Summary Environmental Impact Assessment Reportkspcb.kar.nic.in/PH/RKPPL Exe_Summary (English).pdf · Summary Environmental Impact Assessment Report ... jaggery, khandsari and white

R K Powergen Private Limited

Proposed Sugar Plant (5000 TCPD), Distillery (45 KLPD) andCogeneration Power Plant (34 MW)

Village Madikechilur, Tehsil & District Shimoga, Karnataka State

Environmental Clearance under EIA Notification 2006Schedule Sl. No. 5(g) & 5(j)

Category ‘A’

Summary Environmental Impact Assessment ReportJanuary 2012

EIA ConsultantEnvironmental System Consultants &

Ambiente Lab Solutions Private Limited(EIA Consultant No. 200 under NABET Scheme)

Old 7, New 14, Shanmuga Naicker Street,K K Nagar, Chennai-600 078.

Phone : 044-2364 3663; Fax-044-2364 2663e-mail : [email protected]

MoEF File No. J-11011/91/2011-IA II (I)

R K Powergen Private Limited Sugar Plant, Distillery & Cogeneration Power Plant, Madikechilur, Shimoga, Karnataka

Ensyscon & Amblabs, Chennai-78

Summary Environmental Impact Assessment

1.1 Project Description

Karnataka Sugar Industry : Karnataka State is one of the major sugarcane and sugar-producing statesin the Country. Sugarcane is being cultivated in large areas since many decades for manufacture ofjaggery, khandsari and white sugar. Sugar industry is a major livelihood provider to millions of agriculturalfamilies and their dependents particularly in rural areas. About a million lakh people depend upon sugarindustry, directly or indirectly. Apart from this, sugar factories are considered to be Welfare Centers inrural areas, as they give scope for establishment of educational institutions, hospitals, communication &transportation facilities, etc.

Karnataka has conducive agro climatic conditions for sugarcane cultivation resulting in increasedsugarcane production year after year, giving scope for establishment of more sugar units in the state. InKarnataka sugarcane is produced to the tune of 375.95 lakh tones during 2010-11 with an average sugarrecovery of 11.01%.

Karnataka Sugar Industry ranks 3rd in terms of its contribution of Sugar in the total sugar production ofIndia. Karnataka stands 4th in the Country in the cultivation of sugarcane. Sugar Industry in Karnatakacontributes around Rs.36 crore per year to the State Exchequer as central excise duty. It also contributesmore than Rs. 900 crore in the form of turnover tax and sales tax to the State Exchequer.

Project Proponent : M/s. R K Powergen Private Limited (RKPPL) Chennai is a company promoted by agroup of Women Entrepreneurs belonging to the Industrial House of Late Shri N P V RamaswamyUdayar. They have Business interests in the fields of Industrial Chemicals, Food Products, PowerGeneration, Bottling Plants, Medical Care, Textiles, Educational & Research Institutions, etc. TheGroup’s asset value is about Rs.4,500 crores.

RKPPL is successfully operating a 20 MW Biomass Power Plant at Hiriyur in Chitradurga District ofKarnataka State. On completion of Hiriyur Biomass Power Plant, RKPPL has made an application andobtained the In-Principle Approval from the State Government of Karnataka for setting up the Sugar Plantalong with Distillery and Cogeneration Power Plant in Shimoga District (Reference : Government ofKarnataka Proceedings of the 89th High Level Committee meeting held on 11th April 2002).

Shimoga District is the Granary of Paddy in Karnataka. Shimoga farmers are producing good qualitypaddy, coconut, ragi, pepper, areca and Sugarcane. The proposed Sugar Plant will cater the immediatedemand of local farmers of the District. The Plant will also be able to generate sufficient power to exportto the State Grid, after meeting its captive demand.

Proposed Site : RKPPL has identified and purchased 18.82 Ha (46.50 acres) of dry agricultural pattalands falling in SF Nos. 76/2-17, 77/1,2,4-8,10, 80/2, 80/6, 80/7, 80/9-12,105/1&2, 106/1, 107, etc. inMadikechilur village, Tehsil & District Shimoga of Karnataka State (Fig. 1.1). The entire land is registeredin favour of RKPPL and in RKPPL possession. For Green Belt development and others, RKPPL wouldacquire additional lands of about 10 Ha adjacent to the Plant Site both in Shimoga and DavangereDistricts. Thus, total land extent is 28.82 Ha.





There is no forest land envisaged for the Project and there is also no Rehabilitation & Resettlement (R&R)issues involved. There is no litigation/pending case against the proposal. The site is not falling inindustrially polluted clusters notified by CPCB.

Shimoga Sugar Project :

The green field Sugar Complex would be 5000 Tons Crushing per Day (TCPD) Sugar Plant operablefrom 3500 to 5000 TCD for producing Plantation White Sugar, 45 Kilo Liters per Day (KLPD) Distilleryand 34 MW Cogeneration Power Plant (Baggase & Coal based).

The Government of Karnataka, vide Cane Allocation Order No. C1 46 SGF 04 (Part-I) dated 25.09.2008,has allotted 89 villages in Shimoga Taluk, 44 villages in Bhadravathi Taluk, 121 villages in ShikaripuraTaluk and 40 villages in Honnali Taluk for the Project.

