FINAL ENVIRONMENT IMPACT ASSESSMENT...

FINAL ENVIRONMENT IMPACT ASSESSMENT

REPORT

NEW

MOLASSES BASED DISTILLERY

(100 KLPD)

For

KARAN SUGARS PVT. LTD. GAT No: 487/488 A/2 & 488A/3, HARWAD,

TAL: SHIROL, DIST: KOLHAPUR. (M.S)

Prepared By

Mantras Green Resources Ltd. (Engineers & Environmental Consultant)

NABET/QCI Accredited Consultant Sr. No 96th (List 5 September, 2014) An ISO 9001:2008 Certified.

B-5,B-7, Flushing Meadows, Plot No. 63, Mahatma nagar Nashik-422007

Ph- +253 2355665/2355086 E-Mail: [email protected]

[email protected]

September 2014

TOR Index TOR

point

Description Page No/

Annexure no

1 Layout maps indicating existing unit as well as proposed unit indicating

storage area, plant area, greenbelt area, utilities etc Refer annexure

XLVII, VIII

2 Details of proposed products along with manufacturing capacity Chapter-2 page No. 4

3 Number of working days of the distillery unit. 330 days Chapter-2

page No. 14 4 Details of raw materials, its source with availability of molasses Chapter-2

page No. 13 5 Manufacturing process details of distillery along with process flow chart Chapter-2

Page No. 5 - 10 6 Sources and quantity of fuel (rice husk/bagasse/ coal etc.) for the boiler.

Measures to take care of SO2 emission. A copy of Memorandum of

Understanding (MoU) signed with the coal suppliers should be submitted.

Chapter-2 page No. 11

7 Storage facilities for raw materials, prepared alcohol, fuels and fly ash. Annexure XL VIII

8 One season site-specific micro-meteorological data using temperature,

relative humidity, hourly wind speed and direction and rainfall and AAQ

data (except monsoon) for PM10, PM2.5, SO2, NOX , CO and HC (methane

& non methane) shall be collected. The monitoring stations should take into

account the pre-dominant wind direction, population zone and sensitive

receptors including reserved forests. Data for water and noise monitoring

should also be included.

Chapter 3

9 Mathematical modeling for calculating the dispersion of air pollutants and

ground level concentration along with emissions from the boiler’s stack.

Annexure 5

10 Details of boiler and its capacity. Details of the use of steam from the boiler. Chapter-2

Page No. 10

11 Ground water quality around proposed spent wash storage lagoon and the

project area

Chapter 3

12 Details of water requirement, water balance chart for proposed project.

Measures for conservation water by recycling and reuse to minimize the

fresh water requirement.

Chapter-4

Page No. 5

13 Source of water supply and permission of withdrawal of water from

Competent Authority Annexure

14 Proposed effluent treatment system for grain/molasses based distillery (spent

wash and spent lees) along with utility wastewater including CPP/Co-gen

Unit (wherever applicable) as well as domestic sewage and scheme for

achieving zero discharge. Details of treatment of effluent generation from

sugar unit

Chapter 2

Page No. 16

15 Spent wash generation should not exceed 8 KL/KL of alcohol production.

Details of the spent wash treatment for molasses based distillery based

distillery.

Chapter-4

page No.7

16 Capacity for spent wash holding tank and action plan to control ground

water pollution 30 days

Chapter 4 Page 7 to 9

17 Layout for storage of bagasse/biomass/coal. Annexure XLVIII

18 Capacity for spent wash holding tank and action plan to control ground

water pollution. 30 days

Chapter 4 Page 7 to 9

19 Dryer shall be installed to dry DWGS Not applicable

20 Layout for storage of rice husk/biomass/coal. Not applicable

21 Details of solid waste management including management of boiler ash. Chapter-6

page No.4

22 Risk assessment for storage and handling of alcohol and mitigation measure

due to fire and explosion and handling areas

Chapter-8

page No.10

23 Alcohol storage and handling area fire fighting facility as per norms.

Provision of Foam System for fire fighting to control fire from the alcohol

storage tank.

Chapter-8

page No.5

24 Action plan for development of green belt over 33 % of the total project area

within plant premises with at least 10 meter wide green belt on all sides

along the periphery of the project area, in downward direction, and along

road sides etc

Chapter-6

page No.5

25 Detailed Environment management Plan (EMP) with specific reference to

details of air pollution control system, water & wastewater management,

monitoring frequency, responsibility and time bound implementation plan

for mitigation measure should be provided.

Chapter-6

page No.1-8

26 EMP should also include the concept of waste-minimization, recycle/reuse/

recover techniques, Energy conservation, and natural resource conservation.

Chapter-6

page No.1-8

27 Action plan for rainwater harvesting measures at plant site should be

included to harvest rainwater from the roof tops and storm water drains to

recharge the ground water.

Chapter-4

page No.11

28 Details of occupational health surveillance programme Chapter-6 page No.6

29 Transportation of raw materials and finished products for the project

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

frequency of vehicles for transportation of materials, additional traffic due to

proposed project, parking arrangement etc

Chapter 4 Page 13

30 Action plan for post-project environmental monitoring. Chapter-7

31 Corporate Environmental Responsibility

32 (a) Does the company have a well laid down Environment Policy approved

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

(b) Does the Environmental Policy prescribe for standard operating

process/procedures to bring into focus any infringement / deviation /

violation of the environmental or forest norms / conditions? If so, it may be

detailed in the EIA report.

(c) What is the hierarchical system or Administrative order of the company

to deal with the environmental issues and for ensuring compliance with the

EC conditions. Details of this system may be given.

(d) Does the company have a system of reporting of non compliance /

violations of environmental norms to the Board of Directors of the company

and / or shareholders or stakeholders at large? This reporting mechanism

should be detailed in the EIA report.

Chapter 7

33 At least 5 % of the total cost of the project should be earmarked towards the

Enterprise Social Commitment based on Public Hearing issues and item-

wise details along with time bound action plan should be prepared and

incorporated

Confirmed

EXECUTIVE SUMMARY

1.0 INTRODUCTION

Karan Sugars Pvt. Ltd hereafter being referred as project proponent or KSPL or project

proponent (PP) in this text belongs to Kalani Group of companies. The group has diverse

interests in packaging, distillery and bottling, dairy and dairy products etc. KSPL is owned by Mr

Dharmpal Kalani and his associates. KSPL purchased an existing distillery of 30 KLPD owned

by Shetmal Sahakari Prakriaya Sansthan Ltd located at village Herwad in taluka Shirol in district

Kolhapur.. The unit was producing alcohol from cane juice.

The company was not able to operate and suffered losses due to several reasons major one being

non availability of cane for juice extraction. Cane was being picked up by sugar mills in the

vicinity and severe price fluctuations in cane price affected profitability.

Unit was non operational much before the present project proponent took over.

There are several sugar mills in area who do not have own distillery. Hence sufficient

molasses and bagasse are available from within 50 km area of location. A detailed list of

surrounding sugar mills, their installed capacity and capacity of distillery installed if any is

reproduced below:

Name of factory Distance Capacity

TCD

last year

Crushing

Distillery

KLPD

Shree Datta sahakari sakhar karkhana Ltd

Sirod, Dist- Kolhapur

18 Km 7000 91800 60

Shree Gurudutta Sucrose Ltd Takrewadi

Sirod Dist- Kolhapur

8 KM 2500 670000 Nil

Shree Jawahar Shetkari Sahakari Sakhar

Karkhana Ltd, Hupari,Tal- Hatkanangale

Dist- Kolhapur

23 KM 9000 1428000 Nil

Shri Sharad Sahakari Sakhar Karkhana Ltd

Narande Tal- Tal- Hatkanangale Dist-

45 KM 2500 589000 Nil

Environment Impact Assessment Executive summary New 100 KLPD Molasses based distillery

Karan Sugars Pvt Ltd 2 Herwad Taluka Shirol,Dist Kolahapur

Kolhapur

Shree Panchganga Sahakari Sakhar Karkhana

Ltd Ganganagar Ichalkaranji

Tal- Hatkanangale Dist- kolhapur

23 KM 5000 740000 Nil

Shri Chhatrapati Rajaram Sahakari Sakhar

Karkhana Ltd, kasba bawda, Dist Kolhapur

49 Km 2200 410000 Nil

Shree Chattrapati Shahu SSKL Kagal Tal-

kagal Dist- Kolhapur

36 Km 3500 731000 45

Vasantdado SSKL Madhavnagar Sangali

Tal Miraj Dist - Sangli

34 Km 5000 530000 Nil

Shree Guppy Sugar Works Ltd, Kagwad, Tal

– chikkodi Dist – Belgaon Karnataka

30 Km 5000 46600 Nil

Shree Shiv Shakti Sugar ltd Yadrav Ankali

tal- Chikodi, Dist Belgaum Karnataka

41 Km 2500 390000 Nil

Dudhganga- Krushna SSK Ltd, Nanandi, tal-

Chikkodi Dist Belgaon, Karnataka

32 Km 60000 836000 Nil

Venkateshwara Power Project Bedkihal Tal-

Chikodi dist- Belgaum Karnataka

18 Km 3500 707000 Nil

Uugar Sugar Ltd, Ugar khurd Tal-Chikodi

dist- Belgaum Karnataka

48 Km 10,000 1156000 Old

30 KLPD

New

45 KLPD

Total 117700 180 KLPD

Molasses generated / required 4708 MT 720 KLPD

Molasses required for 100 KLPD distillery proposed 400 KLPD

All above units are operational as shown in column showing total cane crushed last year. If cane

crushed by Karnataka factories 81,000 MTD is excluded still 1468 KLPD molasses is available

for alcohol production from nearby factories in Maharashtra..



Hence it was clear to new management that a molasses based distillery is feasible at this site and

it will present an opportunity for surrounding sugar mills to dispose molasses generated in their

factory for profit at a site not involving much transportation.

Karan Sugars Pvt. Ltd. proposes to dismantle existing sugar cane based distillery of 30 KLPD

and install a new molasses based distillery of capacity 100 KLPD. Since the project falls in

category “A” of schedule of activities 5(g) of EIA notification SO1533 dated 14th September

2006 the proposed activity is under the preview of notification. The industry applied for TOR to

the Ministry of Environment and Forest (MoEF) India and received approved TOR wide MoEF

reference F. No. J-11011/857/2008- IA II (I) dated 25 Feb. 2009.

There will be no shortage of raw material for the proposal.

Hence new management decided to dismantle the old unit with old sugar cane based

process.

KSPL plans to use existing building as it is, hence no dismantling of building and administrative

offices is involved. Existing boiler and Existing turbine will be retained as stand by. Other

equipments like cane unloading arrangement, cane crusher, cane conveyor and associated

accessories will be sold as scrap. New equipment suitable to manufacture 100 KLD alcohols

from molasses will be procured.

The process will be based on Continuous fermentation Technology.

KSPL will generate electrical power 2250 KW suitable to meet its own requirement.

Special incineration boiler will be procured which shall use bagasse as fuel sources and will

be suitable for spraying concentrated spent wash to ensure zero discharge.

100% power so generated will be used for own production and no supplies shall be made to

MSEB grid.

Project proponent applied to MoEF in prescribed format for “TOR”. Since there was an

existing distillery of 30 KLPD, the application was made for expansion from 30 KLPD to

100 KLPD with change in process from cane juice based to molasses based.

Project was discussed in 91st EAC meeting under item no 4.3 held on 9/2/2009



MoEF allotted “TOR” for proposal on 25/02/2009. However “TOR” did not mention

change in process.

Consultant prepared draft EIA for indicating full capacity generation from molasses and

submitted same to MPCB for conducting public hearing as it was specified in “TOR”

First Public hearing for proposed project was conducted at Meeting hall at existing Factory site,

Herwad, Tal Shirol Dist. Kolhapur (M.S.) on 23-5-2012

The public hearing process was supervised and presided by Mr. Tushar Thombre–SDO as

Additional Collector and District Magistrate -District was not available.

We incorporated public comments, prepared final EIA and applied to MoEF on 16th July 2012

for consideration of EC

Proceedings of this public hearing was rejected by MoEF as it was presided by an officer of

SDO rank under ref letter no. J-11011/857/2008- IA II (I) dated 9th May 2013.

MoEF directed to conduct fresh public hearing wide above letter.

Public hearing was re-conducted at same location at Meeting hall of existing Factory on 8th

November 2013.

The public hearing process was supervised and presided by Mr. Sanjay Pawar –Additional

Collector and District Magistrate -District Kolhapur (Maharashtra ).

Shri S.S. Doke -Regional Officer -Maharashtra Pollution Control Board MPCB- Kolhapur

was present as panel member.

Consultant incorporated public comments, prepared final EIA and submitted same to

MoEF for EC on 6th December 2013. Case was discussed in 17th meeting of reconstituted

expert appraisal committee meeting held on 18 March 2014 under item no 17.6.6

During the discussions EAC pointed out that original TOR issued to us did not include

change in process as from cane juice based to molasses based.

Committee directed PP to amend form-1 and prefeasibility report proposing new distillery

of 100 KLPD capacity, totally molasses based is proposed. Existing sugar cane juice based

distillery shall be dismantled.



Committee also indicated proceedings of second public hearing will be acceptable.

Following is the test of minutes of meeting

“The existing project had obtained an EC in 2003 in the name of another company. The

existing unit was transferred to Karan Sugars. The Committee noted that PP has submitted

EIA-EMP report for expansion of distillery from 30 KLPD to 100 KLPD with change in

process cane juice based to molasses, in the existing premises. PP also clarified that the

existing 30 KLPD distillery will be scrapped and complete 100 KLPD distillery based on

molasses will be installed. Thus there is change in the scope of project. It was also noted

that existing EC was issued in the name of some other Company. The Committee after

deliberations recommended the PP to submit revised Form-1 along with pre-feasibility

report along with documents/details of transfer. Based on submitted documents, further

course of action will be decided in this regard.”

Hence we revised basic information; form-1 and prefeasibility report as directed by EAC

as per 17th EAC MOM and resubmitted same on 17th April 2014. As committed EAC

amended the TOR wide their minutes of meeting on 29th Sept 2014 and accepted

proceedings of second public hearing.

The present EIA is modified as per amended TOR issued.

2.0 PROJECT DETAILS

KSPL proposes to dismantle existing industry at its site and install a new distillery molasses

based at this site.

Sr No Proposal

1. Capacity ( Tor point. 2) 100 KLPD

2. Product ( Tor point. 2) RS/AA/ENA

3. Raw material Molasses

4. Raw material required 400 MT/day

5. Raw material sources Sugar mills in vicinity

6. Steam consumption 528 MT/day

7. Boiler 25 TPH



8. Fuel bagasse

Bagasse plus spent wash

270 MT/day

142 MTD bagasse Plus 6.15 MTD spent

wash

9. Ash generation 13.5 MT/day

10. Control equipment Bag filter

11. Ash disposal Brick manufacturing

12. Cogeneration of power 2.2 MW

13. Power required 2.2 MW

14. Water requirement 805 m3/day

15. Source of water Panchganga rive 2.7 km away

16. Spent wash generation 800 m3/day

17. Biogas generation 26000 m3/day

18. Spent wash after concentration 150 m3/day

19. Disposal Burning with bagasse in incineration boiler

Zero Discharge

3.0 LAND UTILIZATION

PP has in possession 25 acres land. 33% of available land will be reserved for green belt

development in conformity with amended TOR. About 300 plants have been planted. Balance

land has been used for manufacturing, storage, bagasse storage, ash storage, biodigestor followed

by multiple effect evaporator, utilities like incineration boiler, turbine and others.

The new project will be installed in existing land in possession of KSPL hence no additional land

purchase is involved and no resettlement and rehabilitation issues are involved.

4.0 LOCATION

The distillery site is located at Village – Harwad, Tal. – Shirol, Dist. – Kolhapur, Maharashtra.

The surrounding villages are Kurundwad, Herwad, Abdulat, Latwadi, Ghosarwadi, Akiwat,

Takaliwadi, Majarewadi, and Shirdawad surrounded to the site.



The study area lies between the North Latitude: - 160 38’ to170 34’ and East Longitude: - 740 34’

to 75019’ and can be located in survey of India Toposheet Nos: -47 L/10.

The area surrounding the proposed plant site is flat and is at the elevation about 557 meters

above the sea level. The surface soil in the area is mainly red brown and light brown soil.

Rivers and Water Bodies:-

Panchganga River flows 2.7 km away from the site.

Nearest city : Kurundwad 5.3 KM

Nearest highway : SH 137 -Echalkanji to Shirol

Nearest airport : Kolhapur 30 Km

Kurundwad is well connected to all the important places by Road.

Maharashtra is the sugar cane growing area and thus the raw material availability is assured.

Being industrially backward area, it attracts government incentives which can help to improve

the economics of the project.

There is no wildlife sanctuary/reserve forest within 10 km radius from the site.

Temple of khindraweshwar is about 8.7 KM crow fly distance which is an archeological

monument.



4.1 COST OF PROJECT

PP has already invested in the existing project a sum of Rs 15.75 crores in procuring the site with

old plany. Old equipments are to be dismantled. Now factory proposes to set up modified

equipment for molasses based process, treatment of spent wash by biodigester followed by

multiple effect evaporator and burning in boiler, increased steam generation and cogeneration of

power, Additional total estimated cost for above change is estimated as Rs 22 crores.

Hence presently the total cost of project is estimated as Rs 37.75 Cr.

5.1 WATER BUDGET (Tor Point.12)

Water requirement of existing project the increase due to expansion and change in process and

total requirement during start up are detailed below: All values in m3/day

Particular Total

(m3/day)

Reuse

(m3/day)

Reason

Process 1260 330 Water recovery

Condensing, cooling and blow

down

200 -- Loss

Boiler Make up 466 346 Condensate recovery

Floor washing 15 15 By treated effluent

Sanitary 15 15 By treated effluent

Drinking 15 --

Greenbelt 30 By treated effluent

Fire services 20 20 Not required daily

490 Water recovery from MEE

Total 2021 1216

Final Water requirement 805



5.1. POWER REQUIRED

The power required for the operating Molasses based distillery plant would be 2.2 MW. For

uninterrupted operation of the plant a Turbo Generator set will be necessary. Existing TG set

producing 750 KW/hr power will be retained and additional TG set to generate 1500 KW/hr

shall be installed making factory self reliant on its requirement of 2200 KW/hr power.

