 750 M3 Material: M.S.

Diameter – 9.14 Height -11.6 m

-- -- Site

Fabricated

9. Ethanol/AA Bulk Storage Tank

Quantity: 2 No. Capacity: 1000 M3 Material: M.S.

Diameter –11.0 m Height -11.5 m


Diameter –15.0 m Height -21 m

Site Fabricated

10. S.D.S. Bulk Storage Tank


Diameter –9.14 Height -11.5

-- -- Site

Fabricated

11. Impure Spirit Bulk Storage Tank


Diameter –4.6 Height -6.127

-- -- Site

Fabricated

12. Day Tank For Ethanol Feed

Quantity: 1 Capacity: 170 KL, Material: M.S.

Diameter – 5.4 Height -8


A question was asked regarding manufacturing process. Consultant replied to public thatalcohol is manufactured by means of micro organism viz. Yeast through fermentation and distillation. The storage of alcohol is for limited period only (One Month Storage in vertical Cylindrical M.S. Tanks). Detailed manufacturing process is given at section 2.6.5.

30


Figure 2.2 Mass Balance and Process Flow Chart for 60 KLPD Distillery

Figure2.3 MassBalance and Process Flow Chart for 150KLPD Distillery

31


2.6.5.6 Manufacturing Process for Sugar

Sugar is manufactured by using sugarcane as raw material. Juice is extracted from cane and boiled to process sugar .Mass balance for sugar production is as follow-

Figure 2.4 Mass Balance and Process Flow Chart for 5,500 TCD Sugar Factory

Condensate water. Evaporation losses & vapor added to spray pond. Orange Color Condensate water used in Processing unit. Yellow Color Condensate water used in Turbine Cooling. Blue Color Condensate water used for boiler.

1207

Reject to MEE -165 M3

Permeate to Boiler 720

1375 MT

Sugar 577.5 MT

Centrifugal 825 MT

Crystallizer 729 MT

Vacuum Pan 2104 MT

Pan Condensate

Vapour added to

spray water

137 5M

Molasses 247.5 MT

1001 MT after cooling use as raw

water

96 MT condensate

use for centrifugal

+

1237.5 MT evaporation loss during

cooling

1441 M3 for CPU

885 M3for R O Inlet

CPU Outlet 1425 M3

Turbine cooling make up water - 315 M3+ Brushing - 100 M3 + Mill Bearing - 25 M3 + Vaccum pump sealing - 100 M3 = 225 M3

= 225 +315 = 540 M3

Water for cooling hot vapors

110 MT

1st effect vapors to Heat Exchange 440 MT

Imbibition water from pan condensate 1375 MT

Milling Section, 6875 MT

Juice 5225 MT

4686 MT

5126

5236 MT

Clarification of Juice

Heat Exchange

Sugar Cane 5500

Sulphur 2.75 MT + Lime 8 25 MT

Steam 2090 MT

1650 MT Bagasse use for Boiler

Sediment

Condensate 440 MT after cooling use as raw water

Press mud 220 MT

Vacuum filter

110 MT condensate used

Steam condensate

2, 3 & 4 effect

Multiple Effect

1375 MT Vapors heat to pan

32


Table 2.17 Product and By-product Storage Details

Sr. No.

Products & By-products

Mode of Storage Details of Area

1. Sugar Sugar is filled in 50 Kg bags and these bags are stored in Godowns

There are 6 Nos. of RCC covered Godowns each of 100 M X 75 M dimensions.

2. Bagasse Bagasse is bailed& stored in dedicated separate yard in own premises.

Bagasse Yard Area – 23,000 Sq. M

3. Pressmud Pressmud is stored in dedicated separate yard in own premises

Pressmud is sold to farmers.

4. Molasses In Steel Tanks Refer Table 2.15.

Cane Availability

1. No. of share holders 4,500 2. Land under cane crop of each share holder (Acers) 4 3. Total share holders land under cane crop (Acers) 18,000 4. Avg. yield MT. per Acer 40 5. Total cane available from share holders land (MT) 7,20,000 6. Cane available from Non-share holders land (MT) 4,35,000 7. Total cane available (MT) 11,55,000 8. Avg. distance from sugar factory (Km.) 35

2.6.5.7 Manufacturing Process for Co-generation

Existing co-generation power plant of 32 MW have been installed with double extraction cum condensing type steam turbine which operates on steam of 70 kg/cm2pressure with temperature of 5000C.There is boiler of 140 TPH with steam generation of 72 kg/cm2 and 5150 C.Bagasse generated from cane crushing, excluding handling losses and bagacillo requirements is available for operation of the high pressure boiler during season of 180 days. Saved bagasse could be used during off season period for about 52 days.Steam utilization in power plant for is also done for auxiliary consumptions namely – at high pressure for soot blowing, Steam Jet Air Ejector (SJAE), gland steam condenser (GSC), at medium pressure for twin HP heater and at low pressure for de-aerator. Auxiliary power consumption, for the power plant, is about 7% to 10% of generation during season and off season periods respectively. Colony power requirement will be met by the co-generation power plant, during season& off-season periods. Distribution of electricity generated from co-gen plant is presented in following table 2.18.

Table 2.18 Electricity Distribution Details

Sr. No. Description On Season32 MW capacity Off Season12 MW capacity 1. Sugar 5.25 MW -- 2. Co-gen 2.10 MW 0.5 MW 3. Distillery & Biogas 2 MW 2 MW 4. Colony 1.5 MW 1.5 MW

Total 10.85 MW 4.0 MW 5. MSEB Grid 21.15 MW 10.0 MW

Grant Total 32 MW 14 MW

33


Table 2.19 Bagasse Mass Balance

No. Description Quantity 1. Sugar Cane Crushing 5,500 TCD 2. Working Days of Sugar Factory 180 Days 3. Total Crushing 9,90,000 MT/Season 4. Bagasse Quantity generated @ 30% of cane crushed 1650 MT/Day 5. Total Bagasse quantity during Season 2,97,000MT/Season 6. Daily Bagasse required for Co-gen boilers(140TPH&30TPH) 1,445 MT/Day 7. Bagasse for Co-gen during Season(180 days) 2,60,100 MT/Season 8. Bagasse saved due to Biogas 45,720 MT/Season 9. Total saved Bagasse during Season 82,620 MT / Season 10. Bagasse for Co-gen during Off -Season (52 Days) 75140 MT/Season Bagasse generated from cane crushing, excluding handling losses and bagacillo requirements will be available for operation of the boiler during season as well as non crushing season. Also, Biogas generated from Bio- methanation plant will be used as a fuel for 8 TPH distillery boilers.

Figure 2.5 Process Flow Chart for Co-gen Plant

Condensate

140 TPH + 30 TPH 72 Kg/cm2

Electricity

Exhaust steam for Process

Double Extraction

Condensing Turbine

Bagasse

Boilers 140 TPH + 30 TPH

72 Kg/cm2, 510OC

Condenser

Steam for Sugar Plant

Steam for Distillery

To MSEB power Grid

Power for Inplant use

34


Figure 2.6 Manufacturing Process Details of GIACL Integrated Project

2.7 SOURCES OF POLLUTION AND MITIGATION MEASURES Basic sources of pollution from the existing and proposed distillery operations are mainly operations &processes in the industry, boilers and stand by D. G. set. Detailed identification and quantification of impacts, due to above sources, are separated under various heads. They are – (1) Water Pollution, (2) Air Pollution, (3) Noise Pollution, (4) Hazardous Wastes, (5) Solid Waste and (6) Land Pollution. 2.7.1 Water Pollution (WP)

Assignment w.r.t. water pollution aspect was done by Dr. Sangram Ghugare who is an in-house Functional Area Expert (FAE) for WP. Water pollution may be defined as the presence of impurities in water in such quantities and of such nature that impair / restrict use of water for the stated purpose. Fresh water requirement for existing and proposed activities shall be met from Jayakwadi dam on Godavari river. Total water requirement for 150 KLPD distillery project during sugar crushing season (180 days)would be 1619M3/ Day. Out of the total water requirement, 1506 M3/ Day water would required form industrial purpose, 12 M3/ Day water will required for domestic purpose and 101 M3/ Day. From total water requirement 41M3/Day would be fresh water taken from Jayakwadi dam on Godavari River (fresh water consumption 0.27 KL/KL of Alcohol against norm of 10 KL/KL of alcohol), 7 M3/Day would be STP treated water used for flushing, 230 M3/Day would be excess condensate water from sugar factory & co-gen plant and1578 M3/Day would be MEE condensate and CPU treated water from distillery. About 97% recycle water will be used for distillery during sugar

Sold to farmers Press Mud

To Grid

Power Steam

Sugar Factory

Boiler Turbines

To Factory

Distillation Alcohol

MEE

ATFD

Bio-Methanation

Distillery

Co-Generation Plant

To Godown / Market

Weighed Cane

Cane Milling / Crushing

Juice Clarification

Juice Sulphitation

Syrup Boiling

Centrifuging

Sugar

Bagasse

Molasses Fermentation

Powdered Spentwash

Powder with 95% solids – Mixed with

ash-manure

Powder with 99% solids –

manure Biogas to boiler

35


cane crushing season. During non-sugar cane crushing season (150 Days); total1619 M3/Day water will be required. out of this 271 M3/Day would be fresh water taken from Jayakwadi dam on Godavari River,1341 M3/Day would be MEE condensate and CPU treated water from distillery and7 M3/Day will be treated water from STP used for flushing. For non-sugar cane crushing season about 83% of water will be recycled water. Fresh water consumption for non-sugar cane crushing season will be 1.80 KL/KL of Alcohol against norm of 10 KL/KL of alcohol. Refer Appendix – D for water lifting permission letter.

Table 2.20 Water Consumption for Distillery (During Sugar cane Crushing Season - 180 days)

No. Purpose Existing

60 KLPD (CMD) Total after Expansion

150 KLPD (CMD) I Industrial

Process 490 (#90 + *400) *1240 Fermenter &Condenser Coolingtower replenishment

$140 $230

Boiler Feed #7 #19 Washing #4 #14 Laboratory #1 #3

Total 642 (#102 + $140+ *400) 1506 (#36+ $230 + *1240) II Domestic 10 (#3+₤7) 12 (#5+₤7) III Gardening & Green Belt #50 * 101 Grand Total 702(#155+₤7+$140+*400)

(78% Recycle) 1619(#41+ +₤7 + $230 + *1578)

(97 % Recycle) Note- # - Actual quantity of water taken from outside water supply source such as River.

* - Water taken from MEE Condensate and CPU treated effluent $ - Excess cane condensate & CPU treated Water Quantity from sugar factory & Co-gen. ₤- Treated water from STP used for flushing

Table 2.21 Water Consumption for Distillery (During non- Sugar cane Crushing Season - 150 days)

No. Purpose Existing

60 KLPD (CMD) Total after Expansion

150 KLPD (CMD) I Industrial

Process 490 (#90 + *400) *1240 Fermenter &Condenser Cooling tower replenishment

#140 #230

Boiler Feed #7 #19 Washing #4 #14 Laboratory #1 #3

Total 642 (#242 + *400) 1506 (#266 + *1240) II Domestic 10 (#3+₤7) 12 (#5+₤7) III Gardening & Green Belt #50 * 101 Grand Total 702 (#295+₤7+*400)

(58% Recycle) 1619 (#271+ +₤7 + *1341)

(83 % Recycle) Note# - Actual quantity of water taken from outside water supply source such as River.

* - Water taken from MEE Condensate and CPU treated effluent ₤ - Treated water from STP used for flushing

36


Table 2.22 Effluent Generation and Disposal in Existing & Expansion Distillery

Purpose Quantity (M3/Day) Remarks Existing (60

KLPD) Total

(150 KLPD) A. Industrial Process

Spentwash- 473

Conc. Sp. wash 189

Sp. wash of 1182 Sp.wash powder after Dryer – 97

1. Raw Spentwash of 1182 shall be primarily treated in bio-methanation Plant followed by Conc. in MEE.

2. Conc. Sp.twash of 443 shall be forwarded to Agitator Thin Film Dryer (ATFD) for drying and forms dry powder 95% or 99% solids.

3. 95% powder would be mixed with boiler ash to form manure during crushing season.

4. 99% powder bagged and sold during non-crushing season.

Spent lees - 127 MEE Condensate

- 284

Spent lees – 339 MEE condensate

- 1086

Other Effluents (36.25) viz. cooling blow down, lab & washing shall be forwarded to CPU along with spent lees (339) and MEE condensate (1086).

Fermenter &Condenser Cooling Blow down

16.25

36.25

Boiler Blow down Washing & Lab.

B. Domestic 8 8 Treated in STP 2.7.1.1 Domestic effluent Quantity of domestic effluent from existing distillery is to the tune of 8 M3/ Day. No effluent shall be generated form expansion activity. Existing domestic effluent is treated separately in Sewage Treatment Plant (STP) provided on site. 2.7.1.2 Industrial effluent Industrial effluent would be generated from the various operations & processes in the distillery. From molasses based distillery effluent generated in the form of spentwash, spentlees and other effluents such as effluent from lab & washing, boiler blow downs, cooling blow downs etc. In 60 KLPD distillery raw spentwash @ 473M3/Day is bio-methanated in bio-methanation plant and then concentrated in Multiple Effect Evaporator (MEE). Concentrated spentwash from MEE was used for bio-composting along with filler material such as boiler ash, pressmud, yeast sludge etc. After expansion of distillery total raw spentwash generated from 150 KLPD molasses based distillery will be to the tune of 1182M3/Day (7.8KL/KL of Alcohol). Same will be bio-methanated and then concentrated in MEE. MEE concentrated spentwash to the tune of 443M3/Day (2.9 KL/KL of Alcohol)will be then subjected to Agitated Thin Film Dryer(ATFD). Liquid spentwash will be converted in to powder up to 95 % to 99 % solids. Powder is potash rich (28% Potash) is mixed with boiler ash press mud and sold as manure to the cane grower farmers command area of the industry.MEE condensate @ 1086M3/Day, spentlees @ 339 M3/Day and Other @ 36.25 M3/Day will be treat in CPU. Under expansion one new CPU will be constructed. Treated water from CPU will be recycled back in process for dilution of molasses and for cooling purpose. This achieves Zero Liquid Discharge (ZLD). Table 2.20, table 2.21 & table 2.22

37


gives at glance details w.r.t. water consumption, losses, generation of effluents as far as the distillery is concerned. Details of bio-methanation plant and MEE plant is presented at table 2.23and table 2.24 respectively. During public hearing a question was asked that quantity of spentwash generation and disposal of same. I was replied to public that spentwash generated after expansion of distillery will be forwarded to bio-methanation followed by concentration in MEE. Conc. Spentwash will be subjected to ATFD to form spentwash powder. Other effluent will be treated in existing as well as proposed CPU plant. Details of same are given in section 2.7.1.2.

Table 2.23 Bio-gas Plant Details

Existing Biogas Plant Proposed Biogas Plant Type Continuous Stirred Tank Reactor (CSTR) Make MM Enviro Projects Pvt. Ltd. Nagpur MS Capacity 600M3 / day 800 M3/day Calorific Value 4,600 – 4,750 Kcal/ kg COD Reduction 70 % Gas Generation Rate 1 Kg of COD reduction gives 0.5 NM3 Gas Gas Generation 16000 – 16500 NM3/ Day 41000-42000 NM3/Day Feed Rate 10 M3/ Hr. 33 M3/Hr Cost Rs. 3.5 Crores Rs. 5.62 Crores

Table 2.24 Details of Multiple (Five) Effect Evaporator (MEE)

Existing MEE Proposed MEE Make SSP / SS TECHO. Type Forced Evaporator Capacity 600 M3/D 800 M3/day Volume Reduction 80% Inlet Solids 6% Out let Solids 30% Cost Rs. 9.46 Crores Rs. 5.62 Crores

Table 2.25 Details of Agitator Thin Film Dryer (ATFD)

Sr. No. Description Specification

Dryer Evaporation 1. Type Forced Circulation 2. No. of effects Three 3. Capacity 464 M3/day 4. Inlet Solids 30% 5. Out let Solids 65 % 6. Cost (Rs. In Lac) 562.00

Dryer Section 7. Type Agitated Thin Film Dryer(ATFD) 8. No. of effects Four 9. Inlet Solids 65% 10. Out let Solids 98%

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Figure 2.7Process Flow Diagram of Proposed CPU for Distillery

Figure 2.8 Process Flow Diagram of Existing CPU for Distillery

Table 2.26 Inlet and Outlet Parameters of Distillery CPU

No. Parameter Inlet Outlet 1. PH 9.1 to 9.5 7.0-7.8 2. COD mg/L 5000 to 5500 Below 100 3. Total hardness mg/L 50-60 40-50 4. Total Dissolved Solids mg/L 1600-1700 200-250 5. TemperatureºC 50-52 Ambient 6. Colour Crystal Clear Crystal clear

39


Presently, for spentwash management at GIACL, there are two tanks for storage of spentwash provided on site. One of 30 days storage capacity for digested spentwash while other is of 5 days storage capacity for raw spentwash. These tanks have been designed as per CPCB norms wherein HDPE liners of 500 microns thickness and RCC lining have been provided to avoid seepages and ground water contamination. Following Figure - 2.8showscrosssection of the spentwash storage tank. Raw spentwash shall be feed to biogas plant for bio-methanation process. Digested spentwash coming out of bio-methanation plant shall be concentrated in MEE. Concentrated spent wash from MEE shall be subjected to ATFD to form powdered spentwash. Spentwash powder having 95% of solids are mixed with boiler ash and sold as manure. Also, during non crushing season spentwash powder of 99% solids will be used as manure in farmlands.

Table 2.27 Spentwash Characteristics

Sr. No.

Parameter Before Bio-Methanation

After Bio-

Methanation

After Bio-Methanation

and Conc. 1. pH 3.9 – 4.5 7.0 – 7.8 6.5 – 8.0 2. Total Solids (mg/l) 1,00,000- 1,15,000 20,000 – 25,000 60,000 – 80,000 3. Suspended Solids 15,000 - 20,000 5,000- 7,000 10,000-15,000 4. Total Dissolved Solids 80,000 – 90,000 15,000 – 18,000 50,000–65,000 5. BOD (mg/l) 60,000 - 80,000 9,000 – 12,000 35,000 – 50,000 6. COD (mg/l) 1,20,000-1,40,000 30,000 – 35,000 70,000 – 90,000

Figure 2.9 Cross-Section of GIACL Spentwash Storage Tank

Water requirement for sugar factory and co-gen plant -is 3,550 M3/Day out of which 3 M3/Day is fresh water used for drinking purpose. 17 M3/Day is STP treated water used for flushing purpose, 165 M3/Day is ETP treated water used for gardening in own premises and 3,365M3/Day is cane condensate and CPU treated water from sugar factory. Out of total water requirement 3547 M3/Day i.e. 99.9% of water is recycled water. Only 3 M3/Day of water is fresh water taken from river used for drinking purpose. In order to utilize the cane condensate to its maximum extent CPU has been provided to treat the condensate water from

40


sugar factory. Effluent generation for sugar factory and co-gen plant is 564 CMD which is treated in an existing ETP provided on the site.

Table 2.28 Water Consumption for Sugar factory & Co-gen Plant

(During Sugar cane Crushing Season - 180 days)

Sr. No

Description Total Water Consumption

(M3/Day) Losses

Effluent Generation (M3/Day)

Remark

1. Domestic 20(#3+₤17) 2 18 Treated in STP. 2. Industrial

a. Process $1806 1431 375 Industrial Effluent is being treated in existing ETP.

b. Cooling $820 720 100 c. Boiler feed / R.O. $720 650 70 d. Lab & Washing $19 - 19 e. Gardening Ω165 165 -- Total 3,530(Ω165+ $3365) 2966 564

Grand Total 3,550 (#3+₤17+Ω165+ $3365)

(99.9 % Recycle)

---- ---- -----

Note: # - Actual quantity of water taken from outside water supply source such as River

$- Cane condensate and CPU treated Water Quantity from sugar factory and Co-generation Plant. ₤-Treated water from STP used for flushing Ω - Treated water from ETP.

Table 2.29 Water Consumption for Co-gen Plant (During Non Sugar cane Crushing Season - 52 days)

Sr. No

Description Water Consumption (M3/Day) Losses Effluent Generation

(M3/Day) Remark

1. Industrial Boiler feed/R.O. #175 157 18 Effluent treated

in distillery CPU Total #175 157 18

2. Domestic 20 (#3+₤17) 2 18 Treated in STP.

Grand Total 195(#178+₤17) 159 ---- ----- Note: # - Actual quantity of water taken from outside water supply source such as River

₤ - Treated water from STP used for flushing 2.7.1.3 Balance of Sugar Factory Condensate

Sugar Factory Capacity 5500 TCD Water in Cane getting as Condensate@ 68% 3740 CMD Recycle in Sugar Factory 3365 CMD Excess Condensate 375 CMD Quantity to be used for 150 KLPD Distillery during Sugar cane Crushing Season

230 CMD

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2.7.1.4 Total Water Requirement in GIACL Integrated Complex

Table 2.30 Water Requirement (During Crushing Season)

Sr. No.

Activity Fresh Water Consumption

(M3/Day)

Treated effluent / Condensate (M3/Day)

Total water

1. Distillery(150 KLPD) 41 1578 1619 2. Sugar - 5500 TCD&

Co-gen - 32 MW 3 3547 3550

Total 44 5125 5169

Table 2.31 Water Requirement (During Non-Crushing Season)

Sr. No.

Activity Fresh Water Consumption

(M3/Day)

Treated effluent / Condensate (M3/Day)

Total water

1. Distillery (150 KLPD) 271 1348 1619 2. Co-gen - 32 MW 178 17 195 Total 449 1365 1841

For the working pattern in GIACL complex, overall water requirement becomes as follows – A. For Crushing Season: 1. For Sugar Factory and Co-gen Plant; total fresh water requirement in a season of 180

Days shall be - 3 CMD X 180 Days = 540 M3/Season

2. For Distillery, total fresh water requirement in a season of 330 Days shall be - 41 X 180 =7,380 M3/Season Hence, total water requirement during crushing shall be – 7,920M3/Season.

B. For Non- Crushing Season: 1. For Co-gen Plant; total fresh water requirement in non crushing season of 52 Days shall

be - 178 CMD X 52 Days = 9,256 M3/Season

2. For Distillery, total fresh water requirement in a season of 330 Days shall be - 271 X 150 = 40,650 M3/Season

Hence, total water requirement during non crushing shall be – 49,906 M3/Season.

From above calculations; it is seen that total fresh water requirement in GIACL campus is 57,826 M3 (7,920 M3+ 49,906 M3). This figure works out to be 0.057 Million M3. Permission granted to GIACL by Irrigation Department; Govt. of Maharashtra for lifting fresh water from the 'Jaikwadi Dam' reservoir is 0.071 Million M3 which is much lesser than the actual total usage of water quantity.

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Figure 2.10 Process Flow Diagram of CPU for Sugar Factory

Figure 2.11 Sugar Factory& Co-gen Plant ETP Flow Diagram

No Parameters Unit Inlet Outlet 1. pH --- 5 - 6 7 – 8 2. COD mg/lit 2000 - 2500 < 250 3. BOD mg/lit 1000 - 1500 < 100 4. TDS mg/lit 1800 - 2200 < 2100 5. SS mg/lit 250 - 300 < 100

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Table 2.32 Units in ETP of Sugar Factory& Co-gen Plant

Sr. No. Unit Dimensions No. of units 1. Balancing Tank 8 M x10 M x 1.8 M 1 2. Equalization Tank 10 M x 12 M x 1.8 M 1 3. Reaction Tank - 2 Nos. 2 M x 2 M x 2.5 M 2 4. Primary Clarifier 6 M Dia. & 3 M SWD 1 5. Aeration Tank – I 22 M x 10 M x 4 M 1 6. Aeration Tank – II 14 M x 10 M x 4 M 1 7. Secondary Clarifier 8 M Dia. & 3 M SWD 1 8. Pressure Sand Filter ---- 1 9. Activated Carbon Filter ---- 1 10. 15 Days Storage Tank 30 M x 30 M x 5 M 1

2.7.2 Air Pollution (AP) Air Pollution can be defined as the presence in the outdoor atmosphere, of one or more air contaminants (i.e. dust, fumes, gas, mist, odour, smoke or vapour) in sufficient quantities, of such characteristics and of such duration so as to threaten or to be injurious to human, plant or animal life or to property, or which reasonably interfere with the comfortable enjoyment of life or property. Assignment w.r.t AP is done by in-house FAE of EEIPL Dr. Sangram Ghugare. Moreover, the in-house FAE Mr. Yuvraj Damugde is involved in the overall exercise w.r.t. Air Quality (AQ) and Modeling. Steam required for expansion of molasses based distillery would be taken from 8 TPH existing distillery boiler. Also, a boiler from existing co-gen plant having capacity 30 TPH will be modified to 40 TPH under distillery expansion. Steam from both boilers (8 TPH and 40 TPH) will be used during operation of 150 KLPD distillery. For 8 TPH boiler, primarily biogas to the tune of 675 M3/Hr shall be used as fuel with FO to the tune of 502 Kg/Hr is used as start up fuel. Stack provided for boiler is of 45 M height. Fuel for Boilers is methane gas which is generated subsequent to bio-methanation of distillery process effluent – spentwash. Biogas comprising of about 60% methane; is a clean fuel without any problems such as ash and particulate matter pollution which is generally the case with solid fuel burning (like coal, bagasse etc.).Methane has more potential as a greenhouse gas than CO2 or other gases. With burning of same in boilers, its composition gets totally changed in to CO2 and water vapours thus having positive impact on air pollution control and air quality. Details of DG set installed under distillery as well as sugar factory and co-gen plant are listed in table 2.30 and 2.31 respectively. Same would be operated only during power failure situations. In sugar factory and co-gen complex, two boilers of capacity 140 TPH and 30 TPH are already exists. Boiler of 30 TPH capacity will be upgraded to 40 TPH during expansion of distillery to meet steam requirement. Steam generated from boilers is used for various processes. An Electro Static Precipitator (ESP) is installed as APC to the same followed by stack of 76 M height. Details of sugar factory boilers and DG set is presented at table – 2.31.

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Table 2.33 Details of Boiler & DG under existing Distillery project –

No. Fuel Consumption Bagasse Biogas Furnace Oil HSD 1 Fuel consumption 3 MT/Hr 675 M3/Hr 502 Kg /Hr 4800 Lit /Day

2 Calorific value 2200 Kcal/Kg

4,600 – 4,750 Kcal/ kg 9800 Kcal/ kg 10,200

Kcal/Kg

3 Stack Number (s) Existing 1 No. 1 No. 1 No.

4 Attached to Boiler Boiler D.G Set

5 Capacity

Additional 10 TPH in Existing 30 TPH Boiler

8 TPH 900 KVA

6 Fuel type Bagasse Biogas/Furnace Oil Diesel 7 Fuel quantity 3 MT/Hr 675 M3/Hr or 502 Kg /Hr 200 Lit / Hr.

8 Material of construction M.S. M.S. M.S.

9 Shape Round Round Round

10 Height, M (above ground level) 76 M 45 M 5.5 M

11 Diameter / size 1.2 M 0.2 M

12 Control equipment preceding the stack ESP -- Silencers

13 Nature of pollutant PM10 , PM2.5 SO2, NOx SPM, SO2, NOx

Table 2.34 Details of DG& Boilers in Existing Sugar Factory and Co-Gen Plant

No. Description Details 1. Stack No. Stack I Stack II Stack III Stack IV 2. Attached to Boiler D.G. Set 1 D.G. Set 2 D.G. Set 3 3. Capacity 140 TPH&30 TPH 500 KVA 320 KVA 380 KVA 4. Fuel type Bagasse Diesel Diesel Diesel 5. Fuel Quantity 1445 MT/ Day 65 Lit/Hr 50 Lit/Hr 55 Lit/Hr 6. MoC RCC MS 7. Shape Round --- 8. Height 76 M AGL 18 M ARL 5 M ARL 9. Diameter 4 M 0.2 M 0.1 M 10. Control equipment ESP --- 11. Nature of

pollutants SPM SO2, NOx,

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Table 2.35 Details of ESP provided for Boilers of Existing Sugar Factory

Sr. No. Description Details 1. ESP make VT CORP. Pvt. Ltd. 2. Gas Flow Inlet 78.32 M3/Sec 3. Temp Inlet 1600c 4. Dust Load at ESP Outlet Less than 100 mg/Nm3 5. Inlet Dust Conc. 6 gm/NM3 6. Overall Dust Collection Efficiency with all

fields 98.08 %

7. Effective Migration Velocity 11.32 cm/sec 8. Treatment Time 7.03 Second

Table 2.36 Characteristics of Fuels to be used

No Description Biogas Bagasse Diesel 1 Calorific value 4,750 Kcal/ kg 2,200 Kcal/Kg 10,200 Kcal/Kg 2 Ash content % -- 3 % 0.1 % 3 Sulphur content % -- 0.05% 1.0 %

2.7.2.1. Fugitive Emissions Fugitive emission under GIACL project complex shall be mainly the dust emissions. Sources of same are mill house, sugar bagging, bagasse yard, pressmud yard, internal kuccha roads, bagasse conveyor; feeding section and ash storage yard in co-gen plant, improper function of APC equipment etc. Trouble with dust in work zone and ambient atmospheres shall be controlled by certain dedicated measures. An action plan has been prepared in the industry that includes – proper exhaust and ventilation arrangements, monitoring of proper working of pollution control equipment, proper handling; storage and disposal of dust collected, use of PPEs for staff and workers, augmentation of existing green belt with adequate density and type to control and attenuate dust transfer in the premises, properly surfaced internal tarred roads and work premises. Refer annexure – M for photographs of internal tarred roads. 2.7.2.2. Process Emissions There are no any sources of process emissions from sugar factory and co-gen Plant. CO2 generation shall take place in fermenters of the distillery. CO2 to the tune of 113 MT/Day shall be released from 150 KLPD distillery plant. In a fermenter, sugar in the wash gets converted to ethyl alcohol through metabolic activities of yeast. Consequently, CO2 will evolved as emission of the bio-chemical reaction. CO2 has been labeled as one of the major gases responsible for the green-house effect, its release in the atmosphere has to be properly controlled. To curb this process emission CO2 shall be bottled and supplied to manufacturers of beverages. 2.7.3 Noise Pollution

Noise is normally defined as objectionable or unwanted sound, which is without agreeable quality and essentially non-euphonious. Concern on noise depends upon the noise level near the source, on the work environment and near the residential zone. Earlier, noise was summarized to be exclusively an occupational problem. But, since the effects are found also

46


on people who are not directly involved, it has acquired wider dimension. Hence it is necessary to know the noise levels near the sources as well as near the residential colonies. 2.7.3.1 Sources of Noise Pollution 1. In the distillery, very high noise generating sources do not exist. D.G. set would be one of

the sources of noise pollution. Operation of same would be only in case of power failure. Expected noise levels in the section would be about 70 dB(A) or so. Adequate noise abatement measures like silencer would be implemented in this section. Moreover, enclosures to the machinery would be provided wherever possible.

2. Distillation section & fermentation section would be other minor noise generating sources. Expected noise levels in these sections would be in the range of 60 to 65dB(A). All preventive measures such as regular operation & maintenance of pumps, motors, and compressors would be carried out and enclosures would be provided to abate noise levels at source.

3. It is predicted from an experience elsewhere that the magnitude of noise levels, from various sources in the proposed unit, to the human habitation at a distance of 0.5 Km would be around 12 dB(A). Therefore, there would be no any significant change in the background noise levels in the premises of the industrial unit.

4. Already a green belt has been provided in and around the industry. Same would be further augmented adequately and properly so that it would further attenuate the noise levels.

5. Noise would also be created by movement of trucks/ tractor trolleys and other vehicles for material transportation. However, this would not be of a continuous nature and would not have much impact on the work environment of the project site.

6. Insulation helps considerably in limiting noise levels. Workers entering plant shall be protected by earmuffs, which would give the reduction of about 30 dB(A). D.G. set installed under GIACL complex are one of major noise generation sources. However, this is not continuous source. D.G. set is operated only during power failure and same is enclosed in a canopy as per the Noise Pollution (Regulation & Control) Rules, 2010. Further, people working in close vicinity of the high noise generating equipments and sources in the project complex are provided with PPE such as ear plugs, ear muffs etc. so as to attenuate the noise levels and minimize bad effects of exposure to high sound. Moreover, a care towards working pattern is taken due to which no person is subjected to high noise levels beyond the stipulated time schedule for exposure.

2.7.4 Solid Waste Solid wastes from the industries are categorized as hazardous and non-hazardous. Wastes that pose a substantial danger immediately or over a period of time to human, plant or animal life are classified as hazardous wastes. Non- hazardous waste is defined as the waste that contributes no damage to human or animal life. However, it only adds to the quantity of waste. Assignment w.r.t. Solid and Hazardous waste (SHW) was done by Dr. Sangram Ghugare who is FAE of EEIPL for SHW.

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Table 2.37 Solid Waste Generation, Storage and Disposal Details

No. Industrial Waste Type

Quantity (MT/M) Storage Disposal Existing Expansion Total

After Expansion

1. Distillery Yeast Sludge

450 750 1200 Immediate utilization

Used as manure

2. Co-gen Plant

Boiler Ash

1485 60 1545 Silo of Cap.50

MT

Mixed with 95% spentwash powder and used as manure.

3. ETP Sludge

2.5 -- -- Immediate utilization

Used as Manure

2.7.5 Hazardous Wastes Different types of hazardous wastes being generated from existing as well as expansion activities and their disposal methods are presented in following table 2.34.

Table 2.38 Hazardous Waste Generated in GIACL Complex

Sr. No.

Industrial Unit

Hazardous Waste Category

Quantity Disposal

1. Distillery Used Oil (Cat. 5.1) 2 MT/Yr Authorized Re-processor

2. Co-gen Plant Spent Oil(Cat. 5.1) 65 MT / Yr Burnt in Boiler.

Refer the figure 2.12- given below for storage yard of hazardous waste

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Figure 2.12 Storage Yard for Solid & Hazardous Waste

2.7.6 Odour Pollution Under expansion of distillery project, spentwash shall be carried through closed pipeline for bio-methanation followed by concentration in MEE and dried in ATFD dryer. Hence, odour nuisance due to spentwash storage activity shall be entirely eliminated. To abate the odour nuisance, the GIACL has a concrete planning which includes following steps and actions – 1. It is proposed to provide covered fermentation and tapping of CO2 gas, 2. Collection of waste yeast sludge from fermentation section in a closed system and its

immediate and proper disposal. 3. Reduced volume of effluents (spentwash, spent leese) by adopting strategic approaches

such as use of the effluents back in process under Reduce-Reuse-Recycle planning. 4. Closed and online system for carrying spentwash to the treatment units, viz. Bio-

methanation Plant, MEE and ATFD etc. 5. Suitable plantation in and around the treatment units, which can minimize undesirable

smells around the treatment units. 6. Adoption ofGMPs(Good Management Practices). 7. Arranging awareness and training camps for workers. 8. Use of PPE like masks at odour prone areas.

49


9. Proper House Keeping 10. Prompt Sludge Management in Biological Treatment Units 11. Prompt and proper handling and disposal of Pressmud

2.7.7 Land Pollution Land pollution may take place due to use of untreated effluent for gardening / irrigation purpose. Fly ash, if deposited on land, would lead to land pollution. Spentwash from distillery would be conc. in MEE subsequent to bio-methanation and concentrated spentwash shall be forwarded to ATFD for drying. Other effluents generated from distillery activities like spentlees, boiler & cooling blow downs would be treated along with condensate from MEE in a dedicated CPU. Treated effluent shall be mostly recycled in process operations like molasses dilution in fermenters, cooling top up etc. From sugar factory and co-gen unit; solid waste in the form of boiler ash generated. Same is mixed with powdered spentwash having 95% solids and used as manure in field. Also, spent oil is burnt in co-gen boiler along with bagasse. Used oil sold to authorized re-processor.

2.7.8 Budgetary Allocation by Industry towards Environment Protection Capital as well as O & M cost towards environmental aspects under existing activities is as follows –

Table 2.39 Capital As Well As O & M Cost (Existing Activities) Sr. No.

Description Cost Component (Rs. in Lakhs) Capital Annual O & M

1 Air Pollution Control: (ESP for existing Co-gen Boiler), Stack 76 M

300 30

2 Spentwash Treatment: Bio-methanation Plant (Rs. 600 Lakhs), MEE (Rs. 946 Lakhs), Bio-composting Infrastructure, Sugar ETP & CPU.

1,800 180

3 Noise Pollution: Insulation, Isolation, Attenuation Infrastructure of Plant & Machinery, PPEs

20 2

4 Env. Monitoring , Online Systems for Stack & ETP 35 3 5 Occupational Health and Safety 25 10 6. Green Belt Development & Rain Water Harvesting 50 5 7. Provision towards CER in Five Years 225 -- TOTAL Rs. 2,455Lakhs Rs. 230 Lakhs

Capital as well as O & M cost towards environmental aspects under expansion activities would be as follows –

50


Table 2.40 Capital As Well As O & M Cost (Expansion Activities)

Sr. No.

Description Cost Component (Rs. in Lakhs) Capital Annual O & M

1 Installation of ATFD 150 10 2 Spentwash Treatment: Installation of new

Bio-methanation Plant 250 18

Installation of MEE 250 10 Proposed CPU 60 5

3 Environmental Monitoring and Management 10 10 4 Provision towards CER in Five Years 50 -- Total Rs. 770 Lakhs Rs. 53 Lakhs

2.7.9 Occupational Health Hazards and Safety • OHS hazards anticipated in GIACL complex is mostly due to chemical exposure hazard,

physical hazard due to electrical & mechanical operations & maintenance works. • Major anticipated occupational health & safety hazards are due to fire in bagasse yard. • Accidental skin or eye irritation & burns, respiratory & pulmonary diseases on exposure to

chemicals, fire etc. • Accidents resulting from unsafe conditions due to poor housekeeping& not using PPE’s • Accidents due to unsafe practice of operation and maintenance like gas cutting and

wielding may lead to injuries to various parts of the body. • Muscular & skeletal disorders like muscular pains, spinal & joint pains due to ergonomic

problems, lifting with wrong postures etc.

2.7.10 Waste Minimization Techniques in GIACL Project Complex

Table 2.37Section & Area Wise Waste Minimization Techniques

Sr. No.

Station Pollutant Nature Action Waste Management

Options

Cost

1. Bagasse Storage Yard

Solid Bagasse Collect at the end of the season

Burnt in boiler Low

2. Milling Section

Liquid Oil & grease Collect in trays which can be easily lifted &stored in drum

Can be sold as low grade lubricants or burnt in boilers after mixing with Bagasse

Low

Liquid Floor washings

Adopt dry cleaning, Give proper slope to floors, improve collection system etc.

------ Low

Liquid Leakages & spillovers

Use mechanical seals for all pump glands &alarms for overflow

Collect leakages &spillages in a pit and recycle into process

Low

Liquid Cooling Collect desuper heater & Recycle Low

51


Sr. No.


Options

Cost

waters mill bearing cooling water

3. Cane Carrier

Solid Bagasse Use closed transfer system

Cover the drains so that Bagasse do not enter into drains

High

4. Sulphur Burner

Gaseous SO2 Operate scrubbers Efficiently

Provide mask to operators

Low

5. Lime Station

Semisolid Lime solution Provide proper slope to the drain

Allow it to mix with the effluent

Low

6. Clarification and Vacuum Filters

Liquid Leakages from pumps glands & pipe overflow

Install overflow alarms & provide mechanical seals

Recycle cooling waters

Low

7. Boiler House

Liquid Boiler blow Down

Maintain boiler condition & also feed water quality

Use it for irrigation along with other effluents

Low

Gaseous Stack emissions

Adjust air fuel ratio for efficient Combustion. Check the air pollution control equipment performance

Fly ash mixed with spentwash powder having 95% solids and sold as manure.

High

8. Crystallizer & Pan Boiling

Liquid

Leakages from pumps Spillovers

Provide Mechanical seals wherever it is appropriate Recycle all cooling Waters Avoid overloading the Equipment

Recycle the cooling water Collect spillages & recycle in process

Low

9. Evaporator & Juice Heating

Liquid Sugar entrainment

-Provide additional external catchers for the last body evaporators & all vacuum pans - Use poly baffle stainless steel instead of umbrella type save alls - Pump gland shall be provided with mechanical seals to prevent leakages

Recycle the water If there is no entrainment and in case there is entrainment use it for irrigation

High

10. Cleanings of Vessels, Boilers etc., & Laboratory Washings

Liquid High BOD & COD, chemicals as NaOH, Sulphamic Acid, lead

-Recycle NaOH for next cleaning -Provide standby units to have continuous operations -Store the effluent in a holding tank to avoid shock loads on ETP

Controlled loading in ETP from a storage Tank Segregate laboratory effluents and join to storage tank

High

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Sr. No.


Options

Cost

11. Pressmud Solid Soil conditioner

Immediate disposal Sold to farmers Low

12. Molasses Semisolid By-product Use only steel tanks Raw material for distillery

High

13. Fermenter Semisolid Yeast sludge Immediate utilization Used as manure Low 14. Distillation

Column Liquid Spent wash

(High organic Effluent). Spent lees Effluent, MEE Condensate and other effluents

Immediate disposal Appropriate Treatment

Bio-methanation Plant – MEE Concentration- Drying in ATFD. Forwarded to CPU to be installed under proposed expansion

High

15. *Fugitive Emission

Gaseous Sugar dust SO2

Dust collectors Scrubbers

Recycle High

16. Vibrating & Heavy Machinery

Noise Sound Use silencer pads & closed rooms

Provide earplugs & earmuffs to workers and also change the work environment frequently

Low

17. ETP Sludge Pri. & sec. sludge

H.W. as per notification of 2016

Used as manure Medium

18. Bagasse Solid Dust & Fire Provide proper Ventilation for storage & also stand posts in case of fire

Store it far away from the industry

Low

19. Odor Gaseous ETP, Molasses tank, stale cane Stale cane, bad mill sanitation, Bacterial growth in interconnecting pipes & unattended drains

Proper House Keeping, Better cane management to avoid staling of sugar

Sludge management in biological ETP units, Steaming of major pipe lines, Regular use of Bleaching powder in the drains, Efficient handling, prompt & proper disposal of Pressmud

Low

*The fugitive emissions are mainly sugar dust emanating from sugar graders. The SO2 emissions are from Sulphur Burner. The chimney height should be above the roof level. If there are leakages, the SO2 gas may cause air pollution and hence, the provision for scrubbing of the SO2 shall be made.

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2.8 GREEN BELT DEVELOPMENT PLAN 2.8.1. Criteria for Green Belt Development Plan Emission of SPM, SO2 is the main criteria for consideration of green belt development. The green belt development is provided to abate effects of the emissions of SPM & SO2. Moreover, there would also be control on noise from the industry to surrounding localities as considerable attenuation would occur due to the barrier of trees in proposed green belt. GIACL has already developed land area of 61,350 Sq. M (6.1 Ha) under greenbelt in existing premises is which is 23% of total plot area. As per MoEFCC, New Delhi & CPCB guidelines industry has to develop green belt on area of about 33% of total plot area. To comply this condition GIACL has procured additional land of area 60,000 Sq.M. (6 Ha) near existing industrial premises for development of more green belt. On that additional land, an area of 4.07 Ha is developed as green belt. Hence total green belt developed by GIACL is about 10.17 ha which is about 38% of industrial total plot area. Under existing green belt, about 10,305 no. of trees are already planted. In 2018 monsoon GIACL has planted additional 5353no. of trees. Details of list of trees planted by GIACL is presented at appendix G along with photographs of green belt & layout showing green belt. 2.9 RAIN WATER HARVESTING Rain harvesting could be of two types namely harvesting from ground and harvesting from rooftops. Quantity of harvested rainwater that becomes available during and after precipitation depends upon a number of factors such as area of land, nature of soil, impervious or paved areas, plantation on the land, average annual rainfall in the region, ambient temperatures of the region, wind direction and speed etc. Total plot area acquired by GIACL is 2,70,661 M2. Out of this area, actual activities of industry would be carried out on 1,79,501 M2and a space of about 91,160 M2 would be left as open space. Details of rain water harvesting under GIACL complex is presented as - A. Rooftop Harvesting

Here collection of the rainwater getting accumulated from direct precipitation on the total roof area is taken in to account. Rainwater thus becoming available from terraces as well as roofs of various structures and units in the industrial premises would be collected through arrangements of channels and pipes to be provided as per appropriate slopes at the roof level. Collected rain water is recharges to sub surface aquifers. A first flush assembly, provided at the outlet of roof top drain. RWH filters of desired capacity are provided after the outlet from the roof top, for purification or to avoid clogging due to floating material. Harvested rain water is charged directly to bore wells to be provided in the premises. For the calculation of rain water quantity that is going to become available subsequent to rooftop harvesting, a computation method from the ‘Hydrology and Water Resources Engineering’ has been adopted. Thereunder, A.N. Khosala’s formula has been followed. The allied calculations are as under- Average annual rainfall in the area = 583 mm.

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Now, as per “A. N. Khosla’s Formula”, the average annual accumulation can be calculated by using the following equation:

R = (P- t / 2.12) Where, R=Average annual accumulation in cm, for the catchment area. P=The corresponding average annual rainfall or precipitation, in cm, over the entire

catchment. (In current case it is 583 mm i.e.58.3 cm) t = Mean annual temperature in deg. Centigrade. (In current case it is 330C.) ∴The accumulation on the entire catchment area will be, R=(58.3 – 33/2.12) =42.8 say 43 Cm.