Plant Layout : The plant & machinery layout for factory is designed such that the plant expansion can beeasily carried out by modular additions of equipment without disturbing the initial layout (Fig. 1.3). Thesugar, cogeneration & distillery plants are completely integrated so that utilities such as water / electricityand steam are optimally shared within the three plants so as to obtain the best performance efficiency &lowest external inputs. A Colony with 100 Quarters is also proposed.

The Project will give direct employment to about 300 persons and indirect employment to about 400persons.

Proposed Land Use :

Proposed Land Use Area, sq. m

Buildings/Structures ((with Roof Top) 42930

Green Belt 99960

Roads/Paved Areas 95976

Vaccant Area 49334

Total Extent 288200

Sugar Plant Profile : Operating Capacity of Sugar Factory is 3520 TCD @ 160 tch for first three yearsand fourth year onwards 5060 TCD @. 230 tch. Double Sulphitation process with 4 massecuite boilingscheme shall be adopted for production of plantation white sugar. 90% of total sugar produced isconsidered as free sugar sale and 10% is considered as Levy Sugar (Govt. Quota). Number of days ofoperation of Sugar Factory is 180 days.

The sugar cane is received from the farm lands to the Plant through trucks, weighed and unloaded in themilling carrier. The cane is passed through series of rotating knives and shredding the cane into pieces.The shredded pieces of sugarcane travel on the conveyer through diffuser and dewatering mills whichextract juice from the cane. Hot water is added in the course of crushing as imbibition water for betterextraction of juice from sugar cane. The raw juice is sent to boiling house for further process and leavingthe Bagasse. Bagasses will be used as fuel in the Cogeneration Plant.





The weighed quantity of juice is primarily heated to 70-75 oC in juice heaters. Sulphur dioxide and themilk of a lime are then added to the juice and is heated to 102° C and transferd to clarifier for settling ofcalcium sulphate and sulphite precipitate formed due to sulphitation reaction. The clarifier underflow isfiltered in rotary vacuum filter. The filtrate is returned to sulphiter whereas press mud or filter cake isdiscarded.

The clear juice from the clarifying process is evaporated in evaporator station. The juice of 15 oBrix isconcentrated in the evaporators to syrup of 60 oBrix. The syrup obtained from evaporator is again treatedwith SO2 gas. The sulphited syrup is transferred to the pan station for pan boiling where the syrupconcentrates and attains super saturation stage. In such a condition, sugar grains are formed in thesyrup. The syrup mass with sugar particles is called massecuite. The massecuite is dropped incrystallizers and cooled to complete the crystallization.

Massecuite is taken into the high speed centrifugal machine. Sugar crystals are separated from motherliquor and sent to driers. Non crystallisable matter from the massecuite called Molasses and is drainedout from the centrifuge. The molasses is weighed and sent to storage tank.

Sugar is dried in the vibrating hopper and graded by passing through standard sieves. The graded sugaris bagged, weighed, stitched, numbered and stacked in sugar godown.

Raw Materials required are :

Cane : 1,50,000 Tons/monthLime (from Local market) : 225 Tons/monthSulphur : 150 Tons/monthHCL : 3 Tons/monthCaustic soda lye : 3 Tons/month.

Molasses produced is given to its own Distillery at free of cost. Recovery of sugar considered for sugarproduction is 10.43% and Recovery of molasses sent to distillery is 4.50%. Factory generated Bagasse isgiven to the Cogeneration Plant and required steam and power is consumed from Cogeneration Plant.

Description Unit ValueCane crushing capacity TCD 5000Cane crushing capacity Tch 230Cane crushing Days 180Capacity utilization % 92Cane crushing ( Net) hrs. 3,974Cane crushed MT 9,14,000Sugar produced (White) Qtls. 9,53,422Bagasse % cane 29.07Steam consumption % cane 44.00 % for Sugar factory

4.35 % (10 T/H) for Distillery PlantSugar recovery % cane 10.43Molasses % cane 4.50Baggase Generation TPD 1582



DECANTER

0.15

SLU

DG

E

0.07

LEE

SS

PE

NT

5.18

DM

WA

TE

R15

SP

EN

T W

AS

H

STE

AM

/MO

L1.

24T/

H1.

59C

O2

BA

GA

SS

E66

.87

T/H

WA

TE

R10

0.09

T/H

FILT

RA

TE

18.8

6T/

H

BA

GA

CIL

LO0.

63T/

H

WA

TE

R2.