Power plant will be operated by steam generated from 25 TPH boiler using bagasse and

concentrated spent wash as fuel. Plant steam requirements will be met from extracting steam at

required pressure from turbine exhaust.

5 .2 MANPOWER REQUIREMENT

Total number of persons proposed to be employed for the proposed distillery is expected to be 70

in direct employment. In addition about 100 unskilled persons will be engaged in bagasse

handling, ash processing, coal handling and transportation and will be indirectly employed.

5.3 MANUFACTURING PROCESS

Molasses is the major raw material used in India for production of Alcohol. Molasses contains

about 50% total sugars, of which, 30 to 33% are cane sugar and the rest are reducing sugar.

During the fermentation, yeast strains of the species saccharomyces cerevisiae, a living

micro-organism belonging to class fungi converts sugar present in the molasses, such

as sucrose or glucose to alcohol. Chemically this transformation for sucrose to alcohol

can be approximated by the equation.

I) C12H 22O11 + H2O = C6H12O6 * C6H12O6

Sucrose Water = Glucose Fructose

II) C6H12O 6 = 2C2H5OH + 2CO2

180 = 2x46 + 2x44

Glucose Ethyl Alcohol Carbon- dioxide



The 180 gm of sugars on reaction gives 92 gm of alcohol. Therefore, 1 ton of sugar will yield

511kgs of alcohol. The sq. gravity of alcohol is 0.7934.

Therefore, 511kg of alcohol is equivalent to 511/0.7934=644 lire of Alcohol.

During fermentation other by products like glycerin, succinine acid etc. are also formed form

sugars. Therefore actually 94.5% total fermentable sugars are available for conversion to alcohol

theoretically.

Hence normally only 80 to 82% efficiencies are realized on plant. One ton of molasses

containing 45% F sugars and gives alcoholic yield 255- 265 liters per ton.

Above biochemical reaction requires proper and careful handling of yeast, maintaining pH

and proper temperature control and substrate concentration by which maximum conversion

of sugars to alcohol is achieved.

The process of manufacture is illustrated in a flow chart on next page.



Molasses storage

Molasses Weighed and Diluted

Yeast Propagated with Molasses in Sterilized Separate Vessel

Fermentation

Clarified Wash Tank

Analyzer Column

Pre – Rectifier Column if Required

Rectifier Column

Exhaust Column

Re - Boiler

Fusel Oil Separated & Alcohol Returned

RS/ENA/AA

Process Flow Chart



7.0 EMISSIONS AND DISCHARGES DUE TO PROPOSAL

7.1 Emissions in air:

When new boiler of 25 TPH will be run the existing boilers will not be required to operate. An

estimated 1.35 MT/day of fly ash discharge is expected in air due to boiler operation.

7.2 Water pollution

The industry will utilize latest technology of treatment of spent wash 800 m3/day by recovering

biogas and then concentrating followed by burning of spent wash in boiler, thus adopting zero

effluent discharge system.

7.3 Noise pollution

Operation of a distillery does not involve any heavy duty impact type of machinery operation

hence does not contribute to noise pollution.

7.4 SOLID WASTE MANAGEMENT


estimated 12.15 MT/day of bottom ash discharge is expected in due to boiler operation.

7.5 Biodiversity

The proposed activity is to be done at existing site itself. Further industry has opted for zero

discharge system of spent wash treatment hence no effect is expected on existing biodiversity of

region.

8.0 BASELINE STUDIES (ToR Point. 05)

The actual on site monitoring of existing environmental setting was done to establish the baseline

conditions with respect to climate, hydrological aspects, atmospheric conditions, water quality,

soil quality, vegetation pattern, ecology, socio-economic profile. The study covered an area

within 10 km radius from the Plant site. The studies for the project was carried out in the study

area in winter month after monsoon in 2012 Data on baseline condition of water environment of

the study area was collected and observations are as under:



Parameters Actual average values Ambient Air quality

PM10 70 100

PM 2.5 45 60

SO2 9.2 80

NOx 7.6 80

It may be seen observed values of monitored parameters are within prescribed standards.

(Monitoring location: Project site, Herwad, Takaliwadi, Dattawad and Abdul lat etc)

8.1 GROUND WATER

pH in ground water sample was observed at (Project site, Dattawad, Takaliwadi, Herwad) to be

in the range 7.0 to 7.5 while conductivity was observed in the range of 1-3 . The value of

alkalinity and hardness were observed in the range of 150 -200 mg/l and 400 to 450 mg/l

respectively. Whereas heavy metal was found to be within the limit.

8.2 SURFACE WATER

There is rivers in the study area is Panchganga River. The sampling locations were selected at 3

different stations of river at a distance of 500m.

Samples were collected and analyzed as per standard methods and frequency of sampling was

thrice /station. pH observed to be in the range of 7.3 to 7.5 and conductivity varies from 0.5 – 0.8

mg/l. Chloride and Sulphate were observed to be in the range of 89 to 24 mg/l and from mg/l

respectively. The heavy metal contents are found well within the limit.

8.3 NOISE ENVIRONMENT:

Noise level measurement was carried out at each ambient air quality station and also within the

existing plant premises.

The frequency of ambient noise level monitoring and noise level at source were

twice/week/station and thrice/station respectively. Ambient noise levels were recorded in

following time schedule:



Day time - 6 am to 7 am. 9 am to 10 am.1 pm to 2 pm, 5 pm to 6 pm, 9 pm to 10 pm Night time -

at 10 pm to 6 am.

Location Day (dB unit) Night (dB unit)

Project Site 56 44

Herwad 58 40

Takaliwadi 56 40

Abdul lat 59 36

Dattawad 54 35

9.0 PREDICTION AND MITIGATIONOF IMPACTS

9.1 EMISSIONS IN AIR:


estimated 1.35 MT/day of fly ash discharge is expected in air due to boiler operation. As per

CPCB standards 800 mg/Nm3 limit is prescribed for air emission due to spreader stoker boiler

using biofuels like bagasse.

PP proposes to install bag filter type of dust collector and achieve the prescribed limit of fly ash

discharge of 150 mg/nm3..

9.2 WATER POLLUTION

The industry will utilize latest technology of treatment of spent wash 800 m3/day by recovering

biogas and then concentrating followed by burning of spent wash in boiler, thus adopting zero

effluent discharge system.

9.3 NOISE POLLUTION

Operation of a distillery does not involve any heavy duty impact type of machinery operation

hence does not contribute to noise pollution.

Operators in boiler and turbine sections will be required to use personal protective equipments

when operating the system.



9.4 SOLID WASTE DISPOSAL


estimated 12.15 MT/day of bottom ash discharge is expected in due to boiler operation.

This ash will be used by brick manufacturers.

Concentrated spent wash will be burnt in the boiler.

10.0 ENVIRONMENT MANAGEMENT PLAN (EMP)

KSPL has drawn an Environment Management Plan (EMP) to conserve the resources, minimize

the waste generation, treatment of waste, recovery of by products and recycling of material. It

will also take into consideration vegetation and landscaping of open area. and also The post

project quality monitoring to ensure and check compliance to proposed mitigation measures and

preservation of environmental quality is integral part of EMP.

Management has made following budgetary allocation to ensure EMP is properly implemented

and no financial constraints will be allowed.

Budget provision for Environmental Management plan

SL No

Item

Recurring Cost

per annum

(Lac)

Capital Cost

(Lac)

1 Air Pollution Control 12.5 70.00

2 Water Pollution Control 5.0 400.00

3 Noise Pollution Control ---- 03.00

4 Environment Monitoring and

Management

0.45 03.00

5 Occupational Health 1.00 12.00

6 Green Belt 1.00 25.00



7 Salary of EMP staff 6.8 ----

8 Safety management. 12.00

9 Laboratory and chemicals 05.0 28.00

10 Maintenance of ETP and wages of

workers.

15.0 22.00

Total 46.75 575.00

The EMP is carefully prepared so as all the affected components/areas have been covered and

monitored and mitigated as per requirement during construction and operation of proposed

expansion cum modernization.

The following aspects have been covered under EMP

1 Air Pollution Control Provision of bag filter for fly ash collection

2 Water Pollution Control ETP to ensure zero discharge, STP with septic tank

3 Water conservation Recycling of condensate water from distillation

and cogeneration

4 Noise Pollution Control Provision of vibration isolators, acoustic

enclosures


Management

Planned monitoring of air, water, noise and soil

parameters

6 Occupational Health Regular health check-up of the workers

7 Green Belt Tree Plantation

8 Safety management. Safety measures like ear muffs , gloves, helmet

shoes, goggles, aprons to the workers



11.0 ENVIRONMENT MANAGEMENT CELL

A separate Environment Management Cell will be established to look after the Effluent

Treatment Facility and to monitor and control the environmental quality. This cell would

comprise of following members:

Environmental Engineer 1 No.

Environmental Chemist 1 No.

Laboratory Attendants 2 No.

Safety Officer 1 No.

Plant Operator 3 No.

Supporting Staff 2 No.

Members of the Environmental Cell would be well qualified and experienced in the concerned

field. Some of the routine tests of wastewater such as pH, solids, temperature, etc. will be carried

out in the laboratory of distillery. However, for additional tests of water, wastewater, soil, air etc.

services of reputed laboratories as well as that of a consultant would be hired.

12.0 CONCLUSION:

Setting up of a Molasses based distillery unit will be helpful to the industrial development

in this region.

The use of Molasses by the distillery will help the farmers in this region for marketing

their products i.e. Sugar Cane and get extra benefits by value addition.

Molasses generated by neighboring sugar industries will be used for useful financial

benefits

The project will be a boon to the farmers indirectly as factory will need molasses from

nearby sugar industries that in turn will need sugar cane as raw material.

The sale of alcohol will generate large amount of revenue by way of excise duties levied

on the local front



The distillery will also generate direct employment to a large number of local skilled,

semiskilled and unskilled workers. The distillery can also generate revenue for local

population by the services that they render to the industry

Project implementation will induce infrastructural development in the surrounding

villages i.e. educational, social institutions, cultural institutions, health care facilities.

Road development, sewage treatment facilities etc.

Safety council will be established by the safety officer to take safety steps for employees.

The promoter has selected industrial backward area in Maharashtra state.

It would be advantageous to implement it as quickly as possible in order to improve the

socio- economic in the area as it will improve the regional economy.

Since the project is conceived as zero discharge projects, self sufficient in its electricity

requirement and concerns of environment properly addressed, it may be recommended

for early environmental clearance.

CHAPTER-1

INTRODUCTION

1.1 PURPOSE OF REPORT

Karan Sugars Pvt. Ltd. hereafter being referred as KSPL or the project proponent (PP), had an

existing distillery of 30 KLPD capacity. The process of manufacture was sugar cane based.

KSPL propose to expand this unit to 100 KLPD capacity with change in manufacturing process

from sugar cane juice based to molasses based. Factory location is at Village – Harwad, Tal. –

Shirol, Dist. – Kolhapur, in state of Maharashtra.

Since the project falls in category “A” of schedule of activities 5(g) of EIA notification SO1533

dated 14th September 2006 the proposed activity is under the preview of EIA notification. The

industry applied for TOR to the Ministry of Environment and Forest (MoEF) India and received

approved TOR wide MoEF reference F. No. J-11011/857/2008- IA II (I) dated 25 Feb. 2009.This

“TOR” was for expansion of existing industry with change in process from cane juice based to

molasses based.

The industry prepared draft environmental impact assessment (EIA) due to proposed activity in

line with “TOR” allotted. The draft EIA was submitted to MPCB and a public hearing was

organized on project site 23rd May 2012. MPCB had invited officer as per MoEF circular but on

date of public hearing he had another assignment and deputed officer of SDO rank to preside

over public hearing.

KSPL prepared final EIA incorporating public hearing comments and submitted same for EC.

Before EAC meeting could take place, proceedings of this public hearing were rejected by

MOEF wide letter reference J/11011/857/2008-IAII (I) dated 9th May 2013 as it was conducted

by an officer below ADM rank.

KSPL was ordered to re-conduct public hearing.

The second public hearing was conducted on 9th November 2013 at factory premises.

The draft EIA was revised after incorporating public comments in 1st as well as 2nd public

hearing as well as MOEF minutes and final EIA has been prepared.

Environment Impact Assessment Chapter-1 New 100 KLPD Molasses based distillery


During this period the existing distillery was non operational and KSPL decided to

dismantle same totally as they had plans to install molasses based distillery which is a

different process. Hence KSPL approached MOEF with revised form-1 and revised

prefeasibility report for issue of fresh “TOR” for 100 KLPD distillery, a new unit, with

100% molasses as raw material source.

The present EIA is based on installation of new 100 KLPD molasses based distillery.

1.2 PROJECT PROPONENT

Karan Sugars Pvt Ltd is a company in private sector with constitution as private limited

company. It is registered under company’s act under reference U-15420 MH 2005 PTC 154288

dated 28 June 2005.

Given below is the list of existing directors of the company their educational background and

experience in the industry:

Dharampal Kimatram Kalani.

Educational qualification: B.E (Electronics), MBA

Industrial Exp: 10 Years.

Hiralal Kimatram Kalani.

Educational qualification: Graduate (Com).


Kanyalal K Kalani.

Educational qualification: Graduate (Com)


Sharad G. Shete.

Educational qualification: B.Sc. Alcohol Tech.(Fermentation Tech.)

Industrial Exp.: 25 Years.

1.3 BACKGROUND

Karan Sugars Pvt. Ltd hereafter being referred as project proponent (PP) or simply KSPL has

diverse interests in packaging, distillery and bottling, dairy and dairy products. The company is

owned by Mr Dharmpal Kalani and his associates. The group owns Karan Distilleries Pvt limited

of 29 KLPD capacity grain based near Bhandara, Trupti Containers manufacturing corrugated



boxes, Kalani packaging Pvt. Ltd. and Brihan Karan Sugar Syndicate Pvt Ltd, which is a bottling

unit.

1.4 CURRENT ACTIVITIES KSPL has procured an existing distillery which was producing alcohol @ 30 KLPD from cane

juice. The factory is non operational. The existing factory is to be dismantled as KSPL will start

a new unit with different manufacturing technique. The unit is located at village Herwad in

taluka Shirol in district Kolhapur.

When procured factory was not in operation. Presently there is no activity at site and PP is

waiting for environmental clearance from MoEF for his new proposal.

1.5 FUTURE PLANS

KSPL now wishes to install a 100% molasses based new unit to manufacture 100 KLPD

ENA/RS/AA. Since availability of molasses is assured within the state of Maharashtra from

working sugar mills within 50 KM radius, company plans to install a new molasses based

distillery unit.

The existing unit will be scrapped.

In new plant will be a state of art plant incorporating latest techniques of pollution control. PP

plans to ensure zero discharge by incineration of spent wash. Generation of 800 KL per day of

spent wash is expected. Biogas will be recovered from spent wash @ 26000 m3/day in a suitably

designed biodigestor. It will be concentrated to 150 KL per day in multiple effect evaporators.

Water recovered will be recycled and reused to reduce fresh water consumption.

Concentrated spent wash will be directly burnt in the specially designed incineration boiler.

1.6 PROPOSAL

Karan Sugars Pvt. Ltd propose to install a new distillery of 100 KLPD capacity. The process of

manufacture will be multi-pressure distillation based using molasses as raw material. Treatment

procedure of spent wash generated will be zero discharge by burning in incineration boiler

Biogas will be recovered from spent wash in a suitably designed biodigestor. It will be

concentrated in multiple effect evaporators. Concentrated spent wash will be directly burnt in

the boiler.



KSPL will generate electrical power of 2.2 MW from steam before being used for process

requirement. KSPL will be independent of its power requirement from state grid and will not

export any power. Power will be generated by rotating turbo generator set by high pressure steam

generated in a new boiler. Hence a new boiler of 25 TPH steam generating capacity will be

provided. It will be suitable to burn concentrated spent wash as fuel.

1.7 LOCATION

The distillery site is located at Village – Harwad, Tal. – Shirol, Dist. – Kolhapur, Maharashtra.

The surrounding villages are Kurundwad, Herwad, Latwadi, Ghosarwadi, Akiwat, Takkiwadi,

Majarewadi, and Bunal surrounded to the site.

The plot lies between the North Latitude:- 160 38’ to170 34’ and East Longitude:- 740 34’ to

75019’

The area surrounding the proposed plant site is flat and is at the elevation about 557 meters

above the sea level. The surface soil in the area is mainly red brown and light brown soil.

Panchganga River flows approx 2.7 km away from the site.

Nearest city : Kurundwad 5.3 KM

Nearest highway : SH 137 -Echalkanji to Shirol

Nearest airport : Kolhapur 30 Km

Kurundwad is well connected to all the important places by Road.

There is no wildlife sanctuary/reserve forest within 10 km radius from the site. Archeological

monument of temple of Kopeshwar in village Khidrapur lies 8.7 km from site.

Interstate boundary Maharashtra -Karanataka is 3 Km from site.



1.8 MAGNITUDE OF OPERATION

Table 1: Following chart details give an idea of magnitude of operation:

Sr.

No

Proposed

1 Capacity 100 KLPD

2. Product ENA/AA/RS

3. Raw material Molasses

4. Raw material required 400 MT/day

5. Raw material sources Sugar mills in vicinity

6. Steam consumption 528 MT/day

7. Boiler 25 TPH @46 kg/cm2

8. Fuel bagasse /spent wash 270 MT/day

9. Ash generation 13.5 MT/day

10. Control equipment Bag filter for fly ash

11. Ash disposal To farmers and or to brick

manufacturers

12. Cogeneration of power 2.2 MW

13. Power required 2.2 MW

14. Water requirement 805 m3/day

15. Source of water Panchganga river @2.7 km

16. Spent wash generation 800 m3/day

17. After concentration 150 m3/day

18. Bio-digester capacity 26000 m3/day

19. Disposal Burning in boiler

1.9 NEED OF PROJECT

The unit is located at village Herwad in taluka Shirol in district Kolhapur. There are several

sugar mills in the vicinity of project. Some are having own distillery unit while several others do



not have own distillery. After recovery of sugar molasses need to be disposed of. It is highly

polluting chemical. With latest technology it is possible to convert molasses into useful product-

alcohol. KSPL proposed unit will convert potentially hazardous by product of sugar industry

molasses into useful products, create job opportunities for local people and increase earnings of

local farmers indirectly.

In order to control ground water contamination and soil contamination CPCB is no more

allowing treatment of spent wash by composting for stand alone distilleries. Hence in present

proposal zero discharge of spent wash will be achieved by incineration of spent wash in boiler.