Table 2.39 Roof top area covered by GIACL under RWH

Sr. No. Area taken for RWH Area (M2) 1. Administration Building 1,040 2. Canteen 771 3. Sugar Godowns, Mill House &Processing Unit, Colony 41,860

Total Roof top area for RWH 41,860 ∴ Volume acquired by this accumulation water will be, = 43 Cm × Roof Top Area = 0.43 M × 41,860 M2 = 18,778.5 M3Say 18,779 M3 Thus, about 18,779 M3 of rainwater could become available during every season from the ‘Roof Top Harvesting’ operations. This when charged to open / bore wells would definitely have a positive impact on the ground water quantity. B. Surface Harvesting Under this type of harvesting, the rainwater getting accumulated through surface runoff, from land area in the industrial premises, would be collected and stored in open excavated tanks / pits to be provided in the industrial plot. This harvested rainwater would recharge the ground water through actions namely seepage and infiltration to the aquifers. On the open land in the premises counter bunding, terracing and dressing would be done so as to divert the rainwater as per natural slopes to various tranches excavated on the plot in a decentralized manner. The entire industrial premises would be divided in zones and the harvested water from such zone would be directed to the nearest available ditch / tank constructed as mentioned above. Further, the recharge points would be located as per geometry of zones.

Table 2.43 Open Area at GIACL consider for RWH

Sr. No. Area taken for RWH Area (M2) 1. Open Area 91,160 2. Area under Roads 29,261

Total open area for RWH 1,20,421

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Now, a. Average annual rainfall in the Ahmednagar area - 583 mm b. Open land area in the industrial premises – 1,20,421 M2 c. Type and nature of the Area with about 30% area being impervious (paved). Here an area

under curing yard and storage yards as well as roads comes in the category of paved surfaces.

d. Type of Land- On an average, the land in Ahmednagar belongs to flat and barren. e. Value of Runoff Co-efficient based on type and nature of area as well as the land – 0.40 f. Runoff getting accumulated from the land area under above point No. b -

1,20,421 M2X 0.58 M x 0.4 = 27,937 M3 Hence, the total water becoming available after rooftop and surface harvesting would be -

Rooftop Harvesting + Surface Harvesting = Total RWH Yield

18,779 M3 + 27,937 M3 = 46,716.67 M3. Say 46,717 M3

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Chapter 3

DESCRIPTION OF THE

ENVIRONMENT

DESCRIPTION OF THE ENVIRONMENT…3

3.1 INTRODUCTION This chapter incorporates description of existing environmental status in the 'Study Area' which is a region within a circle of 10 Km radius with the industry plant at its centre. Existing environmental condition is representative of impacts of all the units and is described with respect to the Topography, Climate, Hydro-Geological Aspects, Atmospheric Conditions, Water Quality, Soil Characteristics, Flora, Fauna, Socio-Economic Profile, Land Use and places of Archeological importance. Study area in respect of expansion of distillery by GIACL is located in village Najik Babhulgaon, Tal: Shevgaon and Dist.: Ahmednagar. Ahmednagar is the largest district. 3.2 LAND USE AND LAND COVER (LU & LC) Land Use relates to the human activity or economic function associated with a specific piece of Land, while the term Land Cover relates to the type of feature present on the surface of the earth (Lilles and Kiefer, 2000). The knowledge of Land Use Land Cover is important for many planning and management activities as it is considered as an essential element for modeling and understanding the earth system. Land use maps are presently being developed from local to National to Global Scales for Environmental Impact Studies. The satellite Remote Sensing technology has found its acceptance worldwide for rapid resource assessment and monitoring, particularly in the developing world. All these advancement have widened the applicability of Remotely Sensed data in various areas, like forest cover, vegetation type mapping, and their changes in regional scale. If satellite data is judiciously used along with the sufficient ground data, it is possible to carry out detailed forest inventories, monitoring of land Use and vegetation cover at various scales. Assignment w.r.t. LULC mapping of study area using LISS IV satellite image has been done by Mr. Vinaykumar Kurakula who is an empanelled FAE of EEIPL for LU & LC. Scope of work methodology involved and allied details are presented in following paragraphs. 3.2.1 Scope of Work LULC study shall be carried out for a study area of 10 km radius taking site as centre using the satellite imageries (IRS P6 LISS IV MX). 3.2.2 Procurement of latest satellite imagery obtained from NRSC. Satellite imagery processing and interpretation of land use as per land use classification

covering 10 km radius of proposed GIACL Calculation of land use breakup w.r.t. each land use category covering 10 km of proposed

GIACL. Preparation and submission of draft and final reports, satellite imageries and maps. 3.2.3 Study Area

Area of Study: Area of Interest is of 314.15 Sq. Km. 10 km radius from the proposed site. Site Coordinates: Longitude 75°17’00.72” E, Latitude19°22’47.28” N

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Population Census: Ahmednagar District as per 2011 census is 4,543,159 of which male and female were 2,342,825 and 2,200,334 respectively. Average literacy rate of Ahmednagar in 2011 were 79.05%. For present study, location of the industry is shown on satellite image in Figure 3.3 and visual interpretation keys used for the study are given in Figure 3.4. 3.2.4 Purpose of Land Use Mapping Land use study requires data regarding topography, zoning, settlement, industry, forest, roads and traffic etc. Collection of this data was done from various secondary sources viz. Census books, Revenue records, State & Central Government Offices, Survey of India toposheet etc. and through primary field surveys as well as High Resolution Multi Spectral Satellite Image from IRS RESOURCESAT2 Satellite with LISS IV sensor. Since all the data of the study area were geo-referenced to UTM 43N WGS84 projection system, the satellite images were also obtained with the same coordinate system from NRSA. Date of pass of the image is 25.10.2017. Apart from LULC Map, topographic features of the region were extracted within 10 Km radius covering village locations, streams, roads, river in the satellite image. In addition to this, natural drainage network is also captured to prepare drainage map as required. Purposes of land use studies are - • To determine the present land use pattern; • To determine the temporal changes in land use pattern over a period of ten years or so; • To analyze the impact on land use due to industrial growth in the study area; • To give recommendations for optimizing the future land use pattern vis-à-vis growth of

industries in the study area and its associated impacts.

3.2.5 Land Use Map Analysis Land use Map Analysis done based on the image color, texture, Tone etc. Following steps are used to analyze the Land use pattern of project site: • Collection of IRS Resourcesat2 images and made fused and blended the images for color

combinations using Image interpreter-Utilities and Layer stack option available in ERDAS.

• Identification AOI and made a buffer of 10 km radius. • Enhance the Fused and blended IRS Resourcesat2 image using the Spatial, Radiometric

and Temporal options in ERDAS. • Rectified the IRS Resorcesat2 image using Geo-referencing technique, Toposheet to get

UTM coordinate system. • Subset theirs IRS Resources2 images 10 Kms buffer AOI. • Automatic classifications done for IRS Resorcesat2 images using maximum iterations and

number of options in unsupervised classification options. • Created the signature file by selecting the more samples of different features with AOI on

Unsupervised classification image. • Export to Vector layer from supervised classification image. • Gone through the QC / QA and finalized the data.

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3.2.6 Data Used

The data is used for the preparation of different maps for the study natural resources. The data is used by using the application of Remote Sensing and GIS technologies. 3.2.7 Details of Sources &the Maps Prepared

No. Source Maps Prepared 1 SOI topographic maps &satellite imageries Base map and Drainage map 2 Satellite Imageries Land use / Land cover

3.2.8 Methodology for LU &LC Study

Overall methodology adopted and followed to achieve objectives of the present study involved certain steps - Satellite data of IRS Resourcesat-2 sensor was used and geometrically corrected using principal component method and Nearest Neighborhood resampling technique. Preparation of basic themes like layout map, transport & settlement map and from the satellite image by visual interpretation and ground truth verification. Essential maps (related to natural resources) like Land use / Land cover map are prepared by visual interpretation of the satellite imagery. Visual interpretation is carried out based on the image characteristics like tone, size, shape, pattern, texture, location, association, background etc. in conjunction with existing maps/ literature. Preliminary quality check and necessary corrections are carried out for all the maps prepared. All the maps prepared are converted into soft copy by digitization of contours and drainages. In that process editing, labeling, mosaicing, quality checking, data integration etc are done, finally Land use areas are measured in Square Kilometers.

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Figure 3.1Process Flow Chart

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Figure 3.2 Google Image

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Figure 3.3SatelliteImage

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Figure3.4Visual Interpretation Key Used for the Study

Crop Land

Fallow Land

Water Bodies

Settlement

Industrial Area

Canal

Roads

Scrub Land

Barren Land

Before satellite image land use classification was carried out, the satellite images was pre-processed. All the processing and classification of the satellite images were performed in the ERDAS Imagine 9.1 software. The data was delivered in separate bands of 2, 3 and 4. 3.3 LAND USE STUDIES It includes study of topographic features and land use under which area statistics for LULC classes and LULC statistics are included. 3.3.1 Land Use of Study Area Land use map developed was based on the image color, texture, tone and also ground truth verification data. Ground truth verification was carried out to validate the results of classified image and reconciliation was carried out with actual location of land mark features such as water bodies, forest land, agriculture land etc. Supervised classification of the satellite image yielded the classes as per table 3.1.Graphical presentation of land use classification within 10 km radius of project is presented at figure 3.7.

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Table 3.1 Area Statistics for Land Use Land Cover Classes

Sr. No. Class Area in Ha. Percentage 1 Built Up Area 1350 4.30 2 Crop Land 18388 58.53 3 Fallow Land 7684 24.46 4 Water Bodies 3023 9.62 5 Barren Land 840 2.67 6 Grass Land with Open scrub 130 0.41 Total 31415 100.00

Figure 3.5 Land Use Land Cover Statistics

a. Built Up Area - Built up Area cover about 4.30 % of area within 10km radius of study area. The surrounding villages around the project site are well developed with road electricity, and water connectivity.

b. Cropland – Major part of study area is crop land covering58.53%. This area has good

water supply from nathsagarreservoir. Major crop cultivated is sugar cane. c. Fallow land – Fallow land, that cover about 24.46 % area within 10km radius buffer.

This fallow land is because of changing of crop type and also because of leaving the land uncultivated to get fertile. Some of the fallow land is seen because of hilly region where there is lack of continuous water supply.

d. Water Bodies – Some part of Nath Sagar reservoir comes under the 10 km radius study

area which contributes to 9.62% of area within 10km radius from the plant site. e. Scrub– It is found that the some part of study area is also covered with Open scrub

covering about 0.41% of total study area. f. Barren Land – Some parts of the study area mostly western side of plant, is dry area

with hard rocky surface where there is not soil and plants. The barren land cover of about 2.67 % of study area.

4.30%

58.53%

24.46%

9.62%2.67%

0.41%

Land Use Classification

Built Up Area

Crop Land

Fallow Land

Water Bodies

Barren Land

Grass Land with Open scrub

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3.3.2 Topographical Features Topographical map of industrial site is of scale 1:50,000 which were obtained from Survey of India (SOI). Overall map is prepared with two topographical maps to cover the study area of 10 Km radius buffer. Topographical Map

Sr. No. Toposheet No. Type Scale 1 47M3, 47M7 Scanned 1:50,000

Creating a GIS spatial database is a complex operation and it is the heart of the entire work; it involves data capture, verification and structuring processes. In the present study, the essential maps generated from topographical sheets are layout map, drainage map, Contour Map. The maps are prepared to a certain scale and with attributes complying with the requirement of TOR. For topographical map refer Figure 3.7. General topography of the area is flat with gentle slope towards west. This area has little vegetation. There is a reservoir at the northern side called “Nath Sagar” formed due to the ‘Jaykwadi Dam’ located on Godavari River. This is a major source of water, worth mentioning in the study area. This area has moderate rainfall. Vegetative growth is limited near water sources as well as in small pockets in the study area. 3.3.3 Settlement map

Area has good literacy rate and there is a lot of development taking place in this area. All villages are well connected with the roads. Because of existing industries, the area is well developed. All villages are well connected with the roads, water and electricity supply. Settlement map (Figure 3.8) showing location of villages and other allied details is presented below. 3.3.4 Contour Map

Contours are digitized using the topographical maps with scale 1:50,000. The contours levels range from 460 to 520 mt in the 10 km buffer zone. Contour map has been developed with the contour interval of 20 mt.In order to know the height information, the contour liners are indicated with different colors. Elevation of proposed site is 490 M from mean sea level. Source of the contour is from survey of India, topographical map. Contour map of the study area is presented at figure – 3.9 3.3.5 Drainage Map Drainage map of the study area was mapped using the field data and topographical map. Drainage map shows that there is a major water body named Nath Sagar at the North east side of proposed site. Nath Sagar is a tributary of river Godavari. Water from the reservoir Nath Sagar is used for irrigation, portable and to supply nearby industries. GIACL site is located at the southern side of the reservoir; there are no chances of flooding at the proposed site due to reservoir. However, it should be noted that, the treated effluent from the proposed expansion should not be let into the nearby streams or drains that are connected to the drains of Nath Sagar reservoir.

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Figure3.6Land Use and Land Cover Map

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Figure 3.7 Topographical Map

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Figure 3.8 Settlement Map

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Figure 3.9 Contour Map

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3.4 SOIL CHARACTERISTICS 3.4.1 Introduction Agriculture is the main occupation pattern in the area. Hence, it is essential to determine agriculture potential of soil from the area and identify the impacts of urbanization and industrialization in the area. Study has been conducted to determine the agricultural and afforestation potential of the soil.Assignment w.r.t. Soil Conservation (SC) was done by Mr. Balkrishna Lole; the FAE for SC 3.4.2 Soil Quality: Present status Soil quality is the capacity of a specific kind of soil to function, within natural or Managed ecosystem boundaries, to sustain plant and animal productivity, maintain or enhance water and air quality and support human health and habitation. Soil quality reflects how well a soil performs functions of maintaining biodiversity and productivity, partitioning water and solute flow, filtering and buffering, nutrient cycling and providing support for plants and other structures. Thus, soil quality plays vital role in any particular geographical phenomenon of ecology as well as physico-chemical environment. Soil quality can indicate the current as well as future issues related with the water, ecology and life in particular region. Thus, it is clearly visible that soilcontamination may result in eventuality in form of contamination of water, ecological destruction, and loss of productivity, food crisis and so threat to life. Major source of contamination is wastes from industries as well as overuse of fertilizers & pesticide. Thus, to determine the exact impacts of any proposed project, it is very essential to determine the existing status of soil quality and existing stress through a study of soil quality assessment. Considering this, for studying soils of the region, sampling locations were selected to assess the existing soil conditions in and around the project area representing various, physiographic conditions, geology, land form and land use conditions. Physical, chemical characteristics were determined. Samples were collected by soil auger and other required equipments, up to a depth of 30 cm. as per standard soil sampling procedure , given in Soil survey manual , All India soil and land use survey, New Delhi-1970 of Ministry of agriculture, Govt. of India. Present study of the soil profile establishes the baseline characteristics and this will help in future identification of the incremental concentrations if any, due to the operation of the project. Sampling locations have been identified with the following objectives: • To determine the baseline soil characteristics of the study area; • To determine the impact of industrialization on soil characteristics; and • To determine the impact on soils more importantly from agricultural productivity point of

view. 3.4.3 Methodology Eight locationsin and around the proposed plant boundary were selected for soil sampling. At each location, soil samples were collected from surface 0 to 30 cm depth and are homogenized and collected after quartering. The homogenized samples were analyzed for physical and chemical characteristics. The soil samples were collected during post-monsoon season.

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3.4.3.1 Methodology of Data Generation In addition to field surveys, the other sources of information were offices of National Bureau of Soil Survey and Land Use Planning (NBSS and LUP) as well as District Census Data from Census of India, 2011.

Table 3.2 Analytical Techniques For Soil Analysis

Parameter Method (ASTM Number) Grain size distribution Sieve analysis (D 422 – 63) Textural classification Chart developed by Public Roads Administration Bulk density Sand replacement, core cutter Sodium absorption ratio Flame photometric (D 1428-82) pH pH meter (D 1293-84) Electrical conductivity Conductivity meter (D 1125-82) Nitrogen Kjeldahl distillation (D 3590-84) Phosphorus Molybdenum blue, colourimetric (D 515-82) Potassium Flame photometric (D 1428-82) Iron AAS (D 1068-84) Zinc AAS (D 1691-84) Boron Surcumin, colourimetric (D 3082-79) Chlorides Argentometric (D 512-81 Rev 85)

Table 3.3 Soil Sampling Locations

Sample

No. Locations Latitude/ Longitude Distance from site (In Km)

Direction from site

S1 Near Site (Village Najik Babhulgaon)

19°22'35.00"N, 75°16'57.10"E 2.68 SE

S2 Kurudgaon 19°22'41.40"N, 5°18'46.80"E 5.11 E S3 Rakshi 19°21'38.50"N, 75°19'12.60"E 4.40 SE S4 Kolgaon 19°10'03.30"N, 75°19'54.60"E 7.10 SE S5 Shevgaon 19°25'00.00"N, 75°40'58.60"E 7.50 SW S6 Talani 19°26'50.70"N, 75°15'27.80"E 2.72 W S7 Dahifal 19°22'47.30’’N, 75°15'22.20"E 7.00 NW S8 Ghotan 19°24'80.00"N, 75°17'40.50"E 2.45 N

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Table 3.4Existing Soil Characteristics Sr. No

Parameter Unit Location S1 S2 S3 S4 S5 S6 S7 S8

1 Color -- Brown Brown Brown Brown Brown Brown Brown Brown 2 pH -- 7.40 7.53 7.51 7.46 7.34 7.65 7.61 7.54 3 Soil Texture -- Silty Clay Silty Clay Silty Clay Silty Clay Silty Clay Silty Clay Silty Clay Silty Clay

a Sand % 27 14 10 14 12 14 11 14 b Silt % 37 38 39 39 39 40 36 36 c Clay % 36 48 51 47 49 46 53 50

4 Electrical Conductivity mS/cm 1.19 2.70 2.74 2.81 2.88 2.92 2.94 2.96 5 Porosity % 53.13 57.59 59.27 62.23 64.72 67.87 69.63 70.02 6 Infiltration Rate cm/hr 1.57 1.24 1.14 0.84 0.79 0.61 0.56 0.53 7 Bulk Density gm/cc 1.30 1.25 1.24 1.21 1.19 1.18 1.12 1.10 8 Water Holding capacity % 53.89 58.75 60.55 62.61 64.90 66.44 70.67 70.45 9 Cation Exchange Capacity meq/ 100gm 18.33 25.97 27.76 28.49 29.63 30.85 31.49 32.62 10 Exchangeable Potassium meq/ 100gm 1.34 1.92 2.05 2.19 2.44 2.55 2.69 2.75 11 Exchangeable Sodium meq/100gm 0.59 0.63 0.73 0.78 0.84 0.87 0.98 1.07 12 Exchangeable Calcium meq/100gm 9.70 13.79 14.44 14.61 15.03 15.58 15.81 16.30 13 Exchangeable Magnesium meq/100gm 6.70 9.63 10.54 10.91 11.32 11.85 12.01 12.50 14 Sodium Absorption Ratio (SAR) 0.15 0.18 0.21 0.22 0.23 0.23 0.26 0.28 15 Nitrogen (N) mg/kg 141.40 651.91 663.82 824.70 861.50 885.70 927.50 953.56 16 Available Phosphorous (P) mg/kg 24.12 77.14 94.13 104.23 115.95 135.63 138.21 145.64 17 Available Potassium (K) mg/kg 158.93 160.35 184.63 256.92 365.20 384.27 395.39 412.26 18 Chloride (Cl) mg/kg 17.90 18.50 19.30 28.30 36.30 38.50 39.50 45.20 19 Sulphate (SO4) mg/kg 14.33 17.56 18.30 23.58 25.32 29.98 30.39 36.98 20 Organic Carbon % 0.25 0.32 0.38 0.43 0.47 0.57 0.62 0.98 21 Organic Matter % 0.43 0.55 0.65 0.74 0.81 0.98 1.07 1.69 22 Aluminum (Al) mg/kg 0.01 0.02 0.02 0.03 0.02 0.04 0.04 0.05 23 Iron (Fe) mg/kg 4.53 5.67 5.79 5.81 5.86 5.94 5.95 5.99 24 Manganese (Mn) mg/kg 3.40 3.80 3.60 3.10 2.90 2.90 3.32 3.40

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Sr. No

Parameter Unit Location S1 S2 S3 S4 S5 S6 S7 S8

25 Boron (B) mg/kg 0.90 1.00 1.50 1.70 1.90 2.10 2.30 2.40 26 Zinc ( Zn) mg/kg 2.10 2.40 2.40 2.90 3.00 3.20 3.30 3.40 27 Chromium (Cr) mg/kg Nil Nil Nil Nil Nil Nil Nil Nil 28 Lead (Pb) mg/kg Nil Nil Nil Nil Nil Nil Nil Nil 29 Nickel (Ni) mg/kg 0.05 0.06 0.09 0.01 0.01 0.18 0.03 0.03 30 Arsenic (As) mg/kg BDL BDL BDL BDL BDL BDL BDL BDL 31 Mercury (Hg) mg/kg BDL BDL BDL BDL BDL BDL BDL BDL 32 Cadmium (Cd) mg/kg BDL BDL BDL BDL BDL BDL BDL BDL

Table 3.5 Standard Soil Classification

No Soil Tests Classification 1. pH <4.50 extremely acidic

4.50-5.50 very strongly acidic 5.00-5.50 strongly acidic

5.50-6.00 moderately acidic 6.00-6.50 slightly acidic 6.5-7.3 neutral * 7.3-7.8 slightly alkaline *

7.6-8.5 moderately alkaline* 8.5-9.0 strongly alkaline 9.0 very strongly alkaline (* tolerable to crops)

2. Salinity Electrical conductivity (mhos/ cm) (1 mhos/ cm = 640 PPM)

upto 1.00 average 1.01-2.00 harmful to germination

2.01-3.00 harmful to crops sensitive to salts

--

3. Organic Carbon upto 0.2 very less 0.21-0.4 less 0.41-0.5 medium

0.61-0.8 on an average sufficient 0.81-1.0 sufficient >1.0 more than sufficient

--

4. Nitrogen (kg/ha) upto 50 very less 51-100 less, 101-150 good

151-300 better above 300 sufficient

--

5. Phosphorus (kg/ha) upto 15 very less 16-30 less 31-50 medium

51-65 on an average sufficient 65-80 sufficient above 80 more than sufficient

--

6. Potash (kg/ha) 0 very less 120-180 less

181-240 medium 240-300 average

301-360 better above 360 more than sufficient

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Figure 3.10 Soil Map

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3.4.4 Comments on soil characteristics are as follows – From the interpretation of field data, physical and chemical data it can be concluded that- As per the physical data soils are fine texture, having low bulk density, imperatively good water holding capacity, and very slow to slow permeability. As per physical characters soils are rated as moderate to good for agriculture. As per chemical characters soil reaction (pH) soils are neutral and electrical conductivity (EC) is non saline (normal). Organic matter is sufficient. Macro nutrient like nitrogen is sufficient and phosphorus is medium to sufficient, potassium is sufficient, calcium, magnesium are good and base saturation is good Sodium is below the limit to make soil saline or sodic or alkali. Micro-nutrients, Mn (very low may cause deficiency), Zn, Fe ,Al ( nil to low, will cause deficiency), B is low( may cause deficiency) SO4 very low and Cl are medium. Cation Exchange capacity is high indicating moderate to good fertility. Exchangeable Ca is medium to good with medium to good base saturation, Ex K is low, and Ex Na is also low not indicating any alkalinity. Sodium adsorption ratio indicates the soils are normal. As observed during field visit of 10 km buffer area from boundary of proposed plant. Area is located as part of Deccan plateau 10 km buffer is undulating plateau plain, forming a part of Godavari and Bhima basin. In general, area is characterized by slightly undulating and flat terrain. As per soil map of Maharashtra at 1:500000 scale by NBSS&LUP, the soil family association observed in the area are:1 Slightly deep, moderately well drained, moderately calcareous fine soils, on very gently sloping lands with plains, moderate erosion, associated with very shallow, well drained clayed, moderately calcareous soils with moderate erosion.2.Deep, moderately well drained, fine calcareous soils on very gently sloping plains and moderate erosion, associated with moderately deep, moderately well grained, fine calcareous soils with moderate erosion.3.Very deep, moderately well drained, fine calcareous soils, on very gently sloping plain and valleys, with moderate erosion, associated with deep, moderately well drained, fine calcareous soils with moderate erosion.4. Very shallow, well drained, loamy soils on gently sloping, rolling lands with Mesas and Buttes, with severe erosion and moderate stoniness, associated with very shallow, well drained, clayey soils with moderate erosion. Thus as per analysis of soils data and field observation the land represented by eight samples can be classified as class II e land i.e. moderate soils on plain to gentle slopes subject to water erosion, as per land capability classification (USDA) 3.4.5 Physical characters Physical characters include Bulk density, grain size distribution (textural analysis). a. Grain size distribution: Texture indicates relative proportion of various sizes of primary

soil particles such as sand, silt and clay present in the soil. Based on their quantities present in the soil sample and using the textural classification diagram. The textural classes of eight soil samples are clay loam to clay (fine textured) Bulk density values confirm the textural class.

b. Bulk Density: In case of bulk density total soil space (space occupied by solid and pore spaces combined) are taken in to consideration. Thus Bulk Density is defined as the mass (weight) of a unit volume of a dry soil. This volume would, off course include both solids and pores. Soil texture, soil structure and organic matter content are the factors influencing the bulk density of a soil. Bulk Density, besides being an interesting and significant physical characteristic, is very important as a basis for certain computations.

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The Bulk density of the eight soil sample under consideration ranges between1.10 to 1.30 gm/cc, and confirms the fine texture of the soils of the area under study.

c. Porosity: The pore space of a soil is the space occupied by air and water and is expressed

as percent pore space. The amount of this pore space is determined by structural conditions, that is by inter- related influence of texture, compactness and aggregation. Porosity is also related to aeration and retention and movement of water in the soil. The porosity of eight soil sample ranges between53.13 to 70.02 % and is moderate to good in accordance to the texture of soil, and considered moderate to good for air and water movement in the soil for crops.

d. Permeability: permeability is the entry of fluid from one medium to another. In soil –

water relationship, it means entry of water from air in to soil. : permeability rate is defined as maximum rate at which a soil in a given condition can absorb rain or irrigation water as it comes at soil surface, permeability rate is the rate of water entry in to the soil when flow is non-divergent. It is a surface and sub surface character, and is expressed as mm/sec or cm/hr .Permeability of eight samples under study is between 0.53. to 1.57 cm /hour, and classified as very slow to slow for agriculture and conservation, indicating good availability of moisture to cops after rain or irrigation.

e. Water Holding Capacity (WHC): Water holding capacity of soil is the maximum

amount of moisture, a dry soil is capable of holding, under given standard condition. If the moisture content is increased further percolation result WHC is of great value to practical agriculture, since it provides a simple means to determine moisture content. WHC required for good crop growth is 35 to 70%. The WHC of the eight soil samples is between 53.89 to70.67 % and is high indicating good availability of water for crop growth indicating less frequent water application for growing crops

3.4.6 Chemical Characters:

Parameters considered for chemical analysis are: Soil reaction (pH), Electrical conductivity (EC), Cation Exchange Capacity (CEC)) Cations, like Calcium, Magnesium, Sodium and Potassium, water soluble sulphates ,and chlorides, sodium Adsorption Ratio (SAR).,, Macro nutrients like Available Nitrogen, total Organic carbon, organic matter Available phosphorus, available potassium Micro nutrients like Iron Zinc, manganese and boron. Heavy metals like, Chromium (Cr), Lead (Pb), Nickel (Ni), Arsenic(As), Mercury (Hg) and Cadmium (Cd). a. Soil reaction (pH):The nutritional importance of pH is illustrated, thus hydrogen ion

concentration has influence not only on, solubility of nutrients, but also upon facility with which these nutrients are absorbed by plants, even already in soil solution for e.g. Fe, Mn and Zn become less available as pH rises from 4.5 to 7. At pH 6.5 to7.0 utilization of nitrate and ammonia nitrogen becomes more available. In case of phosphorus it becomes less available to plant as pH increases above 8.5, due to its fixation in exchange complex of soil. For the eight soil sample under consideration the pH ranges between 7.4 to 7.65 indicating soils are neutral, and suitable for growing all crops.

b. Electrical conductivity (EC): The salt content of the soils are estimated by EC measurements, and is useful to designate soils as normal or sodic (saline). Electrical conductivity is expressed as µmhos/cm at 25C, µsmhos/ cm or mmhos /cm or sm/cm. The EC of eight soil samples is between1.19 to 2.96 µs/cm and are below the limits to be called as saline and hence the soils are normal for crop growth.

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c. Organic Carbon / Organic matter( %)Although accounting for only a small part of the total soil mass in mineral soils, organic matter influences physical, chemical, and biological activities in the soil. Organic matter in the soil is plant and animal residue which serves as a reserve for many essential nutrients, especially nitrogen. Determination of organic matter helps to estimate the nitrogen which will be released by bacterial activity for the next season depending on the conditions, soil aeration, pH, type of organic material, and other factors. The eight soil samples under consideration contain 1.19 to 2.96 % organic matter; OM is calculated from organic carbon estimation. As per crop requirements the soils are having sufficient organic matter content in different samples, required for growing crop in next season.

d. Available Nitrogen (N) Nitrogen is a part of all living cells and is a necessary part of all

proteins, enzymes and metabolic processes involved in the synthesis and transfer of energy. Nitrogen is a part of chlorophyll, the green pigment of the plant that is responsible for photosynthesis. Helps plants with rapid growth, increasing seed and fruit production and improving the quality of leaf and forage crops. The available nitrogen in the eight samples in question, as per analysis ranges between 183.8 to 823.1 kg / ha showing better to sufficient nitrogen content for crop growth.

e. Available Phosphorus (P): Like nitrogen, phosphorus (P) is an essential part of the process of photosynthesis. Involved in the formation of all oils, sugars, starches, etc. Helps with the transformation of solar energy into chemical energy; proper plant maturation; withstanding stress. Effects rapid growth, .Encourages blooming, and root growth. The phosphorus content of soil of eight samples ranges between 31.4 to 116.7 kg/ha and falls under medium, sufficient to more than sufficient category for crop growth.

f. Available Potassium (K): Potassium is absorbed by plants in larger amounts than any

other mineral element except nitrogen and, in some cases, calcium. Helps in the building, of protein, photosynthesis, fruit quality and reduction of diseases. The Potassium content of eight soil samples ranges between 200.4 to288.5 kg/ha and is average to medium for crop growth.

g. Cation Exchange capacity (CEC): The total amount of exchangeable cations that a soil

can retain is designated as cation exchange capacity (CEC) and usually expressed as me/100gm of soil. Determination of amount of cations present in soil is useful, because CEC influences the availability of adsorbed cations to both higher plants and soil microorganisms. Thus CEC is directly related to fertility of soils. The CEC of the eight samples ranges between 18.33 to 32.62 me / 100gm soil. A soil with low CEC indicates low fertility and soils with high CEC indicates high fertility. Eight soil samples are fine textured having high percentage of clay with dominating montmorillonitic clay mineral, showing high CEC, in turn fertility is also high.

h. Exchangeable Calcium (Ca++) Calcium, an essential part of plant cell wall structure, provides for normal transport and retention of other elements as well as strength in the plant. It is also thought to counteract the effect of alkali salts and organic acids within a plant and soil acidity. The exchangeable calcium content of eight soil samples ranges between 9.70 to 16.30 me/100gm soil, and having moderate to good base saturation percentage (ranging from 50 to 55%). For normal crop growth a calcium base saturation percent of soils between 50 to 75% is required.

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i. Exchangeable Magnesium (Mg++): Magnesium is part of the chlorophyll in all green plants and essential for photosynthesis. It also helps activate many plant enzymes needed for growth. The magnesium content of the eight soil samples ranges between 6.70 to 12.5 0m e /100 gm soil( BS % ranges between25 to 30), which is further adding to base saturation. Magnesium base saturation percent of 5 to 15 % is normal.

j. Exchangeable Sodium (Na+): Though sodium is not an essential plant nutrient, but it

has some role in potassium nutrition. Sodium also has a role in affecting the pH of soils; Sodium present above a certain limit makes soil alkaline which affect soil physical condition, and fixing of available phosphorus. Out of the eight samples sodium ranges between 0.59 to1.09 me/100gm soil, which is below the content(i.e. ESP is below 15%) at which soil show, saline alkali or alkaline properties, hence no adverse effect on soils.

k. Sodium Adsorption ratio (SAR): Sodium adsorption ratio is ratio of Na+ to under root of Ca + +Mg++ by 2. SAR values of soil solution along with EC and pH helps in diagnosing soils as normal, saline, saline-alkali or alkali. The eight soil samples show SAR values between 0.15 to 0.28 and indicate that samples are normal (SAR below 13)

l. Iron (Fe): Iron is essential for crop and other plants for chlorophyll formation Iron deficiency likely occurs in soils with high pH, poor aeration, excessive phosphorus, or low organic matter. It may be produced also by an imbalance of Mo, Cu, and Mn. In plants, the deficiency shows up as a pale green leaf color (chlorosis) with sharp distinction between green veins and yellow inter-venial tissues. The iron content of eight samples ranges between4.53 to5.99 mg/kg and is very low to low. Thus may cause problem of iron deficiency.

m. Aluminum (Al) Exchangeable Aluminum (Al) is not present in a plant available form in soils with a pH above 5.5 and therefore tests for extractable aluminum need only be done on distinctly acid soils. In soils with a pH range of 4.5 - 5.5 are those most likely to be affected by aluminum toxicity. In the eight samples the total Aluminum is 0.01 to 0.05

n. Manganese( Mn): Is an important plant micro nutrient and is required by plants in second greater quantity compared to iron, like any other element, it can have limiting factor on plant growth, if it is deficient or toxic in plant tissue. Manganese is used in plants as major contribution to various biological systems, including photo synthesis, respiration and nitrogen assimilation. Mn content in the eight samples ranges between 2.90 to 3.80 mg/kg and is low and may cause deficiency in plants.

o. Zinc (Zn) Zn deficiency most often is present in sandy soils with neutral or alkaline pH, or with low organic matter. Total zinc may be high but the availability depends on other factors. In the present eight samples Zinc content ranges between2.10 to 3.40 mg/kg or ppm and are low, considered deficient for crop growth.

p. Boron (B).There is a very narrow range between deficiency and toxicity in boron.

Deficiencies are more often when organic matter is low and dry weather slows the decomposition. Uptake of boron is reduced at pH level higher than 7.0 Plant toxicity symptoms manifest as leaf tip and marginal chlorosis. Boron toxicity occurs in dry areas and is generally associated with irrigation water. In the eight samples of the project the boron content is between 0.90 to2.40 is low and will cause deficiency to crops.

q. Water-Soluble Sulphates as SO4: This test measures readily available sulphur in the form of dissolved plus absorbed sulphate. Sulphur testing is important where low sulphur

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or sulphur-free fertilizers are used, such as high analysis NPK fertilizers. Retention of sulphate sulphur by the soil is related to its phosphate retention, with high leaching losses of sulphate being associated with low phosphate retention soils. This should also be taken into account when considering sulphur fertilizer options. In the eight samples the water soluble sulphate as SO4 ranges between 14.33 to 36.98 mg/kg and very low.

r. Water Soluble Chlorides as Cl: Cl−anion does not form complexes readily, and shows little affinity (or specificity) in its adsorption to soil components. Thus, Cl− movement within the soil is largely determined by water flows. Chlorine is an essential micronutrient for higher plants. It is present mainly as Cl−. Chloride is a major osmotically active solute in the vacuole and is involved in both turgor- and osmo regulation. In the cytoplasm it may regulate the activities of key enzymes. In addition, Cl−also acts as a counter anion and Cl− fluxes are implicated in the stabilization of membrane potential, regulation of intracellular pH gradients and electrical excitability. In the eight samples the water soluble chloride ranges between17.90 to 45.2 mg/kg and is medium to high.

s. Heavy Metals: Soils may become contaminated by the accumulation of heavy metals and metalloids through emissions from the rapidly expanding industrial areas, mine tailings, disposal of high metal wastes, leaded gasoline and paints, land application of fertilizers, animal manures, sewage sludge, pesticides, wastewater irrigation, coal combustion residues, spillage of petrochemicals, and atmospheric deposition. Heavy metals constitute an ill-defined group of inorganic chemical hazards, and those most commonly found at contaminated sites are lead (Pb), chromium (Cr), arsenic (As), zinc (Zn), cadmium (Cd), mercury (Hg), and nickel (Ni) Soils are the major sink for heavy metals released into the environment by aforementioned anthropogenic activities and unlike organic contaminants which are oxidized to carbon (IV) oxide by microbial action, most metals do not undergo microbial or chemical degradation and their total concentration in soils persists for a long time after their introduction Changes in their chemical forms (speciation) and bioavailability are, however, possible. The presence of toxic metals in soil can severely inhibit the biodegradation of organic contaminants. Heavy metal contamination of soil may pose risks and hazards to humans and the ecosystem through: direct ingestion or contact with contaminated soil, the food chain (soil-plant-human or soil-plant-animal-human), drinking of contaminated ground water, reduction in food quality (safety and marketability) via phyto-toxicity, reduction in land usability for agricultural production causing food insecurity, and land tenure problems.

t. Chromium (Cr): Chromium mobility depends on sorption characteristics of the soil, including clay content, iron oxide content, and the amount of organic matter present. Chromium can be transported by surface runoff to surface waters in its soluble or precipitated form. Soluble and un-adsorbed chromium complexes can leach from soil into groundwater. The leachability of Cr (VI) increases as soil pH increases. Most of Cr released into natural waters is particle associated, however, and is ultimately deposited into the sediment. In the eight samples the chromium is nil hence no chromium contamination.

u. Lead (Pb): Typical mean Pb concentration for surface soils worldwide averages 32 mg kg−1 and ranges from 10 to 67 mg kg−1 The most serious source of exposure to soil lead is through direct ingestion of contaminated soil or dust. In general, plants do not absorb or accumulate lead. However, in soils testing high in lead, it is possible for some lead to be taken up. Studies have shown that lead does not readily accumulate in the fruiting parts of vegetable and fruit crops (e.g., corn, beans, squash, tomatoes,

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strawberries, and apples). Higher concentrations are more likely to be found in leafy vegetables (e.g., lettuce) and on the surface of root crops (e.g., carrots). Since plants do not take up large quantities of soil lead, the lead levels in soil considered safe for plants will be much higher than soil lead levels where eating of soil is a concern (pica). Generally, it has been considered safe to use garden produce grown in soils with total lead levels less than 300 ppm. The risk of lead poisoning through the food chain increases as the soil lead level rises above this concentration. Even at soil levels above 300 ppm, most of the risk is from lead contaminated soil or dust deposits on the plants rather than from uptake of lead by the plant. In the eight samples the Lead is nil and no contamination.

v. Nickel (Ni): Nickel is an element that occurs in the environment only at very low levels and is essential in small doses, but it can be dangerous when the maximum tolerable amounts are exceeded. . It usually takes a long time for nickel to be removed from air. The larger part of all Ni compounds that are released to the environment will adsorb to sediment or soil particles and become immobile as a result. In acidic soils, however, Ni becomes more mobile and often leaches down to the adjacent groundwater. In the eight soil samples, the nickel content is between0.01 to 0.18 and below limit of contamination.

w. Arsenic (As): Arsenate can adsorb or co precipitates with metal sulfides and has a high affinity for other sulfur compounds. Elemental arsenic and arsine, AsH3, may be present under extreme reducing conditions. Biotransformation (via methylation) of arsenic creates methylated derivatives of arsine. As compounds adsorb strongly to soils and are therefore transported only over short distances in groundwater and surface water. In the eight samples the arsenic values are below detectible limit and within permissible limit of contamination.

x. Mercury (Hg): Sorption to soils, sediments, and humic materials is an important mechanism for the removal of Hg from solution. Sorption is pH dependent and increases as pH increases. Mercury may also be removed from solution by co-precipitation with sulphides. Under anaerobic conditions, both organic and inorganic forms of Hg may be converted to alkylated forms by microbial activity, such as by sulfur-reducing bacteria. Elemental mercury may also be formed under anaerobic conditions by demethylation of methyl mercury, or by reduction of Hg (II). Acidic conditions (pH < 4) also favor the formation of methyl mercury, whereas higher pH values favor precipitation of HgS(s) .In the eight samples the mercury content is below detectible limit and within permissible limit of contamination..

y. Cadmium (Cd):Application of agricultural inputs such as fertilizers, pesticides, and bio-solids (sewage sludge), the disposal of industrial wastes or the deposition of atmospheric contaminants increases the total concentration of Cd in soils, and the bioavailability of this Cd determines whether plant Cd uptake occurs to a significant degree. Cadmium is very bio -persistent but has few toxicological properties and, once absorbed by an organism, remains resident for many years. The eight samples contain cadmium is below detectible limit and within permissible limits of contamination.

3.5 DRAINAGE AND GEOMORPHOLOGY Assignment w.r.t. Hydrology, Ground water & Water conservation and Geology (HG & GEO) has been done by Dr. J. B. Pishte who is an empanelled FAE of EEIPL for HG & GEO. Scope of work methodology involved and allied details are presented in following paragraphs. Present report covers geological and hydro-geological studies in the area falling

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within 10 km of radius around project site to assess the possible environmental impact of the project. 3.5.1 Geomorphology and Drainage

3.5.1.1 Geomorphology Landforms in Ahmednagar district have been divided into three groups on the basis of their origin, namely –

1. Western hilly region 2. Central plateau region and 3. Northern and Sourthern plains region.

GIACL present project is situated in northern plain region close to Nath Sagar Project at Jaykwadi on Godavari River. The area exhibits rolling country. No prominent hills or other geomorphologic features are visible in the area. The relief in the area is of the order of only about 50 m with less than 460 m elevation towards north and over 500 m towards south. The overall gradient is towards north i. e. towards the Nath Sagar. 3.5.1.2 Drainage

The area under study forms a part of Godavari Basin. Many tributary streams of Godavari River originate in the area adjacent to the project. Most of them are seasonal, flowing only temporarily during rainy season. They show dendritic pattern in general. There are two small streams close to the project. One is on north and the other on the south side of the project. They join together northwards and join the Nath Sagar Reservoir. Refer figure –3.12 for drainage map.

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Fig. 3.11 Geomorphological Map of Project Area

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Fig. 3.12 Drainage Map

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3.5.2 Geology and Hydrogeology

3.5.2.1. Geology

Geologically the area falls roughly in the middle part of the Deccan Volcanic Province (DVP) of Peninsular India. The DVP is dominated by basaltic lava flows of Deccan Traps. The lava flows of Deccan Traps are laterally continuous for considerable distances. It is possible to trace them laterally in exposures and sections on hill slopes and streams, and dug-wells on the basis of their physical properties.

Figure 3.13 Extension of Deccan Trap Province

Two different types of lava flows have been recognised in Deccan Traps. The flows which are made up of sub-flows or lobes are called ‘compound’ flows. ‘Simple’ flows are without sub-flows or lobes. Compound flows are generally made up of vesicular and amygdular basalt whereas the simple flows can be those of vesicular/amygdular or compact, massive or jointed basalt. Both types of basalt flows tend to weather variably even across small outcrops.

In the study area the compact basalt occurs as small patches or lenses in the vesicular type. This rock is dark grey to black in color. It is dense, hard, fine grained and show sparsely distributed vesicles or amygdales at some places. The jointed part of this rock is suitable for movement and storage of groundwater. The vesicular basalt is generally massive without joints. It shows irregular fractures at places. Weathered portions of this rock have good permeability, hence it is more favorable for movement and storage of groundwater.

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Figure 3.14: Geological Map of Project Area

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Basic dykes intrusive into lava flows in this area serve as good passage ways for groundwater due to their jointed nature. This is especially true when they are intrusive into impermeable un-weathered vesicular basalt.

Figure 3.15 Lithological section at Project area

3.5.3 Hydrogeology

Hydrogeology of Deccan Trap terrain is governed by physical nature of basaltic lava flows. The weathered portions of vesicular and compact basalt at shallow depth have better porosity and permeability. Close spaced jointing is favorable for movement and storage of groundwater. Open joints or fissures in rock serve as good passage ways for groundwater. 3.5.3.1. Groundwater Resources

Area on north side of the Project Site has limited groundwater resources (towards Ghotan). There are many dug wells and bore wells sunk for irrigation purpose, but their reported yield is insufficient. In some farmlands along stream course towards the south of the Project site (towards Najik Babhulgaon) sugarcane, is grown in the area adjacent to the compound wall of the sugar factory. The water for irrigating these fields is obtained from dug wells and bore wells. Thus, it can be safely said that the unconfined aquifer is insufficient to support perennial farming in the area; it has to be supplemented by groundwater from confined aquifers at depth. Most of the area around the project site has seasonal crop pattern.