76T/

H

MU

DD

Y J

UIC

E21

.6T/

H

2.55

T/H

FLA

SH

1.09

T/H

CS

UG

AR

BS

UG

AR

A1S

UG

AR

SY

RU

P51

.36

T/H

SUGAR COMPLEX MATERIAL BALANCE

CANE CANE CANE JUICE MIXED JUICE CLEAR JUICE COND. & LOSSES230 T/H

(180 DAYS)PREPARATION 230 T/H EXTRACTION 264.46 T/H

CLARIFICATION260.63 T/H

EVAPORATOR7.56 T/H

VAPOUR TO JH54.29 T/H

VAPOUR TO PAN47.33 T/H

0.1

25.5 MW

2.08

140 T/H

14.9011.00

FILTER

FILTER CAKE

A STATION

A1 STATION

B STATION

23.99 T/H

ETHANOL TO STORAGE1.48

3.90

DEHYDRATIONRS TO ETHANOL PLANT

1.55

11.00

DISTILLATIONFERMENTED WASH

24.62 FERMENTATIONMOLASSES

7.81

DOSING1.13

MOLASSES

FINAL MOLASSES10.36 T/H

C STATION

TO COOLING TOWER MAKEUP18.39

TO CO2 SCRUBBER0.32

REJECT FROM CPU

YEAST SEPARATOR STORAGE

CONDENSATE11.54 EVAPORATOR

CONCENTRATED SPENT WASH3.46

INCINERATOR

Distillery Profile :

Molasses is the chief raw material used for the production of Alcohol. Molasses contains about 45% totalsugars of which 30-33% is cane sugar and the rest is reduced sugar. During the fermentation, yeaststrains, a living micro-organism, converts the sugar in the molasses to alcohol. One ton of molasses with45% sugar gives an alcoholic yield of 250-285 litres.

Principle product of the Distillery Plant will be Fuel Ethanol (ENA)/Absolute Alcohol (AA). AA productioncapability will be minimum 45 KLPD (Kilo-litres Ethanol per Day). ENA production capability will beminimum 45 KLPD (Kilo-litres Ethanol per Day) along with technical alcohol of 5 KLPD. It is proposed toadopt ‘Batch Cascade Type Continuous Fermentation Technology’. Salient Features of the Distillery are :

Distillery Plant-Salient Features

Sl. No. Description Unit Value1 Distillery Plant Capacity ( KLPD) KLPD 452 Distillery Plant operation Days 2203 Molasses Recovery % cane 4.50 %4 Over all Capacity Utilization % 95 %5 Fuel Ethanol per annum KLPA 9,108

Distillery will be operating for 220 days in a year. Distillery will be operating only on own sugar plantgenerated molasses.



Distillery will be operating only on own sugar plant generated molasses. Steam (In equipment cost ofpower) and power will be considered as free of cost from Sugar Factory and Cogeneration Plants.

Cogen Plan Profile : Cogeneration is the simultaneous production of power and heat - usually in the formof electricity and steam using a single fuel such as bagasse. With solid fuels, high pressure steam is usuallyraised in a boiler and passed through a turbine to generate power. The heat produced from the electricitygenerating process (for example from the exhaust systems of a gas turbine) is captured and utilised toproduce high and low level steam. The steam is used as a heat source for industrial purposes.

Bagasse-based cogeneration utilizes the waste material which is otherwise a hazard as well as anenvironmental concern as the decomposition of bagasse releases methane, a more potent greenhousegas than carbon dioxide.

The Co-generation Plant has been evolved for the energy demand of the Sugar Factory at 230 tch and45 KLPD distillery. Plant size is based on available own bagasse operation (230 TCH) for duration of 180days (season). Boiler is 1 x 140 TPH capacity and Turbo alternator-1 x 26 MW (Extraction cum Backpressure type) and 1 x 8 MW (Extraction cum Condensing type).

Total units exported in this option are 70,000 MWh in 180 days in season and 73,885 MWh in 140 daysduring offseason. Boiler can run on coal during offseason operation. Coal requirement in off-season is56,838 tons of Indonesian coal of 5,500 kcal/kg calorific value with 5-7% ash and <1% sulphur.

Boiler type : Natural circulation, bi-drum, water tube boiler, top supportedCapacity (MCR) : 140 tons/hrPressure at super heater header : 87 bar (a)

oSteam temperature header C : 520+5

Fuel : Bagasse with 50 % moisture content, having GCV 2200 kcal/kg and Indonesian Coal with 5-7%ash content.

Power will be purchased by KPCL with unit rate for 10 years along with CDM Benefits. Carbon Credit isavailable at the rate of 10 USD / ton of CO2 and 800 Kg of CO2 Emission Reduction/ MWh. With theestimation, carbon credit will be 0.410 Rs/Kwh.

Project Cost & EMP Budget : The project cost is Rs. 367.23 crores as detailed below :Unit : Rs. crores

Component Sugar Plant Distillery Cogen. Plant Grand Total

Land cost 4.89 1.39 3.50 9.78Building & Structurals 7.47 2.06 3.35 12.88Plant & Machineries 153.43 42.27 113.71 309.41

Others 19.05 4.61 11.50 35.16Total 184.84 50.33 132.06 367.23

Capital Cost for Pollution Control Measures would be Rs.10.00 crores with a Recurring Cost of Rs.2.00crores/annum. A budget of Rs.5.00 lakhs/annum is earmarked for Green Belt & Environmental Monitoring



works, Rs.5.00 lakhs/annum for Social Measures and Rs.3.00 lakhs/annum for Occupational Health &Safety Measures.