1.10 TERMS OF REFERENCE ALLOTTED BY MOEF

In the minutes of 24th reconstituted expert appraisal committee (industry) held during

29th- 30th September, 2014 under item no 24.4.6 the Committee prescribed the following

TORs for undertaking detailed EIA study after due consideration of revised Form-1 and

prefeasibility report:

1. Layout maps indicating existing unit as well as proposed unit indicating storage area,

plant area, greenbelt area, utilities etc

2. Details of proposed products along with manufacturing capacity

3. Number of working days of the distillery unit.

4. Details of raw materials, its source with availability of molasses

5. Manufacturing process details of distillery along with process flow chart

6. Sources and quantity of fuel (rice husk/bagasse/ coal etc.) for the boiler. Measures to take

care of SO2 emission. A copy of Memorandum of Understanding (MoU) signed with the

coal suppliers should be submitted.

7. Storage facilities for raw materials, prepared alcohol, fuels and fly ash.

8. One season site-specific micro-meteorological data using temperature, relative humidity,

hourly wind speed and direction and rainfall and AAQ data (except monsoon) for PM10,

PM2.5, SO2, NOX , CO and HC (methane & non methane) shall be collected. The

monitoring stations should take into account the pre-dominant wind direction, population

zone and sensitive receptors including reserved forests. Data for water and noise



monitoring should also be included.

9. Mathematical modeling for calculating the dispersion of air pollutants and ground level

concentration along with emissions from the boiler’s stack.

10. Details of boiler and its capacity. Details of the use of steam from the boiler.

11. Ground water quality around proposed spent wash storage lagoon and the project area

12. Details of water requirement, water balance chart for proposed project. Measures for

conservation water by recycling and reuse to minimize the fresh water requirement.

13. Source of water supply and permission of withdrawal of water from Competent Authority

14. Proposed effluent treatment system for grain/molasses based distillery (spent wash and

spent lees) along with utility wastewater including CPP/Co-gen Unit (wherever

applicable) as well as domestic sewage and scheme for achieving zero discharge. Details

of treatment of effluent generation from sugar unit

15. Spent wash generation should not exceed 8 KL/KL of alcohol production. Details of the

spent wash treatment for molasses based distillery based distillery.

16. Capacity for spent wash holding tank and action plan to control ground water pollution

17. Layout for storage of bagasse/biomass/coal.

18. Capacity for spent wash holding tank and action plan to control ground water pollution.

19. Dryer shall be installed to dry DWGS

20. Layout for storage of rice husk/biomass/coal.

21. Details of solid waste management including management of boiler ash.

22. Risk assessment for storage and handling of alcohol and mitigation measure due to fire

and explosion and handling areas

23. Alcohol storage and handling area fire fighting facility as per norms. Provision of Foam

System for fire fighting to control fire from the alcohol storage tank.

24. Action plan for development of green belt over 33 % of the total project area within plant

premises with at least 10 meter wide green belt on all sides along the periphery of the

project area, in downward direction, and along road sides etc

25. Detailed Environment management Plan (EMP) with specific reference to details of air

pollution control system, water & wastewater management, monitoring frequency,

responsibility and time bound implementation plan for mitigation measure should be



provided.

26. EMP should also include the concept of waste-minimization, recycle/reuse/ recover

techniques, Energy conservation, and natural resource conservation

27. Action plan for rainwater harvesting measures at plant site should be included to harvest

rainwater from the roof tops and storm water drains to recharge the ground water.

28. Details of occupational health surveillance programme

29. Transportation of raw materials and finished products for the project

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

for transportation of materials, additional traffic due to proposed project, parking

arrangement etc

30. Action plan for post-project environmental monitoring.

31. Corporate Environmental Responsibility

32. (a) Does the company have a well laid down Environment Policy approved by its Board of

Directors? If so, it may be detailed in the EIA report.

(b) Does the Environmental Policy prescribe for standard operating process/procedures to

bring into focus any infringement / deviation / violation of the environmental or forest

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

(c) What is the hierarchical system or Administrative order of the company to deal with

the environmental issues and for ensuring compliance with the EC conditions. Details of

this system may be given.

(d) Does the company have a system of reporting of non compliance / violations of

environmental norms to the Board of Directors of the company and / or shareholders or

stakeholders at large? This reporting mechanism should be detailed in the EIA report.

33. At least 5 % of the total cost of the project should be earmarked towards the Enterprise

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

bound action plan should be prepared and incorporated

CHAPTER-2

PROJECT DESCRIPTION

2. 1 TYPE OF PROJECT Karan Sugars Pvt. Ltd. proposes to install a new 100 KLPD capacity molasses based distillery.

The process of manufacture will be by multi-pressure distillation and it will be 100% molasses

based. Since the project falls in category “A” of schedule of activities 5(g) of EIA notification

S.O.1533 dated 14th September 2006 the proposed activity is under the preview of notification.

The industry applied for TOR to the Ministry of Environment and Forest (MoEF) and received

approved TOR wide MoEF reference F. No. J-11011/857/2008- IA II (I) dated 25 Feb. 2009.

2.2. SITE DETAILS

The proposed site is ideal for the proposed Molasses based ethanol project due to following

reasons:

Sufficient land 25 acres is available at the existing KSPL project site at Village Harwad

Tal: Shirol, Dist : Kolhapur, Maharashtra to install distillery and its associated

equipments.

Herwad is the nearest village from site. It is located at the longitude of 74.6 and latitude

of 16.7. Khidrapur is notified archeological site. Located at the longitude of 74.7 and

latitude of 16.6. The total distance between Herwad to Khidrapur is 8.7 KM (kilometers).

Khidrapur. is located nearly west side to Herwad

Harwad is easily accessible by roads. State highway no. 12 is 10 km away on south.

Jaisingpur railway station

State of Karnataka border is 3 Km away.

Maharashtra and Karnataka have several sugar mills in this area. Enough Molasses

supply is available for the proposed project.

Panchganga river flows 2.7 Km away by aerial distance in the north direction from the

proposed site. Water for project will be taken from this river.

No wild life sanctuary / reserved forest within 10 km radial distance.

Problem of rehabilitation and resettlement does not arise because the proposed site is

already in possession of proponent.



Table 2:

Detailed Break-up of Land Area

Particular Total(Acres)

Plant Area 10

Green Belt Area 8

Storage Area 2.5

Administration Bldg 2

ETP Area 2.5

Total 25

2.2.1 Infrastructure of Site

Ease of access to communication.

The site has easy access to latest communication and other social infrastructure facilities,

including telecommunication, schools and colleges, medical & health facilities, commercial

infrastructure, etc.

2.2.2 Topography of site area:

There are no major mountains in the command area, but few hillocks exist. The general elevation

is above MSL = 557 meters.

Topography of site.

North Latitude : 16°38'28.79"N

East Longitude : 74°34'20.77"E

Elevation : 557 meters from MSL

Table 3:

Topography of site area

Direction Nearest villages Nearest Districts

N/E Herwad,Kurundwad Shindhudurg

S/E Latwadi, Ghosarwadi Satara

S/W Akiwat, Takkiwadi Sangli

W/N Majarewadi, Bunal Ratnagiri



Google Image of Site

2.3 COST OF PROJECT

PP has already invested in the existing project a sum of Rs 15.75 crores. Now factory proposes to

set up modified equipment for change in process to molasses based process, treatment of spent

wash by biodigester followed by multiple effect evaporator and burning in boiler, increased

steam generation and cogeneration of power, Additional total estimated cost for above change is

Rs 22 crores. Now the expected cost shall be Rs 37.75 Cr

Table 4:

PROJECT COST

Sl. No. Particulars Total (Rs lacs)

1 Land and Site Development 103

2 Civil Works & Pollution control measures. 945

3 Plant & Machinery 2080

4 Miscellaneous Fixed Assets 150

5 Preliminary & Pre-operative exp. 224.19

6 Supervision charges 100



7 Transmission Line 50

8 Contingencies 103.20

9 Margin Money 20

Total 3775

2.4 PROJECT DETAILS

For a new 100 KLPD molasses based distillery now proposed, condensed requirements are as

follows:

Table 5:

Project Details

Sr. No Proposed

3 Capacity ( Tor point. 2) 100 KLPD

4 Products ( Tor point. 2) RS/AA/ENA

5 Raw material Molasses

6 Raw material required 400 MT/day

7 Raw material sources Sugar mills in vicinity

8 Steam consumption 528 MT/day

9 Boiler 25 TPH@46 kg/cm2

10 Fuel bagasse /spent wash 270 MT/day

11 Ash generation 13.5 MT/day

12 Control equipment Bag filter

13 Ash disposal Farmers /Brick

manufacturing

14 Cogeneration of power 2.2 MW

15 Power required 2.2 MW

16 Water requirement 805 m3/day



17 Source of water Panchganga rive 2.7 km

18 Spent wash generation 800 m3/day

19 Biodigester 26000 m3/day

20 After concentration 150 m3/day

21 Disposal of spent wash Burning in boiler

22 Number of Working days 330 /Annum

TOR Point -3

2.5 PROCESS OF MANUFACTURE (Tor Point. 5)

A) ALCOHOL

2.5.1 Material balance

Molasses is the main raw material used in India for production of Alcohol. Molasses contain

about 50% total sugars, of which, 30 to 33% are cane sugar and the rest are reducing sugar.

During the fermentation, yeast strains of the species Saccharomyces Cerevisiae, a living

micro-organism belonging to class fungi converts sugar present in the molasses, such

as sucrose or glucose to alcohol. Chemically this transformation for sucrose to alcohol

can be approximated by the equation.

I) C12H 22O11 + H2O = C6H12O6 + C6H12O6

Sucrose Glucose fructose

II) C6H12O 6 = 2C2H5OH + 2CO2

180 = 2x46 + 2x44

Glucose Ethyl Alcohol Carbon- dioxide

The 180 gm of sugars on reaction gives 92gm of alcohol.

Therefore, 1 MT of sugar gives 511 kgs of alcohol.

The sq. gravity of alcohol is 0.7934.

Therefore, 511kg of alcohol is equivalent to 511/0.7934=644 liters of Alcohol.



During fermentation other by products like glycerin, succinine acid etc. are also formed form

sugars. Therefore, actually 94.5% total fermentable sugars are available for alcohol, under

ideal condition theoretically. Normally only 80 to 82% efficiencies are realized on plant. One

tone of molasses containing 45% F sugars gives alcoholic yield 255- 265 litres per tone. For

above biochemical reaction proper and careful handling of yeast, maintaining optimum

parameters like pH, temperature, and substrate concentration is required.

For manufacture of yeast, separate equipment known as pure yeast culture apparatus is required.

Initially, yeast is developed in the laboratory from the single cell yeast culture. In the laboratory,

yeast is propagated in a test tube 10 ml. Then it is transferred to a bigger flask of 500 ml flask,

and transferred to 5 litre flask containing the sterilized molasses solution. It is necessary to adjust

the pH of the molasses solution in the range at each stage of development of yeast propagation

i.e 100 liters, 500 liters and 5000 liters. All these equipment’s are designed so as to facilitate

boiling molasses solution in order to sterilize it and also cooing o bring it to the proper

temperature of 33 0C and letting in culture and taking out culture. Boiling, cooling introducing

culture is done in aseptic manner, i.e. keeping the fermentation medium free from any kind of

infection. Further, stages of yeast propagation are done in open tanks i.e. pre-fomenter requires

about 8 hours in order to build up necessary concentration of yeast Finally, pre-fementer is

emptied in an empty previously cleaned fementer, . Dilute molasses solution is allowed to flow

in this fomenter so as to fill it to its working capacity,

The average efficiency of conversion of sugars in molasses to alcohol is 80 to 85% of theoretical

value. All the sugars are not converted to alcohol during the process of fermentation

because chemicals like glycerin; succinine acid, etc. are also produced by yeast during

metabolic process. 100% efficiency of conversion of sugars to alcohol is not possible. The

average yield of alcohol from molasses is about 250 liters from 1 MT of molasses.

FERMENTATION

For fermentation granulating yeast, which settles under gravity is used. Molasses free from

suspended particles is transferred to molasses receiving tank and is weighed. Weighed molasses

is distributed to cell mass propagation, fermentation and yeast activation section. GR yeast is

grown in laboratory during plant start up. Yeast propagation section comprises of molasses

diluter and hygienically engineered yeast vessels equipped with heating, cooling and air sparging



facility. Dilute molasses media is prepared in yeast vessel by recirculation of media

through molasses diluter. Laboratory propagated cell mass is scaled up in series of yeast vessels.

Air is sparged in pasteurized and cooled dilute molasses medium for optimum growth of GR

yeast. The temperature is maintained at 32o C by re circulating cooling water through jacket of

yeast vessels. Cell mass from Yeast vessel is transferred to yeast activation vessel to built up

cell mass required for fermentation (during start up only) by cell mass transfer pump.

At steady stage, activated cell mass from yeast activation vessel is transferred continuously to

fermentor - I. Molasses, process water and vinasse recycle stream from distillation is

added to fermentor. Fermented wash from Fermentor-I overflows continuously to fermentor -II

& then to yeast settling tank.

As ethanol fermentation is exothermic process, optimum temperature required for yeast

activity is maintained by forced recirculation through fermentor wash coolers. Efficient mixers

are provided in both fermentors.

Fermented wash from Fermentor-II is sent to yeast setting tank for separation of yeast

under gravity. Vinasse stream from distillation is recycled to fermentor depending on solids

concentration in fermented wash and molasses composition.

GR yeast having granulation property, settles in yeast settling tank under gravity, while

fermented wash overflows to wash holding tank. Settled yeast is transferred at rated flow to

yeast activation vessel with screw pump. In yeast activation vessel, molasses, process

water, nutrients and additive are added for activation of recycled cell mass. Filtered air

is sparged as required for re-activation of cell membranes and other cell components.

Mixer is provided for better mass transfer in yeast activation vessel. Activated cell mass is

transferred to fermentor- I to maintain desired cell mass concentration in fermentor.

Carbon dioxide generated in fermentation is entrained with alcohol vapours. Alcohol from

Carbon dioxide is scrubbed with water in gas scrubber. The scrubber water is transferred to wash

charger. Fermented wash from wash charger is fed to analyzer column.

DISTILLATION:

The next sage in the manufacture of alcohol is to separate alcohol from fermented wash and to

concentrate it to 95% alcohol called as rectified spirit. For this purpose, method of distillation is



employed. The distillation columns consists number of SIEVE plates where wash is

boiled and alcoholic vapors are separated and concentrated on each place stage by stage.

INTEGRATED DISTILLATION AND EVAPORATION SECTION:

Technology offered (multi-Pressure)

This technology is based on heat recovery principle. The system comprises of 3 columns

operating at different pressures and is designed to produce Rectified Spirit. The columns in order

of flow are as follows:

1. Analyser cum Degasifying (Column (operating under vacuum)

2. Aldehyde Column (operating under Vacuum)

3. Rectifier cum Exhaust Column (Operative under Pressure)

RECTIFIED SPIRIT PRODUCTION:

Fermented wash from the clarified wash tank is pumped to the fermented wash pre - heater and

preheated to about 68-700C by circulating hot spent wash on other side. Incoming spent wash

temperature is 80-820C and after exchanging heat with fermented wash out let lamp of spent

wash remains at 35- 400C this hot fermented wash is then feed at the top of Degasifying column.

Analyzer column cum Degasifying Column:

Analyzer column strips fermented wash before discharging the rest of the material as

spent wash. Metered flow of fermented wash is feed to the top of the analyzer column. Vapours

of rectifier column provide energy to Analyzer column through a evaporator. Rectifier top

vapours are condensed on the shell side of the evaporator and spent wash is re -circulated on tube

side. Vapors generated from the re - boiler are used in the analyzer column consist

approximately 50% alcohol and 50% water with impurities such as higher alcohols,

aldehydes, acids, sulphur dioxide, etc. Spent wash from the analyzer column bottom is sent

for treatment to the Effluent Treatment Plant. The level in the column bottom is controlled to

ensure proper distillation and correct concentration of the spent wash. The vapour draw from

top of the Analyzer is condensed in forth stage of evaporator system and pumped to

Rectifier column for concentration. Analyzer column is operating under vacuum. Using water

ring vacuum pump creates vacuum and the vacuum in the column is maintained by manual

valve, which bleeds extra air in the system.



ALDEHYDE COLUMN:

Aldehyde column is principally used for removal of low boiling impurities. Vapours from

degasifying column are fed to Aldehyde column. The vapours coming out of the top of the

Aldehyde column are fed to the condenser-I where they are partially condensed bypassing

cooling water on the tube side. Balance alcohol vapours are condensed in the condenser- II.

Water is used for the Condensation. From aldehyde column top Technical Alcohol cut of

2% of total plant capacity is taken out. Aldehyde column works under vacuum.

RECTIFIER CUM EXHAUST COLUMN:

Analyzer column top vapours are condensed in forth stage of evaporator and fed to

Rectified column for further concentration. Rectifier column is designed in sieve trays

construction and operates under pressure for obtaining desired strength of alcohol. Condensing

steam provides heat to Rectifier column.

Fusel Oil draws are taken from Rectifier column and are send to fusel oil decanter. The fusel oil

stream is diluted with water for separation of fusel oils. The aqueous layer sends backs to

Rectifier column and fusel oil are sent to storage.

Technical Alcohol cut of 3% of total plant capacity is taken out from top of Rectifier Column.

Rectified Spirit of 95% v/v concentration is drawn from one of the upper trays of

Rectifier Column and sends to storage after cooling.



Molasses Arrives

Molasses Weighed and Diluted

Yeast Propagated with Molasses in Sterilized Separate Vessel

Fermentation

Clarified Wash Tank

Analyzer Column

Pre – Rectifier Column if Required

Rectifier Column

Exhaust Column

Re - Boiler

Fusel Oil Separated & Alcohol Returned

RS/ENA

Process Flow Chart

B) COGENERATION OF POWER

2.5.2 BOILER CAPACITY (TOR POINT. 10)

The proposed Cogeneration plant, will have one (1) No. of 25 TPH capacity boiler generating

steam at 46 ATA & 485 0 C. Bagasse/Agricultural waste/Rice husk/coal will be used as fuel at



the rate of 270 MT/ day and need of steam will be 528 MT/day. Gaseous emission from the

boiler will be directed through the bag filter systems to control the emission level of pollutants

SPM. Concentrated spent wash will be sprayed on bagasse bed in specially degined spray guns

for proper combustion. Since spent wash methane is already recovered its calorific value will be

low.