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3.5.3.2. Groundwater Quality

Groundwater quality in the area north of the Project site is reasonably good. It is used for agricultural purpose and drinking. Towards south-east of the Project site, there are some indications of contamination. This is probably because of the use of diluted molasses for farming in past. 3.6 METEOROLOGY 3.6.1 Introduction Micro-meteorological data within the study area during the air quality survey period is an indispensable part of air pollution studies. Meteorological data recorded during the monitoring period is very useful for proper interpretation of the baseline information as well as for input to the predictive models for air quality dispersion. Historical data on meteorological parameters will also play an important role in identifying the general meteorological status of the region. Site specific data can be compared with the historical data in order to identify changes, which may have taken place due to the rapid industrialization in the area. Micro-meteorological parameters regulate the transport and diffusion of pollutants released into the atmosphere. The principal variables, which affect the micrometeorology, are horizontal connective transport (average wind speed and direction), vertical connective transport (atmospheric stability and inversion conditions) and topography of the area. Climate of the study area and surrounding area is generally dry except in southwest monsoon season. Year may broadly be divided into four seasons. Winter season : December to February Pre-monsoon season : March to May Monsoon season : June to September Post monsoon season : October and November Temperature Average maximum temperature of the district is 38.9oC.With onset of the South-West monsoons, there is drop in temperatures and the day temperatures in the South-West monsoon season may be even lower than those in the cold season. Average minimum temperature of the district is11.7oC. Air is generally dry particularly in the afternoons except during monsoon.In months of April and May, it is the period of continuous increase in temperature. May is the hottest month of the year.In October, again temperature increases. December is the coldest month of the year. Rainfall District gets rainfall from south west as well as north east monsoon during the period from June to September.Amount of rainfall received decreases rapidly from west to east. Western part gets heavy rainfall.Average rainfall of the district is near about 583.8 mm. 3.6.2 Methodology Methodology adopted for monitoring surface observations is as per the standard norms laid down by Bureau of Indian Standards (BIS) and the Indian Meteorology Department (IMD).

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On-site monitoring was undertaken for various meteorological variables in order to generate the data, which is then compared with the meteorological data generated by IMD from nearest station at Ahmednagar. 3.6.2.1 Methodology of Data Generation Meteorological data has been generated at the site. Meteorological parameters were monitored for one season i.e. from March 2018–May 2018. Details of parameters monitored, equipments used and the frequency of monitoring is given in Table 3.8

Table 3.6 Meteorological Parameters

No. Parameters Instrument Frequency 1. Wind Speed Counter Cup Anemometer Every Hour 2. Wind Direction Wind Vane Every Hour 3. Temperature Min. /Max. Thermometer Once in a day 4. Relative Humidity Dry/Wet bulb Thermometer Twice a day

3.6.2.2 Sources of Information Secondary information on meteorological conditions has been collected from the nearest IMD station at Ahmednagar. Also, reference were taken from book climatological Normals (1971-2000). Wind roses, temperature, relative humidity, rainfall intensity have been compiled from IMD station, Ahmednagar. 3.6.2.3 Wind Pattern at Project Site during Study Period Wind Speed and direction are recorded at site every hour. Predominant wind during study season is from North West (NW) direction. 3.7 AIR QUALITY 3.7.1 Introduction Ambient air quality with respect to the study zone of 10 Km radius around GIACL site forms the baseline information. Study area represents mostly rural environment. The various sources of air pollution in the study area are industrial emissions, vehicular traffic and domestic firewood burning. Impact of these emissions is reflected in the results of ambient air quality. Major air pollutants released into atmosphere from the different sources are PM10, PM2.5, SO2, NOx and to small extent CO. However, this again varies with type of the source. Section describes the selection of sampling locations, includes the methodology of sampling and analytical techniques with frequency of sampling. Presentation of results for the March 2018 to May 2018survey is followed by observations. All the requisite monitoring assignments, sampling and analysis was conducted through the laboratory of M/s. Horizon Services, Pune which is NABL accredited and MOEFCC; New Delhi approved organization. Further, same has received certification OHSAS 18001–2007 from DNV. Mr. Yuvraj Damugade and Mr. Sangram Patil who are inhouse FAEs of EEIPL for AQ. Also, the assignment w.r.t. Air Pollution (AP) is done by Dr. Sangram Ghugareand Mr. Sangram Patil who are FAEs of EEIPL for AP.

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3.7.2 Methodology 3.7.2.1 Selection of Sampling Locations Baseline status of the ambient air quality has been assessed through an ambient air quality monitoring network. The design of monitoring network, in the air quality surveillance program, is based on the following considerations namely - (1) Meteorological conditions, (2) Topography of the study area, (3) Representativeness of regional background air quality for obtaining baseline status, and (4) Representativeness of likely industrial impact areas. Ambient air monitoring was conducted in the study area to assess the quality of air for SO2, NOx, CO, PM10 and PM2.5. Ambient AAQM stations were set up at eight locations with due consideration to the above mentioned points, details of which are presented below. Monitoring of air quality was done here over a period of one season.

Table 3.7 Ambient Air Quality Monitoring Locations

AAQM Station Code

Name of the Station Distance from site (In Km)

Direction from site

A1 Industrial Site -- -- A2 Talani 2.75 W A3 Rakshi 4.34 SE A4 Ghotan 2.47 N A5 Kurudgaon 5.21 E A6 Raotale 4.74 E A7 Malegaon Ne. 5.11 S A8 Najik Babhulgaon 2.68 SE

3.7.2.2 Frequency & Parameters for Sampling Frequency adopted for sampling is two days per week 24 hourly for all eight ambient air quality stations. The baseline data of air environment, for all the eight monitoring stations was generated. Details of same are presented in following table-

Table 3.8 AAQ Parameters, Monitoring Frequency & Analysis Methods

No. Parameters Frequency of Monitoring Analysis Methods 1. PM10 Continuous, 24 Hourly,

twice a week Gravimetric Method (IS:5182, Part IV) 2. PM2.5

3. SO2 8 Hourly, three samples/day, twice a week

Modified West and Gaeke Method (IS:5182, Part II; Sodium Tetrachloromercurate).

4. NOx 8 Hourly, three samples/day, twice a week

Jacobs and Hochheiser Method (IS: 5182, Part VI)

5. CO Once in a day, once a week NDIR Method (IS: 5182, Part X) 3.7.3 Presentation of Results Summary of results for analysis of ambient air monitoring is presented in Table 3.11. Permissible ambient air quality limits are also presented in Table 3.12

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Table 3.9 Summary of the AAQ Levels for Monitoring Season [March 2018 to May 2018]

Location

Industrial Site

Talani Rakshi Ghotan Kurudgaon Raotale Malegaon Ne.

Najik Babhulgaon

PM10

µg/M3

Max. 68.2 65.3 64.20 65.10 63.80 62.60 64.30 63.50 Min. 58.5 57.5 55.70 56.70 58.20 56.40 58.50 56.80 Avg. 62.63 60.3 59.98 60.95 60.98 59.64 45.58 60.69

98 Percentile 64.6 62.4 62.32 62.90 62.26 61.16 62.41 62.24 PM2.5

µg/M3

Max. 26.20 22.7 17.70 18.20 20.70 20.40 17.20 18.20 Min. 13.80 15.3 14.90 14.60 14.80 14.30 14.90 14.50 Avg. 20.30 18.3 16.14 16.79 17.15 17.34 12.18 16.67

98 Percentile 22.13 19.4 17.05 17.88 18.38 18.52 17.13 17.63 SO2

µg/M3

Max. 30.20 23.2 21.50 24.20 20.30 23.30 19.50 25.70 Min. 12.20 9.3 10.60 11.10 10.30 10.50 10.17 11.20 Avg. 22.61 16.5 15.99 16.19 15.26 15.94 11.29 17.41

98 Percentile 27.35 21.3 19.99 20.97 19.02 20.73 19.09 23.19 NOx µg/M3

Max. 39.90 28.4 28.40 28.50 28.20 28.30 27.60 29.20 Min. 21.70 15.2 14.30 18.20 18.30 18.30 18.30 19.20 Avg. 31.53 22.6 22.84 23.21 23.14 23.48 17.24 23.76

98 Percentile 35.75 26.9 27.30 27.33 27.15 27.20 26.68 27.85 CO ppm

Max. BDL BDL BDL BDL BDL BDL BDL BDL Min. BDL BDL BDL BDL BDL BDL BDL BDL Avg. BDL BDL BDL BDL BDL BDL BDL BDL

98 Percentile BDL BDL BDL BDL BDL BDL BDL BDL Note:PM10, PM2.5,SO2 and NOx are computed based on 24 hourly values.

CO concentrations were observed to be BDL and hence the same are not mentioned in the above table.

Table 3.10 National Ambient Air Quality Standards (NAAQS) Specified By CPCB Notification (New Delhi, The 18th November, 2009)

Zone Station

Industrial, Residential & Rural Area Ecosensitive Area Notified by Govt. PM10 µg/M3

24 Hr 100 100 A.A. 60 60

PM2.5 µg/M3

24 Hr 60 60 A.A. 40 40

SO2 µg/M3

24 Hr 80 80 A.A. 50 20

NOx µg/M3

24 Hr 80 80 A.A. 40 40

CO mg/M3

24 Hr 4 4 A.A. 2 2

Note: A.A. represents “Annual Average 3.7.4 Observations based on Period March 2018 to May 2018 Results of air monitoring, at eight locations, monitored over a period of three months have been given in table 3.9 the results have been discussed here under.

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Particulate Matter (PM10) PM10 values at all the eight locations are attributed to windblown dust. However, the 98 percentile values at eight stations viz., Industrial site, Talani, Rakshi, Ghotan, Kurudgaon, Raotale,Malegaon and Najik Babhulgaon are observed between 61.16 to 64.6µg/m3 which is below the permissible value of 100 µg/m3 for residential zones. Particulate Matter (PM2.5) All observed values are within the permissible limits for residential and rural conditions i.e. 60 µg/M3. The average values ranges between 12.18µg/M3 to 20.30 µg/M3. Sulphur Dioxide (SO2) All observations are well below the permissible limits of 80 µg/M3. Considering meteorology of the site, average SO2 concentrations ranges between 11.29µg/M3 to 22.61µg/M3. Nitrogen Oxides (NOx) All observed values are within the permissible limits for residential and rural conditions (i.e. 80 µg/M3). Average values ranges between 17.24µg/M3 to 31.53µg/M3. Carbon Monoxide (CO) Values observed for Carbon Monoxide are below detectable level (BDL). 3.8 WATER QUALITY 3.8.1 Introduction Selected water quality parameters, for surface and ground water resources within 10 Km radius from the site (as a center), have been considered for assessing the water environment and evaluate the impact due to the project. Understanding the water quality is important in the preparation of environmental impact assessment and to identify critical issues with a view to suggest appropriate mitigation measures for implementation. 3.8.2 Methodology 3.8.2.1 Methodology of Data Generation Reconnaissance survey was undertaken and monitoring locations were finalized based on (1) topomaps and drainage map to identify major water bodies, and (2) likely areas which can represent baseline conditions.Sampling and analysis of water samples for physical, chemical and heavy metals were undertaken through NABL & MoEFCC; New Delhi approved laboratory of M/s. Horizon Services, Pune. Locations taken for surface water sample and ground water sample are presented at table 3.13 and 3.14 respectively.

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Table 3.11 Monitoring Locations for Surface Water

Station Code

Name of the Station

Distance from site (In Km) Direction from site

SW1 Erandgaon 7.5 N SW2 Kunthefal 5.11 W SW3 KarjatKh. 7.50 NW

Table 3.12 Monitoring Locations for Ground Water

Station Code

Lattitude Longitude Distance from site (In Km)

Direction from site

GW1 19°24'11.10"N 75°17'13.84"E 2.69 N GW2 19°21'16.79"N 75°19'13.51"E 7.48 SE GW3 19°22'18.06"N 75°17'19.95"E 1.03 SE GW4 19°22'59.42"N 75°15'13.10"E 3.10 WNW GW5 19°22'41.71"N 75°16'29.88"E 0.84 W GW6 19°23'14.07"N 75°16'54.26"E 0.92 N GW7 19°22'46.88"N 75°17'59.46"E 1.78 E GW8 19°21'39.74"N 75°16'29.65"E 2.16 SW

3.8.3 Sampling Procedure for Primary Data Generation Ground and surface water sources, covered in an area of 10 Km radius from the proposed site were examined for physico-chemical, heavy metal and bacteriological parameters in order to assess the effect of industrial and other activities on surface and ground water. The samples were collected and analyzed as per procedures specified in ‘Standard Methods for the Examination of Water and Wastewater’ published by American Public Health Association (APHA).Samples for chemical analysis were collected in polyethylene carboys. Samples were collected in sterilized glass bottles for bacteriological portability test. Parameters analyzed at the site were pH, temperature, odour, turbidity and dissolved oxygen using portable water analysis kits. Selected physico-chemical and bacteriological parameters have been analyzed for projecting the existing water quality status in the core area. Results for the parameters analyzed in surface water samples, are compared with Class ‘C’ water as per IS: 10500:1991, Revised 2012; “Specifications for Drinking Water”. 3.8.4 Presentation of Results for Survey from March 2018 to May 2018

3.8.4.1 Surface water- Analysis results for the surface water are given in the table below –

Table 3.13 Surface Water

Sr. No. Parameter Unit

Location Limits IS 10500: 2012 SW1 SW2 SW3

1 Color -- Colorless Colorless Colorless Colorless 2 Odor -- Agreeable Agreeable Agreeable Agreeable 3 pH -- 7.47 7.54 7.50 6.5-8.5 4 Conductivity µS/cm 371.30 499.27 418.42 Not Specified 5 TDS mg/lit 248.78 334.52 280.35 < 500.00 6 Turbidity NTU 0.54 0.77 0.69 <1.00

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Sr. No. Parameter Unit

Location Limits IS 10500: 2012 SW1 SW2 SW3

7 TSS mg/lit 52.69 75.15 70.23 Not Specified 8 COD mg/lit 20.39 28.64 25.98 Not Specified 9 BOD3days a 27oC mg/lit 8.87 11.39 10.25 Not Specified

10 Ammonical Nitrogen mg/lit 0.69 0.89 0.75 Not Specified 11 Nitrate as NO3 mg/lit 14.75 20.25 16.18 45 Max 12 Nitrite asNO2 mg/lit 0.23 0.72 0.45 Not Specified 13 Phosphorous as PO4 mg/lit 0.92 1.16 0.97 Not Specified 14 Nitrogen as N mg/lit 16.20 22.18 18.56 Not Specified 15 Potassium as K mg/lit 1.20 2.50 1.70 Not Specified 16 Sodium as Na mg/lit 3.25 6.15 4.02 Not Specified 17 Calcium as Ca mg/lit 24.53 30.61 29.78 < 75.00 18 Magnesium as Mg mg/lit 15.20 19.44 16.53 < 30.00 19 Total Hardness as CaCO3 mg/lit 123.95 156.62 142.55 < 200.00 20 Carbonates as CO3

2- mg/lit NIL NIL NIL Not Specified 21 Bicarbonates as HCO3 mg/lit 112.35 150.23 126.98 Not Specified 22 Chlorides as Cl- mg/lit 58.63 80.30 62.98 < 250.00 23 Sulphates as SO4 mg/lit 16.52 21.45 19.34 < 200.00 24 Fluorides as F- mg/lit 0.43 0.71 0.59 < 1.00 25 Boron as B mg/lit NIL NIL NIL < 0.50 26 Iron as Fe mg/lit 0.08 0.11 0.10 < 0.30 27 Copper as Cu mg/lit NIL NIL NIL < 0.05 28 Arsenic as As mg/lit NIL NIL NIL < 0.01 29 Zinc as Zn mg/lit NIL NIL NIL <5.00 30 Cadmium as Cd mg/lit NIL NIL NIL <0.03 31 Chromium as Cr mg/lit NIL NIL NIL <0.05 32 Lead as Pb mg/lit NIL NIL NIL <0.01 33 Mercury as Hg mg/lit NIL NIL NIL <0.01

34 Total Coli form No./ 100ml 82 138 108 ABSENT

35 Fecal Coli form No./ 100ml 58 90 72 ABSENT

3.8.4.2 Ground Water - Analysis results for ground water are given in the table 3.15

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Table 3.14 Ground Water

Sr. No. Parameter Unit Location Limits

IS 10500: 2012 GW1 GW2 GW3 GW4 GW5 GW6 GW7 GW8 1 Colour -- Colorless Colorless Colorless Colorless Colorless Colorless Colorless Colorless Colourless 2 Odour -- Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable 3 pH -- 7.73 7.62 7.33 7.28 7.61 7.47 7.65 7.53 6.5-8.5 4 Turbidity NTU 0.2 0.1 0.5 0.2 0.5 0.4 0.4 0.3 < 1.00 5 Conductivity uS/cm 924.38 536.56 1442.46 1178.70 1523.79 1377.40 1298.54 1236.72 Not Specified 6 TDS mg/lit 619.35 359.51 966.47 789.75 1020.96 922.88 870.04 828.62 < 500.00 7 TSS mg/lit 20.21 10.23 50.80 21.52 51.12 41.13 40.96 30.89 Not Specified 8 Nitrite as NO2 mg/lit 0.07 0.05 0.28 0.09 0.33 0.23 0.19 0.12 Not Specified 9 Nitrate as NO3 mg/lit 12.62 3.76 18.95 15.83 19.61 18.84 18.51 17.64 < 45.00 10 Ammonical Nitrogen mg/lit 5.11 4.25 8.67 6.84 9.87 7.87 7.56 7.13 Not Specified 11 Total Nitrogen mg/lit 17.91 8.24 28.04 23.05 29.99 27.13 26.98 25.03 Not Specified 12 Phosphates as PO4 mg/lit NIL NIL 0.07 NIL 0.1 0.03 0.01 NIL Not Specified 13 BOD 3days at 27o C mg/lit 17.98 9.20 28.97 18.96 30.54 25.69 21.59 20.59 Not Specified 14 COD mg/lit 48.71 25.44 74.51 49.84 79.12 69.86 58.13 52.98 Not Specified 15 Potassium as K mg/lit 4.25 3.46 6.18 4.88 6.47 5.93 5.69 5.13 Not Specified 16 Sodium as Na mg/lit 80.12 52.31 98.71 84.56 100.09 97.35 95.84 90.18 Not Specified 17 Calcium as Ca mg/lit 49.52 45.89 76.21 53.87 83.29 67.13 62.87 60.23 < 75.00 18 Magnesium as Mg mg/lit 20.21 17.20 35.69 24.69 38.45 32.56 30.21 29.41 < 30.00 19 Total Hardness as CaCO3 mg/lit 207.07 185.59 337.57 236.40 366.64 301.97 281.64 271.74 < 200.00 20 Carbonate as CO3-- mg/lit NIL NIL NIL NIL NIL NIL NIL NIL Not Specified 21 Bicarbonates as HCO3 mg/lit 296.42 125.87 459.88 400.71 463.72 450.78 428.94 405.23 Not Specified 22 Chlorides as Cl mg/lit 72.96 58.12 120.49 95.19 139.54 115.81 102.58 100.43 < 250.00 23 Sulphates as SO4 mg/lit 59.87 40.18 110.23 78.29 125.89 96.37 88.21 85.96 < 200.00 24 Fluorides as F mg/lit 0.09 0.05 0.18 0.1 0.25 0.16 0.14 0.13 < 1.00 25 Boron as B mg/lit NIL NIL NIL NIL NIL NIL NIL NIL < 0.50 26 Iron as Fe mg/lit 0.049 0.035 0.31 0.062 0.39 0.22 0.18 0.12 < 0.30 27 Copper as Cu mg/lit NIL NIL 0.01 NIL 0.019 0.009 0.004 NIL < 0.05

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Sr. No. Parameter Unit Location Limits

IS 10500: 2012 GW1 GW2 GW3 GW4 GW5 GW6 GW7 GW8 28 Total Chromium as Cr mg/lit NIL NIL 0.002 NIL 0.004 NIL NIL NIL < 0.05 29 Nickel as Ni mg/lit NIL NIL NIL NIL NIL NIL NIL NIL < 0.02 30 Lead as Pb mg/lit NIL NIL NIL NIL NIL NIL NIL NIL < 0.01 31 Mercury as Hg mg/lit NIL NIL NIL NIL NIL NIL NIL NIL < 0.001 32 Cadmium as Cd mg/lit NIL NIL NIL NIL NIL NIL NIL NIL < 0.003 33 Arsenic as As mg/lit NIL NIL NIL NIL NIL NIL NIL NIL < 0.01 34 Zinc as Zn mg/lit 0.15 0.09 2.57 1.59 2.95 2.46 2.13 1.88 <5.00 35 Total Coli form No./1

00ml 28 12 68 42 74 60 56 44 0/100ml

36 Fecal Coli form No./100ml 12 4 38 20 42 32 30 24 0/100ml

3.8.4.3 General Observations

Surface Water: Table 3.15 shows surface water characteristics in study area of GIACL. For this study total three samples were collected from lakes namely Erandgaon, Kunthefal and Karjat Kh. Lake. No any river is present in study area of GIACL hence only water samples from lakes which are available are collected for analysis of surface water. These samples were collected and analyses per APHA (2015) and compared with IS 10500 (2012) standards. All samples were found to be colourless. pH values were observed to be in neutral range. Conductivity in the sampled water ranged between 371.30 to 499.27uS/cm. All sites recorded lower BOD values in the range of 8.87 to 11.39 mg/lit. COD values recorded were between 20.39 to 28.64 mg/lit. All study sites showed presence of fluoride, however, but they were within the permissible limits of 1 mg/lit. Heavy metals namely Cu, As, Zn, Cd, Cr, Pb, Hg and B were not found at all sites. All surface water samples shows presence of coliforms.

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Ground Water:

Table 3.16 shows ground water characteristics in study area of GIACL. Ground water was collected at eight different locations (table 3.16) and sample is analyzed as per APHA (2015) and compared with IS 10500 (2012) for portability. Ground water result of these eight samples sites showed that the water is not potable, these sample contain high TDS, hardness, and coli forms. pH values were observed to be neutral in range. Electrical conductivity of samples ranges between 536.56 to 1523.79 uS/cm. Total dissolve solids are in between range of 359.51 to 1020.96 mg/lit while total suspended solids are in range of 10.23 to 51.12 mg/lit. Nitrate values were between 3.76 to 19.61 mg/lit. BOD and COD are recorded to all sites. BOD values are in the range of 9.20 to 30.54 mg/lit. COD values recorded were between 25.44 to 79.12 mg/lit. All water samples shows hardness of water except at GW2. Carbonates are not observed at all samples while bicarbonates shows in range of 125.87 to 459.88. All study sites showed presence of fluoride, but it is within the permissible limits of 1 mg/lit. Heavy metals namely Ni, Pb, Hg, Cd and As were not found at all sites. Also, all ground samples shows presence of coliforms. All the above results indicates that water is not potable at these eight samples sites. 3.9 NOISE LEVEL SURVEY 3.9.1 Introduction Physical description of sound concerns its loudness as a function of frequency. Noise in general is that sound which is composed of many frequency components of various loudness distributed over the audible frequency range. Various noise scales have been introduced to describe, in a single number, the response of an average human to a complex sound made up of various frequencies at different loudness levels. Most common and universally accepted scale is the ‘A’ weighted scale which is measured as dB (A). This is more suitable for audible range of 20 to 20,000 HZ. The scale has been designed to weigh various components of noise according to the response of a human ear. The impact of noise sources on surrounding community depends on • Characteristics of noise sources (instantaneous, intermittent or continuous in nature). It can

be observed that steady noise is not as annoying as the one, which is of continuously varying loudness.

• The time of day at which noise occurs, for example high noise levels at night in residential areas are not acceptable because of sleep disturbance.

• Location of the noise source, with respect to noise sensitive land use, which determines the loudness and period of exposure.

Environmental impact of noise can have several effects varying from Noise Induced Hearing Loss to Annoyance depending on loudness of noise levels. The environmental impact assessment of 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. Study area of 10 Km radius with reference to the GIACL site has been covered for noise environment. The four zones viz. Residential, Commercial, Industrial and Silent Zones have

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been considered for noise monitoring. Some of the major arterial roads were covered to assess the noise due to traffic. Noise monitoring was undertaken for 24 hours at each location. Main objective of noise pollution impact assessment in the study area is to assess the impact of total noise generated by industries and vehicular traffic on the human settlements within 10 Km radius. The main objectives of the studies conducted are: Assessment of background noise levels Identification and monitoring the major noise sources of the existing activity Impact of noise on the workers as well as on general population.

Assignment of noise was done by FAE of EEIPL for NV - Mr. Vinay Kumar Kurakula in May 2018. 3.9.2 Identification of Sampling Locations Preliminary reconnaissance survey was undertaken to identify the major noise generating sources in the area. Noise generating sources have been identified with respect to the activities, viz. industrial noise and ambient noise due to industries and traffic, which have impact on sensitive areas. Noise sampling locations have been indicated below. 3.9.2.1 Ambient Noise Monitoring Stations

Noise level readings were recorded in 7 locations spread over, in the 10 km radius centering the proposed unit. Noise levels were recorded by the use of a digital noise level meter, The instrument was calibrated before and after each set of readings. Monitoring was carried out on 24-hourly basis and the hourly Leq. Values were derived and reported. The noise monitoring points were selected based on the population, settlement and background noise sources. These locations were in the populated areas mainly at the road side where there is high noise due to vehicle noise. Name of the location along with the distance from proposed unit and the direction of the unit is given in table below -

Table 3.15 Noise Sampling Locations

Station Code

Name of the Sampling Point

Distance from site (In Km) Direction from site

N1 Project Site --- N2 Ghotan N 2.1 N3 Kurudgaon E 2.9 N4 Rakshi SE 4.3 N5 Shevgaon SW 6.6 N6 Malegaon S 5 N7 Khuntephal NW 6

Parameters Measured During Monitoring A noise rating developed by EPA for specification of community noise from all the sources is the day-night sound level, (Ldn). It is similar to a 24-hour equivalent sound level except that during the night-time period, which extends from 10 PM to 6 AM, a 10 dB (A) weighing penalty is added to the instantaneous sound level before computing 24 hour average. This

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night time penalty is added to account for the fact that noise during night, when people usually sleep, is judged more annoying than the same noise during the daytime. For noise levels measured over a given period of time interval, it is possible to describe important features of noise using statistical quantities. This is calculated using the percent of the certain noise levels exceeding during the time interval. As can be seen from the table below, the maximum daytime Leq as well as night time Leq values were found to be 70and 61 dB(A). Maximum values may be attributed towards the nearby commercial activities and traffic movements. Minimum values for day & night time were found to be 52 and 43 dB(A) respectively. 3.9.3 Presentation of Results Ambient noise levels measured are presented in Table. 3.21. Table indicates equivalent noise levels viz. L10, L50, L90, Lday, Lnight and Ldn at different places located within the study area. Similarly, these values viz. Leq, Lday, Lnight and Ldn are compared with the limits.

Table 3.16 Ambient Noise Levels

Sr. No.

Location Average Noise Level in dB(A) L10 L50 L90 Leq(day) Leq(night) Ldn

1. N1 51.9 56.9 59.8 68.9 48.0 67.1 2. N2 43.4 45.4 48.9 50.9 40.9 50.9 3. N3 41.9 44.9 48.1 52.0 39.2 51.2 4. N4 43.1 45.3 48.6 51.8 40.0 51.2 5. N5 40.0 43.7 47.1 52.0 37.1 50.7 6. N6 42.0 44.4 48.5 51.2 39.0 50.5 7. N7 40.3 44.4 46.2 50.4 39.5 50.1 8. N8 39.0 44.0 46.6 49.8 40.2 49.9

3.9.4 Observations of Noise

Industrial Site (N1) Equivalent noise level value, because of activities in the vicinity, observed during day time is below permissible limits for the observation period. Similarly, night time values are also lower than prescribed limits. Najik Babhulgaon (N2) Day time level of 50.9 dB(A) is within the permissible limit. The night time observation 40.9 dB(A) is below permissible limit Ghotan (N3) Noise level during daytime upto 52 dB(A) which is within the permissible limit. Night time observation 39.2 dB(A) is also below permissible limit.

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Talani (N4) Day time level of 51.8 dB(A) is within the permissible limit. Night time observation 40.0 dB(A) is below permissible limit Kurudgaon (N5) Noise level during daytime upto 52 dB(A) which is within the permissible limit. The night time observation 37.1 dB(A) is also below permissible limit. Kuntefal (N6) This represents rural area and traffic density is low. Equivalent noise level during day time is observed to be within the permissible limits. Equivalent value observed during night time is well below the permissible standards Raotale (N7) Day time level of 50.4 dB(A) is within the permissible limit. Night time observation 39.5 dB(A) is below permissible limit Malegaon (N8) This represents rural atmosphere. Daytime level of 49.8 dB (A) is within the permissible limit. Night time observation 40.2 dB (A) is below permissible limit. The noise data was analyzed as per the protocol of CPCB published in 2015.

The noise levels were recorded using a Sound Meter which was calibrated accordingly. The various parameters are recorded for twenty four (24) hours and are as follows

L10is the noise level just exceeded for 10% of the measurement period L50is the noise level just exceeded for 50% of the measurement period L90: is the noise level exceeded for 90% of the measurement period Ldayis the Day equivalent level measured over the 12-hour period (6 AM to 10 PM). Lnightis the Night equivalent level measured over the night 12-hour period (10 PM to 6 AM). 𝑳𝑳𝒅𝒅𝒅𝒅 : is the Day-night equivalent level, measured over the 24 hour period Equivalent Sound Pressure Level (Leq) Leq is the equivalent continuous sound level that is equivalent to the same sound energy as the actual fluctuating sound measured in the same period. This is necessary because sound from noise source often fluctuates widely during a given period of time. This is calculated from the following equation: (L10-L90)2

Leq=L50+ ------------- 60 Ldn: Noise rating developed for community noise from all sources is all Day-Nights Sound Level (Ldn). It is similar to a 24 hr equivalent sound level except during night time period (10 PM to 6 AM) a 10 dB (A) weighing penalty is added to the instantaneous sound level before

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computing the 24 hr average. The Ldn for a given location in a community may be calculated from the hourly Leq’s, by the equation. Ldn=10 log 1/24[15(10 Ld/10) +9 (10(Ln+10)/10)] Where Ld is the equivalent sound level during the daytime (6 AM to 10 PM) and Ln is the equivalent sound level during the nighttime (10 PM to 6 AM). 3.9.4.1 Method of Monitoring A detailed noise level survey was undertaken to study the levels of noise, as the high noise levels may cause adverse effect on human beings and the associated environment. The noise level monitoring was carried out through MoEFCC; New Delhi approved laboratory- M/s. Horizon Services, Pune which is NABL accredited and MOEFCC; New Delhi approved organization. Further, same has received certification OHSAS 18001–2007 from DNV. 3.9.4.2 Standards for Noise Levels MoEFCC has notified ambient air quality standards in respect of noise vide Gazette notification Dated 14th February 2000. It is based on the ‘A’ weighted equivalent noise level (Leq). The standards are given in Table 3.16

Table 3.17 Ambient Noise Level Standards

Area code Category Limits in dB(A) Leq Day Time Night Time

A Industrial Area 75 70 B Commercial Area 65 55 C Residential Area 55 45 D Silence Zone 50 40

Ref: Gazette of India 14th Feb 2000. Standards for Occupational Noise (U.S.A): Industrialized countries have specified limits for occupational noise exposure. Permissible noise exposure limit for industrial workers is primarily concerned with the harmful aspect of noise and its objective is to protect the hearing of majority of working people. American Conference Government of Industrial Hygienists (ACGIH), USA has prescribed the following permissible noise exposure limits for industrial workers. These limits are given in Table 3.19

Table 3.18 Standards for Occupational Exposure

Exposure Time in Hour/day 8 4 2 1 1/2 1/4 1/8 1/16 1/32

Limit in dB(A) 090 093 096 099 102 105 108 111 114 Exposure to continuous or intermittent noise louder than 115 dB(A) should not be permitted. Exposure to pulse or impact noise should not exceed 140 dB (A). OSHA Standards: Occupational Safety and Health Administration (OSHA) have also prescribed the following allowable limits to noise exposure for industrial workers. These are given in the following Table 3.20

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Table 3.19 OSHA Standards for Occupational Exposure

Duration per day (in hours) 8 6 4 3 2 1.5 1 0.5 0.25

Sound level in dB(A) 85 87 90 92 95 97 100 105 110 3.10 SOCIO-ECONOMIC PROFILE 3.10.1 Introduction Socio-economic status of any population is an indicator for development of the region. Any developmental project will have bearing on the living conditions and on the economic base of population in particular and the region as a whole. Similarly, the proposed industry will have its share of socio-economic influence in the study area. Section delineates overall appraisal of socially relevant attributes. This report is a part of an EIA study carried out as per the MoEF Notification No. 1533(E), dated 14th September, 2006. Survey of selected twelve villages, out of the total 27villages was carried out with help of an interview schedule. The objective of this survey was to understand the current socio-economic status of the identified villages and the perception of local people about GIACL as well as to know their awareness about the proposed project. The following data was collected during monitoring period by Dr. Anuradha J. Samant (FAE), Mr. Neeraj D. Powar (FAE). 3.10.2 Methodology The survey of 12 villages, selected out of 27 villages within the 10 Km radius of GIACL, was carried out with the help of a structured close ended interview schedule, comprising of 28 questions in Marathi. The schedule was administered by using Simple random disproportionate sampling technique. A total of 120 locals were covered during the study, (Table 3.20).

Table 3.20 Selected villages and details

Sr. No. Village Sample Size 1. Kharhetakali 10 2. Khanapur 10 3. Thakur Nimgaon 10 4. Rakshi 10 5. AntarvaliKh. 10 6. Raotale 10 7. NajikBabhulgaon 10 8. Ghotan 10 9. Talani 10 10. Erandgaon 10 11. Khuntephal 10 12. Khardgaon 10

Total 120

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3.10.3 Results and Discussion Male: female ratio among the respondents was 64:36 respectively. Special attention was given for incorporating educated females like high school teacher, gram panchayat members, PHC- employees remain and girls taking higher education. This was deliberately done to elicit information from them due to their education, exposure and experience.

Figure 3.16 Age distribution of the respondents within the sample size

Within the sample size, 30% were between the age-group 31 to 40 years,25 % between 21 to 30 years, 19% between 41 to 50 years, 15% between 51 to 60 years and remaining 11 % above 60 years. (Fig.3.16) A majority of the respondents within the sample size were literate as only 5% were illiterate. Among the literates 34% had up to primary, 41% secondary, 11% higher secondary, 3% were graduate. Though the majority of respondents are literate, presence of only 6% graduates and total absence to Post Graduates shows that most respondents have not reached till higher education. Within the surveyed area the respondents were found to be involved in various livelihood activities namely agriculture, service, agriculture labour and occupation. About 90 % of the respondents had agriculture as their main occupation. Around 15 % of the respondents relied on daily wages while 3% were involved in diverse services, like mason work, carpentry, plumbing depending on the demand. Only few (2%) had their own business like general stores, retail stores, mineral water suppliers etc. 47% of the respondents had their annual income between Rs. 1,00,000 to 1,25,000, 39 % of the respondents had their annual income between Rs. 1,25,000 to 1,50,00, 8% had above Rs. 1, 50,000 whereas remaining 6% of the respondents from the study area had an annual income between Rs. 75,000 to 1, 50,000. This shows that most respondents belonged to lower middle class category.

30% 31 to 40 years

25% 21 to 30 years 19% 41 to 50

yeras

15% 51 to 60 years

11% above

60 years

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In all villages 83% respondents depended for drinking water on the Jayakwadi dam. On the other hand only 78% relied on groundwater and other sources such as wells and bore wells. According to (82%) of the respondents there is no shortage of water in the area as it is sufficiently available throughout the year. About 53% of the respondents revealed that there was a change in water quality in their area. Major reasons, according to them were Discharge of Industrial water (53%) as well as Domestic waste water (37%). When enquired about the negative environmental effects of existing factory of GIACL, 72% of the respondents said that they are experiencing the negative environmental effect. The negative effects as quoted by them were Odour problem and effect on health Majority of the respondents (69%) were unaware of the proposed expansion project. When asked about their opinion on this, mixed opinions were expressed. About 53% perceived change in the existing environmental conditions and81% were hopeful about increase in employment. About 19% perceive no change in existing conditions. The unawareness of the locals regarding the expansion of the project may be due to their unconcerned approach as well as non-communication by concerned agencies. 44% of respondents stated that library/ reading room existed in their village which was utilised by villagers. 36% of respondents mentioned that there was a cultural centre for the use of villagers in the village. 97% stated that there was madanpam in front of their temples which was utilised for multiple purposes. About 78% of the respondents said that there are PHC centres in working conditions with availability of doctors in the village existed in the village. According to 86 % of respondents toilet facility was available in their homes. According to all respondents there is sports ground availability in respective schools which is being used by students for various sports activities. According to 86% of the respondents there is a bus stand in their villages and 80% respondents said that there are private vehicles for local transportation. 80% respondent’s said that secondary school facility is available in the villages. According to all respondents there is availability of toilet facility in respective schools. According to all respondents there were self-help groups in their respective areas for socio-economic upliftment of the locals. However no specific business was carried out by these self-help groups except gathering money and releasing loans. There were diverse expectations of the respondents from GIACL. About 53% stressed on the need for better health facility, 31% demanded domestic waste water management and 19% asked for solid waste treatment facilities, to increase the educational standard 31 % wanted good educational facilities, 22% expected road construction. Most (96%) of the respondents had optimistic opinion about the future expansion. This was due to their potential socio-economic dependence on consumption of their additional sugarcane by the distillery after the proposed expansion. However, it was important to note that majority (58%) of the respondents from village Najik Babhulgaon were not satisfied with the existing industry, due to the present level of pollution situation from the existing sugar factory, distillery, and co-generation plant and had apprehension about the proposed expansion.

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3.10.4 Observations It was observed that most of the villages are having facilities like drinking water, educational facilities, toilets and electricity. However, most villages lacked availability good roads, drainage system and solid waste management system. The area being close to Jayakawadi dam Personal observations and interactions with some locals revealed that most respondents from villages Najik Babhulgaon, Talani and Rakshi suffered and also complained about the odour pollution from the industry.It was also observed that respondents from villages Thakur Nimgaon and Antarwadi Kh. did not depend on the industry as very few of the locals cultivated sugarcane. Since there was less sugarcane and sparse agriculture of jowar and bajara, respondents from village Thakur Nimgaon expected job opportunities in the industry. 80% of the locals from village Antarwadi Kh. cultivated pomegranate orchards which had reduced their dependency on the industry. 3.10.5 Conclusion Major respondents from all villages in the study area were dependent on agriculture and allied activities for their livelihood. Major crops grown in the area included sugarcane, jowar, wheat, and vegetables, some grew cotton as well. A large quantity of the sugarcane produced in the study area was supplied to this industry. Therefore the respondents expected that their all sugarcane be accepted in time by the industry. Some of the farmers also increasingly preferred growing fruitorchards like pomegranate, guava and papaya for better economic returns. Most villages, except Najik Babhulgaon, were not directly affectedby pollution due to the industrial activities. This industry had initially created employment opportunities for semiskilled and unskilled labour which resulted in economic benefits for some in the region. Farmers also benefitted due to supply of their sugarcane to this industry due to its closeness. However, the village Najik Babhulgaon was the most affecteddue to its proximity (less than 500m) to this industry and inadequate pollution mitigation measures. Therefore, thelocals complained about different kinds of pollution.. Majority of the respondents demanded healthcare facility on priority in the form of proper medical service through camps along with medicines. Through the observations poor school education facilities were observed by the experts and the same was demanded by the locals. 3.10.6 Suggestions • Substantial efforts should be taken for control of odour pollution. Massive drive for

organic farming with compulsion of drip irrigation needs to be undertaken by the industry by involving government, locals as well as NGOs. The activities like distribution of bio-fertilizer, saplings, at a subsidise rate as well as training programme should be conducted for villages at large which at present is only for share-holders and employees.

• Company should organize medical camps at village and school level proper sanitation facilities is also a necessity of the area.

• ZP should make provision for infrastructure like roads, toilets in public places. • Plantation can be done by companies and later maintained by schools/ gram panchayat/

institution, which will act as absorbers of polluted air. 3.11 ECOLOGY This EB report for GIACL has been prepared by Prof. Dr. Jay S. Samant (FAE), Dr. Rohan Lad (FAE-B) and Mr. Nachiket Patil, Associate.

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3.11.1. Study area Study area i.e. 10 Km radius from project site forms a part of Ahmednagar district. Total 31 villages are located in this area, of which 8 villages fall between 0 to 5 Km radius while remaining 23 villages between 5 to 10 Km radius. Topography of the region is mostly gently undulating land comprising of grassland, mixed with scrub and agricultural as the major habitats. Except border of Jayakwadi Bird sanctuary, in the backwaters of Jayakwadi dam in the north west of the 10km radius, there is no other eco-sensitive zone, National Park or Wildlife Sanctuary in the study area. Area receives low annual rainfall of averaging 580 mm. Earlier two field surveys were conducted for preparation of GIACL EIA reports, for the proposed distillery as well as distillery expansion projects, on 29.04.2013 and 21.05.2013 as well as on 30.03.2015 and 31.03.2015 respectively. During earlier studies, questionnaire survey of all 8 villages within 5 Km as well as 4 villages between 5 to 10 Km was undertaken. During present study, the focus was mainly on 4 villages namely Ghotan and Malegaon (between 0 to 5 Km) and Khanapur and Erandgaon (between 5 to 10 Km). For EB field observations following eight villages’ environs were selected. Table 3.21 Names of villages visited for Ecology and Biodiversity study in 10 km radius

from the project site

Sr. No. Name of Study Village Sr. No. Name of Study Village In radius 0 to 5 Km In radius 5 to 10 Km

1 Najik Babhulgaon 5 Erandgaon 2 Ghotan 6 Khanapur 3 Talni 7 Thakur Nimgaon 4 Malegaon 8 Kuntephal

3.11.2. Methodology

3.11.2.1. Ecology For the EB study Toposheet (surveyed in 1967-68 and updated during 2005-06), IRS LISS IV satellite imagery and LULC maps based on them were used. Appropriate data from District Census (2011), Ahmednagar District Gazetteer and relevant literature were referred. In the ecological study ground truthing was done during field visits after confirming the LULC maps to learn major macro and micro habitats in the study area. In major terrestrial habitats grassland, scrub and in wetland habitats streams, water tanks, river and a dam were identified in the vicinity of the study villages.

Field surveys were conducted during monitoring period. Biodiversity survey was conducted using random sampling method for flora and opportunistic sighting method (Larsen and Viana, 2016), and standard point count method (Altmann, 1974) for fauna were followed. In general visual observation and estimation method was used for qualitative study of the biota. Birds and fish were studied in particular being good indicators of local environmental change. Flora, mainly major tree species, was focused for their identification and species abundance. Binoculars Olympus (12X50-5.2O) and Olympus (7X35-7O) were used for close observation of birds and photo documentation was done for habitats and biodiversity records using Canon-EOS 700D camera, 55-250 mm lens and Canon power-shot SX30IS (HD 35x,). Book

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of Indian Birds by Salim Ali (2002) and Birds of the Indian Subcontinent by Grimmet et al. (2005) for birds and for freshwater fishes by Ranjit Daniels (2002) were referred as field guides and for preparing checklist. The data collected from the survey were used to understand present status of ecology habitats and biodiversity. 3.11.2.2. Questionnaire

A semi-structured close ended interview schedule in Marathi, comprising of 21 ecology-biodiversity related questions, was administered to 16 local respondents from the 4 villages. The method was adopted in order to get perception, mainly of the local elders, about the past and present environmental status and changes in local ecology and biodiversity. During field study direct and indirect environmental impacts of human activities on ecology and biodiversity were photo documented. Due to time constraint, the field study reflected only winter season data, limited to observations during day time and at the selected study sites only. Earlier field observation and questionnaire survey reports of GIACL were also referred (Equinox EIA report, 2012 and 2016). Review of available literature was done to understand possible change in the ecology and biodiversity in the study area 3.11.3. Ecology 3.11.3.1. Field Observations

Field observations were restricted to the 10 Km radius area around the GIACL factory. Most part of which is consisted of large tracts of natural grasslands, which are fragmented and now composed of agricultural land, fallow land, scrub, scattered trees, village settlements and industry (Appendix H). Neem and Babhul are dominant natural tree species in the area. Major crops in the study area are sugarcane, jowar, wheat, cotton, maize, andonion. Plantations of pomegranate and papaya were also observed, especially around villages Rakshi and Thakur Nimgaon. Water supply tanks near villages Kuntephal and Malegaon as well as part of large Jayakwadi dam are the major wetland habitats in the study area. However, due to poor monsoon all water bodies except Jayakwadi dam were partially dry during field visit. 3.11.3.2. Questionnaire Survey

A majority (75%) of the respondents revealed that in the past major part of the area was natural grasslands most which now has been converted into cropland. According to locals other major habitats in the area in the past included mixed agriculture (40%), scrub (30%), fallow land (40%). The present status of theses habitats as per the locals is grassland (40%), scrub (30%), and fallow land (20%). This indicates that there is some (25%) reduction in area under grassland. There is minor change in other remaining land use types. The many (50%) respondent reported that the natural grassland habitat has been drastically reduced due to expansion of sugarcane crop and industrialization. A majority (70%) of the respondents revealed that due to perpetual low rainfall in the region, most water bodies in the area remain dry except villages near Jayakwadi major dam where water is available for longer duration.