EIA Scoping & Awarded TORs : As per EIA Notification 2006, the Sugar Industry of >5000 TCD hasbeen kept at Sl. No. 5 (j) under Category ‘B’ with the application of ‘General Conditions’ and all Molasses

based Distilleries have been kept at Sl. No. 5 (g) under Category ‘A’. As the proposed Sugar Complex(integrated/inter-linked) project involves Category ‘A’ activity, RKCDPL has applied to the Central EIAAuthority at MoEF, New Delhi with Form-1, Proposed TORs and DPR for the Project’s Environmental

Clearance.

The Honourable Expert Appraisal Committee (Industry-2) has deliberated the Project in its 22nd EACMeeting held during 29th & 30th April 2011 and awarded the Terms of References (TORs) for carrying outthe EIA Study vide MoEF Letter J-11011/91/2011-IA II (I) dated 7th June 2011. The awarded TORs havebeen transferred in the name of M/s. R K Powergen Private Limited vide MoEF Letter even Referencedated 13th December 2011.

EIA Consultant : RKPPL has entrusted the EIA Study to M/s. Environmental System Consultants &Ambiente Lab Solutions Private Limited, Chennai. The EIA Consultant has applied to the NationalAccreditation Board for Education & Training (NABET), Quality Council of India for empanelment. TheApplicant Number is 200 in the List of Consultants notified by MoEF.

The Environmental Impact Assessment (EIA) Report and the Summary Environmental ImpactAssessment Report have been prepared as per the generic structure proposed in EIA Notification 2006.The environmental data collected pertaining to the Postmonsoon Season (October-December) 2011 wereused for the EIA Study. The Additional TORs are also incorporated in the EIA Report and submitted alongwith Summary EIA Report (both in English & Kannada) for Public Consultation & Public Hearing.

1.2 Description of the Environment

Environmental Setting : The Project Site falls in Survey of India Topo Sheet Nos. 48 N/13 (Fig. 1.2)bounded by the following co-ordinates:

Latitudes : 14o03’39” - 14o04’06” NorthLongitudes : 75o40’42” - 75o41’04” East.

Haramghatta State Forest (Deciduous) is adjacent to the site in the west. Shettihalli Wild Life Sanctuary isat 21 km distance from the site in the southwest and its buffer area is at 7-9 km distance. The Buffer Areaof Badra Wild Life Sanctuary is at a distance of 12-15 km in the southeast. Thus, there is no ecosensitive zone within 10 km radius. There is no National Parks//Biosphere Reserve/ElephantCorridor/Historical Monuments, etc. exist within 10 km radius area of the Project area.

The Deputy Conservator of Forest-Wild Life Division, Shimoga has issued the NOC for the Project vide hisLetter Sl. No. B5:No Objection:2010-11 dated 18.01.2011 as the site is away by 21 km from the Wild LifeArea. The Deputy Conservator of Forest, Shimoga Division has issued the NOC for the Project vide hisLetter No. B4/Bhoomi/GL-2266/11-12 dated 16.08.2011 with a condition to dig a trench of 1 meter widthall along the boundary adjacent to Haramghatta State Forest Extension Block.




The study area exhibits undulating terrain with a gentle slope towards southeast. The minimum andmaximum elevation of the site is 585 m and 600 m above mean sea level (amsl) respectively.Thungabhadra River drains the region. It flows at a distance of 2 km in the east from the site towardsnorth. Upper Thunga Channel is the eastern boundary to the site. There are first order streamsoriginating from the site and joins Madikechilur pond.

Madikechilur is the nearest village at a distance of 1.1 km in the east with a total population of 1058persons in 232 Households (HHs) as per 2001 Census. Holalur is at 3 km away in the south with 3,887persons in 743 HHs. District Head Quarters Shimoga is at a distance of 17 km (20 km by road) insouthwest with a total population of 2,74,352 persons (1,40,224 males & 1,34,128 females) in 59,005HHs. Badravati Town is at a distance of 25 km in south. State Head Quarters Bengaluru is at a distanceof 240 km in southeast.

Shimoga is well connected by road to all major cities and towns of Karnataka and important cities ofneighbouring states. The site is well connected with road networks. National Highway 206 is connectingShimoga with Bengaluru. NH-13 connecting Shimoga with Mangalore and Solapur. The State HighwaySH-25 connects Shimoga with Hosepet via the site. Site is located in the west of SH at 0.6 km distance.The Southwestern BG Railway line connecting Bengaluru-Arsikere-Birur-Shimoga-Anandpuram &Talguppa runs at a distance of 17 km from the site in southwest. Nearest Railway Station is Shimoga (17km; SW) and the nearest Airport is Mangalore (200 km; SW).

Agro based industries, Automobile based industries and Engineering based industries are mainindustries in the Shimoga District. There is no major industry within the study area. The nearest Plant isMysore Paper Mills Sugar Factory, Badravathi with 2500 TCD Sugar Plant & 18,000 MT/Annum Distillery.