Boiler

Capacity

Quantity of Fuel

(Tor pont.6)

Type of Fuel Source of Fuel

(Tor pont.6)

25 TPH

270 MT/day Bagasse Nearest sugar

factories.

142 MT/day

150 m3/day

Bagasse

Concentrated spent wash

As above and own

production

BOILER FEED WATER AVAILABILITY

As the new plant will be operating with the boilers outlet steam parameters of 46 ata and 5150C,

the boiler feed water requirements will be met essentially by the recycling condensate and using

make up water. The steam condensate temperature will be 950C and will be recycled in the feed

water circuit. The make up for the plant operation will be made with demineralized water for

which adequate capacity water treatment plant will be provided.

COOLING TOWER

The circulating water system will provide cooling water to the condenser for the steam turbine

exhaust steam, and to the cooling water heat exchangers

STEAM PARAMETERS:

The steam parameters at the outlets of the boilers, super heater will be 46 ata with 485 ± 5°C.

Total steam requirement for process is detailed below:

UTILITY Ton/Day

STEAM

For Fermentation 50

For Distillation 300



For Evaporation 178

Total 528

Entire steam generated will be used to run turbine of 2.2 MW DECT type of Turbo Generator set

for generation of power as well as use of steam for distillery and deareator of power plant.

Power generation will be at 440 V. Entire power will be used in operating production, cogen and

utilities facilities.

COGEN FLOW CHART

Condensate

Feed Water

BOILER

DEAERATOR

POWER 2.2 MW

TURBO

SUPERHEATED STEAM 25 TPH at 46 ATA

FEED WATER TANK

BAGASSE 270 MT/day

142 MTD with 150 MTD SW

1st Extraction 3 TPH 6 ATA

2nd Extraction 18 TPH 2 ATA

Condenser 4 TPH



2.5.3 RAW MATERIAL: (TOR POINT. 4)

As the manufacturing process is changed to be molasses based, molasses required is 400

MT/day. Nearby sugar factories with and without own distillery within 50 KM radius is as

detailed below:


TCD

last year

Crushing

Distillery

KLPD

Shree Datta sahakari sakhar karkhana Ltd

sirod, dist- kolhapur

18 Km 7000 91800 60

Shree Gurudutta sucrose Ltd takrewadi sirod

dis- kolapur

8 KM 2500 670000 Nil

Shree jawahar shetkari sahakari sakhar

karkhana Ltd hupari tal- hatkanangale dist-

kolhapur

23 KM 9000 1428000 Nil

Shri sharad sahakari sakhar karkhana Ltd

narande Tal- tal- hatkanangale dist- kolhapur

45 KM 2500 589000 Nil

Shree Panchganga sahakari sakhar Karkhana

Ltd ganganagar ichalkaranji tal- hatkanangale

dist- kolhapur

23 KM 5000 740000 Nil

Shri Chhatrapati rajaram sahakari sakhar

karkhana Ltd kasba bawda, Dist Kolhapur

49 Km 2200 410000 Nil

Shree chattrapati shahu SSKL Kagal Tal-

kagal Dist- Kolhapur

36 Km 3500 731000 45

Vasantdado sskl Madhavnagar sangali

tal Miraj Dist - Sangli

34 Km 5000 530000 Nil

Shree guppy sugar waorks Ltd, Kagwad, Tal

– chikkodi Dist – Belgaon karnataka

30 Km 5000 46600 Nil

Shree Shiv Shakti sugar ltd yadrav ankali tal-

chikodi dist Belgaumkarnataka

41 Km 2500 390000 Nil



Hence proposed project of KSPL is assured of raw material availability within 30 KM of

the proposed site.

2.5.4 DAYS OF OPERATION (Tor Point.3)

The existing unit operations were dictated by availability of sugar cane and pollution control

which restricted the operation during monsoon. This was essential as process involved treatment

of spent wash by bio-composting in open fields. Now PP proposes to change the treatment of

spent wash by concentration in MEE followed by incineration in own boiler. Hence the

monsoon restriction is no more valid.

Now the process of manufacture via cane juice is being scrapped altogether. Instead the process

will be molasses based availability of which is assured from surrounding areas. Hence PP

proposes to run the plant for 330 days with actual working depending upon normal and

unscheduled shut downs that are part of day to day activity.

The availability of other raw material i.e bagasse is also assured. Its requirement at full load shall

be 270 MT/day. It will be further reduced when dried spent wash is burnt in the boiler. Hence

there is no bottleneck in running the boiler for 330 days.

In view of above PP proposes to operate the distillery for 330 days or more.

Dudhganga- krushna sskl nanandi, tal-

chikkodi dist belgaon karnataka

32 Km 60000 836000 Nil

Venkateshwara power project bedkihal tal-

chikodi dist- Belgaum karnataka

18 Km 3500 707000 Nil

Ugar Sugar ltd, Ugarkhurd Tal-chikodi dist-

Belgaum karnataka

48 Km 10,000 1156000 Present

Total 117700 180

KLPD

Molasses generation/requirement 4708 720

Molasses requirement of KSPL 400 KLPD



2.6 ANTICIPATED POLLUTION AND MITIGATION

2.6.1 AIR POLLUTION CONTROL.

The exhaust gases, generated by burning of bagasse/spent wash in boiler will be discharged into

the atmosphere through a stack, after guiding through a bag filter. An independent stack of the

height of 35 meters and has been calculated according to the Central Pollution Control Board,

(CPCB) Govt. of India guidelines based on particulate emission as SO2 emission is very low..

2.6.2 EFFLUENT WATER TREATMENT

The effluent generated from boiler blow down, cooling tower blow down and WTP wash shall be

treated in ETP and treated water will be partly used for ash quenching and partly for gardening.

2.6.3 ZERO DISCHARGE SYSTEM FOR SPENT WASH

Spent wash 800 KLPD will be first concentrated in multiple effect evaporators. It shall be dried

in suitable drier to recover all moisture. Dried spent wash will be burnt in own boiler.

Advantages are availability of heat for burning in boiler and saving in bagasse and at same

time NO discharge from factory.

Refer chapter -4 for details.

2.7 SCHEDULES FOR APPROVAL AND IMPLEMENTATION

100 KLPD distillery with 2.2 MW cogeneration of power.

Sr. No Project activity Activity completion/

expected date

1 Application to MOEF New Delhi for TOR 21/10/2008

2 Final presentation for TOR MoEF New Delhi 22/12/2008

3 Approval of TOR from MoEF New Delhi 25/02/2009

4 Application for public hearing 29/02/2012

5 Application for re-conducting public hearing 20/07/2013

6 Date of public hearing 23/05/2012

7 Date of re-conducting public hearing 08/11/2013

8 Incorporation of public opinion in EIA 30/11/2013

9 Final EIA submission 30/12/2013

10 Submission of consent to establish application to MPCB 22/12/2014



11 Receipt of Consent to establish from MPCB 25/02/2015

12 Final EIA presentation 29/11/2014

13. Issue of specific TOR 29/11/2014

14 Resubmission of EIA incorporating revised TOR 15 Jan 2015

2.8 EMISSION AND DISCHARGES FROM THE PROJECT

2.8.1 WASTEWATER GENERATION AND TREATMENT (TOR POINT. 14)

A. Wastewater is from distillery will be spent wash @ 800 m3/day. Its treatment details have

been described in chapter-4 to ensure total destruction by burning in boiler.

B. Waste water from cogen facilities consists of mostly boiler blowdown and cooling water

blow down. In addition the back wash from softener / D M plant regeneration is

additional constituent. Quantum of waste water generated due to 2.2 MW cogen plant

will be used for ash quenching and green belt irrigation

2.8.2 AIR POLLUTION AND ITS MITIGATION

Particular Stack height

in m

Fuel/Emission/Mitigation

Common boiler for cogen

and distillery @ 25 TPH

35 270MT/day Biomass

1.35 MT/day

Bag filter to restrict emission to 150

mg/nm3

SO2 restricted to 124.8 kg/day

2.8.3 SOLID & HAZARDOUS WASTE GENERATION

The solid waste and hazardous waste generation from the proposed Project is as follow.

25 TPH cogen Boiler Bottom Ash- 12.15 MT/Day

Collection method: Mechanical conveyors into common silo for further disposal.

Mode of disposal: Sale to brick manufactures and used as farm manure.

CHAPTER-3

BASELINE STATUS

3.0. BASELINE STUDIES

The term ’Environment’ include water, air, land and inter-relationship between water, air, land and

human beings, other living creatures, plants micro-organisms and property. Base line status of the

environmental attributes in the study zone of 10 Km radius from the project site is carried out as a

mandatory step in EIA study to determine base line status. This forms the basis for impact

prediction on these environmental issues on establishment of the project. Primary data were

collected based on observation and measurements made during the field survey carried out in the

October 2011 to December 2011. Major thrust area includes ambient air quality, water quality,

noise and flora and fauna of the region and demography of the people. Besides primary data the

secondary data were collected from government’s data sources.

For the present EIA study, the physical dimensions of the environment such as site location and

surroundings, topography, geography, air quality, micrometeorology, noise levels, water quality,

land –use pattern and soil quality, terrestrial flora and fauna and all the other dimensions are

considered. These environmental parameters are studied to establish an existing environmental

scenario of an area covering 10-km radius, which is considered as an impact area.

This Chapter gives a brief description on the existing scenario of various environmental dimensions

along-with the statistical data generated.

3.1 PHYSICAL ENVIRONMENT

Table 3.1: Details of site and information related to environment setting within 10 km radius of the

project site (ToR Point: 06)

Sr. No. Particulars Details

1 Latitude 16°38'28.79"N

2 Longitude 74°34'20.77"E



3 Altitude 557 m MSL

4 Toposheet 47 L/10

5 Seismicity Area falls under least affected

earthquakes zone iii as per IS 1893 –

1984 ( November 2002)

6 Climatic condition Temp. 37.5oC to 14.5oC

7 Nearest village Herwad, Kurundwad, Latwadi,

Ghosarwadi, Akiwat, Takkiwadi,

Majarewadi, Bunal

8 Nearest town Shirol 10km

9 Nearest Highway State highway No. 12 (10 Km)

10 Nearest railway station Jaisingpur 15km

11 Nearest airport Kolhapur 30km

12 Streams/ Rivers Panchganga river (Direction North

South) & Distance 2.7 Kms.

13 Topography Flat

14 Sanctuaries /National

Parks/ Biospheres, etc.

NIL

15 Defense Installations NIL

16 Historical Places NIL

17. Karnataka State Boarder 3 KM

The project site is located at Herwad Tal Shirol Dist. Kolhapur. The Kolhapur district is the

Western most district of Maharashtra state. This District is situated between 15 degrees and 17

degrees longitude on Northern Side and 73 and 74 degrees latitude on Eastern Side and shares

common boundaries with Ratnagiri district East side, Belgaum districts of Karnataka in the West

side, Sangli district in the North , Satara district in the also in north side.



TOPOGRAPHY

The Physical Setting of the Kolhapur district can be best appreciated in the background of its

geology relief and drainage. It may be noted, in general, that over a major portion of the district the

Deccan ' trap' influences the landscape; only in the southern extremities the rocks of the Dharwar

and Lower Kaladgi series introduce a change in the topography. The district, on the whole, is a part

of the Deccan table-land with an average height of 1800 ft. above sea level, with the Sahyadrian

Scarp forming the most prominent feature along its western administrative boundary. From the

gently uneven and mature looking crest-line of the Sahyadries, the Kolhapur portion of the plateau

is marked by several hill ranges which emerge from the main range and develop an eastward or

north-eastward trend. Some of them extend up to 30 miles while others terminate after a short

stretch. But all these ranges have that characteristic ' Lava' topography consisting of flat tops and

steep escarpments on flanks which carry several terraces or ' steps'. The ranges rise to about 1,000

to 1,500 ft. above the valley floors. A long period of erosion on the horizontally laid lava flows

explains their general appearance. Water action has carved out river valleys and their tributary

valleys leaving the harder material as residual hill ranges. From a fairly broad base, these hills rise

in a series of terraces, which are not unlike a flight of steps, culminating in a summit level that is

noted for its remarkably flat table-lands separated by low saddles. A laterite capping marks many of

these plateau tops, and altogether, this step-like mature landscape has earned the Swedish name '

trape ' topography. Such landscape features can be seen in the main Sahyadrian range lying in this

district, in the Vishalgad-Panhala range, in the Phonda-Sangaon, and the Kagal, Bhudargad and

Ajra ranges. Only in the environs of Ajra does this landscape change to some extent due to the

change in the underlying rock.

The drainage pattern of the Kolhapur district has three important aspects. The Sahyadries form the

main water-divide separating the eastern drainage from that flowing in the west to the Arabian Sea.

Secondly, the western flowing streams are ungraded and run down the Sahyadrian scarp face with a

tremendous velocity, with the result that the scarp face presents a highly eroded appearance when

seen from the Konkan side. At the base of the scarp, that is in the Konkan proper, these parallel

flowing streams lose their force, deposit the debris brought from the main range, and develop a

sluggish and meandering course to the Arabian Sea, but it is to be noted that only their upper most

reaches lie within the administrative boundaries of this district. The drainage pattern of the plateau

Kolhapur differs a good deal in several respects from that of the Konkan streams. It is, first of all,



well developed, and geared to the base level of the Krishna which has mastered all the river courses

of the district. The rivers occupy wider valleys; there is a good tributary development, though in

some cases the head-waters have been ' captured' by the fast flowing streams of the main range

draining the region to the Konkan lowlands. Thus, from north to south, the district is drained by the

Varna, Panchaganga, Dudhganga, Vedaganga and Hiranyakeshi. The Varna has a long course, but a

much restricted basin. The Panchaganga, on the other hand, commands a large drainage area

through its main tributaries, the Kasari, Kumbhi, Tulsi and Bhogavati. The southern rivers, the

Dudhaganga with its main tributaries, the Vedaganga and the Hiranyakeshi have long courses but

smaller and independent valleys. There is also an interesting contrast in the direction of flow of

these plateau rivers of the district. The Varna flows from the north-west to south-east, the

Panchaganga from due west to east, while the southern rivers flow from south-west to north-east.

This is most probably due to the geological structure underlying and the denudation sequence of the

Krishna river which controls in a large manner the flow and erosive capacity of these rivers. There

are also some similarities between these rivers. They share a common monsoonal flood regime;

they develop the highly significant flood plains and flood terraces which, locally known as Malai,

are highly prized for soil fertility. The physical setting of the small valleys that the rivers occupy is

suitable for constructing weirs, locally known as bandharas, which facilitate good irrigation. Except

in the Lower Panchaganga these bandharas are quite common. Under the influence of new

economic forces, most of the river valleys which formerly produced good meadow grass, have now

been turned to the cultivation of rice, and more recently to sugarcane, an important crop which

influences practically every aspect of rural economy. The final common feature shared by these

rivers is the control exercised by the Krishna river as a master stream. The Krishna from its

confluence with the Varna forms the eastern boundary of the Kolhapur district down-stream for

about forty miles. It has a well entrenched meandering course through a black soil plain, and is

joined by the Panchaganga near Narsobawadi and by the Dudhaganga near Yedur which is a little

outside the district boundary. The southernmost river, Hiranyakeshi, empties its waters in the

Ghataprabha which in its turn is a tributary of the Krishna, near Ingli outside the limits of this

district.

The district is bounded by South Satara on the north, Ratnagiri on the west, and Belgaum on the

south and the east. From a geographical point of view the Varna in the north forms a common

boundary between it and South Satara; in the north-east the rivers Krishna and Dudhaganga run



between it and Belgaum; and in the west the Sahyadrian water-shed largely separates it from

Ratnagiri.

RIVER SYSTEM

A succession of river valleys draining the land towards the east characterises the landscape of the

district from the Varna valley in the north to the upper tributaries of the Ghataprabha in the south.

From the human point of view these are the most important areas of the district. Well cultivated and

densely peopled, Malkapur, Kasba, Sarud and Kodoli are more important villages of the Varna

valley. In the Kasari valley Gajapur, Bhogaon and Kasar are important villages. Sangrul situated at

the spur of the Pal Donger (or Tymzai Range) is a market village in the Kumbhi valley. In the upper

reaches of the Kumbhi, Kale and Bawada are large sized villages. The road from Kolhapur connects

these places and through a Ghat road it joins Kharepatan. Bid and Koge are important villages of

the confluence plain of the Kumbhi, Tulsi and Bhogawati rivers. The Bhogawati valley is much

better developed economically. A road from Kolhapur to Malvan passes through this valley via

Phonda Ghat and connects several large sized villages live Vashi, Rashiwade and Radhanagari.

Development of hydro-electricity from the Radha-nagari tank and irrigation by means of bunds on

the Bhogawati River has brought in a greater prosperity to this valley through sugar-cane

cultivation. East of Prayag which marks the confluence of the Kasari and Bhogawati, lies the

Panchaganga valley proper. This is a region of rich agriculture and population. A substantial area is

utilized for sugar-cane. East of Kolhapur several commercially important crops are raised. Sugar-

cane continues to dominate the banks of the river. A little in the interior it is succeeded by tobacco,

cotton, millets and wheat. Betel leaf gardens flourish wherever well irrigation is possible. Pulses

and spice crops play an important secondary role. Large sized nucleated village are typical of this

region. Hatkanangale, Shirol and Ichalkaranji are local markets and Taluka towns. Ichalkaranji is

well-known for its handloom products. Narsobawadi situated at the junction of the Panchaganga

with the Krishna, is a place of great sanctity. Jaisingpur is a small but flourishing town that

specialises in tobacco marketing. But the city of Kolhapur through its historical tradition,

administrative and commercial importance dominates the economy of the entire district. The

Phonda-Sangaon range separates the Bhogawati from the Dudhaganga valley. As compared with

the northern valleys the valley of the Dudhaganga river is wider and also correspondingly well-

developed. Its upper regions are partly wooded and partly rice-growing areas. Towards Kagal

cultivation of millets and several other crops increases. The agricultural development of this valley



is well reflected in the numerous large sized villages like Valve, Solankur and Kagal. Kagal is a

town of local importance situated on the Poona-Bangalore trunk road. The Kolhapur limits of the

Dudhaganga valley terminate east of Kagal. A small hill range separates the Dudhaganga from the

upper reaches of the Vedaganga. Gargoti and Murgud are two important market villages. Gargoti is

connected with Kolhapur by a good metalled road across the Vedaganga hilly range and Murgud

lies on the Nippani-Radhanagari Road. The southernmost part of the district as generally hilly and

is marked by several small valleys draining the area eastwards mainly to the Ghataprabha river. In

one of the tributary valleys of the Vedaganga is situated the minor township of Kapshi. Ajra,

Mahagaon and Gadhinglaj are small sized towns lying on the Sankeshwar-Savantwadi road which

passes through the upper Hiranyakeshi river. Economic development of these valleys is very much

similar to that of the Dudhaganga and Vedaganga basins.