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3.11.4. Biodiversity

3.11.4.1. Field Observations

Birds being good bio-indicators of ecosystem status, as the change in the local environment and habitat condition is reflected in their health, composition, behavior and population dynamics. The faunal study was mainly focused on avifauna and Lepidoptera in the study area. According to Ahmednagar Gazetteer (2006) the key mammal carnivorous found in the area include Jackal (Canisaureus indicus), Hyena (Hyaena hyaena), Indian Wolf (Canis lupus pallipes) and Wild Cat (Felis silvestris ornate). The herbivorous commonly include Black Bucks (Antilope cervicarpa), Hare (Lepus nigricollis), and Indian Gazelle (Gazella bennetti). In aquatic habitats common fish fauna from wetland resources comprised mainly cat fishes and local minor carps. The fishes belonging to five major families namely Cyprinidae (9 species), Siluridae (1species), Cobitidae (1species), Channidae (1species) and Mastacembellidae (1 species) occur in the area. In reptiles, around 18 species are known to occur in the district. Jayakwadi Bird Sanctuary is a famous large wetland habitat of national importance and is a recognized Important Bird Area (IBA) as it supports rich aquatic biodiversity and large number of local, regional, and trans boundary migratory birds. During the field study many local avifaunal species with few early migrants were observed in and around Jayakwadi Bird Sanctuary. During the survey, a total bird 64 species belonging to 18 orders and 38 families were recorded, out of which 38 species were common resident, 14 species were not common resident, 9 species were not common winter visitor and 3 species were common winter visitor, Of those 19 were exclusively associated with wetland habitats. Relatively dry open areas with scrub and grasslands and wetlands have been traditionally used by biodiversity as natural habitats, except mosaic of rain fed agriculture fields as artificial habitat which has coexisted for some time which also supports the diverse fauna adapted to the agro climatic conditions. Moreover, according to IUCN, (Red data list 2018), two bird species as globally Near Threatened were recorded namely River Ternand Black-tailed Godwit, were observed at Nath Sagar Bird Sanctuary during the field study. In case of feeding guild 16 species recorded were dependent on multiple sources for feeding, while remaining dependent on single source. Out of the total 64 bird species 13 species were Piscivorous, 16 were Insectivorous, 2 Carnivorous, 5 species were Omnivorous, 6 were Granivorous and 2 were Frugivorous. During earlier study (2016), 49 species of birds were recorded in the study area. When thousands of wetland birds, true and local migrants species, total 13 species of winter visitors, were observed in the backwaters of Jayakwadi Dam in the study area. Conversely, during present study 69 bird species were recorded with only 7 winter visitors and less bird count in general as compared to previous survey. This may be due to difference in seasons as earlier study was undertaken in migratory season while present study was conducted in early winter. During the field study three different herds of Blackbuck (IUCN status-LC / Schedule I), comprising of more than 15 individuals each were observed in areas namely at Talani, Malegaon and Shevgaon-Rakshi road. These areas are within 5 Km from the Project site. The dominant natural tree and shrub species in flora were recorded. Being perennial, these give indications of change in local environmental quality over a period. As birds are mostly associated with tree, shrub and ground flora for their basic requirements, and are therefore themselves sensitive as indicators of environmental change, were observed in the study area.

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In flora, 29 trees and shrub species belonging to 23 families were observed during field investigation. Locally dominant species tree species were Azadirachta indica, Acacia nilotica, Tamarindus indica and Pongamia pinnata. Floral and Faunal species recorded are enclosed in Appendix - H. 3.11.4.2. Questionnaire survey During questionnaire survey on biodiversity, the locals reported 8 common tree species in the study area, namely Banyan, Peepal, Ficus, Tamarind, Drumstick, Babhul, Neem, and Mango. In agriculture the crops grown are Jowar, Wheat, cotton, vegetables, onion and tur. The horticulture is dominated by pomegranate, sapota and papaya. According to the respondents local wildlife is represented by Indian Wolf, Indian Fox, Black buck, Wild Boar, Common Mongoose, Indian Porcupine, Common Langur, Indian Hare, Indian flying fox and Three-striped Palm Squirrel. According to most (70%) respondents the population of blackbuck and wild boar has increased significantly increased in certain areas due to landuse change and natural habitat loss, and now the two herbivores cause some crop damage. More than 90% respondents endorsed occurrence of common birds like Peacock, Common Myna, Sparrow, Crow, Rose-ringed Parakeet, Common Quail, Francolin and Kite. In reptiles a majority (98%) of the respondents reported occurrence of snake species like Spectacled Cobra, Indian Rat Snake, Russel’s viper, Saw-scaled viper and common krait, Indian Monitor Lizard, Garden lizard and Common House Gecko in the area. A majority confirmed presence of frog species like bull frog in the area, as they were not aware and or interested in other species of amphibians. On fish diversity, only 32 % respondents reported presence of fish namely Rohu, Katla and Tilap being main commercial fish. In case of invertebrates, more than 90% knew existence of spiders, butterflies, scorpions, crabs, and other locally common organisms but could not identify or name any one specifically. As per Indian Wildlife Protection Act, 1972(as amended upto 2013; IWPA), out of total six Schedules, Mammal species are given protection in Schedule I-V. During survey various species from all the vertebrate groups and butterflies (included under various schedules of the Act, (1972) are listed in Annexure H. It is revealed that a total of 9 species from the faunal groups are listed under Schedules I and II, In general, there is need to conserve and protect all these species on priority basis. Most (70%) respondents reported steady decline in the biodiversity in the area due to two main factors 1. agriculture expansion (69%) and 2.industrialization (38%). 3.11.5. Green belt 3.11.5.1. Observations

The industry has two plots (Appendix G) of 27.06 Ha and 6 Ha. totaling an area of 33.06 Ha. On the first plot (27.06 ha) entire set up of industry has been erected whereas the second one (6 Ha) is procured solely for development of GB.As per the TOR norms dated 14.04.2018 under section (7) of Impact and Environment Management Plan point (ix), accordingly Green Belt (GB) should be developed on 33% of total area, with not less than 1500 trees per ha shall be planted. This green belt shall be around the project plot boundary and a scheme for greening of the roads used for the project shall be incorporated along with the details of species, width of GB plantation, planning schedule etc. The development of GB is primarily

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for environmental protection purpose, and should be developed along the entire periphery of the total industrial plot by planting large type of local tree species as per the norms of CPCB (2000). In GIACL complex; there is a green belt of 61,350 Sq. M (6.1Ha). This is 23% of total industrial plot area of 27.06 Ha. As per the MoEFCC & norms; the Industry has to grow 33% of plot area as GB. For observing this condition; GIACL has purchased another plot of 6 Ha adjacent to its existing industrial plot. Out of this; 4.07 Ha is developed as green belt. Thus, aggregate GB by GIACL is about 10.17 ha which works out to be 38% of the entire industrial plot.In present green belt, 10305 trees have been grown. In monsoon months of year 2018; additional 5353 trees were planted by the industry. A list of same has been given at Appendix- G. As per the CPCB, (2000) guidelines for the GB, with width of three trees of recommended local large type tree species, should be developed on the periphery of the entire industry plot for environmental protection and as mitigation measure from diverse pollutants, to safeguard the health of workers, neighboring local population and biodiversity in the vicinity. In the GB plantation preferably indigenous, broadleaves, mixed tree species, suitable to the local climatic conditions, are expected to be planted for pollution control and not merely for aesthetic purpose. The avenue trees and ornamental plantations with small trees, shrubs, palms, bamboo, lawns etc. if planted within the plot are supposed to be in addition to the GB tree plantations. 3.11.6. CER Activity

3.11.6.1. Observations and Recommendations

As per the Corporate Environmental Responsibility (CER, 2018) time bound activities for protection and conservation of the natural habitats in the project vicinity, with joint participation of locals and industry, need to be undertaken on priority. The three villages in the study area namely 1) Rakshi, 2) Ghotan and 3) Talani, are rich in ecology, habitat diversity and biodiversity, and thus are recommended for CER activity for protection and conservation of existing local ecology and biodiversity. With reference to local conditions and people’s response, CER activities, such as 1.Roadside and block plantations of local tree species, 2.Removal of weeds and exotics, 3.Solid waste and sewage management, 4.Water and soil conservation and 5. Environment awareness campaign should be undertaken on priority by particularly involving local youth and women self-help groups. In addition to proactively controlling negative impacts of industrial pollution on local ecology, these initiatives would improve villager’s health, most of who are employed in the industry. These activities by GIACL should be need based, time bound and result oriented and the thrust should primarily be focused on eco-friendly, self-reliant and sustainable development of the villages around the industry. This can be achieved by adopting simple alternative green technologies in the villages such as community RO plant for drinking water, block tree plantation at community level, rainwater harvesting, organic farming and others. It was encouraging to note that, under government roadside tree plantation drive, the saplings were nurtured by local village women self help group by reusing discarded plastic drinking water bottles by drip irrigation. Refer appendix -.H

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3.11.7. Eco-Sensitive Map Wild life sanctuary map shows the location of all the national parks, bird reserves and sanctuary of Maharashtra State.

Nathsagar wetland is situated near Paithan in district Aurangabad, Maharashtra. This man-made wetland has been created due to the construction of dam at Paithan on river Godavari. It can be classified as a 'permanent artificial freshwater lake'.This wetland is declared under "Ramser Convention-1971", and has also been notified as 'Jaikwadi Bird Sanctuary' by Govt. of Maharashtra in 1986.Total 200 species of birds can be found in this region, which includes more than 70 species of migratory birds. Out of these, 45 chief species are of international migration. Notable amongst migratory birds are Cranes,Flamingos, Pintails, Wigeon, Shoveller, Brahmany Duck, Pochards, Teals, God Wit, Shauces, Glossy Ibis, etc. Figure 19_shows the distance from the eco -sensitive zone border to the proposed expansion plant. Nearest distance is 5.5 km.

Figure 3.17 - Eco-Sensitive Map

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Figure 3.18 - Jayakwadi Bird Sanctuary Map

Figure 3.19 - Jayakwadi Bird Sanctuary Map

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Chapter 4

ENVIRONMENTAL IMPACTS & MITIGATION MEASURES

ENVIRONMENTAL IMPACTS & MITIGATION MEASURES …4

4.1 INTRODUCTION Evaluation of impacts on the environmental attributes, due to proposed expansion project, is an important aspect to be studied. This chapter incorporates both, qualitative and quantitative descriptions of various environmental impacts due to existing as well as expansion of distillery project by GIACL. Various scientific techniques are available to predict and evaluate the impact of developmental activities on the physical, ecological and socio – economic aspects. Predictions are superimposed over base line status (pre-project) of environmental quality to obtain the final (post- project) environmental conditions. Environmental Impact can be defined as any 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. Generally, environmental impacts can be categorized as either primary or secondary. Primary impacts are those which are attributed directly to the project. On the other hand, secondary impacts are those which are indirectly induced and typically include the associated investments and changed patterns of social and economic activities by the proposed action. Expansion of distillery may influence environments of the study area in two phases as: • Construction Phase: During the construction period, the impact may be temporary.

• Operational Phase: Operational phase impact may have long term effects.

4.2 CONSTRUCTION PHASE Construction phase impacts on the environment can be considered short term. Activities during erection of the plant and civil structures may affect environment of the area surrounding project site. Impacts as well as mitigation measures for the same are described in Table 4.1.

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Table 4.1 Impact Identification and Mitigation Measures due to Construction Phase of GIACL, Ahmednagar.

Sr. No.

Component / Aspect

Parameter Causes Impacts Type of Impact

Mitigation measures / Remarks

1 Air Dust (SPM)

Vehicular movement, drilling

• Respiratory problems - coughing and difficult or painful breathing; irritation in eyes.

• High SO2 and NOX - lung disorders such as wheezing and shortness of breath.

• Obstruction in activities like photosynthesis and evapo-transpiration due to deposition of dust on surface of leaves thereby reducing crop yield.

Minor (Negative Impact)

• SO2 and NOX at single location will not increase as the vehicular movement and machines will be mobile.

• Internal roads are well Paved. • Provision of PPEs (Goggles and Masks) to

staff and workers • Augmentation of green belt.

SO2 Vehicular movement NOX

2 Water Deterioration of Water quantity, quality and aesthetics of water body.

• Water requirement for construction and domestic activities.

• Surface runoff and seepage.

• Domestic effluent. • Spill from fuel, oil and

other chemicals. • Leachate from temporary

waste dumps on site.

Industrial premises at GIACL has already been well developed Hence, construction to be taken up under proposed expansion project shall have no significant impact on water environment. Some minor impacts are as follow- • Water borne disease • Contamination of nearby water body


• Proper and adequate segregation of construction area and appropriate drainages, to minimize runoff

• Cutting and filling work will be avoided during rainy season.

• Stone pitching on the slopes and construction of concrete drains for storm water to minimize soil erosion.

• Augmentation of green belt. • Soil binding and fast growing vegetation to

arrest soil erosion. • Temporary sheds, Mobile toilets as well as

water tank shall be provided for the workers. 3 Noise Noise

Nuisance and Disturbance

• Construction equipment like dozers, scrapers, concrete mixers, cranes, pumps, compressors, pneumatic tools, saws, vibrators etc.

• During construction it is not a continuous source and hence do not pose a health risk or damage peoples' sense of hearing.

• Adversely affects the quality of life of occupants and nearby residents.


• Expansion of distillery will be established in existing distillery, sugar factory co-gen plant by GIACL. There will be minimum construction work.

• Provision of proper acoustic enclosure for noise generating and vibrating machinery.

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Sr. No.

Component / Aspect



• Continuous and intermediate source

• Disturbance in nearby residents. • Constant exposure to high noise

levels can result in damage of ear drums and loss of hearing.

• Increased blood pressure levels, cardio-vascular disease and stress related heart problems.

• Protective equipments such as ear plugs, earmuffs etc for workers will be provided.

• Onsite workers must not be exposed, for more than 8 hours, to high noise generating sources.

4 Soil and Land use

Soil Quality and Topography

• Spill from fuel, oil and other chemicals.

• Substratum excavated during construction of foundations.

• Improper storage of solid waste

• Affects the soil, micro as well as macro flora. Thereby, disturbing the nutritive composition of soil.

• Positive benefits in the form of land levelling and tree plantation in the plant vicinity and other premises.

• Bad aesthetics due to littering.


• Proper maintenance of vehicles as well as machinery used during construction to avoid oil, fuel leakages.

• Disposal of waste to authorised recyclers and resellers.

5 Biodiversity and Habitat

Terrestrial as well as aquatic Flora, Fauna and Avifauna.

• Dust emissions • Noise generation • Influx of onsite workers • Flood lights, high masts

etc.

• No any major impacts envisaged but some minor impacts may be observed.

• Retarded growth and productivity of the plants.

• Avifauna (migratory and residential) nearby water body and in the surrounding areas may get frightened and restless.

• Nocturnal animals and birds may get affected due to flood lights, high masts etc.

• Nesting and roosting sites in surrounding area of the GIACL may get affected through activities like collection of fire wood for cooking, improper sanitation practices etc.


• Noise generating and vibrating machinery would be provided with proper acoustic enclosure

• Water sprinkling arrangement shall be provided to curb dust emissions during construction activities.

• Workers staying onsite shall be supplied with fuel source such as LPG, Kerosene etc. for cooking. Moreover, proper care shall be taken so that the surrounding ecological area is duly conserved.

6 Risk, Hazard Accidental • Lifting of heavy tools and • Physical problems viz. Carpal tunnel Minor • Use of advanced technology and

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Sr. No.

Component / Aspect



and Occupational health & Safety

risk and Hazard

tackles, construction equipment

• Repetitive motion, awkward postures and vibrations

• High noise generating machinery

• Continuous exposure to dust

• Welding of metal parts • Cabling of electrical work. • Unhygienic conditions

resulting from day-to-day activities of workers living in the industrial area.

syndrome, tendonitis, back pain, muscle soreness and nerve damage reduction in hearing efficiency of workers

• Shortness of breath following physical exertion, severe cough and chest pains

• Fatigue and loss of appetite • Eye irritation and eye sight problems • Electrical shock • Spread of various diseases

(Negative Impact)

sophisticated machinery during construction • Maximum Employment of young and

adequately trained persons (above 18 years) • Providing various PPEs like dust masks,

safety glasses, helmets, gum boots, ear plugs and ear muffs etc. to the workers.

• Proper earthing for electrical supply, • Separation of deep excavations and marking

of dangerous areas with barricading etc. • 24 X 7 medical aid with trained doctors and

ambulance facility • Training to the workers from view points of

safety, health and hygiene.

7 Socio-Economic

Social and Economic status

Expansion of distillery • Primary and secondary employment generation

Major (Positive Impact)

There will be positive impact to residents nearby industrial unit in form of new job opportunities and increase in good employment generation potential.

Table 4.2 Disposal of Waste Generation during Construction Phase

Sr. No. Type of Waste Mitigation Measures

1 Metal scrap Sold to scrap dealers for reprocessing. 2 Wooden scrap Utilized by local labours as fuel for domestic operations. 3 Broken bricks, stones and cement concrete wastes Used as filler material in plinth, low lying areas etc. 4 Paint cans, brushes& other plastic waste materials. Sold to re-cyclers, authorized re-processers.

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4.3 OPERATION PHASE Operational phase activities may have impacts - minor or major, positive or negative on environmental disciplines such as soils, surface and ground water hydrology, micro meteorology, land use, water use, water and air quality, ecology, socio economics and noise environment. Descriptions of the various attributes and effects on same have been presented in following paragraphs.

Figure 4.1 Impact Identification Process Flow Chart

Distillery

Conc, Spent Wash

Cogeneration Plant

SHW , Air

Water

Press Mud

To Factory

Weighment & Cane Preparation

Cane Milling/ Crushing

Juice Extraction & Clarification

Juice Sulphitation

Syrup Boiling

Centrifuging

Storage of Sugar

Bagasse Boiler Turbines

To Grid

Power Steam

ATFD

Bio Methanation

Fermentation Distillation Alcohol Storage

Raw Spent Wash Molasses

Biogas To Dist. Boiler

Digested Spent Wash

Air SHW Noise

Air Noise Water SHW

Air Water Soil

RH

Noise Noise SHW Noise Air SHW

SHW , Air

Water Soil EB

Air RH

Powder with 99% solids –manure


h

MEE

To Farmers

Powdered Spentwash

Condensate To Recycle

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Table 4.3 Identification of Impacts on Environment & their Categorization due to Operation Activities under GIACL Project Complex

Sr. No.

Environmental Aspects

Activities / Observation Impact Identification Type of impact Remark

1. Air Cane Yard, Cane Weighment, Milling Section, SO2 preparation section, Lime Slurry preparation, Centrifuge, Sugar bagging house, Bagasse & Pressmud yard, Ash Storage Yard, Molasses Storage Tank, Fermentation.

Generation of fugitive dust, bagasse particles, lime dust, fine sugar dust & water mist, bagasse dust, Odour Nuisance and release of SPM, SO2, CO2 Emissions.

Minor (Non-

quantifiable)

Impacts due to existing boiler operations may not have significant impact on air environment. Quantification of impacts on air due to burning of fuel, fugitive emissions, process emissions etc. is given at Section 4.3.1 of this Chapter. At a glance details of identification & quantification of the impact during operation phase is enclosed at Chapter 4.

Boiler Operation Fuel burning in operation (with APC as ESP to co-gen boiler)

2. Water Milling Section, Juice storage, Juice clarification, Juice Concentration Section, Vacuum Pan, Crystallizer, Centrifuge

If spillage of juice/ syrup accidently discharged into water body, it may cause impact on water quality.

Major (Quantifiable)

Impacts due to operation activities are significant. Quantification of accidental discharge into nearby water body & nalla is given below at Section 4.3.3 of this Chapter.

ETP, CPU Discharge of untreated / partially treated effluent

Molasses storage tank, Distillation, Spentwash storage tank

If spillage of Molasses, Spentwash & spentlees accidently discharged into water body, it may cause impact on water quality.

3. Noise Cane yard, Cane weighment, Milling section, Sugar bagging house, Boiler operations (Fuel Burning, Steam vent off), Turbine

Due to cane transportation activities, Milling operations, Conveyors, trolleys, people, sugar bag packing machines, Boiler operations, High pressure steam injection & high speed turbine rotary motions etc.

Minor (Non-

quantifiable)

The impacts due to operation activities are negligible i.e. insignificant.

4. Solid & Hazardous Waste (SHW)

Cane yard, Milling Section, Vacuum Filtration, Bagasse conveyance, handling, transport & storage yard, Pressmud yard.

Solid waste such as Trash, dung, Lubricant Spills, Pressmud, Bagasse generates.

Minor (Non-

quantifiable)

Impacts due to operation activities are negligible i.e. insignificant. SHW generated would be properly handled and disposed off.

ETP, CPU Non-scientific disposal of sludge, its littering and odour nuisance

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Sr. No.

Environmental Aspects

Activities / Observation Impact Identification Type of impact Remark

5. Soil Boiler Operation (Fuel Burning), Ash storage Yard, Fermentation, Juice Storage, Juice Concentration Section, Vacuum Pan, Crystallizer, Centrifuge, Molasses storage tank, Distillation.

Generation of ash, yeast sludge, spillage of juice/ syrup, molasses, spentwash, spentlees

Minor (Non-

quantifiable)

The impacts due to operation activities are negligible i.e. insignificant.

ETP Discharge of untreated / partially treated effluent on land/ nearby farm

6. Risk & Hazard SO2 Storage & use, Bagasse conveyance, handling, transport and storage yard, Bio-methanation plant, Alcohol Storage Tank

Release of SO2, Sulphur dust explosion, Fire in bagasse yard, Spillage of alcohol accidently, and fire in alcohol storage yard.

Major Worst-case scenarios predicting the impacts due to hazardous raw materials or chemicals are presented in Chapter 7.

7. Ecology & Biodiversity

Distillation Spillage of Spentwash Minor(Non-quantifiable)

Impacts due to operation activities are negligible i.e. insignificant

4.3.1 Impact on Air Quality

A. Emissions from Fuel Burning Major source of air pollution from the proposed expansion project shall be boiler, fermentation section, D.G. set and vehicles used for transportation. Steam required for distillery expansion project would be taken from the existing 8 TPH biogas based boiler distillery boiler as well as 30 TPH boiler from existing sugar factory which will be modified to 40 TPH. 8 TPH boiler is provided with stack of 45 M height. Methane obtained from spentwash digestion is used as fuel boiler leading to conversion of its composition. For modified 30 TPH boiler bagasse will be used as fuel. ESP is already installed as APC along with stack of 76 M height. Other emissions from the distillery process are CO2 and water vapours. CO2 gas to the tune of 45 MT / day shall be produced from manufacturing process and same shall be bottled for its use in beverage industry. Steam taken for sugar factory and Co-gen Plant from boilers of capacities 140 TPH and 30 TPH which will be modified to 40 TPH. Bagasse, a by-product of sugar factory, is used as fuel in the boilers of co-gen plant. A typical chemical analysis of bagasse on a washed and dried basis is represented as - Cellulose: 45–55%, Hemicellulose: 20–25%. Lignin: 18–24%, Ash: 1– 4%, Waxes: <1%. Bagasse when burned in quantity produces sufficient heat energy to meet all the needs of a sugar factory and co-gen plant.

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

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

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

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


During burning of bagasse in boiler, SPM and CO2 will be released. SPM emissions from boilers shall be controlled by installation of APC equipments. Industry will be required to meet the emission standards as prescribed by MPCB. For details of existing boilers and DG sets in GIACL Complex refer Table 2.30 & 2.31 from Chapter 2. SPM forms coating on surface of leaves and retard photosynthetic activity of plants. Thus, plant growth is hampered and ultimately yield from the plant/crop gets reduced. Also, SPM emissions may cause allergic asthma, eye irritation and respiratory problems in workers of GIACL as well as for the nearby residents. Moreover, when settle-down the soil surface, SPM gets mixed with it and may degrade the soil quality (physical and chemical properties, nutrients etc.) thereby making it unfavourable for crop cultivation. Further, oxides of sulphur and nitrogen also adversely affect plants, humans, animals and materials. The plant growth and nutrient quality of plant products could get affected adversely. Also damage to plant tissues causing nicrosis and chlorosis of leaves may be a prominent effect. These oxides cause eye irritation, chest constriction of respiratory track and respiratory disorders among human being and animals. Other important impact of the sulphur and nitrogen oxides is that they react with atmospheric moisture in presences of sunlight and form sulphuric acid and nitric acid which during precipitation cause acid rain. The acid rain severely affects soil properties including its fertility and can damage civil structures, MS installation including historical monuments. Emitted CO presence, in excess than stipulated norm (25 ppm, as per ACGIH recommendation), could react with haemoglobin in blood and thus reduces oxygen carrying capacity of same due to formation of a compound namely carboxy-haemoglobin.

4.3.1.1. GLC Evaluation through Air Dispersion Modelling In order to study the movement of particulate matter and gaseous pollutants' release into atmosphere from the source, Air Dispersion Model – AERMOD developed by the US Environmental Protection Agency (USEPA) is used. Software helps in knowing details of particulate and gases dispersed in the down wind direction and finally reaching the ground at farther distance from the source. Ground level concentrations (GLC) mainly depend upon the strength of emission source & micrometeorology of study area. No new boiler will be installed under the expansion of distillery by GIACL. Hence, AERMOD software is not used for understanding the increase in baseline concentrations of ambient air. Site-specific meteorological data collected for one season for period from March-April-May 2018. Refer Figure 4.2 for windrose. Predominant wind direction & wind speeds are tabulated in following table –

Table 4.4 Predominant Wind Directions

Sr. No.

Season Time (Hrs.) Predominant Wind Direction

Nearest Habitation Downwind

1. Pre-monsoon 08:30 E Talani 17:30 NNE Najik Babhulgaon

2. Monsoon 08:30 E Talani 17:30 NE NajikBabhulgaon

3. Post-monsoon 08:30 W NajikBabhulgaon 17:30 SW Ghotan

4. Winter 08:30 NW Malegaon 17:30 W Rakshi

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Table 4.5 Predominant Wind Direction and Speed Categories

Season Predominance Wind Direction Wind Speed Category (Kmph) March North West 1-8 April North West 1-8 May North West 1-8

Baseline Ambient Air Concentrations 24 hourly averages concentrations of PM10, PM2.5, SO2 and NOx in Ambient Air, recorded during the field study conducted for the season March-April-May 2018 are considered as baseline values. Impact due to operations of existing nearby industries on this region is represented by 98 percentile concentrations of above mentioned parameters at this location, which are considered as ‘Baseline Concentrations’ to determine the impact on ambient air quality. Baseline concentrations at site are summarized in the following table-

Table 4.6 Baseline Concentrations

Parameter Concentration NAAQS Remark PM10 64.30 µg/m3 100 µg/m3

Baseline concentrations are well within the limits. Refer Chapter 3, Section 3.10 for more details.

PM2.5 22.13 µg/m3 60 µg/m3 SO2 27.35 µg/m3 80 µg/m3 NOX 35.75 µg/m3 80 µg/m3 CO BDL 2 mg/m3

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Figure 4.2 Windrose for the Month March 2018 - May 2018

In order to study the movement of particulate matter release into atmosphere from the source, Air Dispersion Model - Industrial Source Complex Short Term (ISCST 3) is Version 02035 developed by the US Environmental Protection Agency (USEPA) is used. The software helps in knowing the details of particulate dispersed in the down wind direction and finally reaching the ground at farther distance from the source. Ground Level Concentrations (GLC) mainly depend upon the strength of the emission source and micrometeorology of the study area.

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I. Predictions for emissions from stack in worse case (Scenario- during -operation of APC)

Table 4.7 GLC with Incremental Increase in PM10 Values (µg/m3)

Sr. No

Location Direction

Distance (Km)

98% baseline PM10 Conc. (µg/m3)

Incremental PM10 GLC)

Total PM10 Predictive GLC

% Incremental Remark Impact

A B C D E F= (D+E) G=(E/D) x 100 -- -- 1. Industrial Site -- -- 64.6 0.0016 64.6016 0.002

Incre. conc. lower than standard

Insignificant

2. Talani W 2.75 62.4 0.005 62.405 0.008 3. Rakshi SE 4.34 62.32 0.005 62.325 0.008 4. Ghotan N 2.47 62.90 0.006 62.906 0.010 5. Kurudgaon E 5.21 62.26 0.004 62.264 0.006 6. Raotale E 4.74 61.16 0.004 61.164 0.007 7. Malegaon Ne. S 5.11 62.41 0.005 62.415 0.008 8. Najik Babhulgaon SE 2.68 62.24 0.01 62.25 0.016 Average 62.53 62.54

Maximum concentration of PM10 is 0.013 μg/m3 towards East direction at 1.11 Km from site.

Table 4.8 GLC with Incremental Increase in PM2.5 Values (µg/m3)

Sr. No

Location Direction

Distance (Km)

98% baseline PM2.5 Conc. (µg/m3)

Incremental PM2.5 GLC)

Total PM2.5 Predictive GLC

% Incremental Remark Impact

A B C D E F= (D+E) G=(E/D) x 100 -- -- 1. Industrial Site -- -- 22.13 0.00039 22.13039 0.00

Incre. conc. lower than standard

Insignificant


Maximum concentration of PM2.5 is 0.0031 μg/m3 towards East direction at 1.11 Km from site.

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From table 4.7 and 4.8, it could be seen that in light of non-operation of ESP max. % of incremental conc. (Col G) for PM10 would be 0.016 % at Najik Babhulgaon and PM2.5 would be 0.01 % at Najik Babhulgaon. Further, Av. predictive conc. (Col. F) for PM10 would be 62.54 µg/m3 and that for the PM2.5 would be 18.51 µg/m3. Therefore, the percentage of predictive concentrations for PM10 would be % and PM2.5 would be 18.51 % of NAAQS standards against the base line concentration percentage 62.53 % for PM10 and 18.51 % for PM2.5. This indicates that there would be raise in PM10 concentration by 0.01 % and PM2.5 concentration by 0.0 %. Hence, there would not be significant impact on existing air quality of study area in light of operation of boiler along with non operation of APC equipment.

II. Predictions for emissions from stack in worse case (Scenario- during non-operation of APC)

Table 4.9 GLC with Incremental Increase in PM10 Values (µg/m3)

Sr. No

Location Direction

Distance (Km)

98% baseline PM10 Conc.

(µg/m3)

Incremental PM10

GLC)

Total PM10 Predictive

GLC

% Incremental

Remark Impact

A B C D E F= (D+E) G=(E/D) x 100 -- --

1. Industrial Site -- -- 64.6 0.078 64.678 0.12

Incre. conc.

lower than standard

Insignificant


Maximum concentration of PM10 is 0.625 μg/m3 towards east direction at 1.11 Km from site.

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Table 4.10 GLC with Incremental Increase in PM2.5 Values (µg/m3)

Sr. No

Location Direction

Distance (Km)

98% baseline PM10 Conc.

(µg/m3)

Incremental PM10

GLC)

Total PM10 Predictive

GLC

% Incremental

Remark Impact

A B C D E F= (D+E) G=(E/D) x 100 -- --

1. Industrial Site -- -- 22.13 0.07 22.2 0.32

Incre. conc.

lower than standard

Insignificant


Maximum concentration of PM2.5 is 0.15 μg/m3 towards East direction at 1.11 Km from site. From table 4.9 and 4.10, it could be seen that in light of non-operation of ESP max. % of incremental conc. (Col G) for PM10 would be 0.8 % at Najik Babhulgaon and PM2.5 would be 2.18 % at Najik Babhulgaon. Further, Av. predictive conc. (Col. F) for PM10 would be 62.75 µg/m3 and that for the PM2.5 would be 18.75 µg/m3. Therefore, the percentage of predictive concentrations for PM10 would be 62.75 % and PM2.5 would be 18.75 % of NAAQS standards against the base line concentration percentage 62.53 % for PM10 and 18.51 % for PM2.5. This indicates that there would be raise in PM10 concentration by 0.22 % and PM2.5 concentration by 0.24 %. Hence, there would not be significant impact on existing air quality of study area in light of operation of boiler along with non operation of APC equipment. B. Fugitive Emissions

Fugitive emission under existing and proposed expansion activities of GIACL shall be mainly the dust emissions. These will impact the working environment of the workers and will also settle on plants in industrial premises. Consequence of this shall be respiratory disorders, aggravated coughing and difficult or painful breathing among the workers and reduced photosynthesis activity which shall impact the plant life.

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Also, inappropriate and non-scientific storage as well as longer holding periods of raw as well as concentrated spentwash in the respective tanks and yeast sludge from fermenters shall lead to formation of aerobic-anaerobic conditions in the tank body thereby resulting in to uncontrolled release of gases comprising prominently of methane, hydrogen sulphide, sulphur dioxide and carbon di-oxide. Hydrogen sulphide imparts foul odour in the premises whereas SO2 lead to corrosive atmosphere. Moreover, inflammation of eyes, throat and respiratory track irritation, are prominent effects observed in case of human being residing nearby the spentwash tank premises. Also, dust emissions from the sugar bagging section shall be a source of fugitive emissions where the fine particulates of sugar may become suspended in the work zone air at the time of sieving (crystal size separation) and while filling as well as packing of sugar in bags for dispatch. Efficient and quick utilization of spentwash from the tanks, its concentration and drying same in to ATFD shall avoid holding up of same for longer periods and prevent formation of above-mentioned gaseous emissions. C. Process Emissions CO2 shall be generated from fermenters under the distillery project. Generation of CO2 after expansion takes place in considerable quantum (113 MT/Day) which when let out in the atmosphere could have undesirable effects in the surrounding ambience. Since CO2 has been labelled as one of the major gases responsible for the green-house effect, its release in the atmosphere has to be curbed as far as possible. Under the GIACL expansion project, this CO2 from fermenters shall be bottled for supply to secondary industrial uses. D. Odour Pollution Odour can result from number of sources and operations in an integrated complex of sugar factory and distillery. They may include stale cane, bad mill sanitation, molasses handling and storage, effluent storage; treatment& disposal, effluent carrying drains, sludge storage areas etc. Under proposed expansion in GIACL, every care shall be taken to avoid the odour generation from above sources and actions so that the eventual nuisance from same shall be abated. Especially, the distillery fermentation section, distillation section for spentwash generation, spentwash handling; storage; concentration shall be provided prompt and proper attention. Anaerobic-aerobic pathways of degradation resulting due to excessively longer storage of spentwash, yeast sludge and similar putrescible materials shall give rise to foul smells as a result of generation of gases like hydrogen sulphide, sulphur di-oxide etc. These gases have very irritating effect on human beings and animals that come in their contact resulting in to coughing, sneezing, inflammation of upper respiratory track, irritation of eyes, sensation of nausea and vomiting. Unsanitary conditions responsible for odour trouble could give rise to other nuisance like fly and insect infestation. 4.3.1.2. Mitigation Measures

A) Emissions from Fuel Burning • Installation of APC Equipment in the form of ESPs to co-gen boiler of plant. • GIACL has already installed continuous online monitoring system for monitoring of

temperature, CO, CO2 and SO2 sensors for monitoring respective parameters of the exhaust gases.

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• Regular self-monitoring of AAQ and work zone air quality is done by the industry through approved labs to check and control dust levels / concentrations at certain places so that same could be kept always below the stipulated norms.

• Efficiencies of dust control equipment in the industry such as ESP shall be monitored regularly (at least once a month) under performance evaluation.

• Inlet and outlet of pollution control equipment shall be provided with all necessary sampling arrangements as per guidelines of CPCB.

• APC equipment would be interlocked with the process as per the guidelines of CPCB.

B) Fugitive Emissions • Installation of appropriate, adequate and efficient exhaust and ventilation system to

remove and control dust from work zone areas. Provision of appropriate APC equipment to collect and remove dust from work zone including their monitoring routinely.

• Dust, ash etc. collected from APC equipment, e.g. fly ash from co-gen boilers, will be properly handled and disposed off periodically by supply to farmers for use as manure. Thus, uncontrolled and prolonged storage of ash on site shall be avoided which could lead to littering and suspension in air due to wind.

• Dedicated and mechanical ash handling system with adequate capacity silos, conveyors, closed conduits, water sprinkling arrangements etc. is installed on site.

• Appropriate PPE are provided to workers. • Augmentation of green belt of adequate density and with appropriate types of plants shall

be made to control and attenuate dust transfer in the premises. This will avoid suspension of bagasse and ash particles in the air which leads to SPM.

• Proper maintenance of existing tar roads provided in the premises of GIACL shall be done. Moreover, all internal roads, yards and open storage areas are properly surfaced.

• Covered / encased conveyors is installed to carry bagasse from milling section to storage yards, from storage yards to boiler section. This avoids littering and free falling of loose bagasse from the belt which leads to suspension of same in air and subsequent spread in the ambient air due to wind currents.

• Quick lifting and disposal of yeast sludge will avoid such troubles. Spentwash will be powdered in ATFD and used as manure in field. Hence there will not be any problem due to spentwash after expansion.

C) Process Emissions To marginally minimize the effects of CO2 which shall be generated from fermenters, a care shall be taken through implementation of the green belt. Adequate density plantation under same can play an important role as 'the sink' by taking up CO2 thus curbing its release to atmosphere from the premises. However, to exercise total control on CO2, there is a future planning (within an year) to collect the gas properly, compress it adequately and bottle subsequently. CO2 cylinders shall then be supplied to manufacturers of beverages or other secondary purposes. This approach shall totally curb the release of CO2 from distillery premises. D) Odour Pollution To abate the odour nuisance, industry has a concrete planning which includes following steps and actions-

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• It is proposed to provide covered fermentation and tapping of CO2 gas, • Collection of yeast sludge from fermentation section in closed silo system, its dewatering

(mechanical) and immediate disposal through supply as manure. • Reduced volume of effluents (spentwash, spent leese) by adopting strategic approaches

such as continuous fermentation, vacuum distillation, reuse of spentwash for molasses dilution, utilization of condensate from MEE for dilution and other process operations as well as in cooling tower make up.

• Adoption of GMPs (good management practices). • Arranging awareness and training camps for workers. • Use of PPE like masks by persons working near odour potential prone areas.

4.3.2 Impact on Climate Impact on the climatic conditions, due to the proposed expansion activities under sugar factory and co-gen is not envisaged, as emissions of flue gases with very high temperatures, to the atmosphere, are not expected. 4.3.3 Impact on Water Resources - Surface Water & Ground Water (Quality &

Quantity) Water requirement of the various units in GIACL campus including that of the proposed distillery expansion shall be met from the Jayakwadi Dam on Godavari river. A permission for lifting fresh water of 0.071 Million M3 per Year has been granted by the Irrigation Dept; Govt. of Maharashtra. However, the entire fresh water demand in GIACL complex after distillery expansion will be to the tune of 0.057 Million M3 per Year. This is lesser than the approved one. Total water requirement for 150 KLPD distillery project during sugar crushing season (180 days) would be 1619 M3/ Day. Out of the total water requirement, 1506 M3/ Day water would required form industrial purpose, 12 M3/ Day water will required for domestic purpose and 101 M3/ Day. From total water requirement 41 M3/Day would be fresh water taken from Jayakwadi dam on Godavari River (fresh water consumption 0.27 KL/KL of Alcohol against norm of 10 KL/KL of alcohol), 7 M3/Day would be STP treated water used for flushing, 230 M3/Day would be excess condensate water from sugar factory & co-gen plant and 1578 M3/Day would be MEE condensate and CPU treated water from distillery. About 97% recycle water will be used for distillery during sugar cane crushing season. During non - sugar cane crushing season (150 Days); total 1619 M3/Day water will be required. Out of this 271 M3/Day would be fresh water taken from Jayakwadi dam on Godavari River, 1341 M3/Day would be MEE condensate and CPU treated water from distillery and 7 M3/Day will be treated water from STP used for flushing. For non-sugar cane crushing season about 83% of water will be recycled water. Fresh water consumption for non-sugar cane crushing season will be 1.80 KL/KL of Alcohol against norm of 10 KL/KL of alcohol. After expansion of distillery total raw spentwash generated from 150 KLPD molasses based distillery will be to the tune of 1182M3/Day (7.8 KL/KL of Alcohol). Same will be bio-methanated and then concentrated in MEE. MEE concentrated spentwash to the tune of 443 M3/Day (2.9 KL/KL of Alcohol) will be then subjected to ATFD. Liquid spentwash will be converted in to powder up to 95 % to 99 % solids. Powder is potash rich (28% Potash) is

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mixed with boiler ash press mud and sold as manure to the cane grower farmers command area of the industry. MEE condensate @ 1086 M3/Day, spentlees @ 339 M3/Day and Other @ 36.25 M3/Day will be treat in CPU. Under expansion one new CPU will be constructed. Treated water from CPU will be recycled back in process for dilution of molasses and for cooling purpose. This achieves ZLD. Water requirement for existing sugar factory and co-gen plant - is 3,550 M3/Day out of which 3 M3/Day is fresh water used for drinking purpose remaining quantity of water @ 3547 M3/Day is sugar cane condensate water as well as treated water from ETP. Effluent generation for sugar factory and co-gen plant is 564 CMD which is treated in an existing ETP provided on the site and used for gardening in own premises as well as for irrigation in nearby farm lands. Chapter 2 may be referred for details of daily water consumption & effluent generation. Spentwash being the highly polluting effluent, quantification of an impact on fresh water under a scenario of its accidental discharge through a nearby nallah/ drains in to nath sagar dam envisaged. During monitoring period of March 2018 to May 2018 there was no water flow in the nearby nallah in the vicinity of industrial site. As such, contamination of stream discharge because of ingress of treated /untreated effluent from the industry was out of question. Hence there will not be any direct impact on surface water body. However, due to topography of the region, accidental discharge of spentwash or other effluents could find direct entry into dry nallah course thereby causing contamination of surface and sub-surface soils as well as ground water. A. Impact due to infiltration: 1. When the spentwash is discharged on ground and infiltrates in the soil, it will affect

porosity and reduce free air spaces in the soil matrix. Salts (TDS) in spentwash cause soil salinity thereby creating infertile soils.

2. Groundwater shall get contaminated severely due to colour, organics and TDS in the spentwash which will increase the hardness and as well as affect palatability and acceptance by people.

3. Because of the acidic pH of spentwash, it will disintegrate the boulders and lumps thereby making them soft which will eventually get converted into finer soils. Particles size distribution, porosity and permeability of soil mass (clayey) could be undesirable in certain agricultural practices.

4. Because of the faster decomposition of high organic matter of spentwash and its ponding anaerobic condition could develop into soil environment leading to foul smell.

4.3.3.1. Mitigation Measures • There shall be maximum use of condensate getting available from cane juice evaporation

in sugar factory as well as MEE condensate in distillery. This shall tremendously reduce fresh water demand.

• Harvested rainwater shall be used for gardening purposes thereby reducing the fresh water demand towards it.

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• After proposed expansion activities, GIACL would not discharge any untreated industrial as well as domestic effluent in to surface water body/ land disposal

• Effluent generated from molasses based distillery treat in CPU. Treated water from CPU shall be recycled back in process. There by achieving ZLD.

• Stopping / arresting spentwash entry to nalla by diverting flow through leaking pipe in to spentwash tank lifting the stored volume upstream the KT weir by portable pumps & sending it back to spentwash tank.

• Pumping of contaminated discharge from nalla from first weir to spentwash tank & action of flushing & dilution to subsequent weirs

• Faster communication to people residing along the nalla & river about ingress of effluents or spentwash in the streams followed by an appeal for not consuming the waters for domestic purposes and animal consumption.

• Online effluent monitoring system shall be installed at inlet and outlet of effluent treatment facility for measurement of parameters like flow, pH, BOD, COD, TDS etc.

• Separate energy meter would be provided to CPU and log shall be maintained for same.

4.3.4 Impact on Water Resources – Ground Water (Quality & Quantity)

• Recharge of ground water in study area is happening through rainfall, seepage from irrigation tanks and ponds in the study area.

• No ground water from any bore well / open well shall be used in manufacturing processes and operations in the industry.

• No direct discharge of any effluent from GIACL complex on land to avoid ground water contamination.

• Spentwash storage tanks shall be constructed as per CPCB guidelines where HDPE liners and RCC lining will be implemented. Making of spentwash handling, storage and disposal systems totally seepage proof shall avoid any chances of groundwater contamination.

• Piezometers are installed all around spentwash storage tank and existing compost yard at strategic locations. Data of ground water levels and quality of same will also be submitted to MPCB & MoEFCC.

4.3.4.1. Mitigation Measures • Recharge of ground water in study area is happening through rainfall, seepage from

irrigation tanks and ponds in the study area. Under expansion project, it is proposed to implement rain water harvesting measures in the industry premises. Rain water from roof top and surface harvesting shall be collected into recharging pit to be provided on site. Harvesting of rainwater and its recharge into the ground is a very important aspect which creates positive impact on the ground water table.

• The total quantity of domestic effluent, after proper treatment, would be used for gardening on own land / irrigation in nearby farms.

• Sugar factory and co-generation plant effluents shall be treated in an upgraded ETP. 4.3.5 Impact on Hydrology

• No adverse impact on the ground water shallow aquifer's storage is expected as fresh

water required for the industrial activity shall be taken from outside sources, mainly from river supplemented by water from MEE condensate and treated water from CPU.

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• Some impact on quality of groundwater in dug-wells south and east of the project site in Najik Babhulgaon area is reported by farmers. However, the chemical Analyses show most of the physical and chemical parameters within desirable limits. The TDS, Hardness, and metallic elements etc seen above prescribed limits are probably due to past use of molasses mixed water for irrigation and use of fertilizers etc.