Environmental Components : Considering the environmental setting of project, project activities andtheir interaction, environmental Regulations and Standards, following Environmental Attributes have beenincluded for the EIA study. The Study Area will be covering 10 km Radius from Site Boundary (Fig. 2.2).The Project site and its environs fall in Industrial, Residential, Rural and Other Areas Category as perNational Ambient Air Quality (NAAQ) Standards revised as per GSR 826(E) dated 16.11.2009.

Site specific Micrometeorological Data for the parameters Wind Speed & direction, Temperature,Humidity, Cloud Cover and Rainfall.

Ambient Air Quality (at 14 locations) for the parameters : PM2.5, PM10, SPM, SO2, NOx, CO, HC &Particulate Lead.

Noise Level Measurements at 14 Locations for both Leq-Day and Leq-Night values. Water Quality-both Surface Waters (8 Locations) and Ground Waters (10 Locations) for IS:10500

Norms. Soil Quality (6 Locations) for Textural & Physical Parameters, Nutrients, etc. Present & Post-project Land Use Pattern based on Satellite Imagery. Biotic Attributes : Flora & Fauna -Core zone & Buffer zone-Diversity Index. Socio-Economic Profile (2001 Census) : Total Population, Household Size, Age, Gender

Composition, SC/ST, Literacy Level, Occupational Structure, etc.






2

The findings of baseline environmental status of the study area are summarized below :

The collected meteorological data during this season represented the local weather phenomena.Neutral and unstable atmospheric conditions were prevailing most of times.

The monitored ambient air quality in the study area was found to be in compliance with the RevisedNational Ambient Air Quality (NAAQ) Norms of 60 ug PM2.5/m3, 100 ug PM10/m3, 80 ug SO /m3 and80 ug NOx/m3 for Industrial, Residential, Rural and other areas.

Ambient equivalent noise levels (Leq) during day times <55 dB(A) and night times <45 dB(A) werefound to be well within the MoEF Norms for Residential Areas.

The water quality of surface waters were found to be in compliance with IS/CPCB norms except forTotal Coliforms due to sewage contamination. The ground water quality was found to be incompliance with the IS:10500 Norms.

The soil in the study area would very well support vegetation after amending it suitably. Presence of number of phanerophytes (shrubs and trees) and therophytes (annuals) indicates

semiarid vegetation structure in the study area. Domesticated animals and common fauna only exist in the study area. The area is thinly populated. The basic amenities are there almost at all villages.

Thus, adequate buffer exists for the proposed Project in the physical, biological and edaphicenvironments of the study area.

3.0 Anticipated Environmental Impact and Mitigation Measures

3.1 Construction Phase

The proposed construction requires/involves : PCC : 15000 m3, RCC : 50000 m3 and RR structures :40,000 m. In an average, 30 Truck loads/day (for transporting all construction materials) will be visitingthe site in a day during the construction period. Construction labourers (100-125 persons/day) will bepooled from the local public for construction.

Ambient air quality : The monitored mean ambient air pollutants values at the sites were found to bevery well within the National Ambient Air Quality Norms. The main sources of emission during theconstruction period are the movement of construction materials and equipments at site and dust emittedduring the construction related activities. The impacts of construction activities on air quality will be forshort duration, confined locally and is expected to be negligible outside the plant boundaries. Also, thereis enough buffer level in the ambient levels in the plant vicinity.

Noise levels : The proposed construction activities would increase the equivalent noise levels by another2-3 dB(A). There will be very less impact on the existing noise levels due to construction, traffic,fabrication and handling of equipments and machineries, etc. which will be confined locally.

Water quality : The construction water requirement of about 100 KLD will be met from existingborewells. As local labourers to be engaged for the construction activities, no sewage generation isanticipated. Thus, impact on water environment is insignificant.

Terrestrial ecology : There is no tree cutting or removal of plantations, etc. involved. No solid/hazardouswastes generation. There is no significant impact is anticipated on the land environment due to theconstruction activities.



Socioeconomics : There are significant numbers of non-workers in the area and the project wouldprovide direct or indirect job opportunities to them.

Thus, the overall impact on environment during construction phase due to the proposed Project would beshort term and insignificant.

3.2 Operation Phase

Land Use : The main plants are coming up in about 5.5 Ha with a Green Belt coverage of 10 Ha(34.7%) of total 28.82 Ha. Bagasse (21 TPD), filter cake and furnace ash are the main solid wastes fromthe Complex. Bagasse ash contains potash, hence can be used as manure also. Filter cake is goodmanure. In most of the sugar factories, Baggase Ash is mixed with filter cake and is used as manure inthe cane fields.

Imported coal of 405 TPD will be used as Boiler fuel for 140 days during Off Season. Ash generationwould be 28 TPD out of which 24 TPD will be Fly Ash and 4 TPD is Bed Ash. Entire quantity of 28 TPDAsh will be given to nearby Cement Industries for PPC manufacture.