HYDRO-GEOLOGICAL STUDY OF THE AREA

HYDROLOGY PROFILE

The study area does not have any manmade big water tanks except for the natural ponds. Due to the

scanty rainfall over the last few years, the tank and streams hold water only during and just after

monsoon season.

HYDROGEOLOGY

Occurrence and Movement of Ground water in Rock Formations

The joints and other openings in gneiss and granites, the pore spaces in the zone of weathering and

bedding planes of the metamorphosis sediments determine the rate of percolation of water into sub -

surface and the yield of the wells in the region. Black cotton soil allows water to infiltrate slowly

after saturation. The impervious calcareous clay bed, below the black cotton soil prevents

the downward movement of water. Whereas, the areas were covered by red loam /sandy solid have

relatively greater percolation because of its relatively high porosity and permeability.

Occurrence of groundwater is mainly controlled by water table conditions. The recharge of the

ground water is mainly due to the rainfall, which is scanty in the region. Therefore, the depth

of water table level in the area is between 35-50m below the ground level.



DEPTH OF GROUND WATER AND SEASONAL VARIATION:

Dug wells are more common and popular in the study area. Nearly 33% of the wells are of shallow

type and water table is within 12m depth, the deep dug wells are upto a depth of 20m. The study of

fluctuating ground water level by the Central Ground Water Board (CGWB) reveals that

the fluctuation is in the order of 1.65 m to 4.42 m with average fluctuation of 3.13m.

GROUND WATER POTENTIAL

Ground Water potential has been assessed as per the data collected from the State Ground Water

Department. The entire region is mainly underlain granite, gneisses and Dharwad schists that are

known to be hard rocks, which have least porosity. Ground water is found in pockets in the area in

the zones of weathered, jointed and fractured rocks. The dug wells in the area generally tap on the

weathered zone. The thickness of the weathered zone varies few centimeters to 20 m. The average

area of the cross section of a domestic well is 6 Sq.m and that of irrigation well varies between 40

Sq.m to 180 Sq.m. The yield of dug wells range from 10 m3 /day to 250 m3 /day for a pumping

period of 4 to 6 hours. Bore wells in the area are of 150mm dia and are normally upto a depth of

40m to 120 m. The yield of these wells is maximum 30 m3 /hr and the pumping period varies from

6 to 8 hours/day. State Public Health Engineering Department (PHED) indicate that nearly 80%

of the bore wells yield between 0.6 to 9 m3 /hr and the maximum yield is obtained from bore

wells drilled between 40 to 60 m depth. Most of the dug wells, dug-cum -bore and shallow bore

wells upto 30 m tap the shallow aquifers and the borewells deeper than 30 m, tap the water from

fractures occurring between 30 m to 100 m depth which tap medium to deep aquifers.

GEOLOGY

The extensive limestone deposit occurring in Kolhapur belongs to the lower Kaladgi formation of

Precambrian sedimentary origin. The stratigraphic sequence is identified for the region.

Geological age Formation Lithology

Recent - Black cotton soil Precambrian Kaladgi group Limestone shale

- Unconformity - Archean Granite Gneises -



The local geology as observed is:

1. Thinly bedded, soil/ black cotton soil

2. Shale

3. Dolomite limestone

4. Gray limestone

5. Siliceous limestone

The arc is mainly covered by black cotton soil of varying thickness (1 to 2 mt) the contact between

Dolomite and high calcium limestone and siliceous limestone are well exposed.

3.2 WATER ENVIRONMENT

Water is one of the vital, prominent resources for all living things on earth. The practice of

inadequate access to clean drinking water and lacking of good and consistent sanitation facilities is

the impetus for the most significant environmental problem and threat to public health in both rural

and urban India. Almost all the surface water sources are contaminated to some extent by organic

pollutants and bacterial contamination and make them unfit for human consumption unless

disinfected.

Data on baseline condition of water environment of the study area was collected with following

objectives:

Qualitative assessment of water sources of the area.

To judge the temporal changes in water quality of different sources.

To predict the impact of Power Plant over water environment of the area.

To judge the water environment of the area, both the sources of water (surface/ground) were given

due consideration. Water samples were collected and analysed for various parameters. Based on the

analysis of different parameters, results were checked up against the limits set up to statuary

authorities

Reconnaissance survey of the area was made for the selection of sampling location for surface and

ground water analysis. Stations were selected keeping the objectives in mind, details of study is

presented below:



3.2.1 SURFACE WATER

There is one river in the study area - Panchganga. The sampling locations were selected at 3

different stations of river at a distance of about 500m. Samples were collected and analyzed as per

standard methods and frequency of sampling was thrice /station. The result of the analysis of

surface water is presented in Table 3.2 the analysis results of the surface & ground water collected

from sampling stations are presented in the Table-3.2 and 3.3.

pH is observed in the range of 7.4 to 7.9 and conductivity varied from 220 to 270 mhos/cm.

Chloride and Sulphate were observed to be in the range of 4.6 - 5.8mg/l and from 3.2 - 4.6mg/l

respectively. The heavy metal contents are found to be negligible. Water quality is excellent but it is

not potable due to presence of coliform. It can be used for drinking purpose after installing

bacteriological treatment devices at individual or at community level.

Table 3.2

Surface Water Analysis Report of Panchganga River

Sr. No. Parameter Results Units

1 pH 7.54 -

2 Conductivity 0.8 mS/cm

3 Temperature, 0C 29 0C

4 Dissolved Oxygen 5.0 Mg/l

5 Turbidity <5 NTU

6 Dissolved Solids 512 Mg/l

7 Suspended Solids 7.1 Mg/l

8 Total Hardness as CaCO3 265 Mg/l

9 BOD BDL Mg/l

10 COD BDL Mg/l

11 Chlorides as Cl 86 Mg/l

Location of Sampling : Surface Water Sample. (From Panchaganga River)

Date of Collection : 12/10/2011, Date of Receiving : 14/10/2011



12 Sulphates as SO4 32 Mg/l

13 Calcium as Ca 48 Mg/l

14 Magnesium as Mg 22 Mg/l

15 Nitrates as NO3 Absent Mg/l

16 Fluorides as F BDL Mg/l

17 Iron as Fe BDL Mg/l

18 Lead as Pb BDL Mg/l

19 Copper as Cu BDL Mg/l

20 Mercury as Hg BDL Mg/l

21 Nickel as Ni BDL Mg/l

22 Zink as Zn BDL Mg/l

23 Chromium as Cr BDL Mg/l

24 Arsenic as As BDL Mg/l

25 Manganese as Mn BDL Mg/l

26 Cadmium as Cd BDL Mg/l

27 Oil & Grease 0.4 Mg/l

28 Total Coliform MPN/100ml 48 MPN/100ml

Location of Sampling : Surface Water Sample. (From Panchaganga River)



1 pH 7.44 -


3 Temperature, 0C 26 0C

4 Dissolved Oxygen 5.0 Mg/l

5 Turbidity <5 NTU

6 Dissolved Solids 494 Mg/l



7 Suspended Solids 6.2 Mg/l


9 BOD BDL Mg/l

10 COD BDL Mg/l






16 Fluorides as F BDL Mg/l






22 Zink as Zn BDL Mg/l





27 Oil & Grease 0.3 Mg/l

28 Total Coliform MPN/100ml 42 MPN/100ml

Date of Collection : 12/12/2011 Date of Receiving : 15/12/2011


1 pH 7.44 -

2 Color 0.3 mS/cm



3 Turbidity 25 0C

4 Conductivity 5.2 Mg/l

5 Dissolved Solid <5 NTU

6 Suspended Solid 190 Mg/l

7 Total Alkalinity 5.3 Mg/l


9 Chlorides as Cl BDL Mg/l

10 Sulphates as SO4 BDL Mg/l

11 Nitrates as NO3 21 Mg/l

12 Phosphate as PO4 24 Mg/l

13 Dissolved Iron as Fe 28 Mg/l

14 Calcium as Ca 11.2 Mg/l

15 Magnesium as Mg Absent Mg/l









24 E-Coli BDL Mg/l



27 Oil & Grease BDL Mg/l

28 Total Coli form 80 MPN/100ml



3.2.2 GROUND WATER

The study region receives about 557 mm of rainfall and it plays an important role in recharging of

ground water. High a lands ensure quick surface runoff and the precipitation received in low–lying

area contribute to a great extent in building of ground water reserve of the area. Water supply in the

most of the villages depends on ground water resources. Well water is used for domestic as well as

irrigation purposes. Sampling was carried out at 4 locations during the study period. Sampling and

analysis was carried out, as per standard methods and frequency of the sampling was thrice/stations.

The result of the analysis of Ground water is presented in Table3.3 and the summary of the results

are presented below: pH in ground water sample was observed to be in the range 7.1 to 7.6 while

conductivity was observed in the range of 242- 252 mohs/cm. The value of alkalinity and hardness

were observed in the range of 132 – 160 mg/l and 158 to 170 mg/l respectively. Whereas heavy

metal was found to be within the limit.

Table 3.3

Ground Water Analysis Report

Location of sampling : Ground Water Sample. (From Dattawad Village)


No. Parameter Results Unit

1 pH 7.46 -

2 Color Colourless Hazon

3 Turbidity <5 NTU


5 Dissolved Solid 746 Mg/l


7 Total Alkalinity 234 Mg/l





12 Phosphate as PO4 BDL Mg/l

13 Dissolved Iron as Fe 0.064 Mg/l




15 Magnesium as Mg 8.6 Mg/l









24 E-Coli Absent MPN/100ml

Location of sampling : Ground Water Sample. (From Karan Sugar Site)

Sample Quantity : 2 liter Date of Collection : 12/10/2011

Sample Collected by : PAPL Date of Receiving : 14/10/2011

Sr.

No. Parameter Results Unit

1 pH 7.34 -


3 Turbidity <5 NTU
























Location of sampling : Ground Water Sample. (From Takaliwadi)



Sr. No. Parameter Results Unit

1 pH 7.46 -


3 Turbidity <5 NTU
























Location of sampling : Ground Water Sample. (From Harwad)




1 pH 7.56 -


3 Turbidity <5 NTU




























1 pH 7.44 -


3 Turbidity <5 NTU






















1 pH 7.34 -


3 Turbidity <5 NTU

4 Conductivity 1.2 mS

































1 pH 7.36 -


3 Turbidity <5 NTU




























1 pH 7.28 -


3 Turbidity <5 NTU




























1 pH 7.36 -


3 Turbidity <5 NTU

























1 pH 7.44 -


3 Turbidity <5 NTU



























Location of sampling : Ground Water Sample. (From Harwad)




1 pH 7.20 -


3 Turbidity <5 NTU
























CONCLUSION:

Analysis of ground water samples from existing site as well as villages surrounding site

confirms there has been no contamination of ground water.

3.3 METEOROLOGY

Meteorological condition plays a vital role in the transport & diffusion of air pollutants into the

atmosphere. Data of meteorological parameters were collected/ generated during the study period

with following objectives:

To characterize the present meteorological status of the area.

To generate a database for air quality dispersion modeling.

To study the temporal changes in the meteorology of the area.

To collect the onsite data for the meteorological parameters a weather monitoring station was

installed at the plant site and it was sited, keeping in mind the recommended principles in this

regard. The meteorological data was also collected from IMD, Shirol.

3.3.0 CLIMATE

There are mainly two seasons i.e. summer and winter. The summer season falls between the months

of April to July and the winter November to March. In summer season the temperature touches

44.20C or even sometimes crosses it. June is the hottest month and January is the coldest one.

Mostly the rain falls in the month of July. The winter rains are experienced during January and

February. The dust storm occurs in the month of May and June.

The brief discussion over the meteorological condition of the area is as below:

3.3.1 TEMPERATURE

Summers are extremely hot in the area where the temperature goes up to 37.5OC in the month of

April, May, and June. In winter the temperature goes down to 14.5 OC in the month of December.

December and January are the coldest months when the minimum average temperature in summer

goes to around Max.37.5oC, &Min.26oC & in winter goes to Max.29.8o & Min 14.5oC



3.3.2 RELATIVE HUMIDITY

The relative humidity varies from season to season. The average lowest relative humidity at 8.30 hr

and 17.30 are observed around 82% and 26% in the summer season. The average highest relative

humidity at 8.30 hr and 17.30 hr are observed around 90 % in the monsoon season. The minimum

Relative Humidity was observed in the month of February at 23 %.

3.3.3 RAINFALL

The south-west monsoon generally arrives in the first week of July and continues up to the end of

August. 70% of the rainfall occurs during this period. The average rainfall of the district is 557

millimeters (average of 5 years). The rainfall in the district is greater in the sub mountain parts of

the district and decreases rapidly towards the southwest.

3.3.4 CLOUD COVER

30 years average data reveals that maximum cloud cover was observed around 7.1 in the month of

July and August. Whereas cloud cover was observed around 2(in OKTAS) in the month of

November, December, January, February and March. The monthly variations of Temperature,

Relative Humidity, Rainfall, Cloud Cover, during study period are tabulated in Table 3.4

3.3.5 WIND PATTERN

Wind pattern reveals that predominant direction of wind is mostly from W, SW and NW.

Table 3.4: Meteorological Data Monitored Showing Max, Min, Average Temperature and

Relative Humidity at Shirol

Month Mean daily

Maximum Temperature

in deg.C

Mean daily

Minimum Temperature

in deg C

Relative

Humidity

(08.30 hrs)

Relative

Humidity

(17.30 hrs)

Jan 30.5 14.5 61 27

Feb 32.1 15.8 57 23

Mar 35.7 18.7 57 26

April 37.05 21.3 64 38

May 34.9 22.3 72 50

June 30.05 22.05 82 70



July 26.3 21.1 89 83

August 26.4 20.8 90 82

Sept. 28.27 20.4 87 73

Oct. 30.2 20.0 82 61

Nov. 30.3 16.2 65 37

Dec. 29.8 14.5 61 30

3.4 AIR ENVIRONMENT

An assessment of the existing air quality is required to establish the reference level. To accomplish

this, Ambient Air Quality Monitoring (AAQM) Stations were set up within 10 km radius of

ongoing mining area. Data over baseline status of ambient air quality was generated with following

objectives:

Qualitative analysis of air environment of the area.

Representation of regional back ground levels

Influence of existing sources of pollution

The major contributors/sources of air pollution in the area are

Vehicular traffic

Windblown Dust

3.4.1. AMBIENT AIR QUALITY

The ambient air quality monitoring was carried out at 5 locations. The location and descriptions of

AAQM stations is shown in Figure 3.5.

1) Plant Site.

2) Herwad Village.

3) Takaliwadi Village.

4) Dattawad Village.

5) Abdul Lat.



Samplings at Five stations were carried out for one season during period October to

December 2011

The parameters monitored during the study period were Suspended Particulate Matters (SPM),

Sulphur dioxide (SO2), Oxides of nitrogen (NOx), Carbon Monoxide (CO) and RSPM. The results

of AAQM are depicted in the Table 3.5

Table 3.5

Ambient Air Quality Monitoring Results.

Date of Sampling 10/10/2011 To 11/10/2011

AMBIENT AIR STATION/HIGH VOLUME SAMPLER (H.V.S.) LOCATION

Location of H. V. S.: At Karan Sugar Site Near Ad Building Duration : 24 Hrs. Time : From 11 am to 11 am

POLLUTION PARAMETERS



Parameter Result National

AAQM Std. Unit Method

Particulate Matter (<10 μm) 62 100 μg/m3 Gravimetric

Particulate Matter (< 2.5 μm) 32 60 μg/m3 Gravimetric

SO2 conc. 10.2 80 μg/m3 IS-5182 (part- 2)

NOx conc. 8.2 80 μg/m3 IS-5182 (part- 6)

METEROLOGICAL DATA

Temperature Variation Max Min Avg Unit

Dry Bulb 28 26 28 0C

Wet Bulb 28 24 26 0C

Wind Velocity 6.2 4.8 5.5 Kmph

Prominent Wind Direction WE --



Location of H. V. S.: Near Herwad Village Duration : 24 Hrs. Time : From 12:00 pm to12:00 pm








METEOROLOGICAL DATA






Wind Velocity 8.8 6.4 7.6 Kmph

Prominent Wind Direction WS --



Location of H. V. S.: Near Takaliwadi Village Duration : 24 Hrs. Time : From 1:00 pm to1:00 pm


Parameter Result

National

AAQM

Std.

Unit Method





METEOROLOGICAL DATA




Wind Velocity 5.6 4.8 5.2 KmPH




Location of H. V. S.: Near Dattawad Village Duration : 24 Hrs. Time : From 2:15 pm to2:15 pm










METEOROLOGICAL DATA



Wet Bulb 26 21 23.5 0C


Prominent Wind Direction NS --



Location of H. V. S.: Near Abdul Lad Village Duration : 24 Hrs. Time : From 3:15 pm to 3:15 pm








METEOROLOGICAL DATA


Dry Bulb 28 21 24.5 0C

Wet Bulb 28 19 23.5 0C







Location of H. V. S.: At Karan Sugar Site near Ad Building Duration : 24 Hrs. Time : From 10.30 am to 10.30 am





Particulate Matter (< 2.5

μm) 26 60 μg/m3 Gravimetric



METEROLOGICAL DATA








Location of H. V. S.: Near Herwad Village Duration : 24 Hrs. Time : From 11:30 am to 11:30 am










METEOROLOGICAL DATA








Location of H. V. S.: Near Takaliwadi Village Duration : 24 Hrs. Time : From 11:00 am to11:00 am








METEOROLOGICAL DATA


Dry Bulb 28 23 25.5 0C




CONCLUSION:

The analysis of ambient air quality data for three months consequently indicates excellent

ambient air conditions at site as well as around the site upstream as well as down stream.

Particulate matter PM10 as well as PM2.5 is within limits prescribed. SO2 and NOx levels are



well below the limits prescribed hence overall picture as far as ambient air is concerned is

positive.