• Spentwash is a highly polluting distillery waste water. As per Brief Summary of the Project it shall be stored at site in the 30-days & 10-days storage tanks and after bio-methanation and concentration in MEE shall be applied on press mud windrows at compost yard during bio-composting process. If this effluent finds its way through seepage, leakage and infiltration / percolation and reaches the ground water regime, then there would be risk of contamination of leading to coloration, increased TDS and conductivity, causing adverse effect on soil porosity, soil salinity etc.

• Villages around the Project site depend solely on ground water for all needs. There are number of percolation tanks and small water storage structures where storage capacity has been reduced due to silting. As per dialogue with authorities of GIACL, they have already taken steps towards de-silting of about 30 tanks and small dams with their own construction and earth moving machinery and equipment. There has been positive impact on surface storage capacity which in turn will facilitate recharging aquifers.

4.3.5.1. Mitigation Measures

• Spentwash handling, storage and disposal system infrastructure must be planned, designed and constructed as per the CREP norms set for distillery industry by MoEF and as per CPCB guidelines. Under the same, spent wash tank; compost yard; leachate management system should be constructed and provided with HDPE liners, RCC liners etc. as per the design details and specific requirements to completely prevent spent wash seepage, percolation and infiltration from the concerned structures into the soil and bedrock as well as to the groundwater storage aquifers.

• Implementation of comprehensive rain water harvesting measures, both for the roof top and ground surface to arrest and collect runoff water and store the same in tanks at appropriate locations considering the topography in the premises. Also, feasibility should be explored to recharge the harvested rain water directly to bore wells located in the industrial premises and those in the nearby areas. Percolation of stored water in the rain water harvesting tanks as mentioned above and recharge to bore wells shall definitely have a positive impact on the ground water table thereby increasing its level in the ground due to addition to the aquifers' storage.

• More percolation tanks and check dams, from the study area, which are heavily silted should be de-silted by GIACL as per its practice over past years. This can be a good CSR provision for the industry. Enhanced water stirage in such tanks is very much desirable to augment aquifer storages there by resulting in to increased ground water availability. This will also facilitate removal of contamination if any over long period.

4.3.6 Impact on Geology

• Geological feature of local, regional or national importance is not present in the area of

influence of the project. • Major excavations that can affect the geological set up in the area are not likely in the

project work. • Therefore, no adverse impact of the project on geology of the area is foreseen.

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4.3.6.1. Mitigation Measures • Adverse impact of the project on geological set-up in the area is not foreseen. On the

contrary, geological phenomenon can be hazardous to the project infrastructure and workforce. Therefore, civil structures should be constructed with earthquake proof technology.

• Also, information regarding geological phenomenon, especially seismicity in the area, should be updated periodically to prevent any untoward incidence.

4.3.7 Impact of Solid and Hazardous Wastes

• Solid wastes to be generated in the form of yeast sludge @ 1200 MT/M, boiler ash @ 1545 MT/M and ETP sludge @ 2.5 MT/M from GIACL complex.

• Yeast sludge from fermenters on inappropriate handling and storage conditions shall lead to formation of aerobic-anaerobic conditions in tank body thereby resulting in to uncontrolled release of gases comprising prominently of methane, hydrogen sulphide, SO2 and CO2. Hydrogen sulphide imparts foul odour in the premises whereas SO2 lead to corrosive atmosphere. Moreover, inflammation of eyes, throat and respiratory track irritation are prominent effects observed in case of human being residing nearby the sludge storage / tank premises.

• CPU & ETP sludge shall contain settled biological flock from secondary treatment units (aeration tanks / reactors). As such they can undergo anaerobic decomposition resulting in to odour problem if not handled, stored and disposed off properly.

• Haphazard and uncontrolled storage of ash on site shall lead to littering and suspension of the particles in air due to strong wind currents causing problems of air pollution and aesthetics.

• Improper utilization / disposal of ash would harm soil quality and fertility of the agriculture fields.

• If the boiler ash storage area is not scientifically maintained (as per CPCB guidelines) then air born particles as well as dust may lead to soil, surface water & ground water contamination.

• Due to improper construction and poor O & M at ash storage yard, there could be every chance that monsoon discharges, leakages and seepages from it may lead to pollution of lands, surface & ground water as a result of leachates through seepages, percolation and direct mixing.

• Hazardous waste namely spent oil or used oil shall be generated. If gets spilled/ littered in environment, can contaminate environment and result in to undesirable aesthetics also. Used oils especially the ones aimed for lubricating, after draining from engines; gearboxes; hydraulic systems; turbines and air compressors shall not be suitable for use as – (1) the oil may be contaminated with wear debris, (2) the lubricating base oil gets deteriorated and degraded to acids, (3) the additives may decompose into other chemical species, (4) the oils may get mixed with process fluids, degreasers and solvents thereby changing nature and properties completely. Used oil contains wear metals such as iron, tin and copper as well as lead and zinc. Many organic molecules arise from the breakdown of additives and base oils. The molecule potentially the most harmful is the polycyclic aromatic hydrocarbon (PAH). he spent oil on spillage tends to accumulate in the environment, causing soil and water pollution. Oil decomposes very slowly. It reduces the oxygen supply to the micro-organisms that break the oil down into non-hazardous

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compounds. Toxic gases and harmful metallic dust particles are produced by the ordinary combustion of used oil. The high concentration of metal ions, lead, zinc, chromium and copper in used oil can be toxic to ecological systems and to human health if they are emitted from the exhaust stack of uncontrolled burners and furnaces. Some of the additives (zincdialkyldithio phosphates, molybdenum disulphide, other organo-metallic compounds etc.) used in lubricants can contaminate the environment severely. Certain compounds in used oils like PAH can be very dangerous to human and animal health being carcinogenic and mutagenic. Lubricating oil is transformed by high temperatures and stress of an engine's operation. This results in oxidation, nitration, cracking of polymers and decomposition of organ- metallic compounds. Other contaminants also accumulate in oil during use - fuel, antifreeze/ coolant, water, wear metals, metal oxides and combustion products.


• Collection of yeast sludge from fermentation section in closed silo system, its dewatering (mechanical) and immediate disposal shall be done. Under existing activities same was mixed in spentwash bio-compost. After expansion same would be used as manure in farm.

• Boiler ash from co-gen boiler shall be handled and collected through dedicated and automatic mechanical system followed by storage in separate silos. Ash shall be sprayed with water to avoid its suspension during all the above processes.

• HW shall be properly collected in HDPE drums / containers and shall be stored at dedicated area to be marked for HW. Spent oil generated from sugar factory shall burnt with bagasse in co-gen boiler. From distillery used oil will generated. It could be send to authorized re-processor.

4.3.8 Impact on Soil and Agriculture Impact on soil characteristics shall be usually attributable to deposition of air pollutants from fuel burning operations in co-gen plant and distillery, wastewater discharges and solid and hazardous waste disposal. Particulate matter and other pollutants emitted into ambient air (especially in very high concentrations due to improper working of APC equipment from co-gen plant) may result in deposition of same on soil and nearby agriculture fields. This can result into alteration of properties of soil and its composition. As such crops and plants grown in such soils may become unable to adapt to soil changes and thus the productivity gets reduced. Also, the contaminants from effluents and solid as well as hazardous wastes could have similar effects on soil through uncontrolled and consistent applications or accidental discharges. Due to this, soil fertility slowly diminishes making it saline and non-suitable for agricultural or and any other vegetation to survive. Moreover, the microbes in soil like fungi and bacteria which can have profound effects on its microbiology and biochemistry may also receive adverse impacts due to pollutants and contaminates through effects like toxicity. Certain alterations in soils' nature may result into physical and structural changes like variation in bonding properties of soils, cohesiveness, permeability, porosity, plasticity etc. This can result in to undesirable effects like excessive erosion, seepages, infiltration. Further, death of many useful organisms in the soil (e.g. earthworms) cancreate troubles w.r.t. soils' fertility and productivity. As already stated in earlier section, if raw effluent is discharged on land, acidic or alkaline pH, high TDS concentrations and organic matter contents could have detrimental effects like loss of nitrogen, increase in conductivity and salinity, reduced porosity etc.

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Impact on surface soils 1. pH : Acidic pH may lead to adverse impact on flora, fauna. Also, useful microbes may

get killed due to acidic pH. 2. Salinity: High TDS will adversely affect conductivity of soil thereby causing mortality of

vegetation in soil. 3. Organic Matter: Because of high organic matter, microbes in the soil start utilizing the

carbon in the organic matter for which they may consume nitrogen from soil. 4. C/N Ratio: While consuming carbon from organic matter, the microbes also need

nitrogen. If there is no sufficient nitrogen is available i.e. C/N ratio is very high they may consume nitrogen present in their metabolism. This will deplete the nitrogen content of the soil which is called robbing of nitrogen. Thus, the soils become unfertile due to reduction of nitrogen content. If the C/N ratio in the soil becomes too low due to spentwash discharge there could be germination disorder of the seeds due to imbalance in the environment.


• Ash is handled and collected through dedicated and automatic mechanical system

followed by storage in separate silos. Ash is sprayed with water to avoid its suspension during all the above processes. It is mixed with powdered spentwash and sold as manure after bagging.

• Effluent from sugar factory & co-gen plant is treated in ETP of sugar factory. Treated water from ETP is used for agricultural purpose.

• Industrial effluent from distillery like spent lees, cooling & boiler blow downs, effluent from lab & washing etc. shall be given proper treatment in a distillery’s CPU. Treated water will be fully recycled back in process for various operations. Bio-methanated and MEE concentrated spentwash will be subjected to ATFD to form powdered spentwash. Powdered spentwash will mixed with boiler ash and sold as manure. This achieves ZLD.

• Domestic effluent is treated in STP. Same practices will be followed after expansion also. 4.3.9 Impact on Noise Levels The criteria on which noise impacts are analyzed depend upon the people who are being affected. Broadly, there are two types viz. people who are working near the source and the people who stay near the industry. People working near the source need risk criteria for hearing damage while the people who stay near the industry need annoyance and psychological damage as the criteria for noise level impact analysis. It is quite obvious that the acceptable noise level for the latter case is less than the former case. So, the noise impact analysis can be of two types namely (1) Noise impact analysis on working environment; and (2) Noise impact analysis on community. 1. Noise Impact Analysis on Working Environment For Noise Levels in the industrial unit, the potential noise generating sources are categorized under three major heads - noise from machinery, noise from sirens / work areas, noise from transportation. GIACL is not a major noise producing industry. However the control measures have been suggested. There shall be no any prominent effect due to vibration at the project site. Total noise generated by operations of all equipment in the premises of all units in an industrial plant (from experience of existing unit) would be between 70 to 85 dB(A).

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Constant exposure to such levels, can result in damage to ear drums and loss of hearing, blood pressure levels, cardio-vascular disease and stress related heart problems among the workers. It may also disturb psychological condition of the workers. Annoyance, increased temper etc. may also be the other significant impacts. The actual resultant noise levels outside the factory will be much lesser in the ambient air after considering attenuation. Therefore, the impact of sugar factory, distillery and co-gen plant w.r.t. noise would be non significant. Noise levels in work environment are compared with the standards prescribed by Occupational Safety and Health Administration (OSHA-USA), which in turn were enforced by Government of India through model rules framed under Factories’ Act. These standards were established with the emphasis on reducing hearing loss

Table 4.11 Permissible Exposure In Case of Continuous Noise Sr. No

Total Time of Exposure (continuous or a number of short term exposures) per Day, in Hours

Sound Pressure dB (A)

Remarks

1. 8.00 90 1. No exposures in excess of dB(A) are permitted. 2. 6.00 92 2. For any period of exposure falling in between

any figure & next higher or lower figure as indicated in column 2, permissible sound pressure level is to be determined by extrapolation on a proportionate scale.

3. 4.00 95 4. 3.00 97 5. 2.00 100 6. 1.50 102 7. 1.00 105 8. 0.75 107 9. 0.50 110 10. 0.25 115

2. Noise Impact Analysis on Community Noise pattern from the source is computed with the help of following formula.

Noise Level at distance r2= (Noise level at distance r1) -20 log (r2/r1)

These noises get reduced considerably in the range of 20-30 % because of natural obstructions. Permissible noise levels, for different categories of area, as prescribed by MoEFCC are given in Table 4.10. Resultant noise levels at the receptor in different areas/zones are envisaged to be within permissible limits, as identified by MoEFCC. If noise levels exceed the limit, people who stay near the industry get disturbed due to reasons like annoyance and psychological reasons. Present ambient noise monitored at all villages in study area is within reasonable limits. Noise generated from an industry gets attenuated considerably because of natural barriers like walls, vegetation, houses etc. or gets deflected along the wind direction. Thus, it can be stated that noise impact due to the proposed expansion activities in GIACL complex could be significant on working environment without control measures, while the noise impact on community would be negligible

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Table 4.12 Standards In Respect of Ambient Noise Levels

Sr. No. Category of Area

Limits in dB (A), Leq Day time

(6 AM to 10 PM) Night time

(10 PM to 6 AM) 1. Industrial area 75 70 2. Commercial area 65 55 3. Residential area 55 45 4. Silence zone (Hospitals, Educational Institutes & Courts) 50 40 Ref: Noise Rules 2000; Gazette of India 14th Feb 2000. 4.3.9.1 Mitigation Measures • Noise monitoring shall be done regularly in noise prone areas and within the industry

where workers will get exposed. • Workers would be trained to take precautionary measures due to noise during

construction phase. All equipments during construction will be operated in a controlled manner

• Heavy duty muffler systems shall be employed for high noise generating equipment. • Proper oiling, lubrication and preventive maintenance shall be carried out for

machineries and equipment to reduce the noise generation. • PPE such as ear muffs, ear plugs, masks will be strictly enforced for the workers engaged

in high noise prone zones. • DG sets shall have standard acoustic enclosure that can reduce insertion loss of about of

25 dB(A). Regular maintenance of DG sets shall be carried out. • For control of noise at source, steps shall be taken like - enclosing machine, reducing

vibrations in components by replacing metal parts with sound absorbing materials, isolating the work place containing noisy equipments, reducing height of fall bins, reinforcing sheet metal constructions by packets, reduce speed of conveyor belts, covering walls/ ceilings with sound absorbing materials, using sound absorbing screens, building sound proof control areas/ rest rooms etc. In short; insulation, isolation, separation techniques shall be implemented.

• Green belt will be augmented which would attenuate noise intensity from the plant to surroundings and thus would prevent the noise pollution.

• Onsite workers shall not be exposed, for more than 8 hours, to high noise generating sources. During each shift of 8 hours duration, maximum permissible limits of 115 dB(A) shall never be exceeded, in the work zone, even for a short duration.

Industry shall administer a 'Hearing Conservation Program' for workers exposed to high noise sources which shall include monitoring, notification, protection, training and record keeping for all employees in danger of exposure. The protocol shall comprise of following- 1. Monitoring shall include developing a sampling strategy to identify employees to be

included in the hearing conservation program. Each employee being monitored shall be notified of the results. Employees may observe the monitoring by the Industry. The Industry shall establish and maintain an audiometric testing program that shall be performed by a qualified person at no cost to the employees.

2. Testing shall include baseline audiograms thereafter. The annual audiogram shall be evaluated for a standard threshold shift of 10dB or more at 2000, 3000, or 4000 hertz (Hz)

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in either ear. Hearing protectors shall be provided by the Industry as part of the hearing conservation program.

3. Training shall comprise of observing a training program in the use and care of hearing protectors for all employees who are exposed to an 8-h TWA ≥ 85 dB(A). The hearing protectors must attenuate 8 - h TWA to at least 90 dB(A) and for employees with a standard threshold shift down to at least 85 dB(A). (TWA: time weighted average)

4. Record keeping will include maintaining audiometric test records by the Industry for the duration of the affected employment.

4.3.10 Impact of Vibration

Vibration is not expected during the industrial operation of GIACL. There would not be any vibration impact due to the expansion operation. 4.3.11 Impact on Land Use Vegetation and drainage of any region are related to each other and reflect inter-locking or inter - connectivity between the same. Healthy vegetation shows well developed drainage pattern. Under GIACL, first major land use is crop land that cover about 58.53 % area within the study area. Fallow land is about 24.46% in study area. Present use of the project land is for industrial purpose wherein the existing sugar factory, co-gen plant and distillery have already been established. Proposed expansion of distillery shall be implemented in existing premises of GIACL and hence no change in the land use pattern is expected. Therefore, impact on the land use is non-significant. Under CER, it is observed that GIACL would support de-siltation of dam/ Bandhara in its command area. Harvested rain water to be stored in these tanks will be beneficial not only for ground water recharge but also cropping pattern in the area could be changed considerably there by again having impact on land use. Further, mass afforestation and plantation in the study area (especially in nearby villages) shall promote development of more green cover on the present somewhat barren landscapes. This shall have a prominent impact where under landuse and land cover patterns could get significantly changed. 4.3.11.1. Mitigation Measures Planning towards development of the study area to be undertaken by GIACL under CSR shall be in line with requirements of the locals and same shall be sustainable. Industrial activities in GIACL (cane harvesting, transportation, manufacturing, effluent treatment and overall environmental management) shall be so managed that there shall not be any significant adverse impact on the existing status of land and its utilization patterns. 4.3.12 Impact on Ecology and Bio-diversity Impacts were considered for worst case scenario i.e. direct discharge of untreated spent wash into the stream reaching Jayakwadi dam. The drainage map reveals that a major stream originates near project site, passes through villages Ghotan and finally reaches Jayakwadi Dam at about 5kms on north-east of the project site. However it is found that the stream is disrupted by agriculture expansion, roads and human habitation and thus the possibility of mixing of effluent discharge into Jayakwadi Dam is remote. It was earlier recorded that the

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spent wash from the plant was directly discharged in the agriculture fields by the industry; this was reported by the respondents as well. This practice has potential threat on the local ecology and biodiversity (Equinox EIA report, 2016). 4.3.12.1 Mitigation Measures • Nature conservation and environmental protection activities involving local youth and

local schools shall be planned on priority under industry’s CER activity. • Activities like slide shows or expert’s lectures on biodiversity shall be arranged for the

staff to make them aware about the plant and animal species found nearby; also it will reduce unnecessary human-wild conflict. This will eventually reduce the damage to biodiversity by the employees

• GIACL, by involving workers and locals, should demonstrate, encourage, and promote suitable eco-friendly alternatives and green technologies under CER activity in the villages in 10 km vicinity, stressing on mass block tree plantation, RWH, solar lighting, organic farming, etc.

• Promoting measures of energy and water conservation, wherever possible, would be adopted.

• Pollution control measures should strictly be implemented by the industry. • Stack and production block shall be provided with APC equipment in form of ESP. • No ash shall be stored outside the industrial premises or disposed off in nearby grasslands • No any untreated effluent shall be let out into nearby water body or land

4.3.13 Impact due to Industrial Operations Involving Risk and Hazard

In an integrated complex, there are number of areas where various operations and actions performed could lead to consequences involving risks & hazards. This section should receive careful consideration in identifying the particular impacts which may be due to number of reasons like – 1. Handling and storage of raw materials, by-products, products etc. 2. Primary and secondary manufacturing operations and running of equipment like boiler, turbine, fans, centrifuge etc. Identification of impacts in above areas and actions as well as mitigation measures towards same have been elaborated separately under Chapter – 7 on ‘Additional Studies’ where the section of ‘Risk Assessment’ under sector of sugar factory, co-gen plant and distillery has been dedicatedly dealt with.

4.3.14 Occupational Health and Safety • Well being and safety of the employees has a direct bearing on the performance of the

project. Therefore, all the measures as envisaged in the risk analysis & HAZOP studies will be implemented with due care.

• All the employees will be provided with PPEs like safety helmets, goggles, face shields, heat resistance shoes, dust masks/ respirators, Self Contained Breathing Apparatus (SCBA), breathing air masks etc.

• Mock drills as per ‘On site Emergency Plan’ as approved by Chief Inspector of factories will be conducted for fire hydrant systems, firefighting equipment. All the emergency systems shall be placed in good working condition. Same shall be made available during emergency conditions by adopting the effective preventive maintenance. Emergency

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preparedness of teams as per the onsite emergency plan shall be ensured by conducting the effective training through mock drills including evacuation plans.

• Company shall make an agreement with the multi-specialty hospitals for medical checkups and emergency services and also with nearby companies for mutual aid during emergencies.

• Inspection & breakdown maintenance of all the equipment including pollution control equipment shall be undertaken by proper work permit systems.

Health Check-up of Workers • Industry shall under take pre-employment health check up followed by periodical health

checkup every year with special attention to occupational health hazards & shall be conducted for all the employees.

• Following parameters shall be the part of pre-employment & annual periodical medical check-up. The company will outsource all the tests with the local hospitals.

Table 4.13 Test Details

No. Test Details (Physical Fitness Certificate) 1 Pulse 2 Blood Pressure 3 Per Abdomen (PA) 4 Complete Blood Examination Hemoglobin% (Hb%), WBC, RBC, etc 5 Vision 6 Central Nervous System (CNS) 7 Respiratory System-Lung Function (RS) 8 Cardio Vascular System (CVS) 9 Electro Cardio Gram (ECG) 10 Chest X-ray 11 Venereal Disease (VD) 12 Total Leucocyte Count (TC) 13 Differential Leucocyte Count (DLC) 14 Absolute Eosinophil Count (AEC) 15 Complete Urine Examination [Physical / Chemical /Albumin, Sugar & Bile Salt etc. 16 Ultrasound with Film for Kidney anomalies 17 Random Blood Sugar 18 Sputum for Acid Fast Bacillus (AFB for Tuberculosis) 19 Lever Function Test

4.3.15 Impact on Historical Places Mahadev Mandir at Ghotan about 2.5 Km from project site, impact is nil. 4.4 EVALUATION OF IMPACT Evaluation of impacts on the environmental parameters due to the proposed expansion of Distillery project is an important aspect to be studied. For evaluation of same, Battelle

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Environmental Evaluation System (BEES) is implemented. Description of BEES is as follows - 4.4.1 Battelle Environmental Evaluation System (BEES) BEES has been used for evaluation of impacts arising out of different project activities. The BEES is a simple yet very effective methodology for conducting environmental impact analysis. It is based on a hierarchical assessment of environmental quality indicators. The system incorporates classification consisting of four levels- • Level I : Categories, • Level II : Components, • Level III: Parameters, and • Level IV: Measurements.

Each category (Level I) is divided into several components, each component (Level II) into several parameters, and each parameter (Level III) into one or more measurements. The Environmental Evaluation System (EES) implied here identifies a total of four (4) categories, twenty (20) components and eighty eight (88) parameters. BEES assessment for environmental impacts of the activities under proposed activities by GIACL is based on commensurate Environmental Impact Units (EIU). Two EIU scores are produced, one 'with' and another 'without' the proposed project. The difference between the two scores is a measure of the environmental impact. The scores are based on the magnitude and importance of specific impacts. In addition to the EIU scores, the EES labels major adverse environmental impacts with a "red flag." These flags point to fragile elements of the environment for which more detailed studies are warranted. Table 4.12 shows a complete list of categories, components, and parameters of the Battelle EES. Column 1 shows the four (4) categories, Column 2 shows the twenty (20) components, and Column 3 shows the eighty eight (88) parameters. BEES methodology is based on assigning importance unit to each of the parameters. Collectively, these "importance units" are referred to as "parameter importance units" or PIU's. Parameters have been assigned important weights by an interdisciplinary team of experts based on the ranked-pair wise comparison techniques. A total of 1000 PIU's are distributed among the 88 parameters based on value judgments. The individual PIU's are shown in Column 4 of Table 4.12, the summation component PIU's are shown in Column 5, and the summation category PIU's are shown in Column 6. Effectively, for each parameter i, its (PIU)i represents a weight wi Each PIUi or wi requires a specific quantitative measurement. The methodology converts different measurements into common units by means of a scalar or "value function." A scalar has the specific measurement on x-axis and a common environmental quality scale or "value" on the y-axis. The latter varies in the range 0 ≤ Vi ≤ 1. A value of Vi = 0 indicates very poor quality, while Vi = 1 indicates very good quality.

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Values of Vi = Vi, 0 are obtained for conditions 'without' the project, and Vi = Vi, 1 for conditions 'with' the project. The condition 'without' the project represents the current condition, while that 'with' the project represents the predicted future condition. The environmental impact EI is evaluated as follows: EI = ∑ [ Vi,1wi ] - ∑ [ Vi,0wi ] for i = 1 to n, where n = number of parameters (88). For EI> 0, the situation 'with' the project is better than 'without' the project, indicating that the project has positive environmental benefits. Conversely, for EI< 0, the situation 'with' the project is worse than 'without' the project, indicating that the project has negative environmental benefits, i.e. certain negative impacts. A large negative value of EI indicates the existence of substantial negative impacts. Assigned weights or PIU's represent the relative importance of each parameter within the overall system. Once established, they should be kept constant; otherwise, the environmental impact assessment would be difficult to replicate. Potential problem areas are represented by those parameters for which the Vi value changes significantly in the adverse direction, as measured by the following relation (in percent)- ΔVi (%) = 100 (Vi,0 - Vi,1) / Vi, 0

These parameters are tagged with 'red flags' to indicate potential problems which may warrant more detailed attention. For parameters in the ecology category, a minor red flag applies when 5% <ΔVi< 10%; a major red flag when ΔVi> 10 %. In all other categories, a minor red flag applies when ΔVi< 30% whereas a major red flag when ΔVi ≥ 30%. EES can be applied for the evaluation of project impacts, to select specific alternatives, or during the planning process to minimize potential adverse impacts of proposed projects. In the latter case, a feedback loop is used to continually modify the proposed project through successive iterations. Projects developed with the help of EES are expected not only to minimize environmental impacts, but also help improve selected portions of the environment. 4.5 ENVIRONMENTAL IMPACT EVALUATION FOR EXPANSION OF GIACL Environmental quality assessment for the proposed project has been undertaken by evaluating relevant environmental parameters. These parameters represent the various components of environment namely- 1. Biological Environment 2. Environmental Pollution

Water Air Soil Noise

3. Aesthetics 4. Human Interest

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Functional relationship (value functions) has been developed for each of the selected parameter, resulting in parameter measurement with environmental quality. Allocation of PIUs, among the selected environmental parameters, represents a consequence of opinion of members of an interdisciplinary team of experts. Accordingly, the major environmental categories i.e. biological environment, environmental pollution, aesthetics and human interests are allocated 240, 402, 158 and 200 PIUs respectively, out of total of 1,000 units. Exhaustive list of parameters and associated PIUs used for impact assessment of proposed Distillery unit of GIACL is presented. Though the BEES is considered to be the best available environmental evaluation technique, conflicting conclusions, among decision makers, could arise in the interpretation of evaluated results. Primary factors giving rise to such difference in opinion are at uncertainty and subjectivity in the allocation of PIUs to different environmental parameters and uncertainty caused by the aggregation of individual parameter scores to yield the final project score under different project impact scenarios. It is, therefore, necessary to take into account such variability and uncertainty while inferring the impact of a development project on the surrounding environment. 4.5.1 Biological Environment GIACL has already developed land area of 61,350 Sq. M (6.1 Ha) under greenbelt in existing premises is which is 23% of total plot area. As per MoEFCC, New Delhi & CPCB guidelines industry has to develop green belt on area of about 33% of total plot area. To comply this condition GIACL has procured additional land of area 60,000 Sq.M. (6 Ha) near existing industrial premises for development of more green belt. On that additional land, an area of 4.07 Ha is developed as green belt. Hence total green belt developed by GIACL is about 10.17 ha which is about 38% of industrial total plot area. Under existing green belt, about 10,305 no. of trees are already planted. In 2018 monsoon GIACL has planted additional 5353no. of trees. Details of list of trees planted by GIACL is presented at appendix G along with photographs of green belt & layout showing green belt. 1. Terrestrial Environment a) Natural Vegetation Natural vegetation comprises of Neem and Babhul are dominant natural tree in the area. Major crops in the study area are sugarcane, jowar, wheat, cotton, maize, and onion. Plantations of pomegranate and papaya were observed. Also, Banyan, Peepal, Ficus, Tamarind, Drumstick, Babhul, Neem, and Mango observed. b) Crops In the study area, under 10 Km radius from the GIACL, sugar cane is commonly and mostly cultivated. In some cases crops like cotton, gram, jowar and bajra are also cultivated. Project would not have any significant negative impact on crops. Infact, same will be having positive impact after using potash rich spentwash powder as a manure. After expansion GIACL will convert spntwash in to powder which will have very good nutrient value for plants. Same shall be supplied to local farmers as organic manure. This being good in N, P and K shall affect the crop yield positively.

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c) Species Diversity No endangered species are found in the area. No negative impacts are envisaged due to the proposed project. However, plantation of variety of the species, as induced in the Environmental Management Plan, would improve the ecosystem of the area. This will improve the ecosystem marginally. d) Food & Web Index

As area would not have any negative impact, no impact on food & web cycle is expected. However, due to afforestation plan in the acquired area, improvement in the food web index is expected. e) Rare & Endangered Species No rare & endangered species are present in the study area. No positive or negative impact is expected on these species- i) Plant Species - These are normal species found in the Maharashtra Zone. Negative impact on these species is not expected. Green belt development plan, as per the EMP, would increase the number of various plant species in the acquired area. ii) Animal Species - Animal species found in the area are cows, buffaloes, horses, donkeys, dogs, cats, bulls etc. These are normal species found in the Maharashtra Zone. Negative or positive impact on these species is not expected. f) Pest Species No major pest or parasitic species are found in the area. No negative or positive impact on same is expected. 2. Aquatic Environment 1. Natural Vegetation Existing quality of natural vegetation is good. No aquatic weeds are observed in surface waters. 2. Species Diversity There are no rare and endangered aquatic species reported in the study area. Hence, no changes in these parameters are anticipated. As the existing and proposed expansion effluent would not be discharged directly to any water body, the species diversity, any plant or animal species will not get affected.

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3. Food & Web Index

As the aquatic life is not going to be affected there will not be any impact on the food and web index. 4. Rare & Endangered Species No rare and endangered species are found in the study area. 4.5.2 Environmental Pollution Parameters for the above-mentioned category are divided into four parts as Water Soil Air Noise Impacts of the proposed molasses based distillery on these components are summarized below & presented in Table: 1. Water Major parameters, which represent the water environment, are pH, COD, BOD, SS and TDS. In case of the distillery effluent, factors like odour and colour are also of importance. Industrial effluent generated by the proposed activities would comprise of various streams namely the process effluents and effluents arising out of other activities namely cooling and boiler blow downs, washing, laboratory etc. Total water requirement for 150 KLPD distillery project during sugar crushing season (180 days) would be 1619 M3/ Day. Out of the total water requirement, 1506 M3/ Day water would required form industrial purpose, 12 M3/ Day water will required for domestic purpose and 101 M3/ Day. From total water requirement 41 M3/Day would be fresh water taken from Jayakwadi dam on Godavari River, 7 M3/Day would be STP treated water used for flushing, 230 M3/Day would be excess condensate water from sugar factory & co-gen plant and 1578 M3/Day would be MEE condensate and CPU treated water from distillery. About 97% recycle water will be used for distillery during sugar cane crushing season. During non - sugar cane crushing season (150 Days); total 1619 M3/Day water will be required. out of this 271 M3/Day would be fresh water taken from Jayakwadi dam on Godavari River, 1341 M3/Day would be MEE condensate and CPU treated water from distillery and 7 M3/Day will be treated water from STP used for flushing. For non-sugar cane crushing season about 83% of water will be recycled water. 2. Soil As NPK values of soils are inadequate at most of the places in study area, good crops cannot be grown without use of chemical fertilizers. In case of the study area, the soil chemistry will not change because there are no any emissions from the existing project. In totality, negative impact on soil chemistry of the premises as well as that of the study area is not expected. Spentwash powder after mixing with boiler ash shall be applied in farm. It is very rich in potash and acts as very good manure than any chemical fertilizer. Hence, after applying the

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same on agricultural soil, fertility of soil will increase leading to enhancement in crop yields, which is a positive impact. a. Land use pattern No changes in the land use pattern of the acquired area are expected. The study area would not have any positive or negative impact, on the land use pattern because of the proposed project. b. Soil chemistry Chief soil found in the study region is very deep, well drained, fine, calcareous soils on very gently sloping lands with means and buttes with moderate erosion; associated with shallow well drained, clayey soils with moderate erosion and moderately saline. Also, the study area consist of shallow, well drained, clayey soils on gently sloping lands with mesas and buttes with moderate erosion and slight stoniness. pH index indicate neutral nature of the soil. Bulk density is observed to be 1.10 to 1.30 gm/cc. Soils from this study area have less EC values. Sodium adsorption ratio (SAR) is in the range of 0.15 to 0.28 .The colour of these soils is brown. They are clayey in texture. c. Soil Erosion

Development of the green belt plan as per the EMP would also prevent the soil erosion from the project premises. Also, grassland on the open lands shall help arresting the erosion of soil. Thus, there will not be any soil erosion from the acquired area. 3. Air Steam required for the proposed distillery would be taken from 8 TPH boiler installed in existing distillery. Same is provided with a stack of 45 M height. Biogas generated from spentwash digestion shall be used as fuel in the boiler. After burning, emission of SO2 and CO2 shall be emitted. As biogas is clean fuel there will not be any problem of particulate matter emissions. Adequate stack height will disperse the SO2 properly in atmosphere. A boiler of capacity 30 TPH from existing sugar factory will be modified to 40 TPH and steam from same shall be used during distillery expansion. Bagasse will be used as fuel for the same. ESP is already installed as APC along with stack of 76M height of stack. After burning of bagasse PM10, PM2.5, SO2 and CO2 shall be emitted. Average PM10, PM2.5 & SO2 monitored at the site show values of 63.65 µg/M3, 18.75 µg/M3 and 11.72 µg/M3 respectively. These are well within the limits specified by MPCB/CPCB. No much increase in same due to fuel burning in boiler is expected. Process emissions from the distillery would be CO2 after fermentation and water vapors. CO2 will be bottled and sold to beverage industries. 4. Noise Source of noise generation would be boiler house, fermentation and distillation sections, pumps, compressors and stand by D.G. Set. However, this would not be the continuous source. Only in case of electricity failure, D.G. Set would be operated. D.G. Set shall be

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enclosed in a separate canopy to reduce the noise levels. Prevention of noise with the plan suggested in EMP would suffice the control of noise pollution. 5. Vibration - No major source of vibration is present. 6. Topographical character a. Landscape Topography and landscape of the area are overall flat. Small changes would occur in the form of general leveling & digging for the construction purpose. Debris arising from the construction would be utilized for filing of low-lying area, if any. Thus, even if some changes may occur in the topography of the area it would bring out positive impact in the form of leveling & landscaping. b. Green belt Natural vegetation and its diversity will increase due to green belt development. c. Visual quality of air There will not be any effect on the visual quality of the air. d. Visual quality of water There will not be any effect on visual quality of the water body present in the study area. Effluent from the existing and expansion distillery activities shall be treated in CPU to be provided on site. Treated effluent shall be recycled in process operations and remaining would be used for gardening in own factory premises as well as for irrigation. e. Sound There might be small increase in noise levels around the factory premises. This can be taken care by implementation of good green belt development plan as suggested in EMP. 4.5.3 Human Interest Expansion of distillery will provide employment to the nearby locality, inducing the positive effect through primary and secondary jobs. a. Community health Project would not have any impact on the sanitation facility. Domestic wastewater generated from GIACL complex will be treat in existing STP and used for flushing purpose. Hence, the sanitation in the study area as well as acquired area would not have any positive or negative impact.

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b. Employment

Skilled labours’ and officers’ requirement for the expansion project would be made available from the local area as well as from outside. Unskilled labours required for daily operations of the unit would be made available from labour force available in the study area. Preference would be given, for the job opportunities, to those labours that are residing nearby. Thus, there would be increase in the employment potential at local level. Secondary employment opportunities, in the form of contract jobs, shall also get enhanced. c. Economy As the project requires unskilled labours, the economic growth in the study area is bound to increase. Totally, economic growth would undergo positive impact. Small contract jobs at local level would improve the economy at the micro level. d. Transportation & communication Due to daily production of alcohol & dispatch as well as transportation of sugar cane & other raw materials, transportation in the study area is bound to be increased. As the project would require transportation of raw materials & products, mostly the local transporters would be benefited because of this project. More loads on communication network is not expected. For dispatch of alcohol to various companies, daily 4 - 5 tankers of 20,000 lit capacity shall be used. These trucks shall be hired from local transport offices. Therefore, there shall not be any major impact on existing traffic density. e. Education

The educational facilities up to higher secondary school are present in nearby town. f. Water supply

The proposed project shall receive water from the Jaikwadi Dam on Godavari River. g. Occupational health

Regular health checkup facility & programs would be carried in the proposed project for workers. The company would imply measures suggested in the EMP. No major occupational health problem is anticipated under the proposed project. Following measures shall be taken up by the Industry – • As per the requirement of Factory Act, provision of Occupational Health Center has been

done on site. • An ambulance is made available all the time i.e. 24X7. • Regular medical checkup of employees shall be carried out and records shall be

maintained as per existing practice. • Workmen Compensation Policy as well as Medi-claim Health Policy shall be done for all

the workers (temporary and permanent) in the Industry and shall be renewed every year. • Workers shall be provided with Personnel Protective Equipment such as ear plug, helmet,

safety shoes, gloves, googles etc.

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Table 4.14 Application of Battelle Environmental Evaluation System (BEES) for GIACL, A/p: Rakshi, Tal.: Shevgaon, Dist.: Ahmednagar

Categories Components Parameters Parameter Importance Units (PIUs) V i,0

Without Project

V i,1

With Project

ΔVi W iΔVi Parameter

PI\Wi Component

PIUs Category

PIUs 1 2 3 4 5 = Sum of 4 6 = Sum of 5 7 8 9=8-7 10=9X4

Biological Environment

(Ecology)

Species & Populations (Terrestrial Flora, Terrestrial Fauna, Aquatic Biota)

1. Terrestrial browsers & grazers

14 240 0.5 0.5 0 0

2. Terrestrial crops (Farm Land)

14 0.7 0.8 0.1 1.4

3. Terrestrial natural vegetation. (Grass, Flowers, Trees & Shrubs.)

14 0.6 0.8 0.2 2.8

4. Terrestrial pest species

14 0.6 0.6 0 0

5. Terrestrial upland birds

14 1.0 1.0 0 0

6. Aquatic commercial fisheries.

14 0.7 0.7 0 0

7. Aquatic natural vegetation

14 0.5 0.5 0 0

8. Aquatic pest species

14 0.6 0.6 0 0

9. Fish 14 0.6 0.6 0 0 10. Water fowl 14 140 0.7 0.7 0 0

Habitats & Communities

11. Terrestrial food web index

08 0.8 0.8 0 0

12. Land use 15 0.6 0.6 0 0 13. Terrestrial rare &

endangered species.

08 0.3 0.3 0 0

14. Terrestrial species diversity

08 0.8 0.8 0 0

15. Aquatic food web index

10 0.7 0.7 0 0

16. Aquatic rare and endangered species

08 0.5 0.5 0 0

17. River characteristics

15 0.5 0.5 0 0

18. Aquatic species diversity

12 0.6 0.6 0 0

19. Habitat Removal, Contamination of

Habitat (Aquatic Biota)

08 0.7 0.7 0 0

20. Terrestrial Fauna -Fragmentation of Terrestrial Habitat,

08 100 0.6 0.6 0 0

Environmental Pollution

Water 21. Basin hydrologic loss (alteration of hydraulic regime, alteration of

25 402 0.6 0.5 -0.1 -2.5

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Without Project

V i,1

With Project


PI\Wi Component

PIUs Category


surface runoff, alteration of aquifers)

22. BOD (Water Quality-WQ)

28 0.6 0.5 -0.1 -2.8

23. Dissolved Oxygen (WQ)

31 0.8 0.7 -0.1 -3.1

24. Fecal Coli-forms (WQ)

10 0.6 0.6 0 0

25. Inorganic carbon(WQ)

22 0.6 0.6 0 0

26. Inorganic nitrogen (WQ)

25 0.6 0.6 0 0

27. Inorganic phosphate (WQ)

28 0.6 0.6 0 0

28. Pesticides (WQ) 10 0.3 0.3 0 0 29. pH (WQ) 22 1.0 1.0 0 0 30. Stream flow

variation (alteration of river, nalla, channel)

28 0.8 0.8 0 0

31. Temperature. 28 1.0 1.0 0 0 32. TDS(WQ) 28 0.8 0.8 0 0 33. Toxic substances

(WQ) 7 0.7 0.7 0 0

34. Turbidity (WQ) 20 312 0.6 0.6 0 0 Air 35. Carbon dioxide

Air Quality (AQ) 10 0.8 0.7 -0.1 -1.0

36. Hydro-carbons (AQ)

5 0.8 0.8 0 0

37. Nitrogen oxides (AQ)

7 0.8 0.8 0 0

38. Particulate matter (AQ)

14 0.6 0.6 0 0

39. Photochemical oxidants (AQ)

3 1.0 1.0 0 0

40. Sulfur dioxide (AQ)

10 0.6 0.6 0 0

41. Other (Climate) 3 52 1.0 1.0 0 0 Land (Soil)

42. Land use 8 0.6 0.8 0.2 1.6 43. Soil erosion 4 0.8 0.8 0 0 44. Soil

Contamination 8 0.8 0.8 0 0

45. Soil Quality 8 28 0.7 0.8 0.1 0.8 Noise 46. Noise 10 10 0.8 0.8 0 0

Aesthetics Cultural

Land

47. Surface material 6 158

0.8 0.9 0.1 0.6 48. Relief &

topographic character

16 1.0 1.0 0 0

49. Width & alignment

10 32 0.8 0.8 0 0

Air 50. Odor & visual 3 0.7 0.5 -0.2 -0.6 51. Sounds 2 5 0.8 0.8 0 0

Water 52. Appearance 16 1.0 1.0 0 0

149



Without Project

V i,1

With Project


PI\Wi Component

PIUs Category


53. Land and water interface

16 1.0 1.0 0 0

54. Odor & floating materials

10 0.8 0.8 0 0

55. Water surface area

10 1.0 1.0 0 0

56. Wooded & geologic shoreline

10 62 0.8 0.8 0 0

Biota 57. Animals- domestic

5 1.0 1.0 0 0

58. Animals – wild 5 0.6 0.6 0 0 59. Diversity of

vegetation types 12 0.7 0.8 0.1 1.2

60. Variety within vegetation types

8 30 0.8 0.9 0.1 0.8

Manmade Objects

61. Manmade objects

9 9 0.8 0.8 0 0

Composition 62. Composite effect 10 0.7 0.7 0 0 63. Unique

composition 10 20 1.0 1.0 0 0

Human Interest (Social, Cultural)

Educational / Scientific Packages

64. Archaeological 6 200 1.0 1.0 0 0 65. Training in new

technologies & skill development

7 0.5 0.6 0.1 0.7

66. Ecological Effects on crops, Reduction of farm

land

12 0.8 0.9 0.1 1.2

67. Geological 11 1.0 1.0 0 0 68. Hydrological 12 48 0.6 0.8 0.2 2.4

Historical Packages

(Infrastructure and services)

69. Architecture and styles

5 1.0 1.0 0 0

70. Conflicts with projects of urban, commercial or industrial development

10 0.9 0.9 0 0

71. Events Recreation

10 1.0 1.0 0 0

72. Persons 12 1.0 1.0 0 0 73. Religions &

Cultures 10 1.0 1.0 0 0

74. Western frontier 8 55 1.0 1.0 0 0 Cultures 75. Indians 13 1.0 1.0 0 0

76. Other ethnic groups

5 1.0 1.0 0 0

77. Religious groups 5 23 1.0 1.0 0 0 Mood/Atmosph

ere 78. Awe-Inspiration 8 1.0 1.0 0 0 79. Isolation /

solitude 8 1.0 1.0 0 0

80. Mystery 4 1.0 1.0 0 0 81. Oneness with

nature 8 28 1.0 1.0 0 0

Security and 82. Increase in crime 5 0.5 0.5 0 0

150



Without Project

V i,1

With Project


PI\Wi Component

PIUs Category


Safety and accidents caused

Health 83. Temporary acute and chronic

5 0.7 0.7 0 0

Life Patterns (Economy)

84. Employment opportunities

(Creation of new economic activities.

Generation of Temporary & Permanent Jobs)

13 0.6 0.9 0.3 3.9

85. Income for state & private sector.

8 0.5 0.6 0.1 0.8

86. Saving for consumers & private consumers

Savings in foreign currency for the state.

5 0.6 0.6 0 0

87. Housing. (Commercial value of properties,

Electricity tariff)

5 0.6 0.7 0.1 0.5

88. Social interactions

(Conflict due to negotiations & / or compensation payments,

Political conflicts, Demonstration and Social Conflicts.

5 46 0.6 0.7 0.1 0.5

The Battelle EES Environmental Impact Analysis Cumulative Index Ei +9.2

Table 4.15 Identification of RED Flags to the Potential Problem Areas in BEES for GIACL

Parameters PIUs

W i V i,0

Without Project V i,1

With Project ΔVi ΔVi, r # Red Flag 1 2 3 4 5 =4-3 6=5/3 X 100 7

21.Basin Hydrologic Loss 25 0.6 0.5 -0.1 -17 Minor 22. BOD 28 0.6 0.5 -0.1 -17 Minor 23. DO 31 0.8 0.7 -0.1 -13 Minor 33. Carbon Dioxide (CO2) 10 0.8 0.7 -0.1 -13 Minor 46.Odor& Visual 3 0.7 0.5 -0.2 -29 Minor # - In the Battelle EES, the potential problem areas are represented by those parameters for which the Vi value changes significantly in the adverse direction, as measured by the following relation (negative values, in percent) - ΔVi, r = 100 [V i,1 - V i,0] / V i,0. These parameters are tagged with 'red flags' to indicate potential problems which may warrant more detailed attention. For parameters in the ecology category, a minor red flag applies when 5% <ΔVi,r ≤ 10%, and a major red flag when ΔVi,r> 10

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%. In all other categories, a minor red flag applies when ΔVi,r ≤ 30% or ΔVi ≤ 0.1, and a major red flag when ΔVi,r> 30% or ΔVi> 0.1.