Air Environment : Boiler shall be provided with electrostatic precipitator to control the dust emission.ESP shall be suitable for bagasse firing as well as coal firing system. The chimney with a height of 72 mis proposed. Inside diameter is 4.5 m. Design SPM emission : 100 mg/Nm3. The stack characteristics wouldbe as follows :

Stack Parameter

Stack Height, m

Boiler

72

Incinerator

50

DG-1

15

DG-2

15

Stack Diameter, m 4.5 1.2 0.3 0.3

Stack Temperature, oC 140 160 250 250

Stack Velocity, m/s 12 15 20 20

Stack Discharge, Nm3/hr. 495500 42000 2900 2900

SPM Concentration, mg/Nm3 100 100 100 100

SPM, g/sec 13.764 1.167 0.081 0.081

SO2, g/sec 56.38 0.583 0.040 0.040

NOx, g/sec 56.43 1.167 0.016 0.016

Industrial Source of Complex Short Term (ISCST3) model by USEPA was used for carrying out theprediction of maximum concentration, the direction and the distance of iits occurrence from the projectsite. The predicted GLCs are tabulated (Table 4.1):

The predicted values were spatially distributed on the existing baseline status and the cumulative impactwas found to be confined locally. While comparing the NAAQ Norms, adequate buffer exists in the studyarea for the operation of the Plant.



Table : 4.1 Predicted GLCs

Sl.No.

Pollutant

BackgroundConcentration

(24-hly.),ug/m3

MaximumPredicted

Ground LevelConcentration,

ug/m3

Distancefrom thePlant, km

TotalConcent-

ration,ug/m3

NAAQNorms,

3ug/m

Buffer Availablein the

Atmosphere, %

1 PM10 26.0 0.08 5 40.83 100 59.17

2 SO2 6.2 2.31 7 8.51 80 89.36

3 NOx 5.5 2.42 7 7.92 80 90.10

* : WORST CASE SCENARIO; SIMULTANEOUS/CUMULATIVE EMISSIONS FROM ALL SOURCES.NOTE : 1. BACKGROUND CONCENTRATION IS THE EXISTING LEVELS IN THE STUDY AREA. 2. NAAQ NORMS-NATIONAL AMBIENT AIR

QUALITY NORM (24/8 HLY.) STIPULATED BY CPCB FOR INDUSTRIAL, RESIDENTIAL AND RURAL AREAS.

Noise : Noise levels from turbine, fans, centrifugal pumps, electric motors etc, shall be kept below thepermissible level of 85 dB (A) at 1m away from the source by proper design. The noise level within theplant at a distance of one meter from the sources are maintained at less than 85 db(A). Noise level atthe plant boundary were monitored to be <55 dB(A) during daytimes and <45 dB(A) during night times.Thus, the noise levels are found to be well within the permissible limits for residential areas.

Noise from safety valves, start up vents, steam jet ejectors of condensers etc, are reduced by providingsilencers at the outlet of down steam piping. The specifications for procuring major noise generatingmachines/ equipment shall include built in design requirements to have minimum noise levels meetingOccupational Safety and Health Association (OSHA) requirement. Appropriate noise barriers/shields,silencers, etc. will be provided in the equipment, wherever feasible. As far as possible noise emanatingfrom noisy equipment should be adequately attenuated by enclosure, insulation etc. Ear plugs will beprovided to workmen working near high noise generating sources.

Traffic Intensity : It is anticipated about 450 vehicles/day (18.75 Vehicles/hour) to the existing 120vehicles/day. Existing State Highway will be adequate for handling the additional traffic volume.

Water Environment : Total water requirement is about 5664 KLD (Kilo Liters per Day) out of whichRecycled water is 2544 KLD and thus the net fresh water demand is 3120 KLD @ 130 KL/hr.. The plantwater system is designed for a maximum water flow rate of 150 KL/hr. In-Principle Approval has beengiven by the State Government for drawl of raw water for the Project @ 150 KL per Hour (3600 KLD)from Thungabhadra River near Madikechalur village.

Total Water Demand : 5,664 KLD FreshWater Demand : 3,120 KLDRecycled/Reused Water : 2,544 KLD (44.92%)

Sugar Plant Water Consumption: (5000/2206.8 =) 2.27 KL/Tonne of Cane CrushedDistillery Water Consumption : (419.52/45 =) 9.32 KL/KL of Alcohal Production

(Norm : < 10 KL/KL)



Total Trade Effluent Generation : (57.6 + 664.96=) 722.56 KLDSpent Wash Generation : (307.68/45=) 6.84 KL/KL of Alcohal Production

(Norm : < 8 KL/KL)Total Sewage Generation : (23 + 67 =) 90 KLD

The Plant will have 2 x 500 KLD Effluent Treatment Plant (ETP) for treating the Effluents of 722.56 KLD. A100 KLD Sewage Treatment Plant (STP) to treat the domestic sewage of 90 KLD from Plant (23 KLD) andColony (67 KLD). The treated wastewaters of 800 KLD will be utilized for Green Belt Development, DustControl Measures, etc.

Spent wash concentration is achieved by way of reboiler. A special boiler of 10 TPH with secondary fuelwill be used. The concentrated spent wash will be used as main fuel for boiler for distillery andevaporation section to achieve ‘Zero Effluent Discharge’.