3.5 LAND USE

3.5.1 SITE & STUDY AREA

Karan Sugars Pvt Ltd Project Site is located at 16°38'28.14"N, 74°34'21.90"E. It is close to Herwad

village.

A study area of 10Km radius has been considered around this location. The study area spans

between 18.70°N to 18.88°N and 74.52°E to 74.71°E.

Figure 3.1: Google Earth image showing Karan Sugars Pvt Ltd Project site

3.5.2 DATA USED

Land use land cover mapping has been done using LISS III image acquired by Resourcesat-2 on

April 05, 2012. The details of the satellite and the sensor are given below:



Resourcesat-2: Resourcesat-2 is a follow on mission to Resourcesat-1 and the eighteenth Remote

Sensing satellite built by ISRO. Resourcesat-2 is intended to continue the remote sensing data

services to global users provided by Resourcesat-1, and to provide data with enhanced multi-

spectral and spatial coverage as well.

Important changes in Resourcesat-2 compared to Resourcesat-1 are: Enhancement of LISS-4

multispectral swath from 23 km to 70 km and improved radiometric accuracy from 7 bits to 10 bits

for LISS-3 and LISS-4 and 10 bits to 12 bits for AWIFS. Besides, suitable changes, including

miniaturization in payload electronics, have been made in Resourcesat-2.

Resourcesat-2 also carries an additional payload known as AIS (Automatic Identification System)

from COMDEV, Canada as an experimental payload for ship surveillance in VHF band to derive

position, speed and other information about ships.

Resourcesat-2 carries two Solid State Recorders with a capacity of 200 Giga Bytes each to store

the images taken by its cameras which can be read out later to ground stations.

Figure 3.2: Illustration of Resourcesat-2 satellite

Resourcesat-2 was launched on April 20, 2011 from Shriharikota. Its mission life is 5 years. It

orbits in circular polar sun-synchronous orbit at an altitude of 822 km + 20 km (3 Sigma). It

completes 14 orbits around the Earth per day.



LISS III: The Linear Imaging Self Scanning Sensor (LISS-III) is a multi-spectral camera operating

in four spectral bands, three in the visible and near infrared and one in the SWIR region. Spatial

resolution of LISS III image is 23.5m and its swath width is 140 Km. It has radiometric resolution

of 7 bits in VNIR and that of 10 bits in SWIR. The revisit period of LISS III is 24 days.

Figure 3.3: Illustration of LISS III camera

3.5.3 METHODOLOGY

Digital Image Processing (DIP) techniques were used to process multi-date LISS IIII image

acquired for the present study. The satellite image was classified using hybrid classification

technique. Hybrid classification refers to combination of unsupervised and supervised classification

techniques. The details are as given below:

Image classification:

Satellite images are made up of pixels arranged in a matrix fashion in columns and rows. Every

pixel carries a number known as Digital Number (DN) or Brightness Value (BV) that represents

reflection of sunlight from the portion of land under that pixel. Digital image classification uses the

spectral information represented by these digital numbers in one or more spectral bands, and

attempts to classify each individual pixel based on this spectral information. This type of

classification is termed spectral pattern recognition.



The objective of image classification is to assign all pixels in the image to particular classes or

themes (e.g. water, coniferous forest, deciduous forest, corn, wheat, etc.). The resulting classified

image is comprised of a mosaic of pixels, each of which belong to a particular theme, and is

essentially a thematic "map" of the original image.

Figure 3.4: Concept of image classification

Common classification procedures can be broken down into two broad subdivisions based on the

method used: supervised classification and unsupervised classification. In a supervised

classification, the analyst identifies in the imagery homogeneous representative samples of the

different surface cover types (information classes) of interest. These samples are referred to as

training areas. The selection of appropriate training areas is based on the analyst's familiarity with

the geographical area and their knowledge of the actual surface cover types present in the image.

Thus, the analyst is "supervising" the categorization of a set of specific classes. The numerical

information in all spectral bands for the pixels comprising these areas are used to "train" the

computer to recognize spectrally similar areas for each class. The computer uses a special program

or algorithm (of which there are several variations), to determine the numerical "signatures" for

each training class. Once the computer has determined the signatures for each class, each pixel in

the image is compared to these signatures and labeled as the class it most closely "resembles"

digitally. Thus, in a supervised classification we are first identifying the information classes which

are then used to determine the spectral classes which represent them.



Figure 3.5: Concept of supervised classification

Unsupervised classification in essence reverses the supervised classification process. Spectral

classes are grouped first, based solely on the numerical information in the data, and are then

matched by the analyst to information classes (if possible). Programs, called clustering algorithms,

are used to determine the natural (statistical) groupings or structures in the data. Usually, the analyst

specifies how many groups or clusters are to be looked for in the data. In addition to specifying the

desired number of classes, the analyst may also specify parameters related to the separation distance

among the clusters and the variation within each cluster. The final result of this iterative clustering

process may result in some clusters that the analyst will want to subsequently combine, or clusters

that should be broken down further - each of these requiring a further application of the clustering

algorithm. Thus, unsupervised classification is not completely without human intervention.

However, it does not start with a pre-determined set of classes as in a supervised classification.



Figure 3.6: Concept of unsupervised classification

The hybrid classification technique used for the present study comprised of unsupervised

classification followed by supervised classification. Following land use classes have been

considered

- Water

- Cropped land

- Cultivable land (un cropped land)

- Other vegetation

- Open scrub

- Habitation

Thematic map so prepared was studied with reference to percentage of each of the above mentioned

class to the total area of study.

Observation

Depicted below is the LISS III image acquired on April 05,2012 with the 10Km buffer area around

the project site marked on it:



Figure 3.7: LISS III image showing an area of 10Km radius around the project site

Total area of study is 314.28 Sq Km. Using digital image processing techniques, land use land

cover map has been prepared for this area and the corresponding statistics have been computed.



Figure 3.8: LISS III image for the study area

Following are the details of land use land cover classification:



SN Class Percentage Area (Sq M) Area (Ha)

1 Water 1.46 4584594.93 458.46

2 Cropped land 48.09 151155337.06 15115.53

3

Un cropped cultivable

land 39.25 123345271.62 12334.53

4 Open scrub 7.02 22061494.07 2206.15

5 Habitation 1.56 4912394.62 491.24

6 Other vegetation 2.62 8226621.99 822.66

Total = 100.00 314285714.29 31428.57

Land use classification details

48.09

1.461.56

7.02

39.25

2.62

Water Cropped landUncropped cultivable land Open scrubHabitation Other vegetation



Karan Sugars Pvt Ltd project site is situated close to Herwad village in Shirol taluka of Kolhapur

district in Maharashtra State. It is very close to the border of Maharashtra & Karnataka.

Rivers visible in the satellite image are Krishna (vertically descending from north to south towards

eastern edge of 10Km buffer area) and Panchganga (branching out and extending to the west)

Considering the area of interest (10km buffer around project site), the general slope is towards the

river & the elevation ranges from 560m (at project site) to 540m at the river.

The land use of the area of interest is mainly agriculture, 87.34% of the total area is under

cultivation. Other vegetation covers 2.62% and water covers 1.46% (as per the satellite image some

stretches of the river bed are under other vegetation instead of being under water). Habitation

covers 1.56% and open scrub covers 7.02% of the total area.

3.6 SOIL

Almost the whole of the western half of the district is covered by the basaltic Sahyadri ranges. The

land gradually slopes towards the east into the Deccan plateau which is gently undulating with

ridges and valleys. Due to these topographical features, the soils in the district vary from tract to

tract, so much so that even in a single village, as between field and field, a variety of soils from

rich-loam to poor thin murmad is met with.

The soils are derived mainly from trap, except in the forest covered mountainous area in the west

where they are of lateritic origin. The laterite overlies the trap rock. Consequently, in the western

portion the hill tops and ridges are covered with lateritic soils; while in the valleys the soils are of

mixed character, varying in colour from brownish to reddish. In the eastern portion, due to its

undulating nature, deeper soils are formed in the low-lying parts, while the ridges are covered by

shallow soils, more or less partially eroded.

Physiographically, Kolhapur district can be divided into three broad soil zones: (a) the western part,

with heavy rainfall (is mountainous and woody and is covered with lateritic soils); (b) the fertile

central part, with brownish well-drained soils of neutral reaction; and (c) the dry eastern zone, with

precarious rainfall and covered with medium black soil of varying depth.



Lateritic Soils.

Lateritic soils (tambad mati) occur mainly in the western hilly tracts of heavy rainfall, on the hill

tops and in the ridges which are not covered by forest, They are found in the western parts of

Karvir, Bhudhargad and Ajra and the whole of Shahuwadi, Panhala, Radhanagari and Bavada

talukas. They are red to brownish-red in colour, mostly eroded and shallow with good drainage. The

soils are acidic with low phosphoric contents and liming has been found to be beneficial. They are

not retentive of moisture and hill millets are predominantly taken from them. When terraced,

applications of nitrogen and phosphorus are found quite useful and in such cases paddy crop can

also be taken from the soil.

Under forests, which abound in valuable trees like teak, undi, jambul etc., the soils are fertile and

rich in humus.

In the valleys, lateritic soils are mixed with trap soils. They vary in colour from brown to black, are

fairly deep retentive of moisture. Paddy is the main crop of this area and in the rabi season vol is

also grown wherever possible. Due to the deforestation of the forests, the soils are well supplied

with nitrogen and organic matter but are very poor in phosphorus and potash. The paddy crop,

therefore, responds well to the application of phosphorus and potash.

Brown Soils.

Brown soils (halki kali mati) are found in the talukas of Hatkanangle, Karvir and Radhanagari and

parts of the Bhudhargad and Ajra talukas in the transition tract. They are mainly derived from trap

and are dark brown in colour, with, a reddish tinge. They are rich and fertile with excellent granular

structure, almost neutral in reaction and well supplied with calcium. These soils respond well to the

application of fertilizers. As this tract receives a guaranteed rainfall of 40"-50", conditions in the

tract are optimum for most of the crops. Rice, jowar, and groundnut are grown on these soils in

kharif season. Sugarcane and vegetables are taken wherever irrigation facilities are available.

Jaggery produced from sugarcane grown in these soils, is well-known throughout India.

Medium and Deep Black Soils.

Medium and Deep Black Soils (madhyam or bhari kali mati) are found in the talukas of Shirol,

Hatkanangle, Karvir, Kagal and Gadhinglaj. They are also derived from trap and vary in depth

considerably, from place to place. In the river valleys, the soils are deep. Medium deep soils are



grey in colour with good granular structure and drainage. The deeper soils are more black in colour

and more clayey. Lime nodules occur in plenty and pH value is between 7.5 and 8.0. The soils are

quite fertile and good crops of kharif jawar and groundnut are obtained. They are fairly rich in

phosphorus contents and the crops respond well to the application of nitrogen to these soils. As

drainage is good, the soils are amenable to irrigation and consequently paddy, sugarcane and

vegetables can be successfully taken from them.

Baseline data over soil environment of the study area was generated during the study period

with following objectives:

To judge the physico-chemical characteristics of the soil.

To analysis the impact of industry over soil environment.

To judge the agricultural productivity of soil.

To study the temporal changes in the soil.

To study soil characteristics of the region, four locations were selected in the study area. Locations

were selected, keeping in mind that study should reflect the characteristics of the area as a whole.

The samples were analysed as per standard methods and frequency of the sampling was thrice/

station. The location of soil sampling is presented in Table: 3.6

TABLE 3.6

DETAILS OF SOIL SAMPLING LOCATIONS

Sr. No. LOCATION

1 Herwad

2 Takaliwadi

3 Dattawad

4 Factory site



The analysis results of soil sampled during the study period are presented in Table: 3.7 It has been

observed that the texture of soil is brown soil, and Light Soil, Sandy Loam to Loam. Most natural

soil but somewhere slight acidic and some where slight saline soil exists.

TABLE 3.7: SOIL ANALYSIS REPORT

Date of Sampling 12/10/2011

Sample Location Herwad


Parameters Result Units

pH 7.48 -

Bulk Density 1.56 Gm/ml

Organic Matter 0.82 %

Texture Brown Amorphous

Powder -

Chlorides as Cl 124 mg/kg

Conductivity (10% Solution) 0.62 ms/cm

Phosphorus Absent mg/kg

Potassium 1.0 mg/kg

Nitrogen as N 1244 mg/kg

BDL : Below Detectable Limit


Sample Location Takaliwadi



pH 7.54 -



Texture Black Soil -






Potassium 0.7 mg/kg




Sample Location Dattawad



pH 7.54 -







Potassium 1.5 mg/kg




Sample Location Karan Sugar Site



pH 7.34 -



Texture Black Slit -



Phosphorus BDL mg/kg



Pottasium Absent mg/kg







pH 7.56 -




Powder -


Conductivity(10% Solution) 0.56 ms/cm


Potassium 1.0 mg/kg







pH 7.66 -









Potassium 0.9 mg/kg




Sample Location Dattawad



pH 7.48 -







Pottasium 1.6 mg/kg


BDL : Below Detectable

Limit





pH 7.34 -






Pottasium BDL mg/kg










pH 7.38 -




Powder -




Pottasium 1.0 mg/kg







pH 7.52 -







Potassium 0.8 mg/kg




BDL : Below Detectable

Limit





pH 7.32 -






Potassium BDL mg/kg




Conclusion

The analysis of soil samples taken in villages of Takaliwadi, Herwad, Dattawad and the

current site of Karan Sugars Pvt Ltd, does not show major variation. The observation is

repeated and proven in all three seasons.

3.7 CROPPING PATTERN

All the cultivable land in the district falls under one of the three categories, namely jirayat (dry crop

land), bagayat (irrigated land) and rice lands. Dry crop lands on account of their dependence on the

monsoon, are further divided into kharif (early monsoon) and rabi (late monsoon) lands. Kharif

crops are brought to maturity by the rains of south-west monsoon whereas rabi crops depend on

north-east monsoon, dew and irrigation.



Kharif season commences in June and terminates in September, draws its rainfall mainly from the

south-west monsoon and from the ante-monsoon showers in May. An average rainfall of 69"

received during this season is on the whole fairly distributed. The main kharif crops of the district

are:-paddy, kharif jawar, bajri, ragi, Italian millets, kodra, vari, sava , maize, turi, kulith, udid,

chavali, groundnut, niger, sugarcane, chillies, brinjals, tomatoes, bhendi, cucurbits and leafy

vegetables. Sowing and reaping of these crops roughly coincides with the commencement and

termination of the monsoon. With the exception of sugarcane, sowing is generally done between

mid June and mid July and harvesting between the middle of September and the end of November.

Kharif Jawar, however, is harvested between the middle of December and the middle of January.

Crops like chillies, turi and cotton are harvested in September, December, January and February

respectively.

In the heavy rainfall zone paddy, ragi, Italian millet, kodra, vari, sava and rala are the main crops

grown. In the central and eastern zone, kharif jawar, turi, groundnut, cotton, tobacco, chillies and all

pulses are grown. Sugarcane, which is the main cash crop of the district, is grown all along the river

valleys. Planting of tobacco is generally done in August and it is harvested in January. Planting of

sugarcane commences from November onwards and is over by the end of January. Cultivators take

ratoon crop of sugarcane at least for four years. There is also the practice of planting of cane by the

rajooing method, especially in the month of August. This is a 16 month crop. Kharif jowar and

groundnut grown in central and eastern zone are dibbled by marking the lands by a marker. Cotton

crop is grown as a miscellaneous crop generally along with chillies. Sowing is over by the end of

July.

Rabi crops such as shalu jowar, gram and wheat are grown in parts of central zone and eastern

zone, along the river-banks submerged during floods. The moisture retained by the soil from

monsoon showers, rains received from north-east monsoon and dew are sufficient for these crops.

In the western zone, after the harvest of paddy, crops such as watana (field peas), val and gram are

taken in the lands retaining sufficient moisture. Advantage of north-east monsoon rainfall is also

taken. Wherever watering facilities are available, wheat, onions, garlic and vegetables such as

carrots, radish, cabbage, brinjals and tomatoes are the other crops grown after the harvesting of

paddy.



3.8 NOISE LEVEL

Noise survey has been conducted in the study area covering residential transportation commercial

and calm zones. The main objective of noise monitoring in the study area is to establish the baseline

noise level, which is needed for assessing impact of total noise which is expected to be generated in

the proposed project activities.

Noise is measured in terms of loudness of the sound. Sound is a form of energy that propagates

through an elastic medium at a speed that is determined by the properties of that medium. Since

loudness of sound is important to the effects of noise on people, dependence of loudness upon

frequency must be taken into account in environmental noise assessments. Several methods have

been developed by researchers using the frequency spectrum of sound arrive at the loudness index

or the given sound. For measuring the intensity of the sound “Sound level meter” is used which

gives intensity of sound in terms of dB.

The basic step associated with impact assessment on the noise components of the environment

involves identification and evaluation of the present noise status on the general population.

Therefore noise level measurement was carried out at each ambient air quality station and also at

site. The objectives of Noise environment studies are:

To assess the ambient noise level in the study area.

To characterize the noise pollution area.

To predict the temporal changes in the ambient noise level of the area.

Noise pollution in the study area is associated with the Industrial activities, Vehicular traffic. To

judge the ambient noise level of the area, noise levels were recorded at 5 locations in dB (A). Noise

level monitoring near to equipments/machines used at Plant site, was also carried out in dB (A)

scale. Locations of ambient noise level monitoring stations are as follows.

1. Project Site.

2. Takaliwad.

3. Near Herwad.

4. Near Abdul Lat.

5. Near Dattawad.

The frequency of ambient noise level monitoring and noise level at source were twice/week/station

and thrice/station respectively. Ambient noise levels were recorded in following time schedule:



Day time - 6 am to 7 am. 9 am to 10 am.1 pm to 2 pm, 5 pm to 6 pm, 9 pm to 10 pm

Night time - at 10 pm to 6 am

During each time schedule reading were recorded for 10 to 15 minutes and logarithmic average

were calculated and the summary of which is reported in Table-3.9

Table 3.9:

Ambient Noise Level Monitoring Results

Sr. No. Location Noise level in dB (A)

Day Time dB(A) Night Time dB(A)

1. Plant site 56.7. 43.3

2. Takavade 62.1 32.5

3. Herwad 62.1 39.8

4. Abdul Lat 59.0 33.8

5. Dattawad 56.4 38.1

3.9 BIOLOGICAL ENVIRONMENT

The changes in ecology system are inevitable, consequences of development process. The

denudation of forests due to increasing population, urbanization industrialization has accelerated the

process of environmental degradation in the district. Therefore preservation of the ecology is one of

the most important goals of the planning.