4.6 MITIGATION MEASURES Potential problem areas mentioned in above Table 4.13 shall be having adverse impact due to the various project activities. Mitigation measures to minimize the impact on different parameters are presented below- 1. Basin Hydrologic Loss Integrated GIACL complex comprises of existing projects namely sugar factory (5500 TCD), Co-gen plant (32 MW) & molasses distillery 60 KLPD. For the working pattern in GIACL complex, overall water requirement becomes as follows – A. For Crushing Season: 180 Days 1. For Sugar Factory and Co-gen Plant; total fresh water requirement in a season of 180

Days shall be - 3 CMD X 180 Days = 540 M3/Season

2. For Distillery, total fresh water requirement in a season of 180 Days shall be - 229 X 180 = 41,220 M3/Season Hence, total water requirement during crushing shall be – 41,760 M3/Season.

B. For Non- Crushing Season: 150 Days 1. For Co-gen Plant; total fresh water requirement in non crushing season of 52 Days shall

be - 178 CMD X 52 Days = 9,256 M3/Season

2. For Distillery; total fresh water requirement in non crushing season of 150 Days shall be 604 CMD X 150 Days = 90,600 M3/Season

3. For Gardening; total fresh water requirement in non crushing season - 90 days 165 CMD X 90 Days = 14,850 M3/Season Hence, total water requirement during non crushing shall be – 1,14,706 M3/Season.

From above calculations; it is seen that total fresh water requirement in GIACL campus is 1,73,910 M3 (41,760 M3+ 1,32,150 M3). This figure works out to be 0.173 Million M3. Permission granted to GIACL by Irrigation Department; Govt. of Maharashtra for lifting fresh water from the 'Jaikwadi Dam' reservoir is 0.071 Million M3 which is much lesser than the actual total usage of water quantity.

For Sugar & Cogen activities about 3547M3/D met from recycled water (i.e.99.9 % Recycle). For distillery @ 879M3/D would be recycled water (60%)

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This reduces use of fresh water requirement in GIACL complex, met through recycle of treated effluents & condensate. In other words, this much quantity of fresh water is saved which is a very positive impact on conserving the precious natural resource - Fresh water. 2. B.O.D. & DO

Through the manufacturing operations in proposed molasses based distillery, various streams of effluent shall be generated. Same shall comprise of spentwash as the main process waste water. Spentwash is a highly polluting effluent with characteristics as – pH: 3-5, TS: 1,10,000 - 1,15,000 mg/l, SS: 15,000 - 20,000 mg/l, BOD: 60,000-80,000 mg/l, COD: 1,20,000 - 1,40,000 mg/l. Extremely acidic nature and very high organic content of the raw spentwash poses a serious threat to environment. Under GIACL distillery expansion program; spentwash shall be initially forwarded to bio-methanation plant which will not only neutralize its pH but also reduce organic content by about 75-80%. As a result biogas contacting about 60% methane is generated which is a very good fuel for distillery boiler. Bio-methanated spentwash shall be concentrated in MEE so as to obtain condensate and concentrated spentwash. Concentrated spent wash from MEE shall be subjected to ATFD to form powdered spentwash. Spentwash powder having 95% of solids are mixed with boiler ash and sold as manure. Also, during non crushing season spentwash powder of 99% solids will be used as manure in farmlands. This methodology of spentwash treatment and disposal shall achieve zero discharge eventually.

Other than the spentwash, spent leese, boiler and cooling tower blow downs, floor washing as well as lab effluent shall also be generated from operations and processes in the distillery. Resultant combined wastewater from other streams shall exhibit characteristics such as -BOD : 800-1000 mg/l, COD : 1600-2000 mg/l, SS : 200-250 mg/l, TDS: 1800-2000 mg/l. BOD is mainly imparted due to organic matter in the effluent stream. This wastewater, if let out in the environment without any treatment, shall cause deleterious effects such as depletion of DO in receiving water bodies. To avoid this, wastewater from distillery shall be treated in CPU. Treated water from CPU will be recycled back in process for various operations. 3. CO2

CO2 generation shall take place in fermenters of the distillery. In a fermenter, sugar in the wash gets converted to ethyl alcohol through metabolic activities of yeast. Consequently, CO2 in evolved as emission of the bio-chemical reaction. Generation of CO2 takes place in considerable quantum which when let out in the atmosphere could have undesirable effects in the surrounding ambience. Since CO2 has been labeled as one of the major gases responsible for the green-house effect, its release in the atmosphere has to be properly controlled. Under the proposed project, this CO2 from fermenters shall be let out for a certain period initially. To minimize the CO2 effects marginally, a care shall be taken through implementation of green belt which can play an important role in curbing its release to atmosphere, from the premises. However, there is a future planning (within an year or so) to collect the CO2 properly, compress it adequately and bottle subsequently. CO2 cylinders shall then be supplied to manufacturers of beverages. This approach shall totally curb the release of CO2 from distillery operations. 4. Odour and Visual

This parameter comes under ‘Aesthetics’ category of BEES. Odor potential, although not much, do exists at certain places especially at the fermenters, yeast sludge separation and

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storage areas etc. Same, if not lifted immediately, within 5 to 6 hours of generation fermentation reactions would set in giving rise to foul smell. Further, development of anaerobic conditions in the equalization tank of ETP due to inadequate mixing and agitation as well as decomposition of sludge could give rise to smell nuisance. Visual appearance is again a major concern related to aesthetics which could be tackled only through BMP’s and good house-keeping. Under the proposed molasses based distillery, effective EMP will be adopted so as to maintain the overall aesthetics in good manner. Also, to maintain an overall good and pleasant aesthetics in the distillery premises, all the requisite care including maintaining good housekeeping shall be practiced. 4.7 IMPACTS DUE TO DECOMMISSIONING ACTIVITY 4.7.1. Decommissioning Phase "Decommissioning" is a procedure to make an equipment or manufacturing setup unfit for its reuse for its designed function. This could be done by cutting project components into small pieces, demolition of buildings, disconnecting circuits and removing of all infrastructure set up thereby making it unusable. Hereunder, impacts of decommissioning have been described.

Table 4.14 Identification of Impacts due to Decommissioning of GIACL

No Env. Aspect Activities /Operation Impact Identification Measures 1. Land Use Dismantling and

decommissioning of industrial set up.

• Land will be barren and vacant after decommissioning

• Existing project being agro-based, post decommissioning use would be residential or agriculture.

--

2. Air • Cutting, demolition and dismantling operations.

• Transportation.

• Release of fumes of acid/ alkali during washing

• Fugitive dust during demolition of building & transportation .

Water sprinkling to suppress dust during demolition work.

3. Water • Washing of manufacturing equipment, mills, pans, centrifuges, pipelines, fermenters, distillation infrastructure, tanks etc. during detoxification

• Washing discharges getting access into nearby nallah under uncontrolled operational conditions.

Washing discharges to ETP; treatment & disposal through same outside industrial premises after achieving specified standards. Demolition of ETP shall be last activity.

4. Solid Waste & Hazardous Waste

• Cutting wastes, scrap, demolition wastes etc.

• Oils and lubricants removed from equipment

• Littering of wastes • Bad aesthetics

Solid wastes generated would be sold to authorized re-processor. Demolition waste to land fill.

5. Noise • Cutting and drilling activities during decommissioning

• Dismantling of heavy machinery & equipment, fermenters,

Increase in noise levels during decommissioning.

PPEs to manpower involved in decommissioning and safety measures to will be followed.

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No Env. Aspect Activities /Operation Impact Identification Measures distillation column, turbines, boilers etc.

6. Risk & Hazard

Dismantling & decommissioning of equipments & buildings.

Accidents, spillage of molasses, alcohols, spentwash etc., storage tanks detoxification, storage tanks dismantling.

Use of PPEs, expert and experienced supervision, due follow up of safety norms & procedures.

4.7.2. Planning for Decommissioning of GIACL Project – When a plan for decommissioning of GIACL plant would be confirmed, initially a detailed survey of the site and entire plant shall be carried out. Detailed photography and videography shall be done. A review of all documents shall be taken and thorough checking shall be done w. r. t. permissions from all concerned Govt. authorities for the decommissioning. If required, competent personnel shall be arranged at the site to supervise the entire assignment. Subsequent to survey, a planning towards sequence and chronology of decommission and dismantling shall be done by taking in to consideration following –

1. Number and types of buildings like administration building, industrial sheds, godowns, residential quarters and security office in RCC and brick work, manufacturing plant in MS & RCC, allied piping, staging and supports etc.

2. All electrification infrastructure with cables and cable trays, transformers, poles and lighting, underground cable trenches, etc.

3. Main production set up comprising of Sugar, power and alcohol manufacturing plants in RCC & fabricated structures, 2 boilers, DG sets, molasses storage tanks of MS, two stacks etc.,

4. Godowns in framed RCC structure / stone masonry with MS Roofing sheets. Spray ponds, cooling tower, ETP, STP, weigh bridge, and utilities infrastructure for pipelines, water storage tanks, pumps etc.

For demolishing RCC structure, no any blasting is recommended. Same would be done by using hydraulic breakers. Fabricated structure would be dismantled by gas cutting. Decommissioning would be done by detoxification followed by dismantling activity under trained manpower and expert supervision. A) Detoxification

For detoxification of tanks, pans, centrifuges, distillation columns, fermenters, following in-situ methods are suggested - a. Hot Water/ Air Purging: Hot air /water shall be purged through the units until specified

criteria are met. b. Alkali Wash: The equipment and pipelines are subjected to thorough alkali solution wash,

with specific criteria for the completion of the wash. The alkali solution shall be 5% to 10% of NaOH.

c. Water Wash: Finally a thorough water wash of the equipment and pipelines is recommended, before they are dismantled from their supports.

Used water shall be diverted to ETP for its treatment and safe disposal.

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B) Dismantling All the equipment, pipelines and structural components shall be dismantled only after in-situ

detoxification has been carried out as specified above. Pipelines would be dismantled first followed by the equipment and finally by the structure. Dismantling of the units will begin from top most floor and proceed towards the ground floor. Large equipment shall be dismantled in sections wherever possible. Dismantled metal components would be disposed off by sale to authorized parties. Demolition of RCC buildings would be done manually and debris generated would be used for filling low lying areas. Structures constructed by cement, concrete such as godowns, buildings would be demolished and debris material used for land filling.

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Chapter 5

ANALYSIS OF ALTERNATIVES

ANALYSIS OF ALTERNATIVES…5

5.1 INTRODUCTION While preparation of EIA report it is necessary that one should consider project alternatives and their relative potential impact on environment. Selection of alternative is thus more critical in an industrial development where time, money, environment and natural resources are at stake. Hence, selection of alternative must be both - practical and rational, taking into consideration the constraint of the proposed project. 5.2 ALTERNATIVE TECHNOLOGIES 5.2.1 Manufacturing Process GIACL has selected Continuous Fermentation Technology with closed Multi Pressure Vaccum Distillation process for production of alcohol. 5.2.2 Technology for Abating Pollution

Effluent generated from distillery is in the form of spentwash, spentlees and other effluents viz. effluent from lab & washing, cooling blow downs, boiler blow downs etc. Spentwash generated from 150 KLPD molasses based distillery will be first treated subjected to bio-methanation followed by concentration in MEE. Bio-methanated and MEE concentrated spentwash then subjected to Agitator Thin Film Dryer (ATFD). Under this three force circulation evaporation bodies will be installed. Two in operation and one in standby mode. Followed by four no. of ATFD three in operation and one in standby mode. In Force circulation evaporators solids raised from 30% to 55% fade to three ATFD in series which ejaculate 95-99% solid spentwash powder. Spentwash powder is potash rich and contains 28% Potash mixed with boiler ash press mud and sold as manure to the cane grower farmers command area of the industry. Spentwash powder with 95% solids will be mixed with boiler ash to form manure during crushing season. During non crushing season GIACL will form spentwash powder of 99% solids. Same will be bagged and sold out. MEE condensate, spentlees and other effluents will treat in CPU. Treated water from CPU will recycled back in process. This achieves ZLD. 5.2.3 Sugar Factory Technological process of sugar manufacturing, involving techniques of cane crushing and juice crystallization, has undergone radical change with developments in the field of science and technology. Techniques of cane crushing and juice crystallization used till date is of Indian origin and traditional in character. Same traditional technique is being practiced for manufacturing of sugar.

5.2.4 Co-gen Plant

Sugar cane is crushed in the milling tandem where after bagasse is produced. Only way to use the bagasse effectively is to consume it by using as fuel in the boiler to generate steam. Generated steam is used for moving the power turbine to produce power. Bagasse based power generation project in premises of GIACL sugar factory fulfills captive need of the industry and make available surplus power to be exported in the grid.

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ANALYSIS OF ALTERNATIVES…5

5.3 ANALYSIS OF ALTERNATIVE SITES Proposed distillery expansion, from 60 KLPD to 150 KLPD (increased by 90 KLPD), will be implemented within existing premises of GIACL. Industry has sufficient land for expansion and hence no any alternative site was considered.

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Chapter 6

ENVIRONMENTAL MONITORING

PROGRAM

ENVIRONMENTAL MONITORING PROGRAM...6 6.1 INTRODUCTION With knowledge of baseline conditions and impacts predicted in Chapter–4, monitoring programme will serve as an indicator for any deterioration in environmental conditions due to operation of project. This will enable in taking up suitable steps, in time, to safeguard the environment. Monitoring is an important tool for control of pollution since the efficiency of control measures can only be determined by monitoring.

In GIACL complex, monitoring of various environmental parameters will be carried out on a regular basis to ascertain the following - • State of pollution within the plant and in its vicinity; • Examine the efficiency of Pollution Control Systems installed in the plant; • Generate data for predictive or corrective purpose in respect of pollution; • To verify the impacts predicated due to the proposed expansion project. • To identify the trends with time in the levels of parameters Environmental monitoring after implementation of expansion project is important to assess performance of pollution control equipments installed. Sampling and analysis of environmental attributes including monitoring locations will be as per guidelines of the CPCB/ SPCB. Accordingly, environmental monitoring will be conducted on regular basis by GIACL to assess the pollution level in the plant as well as in the surrounding area with the following objectives:

• To verify the impacts predicted under proposed expansion project. • To identify the trends with time in the levels of parameters. • To check or assess the efficiency of the various pollution controlling measures. • To ensure that new parameters, other than those identified in the impact assessment study,

do not become critical through commissioning of proposed project. • Establish database for future impact assessment studies towards expansion projects. Details of monitoring program during the construction, post construction and operational phase that have been suggested in order to achieve economic development due to the proposed distillery expansion project without harming the nature. 6.2 MONITORING PROGRAM DURING CONSTRUCTION PHASE As discussed in Chapter – 4 impact during construction phase shall not be permanent and certain minor impacts are predicted on air, water, soil and human health due to dust emission and noise during transportation and construction activity. Hence, there is need to conduct monitoring during construction phase was ruled out. Moreover, necessary mitigation for impacts during this phase is suggested under Chapter-4. During construction phase, following recommendations have been made as far as monitoring of various environmental attributes are concerned.

6.3 MONITORING DURING POST CONSTRUCTION / OPERATIONAL PHASE

During operational stage, continuous air emissions from power boilers, wastewater disposal, non-hazardous waste such as ash, chemicals used in processing, used oily wastes are

160

ENVIRONMENTAL MONITORING PROGRAM...6 expected. Following attributes which merit regular monitoring based on environmental setting and natures of project activities are listed below:

• Source emissions and ambient air quality; • Ground water Levels and ground water quality; • Water and wastewater quality (water quality, effluent & sewage quality etc); • Solid and hazardous waste characterization (fly ash, bottom ash, oily wastes, ETP sludge,

used and waste oil); • Soil quality; • Noise levels (equipment and machinery noise levels, occupational exposures and ambient

noise levels) • Ecological preservation and afforestation. 6.3.1 Air Pollution Management Apart from ambient air and source monitoring during operation stage following recommendations are also suggested - • APC would be interlocked with the process as per the guidelines of CPCB. • In case of power failure, alternate electric source would be provided which would be

sufficient to operate APC equipment continuously. • If emissions exceed standards, corresponding units of plant which are contributing to

excessive pollutant load are stopped till quantity of pollutant discharged from those units are brought down to the required level.

• In case of failure of APC, production process connected to it shall be stopped. • Under no circumstances, emissions shall exceed limits mentioned in EC/consent order. • Monitoring of Stack Emissions and AAQ is routinely done. Same practices will be

followed after expansion also. Refer Table 6.6 for environmental monitoring program schedule.

• Boiler ash generated after burning of bagasse in co-gen boiler is collected from ESP, properly handled and stored on yard. It shall be mixed with powdered spentwash and used as manure in fields.

• Green belt is developed along all internal roads, on outer periphery of industrial & office. • Tarred roads are constructed within premises of GIACL. Approach roads towards industry

is also tarred road. It minimizes dust generation due to vehicular movement. • Online monitoring system is already installed to existing boiler stack under GIACL

complex as per CPCB guidelines. Same practices will be continued under expansion also. 6.3.2 Water Management Total water requirement for 150 KLPD distillery project would be 1619 M3/ Day. Water requirement of sugar factory and co-gen plant is 3550 M3/ Day. For detail water requirement refer Chapter – 2 Effluent generated from distillery shall be in the form of spentwash, spentlees and other effluents. Total spentwash generated from 150 KLPD distillery to the tune of 1182 CMD shall be initially bio-methanated followed by concentration in MEE. Concentrated spentwash to the tune of 443 CMD shall be subjected to ATFD for drying and forms 97 MT/Day spentwas dry powder having 95% or 99% solids. 95% powder would be mixed with boiler

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ENVIRONMENTAL MONITORING PROGRAM...6 ash to form manure during crushing season. While 99% powder bagged and sold during non-crushing season. Treatment to the spentwash is given as per CREP guidelines. Refer Table 2.22 of Chapter - 2 for effluent Treatment & Disposal for distillery. • Industry would observe that the effluent collection, disposal and treatment facilities

always remain in a good shape so as to achieve desired efficiencies. • Spentwash storage lagoon shall be lined to avoid percolation of leachate. • No untreated industrial effluent should be disposed off on land or in any surface water

body. • Pipeline and storage tanks meant for effluent conveyance and storage should be checked

periodically and should not have any leakages. Leakage, if any, will harm the surrounding soil and water environment significantly. HDPE & stainless steel could be used as pipeline and valves material respectively.

• Compliance towards CREP norms shall be strictly followed under GIACL complex. • Pumps in ETP & CPU shall be supplied with alternate electric supply source in case of

power failure. 6.3.3 Noise Level Management Vital aspects of noise pollution and its mitigation measures are mentioned in Chapter 2. Moreover, people working in close vicinity of high noise generating equipments would be provided with PPE such as ear plugs, ear muffs etc. • Industry would take care while procuring major noise generating machines/ equipments to

ensure that manufacturers have taken adequate measures to minimize generation of noise. • Distance between source and receiver would be increased and the relative orientation of

the source and receiver would be altered. • Trees are planted in and around the industrial area to intercept noise transmission to the

nearby villages. GIACL has planned to develop green belt. Augmentation of same is under process.

• Workers are provided with proper PPE like earmuffs & earplugs, noise helmets etc. • Allocation of work is managed so that no worker is exposed to noise more than 90 dB (A)

for more than 8 hours. • Creating awareness about noise pollution among the workers. • Overall noise levels in and around the plant area is kept well within the standards by

providing noise control measures including acoustic hoods, silencers, enclosures etc. on all sources of noise generation. Same practices will be followed after expansion also.

• Record keeping will include maintaining audiometric test records by the industry for duration of the affected employment.

6.3.4 Land Management There are no chances of change in soil characteristics due to air pollutants and suspended particulates from expansion activity as fuel used is a clean fuel. From the existing and proposed expansion project, solid waste generated would be in the form of yeast sludge, spentwash powder, ETP sludge and boiler ash. ETP sludge and yeast sludge shall be used as manure. Boiler ash from co-gen boiler shall be mixes with 95% powdered spent wash and sold as manure. If ash remains then it will be sold to brick manufacturers.

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ENVIRONMENTAL MONITORING PROGRAM...6 • Provision of shrubs and thick trees at storage and disposal places of the solid waste would

be made. • Trees are planted along the roads, solid waste landfill area and along the periphery as

recommended in the plantation program. Water requirement for this purpose expansion as well as existing project would be met from reuse of treated domestic effluent / industrial effluent.

• Water sprinklers are provided to suppress the windblown dust on the ash storage yard. • Collection and transportation of waste would be done in closed container system. • No solid waste shall be allowed to litter around and degrade the land. 6.3.5 Dust Management Trouble with dust in work zone and ambient atmospheres shall be controlled by certain dedicated measures. An action plan has been prepared in industry that includes following- • Installation of appropriate, adequate and efficient exhaust and ventilation system to

remove and control dust from work zone areas. • Inlet and outlet of pollution control equipment shall be provided with necessary sampling

arrangements as per guidelines of CPCB. • Dust collected from the APC equipment e.g. fly ash from boilers will be properly handled

and disposed off by supply to farmers for use as manure. • APC equipment would be interlocked with process as per the guidelines of CPCB. • PPE such as masks, aprons, gloves, goggles etc. shall be provided to workers. • Tarred roads are constructed within premises of GIACL as well as approach roads

towards industry is also constructed. It minimizes dust generation due to vehicular movement.

6.3.6 Odour Management To abate the odour nuisance, industry has a concrete planning which includes following steps and actions- • It is proposed to provide covered fermentation and tapping of CO2 gas. • Collection of yeast sludge from fermentation section in a closed system and its immediate

and proper disposal. • Closed drains carrying spentwash to the treatment units, minimization of fugitive

emissions from anaerobic treatment units. • Proper collection & handling of excess sludge generated from the anaerobic and aerobic

treatment units. • Bio-methanated spentwash conc. in MEE. Conc. spentwash shall be forward to ATFD for

drying and forms powder of spentwash of 95% or 99% solids. 95% solids powder spentwash will mix with boiler ash and sold as a manure. 99% solid containing powdered spentwash will bagged and sold. It can minimize undesirable smells around treatment units

• Adoption of GMPs (Good management practices). • Arranging awareness and training camps for workers. • Use of PPEs like masks by everybody associated with odour potential prone areas.

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ENVIRONMENTAL MONITORING PROGRAM...6 6.4 OPERATION CONTROL AND EQUIPMENT MAINTENANCE All the equipments and machinery used shall be maintained properly and should be kept clean. For expansion of distillery, the acid dosing equipments used in the fermentation processes would be checked regularly to prevent any leakages. Fermenters should be maintained properly and should be kept clean to avoid any contamination that would affect the quality of alcohol. Quality of stack emission depends very much on the operating parameters of plant. Improper combustion of fuel in the boilers increases unburnt carbon particles in the exhaust flue gases therefore proper maintenance is an important factor. Lubricants used for various equipment and fuel-handling areas would contribute to the pollution aspect. It would be taken care of, at the source, by looking after possible spillage, drippings, leakage etc. in the plant. 6.5 OCCUPATIONAL HEALTH & SAFETY MEASURES

Following measures are been taken up by the existing unit. Same practices will be followed after expansion also. - • As per the requirement of Factory Act, there is provision of Occupational Health Centre.

There under, a qualified visiting doctor has been appointed. • Infrastructure of existing Occupational Health Centre shall be enhanced in order to

provide medical facilities to all the workers as well as nearby village/town people. • Regular medical checkup of employees is carried out and records are maintained. • Provision of workmen compensation policy as well as mediclaim health policy shall be

done for the workers under expansion (temporary and permanent) and shall be renewed every year.

• Display of sigh boards in hazard areas in local language. • Provision of PPE to all workers. • An ambulance is provided on site 24 x 7 to deal with emergencies if any. • Workmen Compensation Policy as well as Mediclaim Health Policy has been done for all

the workers (temporary and permanent) in the Industry and which is renewed every year.

Table 6.1 Health Care Facility Equipment

No. Instrument Use 1. Stethoscope Used to hear sounds from movements within the body,

like heart beats, intestinal movement, breath sounds, etc. 2. Reflex testing hammer

(padded) To test motor reflexes of the body

3. Sphygmomanometer (Blood pressure meter)

To record the patient's blood pressure

4. A thin beam electric torch To see into the eye, body's natural orifices, etc., and to test for pupillary light reflex, etc.

5. A watch / stopwatch Used in recording rates like heart rate, respiratory rate, etc.; for certain tests of hearing

6. A measuring tape For size measurements

164

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

http://en.wikipedia.org/wiki/Hearing_(sense)

ENVIRONMENTAL MONITORING PROGRAM...6 No. Instrument Use 7. A weighing machine To record the weight 8. Tuning forks To test for deafness and to categorize it 9. Kidney dish As a tray for instruments, gauze, tissue, etc. 10. Thermometer To record the body temperature 11. Gas cylinders Supply of oxygen, nitrous oxide, carbon dioxide, etc. 12. Oxygen mask or tubes Delivering gases up to the nostrils to assist in oxygen

intake or to administer aerosolized or gaseous drugs 13. Vaporizer To produce vapours 14. Instrument sterilizers Used to sterilize instruments in absence of an autoclave 15. Dressing drums Storage of gowns, cotton, linen, etc. 16. Syringe of different sizes

and needles For injections and aspiration of blood or fluid from the body

17. Otoscope To look into the external ear cavity

6.6 MEASURES FOR SOCIO-ECONOMIC DEVELOPMENT 6.6.1. Better Employment Opportunities

In order to run the existing project about 291 workers are already working in industrial complex. Under expansion of distillery about additional 50 workers will be employed. Local persons shall be given preference while appointing the employees. 6.6.2. Corporate Environmental Responsibility (CER) Plan Planning for CER shall be started with identification of activities/ projects and may be

undertaken in the periphery of industrial area. CER action plan shall be prepared based on the casual approach to the project based

accountability approach, integrated with the social and environment concerns related to the business of the integrated project complex.

Selection of activities under CER shall be made to ensure that the benefits reach the smallest unit i.e. village, panchayat, block or district. CER planning shall be done for long-term sustainable approach.

Long term CER plan should be broken down into medium term and short term plans. Each of these plans shall clearly specify:

CER cell is established. Cell looks after the approval & implementation of CER activities. Meetings of CER committee are held once in three month.

Table 6.2 CER cell in GIACL

Sr. No. Name of Member Designation 1 Mr. Vishnu S. Khedekar (Chief Financial Officer) Chairman 2 Mr. G. N. Kharade (Accountant) Secretary 3 Representative of Village Grampanchayat Members 4 Representative of respective Village Members

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

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

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

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

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

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

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

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

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

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

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

http://en.wikipedia.org/wiki/Injection_(medicine)

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

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

ENVIRONMENTAL MONITORING PROGRAM...6 6.6.2.1. CER Plan by GIACL under existing Distillery Project

GIACL has received an environmental clearance to its 60 KLPD distillery in October 2017. Hence these activities are not completed. Capital investment of existing distillery project Rs. 41 Cr. under this project GIACL has earmarked an amount of Rs. 2.25 Cr. (5.48% of capital investment.) towards implementation of CER. Same was certified from BDO, Shevgaon. Copy of same is presented at appendix - I. Activities planned under 60 KLPD distillery are presented at table 6.4 and implementation schedule is presented at table 6.5.

Table 6.3 Existing Corporate Environmental Responsibility (CER) Planning

No. CER Activity Description of work Amount

1. Water Conservation Water Conservation - 10 Villages Dams / Bandharas / Bunds - De-siltation & Gr. Water Recharge; Renovation (30 Nos.)

Rs. 120 Lakhs

2. Education Infrastructure

Education Infrastructure-1Village Construction of Class Rooms and allied school infrastructure (1000 Sq.Ft) at New High School Ghotan; Tal. Shevgaon.

Rs. 35 Lakhs

3. Rural Sanitation - Rural Sanitation - 3 Villages 4 Toilet Units each of 6 Seats (3 Ladies + 3 Gents) with Water Tank of 500 Lit. & Septic Tank at Najik Babhulgaon (2 Unit), Ghotan (1 Unit) & Talani (1 Unit). 4 Units X Rs.7.5 Lakhs = Rs. 30 Lakhs.

Rs. 30 Lakhs

4. Water Supply Infrastructure.

Water Supply Infrastructure. -5 Villages Safe Drinking Water Units with Filtration, RO Module & Storage Tank (1Unit/ Village; 1000 Lit/Hr) - Najik Babhulgaon, Ghotan , Antarwali, Khanapur,& Karhe Takali

Rs. 40 Lakhs

Total Rs. 225 Lakhs ESR Rs. 2.25 Cr i.e. 5.48 % of Cap. Investment

Table 6.4 Existing CER Implementation Schedule

Sr. No. CER Activities Year

2018 Year 2019

Year 2020

Year 2021

Year 2022

Year of Completion

1. Water Conservation 30.0 20.4 27.6 21.0 21.0 2022 2 Education Infrastructure 17.5 17.5 -- -- -- 2019 3 Rural Sanitation - 7.5 7.5 7.5 7.5 -- 2021 4 Water Supply Infrast. 8.0 10 10 8.0 4.0 2022 Total (Amounts in Rs. Lakhs) 63.0 55.4 45.1 36.5 25.0 Expenditure in % 28.0 24.6 20.0 16.2 11.1

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ENVIRONMENTAL MONITORING PROGRAM...6 6.6.2.2. CER plan under Expansion of Distillery Project For expansion of distillery, capital cost is about Rs. 19.18 Cr. An amount of Rs. 50 Lakhs (2.5 % of capital cost of expansion of distillery). Detailed CER which is planned under expansion is presented at table 6.6. Same will be implemented as per implementation schedule mention in table – 6.7

Table 6.5 Proposed Corporate Social Responsibility (CER) Planning

No. CER Activity Description of work Amount 1. Awareness Camps

on Nature Awareness Camps on Environmental Protection for Schools, Colleges, Women Bachat gats by Industry in coordination with local NGO

Rs. 10 Lakhs

2. Provision of solar panels for street lighting and solar lamps in nearby villages

Cost of one solar panel = Rs. 5,000

Solar panels to be provided in 10 villages = 200 Nos.

Total cost for solar panels = Rs. 15 Lakhs

Note: A resolution between Industry and respective Grampanchayat will be done for maintenance of solar panels.

Rs. 15 Lakhs

3. Cost of one solar lamp = Rs. 1000

Solar lamps to be provided in 10 villages for 500 households = 500

Total cost for solar lamps = Rs.5 Lakh

Rs. 5 Lakhs

4. Conservation of Jaikwadi Bird sanctuary

For creating awareness in society towards Conservation of Jaikwadi Bird sanctuary.

Rs. 10 Lakhs

5. Education Infrastructure

Education Infrastructure-1Village Construction of allied school infrastructure at New High School Ghotan; Tal. Shevgaon.

Rs. 10 Lakhs

Total Rs. 50 Lakhs ESR Rs. 50 lakhs i.e. 2.5 % of Cap. Investment

Table 6.6 CER Implementation Schedule

Sr. No. CER Activities Year

2019 Year 2020

Year 2021

Year of Completion

1. Awareness Camps on Nature 3 3 4 2021 2 Provision of solar panels for street lighting

and solar lamps in nearby villages 8 8 4 2021

3 Conservation of Jaikwadi Bird sanctuary -- 5 5 2021 4 Education Infrastructure 10 -- -- 2019 21.0 16.0 13.0 Rs.50.0 lakh Expenditure in % 42.0 32.0 26.0

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ENVIRONMENTAL MONITORING PROGRAM...6 6.6.3. Measures for Improvement of Ecology Following steps should be taken. Afforestation in nearby villages. Keeping noise levels under control at night time. Keeping sufficient height of stacks. General guidelines - 1. Green belt of adequate width and density would be provided to mitigate the effects of

noise. 2. Plantation activities shall be done according to naturally occurring vegetation. Exotic

species shall be avoided. 3. Provision of shrubs and thick trees at storage and disposal places of the solid waste

would be made. 4. Trees would be planted along the roads, around solid waste storage area as well as along

the periphery. 5. All the necessary steps would be taken & care would be observed under the proposed

project regarding proper maintenance of the industrial premises. 6. Use of e-mail and other modern communication systems would be followed to conserve

the papers and attain speedy interaction in daily business activities. 7. Use of recyclable papers, if possible, would be done. 8. Promoting measures of energy and water conservation, wherever possible, would be

adopted.

6.7 ENVIRONMENTAL MONITORING PROGRAM SCHEDULE Following routine monitoring program as detailed in Table - 6.4 shall be implemented at site. Besides to this monitoring, the compliances to all Environmental Clearance conditions and regular permissions from CPCB /MoEFCC shall be monitored and reported periodically.

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ENVIRONMENTAL MONITORING PROGRAM...6

Table 6.7 Plan for Monitoring of Environmental Attributes in and around Industry

No. Description Location Parameters Frequency Conducted by

1 Ambient Air Quality Upwind-1, Downwind-2 (Near bagasse yard, Near compost yard, Near main gate, cane yard.) PM10, PM2.5, SO2, NOx, CO Monthly

MoEFCC and

NABL Approved External

Lab

Study area - (Villages namely - Najik babhulgaon, Talani, Rakshi, Ghotan, Raotale

2 Work Zone Air Quality

4 Locations (Mill section, Fermentation section, Sugar bagging section, Distillation section)

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

3 Fugitive Emissions Ethanol storage area & Distillation column VOC Monthly 4 Stack Emissions Boiler – 2 Nos. (Distillery & Co-gen boiler), D.G Set

– 4 Nos. SPM, SO2, NOx Monthly

5 Ambient Noise 5 Locations (Near main gate, Near ETP, near

Sugar godown , Near compost area, Near fermentation section)

Spot Noise Level recording; Leq(n), Leq(d), Leq(dn)

Monthly

Work zone Noise Premises – 5 Nos (Mill section, Distillation section, Boiler, DG set, Turbine section)

Spot Noise Level, recording; Leq(n), Leq(d), Leq(dn)

Monthly

6 Effluent Treated, Untreated pH, SS, TDS, COD, BOD, Chlorides, Sulphates, Oil & Grease.

Monthly

7 Drinking water Factory canteen Parameters as per drinking water Std IS:10500

Monthly

8 Soil 4 locations within 5 Km (Villages - Najik babhulgaon, Talani, Ghotan, Raotale, Malegaon)

pH, Salinity, Organic Carbon, N, P, K Quaterly

9 Water Quality (Ground Water & Surface Water)

Locations in study area - Ground Water and Surface Water

Parameters as per CPCB guideline for water quality monitoring – MINARS/27/2007-08

Quarterly

10 Waste management Implement waste management plan that Identifies and characterizes every waste associated with proposed and expansion activities and which identifies the procedures

Records of Solid Waste Generation, Treatment and Disposal shall be maintained

Twice in a year

By GIACL

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No. Description Location Parameters Frequency Conducted by

for collection, handling & disposal of each waste arising. 11 Emergency

Preparedness such as fire fighting

Fire protection and safety measures to take care of fire and explosion hazards, to be assessed and steps taken for their prevention.

On site Emergency Plan, Evacuation Plan, fire fighting mock drills

Twice a year

By GIACL

12 Health Check up Employees and migrant labour health check ups

All relevant health checkup parameters as per factories act.

Once in a Year

By GIACL

13 Green Belt Within Industry premises as well as nearby villages Survival rate of planted sapling In consultation with DFO.

By GIACL

14 CER As per activities -- Six Monthly By GIACL

Table 6.8 Environmental Monitoring Schedule within Industrial Premises

No.

Description Schedule of Monitoring

Sep Oct Nov Dec Jan Feb March April May June July Aug 1 AAQ √ √ √ √ √ √ √ √ √ √ √ √ 2 Workzone Air √ √ √ √ √ √ √ √ √ √ √ √ 3 Stack Emissions √ √ √ √ √ √ √ √ √ √ √ √ 4 Noise √ √ √ √ √ √ √ √ √ √ √ √ 5 Effluent √ √ √ √ √ √ √ √ √ √ √ √ 6 Drinking water √ √ √ √ √ √ √ √ √ √ √ √ 7 Fugitive Emissions √ √ √ √ √ √ √ √ √ √ √ 7 Waste management √ √ 8 Emergency preparednes, such as fire fighting √ √ 9 Health Check up √ 10 Green Belt √ √ √ √ √ √ √ √ √ √ √ √

Note: - Sugar Factory Operation period – 180 Days, Co-gen Operation period –180 Days During Season, 52 Days During Off Season, Distillery Operation period – 330 Days

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Table 6.9 Environmental Monitoring Schedule Surrounding Industrial Premises

No

Description Schedule of Monitoring Nov Dec Jan Feb March April May June July Aug Sep Oct

1 AAQ √ √ √ 2 Noise √ √ √ 3 Soil √ 4 GW & SW √ √ √ 5 CER √ √

6.8 COMPLIANCE WITH CREP GUIDELINES MoEFCC has launched the Charter on Corporate Responsibility for Environmental Protection (CREP) with purpose to go beyond the compliance of regulatory norms for control & prevention of pollution through various measures including waste minimization, in-plant process control & adoption of clean technologies. Chapter has set targets concerning conservation of water, energy, recovery of chemicals, reduction in pollution, elimination of toxic pollutants, process & management of residues that are required to be disposed off in an environmentally sound manner. Chapter enlists action points for pollution control for various categories of highly polluting industries. Task Force was constituted for monitoring progress of implementation of CREP recommendations/ action points. Following activities are being undertaken by GIACL and will be continued after proposed expansion under CREP norms. 1. Under existing unit spentwash was subjected to Bio-methanation followed by

concentration in MEE. Concentrated spentwash is used for bio-composting along with other filler material. After expansion the bio-methanated and concentrated spentwash will be subjected to ATFD to form powdered spentwash. Powdered spentwash will be mixed with boiler ash and used as manure in nearby fields.

2. Fuel for Boilers is methane gas which is generated subsequent to bio-methanation of distillery process. Methane is a clean fuel without any problems such as ash and particulate matter pollution which is generally the case with solid fuel burning.

3. Adequate storage capacity of molasses should be provided and molasses should not be stored in kutcha lagoon to avoid groundwater pollution.

4. Priority should be given to distilleries for lifting of press-mud for compost making with the spent wash.

5. Sugar wastewater generation is 100 liters per ton of cane crushed. 6. Fresh water consumption for distillery after expansion will be 0.27KL/KL of alcohol for

sugar crushing season and for non sugar cane crushing season same will be 1.8 KL/KL of alcohol; whereas norm is 10 KL/KL of Alcohol.

7. Raw spentwash generation rate in distillery after expansion will be 7.8 KL/KL of alcohol while conc. spentwash generation will be generated at the rate of 2.9 KL/KL of alcohol whereas norm is 10 KL/KL of Alcohol.

8. Treated water from existing CPU is recycled back in process. Same practices will be followed after expansion of distillery also.

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Chapter 7

ADDITIONAL STUDIES

ADDITIONAL STUDIES…7

7.1 PUBLIC CONSULTATION As per EIA notification 14th September 2006 and standard ToR’s issued by Expert Appraisal Committee (EAC) Ministry of Environment, Forest and Climate Change (MoEFCC), New Delhi Letter No. J-11011/91/2018-IA II(I) dated 14.04.2018. GIACL has conducted Public Hearing (PH) on 17.10.2018 for expansion of molasses based distillery from 60 KLPD to 150 KLPD. 7.1.1 Details of Public Hearing Date of Public Hearing : 17.10.2018 Place of Hearing : At the Factory site of Gangamai Industries And

Construction Ltd.. Najik Babulgaon, Post- Rakshi, Tal.:Shevgaon, Dist.: Ahmednagar, Maharashtra State

Advertisement given : 10.09.2018 News Paper : ‘Lokamat’ (Marathi), Times of India (English)

Copies of news enclosed at Appendix N Members Present :

1 Shri Prashant Patil Additional District Magistrate, Nagar Division Ahmedngar

Chairman

2 Shri P. M. Joshi Regional Officer, Maharashtra Pollution Control Board, Ahmednagar

Convener

3. Shri Ajit Patil Sub-Regional Officer, Maharashtra Pollution Control Board, Ahmednagar

Convener

7.1.2 Minutes of Public Hearing

No. Points Presented by

Public Response Given by PP Remarks

1. Shri Bhagavan Dhorkule, R/o Najik Babhulgaon asked which products will be manufactured under this project?

Consultant replied that in this proposed project industrial alcohol, Extra Neutral Ethanol are the products and Fusel Oil, Biogas Carbon Dioxide are byproducts

Ref.: Chapter-2, Section 2.6, table 2.6 for details of products.

2. Shri Sandip Baban Motkar, R/o Ghotangaon Whether air pollution can cause disease to human beings and what preventive action will be taken by project proponent to control it?

Consultant replied that GIACL will take preventive action that there will be no pollution, for that Project Proponent will install most modernized fully automatic treatment systems and no smell spread out in the air.

Ref.: Chapter-2, Section 2.7.2 for details of air pollution.

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No. Points Presented by Public

Response Given by PP Remarks

3. Shri Tukaram Joshi, R/o Khanapur asked that how many days this project will run and how many days the plant works in one year.

Consultant replied to public that plant will be working 330 days in a year. The project will go on depends upon the demand as there is heavy demand of Ethanol, due increase in petrol prices.

Ref.: Chapter-2, table 2.4 for detailed operational days of GIACL.

4. Namdeo Kanhe, R/o Talani asked how alcohol is manufactured and processed in the plant.

Consultant replied that alcohol is manufactured by means of micro organism viz. Yeast through fermentation and distillation. The storage of alcohol is for limited period only (One Month Storage in vertical Cylindrical M.S. Tanks).

Ref.: Chapter-2, section 2.6.2 for detailed manufacturing process of distillery.

5. Shri Shivaji Kshirasagar, R/o Ghotan asked that what developments the project is providing to the nearby villages and villagers? & What Development Plan Industry is Going to have?

Consultant replied that GIACL had provided employment to 600 youths in the surrounding area based on their qualification and experience. It will be continue in future also. GIACL had constructed few KM Tar roads and so many roads in nearby villages are repaired by means of GIACL Machinery on demand of residents it will be continue in future also.

Ref.: Chapter-8, section 8.2 for existing CER done by GIACL. Ref.: Chapter 6, section 6.6, table 6.4 & 6.6 for detailed CER plan.

6. V. Sunanda Reddy, Environmentalist- In General regarding Environment and he Stated that he Supports Said Project and Congratulated Said Project Proponent.

Environmentalist V. Sunanda Reddy had supported to Gangamai for the proposed expansion. He appealed to the panel members to recommend the proposed expansion, which GIACL has applied for, to the MoEFCC New Delhi.

--

7. Shri Sopan Dhorkule, R/o Najik Babhulgaon asked that is there any air pollution from this project, whether there is any wastage of water from the plant, whether the plant will repair the damaged roads and whether the plant will provide employment to the nearby villagers from the above expansion?

A GIACL propose to install ATFD Dryer to concemtrate the spent wash resulting in granular powder there will be no air pollution. GIACL had provided employment to 600 youths in the surrounding area based on their qualification and experience. It will be continue in future also. GIACL had constructed few KM Tar roads and so many roads in nearby villages are repaired by means of GIACL

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No. Points Presented by Public

Response Given by PP Remarks

Machinery on demand of residents it will be continue in future also.

8. Shri Jalindar Labade, R/o Kharadgaon asked how much alcohol per day will be produced from plant.

Consultant replied that 150 KL of alcohol will be produced per day.

--

9. Shri Arun Katkade, R/o Ghotan asked is the arrangement for production of Alcohol and Storage?

It was informed to public that most modernized fully automatic machinery producing Alcohol will be installed.

Ref.: Chapter-2, section 2.6.2 for detailed manufacturing process of distillery.

10. Shri Sachin Shelke, R/o Ghotan asked if there is fire then what is the facilities available with plant to control the fire

GIACL has all the standard equipments as per MPCB/ Industrial health and safety Law to control the fire. In case, fire is there in the plant. The plant has also ample quantity of water storage for prevention of fire and control the fire, if exists in plant.

Ref.: Chapter-7, section 7.3 and appendix – for for detailed manufacturing process of distillery.

11. Shri Pradeep Tanvade, R/o Shevgaon asked how much spent wash will be produced by the plant and what arrangement has been done by the plant to dispose it.

After expansion Spent wash generation will be 1200 M3 Treatment System will be Bio-methanation - Evaporation followed by ATFD Dryer resulting in Dry granular Powder. The Condensate recovered from the Evaporators and dryers will be treated in CPU and reused for Process.

Ref.: Chapter-2, section 2.7, for detailed of water pollution.