The treated, clear effluent overflowing from the secondary clarifier can be used for irrigation. The effluenttreatment plant designed as per the above scheme shall yield treated effluent satisfying KPCBGuidelines:

Sl.No Parameter Unit Value

1 Temperature raise oC +3 above ambient2 pH - 6.0 – 9.03 BOD-3 days at 27 oC mg/l 504 COD mg/l 2505 Total suspended solids mg/l 506 Total Nitrogen as NH4-N mg/l 107 Total Phosphates mg/l 28 Oil & Grease mg/l 10

ETP Units :

Bar screen chamber 1Oil & Grease trap 1Lime dosing unit 1Equalisation tank 1Alum dosing unit 1Effluent transfer pumps 2Primary clarifier 1Aeration tank 1Diffused aeration system 1Air blowers along with accessory equipment 2Secondary clarifier 1Sludge re-circulating pumps 2Sludge drying beds 5

Biological Environment : No tree cutting and no impact on the nearby Reserved Forests. The proposedGreen Belt will have significant long term impact during the Operation Phase. Only common fauna existsin the study area.



Socioeconomic Environment : The projects would help in generation of direct and indirect employmentfor the local people. This would be a positive long term impact due to the Project. There will be a generalupliftment of standard of living in the region.

Occupational Health : An industrial worker may be exposed to five types of hazards, depending uponhis occupation : Physical, Chemical, Biological, Mechanical and Psychosocial hazards. Accidents are acommon feature in most industries. All efforts will be taken to avoid the accidents and have a good‘Occupational Environment’.

Solid Wastes : Bagasse, filter cake and furnace ash are the main solid wastes from the Complex.

Baggase generation & utilization : 1406 TPDBaggase ash generation : 21 TPD

Baggase ash will be used for landfill. Bagasse ash contains potash, hence can be used as manure also.Filter cake is good manure. In most of the sugar factories, Baggase Ash is mixed with filter cake and isused as manure in the cane fields.

Ash Generation : Imported coal of 405 TPD will be used as Boiler fuel for 140 days during OffSeason.With 7% Ash content (worst case), Ash generation would be 28 TPD out of which 24 TPD will beFly Ash and 4 TPD is Bed Ash. Ash will be stored in Ash Silos. Entire quantity of 28 TPD Ash will begiven to nearby Cement Industries for PPC manufacture and brick manufacturing units.

4.0 Environmental Monitoring Programme

For effective implementations of Environmental Management Plan, RKPPL will have the EnvironmentMonitoring Cell reporting to the Factory Head. The quality of air, water, soil and noise levels will bemonitored as per specified norms and the reports will be submitted to MoEF and KSPCB on regularbasis.

5.0 Additional Studies

Rain Water Harvesting : The roof water collection is estimated as 86756 CUM/Year. 5 sumps with a totalcapacity of 4000 CUM (800 CUM each) have been suggested to capture the roof water.The rainwaterthat is been generated from the roof is proposed to pass through a filter media. The proposed filtermedia is multiplayer vertical filters. The size of the multiplayer vertical filter is 2m X 2m X 1.2 m. Theoutlet pipes from the roof area are connected with 115 mm dia PVC pipe allowing the water to passthrough the filter media before storing in the sump. The 100% of the total requirement of water is metthrough the rain water harvested at the project site.

Water Reservoir : A pond of 12000 cu.m has been proposed for surface runoff collections. It isestimated as 132857 cu. m per annum.

Risk Assessment and DMP : Fire, electrical shock, natural calamities, etc. are the risks associated with theactivities. Detailed assessment and mitigative measures are delineated and an effective DisasterManagement Plan is also envisaged in the EIA Report.



6.0 Project Benefits

The major benefit of the Sugar Complex is that it would generate many facilities in the Region such ascommunication, employment and transport. It will also benefit the State by the development of the ruralareas. Shimoga District is the Granary of Paddy in Karnataka. Shimoga farmers are producing goodquality paddy, coconut, ragi, pepper, areca and Sugarcane. The major share of the District income isfrom the Agriculture sector. Agricultural resources can be properly used for conversion into value addedproducts.

The proposed Sugar Plant will cater the immediate demand of local farmers of the District. The Plant willalso be able to generate sufficient power to export to the State Grid, after meeting its captive demand.The Project will give direct employment to about 300 persons and indirect employment to about 400persons.

7.0 Environmental Management Plan

EMP is formulated for mitigation of adverse impacts and is based on present environmental status andimpact appraisal. EMP includes formulation, implementation and monitoring of environmental protectionmeasures.

It is mandatory to comply with the various regulatory Norms for Prevention and Control of Pollution.Alongside, it is also imperative to go beyond compliance through adoption of cleaner technologies andimprovement in Management practices.

7.1 Air Environment

All sources of dust generation in the Sugar and Power Plants shall be well designed for producingminimum dust and shall be provided with high efficiency Bag Filters and ESP.