Baseline data over biological environment of the study area was collected/generated during the

study period with following objectives:

To study the existing condition of aquatic/ terrestrial flora and fauna.

To predict/estimate the effect of Plant along over the biological environment.

Study was carried out for aquatic/terrestrial flora and fauna, detail of which is as under:

3.9.1 TERRESTRIAL BIOLOGICAL ENVIRONMENT

The Forest area of Kolhapur District is mainly situated at is one of the block among seven blocks of

the, having Forest.



Forest

General distribution.

Physically, the forests of Kolhapur are a southward extension of the forest types of Poona and

Satara districts. The wooded areas are confined to the western half of the tract. The western rim and

its descending slopes claim a stunted type of evergreen vegetation. On the eastern fringes the over-

wood consists of deciduous species with a ground-flora of evergreen species. The dry eastern plan

claim scanty patches of wood-growth in land pockets. Three main forests types can be distinctly

located, viz., (1) the sub-tropical evergreen, (2) the moist deciduous and the semi-evergreen, and (3)

the dry deciduous forests.

Sub-Tropical Evergreen.

These occupy the high rainfall regions in the extreme west of the district. No particular plant

species can be marked as principal in the composition. Jambhul, hirda, anjani, surangi, panjambhul

get mixed up in the top canopy with pnansi, etc., mostly coming in as sub-dominants. The lower

storey and ground flora mostly consist of karvi, bracken fern and others. This composition is mainly

confined to elevations round about 2,200' above the mean sea level.

Semi evergreen and moist deciduous.

Barring the prominent existence of the deciduous species in the typical deciduous deciduous

formation, the composition of the two is made of jambhul, amba, nana, sissum, asana, kumbhi,

bhava, panjambhul, kinjal, ain, kinai, umbar, biba, cnanste and others. In forests of this type in

Ajra mahal, the famous scented wood species, chandan (sandalwood) occurs profusely. Bamboos

are sparse.

Dry-deciduous type.

The dry deciduous forests are strewn far and wide in small patches. The usual species of the drier

zones occur here. The prominent feature in these forests is the total absence of dhavda and a greater

incidence of sissum.

Area statement of forest.

The area statement of the forests in various Ranges of Kolhapur District is given below: -



Name of the

Range.

Area of Reserved

Forest. Area of Protected Forest

Area of

Unreleased

Forest.

Total

A. g. A. g. A. g. A. g.

1. Karvir 10,437 25 12,476 38 824 15 23,738 38

2. Panhala 47,783 12 21,343 13 -- -- 69,126 25

3. Bhudargad 48,886 15 20,487 11 -- -- 69,373 26

4. Ajra 15,036 33 18,323 03 243 15 33,603 11

5. Vishalgad 44,480 26 4,427 34 -- -- 48,908 20

6. Bavada 18,318 10 -- -- -- -- 18,318 10

7. Radhanagari 45,760 39 37,928 31 -- -- 83,689 30

Total 2,30,704 00 1,14,987 10 1,067 30 3,46,759 00

These forests have been classified as reserved, protected etc. by the former Kolhapur State.

However, a regular forest settlement and demarcation as per the procedure laid down in the Indian

Forest Act will have to be done. Besides, there are extensive areas known as Sheri lands claimed by

H. H. the Chhatrapati Maharaja of Kolhapur as his private property, which are well stocked with

forests. The legal position of these sheri lands have not been finally decided.

Forest produce.

Firewood and grass are the main marketable products from these forests. Timber is of a very poor

quality and meagre. Hirda fruit is produced in large quantities and most of it is consumed in the

factory of the Amba Tannin and Pharmaceutical Limited for the extraction of tannin. This tannin

extraction factory is the only one of its type in the State. The other minor forest products are

enumerated below: -

(1) Kaju fruits. (2) Watsol. (3) Cocumbs. (4) Mango fruit.(5) Bibi fruits. (6) Shikekai. (7) Palas

leaves. (8) Kuchala seeds. (9) Kumkum fal. (10) Silver cotton. (11) Honey and Wax. (12) Karanj

seeds. (13) Rameta bark. (14) Reeds. (15) Wavding. (16) Tembhurni leaves. (17) Pisa fruits.



Flora

Flora of any region may be termed as the lungs of the region or area. Besides its ecological and

economic values, it also helps to control pollution in air and water. It works as curtain to check air

pollution and noise. The flora of the area is composed of a large number of common species. The

species are listed in Table 3.10.

TABLE 3.10:

Details of Flora around the study area

Local Vernacular

Name. Scientific Name.

Local Vernacular

Name. Scientific Name.

TREES SHRUBS

Ain Terminalia tomentosa. Dinda Leea macrophylla.

Ain Terminalia crenulata. Duranta Duranta plumerii.

Akas-Nimb Millingtonia hortensis. Erand Ricinus communis.

Al or Bartondi Morinda tinctoria. Ghagri Crotalaria retusa.

Alu Vengueria spinosa. Ghaneri, Tanatani Lantana camara.

Amba Mangifera indica. Ghatbor Zizyphus xylopyra.

Amberi Nothopegia

colebrookiana. Ghaypat Agave sisalana.

Ambgool, Narali Elceagnus latijolia. Harki Rauwolfia

serpentina.

Anjani Memecylon edule. Hasoli, Asolin, Shirul Grewia microcos.

Apta Bauhinia recemosa. Henkal Gymnosporia

montana.

Arjun-Sadada '

Dhavada'. Terminalia arjuna. Huli, Gowari Hibiscus furcatus.

Asana, Katak Bridelia retusa. Ingali Gymnosporia



emarginata.

Avala Phyllanthus embilica. Jephali Jatropha curcas.

Babul Acacia arabica. Kanguli, Bandgul

Loranthus

longiflorus (on

teak, ain amba and

Kumbhi) L.

cunearus (on

Kinjal).

Bahawa Cassia fistula. Kanheri Nerium odorum.

Behada, Vehola, Hela Terminalia belerica. Kanphulia, Bisur Callicarpa lanata.

Bel Aegle marmelos. Kankuti Flemingia

strobilifera.

Bhamini Colebrookia

oppositifolia. Kare

Webera

corymbosa.

Bhendi Thespesia polulnea. Karhi-Nimb Murraya koenigii.

Bhokar Cordia myxa. Kari, Bhandire Clerodendron

infortunatum.

Bhoma Glochvdion

lanceolarium. Karwand Carissa carendas.

Bhutkes Mussaenda frondosa. Karvi Strobilanthes

callosus.

Bhutya Elaeodendron

glaucum. Kate-ringani

Solanum

xanthocarpum.

Biba Semecarpus

anacardium. Kaundal

Trichosanthes

palmata.

Bibi Holigarna arnottiana. Kavli Phyllanthus

reticulatus.



Bibla, Asan Pterocarpus

marsupium. Kevani Helicteres isora.

Bocha Salix ichnostachya. Kusari Jasminum

arboresoens.

Bondara, Lendi Lagerstroemia

parviflora. Lal Chameli Quisqualis indica.

Bor Zizyphus jujuba. Lajalu Mimosa pudica.

Chandan Santalum album. Madzhing Dolichondronl

falcata.

Chandida Macaranga

roxburghii. Mahalunga Citrus medica.

Chapha Michelia champaca. Mondie Lawsonia alba.

Char, Charoli Buchanania latifolia. Morbel Clematis triloba.

Chera Erincarpus

nimmoanus. Moriel Clematis gouriana.

Chinch Tamarindus indica. Nagphani Opuntia dilleni.

Dahiwan Cordia macleodii. Nakchikni Maravellia

zeylanica.

Kumbhi Careya arborea. Neptad Capparis aphylla.

Kumkum Shendri Mallotus

philippinensis. Nigdi Vitex trifolia.

Krpa Hemigyrosa

canescens. Nil

Indigofera

tinctoria.

Kurwat Ficus hispida. Nivdung Euphorbia

neriifolia.

Kurkuti Connarus wightii. Nivdung Euphorbia

antiquorum.



Lodhra, Lodhya, Hura Symplocos beddomei. Pandhari Murraya exotica.

Lokhandi Ixora parviflora. Pandharphali Flueggia

microcarpa.

Maharukh Ailanthus excelsa. Pitkuli Eugenia zeylanica.

Moha Rassia latifolia. Pitkuli Pendgul Ixora coccinea.

Moina, Shemat Lannea grandis. Pilu Katri Salvadora

oleocides.

Mana Legerstraemia

lanceolata. Pithori

Gymnosporia

Konkanensis.

Nandruk Ficus retuse. Phulati Acacia latronum.

Neem Azadirachta indica. Rametha Lasiosiphon

eriocephalus.

Nimbara Malia dubia. Rui Catstropia

gigantea.

Padali Stereospermum

chalonoides. BAMBOO.

Palas Bhutea jrondosa. Chiva, Tokar, Modar,

Mace.

Dendrocalamus

strictus.

Pangara Erythrina indica. Konda Oxytenanthera

stocksii.

Pajarabhul Olea dioica. Ranchiva Oxytenanthera

monostigma.

Parvi Wendlandia

notoniana. Velu, Kalak, Padhai

Bambusa

arundinacea.

Petari Trewia nudiflora. GRASSES.

Phanas Artocarpus

integrifolia. Bhongrat Anthistiria ciliata.



Phansi Carallia integerrima. Bhale kusal Andropogon

tricticeus.

Pimpal Ficus religiosa. Buld grass Cyperus bulbosus.

Pimpar Ficus arnottiana. Chirka Eragrestis tremula.

Pimpri Ficus tsiela. Chanya marvel Andropogon

pertusus.

Putranjiva Putranjiva roxburghii. Condal Andropogon

permilis.

Ranbhendi Thespesia lampas. Harali Cynodon dactylon.

Ranaphanas Artocarpus hirsuta. Kunda Ischaemum

pilosum.

Ratamba, Kokam Carvcinia indica. Kusali Andropogon

contortus.

Ritha Sapindus emarginata. Marvel Andropogon

annulatus.

Sag, Teak Tectona grandis. Hut grass Cyperus rotundus.

Satwin Alstonia schloris. Pandhari kusal Aristida

paniculata.

Sawar Sewar Bombax malabaricum. Pavnya Ischoenum

sulcatum.

Sawar Bombax insigne. Phuli Apluda varia.

Shindi Phcenix sylvestris. Rosha Andropogon

schoenanihus.

Shiras Albizzia lebbek. Shenda Ischcenurn laxum.

Shiras, Kala Albizzia odoratissima. Shimpi Panicum isachne.

Shissam Dalbergia latijolia. Wavashi Saccharum

procerum



Shivan Gmelina arborea.

Sitaphal Anona squamosa.

Surangi, Undin Calophyllum inophyllum.

Surangi Ochrocarpus longifolius.

Tad Borassus flabellifer.

Tamalpatra Cinnamomum tamala.

Tembhurni (Diospros melanoxylon). Oroxylum indicum.

Tetu Zeanthoxylum rhetsa.

Triphal

Tiwas Ougenia dalbergioides.

Tugal, Lallai Albizzia amara.

Um, Hoom Polyalthisucerasoides.

Umber Ficus glmoerata.

Wad Ficus bengalensis.

Warang Kydia calycina.

Waras Heterophragma roxburghii.

Wavla Holoptelia integrifolia.

Wumb Hephelium longana.

Fauna

Fauna in the study area was identified during the survey and collected from secondary sources.

This list of common species found in the study area is presented in Table 3.14.



Table no. 3.11:

For Various Species of Fauna in the Study Area

Zoological name English name Local name

Macaca mulatta Monkey Bandar

Felis chaus Wild cat Jungali billi

Canis aureus Jackal Gidar

Herpestes Common Mongoose Newla

Funambulus pennati Squirral Gilhree

Rattus rattus Common house rat Chuha

Lapus nigricollis Rabbit Kharagosh

Cunopterus sphinx Bat Chamgadar

Vulpus bengalensis Indian fox Lomdi

Table No. 3.12:

For Various Bird Species in Study Area

Zoological name English name Local name

Dinipium benghalense Wood peaker Kathfoda

Francolinus pondicerianus Grey partridge Titar

Coturnix coturnix Common quail Bater

Pavo cristatus Pea fowl Mor

Gyps bengalensis Bengal vulture Giddh

Columbia livia Blue rock pigeon Kabutar

Flanus caeruleus Black kite Cheel

Erithacus svecicus Blue throatal Neelkanth

Corvus splendens House crow Kauwa



Corvus macrorhynchos Jungle crow ----

Psittacula crameri Parrot Tota

Eudynamys scolopacea Koel Koyal

Otus scops Owl Ullu

Acridotheres Sparrow House sparrow

Hemidactylis species Wall Lizard Chipakli

Calots Versicular Garden lizard Girgit

3.10 DOMESTIC ANIMALS

Animal husbandry plays an important role in rural economy and its contribution for the

economic up liftment of the rural area is now considered as important as agriculture. Owing to

the availability of green fodder throughout the year, the environment of the area is congenial for

domestication of animals. The farmers of the area keep live stock for satisfying their daily

requirement. In the study area the animal population comprises of Cows, Buffaloes, Goats,

Horses and Pigs. The poultry population largely comprises of Cocks & Hens etc.

3.11 SOCIO-ECONOMIC ENVIRONMENT

Assessment of Socio-economic environment forms an integral part of an EIA study. The socio-

economic status of the study area was collected / generated by survey and the secondary sources

i.e. Census book. The study includes description of demography of the area and existing basic

amenities in this area.

3.12 BASIC AMENITIES

In the matter of civic and other amenities, Kolhapur stands at the top in the district. The civic

amenities provided by the municipality include street lighting protected water-supply and

arrangements for cleanliness of the town and disposal of the town refuse. Sewerage in the town

has been improved lately by a network of underground system. A network of fire-fighting

service is also available. Besides, the municipality runs four Ayurvedic Dispensaries, a



Maternity and Child Welfare Centre and a Sub-Centre and a Family Planning Centre. It also

runs a library cum reading room.

A high powered Development Board has been constituted for the speedy development and

growth of the Kolhapur town.

Education

The educational standards in the district are in keeping with the general educational

backwardness in the country. However, the major portion of the district which was under the

sovereignty of the former Indian ruler could be regarded as possessing better literacy standards

as compared to other parts in the State due to superior educational reforms introduced by the

ruler of the State. The gradual increase in the number of literates from 34,334 in 1911 to

1,30,895 in 1951 is a sufficient testimony to this fact. With the exception of the Government's

Arts and Science College, facilities for higher education were few and far between. The middle

and secondary schools were located in a few important towns only, so that upper primary

educational facilities were available only to a part of urban populace. Education was rather a

dream to the ruralites. The last few years have witnessed a radical change in the whole structure

of education in the district. There are quite a few colleges giving education in different faculties.

Practically any place with a population of more than 5,000 or over has a secondary and upper

middle school. All the villages have been provided with educational facilities under various

schemes undertaken and implemented by the Government. The following few figures give an

idea of the varied education received by the people of the district:-

Total literates 1,30,895

Middle School 15,126

S. L. C. or Matriculates 4,189

Intermediate Arts or Science 972

Graduates 1,019

Post Graduates in Arts, Commerce and Science 89

Teaching 656

Engineering 87



Agriculture 18

Veterinary 5

Commerce 36

Law 386

Medicine 190

Other 56

3.13 Industries located in 10 km radius study area

Gurudatta Sugar Factory: 05 Kms.

The list of other industries is as follows –

Dattashirol S.S.K.Ltd., Shirol. 14 Kms.

Panchganga S.S.K. Ltd., Ichalkargi. 22 Kms.

Indira Mahila Sppinning Mill. Shivnakwadi. 12 Kms.

Deccan Sppinng Mill. Ichalkarangi. 17

3.14 MINERALS

The district is well endowed with building stones. Hard, compact, fine to medium grained

Kaladgi sandstones and quartzites are quarried for construction materials near Nesri, Harur,

Gajargaon, Ajra and Gargoti. They are also worked for road metal near Harali Budrukh and

Harali Khurd. Some of the harder varieties of Deccan trap are extremely good for building

purposes and are worked in the Jotiba hill quarries. The rock is fine grained, hard, compact,

bluish-grey and can be traced up to the Panhala fort and along the range for many miles. It is also

quarried near Ajra, Gandhinglaj, Gargotti, Kagal etc.

Laterite.- Laterite is abundant and has been largely used for walls and buildings in many of the

old forts and is still used in many of the villages in the district. Irregular nodules of kankar occur

in the soil, especially in the eastern part of the district, and is locally used for lime-burning.

Copper.- Traces of thin films of metallic copper are reported in some excavations in the trap near

Kolhapur and also in a railway cutting 11½ miles from Kolhapur. These are of academic

importance only.



Gypsum. - Some irregular nodules of fibrous gypsum found in red clay are reported near

Tambiyadi. This has no economic value.

Iron.-Fair quality iron-ore occurs in small quantities in the laterite throughout the district but is

useless at present as source of raw material for smelting.

Kaolin.-Small quantities of inferior type of kaolin are noticed near Panhalla fort, Gudalkop,

Gadhinglaj and Budargarh fort, but these occurrences are not important economically.

CHAPTER 4

ANTICIPATED ENVIRONMENTAL IMPACT & MITIGATION

4.0 ENVIRONMENTAL IMPACT PREDICTION

Identification, prediction and assessment of potential impacts of the proposed project on the

surrounding environment during construction and thereafter during operation stage have been

discussed in this section. In line with any industrial development, the distillery projects have

environmental impacts during construction and operational phases. By and large the impacts are

local and there are no major sub regional or regional negative impacts.

The proposed molasses based distillery installation will involve activities such as dismantling of

existing 30 KLPD sugar cane based distillery, erection and installation of new plant and

machinery for 100 KLPD molasses based distillery, creation of infrastructure to transport raw

material and finished products as the main activities during construction phase. These activities

during construction phase will have impacts on air & water quality, noise levels, socio-economic

conditions. However the impact on environment will be limited to construction phase.

Following paragraphs give a brief description of the environmental impacts of proposed of

Distillery projects during construction and operational phases.