7.2 R & R ACTION PLAN There is no R & R action plan because proposed expansion shall be taken up in existing premises of distillery and sugar factory of GIACL located at Najik Babhulgaon, Post: Rakshi, Tal.: Shevgaon, Dist.: Ahmednagar, Maharashtra. 7.3 POTENTIAL AND MAJOR HAZARDS IN SUGAR FACTORY Process for manufacturing and refining sugar is a standard process. he risk assessment and hazard management study was done by Mr. Vinod Sahasrabude who is FAE for RH in respect of EEIPL. Areas of concern from hazard and risk points of view in the plant manufacturing of sugar are as follows-

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7.4 OBJECTIVES AND SCOPE OF THE RH REPORT: 7.4.1 Objective of the Risk and Hazard analysis is to 1) Identify hazards and nature of hazard in the process, storage and handling of hazardous

chemicals. 2) Carry out Qualitative risk analysis for the process and suggest mitigation measures. 3) Carry out Quantitative risk analysis of the storage of hazardous chemicals and estimate

the threat zones for Most Credible and Worst case scenarios 4) Suggest mitigation measures to reduce the risk/probability of the accident to the

minimum. 5) Incorporate these measures for ensuring safe operations and safe layout to mitigate hazard

and for effectively encounter any accident reduce the damages to the minimum. 6) Help in preparation of preparation of On-site and Off-site emergency plans 7) Suggest Guidelines for on-site and off - site emergency plan 7.4.2 Methodology 7.4.2.1. Identify hazards based on • Processes description received based. • Identify Hazardous Chemicals handled and stored. • Inventory of Hazardous chemicals • Proposed storage facilities for hazardous chemicals • Plant layout • Safety measures to be adopted by the company 7.4.2.2. Hazard Assessment • By Qualitative Risk Assessment • By Quantitative Risk Assessment by Hazard index calculations and estimate threat zones

by using ALOHO

7.4.2.3. Recommendations • Recommend mitigation measures based upon the above • Recommending guidelines for the preparation of On-site Emergency plan. 7.5 HAZARD IDENTIFICATION 7.5.1. Identification of types of Hazards in Distillery Potential hazardous areas and the likely accidents with the concerned area have been enlisted below-

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Table 7.1 Possible Hazardous Locations onsite

Sr. No.

Hazardous Area

Hazard identified

Mitigation measures Mitigation measures in place

/have to be in place for running

plant

Comments/ Additional measures

1 Boiler Area Explosion IBR rules for design, maintenance and operation of boilers by certified boiler attendants in mandatory

These measures are in place as the boiler is in operation for the existing capacity.

Will be adopted for the additional boiler capacity

2 All over the plant

Lightening To design and install adequate number of best available lightening arrestors.

These measures are in place as the boiler is in operation for the existing capacity.

If additional are required for increased area of operations these will be installed

3 Electrocution Lose fitting Regular maintenance, internal safety audit, and external safety audit at regular intervals.

These are in place for the operation of the existing capacity

4 Electrical rooms

Fire and electrocution

Regular maintenance, internal safety audit, and external safety audit at regular intervals.


5 Transformer area

Fire and electrocution



6 Cable tunnel Fire and electrocution



9 Alcohol production area

Fire and Alcohol vapour release

HAZOP study is strongly recommended for the production as well as Alcohol Storage area. And adequate safety instrumentation with alarms and interlocks to be incorporated to make the design and plant operation

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Sr. No.

Hazardous Area

Hazard identified

Mitigation measures Mitigation measures in place

/have to be in place for running

plant

Comments/ Additional measures

intrinsically safe. 10 Distillery

(ethanol storage tank)

Fire Detailed measures have been suggested in the report, in the later part. And QRA results and based on failure frequency risk has been calculated. Fire hydrant will be laid around with foam fighting arrangements.

7.5.1.1. Mitigation Measures to avoid accidents: (A) Preventive Measures for Electricity Hazard:

• All electrical equipment is to be provided with proper earthing. Earthed electrode are

periodically tested and maintained. • Emergency lighting is to be available at all critical locations including the operator’s

room to carry out safe shut down of the plant. • Easy accessibility of fire fighting facilities such as fire water pumps and fire alarm

stations is considered. • All electrical equipments to be free from carbon dust, oil deposits, and grease. • Use of approved insulated tools, rubber mats, shockproof gloves and boots, tester, fuse

tongs, discharge rod, safety belt, hand lamp, wooden or insulated ladder and not wearing metal ring and chain.

• Flame and shock detectors and central fire announcement system for fire safety are to be provided.

• Temperature sensitive alarm and protective relays to make alert and disconnect equipment before overheating is to be considered

• Danger from excess current due to overload or short circuit is to be prevented by providing fuses, circuit breakers, thermal protection

(B) Fuel Storage:

• Workers to be trained to be vigilant and keep water hose with ready water supply to extinguish small fires during hot season.

• Fire fighting measures, alarm measures and fire hydrant line to be provided around the Baggase storage area to immediately and effectively deal with fire. This is already in place.

• Measures are taken to control the air pollution during loading/handling coal

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7.6 ACCIDENTAL RELEASE MEASURES, SAFETY MEASURES FOR STORAGE & HANDLING

7.6.1 Distillery Plant

7.6.1.1. Alcohol Handling and storage -

Keeping away from heat, sparks and open flame, care will be taken for avoidance of spillage, skin and eye contact, well ventilation, Use of approved respirator if concentration of alcohol in air is above acceptable level will be promoted. For Storage and handling following precautions will be taken: • Keeping away from oxidizers, heat and flames. • Cool, dry, & ventilated storage and closed containers. • Grounding of the container and transferring of equipment to eliminate static Electric

sparks. 7.6.1.2. Establishing a Fire Fighting Group

A small spark of fire may result into loss of lives, machines and the damage by fire may result in high economic losses. This type of losses can be avoided by preventing and controlling the fire instantly for which fire–fighting group will be established. Fire fighting group would house and keep in readiness, the following types of equipment and arrangements. • CO2 extinguishers • Dry powder chemical extinguishers • Foam extinguishers • 80 mm. spray hoses • Fire brigade

7.6.2 Sugar Production Plant Hazard Identification - Following areas in Sugar Production are identified as hazard prone: 1. Bagasse Storage: For fire 2. Molasses storage: Environment hazard on leakage and likely fire and explosion 3. Sulphur Storage and SO2 production: Fire and toxic gas leakage affecting workers.

7.6.2.1. Bagasse Storage

The company has 23,000 Sq. M. of area reserved for the storage of Bagasse, used as fuel for the boiler.

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Fire hazard Bagasse is produced after crushing of sugar cane. In dried form it is used as fuel for boiler. Small spark or ignition will cause fire and will spread rapidly leading to injury and loss of life, and damage to the property. 7.6.2.2. Mitigation Measures

Following mitigation measures to eliminate the fire hazard are in place and some additional measures are suggested as below: 1. It should be ensured while routing high tension voltage lines to avoid storage of bagasse

storage below & near high voltage (H.T.) transmission lines. Avoid routing of electric supply cables &cable trenches near to bagasse storage and if unavoidable locate these as far away from stored bagasse or bagasse heaps. 2. Always keep other raw materials & useful material far away from storage of bagasse area. 3. Installation of Fire Hydrant (self auto-mode fire fighting) system around the area of

bagaasse yard. Fire hydrant has been/will be laid around the bagasse storage area as shown in the drawing mentioned above. Fire hydrant system will be designed as per IS code and as per the applicable relevant code.

4. Creating awareness among workers about sudden bagasse fire and emergency action plan will definitely avoid risks of heavy fire. In this way we can save a valuable fuel & life of human being working near bagasse.

5. Posting of proper supervision staff with necessary communication facility. 6. Hot work, like welding, gas cutting should not be carried out near bagasse storage. Or

only after issue of proper work permit and making necessary arrangements 7. Daily record of bagasse storage data must be maintained and proper review of storage

conditions must be taken by higher authority. 8. Training of all the involved staff in firefighting in normal & emergency operating system. 9. Proper planning & installation of fire hydrant system around the bagaase storage yard and

should not depend exclusively on fire tender for fire fighting. 10. Creating awareness among workers about sudden bagasse fire and emergency action plan

will definitely avoid risks of heavy fire. In this way we can save a valuable fuel & life of human being working near bagasse.

7.6.2.3. Sulphur Storage

Storage and handling of Sulphur: Exposure to dust, dust explosion, Hazard Identification Sulphur 50 MT is MT is stored in a closed shed of area in a warehouse of 315 sq m area. It is transferred manually to the SO2 production unit manually as per the requirement in bags. Following are the hazards in storage and handling Sulphur.

1. Dust Explosion 2. Fire

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1. Dust Explosion As Sulphur is stored and handled in granular form, there is always some dust formation, which can lead to dust explosion. A dust explosion occurs when a fine dust in suspension in air is ignited, resulting in a very rapid burning, and the release of large quantities of gaseous products. This in turn creates a subsequent pressure rise of explosive force capable of damaging plant and buildings and injuring people. It is generally considered that a dust explosion can only be initiated by dust particles less than 500 microns diameter. Conditions for a Dust Explosion Following conditions are necessary before a dust explosion can take place. (a) The dust must be combustible. (b) The dust cloud must be of explosive concentration, i.e. between the lower and upper explosion limits for the dusts. Sulphur is a flammable substance in both the solid and liquid states. The dust is characterized by a very low ignition point of 190°C compared to other combustible dusts, and dust clouds are readily ignited by weak frictional sparks. Dusts containing 25% or more elemental Sulphur may be almost as explosive as pure sulphur. (c) There must be sufficient oxygen in the atmosphere to support and sustain combustion. (d) A source of ignition must be present. (e) The dust must be fine enough to support an explosion. Mitigation Measures: Explosion Prevention: Dust explosions can be prevented by ensuring that the following conditions are met: • Formation and Suspensions of Sulphur dust in air are avoided. a. To prevent dust formation during the storage and handling of Sulphur, it is necessary to

take necessary precautions to avoid spillage and crushing of granular Sulphur during bulk loading and unloading in the storage area.

b. Storage shed should be constructed with a minimum number of horizontal surfaces to avoid dust must accumulation.

c. Bulk accumulations of fine Sulphur may also be removed using soft push brooms, having natural bristles and non-sparking scoops or shovels before vacuum cleaning equipment is used.

d. The use of compressed air to remove dust from any surface, vigorous sweeping or any other method of cleaning which may raise a dust cloud is prohibited.

e. All sources of ignition are excluded. f. Presence of moisture helps in preventing dust explosion. 2. Fire in Sulphur storage:

There is a risk of fire in Sulphur storage as ignition temperature is low 190 deg C. Solid and liquid Sulphur will burn to produce Sulphur dioxide gas, which is extremely irritating and toxic. The effects of the fire hazard itself are slight.

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Mitigation Measures: • Smoking and the use of matches shall be prohibited in all areas where sulphur dust is

likely to be present. Prominent NO SMOKING signs shall be placed around such areas. • Naked flames or lights and the use of gas cutting or welding equipment is prohibited

during the normal operation of the plant. Repairs involving the use of flames, heat, or hand or power tools in areas where sulphur may be present shall be made only after getting hot work permit from the authorities.

• Where this is not possible the sulphur shall be wetted down. 7.6.2.4. Safety and Fire Fighting Tips

• Always use Self Contained Breathing Apparatus (SCBA). Sulphur fires produce

hazardous sulphur dioxide gas. Sulphur dioxide gas is heavier than air and will accumulate in the vapour spaces of the rail car.

• Automatic sprinkler systems which comply with relevant Indian Standards and provide a fine spray or mist are recommended as the most satisfactory extinguishing system for bulk stores. Fire hoses and extinguishers must be fitted with fine spray nozzles to ensure that Sulphur dust clouds are not raised, as these can explode on contact with the fire.

• Small Sulphur fires are easily extinguished by adding more sulphur on top of the burning Sulphur. This depletes the oxygen and smothers the fire.

• For larger Sulphur fires use a light water fog or CO2 to extinguish. Do not use heavy water streams as this may create Sulphur dust which could potentially explode.

7.6.3 Sulphur di oxide (SO2) production and handling: 7.6.3.1. Hazard Identification Company has standard SO2 production facility. The description given below: is for standard plant normally operated in Sugar manufacturing plants. Standard plant has Sulphur di oxide(SO2) production unit. The existing production capacity is adequate to cater to the additional requirement of Sulphur di oxide(SO2) for increased production. The unit produces required amount of Sulphur di oxide(SO2) at the required rate by changing sulphur feed to the melter at a temp of 120 to 150 deg C , it is melted at and charged to the burner chamber, where in the air at controlled rate is fed to burner to produce Sulphur di oxide(SO2). Gas at high temp of 400 to 600 deg C, secondary air is passed to secondary after burner at 250 -300 deg C. It is cooled to 70 to 80 deg C in secondary cooler and sent to the user unit through 100/150 mm piping at 1.5 to 1.7 atm pressure with approximate length of 20 meters. This is unit designed for insitue production and use of Sulphur di oxide(SO2). There is practically no inventory of gas in the Sulphur burner unit and the inventory of the gas is in the pipeline from the unit to the sulphiter only. Major hazard is leakage, being toxic it can lead to serious injuries and health concerns.

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7.6.3.2. Mitigation Measures suggested and measures which are in place A. Safety Precautions in place 1) Handling.‐ Safety goggle &hand gloves used. 2) If SO2 gas leakage first air stopped by manually and leakage attend. PPEs including Self Breathing Apparatus and gas masks should be readily available at the operation site. 1) Eye – Contact with eye immedetely flush with clean water for 15 min. seek medical attention. 2) Skin – Remove contaminated clothing wash contaminated area by soap there may burn immediate medical attention. Eye showers should be installed in the near vicinity. 3) Vomiting occurs medical attention. 4) Inhalation ‐ Remove person to fresh air seek medical attention immediately. B. Other additional mitigation measures suggested 1) Standard Operating Procedure (SOP) for the unit SHOULD BE available. 2) Emergency Shutdown procedure SHOULD BE available. Operators are trained. 3) Emergency Shutdown procedure, in local language should be displayed. 4) SO2 leak detectors can be installed in the plant for early warning. 7.6.3.3. Hazard quantification Following are the toxic properties of SO2 NFPA rating N(H)=3, N(F)=0 and N(R)=0, TLV= 2 ppm Toxicity Index Toxicity Number: The toxicity number (Th) is derived from the NFPA health factor Nh. Nh is an integer number ranging from 0 to 4.

Table 7.2 Toxicity Number

Nh 0 1 2 3 4 Th 0 50 125 250 350

PENALTY FACTOR: The Penalty Factor (Ts) is the second toxicity parameter used to determine the TI. The Ts value is derived from the ‘Threshold Limit Values (TLV)’. The TLV-values are drawn up by the American Conference of Governmental Industrial Hygienists. TLV represents a time weighted average (TWA) air concentration to which workers can be exposed during a normal working week of 6 days at 8 hrs per day, without ill effects. The penalty factor is determined from the table below:

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Table 7.3 TLV Level

TLV <5 5-50 >50 Penalty factor Ts 125 75 5

Toxicity Index TI= Th+Ts/100 X (1+1.75+2.4) TI= 250+125/100 (5,15) = 3.75X 5.15, which is equal to 19.3 Resulting TI values are ranked into three categories: 1-5 Light 6-9 Moderate 10-up High Hence Toxicity index is in HIGH range. Sulphur di oxide is produced by oxidation of molten Sulphur in situ in a standard readymade unit as described above and is used in Sulfitation of Sugar cane juice. There is no storage of Sulphur di oxide, as it is produced at the consumption rate and when required.

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7.6.3.4. Quantitative Risk Analysis (QRA)

Sr. No.

Name Of Chemical Site Data Chemical Data Atmospheric

Data Source Of Chemical Source Strength Threat Zone

1. SULFUR DIOXIDE

• Location: GANGAMAI INDUSTRIES AND CONS, INDIA

• Building Air

Exchanges Per Hour: 0.65(unsheltered single storied)

• Chemical Name: SULFUR DIOXIDE

• Molecular Weight: 64.06 g/mol

• Ambient

Boiling Point: 11.2° C

• Vapor Pressure

at Ambient Temperature: greater than 1 atm

• Ambient Saturation Concentration: 1,000,000 ppm or 100.0%

• Wind: 3 meters/second from NW at 10 meters

• Ground Roughness: open country

• Cloud Cover: 0 tenths

• Air Temperature: 35° C

• Stability Class: C

• No Inversion :Height.

• Relative Humidity: 5%

Gas flow through pipe

• Non-flammable gas is escaping from pipe

• Pipe Diameter: 15 centimeters

• Pipe Length: 30 meters

• Unbroken end of the pipe is closed off

• Pipe Roughness: smooth

• Hole Area: 177 sq cm

• Pipe Press: 2.7 atmospheres

• Pipe Temperature: 50° C

• Release Duration: 1 minute

• Max Average Sustained Release Rate: 37.4 grams/sec (averaged over a minute or more)

• Total Amount Released: 2.24kilograms

• Model Run: Heavy Gas

• Red : 72 meters --- (100 ppm = IDLH)

• Orange: 873 meters --- (0.75 ppm = AEGL-2 [60 min])

• Yellow: 1.45 kilometers --- (0.2 ppm = AEGL-1 [60 min])

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Mitigation Measures suggested and based on QRA: 1. Before the plant start up and every six months, pressure test and thickness test of all the

equipments and piping carrying Sulphur di oxide must be carried out to avoid leakage. 2. There must be alarm system, in case, SO2 leakage is suspected and detected by smell, to

warn all workers of the leakage. 3. SO2 leak detectors may be installed. 4. All operators must be aware of Emergency Shutdown procedure and action to be taken to

warn authorities to sound alarm. 5. Emergency Shutdown procedure and action to be taken should be displayed in the SO2

production area in the local language. 6. It should form an important part of mock drill to be carried out as per on-site emergency

plan. 7. In case of leakage as envisaged in MCA of flange joint leakage, area around SO2

production unit and part of the main plant must be vacated immediately. 8. In case of major leakage as envisaged in first case, if there is sudden breakage of pipeline

there will be Immediate Danger to Life and Health in the area within 50-60 meters area around 120 meters to 700 meters will be heavily affected and full onsite emergency plan for the entire plant will have to put in action and if necessary population around 1 to 1.5 km will have to be warned.

9. In case the leakage is through the 5 mm hole, and the action is not taken for 30 minutes the area affected is predicted in the second case.

10. The workers in the area should wear SCBA before taking action to plug the hole or any rectifying action. All workers in the vicinity of 300 meters should be evacuated.

7.6.4 Co-generation plant The company has 32 MW capacity Co-gen plant. 1. In distillery, steam will be taken from existing 8 TPH capacity boiler which is operated by

using Biogas as fuel with normal operating pressure of 3.43 bar. Also, existing boiler from sugar factory having capacity 30 TPH and bagasse as fuel will be modified to 40 TPH under distillery expansion. Steam will be taken from this boiler too. Normal operating pressure of this boiler is 3.43 bar.

The boiler is as per IBR design standards, maintained and approved by IBR authority’s rules and regulations. The steam produced is used for power generation through turbine and the extracted steam is used for internal consumption for Sugar plant and Distillery operation. The boiler and Co-generation unit incorporates all the necessary instrumentation, alarms and interlocks and is operated through DSC system to ensure the safe operation. Hazard identification: Heavy high pressure steam leakage, resulting in noise pollution, and in the worst case explosion involving boiler. Mitigation measures should be place: 1. As mentioned above all the precautions and mitigation measures as per the statutory rule

are in place and are strictly observed.

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2. Important interlocks such as boiler water control, fans tripping on backfire, steam pressure, noise have been provided for boiler.

3. Turbine and power generation plan is PLC operated sequential start up and shutdown procedure built in. The plant is equipped with standard instrumentation, alarms, and interlocks, trips, such high speed trip, bearing vibration, bearing oil circulation, oil temperature, and turbine alignment.

Note: Detailed Alarm and interlock system for Boiler and Co-gen plant, which are standard features of Co-gen plant, is given in Appendix P

7.7 FIRE HAZARD 7.7.1. Sugar Factory – Molasses Storage 1. There are 5 molasses storage tanks and details of same are as follows –

No. Description Tank Details Dimensions Remark 1 Molasses Storage Tanks

(In Sugar Factory) Quantity: 2 Capacity: 10,000MT each

Diameter – 30 m Height -10 m

Existing Tanks



Diameter 25 m Height -10 m

Existing Tanks



Diameter –28 m Height -10 m

Expansion Tanks

Mitigation Measures: It is necessary to take following mitigation measures to prevent bursting of tanks, and heavy leakage and loss of life. Hazard Identification: Areas of concern are -Molasses storage: Heavy leakage of Molasses, total breakage of tank, leading to loss of life and pollution.

Mitigation Measures- Storage of Molasses 1. Molasses should be stored in good quality and leak proof mild steel tanks. 2. Adequate safety factor should be incorporated into the design of wall thickness

considering deterioration that will occur due to corrosion over a period of time. 3. Regular internal and external inspection should be scheduled for checking wall thickness

of the tanks. 4. Dyke/ Bund walls should be constructed around the tank or tanks. 5. It must be ensured while finalizing the dyke dimensions and that thickness that clear

volume inside the dyke walls is equal or more than 1.2 x volume of tank storage capacity. 6. Continuous mixing of molasses through external pump circulation should be done. 7. If there is increase in temperature beyond 300C external cooling of tanks shall be

provided by heat exchanger in the circulation line. 8. Frequent Temperature monitoring, manually or by recorder is strongly advised.

If there is leakage –

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a. Leakage should be washed out and diluted and should be recycled as far as possible or must be properly treated in Effluent treatment plant.

b. Replacing of leaky gaskets, joints, should be done strictly by following work permit system.

c. Leakage of pipelines, welding repairs should be attended / carried out outside the plant. The necessary hot work permit should be issued after taking necessary precautions and fire fighting measures for onsite hot work, by the concerned authority before any hot work in undertaken

d. Leakage through pump gland shall be reduced to the minimum by installing mechanical seals.

e. To attend all major leakage in tanks the following procedure should be followed (i) Transfer the material to other tank. (ii) Prepare the tank for welding repairs by making sure that it is positively isolated with

blinds from other vessels and ensuring that it is free of the chemicals and gases by purging air and carrying out air analysis before any hot work is undertaken and this should be done by skilled workers. For this purpose safety permit should be given.

f. During the shutdown Molasses tank are emptied for cleaning sludge and maintenance. General practice is to manually remove the sludge/tank bottoms and drain this in the open without treatment. If such practice is being followed, It is strongly recommended to discontinue this practice and use pump/suitable for pumping viscous sludge by diluting it and let out after proper effluent treatment.

7.7.2. Distillery – Alcohol Storage The Company proposes to expand distillery capacity from 60 KLPD to 150 KLPD by increasing additional facility of 90 KLPD. For this company proposes to achieve this by installing additional equipments. List of additional equipments in appendix - E , additional Alcohol storage tanks is given in chapter – 2 Hazard Identification Major hazard identified in the production unit is release of alcohol vapours and fire. It is recommended to eliminate the risk and hazard at the design stage of the expansion itself by carrying out detailed systematic HAZOP study of the entire process and make the process and operation intrinsically safe. Major area of concern from Risk and hazard is Alcohol storage: NFPA rating for Alcohol is NH (Helth Factor) NF (Fire Factor) NR (Reactivity) NF= 3, NH = 2 and NR=0, indicating fire as the major hazard in handling and storage of Alcohol

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Qualitative Risk analysis: For the storage of alcohol Fire and Explosion index has been calculated to be 72 based on the Material Factor MF= 16 and storage conditions (Degree of Hazard is rated based on of Fire and explosion index as follows )

Table 7.4 Degree of Hazard and F&EI Index

F&EI Index Range Degree of Hazard 1-60 Light 61-96 Moderate 97-127 Intermedite

128- 158 Heavy MORE THAN 159 Severe

F&EI index is in the range of moderate Mitigation Measures: 1. Based on standard recommendations for moderate hazard is it is recommended to have

Alcohol storage tanks should be in open in dyke walls and must have spill collection and control (recycle) arrangement to pump into another tank.

2. As indicated the storage should be in open with dyke walls. It is indicated that the dyke wall with 25 M X 25 M and 0.25 M thick has been provided with drain pit valve and transferring the leakage through the pump.

3. Clear distance between tanks will be provided as per the requirement of Petroleum Rules Table 1 SCHEDULE II. Particularly for storage tanks mentioned in 8, 9, and 10 in the table given above.

4. Location of pumps, location of tank farm in the factory should be as per the requirements of Petroleum rules.

5. Proper firefighting system, inside the plant and around the storage tanks has been designed as per IS or international code. And is shown in the factory layout drawing. And Fire NOC will be obtained.

6. Fire fighting around Alcohol storage will be as per the accepted IS or international standard with sprinkler system and foam based fire fighting arrangement.

7. As the QRA reveals the distance between two tanks should be minimum ½ the tank diameter, as in case of even pool fire the tanks too close less than flame length of 4 meters will get heated directly leading to a bigger disaster of BELEV.

8. This also emphasizes the need for tank cooling as per acceted norms. 9. Quantitative Risk Analysis: 10. F&EI index can also be used for estimating the damage that would probably result from

the accident/fire. And it is converted to radius of exposure by multiplying it by 0.84 to feet. Thus radius of exposure in this case will be 0.84X72= 60 feet or 18 meters

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7.7.2.1. QRA for existing Alcohol storage tanks:

Sr. No.

Name Of Chemical Site Data Chemical Data Atmospheric

Data Source Of Chemical Source Strength Threat Zone

1. ETHANOL

• Location: GANGAMAI INDUSTRIES AND CONS, INDIA

• Building Air

Exchanges Per Hour: 0.65(unsheltered single storied)

• Chemical Name: Ethanol

• Molecular Weight: 46.07 g/mol

• Ambient Boiling Point: 77° C

• Vapor Pressure at Ambient Temperature: 0.14 atm

• Ambient Saturation Concentration: 144,032 ppm or 14.4%

• Wind: 5 meters/second from NE at 3 meters

• Ground Roughness: open country

• Cloud Cover: 0 tenths

• Air Temperature: 35° C .

• Stability Class: C

• No Inversion :Height.

• Relative Humidity: 5%

• Leak from hole in vertical cylindrical tank

• Flammable chemical is burning as it escapes from tank

• Tank Diameter: 11 meters • Tank Length: 11.5 meters • Tank Volume: 1,093 cubic

meters • Tank contains liquid

Internal Temperature: 35° C • Chemical Mass in Tank: 749

tons Tank is 80% full • Circular Opening Diameter:

0.01 meters • Opening is 0.58 meters from

tank bottom • Max Flame Length: 2 meters • Burn Duration: ALOHA

limited the duration to 1 hour • Max Burn Rate: 3.61

kilograms/min • Total Amount Burned: 209 kilograms Note: The chemical escaped as a liquid and formed a burning puddle. • The puddle spread to a

diameter of 1.7 meters.

• Threat Modeled: Thermal radiation from pool fire

• Red : less than 10 meters(10.9 yards) --- (10.0 kW/(sq m) = potentially lethal within 60 sec)

• Orange: less than 10 meters(10.9 yards) --- (5.0 kW/(sq m) = 2nd degree burns within 60 sec)

• Yellow: less than 10 meters(10.9 yards) --- (2.0 kW/(sq m) = pain within 60 sec)

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7.8 FIRE FIGHTING DETAILS AS FOLLOWS: The company has adequate water storage reserved for fire fighting, main fire hydrant pump, pump running on HSD, alarm system. Details are as follows -

1. Water storage for firefighting = 2500 M3

2. Hydrant line pressure = 7.5 kg/cm2

3. Number of hydrant point =5 4. Main hydrant pump capacity = 171M3/hr 5. Jockey pump capacity = 10.8M3/hr 6. Jockey pump starts at = after opening of Fire hydrant valve 7. Jockey pump starts at = 8. Main pump starts at = after start of jockey pump 9. Diesel pump starts at = in absence of power after start of jokey pump 10. Stops manually IS Code or International code used for design of fire hydrant system is laid and will be modified before expansion. Foam based fire extinguisher system will be laid around the alcohol storage. 7.9 ON-SITE EMERGENCY PLAN It was informed that that company has prepared on-site emergency plan for the existing facilities. This has to be implemented completely taking into consideration the safety audit report and conducting regular mockdrills. It is suggested to modify the same for the expanded capacity taking in to consideration Quantitative Risk analysis results given above and Mitigation measures and other suggested above. 7.9.1. Safety Measures during regular and shut-down: It must be remembered that shutdown plant are also and sometimes more prone to accidents. Hence it is suggested that all workers, regular and contract workers should be issued proper PPE, like helmet, safety shoes etc. as necessary. All work, hot work, working at height etc. during working and shutdown period should be carried out with proper work permit and under proper supervision. 7.9.2. DMP It is part of On-site Emergency plan as it is stand alone industry and has to co-ordinate with local and nearest hospitals, police, fire brigade and Government officials. 7.10 OCCUPATIONAL HEALTH ASPECTS & MEDICAL PROVISION IN GIACL 7.10.1. Facilities available to workers i) Full time medical officer. ii) OHC with 2 rooms equipped all emergencies iii) one compounder and one ward boy An ambulance with driver 24 by 7 iv) Regular medical check up of workers carried out, as per the requirements of Factory

act and reports are available in the factory records

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7.10.2. Effects of Alcohol on Health

Following is the additional information and suggestions with regard alcohol exposure – It reacts vigorously with oxidizing materials. TLV for 8 hr. is 1000 ppm (ACGIH). Minimum identifiable concentration has been reported as 350 ppm. Exposure to concentrations of 5000 - 10000 ppm results in irritation of eyes and mucous membranes of the upper respiratory tract. Effects of exposure to higher concentration of Alcohol in the atmosphere are given in the following table

Table 7.5 - EFFECT OF ETHYL ALCOHOL

mg/l Ppm Effects in human 10-20 5300 –

10,640 Some transient coughing and smarting of eyes and nose, not tolerable

30 15,960 Continuous lacrimation and marked coughing; could be tolerated with discomfort.

40 21,280 Just tolerable for short period > 40 >21,280 Intolerable

To prevent injury to workers, standard PPEs will be provided. In addition, sufficient number of Self-contained breathing apparatus will be provided to be used in case of major alcohol leakage to avoid exposure to higher levels of Alcohol.

All precautionary methods will be adopted by the company to reduce the risk of exposure of employees to occupational safety and health hazards. 7.10.3. Medical check-up Pre & post medical check-ups will be done of all the employees. Employees will be regularly examined and the medical records will be maintained for each employee. Pulmonary function test and periodical medical checkup shall be done once in every year. The following tests will be conducted for each worker:

• Lung Function Test • Radiology – X-ray • Pulmonary Function Test • Audiometric Test • General clinical examination with emphasis on respiratory system • Pre employment examinations • Periodical medical examinations at the time of employment and after completion of

employment.

The company will have OHC and other medical facilities at the site as per the factories act, and number of employees. Some guide lines are given below: Standard Medical facilities as required by Factory rule are expected to have been provided in the OHC for the existing plant, some important are illustrated below:

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1. Well equipped First Aid Boxes will be provided in each Section of the factory. 2. Snake bite Lancet 3. In case of need, factory will be having dispensary to give effective medical facility to

workers. In dispensary, sufficient stock of medicines will be available to provide to workers in case of any major emergent situation.

4. A vehicle will be always available to shift the sick/injured person to District Hospital. 5. Ambulance will be made available 24X7 in the factory to deal and take the injured

workers to the district hospital.

7.11 EHS policy The Company’s EHS policy, if needed will be prepared (If not available) modified and displayed and known to the employees must inform district officials.

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Chapter 8

PROJECT BENEFITS

PROJECT BENEFITS…8

8.1 INTRODUCTION Any industrial activity helps in improving social status of the locality. Existing project by GIACL has helped in improvement of infrastructure and social structure in the command area. Community that inhabit in nearby areas will be benefited directly or indirectly by this expansion project. Following benefits due to the proposed expansion project are expected. 8.1.1 Improvement in the Physical Infrastructure Due to a number of actions and planning proposed by the GIACL management, the status of physical infrastructure in command area of the industry is bound to improve. Thus there shall be a positive impact on this aspect. Following are certain steps that the industry would take – • Industry has constructed well paved roads for easy access from industry to nearby

villages as well as internal roads of villages in study area. This benefits to the local residents, industry people and workers. Thus, the same will not only help improve shipping of raw materials and products to and from the industry but also it will enhance overall transportation facilities and road connectivity in the area.

• GIACL has implemented good infrastructure of RWH in its premises. This will improve the ground water table status in the area. This will have a positive impact on ground water quantity in the study region.

• Implementation of sanitation and MSW management infrastructure in the nearby villages around GIACL complex as well as improvement in the existing facilities for same shall put a positive impact on living standard of the population.

• Plantation of trees in surrounding the industry as well as in nearby villages after expansion shall help in improving the aesthetics and beauty of the surrounding environment giving a pleasant look and improvising the air quality. Also, the green belt will help in arresting dust emissions as well as noise.

8.1.2 Improvement in the Social Infrastructure Benefits of GIACL projects in improving overall socioeconomic status of the study area are as under – • Presence of GIACL has created enormous potential towards creating employment in the

region. It gives primary and secondary employment to people which principally benefit the local residents. As much as 75% of the nearby villagers have been employed in existing set up. Same practice shall be continued under the expansion projects also.

• Due to expansion, frequency of the local transportation will increase in this area. This will help shorten the time reaching destination and utilize it for some fruitful productive work.

• GIACL undertake awareness and promotional programs such as education, literacy, safety and personal wellbeing, family planning, blood donation, care to be taken to avoid diseases like aids, swine flu, dengue etc.

• Industry shall organize various campaigns and workshops regarding medical and health check up for workers/ labours and for the local people. This will help improve overall health status. Moreover, practice of good sanitation, personal hygiene and health awareness among the people shall increase. Facilities like doctors and ambulance available in GIACL campus shall be extended to all needy people from the study area.

• 95% Powdered spentwash will mixes with boiler ash and used as manure in farmlands or 99% powdered spentwash will as it is used in field as manure. Availability of good

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organic manure and water at very low cost shall be a boon to farmers in light of ever increasing costs of the chemical fertilizers and high cost of fresh water and its adequacy in the area.

8.2 ACTIVITIES DONE BY GIACL UNDER CER

Details about CER already undertaken by GIACL through existing units are as follows:

a. Renovation Work of Bandharas (Bandhas) / Dams: GIACL undertook de-silting of the 78

Bandhas (dams) through ‘Gangamai Pattern’ from 2013 to till date. For this work ther have spent an amount of Rs. 4.57 Cr. Refer appendix G for photographs of desilted bandharas as well as for details of bandharas. It results in to rise in ground water table from 20 M to 9 M.

b. Supply of School bus: GIACL has provided school bus facility for the children of employee and nearby residents. (Capital investment Rs.10 Lakhs + Annual O & M; Provision of Rs.12 Lakhs towards salary of driver, attendant and consumables)

c. Medical Facilities: Own dispensary with MBBS Doctor and 24X7 ambulance facility at the GIACL plant site. The facilities are extended to nearby village residents also.

d. Supply of saplings: Supply of 19,000 Sapling in village namely Najik Babhulgaon, Ghotan, Talani. Spent Rs.11.55 Lakh for same.

e. Sanitation Facilities: Supply of 10 sanitation infrastructures having cluster of 3 toilets. f. Employment generation to local people through direct or indirect manner. g. Arrangement of medical camps for the cane harvesting labors. h. Arrangement of veterinary medical camps for the animals of cane harvesting labors.. i. Annual health check-up: All employees by Govt. medical officer. The campaign is

availed by residents of nearby villages. j. Workmen’s compensation policy: Annual workmen’s compensation policy with medical

reimbursement up to Rs. 50,000/- per employee. k. Promotion program for use of Drip irrigation: GIACL promoted farmers for use of Drip

Irrigation. After this program about 300 Ha. farmland is come under drip irrigarion. l. Supply of HDPE Syntex Water storage tanks in the drought affected villages. (20 Nos.

with a Cost of Rs.2,25,000)

8.2.1 Proposed CER Plan GIACL has received an EC for its existing 60 KLPD distillery in October 2017. Under this project an amount of Rs. 2.25 Cr. have been earmarked towards CER activities. Detailed CER plan have been at chapter 6, section 6.6.2, table 6.4. Under proposed expansion project GIACL has allocated an amount of Rs. 50 lakhs which is 2.5% of expansion cost of project (Rs. 19.18 Cr.). Detailed CER plan have been at chapter 6, section 6.6.2, table 6.6.

8.3 EMPLOYMENT POTENTIAL

In any industrial activity; all three types i.e. skilled, semi skilled and unskilled people are required. In GIACL complex; preference is given for employment to local people based on qualifications and requirement. When the production of sugar, alcohol and power manufacturing becomes stable expansion may become possible further and then employment availability may further enhance. Hence, it can be stated that by the existing and proposed

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activities in GIACL, employment potential certainly will have positive impact for all the three classes namely - skilled, semi-skilled and unskilled. 8.4 OTHER TANGIBLE BENEFITS After execution of the project the above mentioned benefits shall accrue. Apart from this other tangible benefits are mentioned below - • After establishment, the industry will meet the national interest of economical growth

through sustainable development, as alcohol has been a great source of revenue through excise duty levied by the Government.

• First Aid Training and fire safety training will be given to all the workers. • Insurance Policies for the workers and local people will be made available. • Improvement in the aesthetic through green belt development. • Ground water recharging shall be done by arresting rain water.

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Chapter 9

ENVIRONMENTAL MANAGEMENT PLAN (EMP)

ENVIRONMENTAL MANAGEMENT PLAN...9

9.1 INTRODUCTION Environment Management Plan (EMP) is required for ensuring sustainable development. It should not affect the surrounding environment adversely. Management plan presented in this chapter needs to be implemented by the expansion of distillery. EMP aims towards controlling pollution at source with available and affordable technology followed by treatment measures. Waste minimization and waste recycling measures are emphasized. In addition to the industry specific control measures, the proposed industry should adopt following guidelines- • Application of low and non waste technology in the production process; • Adoption of reuse and recycling technologies to reduce generation of wastes and to

optimize the production cost of the industry. Recycling and reuse of industrial waste not only reduces the waste generation but also can be economic gain to the industry. GIACL has already taken necessary steps towards controlling the environmental pollution and for mitigation of the same. Same practices will be followed after expansion also. Moreover, while implementing the project, the management will follow guidelines issued by CPCB. EMP is prepared based on the existing environmental status of the project location and the anticipated impacts of the project activities on environment. 9.2 ENVIRONMENTAL MANAGEMENT CELL (EMC) As a part of the EMP, it is essential to formulate an Environmental Management Cell (EMC). GIACL is already having a well functioning cell under its existing sugar factory and distillery projects. Cell works under Vice President of the industry and responsible persons from certain departments have been taken as members. EMC is responsible for all the activities and actions as well as outputs and management of entire infrastructure provided for control and abatement of pollution in GIACL project complex. Further, the cell is also active in protecting state of environment in the study area around existing campus of GIACL. Various programs and tasks towards conservation, awareness, promotion, review etc. are undertaken and implemented through existing EMC of GIACL. This cell will also be responsible for taking care of actions and implementations subsequent to the expansion program of the distillery. Following table gives details about EMC in the industry.

Table 9.1 Environmental Management Cell in GIACL

No. Name of Member Designation No. of Person(s) 1 Mr. Vishnu S. Khedekar Chief Financial Officer 1 2 Mr. P. H. Chimane Distillery Manager 1 3 Mr. S. D. Pawar Chief Engineer 1 4 Dr. Sangram Ghugare Env. Consultant

Equinox Environments (I) Pvt. Ltd. 1

5 Mr. M. G. Shaikh Sr. Engineer 1 6 Mr. G. S. Walke Chief Chemist 1

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No. Name of Member Designation No. of Person(s) 7 Mr. J. D. Jadhav Safety Officer 1 8 Mr. G. N. Kharde Environmental Manager

(Distillery) 1

9 Mr. S. P. Ghule Sr. Executive (EHS) 1 10 Mr. D. K. Darekar Environmental Chemist 1 11 ---- Lab Analyst & Attendants 3 12 ----- ETP Operators and Supporting Staff 6 Total 19

Above EMC shall look after GIACL project activities namely the existing Sugar factory (5,500 TCD), Co-generation Plant (32 MW) and existing molasses based Distillery (60 KLPD) as well as proposed expansion of the Distillery (by 90 KLPD).

Figure 9.1 Environmental Management Cell and Responsibilities

Members of the environmental cell are well qualified and experienced in the concerned fields. Some of the routine tests of wastewater such as pH, solids, temperature etc. will be carried out in the laboratory that would be established at the site. However, for additional tests of

Safety Officer Developing & implementing occupational health and safety policy, program & procedure, Increasing health & safety awareness at all levels within the organizations.

Vice President Effective implementation of EMP

Sugar Factory Team Responsible for all activities in this unit related to Safety, Health and Environment (SHE)

Health and Safety Manager Reporting the Vice President, Operational Risk Committee and the Board on matters regarding SHE performance, SHE Management System performance and the SHE risk position in the Industry

Environmental Engineer Providing technical advice on implementation of SHE management plan.

Environmental Chemist Collecting and analyzing the samples and developing remediation programs.

Distillery Team Responsible for all activities in this unit related to Safety, Health and Environment (SHE)

Co-gen Team Responsible for all activities in this unit related to Safety, Health and Environment (SHE)

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water, wastewater, soil, air etc., services of accredited laboratories as well as that of a consultant would be hired. 9.3 WORKING OF ENVIRONMENTAL MANAGEMENT PLAN

Figure 9.2 Environmental Management Plan

9.4 RECOMMENDATION & IMPLEMENTATION SCHEDULE Mitigation measures suggested in Chapter 4 would be implemented. This will reduce impact on environment due to the proposed molasses based distillery expansion project. To facilitate easy implementation, the recommendations suggested are grouped in different phases. The most important measures are accommodated in earlier phase whereas the lesser important ones are grouped in later phase. 9.4.1 Summary of Recommendations

Table 9.2 Summary of Recommendations Sr. No

Aspect Description Recommendations & Proposed Actions

1. Water Consumption

• Distillery: As far as the water conservation is concerned, it has been suggested to the Project Proponents (PP) to make maximum use of CPU treated water, water from cane condensate during sugar cane crushing season as well as treated water from STP for flushing purpose so as to reduce the fresh water demand during the crushing thus saving the fresh water demand. Industry has fresh water permission of 0.071 Million M3 per Year as granted by irrigation Department. GIACL is taking

• After expansion raw spentwash subjected to bio-methanation & Bio-methanated spentwash conc. in MEE. Conc. spentwash subjected to ATFD to form spentwash powder.

• Spentwash powder sold as manure.

• Existing water consumption rate in distillery during sugar crushing season will be 0.27 KL /KL of alcohol while during non sugar cane crushing season

Environmental Policy

Planning • Environmental Aspects • Objectives & Targets • EMP

Implementation • Implementation of EMP in all the three

plants - Sugar factory, Co - gen & Distillery

• Document Control • Operational Control

Checking / Corrective Action • Monitoring & Measurement • Non-conformance & Corrective & Preventive Action

• Records • EMS Audits

Management Review Preparing Environmental

Plan and Policy

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Sr. No


fresh water from Jaikwadi Dam and has implemented pumping scheme accordingly. Granted permission is lesser than requirement. However, the entire fresh water demand in GIACL complex after expansion will be to the tune of 0.057 Million M3 per Year.

• Sugar factory & Co-gen plant: 3,550 CMD out of which 3 CMD is fresh water used for drinking purpose. 17 CMD is STP treated water used for flushing purpose, 165 CMD is ETP treated water used for gardening in own premises and 3,365 CMD is cane condensate and CPU treated water from sugar factory. 99.9% of water is recycled water.

water consumption rate will be 1.80 KL /KL of alcohol which will be less than 10 KL/KL of alcohol.

2. Effluent Treatment

• Distillery: Raw spentwash quantity from 150 KLPD distillery (1182 CMD) shall be initially bio-methanated followed by concentration in MEE. Conc. spentwash (443 CMD) shall be subjected to ATFD for drying and forms dry powder 95% or 99% solids. 95% powder would be mixed with boiler ash to form manure during crushing season. While 99% powder bagged and sold during non-crushing season.

• MEE condensate & other effluents namely spentlees, boiler and cooling blow downs, effluent from lab & washing is treated in CPU and maximum quantity shall be recycled back for various processes. Same practices will be followed after expansion also.

• Sugar factory & Co-gen plant: Effluent generation for sugar factory and co-gen plant is 564 CMD which is treated in an existing ETP provided on the site.

• Raw spentwash generation will be 7.88 KL/KL after expansion. while conc. spentwash generation will be 2.95 KL /KL of alcohol and same should be brought down to 8 KL/KL. Conc. spentwash will be powdered & sold as manure.

• Under expansion activities new CPU will be installed for treatment of other effluents. This achieves ZLD in distillery.

• Entire trade effluent from sugar factory is treated in ETP & given to nearby farmers for irrigation purpose.

• Existing domestic effluent is treated in STP. Same practices will be followed after expansion also.

• Storm water drains would be kept separate from other drains. Natural drains if found, would not be altered under any circumstances.

• No drains will be kept open in the plant.

3. Air Pollution Control

• Distillery: Steam required for the distillery operations in expansion shall be taken from the existing 8 TPH biogas based boiler from existing distillery. A stack of 45M height is provided.

• Also, a D.G. Set (1 No.; 900 KVA) in existing distillery is provided with adequate stack height of 5.5 M.

• Inlet and outlet of pollution control equipment shall be provided with all necessary sampling arrangements as per guidelines of CPCB.