SPM emission level in exhaust air shall be <100 mg/Nm3. SO2 concentration shall be negligible and the stack height will be 72 m as proposed. The periodical evaluation for the efficiency performance of ESPs and Bag Filters shall be carried out. For controlling fugitive dust, in hopper, reclaimer, conveyors, silos etc., bag filters shall be installed. Fugitive emissions due to storage, transportation, etc. and the leakages and spillages shall be

continuously monitored and controlled. Water conservation measures shall be undertaken for effective implementation. Cooling water is put

into closed circuit to minimize the evaporation losses. Thermal insulation is provided wherever necessary to minimize heat radiation from the equipment,

piping etc, to ensure protection of personnel. As far as gaseous pollution is concerned, the impact of carbon monoxide (CO) emission is negligible

in view of the firing technique of keeping a positive oxygen balance.

7.2 Noise Levels

The design features of machineries shall be provided to ensure low noise levels in the working areas. All rotating items are well lubricated and provided with enclosures as far as possible to reduce noise.



Extensive vibration monitoring system are provided to check and reduce vibrations. For all fans,compressors etc. vibration isolators are provided to reduce vibration and noise.

Noise generating items such as fans, blowers, compressors, pumps, motors etc. shall be runningwith speed less than 1500 rpm and reduce noise levels. Static and dynamic balancing of equipmentare being done regularly.

Provision of silencers are made wherever possible. Green Belt proposed in the Plants and Township are also act as noise reducers. Layouts, equipment foundations and structures are designed keeping the requirement of noise

abatement in view. Necessary enclosures are also provided on the working platform/areas to provide local protection in

high noise level areas. All heavy earthmoving equipment is kept in a well maintained condition. Proper lubrication and house keeping are maintained to avoid excessive noise generation. In case where the operation of the equipment warranted the presence of operators in close proximity

to equipment, the operator provided with the necessary safety and protection equipment like earplugs, ear muffs etc.

7.3 Water Environment

Water control measures shall be undertaken. No trade effluent shall be discharged from the Plants. Cooling water is put into closed circuit to minimize the evaporation losses. The domestic sewages from the Plants, Power Plant and Township shall be treated in the proposed

100 KLD Sewage Treatment Plant to meet the Statutory Discharge Norms and the treated sewageshall be used for Green Belt.

No percolation of treated water to the deep ground water table is done. Periodical monitoring for specific parameters shall be done regularly. Rain water harvesting structures shall also be developed as proposed from the roof tops of Plants as

well as Township areas to supplement the water supply from the river.

7.4 Land Environment

It should be ensured that there is no industrial solid waste from the Plants. The fly ash and Baggase ash from the Power Plant will be consumed fully. Solid wastes from STP Plant shall be used as manure for Green Belt. Waste Oil shall be collected and sold to the MoEF/KSPCB authorised Agency for further treatment &

disposal. The municipal wastes from Plants & Township shall be collected, transported, treated in a landfill

(composting) within the Plant vicinity to make use of it as manure for Green Belt. The land fill sites are clearly demarcated indicating the period during which they have been filled.

7.5 Green Belt

An effective Green Belt will be carried out in an area of 10 Ha (34.7% coverage of total area) andmaintained with the guidance of DFO. A mixture of fruit, fuel, fodder and quick growing timber tree



saplings, predominantly local flora/vegetations, are proposed to be planted keeping in view the agro-ecological and edaphic conditions of the areas.

About 5,000 trees will be planted in a year in the earmarked areas. The maintenance contract shall beawarded to the Women Self Help Groups and Local Panchayats of the nearby villages.

7.6 Occupational Health Measures

RKPPL is committed to provide a safety & healthy working conditions and continually improve theoccupational health and safety performance. It’s SHE Policy objectives are : to achieve zero accident and

safe work environment, to improve moral and health of all employees and to maintain the emission levelsbelow the norms. Also, RKPPL will provide ergonomic support in work comfortness with periodicalreview.

A qualified Doctor having the required qualification shall be employed in the Occupational Health Centreat the Plant. An Environmental Cell will be created as a department consisting of officers from variousdisciplines to coordinate the activities concerned with the management and implementation of theenvironmental control measures, SHE and Occupational Health Policies of the Company.

7.7 Social Measures

RKPPL will be carrying out various Social Measures for the local as well as regional populations in thefollowing areas.

Drinking water supply to the villages Free Medical Camps Welfare measures for upliftment of economically weaker sections Construction and renovation of school & hospital buildings Construction of approach roads to the villages, cause ways, bridges, etc. Construction and renovation of temples Extending Educational Facilities. Self employment programmes for Self Help Women Groups of nearby villages.

7.8 Rain Water Harvesting

Rainwater collection from the rooftop area, recharge structures and surface runoff storage reservoirsshall be undertaken and maximum quantity of rain water shall be utilized.

8.9 EMP Budget

The project cost is Rs. 367.23 crores. Capital Cost for Pollution Control Measures is Rs.10.00 crores(2.7%) with a Recurring Cost of Rs.2.00 crores/annum. A budget of Rs.5.00 lakhs/annum is earmarkedfor Green Belt & Environmental Monitoring works, Rs.5.00 lakhs/annum for Social Measures and Rs.3.00lakhs/annum for Occupational Health & Safety Measures.

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Documents

Summary Environmental Impact Assessment Reportkspcb.kar.nic.in/PH/RKPPL Exe_Summary (English).pdf · Summary Environmental Impact Assessment Report ... jaggery, khandsari and white