• Regular self-monitoring of AAQ and work zone AQ be done by the industry through

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Sr. No


• Sugar factory & Co-gen plant: Bagasse based boilers of 140 TPH & 30 TPH is installed under sugar factory & co-gen plant. 30 TPH boiler from existing sugar factory will be modified to 40 TPH under distillery expansion. For 40 TPH boiler. ESP is installed to boilers installed to sugar factory & co-gen plant. Stack of 76 M height is installed to same

• Also, a D.G. Sets (500 KVA, 320 KVA, 380 KVA) in existing sugar factory is provided with adequate stack height.

approved labs to check and control dust levels / concentrations at certain places so that same could be kept always below the stipulated norms.

• Efficiencies of dust control equipment in the industry shall be monitored regularly (at least once a month) under performance evaluation.

• Regularly stack emissions, AAQM and work zone air quality monitor.

• Self-monitoring practices, interlocks and OCMS fitted & properly operated.

4. Solid Waste Management

• Also from sugar factory & co-gen plant boiler ash and ETP Sludge. Boiler ash mixed with spentwash powder and used as manure. Remaining boiler ash sold to brick manufacturer. ETP sludge utilized as manure.

• Hazardous waste generated in the form of used oil and spent oil. Used oil will be sold to authorized re-processor and spent oil will be burnt with bagasse in co-gen boiler.

• Recommendations have been made toward storage of ash in silo and transportation of same disposal site through covered vehicles.

• Adequate storage, disposal shall be done.

• distillery shall have to operate & maintain composting facility as per CREP norms and stipulations of CPCB and MoEFCC.

5. Socio-Economic Aspects

• Under proposed expansion of distillery in GIACL; it will generate primary and secondary employment in region.

• Programs related to health, hygiene and education will be arranged and workshops as well as seminars would be conducted in nearby vicinity for creating public awareness.

• Active participation shall be done in the activities considered under CER.

•

6. Noise Control Measures

• Sources: Boiler house, Distillation section, DG Sets, turbine rooms, cane crushing section and mill house, etc.

• Expected noise levels in these sections would be in the range of 65 to 70 dB (A).

• Provision & use of earmuffs in High Noise Area.

• Providing separate sitting & control room for workers.

• Changing of shifts and exposure time to high Noise Area would be reduced

7. CER • Implementations under CER shall be done in a time bound manner.

• Planning for CER shall be started with the identification of activities/ projects

• Industry, by involving workers and locals, shall demonstrate, encourage and promote suitable eco-friendly alternatives and

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Sr. No


and may be undertaken in periphery of industrial area.

green technologies in the villages in the vicinity. Details are given at Chapter 6, section 6.6.2

9.5 ENVIRONMENTAL POST MONITORING PROGRAMMES After commissioning of the expansion project, monitoring of Environmental Attributes such as AAQM, Stack Emissions, Noise and Effluent would be done on regular basis.

Table 9.3 Implementation Schedule

Sr. No.

Aspect Time period Implementation Schedule Immediate Progressive As per Time

Schedule of Unit 1. Water Pollution

Control (Spentwash Bio-methanation, MEE, ATFD)

Before commissioning of the Expansion Project.

* - -

2. Noise Control (Green belt development as well as isolation and Insulation)

Before commissioning of the Expansion Project.

* - -

3. Solid waste Management

Stage Wise - * -

4. Socio-economic aspects (CER)

Stage wise - - *

Note :-‘ * ’ indicates implementation of recommendations Post environmental clearance monitoring for industrial premises & for study area around the GIACL is given at chapter 6, Refer table 6.8 for details. Following compliance against the consent conditions after commissioning of project would be observed under the Water (Prevention & Control of Pollution) Act ,1974, Air (Prevention & Control of Pollution) Act, 1981, Hazardous Waste (Management, Handling & Trasnboundry Movement) Rules 2010.

Table 9.4 Compliance against the Consent Condition

No. Description Frequency Remark 1. Renewal of

Consent Once in a

year Application for renewal shall be done 60 days before the expiry date.

2. Environmental Statement

Once in a year

Would be submitted for every financial year before 30th September of next year.

3. Hazardous Waste Returns

Once in a year

Would be submitted for every financial year before 30th June of next year.

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9.6 MONITORING EQUIPMENT A. Air Quality and Meteorological Instruments 1. Fine Dust Sampler 2. Weather station with Wind Vane, Anemometer, Thermometer, Dry/ Wet Bulb

Thermometer, Rain-gauge 3. Spectrophotometer 4. Single pan balance up to 0.0001 gms detection levels. 5. Relevant chemicals as required 6. Oven B. Water and Wastewater Quality 1. BOD Incubator 2. COD reflux assembly 3. Refrigerator 4. Thermometer 5. pH meter 6. Stop watch 7. Distilled water plant 8. Pipette box 9. Titration set 10. Relevant chemicals and glass wares C. Noise Levels Sound level meter in different scales like A, B and C with slow and fast response options D. Soil Characteristics Soil sampler (auger) to collect soil samples.

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Chapter 10

SUMMARY AND CONCLUSION

SUMMARY AND CONCLUSION…10

10.1 INTRODUCTION This EIA report has been prepared for distillery expansion project by Gangamai Industries And Constructions Ltd. (GIACL) located at village Najik Babhulagon, Post: Rakshi, Tal.: Shevgaon, Dist.: Ahmednagar. Existing distillery capacity is 60 KLPD. GIACL has planned to go for distillery expansion by another 90 KLPD capacity so as to have total alcohol production of 150 KLPD. Above mentioned expansion project attracts condition of prior Environmental Clearance (EC) procurement as per EIA Notification No. S. O. 1533 (E) dated 14.09.2006 and amendments thereto. Accordingly, it has been listed under Category – A; Item No.: 5 (g). Expansion project was submitted on ministries website on 10.03.2018. Same was granted standard ToR’s by ministry on 14.04.2018. Distillery expansion shall be implemented in existing premises of GIACL complex. In addition to the distillery; there are two more projects namely sugar factory (5500 TCD) and co-generation plant (32 MW). Capital investment of sugar factory and co-gen project is 209.55 Cr. where as that of the existing distillery is Rs. 55.93 Cr. For the proposed 90 KLPD distillery, capital investment will be Rs.19.18 Cr. 10.2 PROJECT AT A GLANCE

Table 10.1 GIACL Expansion Project Details

Sr. No.

Particulars Details

1. Name and Address of the Industry

Gangamai Industries And Constructions Ltd. (GIACL) Gat No.: 6, 222/3, 223, 224, 228/1, 228/2, 228/3, 233, 234 529 and 210/5 Najik Babulgaon, Post- Rakshi, Tal.: Shevgaon, Dist.: Ahmednagar, Maharashtra State.

2 Type and capacity of Project

Proposed Expansion of molasses based Distillery form 60 KLPD to 150 KLPD

3

Latitude, Longitude and Elevation

19° 22' 47.28”N Latitude, 75° 17' 00.72”E Longitude 450 M above MSL

4 Land area and break up Total Plot Area – 33.06 Ha Built - Up Area – 17.95 Ha Green belt - Total - 1,01,700 Sq.M.(38% of industrial total plot

area) 5 Nearest habitation Najik Babhulgaon (1.16 Km) 6 Nearest city Shevgaon (7.19 Km) 7 Nearest highway SH- 44 (2.60 Km ) & SH-148 ( 1.63 Km) 8 Nearest railway station Ahmednagar (68 Km) 9 Nearest airport Aurangabad Airport (50 Km) 10 Nearest Rivers Godavari River (13 Km) 11 Distance from boundary

of Jaikwadi Sanctuary as well as Eco-Sensitive Zone (ESZ).

Project site is located 5.51 Km from ESZ Sanctuary. ESZ for Jaykwadi bird sanctuary got finalized vide MoEFCC Notification No. SO-2202 E dated 12th July 2017. As per this notification, our project is not located within ESZ. We have obtained No Objection Certificate (NOC) from Deputy Conservator of Forests (DCF), Aurangabad regarding our project. Refer appendix – B for copy of

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Sr. No.

Particulars Details

NOC obtained from Forest Department, Aurangabad. 12 Site Co-ordinates (all

corners) 19°22'55.19"N, 75°16'50.20"E, 19°22'54.51"N, 75°17'08.36"E 19°22'42.14"N, 75°17'09.86"E, 19°22'38.32"N, 75°16'56.97"E 19°22'41.97"N, 75°16'49.82"E, 19°22'46.92"N, 75°16'48.82"E

13 Capital & Recurring Cost towards EMP

Sr. No.

Description Cost (Rs. in Lakhs) Capital O & M

1 Installation of ATFD 150 10 2 Spentwash Treatment: Installation

of new Bio-methanation Plant 250 18

Installation of MEE 250 10 Proposed CPU 60 5

3 Environmental Monitoring & Management

10 10

4 Provision towards CER in 5 Years 50 -- Total Rs. 770

Lakhs Rs. 53 Lakhs

10.3 PROCESS DESCRIPTION 10.3.1 Product and Raw Material Details of raw materials and products that are being manufactured under existing distillery as well as those to be manufactured under expansion are presented in following table-

Table 10.2 Products of the Distillery

Industrial Unit

Product Quantity Existing


Total (150 KLPD)

Distillery Ethanol 1800 KL/M 2700 KL/M 4500 KL/M Rectified Spirit 1800 KL/M 2700 KL/M 4500 KL/M Extra Neutral Alcohol 1800 KL/M 2700 KL/M 4500 KL/M

By-product Fusel Oil 34 KL/Annum 47 KL/Annum 81KL/Annum CO2 gas 1380 MT/M 2036 MT/M 3416 MT/M Compost (from Spent wash treatment)

20935 MT/Annum

-- 20935 MT/Annum


-- -- 3000 MT/M


-- -- 2190 MT/M

* Under existing scenario of 60 KLPD conc. spent wash was mix with Boiler ash and sold out as bio-compost to the tune of 16,700 MT/Season. After expansion all spentwash will be dried in ATFD and convert in powder.

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Table 10.3 Products under Sugar and Co-gen Units

Industrial Unit Product Quantity (MT/M) Sugar Factory (5500 TCD ) White Sugar 18,150

By - product Molasses 6,600 Bagasse 49,500 Press mud 6,600

Co- Generation (32 MW) Electricity 32 MW

Table 10.4 Raw Materials for Distillery

Industrial Unit

Raw material Quantity Source of Material Existing


Total (150 KLPD)

Distillery Molasses 7,200 MT/M 10,800 MT/M 18,000 MT/M

Form Own Factory as well as outside factories

Urea 2,400 Kg/M 2,600 Kg/M 5,000 Kg/M Local Vendors DAP 2,400 Kg/M 2,600 Kg/M 5,000 Kg/M

Formalin 200 Lit/M 100 Lit/M 300 Lit/M Bleaching Powder 120 Kg/M 180 Kg/M 300 Kg/M Sulphuric Acid 6,000 Kg/M -- 6000 Kg/M Caustic Soda 400 Kg/M 1100 Kg/M 1500 Kg/M Yeast Culture Test tube

culture Test tube

culture Test tube

culture

Table 10.5 Raw Materials for Sugar Factory and Co-gen Plant

Industrial Unit Raw Material Quantity Source of Material Sugar Factory (5500 TCD )

Sugarcane 1,65,000 MT/M Nearby Farms Sulphur 99 MT/M

Supplied by outside parties

Lime 330 MT/M Oil & Grease 9.9 MT/M Phosphoric Acid 3.3 MT/M

Co- Generation (32 MW) Bagasse 49,500 MT/M Own Sugar Factory

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Figure 10.1 Manufacturing Process Details of GIACL Integrated Project

10.4 SOURCES OF POLLUTION AND MITIGATION MEASURES 10.4.1 Water Pollution

10.4.1.1 Distillery

• Total water requirement for 150 KLPD distillery project during sugar crushing season

(180 days) would be 1619 M3/ Day. Out of the total water requirement, 1506 M3/ Day water would required form industrial purpose, 12 M3/Day water will required for domestic purpose and 101 M3/ Day. From total water requirement 41 M3/Day would be fresh water taken from Jayakwadi dam on Godavari River (fresh water consumption 0.27 KL/KL of Alcohol against norm of 10 KL/KL of alcohol), 7 M3/Day would be STP treated water used for flushing, 230 M3/Day would be excess condensate water from sugar factory & co-gen plant and 1578 M3/Day would be MEE condensate and CPU treated water from distillery. About 97% recycle water will be used for distillery during sugar cane crushing season.

• During non - sugar cane crushing season (150 Days); total 1619 M3/ Day water will be required. out of this 271 M3/Day would be fresh water taken from Jayakwadi dam on Godavari River, 1341 M3/Day would be MEE condensate and CPU treated water from distillery and 7 M3/Day will be treated water from STP used for flushing. For non-sugar cane crushing season about 83% of water will be recycled water. Fresh water consumption for non-sugar cane crushing season will be 1.80 KL/KL of Alcohol against norm of 10 KL/KL of alcohol.

Sold to farmers Press Mud

To Grid

Power Steam

Sugar Factory

Boiler Turbines

To Factory

Distillation Alcohol

MEE

ATFD

Bio-Methanation

Distillery

Co-Generation Plant

To Godown / Market

Weighed Cane

Cane Milling / Crushing

Juice Clarification

Juice Sulphitation

Syrup Boiling

Centrifuging

Sugar

Bagasse

Molasses Fermentation

Powdered Spentwash


ash-manure

Powder with 99% solids –

manure Biogas to Distillery

boiler

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• After expansion of distillery total raw spentwash generated from 150 KLPD molasses based distillery will be to the tune of 1182 M3/Day (7.8 KL/KL of Alcohol). Same will be bio-methanated and then concentrated in MEE. MEE concentrated spentwash to the tune of 443 M3/Day (2.9 KL/KL of Alcohol) will be then subjected to Agitated Thin Film Dryer (ATFD). Liquid spentwash will be converted in to powder up to 95 % to 99 % solids. Powder will be mixed with boiler ash, press mud and sold as manure to the cane grower farmers command area of the industry. MEE condensate @ 1086 M3/Day, spentlees @ 339 M3/Day and Other @ 36.25 M3/Day will be treat in CPU. Under expansion one new CPU will be constructed. Treated water from CPU will be recycled back in process for dilution of molasses and for cooling purpose. This achieves ZLD.

10.4.1.2 Sugar Factory and Co-gen Plant

• Water requirement for other projects in the complex namely Sugar Factory and Co-gen Plant is 3,550 CMD out of which 3 M3/Day is fresh water used for drinking purpose. 17 M3/Day is STP treated water used for flushing purpose, 165 M3/Day is EP treated water used for gardening in own premises and 3,365 M3/Day is cane condensate and CPU treated water from sugar factory. Out of total water requirement 3547 M3/Day i.e. 99.9% of water is recycled water. Only 3 M3/Day of water is fresh water taken from river used for drinking purpose. For more details refer Section 2.7.1 of Chapter 2

• Treated effluent from sugar factory would be used for green belt as well as on land of nearby farmers of 45.3 Acre.

10.4.1.3 Domestic Effluent Domestic effluent to the tune of 26 M3/day is being treated in a STP.

10.4.2 Air Pollution

• Steam required for expansion of molasses based distillery would be taken from 8 TPH

existing distillery boiler. Also, a boiler from existing co-gen plant having capacity 30 TPH will be modified to 40 TPH under distillery expansion.

• Fuel for 8 TPH distillery boilers is methane gas to the tune of 675 M3/Hr which is generated subsequent to bio-methanation of distillery process effluent – spentwash. FO shall be used to the tune of 502 Kg/Hr as a startup fuel. Existing 8 TPH boiler has been provided with a stack of 45 M height.

• For 40 TPH boiler bagasse is used as fuel. ESP is already installed as APC along with stack of 76 M height.

• D.G. Set of 900 KVA capacity has been installed under existing unit with adequate stack height and acoustic enclosure

• Green belt developed in the premises shall act in curbing dust suspension and transfer as well as in controlling CO2 emissions.

For More details w.r.t boiler and Stack details refer Table 2.30 from chapter 2.

10.4.3 Noise Pollution • In the distillery, very high noise generating sources do not exist. Boiler house, distillation

& fermentation section would be the minor sources of noise.

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• Noise levels, as measured at various points in the boiler house, are not more than 85 dB (A). Adequate care shall be taken under expansion process also so that the noise from all the concerned sections shall be properly attenuated and controlled through insulation, isolation, separation techniques.

• Green belt to be developed further shall play an important role to attenuate the noise levels from industry to surroundings.

10.4.4 Solid Waste Table 10.6 Solid Waste Details

No. Industrial Waste

Type Quantity (MT/M) Storage Disposal

Existing Expansion Total 1. Distillery Yeast

Sludge 450 750 1200 Immediate

utilization Used as manure

2. Co-gen Plant

Boiler Ash

1485 60 1545 Silo of Cap.50 MT

Mixed with 95% spentwash powder; used as manure.

3. ETP Sludge

2.5 -- -- Immediate utilization

Used as Manure

10.4.5 Hazardous Waste

Table 10.7 Hazardous Waste Generated in GIACL complex

Sr. No.

Industrial Unit

Hazardous Waste Category

Quantity Disposal

1. Distillery Used Oil (Cat. 5.1) 2 MT/Yr Authorized Re-processor 2. Co-gen Plant Spent Oil (Cat. 5.1) 65 MT / Yr Burnt in Boiler.

10.4.6 Odour Pollution In the distillery, sources of odour are molasses tanks, fermentation section, yeast sludge, spentwash storage tanks, bio-composting site. Spentwash shall be carried through closed pipeline for bio-methanation followed by concentration in MEE. Spentwash further dried in ATFD for drying and forms dry powder. Due to appropriate and adequate steps towards handing, conveyance, usage, housekeeping and O & M; there is no any odour problem under existing distillery unit. Similar care shall be taken during expansion project also. For more details towards mitigation of odour problems, Chapter 2 (Section 2.7.6) may be referred. 10.5 GREEN BELT DEVELOPMENT GIACL has developed an land under greenbelt in GIACL’s premises is 61,350 Sq. M (6.1Ha) which is 23% of total plot area. GIACL has procured additional land of area 60,000 Sq.M. (6 Ha) near existing industrial premises for development of more green belt. On that additional land, an area of 4.07 Ha is developed as green belt. Hence total green belt developed by GIACL is about 10.17 ha which is about 38% of industrial total plot area. Under existing green belt, about 10,305 no. of trees are already planted. In 2018 monsoon GIACL has planted additional 5353 no. of trees.

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10.6 ENVIRONMENTAL MONITORING PROGRAM Monitoring of various environmental parameters will be carried out on a regular basis to ascertain the following: • State of pollution within the plant and in its vicinity; • Examine the efficiency of pollution control systems installed in the plant; • Generate data for predictive or corrective purpose in respect of pollution; • To assess environmental impacts

Project management will carry out monitoring regularly and record shall be maintained of the same. For details w.r.t post monitoring program to be conducted; refer Chapter - 6 Table 6.8. 10.7 ENVIRONMENT MANAGEMENT PLAN Environment Management Plan aims at controlling pollution at source with available and affordable technology followed by treatment measures. Under existing sugar factory, co-generation plant and distillery, GIACL has effectively implemented the EMP. As a part of EMP, it is essential to formulate an EMC. GIACL is already having a cell functioning under its existing sugar factory and distillery projects. For more details, the separate chapter on EMP may be referred. 10.8 CONCLUSION Proposed expansion of distillery by GIACL will help to elevate the economic growth at the local level as well as national level. It will also generate the employment in the study region, thereby improving the standard of living of people in the area. The expansion activity shall not disturb the land use pattern in the study area of 10 Km. No Rehabilitation is involved under this project since expansion is to be done in the existing unit. The waste material generated from the distillery in the form of yeast sludge will be used in bio-compost. While undertaking this expansion activity the farmers shall also be partially benefitted as their farm lands will be irrigated by the treated water from sugar ETP. Moreover, the spentwash powder generated from distillery will be mixed with boiler ash and used as manure in farms. It is rich in potash. Hence it act as good conditioner for soil. Thus, the GIACL expansion project is beneficial for society without hampering the environment and thereby accomplishing the aim of sustainable development.

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Chapter 11

DISCLOSURE OF CONSULTANT ORGANIZATION

DISCLOSURE OF CONSULTANTS ENGAGED…11

11 THE ORGANIZATION Equinox Environments (India) Pvt. Ltd. (EEIPL) is a major company under the 'Equinox Group'. It is one of the leading environmental consultants in the country and renders all the environmental services, under one roof, needed by various industries. EEIPL is an ISO 9001:2015 certified organization (DNV-GL) that has been duly accredited through QCI – NABET for the Ministry of Environment, Forest & Climate Change (MoEFCC); New Delhi as recognized and approved ‘Environmental Consultant’ at the National Level. EEIPL operates through its offices located in Kolhapur, Pune, New Mumbai, New Delhi, Hydrabad and Baltimore (US). Through the organization, various services are offered that are related to environmental engineering, pollution control & its abatement, industrial safety, health & hygiene. EEIPL's set up comprises of engineers, eminent scientists, chemists, technicians & associates. Moreover, organization is having back up of a most modern laboratory infrastructure. NABL accredited lab, also approved by Govt. of India through the MoEF; New Delhi has received OHSAS 18001:2007 certifications from DNV GL. The 'Equinox Group' is in the environmental business for last nineteen years and have rendered services as well as expert consultation to a number of industries such as sugar factories, power plants, distilleries, foundries, sponge iron & steel plants, textile industries, bulk drug manufacturing units and chemical industries, food processing & beverage manufacturing units, asbestos products & roofing, timber and particle board Industries etc. Further our website – www.equinoxenvi.com – may be visited for additional details regarding our activities, achievements and list of our esteemed clients as well as our Key Personnel.

211

http://www.equinoxenvi.com/

209

SA- 216thAC Meeting Feb 9,2018 Page 1

NATIONAL ACCREDITATION BOARD FOR EDUCATION & TRAINING

QUALITY COUNCIL OF INDIA

QCI Office, 6th Floor, ITPI Building, Ring Road, I.P. Estate, New Delhi

Scheme for Accreditation of EIA Consultant Organizations

Accreditation Committee Meeting for Surveillance Assessment held on

February 09, 2018

The following members were present during the meeting:

1. Dr. S.R. Wate - Chairman

2. Dr. G.K. Pandey - Member

3. Dr. S. P.Chakrabarti - Member

4. Prof. Umesh Kulshrestha - Member

Prof. B.B. Dhar, Dr. Nalini Bhat , Prof. C.P. Kaushik and Prof. G.J. Chakrapani expressed their inability to

attend the meeting.

Mr. A.K. Jha – Senior Director, Dr.S.K Mishra – Joint Director, Dr. Pawan Kumar Singh – Assisstant Director and Ms.Meenakshi Arora – Accreditation Officer were present in the meeting.

1.0 Case for Surveillance Assessment The following case was discussed and decisions taken as noted below.

1.1 Equinox Environments (I) Pvt. Ltd, Kolhapur

The ACO has been assessed as per Version 3 of the Scheme. Result of the 2nd Surveillance assessment (SA) is given below :

1.1.1 Category of Approval :

ACO has scored more than 60% marks. Hence, the organization accreditation is continued with

Cat.A.

1.1.2 Scope of Accreditation

Sl. No.

NABET Scheme Sectors

Sector Description Cat.

Sector No.(MoEFCC Notification dated Sep. 14, 2006 and Amendments)

1 1 Mining of minerals including opencast / underground mining

A 1 (a) (i)

2 4 Thermal power plants B 1 (d)

210


1.1.3 Sectors approved for EIA Coordinators (ECs) a.Assessed as per SA norms – for ECs approved earlier:

Sl. No.

Name

Earlier approval status (in RA/subsequently)

Approval status (after SA)

Remarks Sectors

approved Cat.

Sectors approved

Cat.

In-house

1 Sangram Ghugare

4 B CA B

Upgraded to Cat. A in Sector 21. 21 B CA A

22 A CA A

25 B CA B

2 Sulakshana Ayarekar 21 B CA A Upgraded to Cat. A in Sector 21.

Empanelled

3 Vinay kumar Kurakula 32 B CA A

Upgraded to Cat. A in Sector 32 37 B CA B

b. Assessed as per IA norms – for new Sectors of approved ECs and fresh ECs proposed:

Sl. No.

Name Functional Area

Cat. Remarks Applied Recommended Approved

3 8 Metallurgical industries both primary & secondary B 3 (a) 4 12 Asbestos milling and asbestos based products A 4 (c ) 5 13 Chlor-alkali industry A 4 (d)

6 17 Pesticides industry and pesticide specific intermediates (excluding formulations)

A 5 (b)

7 18 Petro-chemical complexes (industries based on processing of petroleum fractions & natural gas and/or reforming to aromatics)

A 5 (c)

8 20

Petrochemical based processing (processes other than cracking &reformation and not covered under the complexes)

A 5 (e)

9 21

Synthetic organic chemicals industry (dyes & dye intermediates; bulk drugs and intermediates excluding drug formulations; synthetic rubbers; basic organic chemicals, other synthetic organic chemicals and chemical intermediates)

A 5 (f)

10 22 Distilleries A 5 (g)

11 25 Sugar Industry B 5 (j)

12 32 Common hazardous waste treatment, storage and disposal facilities (TSDFs)

A 7 (d)

13 37 Common municipal solid waste management facility (CMSWMF)

B 7 (i)

14 38 Building and construction projects B 8 (a)

15 39 Townships and Area development projects B 8 (b)

16 40(ii) Electro Plating and metal Processing A -

17 40(v) Food Processing A -

211


Sl. No.



In-house

1 Dipali Survase 1 No No - Absent

2 Sulakshana Ayarekar

12 Yes Yes A

None 22 Yes Yes A

25 Yes Yes B

3 Sangram Ghugare 8 Yes Yes B None

Empanelled

5 Ramdas Wani

13 Yes Yes A

None

20 Yes Yes A

21 Yes Yes A

38 Yes Yes B

39 Yes Yes B

6 Vivek Navare 1 Yes Yes A None

7 Bhaskar Thorat

17 Yes Yes A

*40(ii & v only)

18 Yes Yes A

21 Yes Yes A

22 Yes Yes A

40* Yes Yes A

1.1.4 Functional Areas (FA) approved for Functional Area Experts (FAEs) a. Assessed as per SA norms – for FAEs approved earlier:

Sl. No. Name



Remarks FAs approved

Cat. FAs

approved Cat.

In-house

1

Sangram P. Ghugare

AP A CA A

None WP A CA A

SHW A CA A

2 Sulakshna Ayarekar EB B CA A Upgraded to Cat. A.

3 Yuvraj Damugade

AQ B CA A Upgraded to Cat. A in

AQ and AP. AP B CA A

HW B CA B

4 Jay Samant EB A CA A None

5 Anuradha J. Samant SE A CA A None

6 Jaydeep Patil WP B CA B None

7 Rohan Lad AP B CA B

None EB B CA B

Empanelled

8 Jayant M. Gadgil AQ A CA A None

9 Jotiram Pishte Geo A CA A

None HG A CA A

10 Vinod Sahasrabuddhe RH A CA A None

11 Ramdas Wani RH A CA A

None SHW A CA A

12 B. N. Patil SE B ANC - Absent.

13 Vinay Kumar Kuruakula LU A CA A None

212


Sl. No. Name



Remarks FAs approved

Cat. FAs

approved Cat.

NV A CA A

SHW B CA B

b. Assessed as per IA norms – approved experts for new functional areas and fresh FAEs proposed:

Sl. No.



Inhouse

1 Sandip Manglekar

AP Yes Yes B None

NV Yes Yes B

2 SwapnaN. Ghatge SHW - - - Candidature withdrawn

RH - - -

3 Tejas Patil AQ Yes Yes B None

4 Pragatee Murkute

SHW - - - Candidature withdrawn

RH - - -

NV - - -

5 Rohan Lad RH Yes Yes B None

6 Sai Mohite WP Yes Yes B None

7 Neeraj Powar SE Yes Yes B None

8 Vaibhav Survase

HG Yes Yes B None

Geo Yes Yes B

Empanelled

9 Jayant Gadgil

AP Yes Yes A None

WP Yes Yes A

10 B.S. Lole SC Yes Yes A None

11 Sunil Shaha

WP Yes Yes A None

SW Yes Yes A

12 Ramdas Wani

RH Yes Yes A

None SHW Yes Yes A

AQ Yes Yes B

13 Bhaskar Thorat

RH Yes Yes A

*HW only. WP Yes Yes A

SHW* Yes Yes A

1.1.5 Functional Area Associates (FAAs) a.FAAs Approved

SI. No. Name Approval status

(after SA) Name of FAE/Mentor Remarks

FA Status

In-house

1 Tejas Patil AP Continue Sangram Ghugare None

HW Continue Sangram Ghugare

213


b.FAAs Proposed

SI. No. Name Approval status

(after SA) FAE/Mentor Remarks

Applied Approved

In-house

1 Gandhar Ghanekar HW Yes Vinay Kumar None

2 Snehal Powar

SC Yes B.S. Lole None

NV Yes Vinay Kumar

3 Pooja Sarnaik

WP Yes Sai Mohite None

SHW Yes Sangram Ghugare

Note: The following will be communicated to the ACO by NABET 1. Detailed observations and reasons for alerts 2. Results of balance candidates and details of the assessment

The meeting concluded with a vote of thanks to the Chair.

Issued by A K Jha Senior Director QCI-NABET

214


Abbreviations:

ACO - Accredited Consultant Organization AC - Accreditation Committee IA - Initial Accreditation SA - Surveillance Assessment EC - EIA Coordinator FA - Functional Area FAE - Functional Area Expert FAA - Functional Area Associate CA - Continue by Assessment CWA - Continue with alert ANC - Approval Not continued

215

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744 GU20t1

ENCLOSURE – I

No.IA-J-11011/91/2018-IA-II(I)

Goverment of India

Minister of Enviroment,Forest and Climate Change

Impact Assessment Division

***

Indira Paryavaran Bhavan,

Vayu Wing,3rd Floor,Aliganj,

Jor Bagh Road,New Delhi-110003

14 Apr 2018

To,

M/s Mr. A. L. More

6,222/3,223,224,228/1,228/2,228/3,233,234Shevgaon,

Ahmednagar-431001

Maharashtra

Tel.No.0240-2333933; Email:[email protected]

Sir/Madam,

This has reference to the proposal submitted in the Ministry of Environment, Forest

and Climate Change to prescribe the Terms of Reference (TOR) for undertaking detailed EIA

study for the purpose of obtaining Environmental Clearance in accordance with the provisions of

the EIA Notification, 2006. For this purpose, the proponent had submitted online information in the

prescribed format (Form-1 ) along with a Pre-feasibility Report. The details of the proposal are

given below:

1. Proposal No.: IA/MH/IND2/73430/2018

2. Name of the Proposal: Gangamai Industries & Constructions Ltd.

3. Category of the Proposal: Industrial Projects - 2

4. Project/Activity applied for: 5(g) Distilleries

5. Date of submission for TOR: 10 Mar 2018

In this regard, under the provisions of the EIA Notification 2006 as amended, the Standard TOR

for the purpose of preparing environment impact assessment report and environment

management plan for obtaining prior environment clearance is prescribed with public consultation

as follows:

STANDARD TERMS OF REFERENCE (TOR) FOR EIA/EMP REPORT FORPROJECTS/ACTIVITIES REQUIRING ENVIRONMENT CLEARANCE

5(g): STANDARD TERMS OF REFERENCE FOR CONDUCTINGENVIRONMENT IMPACT ASSESSMENT STUDY FORDISTILLERIES AND INFORMATION TO BE INCLUDED IN EIA/EMPREPORT

A. STANDARD TERMS OF REFERENCE

1) Executive Summary

2) Introduction

i. Details of the EIA Consultant including NABET accreditation

ii. Information about the project proponent

iii. Importance and benefits of the project

3) Project Description

i. Cost of project and time of completion.

ii. Products with capacities for the proposed project.

iii. If expansion project, details of existing products with capacities and whether adequate landis available for expansion, reference of earlier EC if any.

iv. List of raw materials required and their source along with mode of transportation.

v. Other chemicals and materials required with quantities and storage capacities

vi. Details of Emission, effluents, hazardous waste generation and their management.

vii. Requirement of water, power, with source of supply, status of approval, water balance diagram,man-power requirement (regular and contract)

viii. Process description along with major equipments and machineries, process flow sheet(quantative) from raw material to products to be provided

ix. Hazard identification and details of proposed safety systems.

x. Expansion/modernization proposals:

a. Copy of all the Environmental Clearance(s) including Amendments thereto obtained forthe project from MOEF/SEIAA shall be attached as an Annexure. A certified copy of thelatest Monitoring Report of the Regional Office of the Ministry of Environment and Forestsas per circular dated 30th May, 2012 on the status of compliance of conditions stipulatedin all the existing environmental clearances including Amendments shall be provided. Inaddition, status of compliance of Consent to Operate for the ongoing Iexisting operationof the project from SPCB shall be attached with the EIA-EMP report.

b. In case the existing project has not obtained environmental clearance, reasons for nottaking EC under the provisions of the EIA Notification 1994 and/or EIA Notification

STANDARD TERMS OF REFERENCE (TOR) FOR EIA/EMP REPORT FOR PROJECTS/ACTIVITIES REQUIRING ENVIRONMENT CLEARANCE

2006 shall be provided. Copies of Consent to Establish/No Objection Certificate andConsent to Operate (in case of units operating prior to EIA Notification 2006, CTE andCTO of FY 2005-2006) obtained from the SPCB shall be submitted. Further, compliancereport to the conditions of consents from the SPCB shall be submitted.

4) Site Details

i. Location of the project site covering village, Taluka/Tehsil, District and State, Justificationfor selecting the site, whether other sites were considered.

ii. A toposheet of the study area of radius of 10km and site location on 1:50,000/1:25,000 scaleon an A3/A2 sheet. (including all eco-sensitive areas and environmentally sensitive places)

iii. Details w.r.t. option analysis for selection of site

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

v. Google map-Earth downloaded of the project site.

vi. Layout maps indicating existing unit as well as proposed unit indicating storage area, plantarea, greenbelt area, utilities etc. If located within an Industrial area/Estate/Complex, layoutof Industrial Area indicating location of unit within the Industrial area/Estate.

vii. Photographs of the proposed and existing (if applicable) plant site. If existing, showphotographs of plantation/greenbelt, in particular.

viii. Landuse break-up of total land of the project site (identified and acquired), government/private - agricultural, forest, wasteland, water bodies, settlements, etc shall be included. (notrequired for industrial area)

ix. A list of major industries with name and type within study area (10km radius) shall beincorporated. Land use details of the study area

x. Geological features and Geo-hydrological status of the study area shall be included.

xi. Details of Drainage of the project upto 5km radius of study area. If the site is within 1 kmradius of any major river, peak and lean season river discharge as well as flood occurrencefrequency based on peak rainfall data of the past 30 years. Details of Flood Level of theproject site and maximum Flood Level of the river shall also be provided. (mega green fieldprojects)

xii. Status of acquisition of land. If acquisition is not complete, stage of the acquisition processand expected time of complete possession of the land.

xiii. R&R details in respect of land in line with state Government policy

5) Forest and wildlife related issues (if applicable):

i. Permission and approval for the use of forest land (forestry clearance), if any, andrecommendations of the State Forest Department. (if applicable)


ii. Landuse map based on High resolution satellite imagery (GPS) of the proposed site delineatingthe forestland (in case of projects involving forest land more than 40 ha)

iii. Status of Application submitted for obtaining the stage I forestry clearance along with lateststatus shall be submitted.

iv. The projects to be located within 10 km of the National Parks, Sanctuaries, Biosphere Reserves,Migratory Corridors of Wild Animals, the project proponent shall submit the map dulyauthenticated by Chief Wildlife Warden showing these features vis-à-vis the project locationand the recommendations or comments of the Chief Wildlife Warden-thereon

v. Wildlife Conservation Plan duly authenticated by the Chief Wildlife Warden of the StateGovernment for conservation of Schedule I fauna, if any exists in the study area

vi. Copy of application submitted for clearance under the Wildlife (Protection) Act, 1972, to theStanding Committee of the National Board for Wildlife

6) Environmental Status

i. Determination of atmospheric inversion level at the project site and site-specific micro-meteorological data using temperature, relative humidity, hourly wind speed and directionand rainfall.

ii. AAQ data (except monsoon) at 8 locations for PM10, PM2.5, SO2, NOX, CO and otherparameters relevant to the project shall be collected. The monitoring stations shall be basedCPCB guidelines and take into account the pre-dominant wind direction, population zoneand sensitive receptors including reserved forests.

iii. Raw data of all AAQ measurement for 12 weeks of all stations as per frequency given in theNAQQM Notification of Nov. 2009 along with - min., max., average and 98% values foreach of the AAQ parameters from data of all AAQ stations should be provided as an annexureto the EIA Report.

iv. Surface water quality of nearby River (100m upstream and downstream of discharge point)and other surface drains at eight locations as per CPCB/MoEF&CC guidelines.

v. Whether the site falls near to polluted stretch of river identified by the CPCB/MoEF&CC, ifyes give details.

vi. Ground water monitoring at minimum at 8 locations shall be included.

vii. Noise levels monitoring at 8 locations within the study area.

viii. Soil Characteristic as per CPCB guidelines.

ix. Traffic study of the area, type of vehicles, frequency of vehicles for transportation of materials,additional traffic due to proposed project, parking arrangement etc.

x. Detailed description of flora and fauna (terrestrial and aquatic) existing in the study areashall be given with special reference to rare, endemic and endangered species. If Schedule-Ifauna are found within the study area, a Wildlife Conservation Plan shall be prepared andfurnished.

xi. Socio-economic status of the study area.


7) Impact and Environment Management Plan

i. Assessment of ground level concentration of pollutants from the stack emission based onsite-specific meteorological features. In case the project is located on a hilly terrain, theAQIP Modelling shall be done using inputs of the specific terrain characteristics fordetermining the potential impacts of the project on the AAQ. Cumulative impact of all sourcesof emissions (including transportation) on the AAQ of the area shall be assessed. Details ofthe model used and the input data used for modelling shall also be provided. The air qualitycontours shall be plotted on a location map showing the location of project site, habitationnearby, sensitive receptors, if any.

ii. Water Quality modelling - in case of discharge in water body

iii. Impact of the transport of the raw materials and end products on the surrounding environmentshall be assessed and provided. In this regard, options for transport of raw materials andfinished products and wastes (large quantities) by rail or rail-cum road transport or conveyor-cum-rail transport shall be examined.

iv. A note on treatment of wastewater from different plant operations, extent recycled and reusedfor different purposes shall be included. Complete scheme of effluent treatment. Characteristicsof untreated and treated effluent to meet the prescribed standards of discharge under E(P)Rules.

v. Details of stack emission and action plan for control of emissions to meet standards.

vi. Measures for fugitive emission control

vii. Details of hazardous waste generation and their storage, utilization and management. Copiesof MOU regarding utilization of solid and hazardous waste in cement plant shall also beincluded. EMP shall include the concept of waste-minimization, recycle/reuse/recovertechniques, Energy conservation, and natural resource conservation.

viii. Proper utilization of fly ash shall be ensured as per Fly Ash Notification, 2009. A detailedplan of action shall be provided.

ix. Action plan for the green belt development plan in 33 % area i.e. land with not less than1,500 trees per ha. Giving details of species, width of plantation, planning schedule etc. shallbe included. The green belt shall be around the project boundary and a scheme for greeningof the roads used for the project shall also be incorporated.

x. Action plan for rainwater harvesting measures at plant site shall be submitted to harvestrainwater from the roof tops and storm water drains to recharge the ground water and also touse for the various activities at the project site to conserve fresh water and reduce the waterrequirement from other sources.

xi. Total capital cost and recurring cost/annum for environmental pollution control measuresshall be included.

xii. Action plan for post-project environmental monitoring shall be submitted.


xiii. Onsite and Offsite Disaster (natural and Man-made) Preparedness and Emergency ManagementPlan including Risk Assessment and damage control. Disaster management plan should belinked with District Disaster Management Plan.

8) Occupational health

i. Plan and fund allocation to ensure the occupational health & safety of all contract and casualworkers

ii. Details of exposure specific health status evaluation of worker. If the workers' health is beingevaluated by pre designed format, chest x rays, Audiometry, Spirometry, Vision testing (Far& Near vision, colour vision and any other ocular defect) ECG, during pre placement andperiodical examinations give the details of the same. Details regarding last month analyzeddata of above mentioned parameters as per age, sex, duration of exposure and departmentwise.

iii. Details of existing Occupational & Safety Hazards. What are the exposure levels of hazardsand whether they are within Permissible Exposure level (PEL). If these are not within PEL,what measures the company has adopted to keep them within PEL so that health of the workerscan be preserved,

iv. Annual report of heath status of workers with special reference to Occupational Health andSafety.

9) Corporate Environment Policy

i. Does the company have a well laid down Environment Policy approved by its Board ofDirectors? If so, it may be detailed in the EIA report.

ii. Does the Environment Policy prescribe for standard operating process / procedures to bringinto focus any infringement / deviation / violation of the environmental or forest norms /conditions? If so, it may be detailed in the EIA.

iii. What is the hierarchical system or Administrative order of the company to deal with theenvironmental issues and for ensuring compliance with the environmental clearanceconditions? Details of this system may be given.

iv. Does the company have system of reporting of non compliances / violations of environmentalnorms to the Board of Directors of the company and / or shareholders or stakeholders atlarge? This reporting mechanism shall be detailed in the EIA report

10) Details regarding infrastructure facilities such as sanitation, fuel, restroom etc. to be provided to thelabour force during construction as well as to the casual workers including truck drivers duringoperation phase.

11) Enterprise Social Commitment (ESC)

i. Adequate funds (at least 2.5 % of the project cost) shall be earmarked towards the EnterpriseSocial Commitment based on Public Hearing issues and item-wise details along with time


bound action plan shall be included. Socio-economic development activities need to beelaborated upon.

12) Any litigation pending against the project and/or any direction/order passed by any Court of Lawagainst the project, if so, details thereof shall also be included. Has the unit received any noticeunder the Section 5 of Environment (Protection) Act, 1986 or relevant Sections of Air and WaterActs? If so, details thereof and compliance/ATR to the notice(s) and present status of the case.

13) 'A tabular chart with index for point wise compliance of above TOR.

B. SPECIFIC TERMS OF REFERENCE FOR EIASTUDIES FORDISTILLERIES

1. List of existing distillery units in the study area along with their capacity and sourcing of rawmaterial.

2. Number of working days of the distillery unit.

3. Details of raw materials such as molasses/grains, their source with availability.

4. Details of the use of steam from the boiler.

5. Surface and Ground water quality around proposed spent wash storage lagoon, and compost yard.

6. Plan to reduce spent wash generation within 6-8 KL/KL of alcohol produced.

7. Proposed effluent treatment system for molasses/grain based distillery (spent wash, spent lees,condensate and utilities) as well as domestic sewage and scheme for achieving zero effluent discharge(ZLD).

8. Proposed action to restrict fresh water consumption within 10 KL/KL of alcohol production.

9. Details about capacity of spent wash holding tank, material used, design consideration. No. ofpeizometers to be proposed around spent wash holding tank.

10. Action plan to control ground water pollution.

11. Details of solid waste management including management of boiler ash, yeast, etc. Details ofincinerated spent wash ash generation and its disposal.

12. Details of bio-composting yard (if applicable).

13. Action plan to control odour pollution.

14. Arrangements for installation of continuous online monitoring system (24x7 monitoring device)

***

GIACL

DECLARATION

G,ANGiAMAIIIDUSTRIES & COI*STRUCTE!*S LTD.

This is to state that the 'Final EIA Report' submitted herewith has been prepared in respect of our

Proposed expansion of molasses based Distillery from 60 KLPD to 150 KLPD (expansion by g0 KLpD)

of Gangamai lndustries And Construction Ltd. (GIACL), Najik Babhulgaon, post.:Rakshi, Tal.:

Shevgaon, Dist, : Ahmednagar, Maharashtra.

lnformation, data and details presented in this report are true to the best of our knowledge.

Primary and secondary data have been generated through actual exercise conducted from time totime as well as procured from the concerned Govt. offices / departments has been incorporated

here subsequent to necessary processing, formulation and compilation.

Vishnu S. Khedekar(Chief Financial Officer)

[fangamai lndustries And Constructions ttd. (GtACt)\*Najik Babhulgaon, post.:Rakshi, Tal.: Shevgaon,

Dist.: Ahmednagar.

Dr. Sangram P. Ghugare (CMD)M/s. Equinox Environments (t) pvt. Ltd., (EEtpL)

F-L1, Namdev Nest L160 - B 'E' Ward, SykesExtension opp. of Kamla College,

Kolhapur 416 001

Environmental Consultant

Operations : Harinagar, Najik Babhulgaon, Post : Rakshi, Tq. Shevgaon, Dist. Ahmednagar (M.S.) - 414502, Telefar +91 (O2429) - 217251,Mob.: +9't - 9921994999, 9921995999, E-mail: [email protected], [email protected]

Corporate Office : 2* Floo1 Tapadia Tenaces, Adalat Road, Aurangabad431O0l . Tel-: +91 (24O) 2333933, 2332572,Fax: +91' (24A) 2333335, Email: [email protected]

*

Documents

GANGAMAI INDUSTRIES AND CONSTRUCTIONS LTD. (GIACL)environmentclearance.nic.in › writereaddata › EIA › 07012019... · 2019-01-07 · SRSL Shree Renuka Sugars Ltd. SS Suspended