4.1 IMPACT DURING CONSTRUCTION PHASE The construction phase is expected to last for four to six months. Construction activity is limited

to foundation works for various plant and machinery as detailed in chapter-2. Hence, the

quantum of construction material such as stone, bricks and gravel is also small, as mostly

foundation work is involved. Approximately 200 employees will be engaged in construction

work. These workers will not reside in the premises. They come from nearby villages. The

generation of wastes including gaseous emissions, waste water and solid wastes will not be

significant.

The activities may have small impact on land environment, water environment, air environment

and noise level and these are discussed below.



4.1.1 IMPACT ON AIR ENVIRONMENT During construction phase, suspended particulate matter will be the main pollutant, which will be

generated from site development activities and movement of vehicles. The impact will be mostly

confined within the project boundary and is expected to be negligible outside the plant boundary.

The transportation and construction activity will be for a limited period and therefore the air

emissions due to vehicles or construction equipment will be for a limited period only.

The impact of such activities would be temporary and restricted to construction phase.

The internal roads will be paved or tarred. Proper upkeep and maintenance of vehicles,

sprinkling of water on roads and construction site are some of the measures that would greatly

mitigate the impacts on air environment during the construction phase.

All the vehicles permitted at the project site will be possessing Pollution Under Control

certificate.

All the contractors will be instructed to carry out regular maintenance of vehicles in order to

keep pollution under check.

4.1.2 IMPACT ON WATER ENVIRONMENT Due to civil construction activities, during rainy season the surface run off may contain more of

eroded soil and other loose matter. Construction activities may be avoided during rainy days to

mitigate the small impacts on soil quality caused due to construction activity. Segregation of

construction area and proper drainages facilities will prevent the contamination of water due to

during construction. Proper garland drains will be provided so as contaminants like oil and

grease, diesel fuel, paints etc do not mix with soil. Water after washing will be collected in drain

in an impervious pond, filtered and used for irrigation.

Proper drinking and sanitation facilities will be constructed first for workers. The sewage will be

collected in a septic tank with overflow as well as sludge will be used for irrigation.

4.1.3 IMPACT ON NOISE ENVIRONMENT

Noise will be generated during the construction phase due to vehicular traffic, movement and

operation of construction equipment like dozers, scrapers, concrete mixer, cranes, generators,

compressors, vibrators etc. The operation of these equipments will generate noise ranging



between 70-85 dB (A). Major construction work will be carried during the day time. Personnel

protective devises such as ear muffs will be provided to the operators of this machinery to

prevent harm due to noise.

Since noise levels reduce @ square of distance, effect of construction activity noise shall not be

significant on surrounding areas.

As construction phase is temporary, impact, though insignificant, will also be temporary

and limited to earlier part of construction phase.

4.1.4 IMPACT ON LAND ENVIRONMENT

Construction will be carried out in land already available. Land is already developed with factory

shed already constructed. It can be used to house proposed 100 KLPD molasses based distillery

equipments.. No earth moving / leveling is involved. There is no vegetation or trees or water

bodies present on factory land. Most of the land is open with storage sheds, roads, effluent

treatment systems installed.

33% of open land and belt around the factory premises is partly developed and will be developed

as green belt. Plant sampling suiting local conditions will be planted.

4.1.5 IMPACT ON BIO DIVERSITY

Since the project is on a barren land devoid of vegetation, there will be no negative impact on bio

diversity. Green cover will improve as plants compatible with local ecology will be planted.

The site does not have any significant habitant for animals. Reptiles, snakes etc if present will

shift to nearby areas not so much distant and overall effect will be insignificant.

4.1.6 IMPACT ON SOCIO ECONOMIC ENVIRONMENT

Since the factory construction is proposed on vacant land with ownership rights with project

proponent, no rehabilitation or resettlement (R & R) issues are involved.

The construction phase will be for a limited time and will provide employment to skilled,

semiskilled and unskilled (mostly women) labour, hence a small number of such families about

200 numbers will find employment for duration of construction phase.



4.1.7. OCCUPATIONAL SAFETY

During the construction it is likely to occur minor or major accidents at the site.

Mitigation

All the workers will be provided Helmets, gumshoes, goggles and safety instructions such as use

of siren to inform management and first aid will be given. Immediately a call to fire brigade as

well as ambulance will be made.

4.2 IMPACT DURING OPERATIONAL PHASE

The operations of distillery unit have potential of negative impact on the components of

environment as discussed below:

4.2.1 AIR POLLUTION:

Steam Generating Unit generates air pollution due to suspended particulate emission in air after

using Bagasse as a fuel. If steam boiler of 25 TPH steam generation capacity is operated at full

load it will consume 270 MT per day bagasse. Considering 5% ash in bagasse it will create 13.5

MT of ash per day. In addition 80 TPD concentrated spent wash will be sprayed for destruction.

About 10% of total ash will appear as fly ash i.e. 1.35 MT/day will be transported with flue gas.

A bag filter installed just before I D fan will arrest most of this emission and is expected to

restrict emission to below 150 mg/Nm3 accepted norm for bagasse fired boilers.

4.2.2 SOLID WASTE GENERATION

The same operation the remaining ash i.e. 12.15 MT/day will appear as bottom ash. It is a

nonhazardous commodity readily picked up by brick manufacturers and will be disposed to

them. This way there is indirect benefit of saving in soil.

4.2.3 NOISE POLLUTION

Noise will be generated due to boiler and Turbine operation. Personnel operating in these areas

will need to use ear muffs. Since noise reduces @ square of distance, effect of noise will not be

felt outside the factory boundary.



4.2.4 WATER POLLUTION

Water pollution is the real problem in distillery. Distillery operation generates highly polluting

spent wash @ 800 m3/day the detailed treatment of it is described in following text. Water

requirement for the project is detailed below:

4.2.4.1 WATER BUDGET

The total water requirement will be 1435 m3/day. The water requirement will be fulfilled from

Panchganga River.

Particular Total

Process 1260

Condensing, cooling and blow down 200

Boiler Make up 466

Floor washing 15

Sanitary 15

Drinking 15

Greenbelt 30

Fire services 20

Total 2021

Boiler Blow down and cooling tower blow down are other waste water which gets purified by

settling and can be used for ash quenching.

4.2.4.2 WATER CONSERVATION (TOR POINT.12)

KSPL plans to initiate substantial saving in water requirement by recovering, reusing and

recycling of process water. Following table indicates amount of recovery planned and saving

expected from individual water consumption and user section:



Particular Total

(m3/day)

Reuse

(m3/day)

Reason

Process 1260 330 Water recovery

Condensing, cooling and blow

down

200 -- Loss

Boiler Make up 466 346 Condensate recovery

Floor washing 15 15 By treated effluent

Sanitary 15 15 By treated effluent

Drinking 15 --

Greenbelt 30 -- By treated effluent

Fire services 20 20 Not required daily

490 Water recovery from MEE

Total 2021 1216

Final Water requirement -- 805

By adopting such conservation techniques KSPL will restrict fresh water consumption to

805 KLPD as against expected water requirement of 2011 KLPD even though

manufacturing capacity is planned to be raised to 100 KLPD .

Less water consumption automatically reflects in less effluent generation.

4.2.4.3. MITIGATION OF WATER POLLUTION

Spent Wash generated in a molasses based distillery is high density organic waste water with

COD as high as 100,000 mg/L, BOD is as high as above 35000 mg/liter, It is dark in color and

high in viscosity, pH is about 4 to 4.5 and very corrosive. To produce one ton of alcohol, there

will be 10 tons of wastewater which pollutes the environment seriously. Treatment for molasses

alcohol spent wash has long been the crux of environmental protection. Experts all over world

have tried many ways, among which concentration burning treatment was reckoned the thorough

list way since it can recover the energy and ash. This process design adopts many technologies



developed, solving the problems of corrosion, ash fouling, coking in the concentration burning

spent wash around the years.

Detailed below is the scheme proposed by KSPL to ensure maximum water and energy

conservation as well as achieve zero discharge:

The scheme will be implemented in following three simple steps: (Tor Point. 15)

A. Reduction in COD and recovery of biogas

B. Concentration of spent wash in multiple effect evaporator

C. Incineration of concentrated spent wash in boiler

A. Reduction in COD and recovery of biogas

By use of most modern technology the production of spent wash will be restricted to 800 KLPD.

Spent wash generation : 8 liters / liter of spirit

Spent wash generated : 800 m3/day

Spent wash solid : 10-11% w/w

Digestive COD in spent wash : 80,000- 100,000 mg/lit

Digestive BOD in spent wash : 30,000- 45,000 mg/lit

TSS in spent wash : 3500 mg/lit (max)

Spent wash temperature : 30-35 deg C

Spent wash pH : 4.0- 5.0

This spent wash will be treated in biomethanation plant for biogas recovery for energy

conservation. Biomethanation plant will consist of:

Bio-digester,

Degassing tank

Clarifier

Gas holding tank

Gas blower and flare arrangement



Process Parameter Quantity / Value

Spent wash generation 8 kl / kl of alcohol 800 KL/day

spent wash COD 100,000 mg/lit

Total COD Available 80,000 kg/day

Reduction in biodigestor COD 65%

Total reduction COD 52000 kg/day

Biogas generation 0.5 nm3/kg of COD reduction

26000 nm3/day

Use in heating Calorific value 4500 kcal/nm3

Steam generation By biogas 126 MT/day

Equivalent bagasse Saving 54 MT/day

Thus by generation of biogas 126 MT/day of steam generation will be possible and it will

reflect in 54 MT/day of bagasse saving.

B Concentration of spent wash in multiple effect evaporators Basis: 100 KL/day of

alcohol Production = 80 ton/day

Its waste water is 100 x 8 = 800 ton/day = 33.3 ton/hr.

The concentrated slops = 33.33 x 12% / 65% = 6.15 Ton/hr

Water evaporate = (33.33 – 6.15) = 27.18 ton/hr

Total water evaporated : 27.18 X 24 = 652 MT/day of 652 m3/day

Assuming losses and plant factor : 25%

Actual water available for reuse: 490 m3/day

C Incineration of spent wash:

The solid content in the waste water is 12% with 9-10% organic material and 2-3% ash. The

concentrated spent wash for burning is required to have at least 60-65% of solid Content. It

means the evaporator has to concentrate the waste water from 12% to 65%. Now it has heating

value 1000 Kcal/kg and it can be burned directly after spaying on bagasse without any assistant

fuel.



Calculation:

The concentration section will have four effect evaporator. To evaporate 1 ton of water 0.3 ton of

steam is required, so the steam consumption is 27.18 x 0.3 = 8.15 ton/hr.

Calculation for burning of concentration spent wash

Burning the slops can provide heat of 6.15 MT or 6150 kg X 1000 = 6150000 kcal /day

Enthalpy of steam : 638 Kcal

Steam generation : 9639 kg/hr

Boiler efficiency : 75%

Final steam generation : 7229 kg/hr

Equivalent bagasse saving : 3076 kg/hr or 74 MT/day

Burning Process: The boiler meant to burn concentrated spent wash during the startup first

burns coal to raise the initial furnace and bed temperature to 900 deg. C to 1200 deg. C. The

concentrated slops are injected in by a high pressure pump and is sprayed to be burned in the

boiler. There is need to use coal as an auxiliary fuel up to 25%. So 1.75 t/h coal or paddy shell

(low heat value is 3000 kal/kg) will be used simultaneously as steam generation will be raised to

25t/h to meet the need of steam and power required for production.

The flue gas generated due to burning will first pass through the ash separator in the furnace

outlet where part of the coarse ash is separated followed by economizer to recover the heat and

by heating the incoming feed water. Flue gases then pass through multi-cyclone separator

before being discharged into the air through stack. The coarse ash from the burning and the ash

collected by the dust collector about 12.15 tons each day, will be recovered and picked up by

brick manufacturers for use in brick making.

In this way the distillery will NOT discharge any waste water and most problematic part of

alcohol distillation is taken care of.

4.3 AIR POLLUTION CONTROL (TOR point no 6)

The exhaust gases, generated by burning of fuel, will be discharged into the atmosphere through

an stack after passing through the multi-cyclone separator. An independent stack has been



proposed of the height of 35 meters according to the Central Pollution Control Board, (CPCB)

Govt. of India guidelines will be provided.

By adaptation of bagasse saving techniques actual use of bagasse will be restricted to 142

MT/day and spent wash 6.15 MTD. fly ash generation will be restricted 142 x 5% x10%=0.71

MTD or 0.02958 MT/hr plus 6.15 x 10.7% x 10% /24= 0.0027 MT/hr Total = 0.2965 MT/hr

Height of stack : 74 Q 0.27 m

: 74 x 0 .32 0.27

: 74 x 0.39 = 28.8 M

In case 100 % bagasse is used 270 MT/day and fly ash generation will be restricted to 1.35

MT/day

And stack height requirement in this case will be

: 74 X 0.0560.27 m

: 34 M

As the boiler is primarily bagasse fired boiler emission level of 800 mg/nm3 as per the Central

Pollution Control Board, (CPCB) Govt. of India guidelines will be adhered to. However KSPL

will provide a better emission control to limit emission to within 150 mg/nm3 by using bag filter

before chimney.

Calculation of chimney height based on SO2 emission:

Case A : 100% bagasse

Raw material = 270 MT/day

Sulphur percentage is bagasse = 0.02%

SO2 emission= 4.5kg/Hr

Stack height H=14 Q0.3

=14*4.50.3

=21.98 m

Case B bagasse with spent wash

Raw material = 142 MT/day

Sulphur percentage is bagasse = 0.02

SO2 emission= 2.4 kg/Hr




=14*2.40.3

=18.12 m

Spent wash Raw material = 6.15 MT/day

Sulphur percentage is bagasse = 0.55

SO2 emission= 2.81 kg/Hr


=14*2.810.3

= 19.08m

With combined considerations of particulate emissions and SO2 emission, maximum height

required works out to be 34 M.

KSPL will provide a stack of 35 M height.

KSPL do not intend to use coal as fuel for the boiler . bagasse and spent wash will be the fuel.

Since bagasse sulphur content is very low ().02% total SO2 emission will be restricted to 2.4

Kg/hr plus 2.8 Kg/hr =5.2 Kg/hr or 124.8 kg/day.

In this way KSPL intends to control SO2 emissions due to its proposal to as low as 124.8

kg/day

4.4 SOLID WASTE MANAGEMENT (TOR POINT.27)

Solid wastes generated from the process are:

Ash - 5 %.

Yeast sludge - 2 M3/day

Bottom ash - 12.15 MT/day

Since KSPL has planned elaborate procedures of energy conservation by way of recovery of

biogas and incineration of spent wash, the bagasse consumption will reduce:

Total bagasse required : 270 MT/day for 25 TPH steam boiler

Saving in bagasse : 54 MT/day by use of biogas in boiler obtained from

biomethanation

: 74 MT/day due to burning of spent wash

Total savings : 128 MT/day

Bagasse required : 270 MT/day - 128 MT/day = 142 MT/day



Assuming 5% ash due to bagasse as well as spent wash ash generation will be 0.8 MT/day fly

ash and 3.2 MT/day bottom ash.

4.5 GREEN BELT DEVELOPMENT

Development of green belt in and around KSPL complex will be done in 8 acres of plot to curtail

the dispersion of pollutants in the surrounding areas. Height, width, foliage, surface area, density

of the leaf, etc are the factors that affect degree of pollution attenuation by a green belt. Various

common plant species like Banyan Mango, Neem, etc. are proposed to be planted in green belt of

distillery. On the boundary side species like Safeda [Eucalyptus hybrid], Subabhul [Leucaenea

leucocephala], Poplar [Poplus alba], Shatut [Morus alba] will be planted. Fruit trees like Mango,

Jamun, Amrud, Ber, Neebu, Banana, and Papita will be in the inner sector. Also herbs and shrubs

like Munj, Behaya, Bhang, Dub, and Kanas are proposed for plantation. Almost 2700 various

species are planned to be planted.

The main objectives of the green belt development in and around the proposed distillery will be

to

Provide a barrier to absorb sound waves and avoid noise pollution

Act as windbreakers.

Mitigate impact due to fugitive emissions.

Create an aesthetic environment.

Create a complex bio-diverse ecology.

Restore the water balance

Prevent soil erosion & surface run off.

About 2700 trees are planned for plantation and greenbelt in 8 acres of land will be

developed.

4.6 RAIN WATER HARVESTING (TOR Point.27)

The distillery unit does not provide large scope of rainwater collection from roof as plant

building is usually structural work in concrete. However a large area will be available unpaved

for water percolation within ground in raining season.



KSPL plans to construct storm water drains in such a way so as to have rain water harvesting pits

constructed in path of storm water. The drain will lead to an underground collection tank were

excess storm water will be collected.

Overflow of storm water drain shall be connected to fire water tank.

Excess storm water will be filtered of dust and other foreign particulates and used in non process

application.

4.7 Traffic management:

The unit will not produce molaases. It will require 400 MT of molaases to be brought in from

nearby sugar mills within 50 KM of area. This will impost 40 tankers to bring in molasses on per

day basis.

The other raw material is bagasse. This will be 270 MT/day to be brought in from sugar mills

only in tractor troyelleys. These troyelleys have two trailers attached and carry about 10 MT of

material. Hence minimum 27 tractor troyelleys will ferry bagasse from neaby sugar mills for a

distance of 50 km from plant site.

The fina product will be ethanol 100 KLPD. It will be transported to buyers in 10 steel tankers.

Thus overall about 50 tankers and 27 trolleys will be required to operate per day. It amounts to

ales than 2 vehicles in an hour.

This is insignificant and is not expected to pose any traffic problems due to raw material and

product movement due to proposed project.

CHAPTER 5

ENVIRONMENTAL IMPACT ANALYSIS

5.0 ENVIONMENTAL IMPACT ANALYSIS

Legislations implemented in India related to environment conservation brought awareness in

people as well as the administrators. It created the logical first step in this process of

environmental impact assessment. It presents the opportunity for the authorities to consider, in

their decision making, the effects of actions that are not accounted for in the normal market

exchange of goods and services. Adherence to pure economic exchange theory and practice for

decision making usually results in adverse consequences at the proposed site where the project is

going to be implemented.

The environmental impact assessment is the documentation of environmental analysis, which

includes identification, interpretation, prediction and mitigation methods and its effectiveness on

proposed project. A properly studied assessment should enable the planner to conclude whether

the proposal should or should not be implemented, or whether the environmental impact is or is

not significant and if the action will be or will not be environmentally controversial. Whenever it

is concluded that significant environmental impact will result from a proposed action, or it may

become environmental controversial, other avenues should be explored.

The process of environmental impact analysis serves to meet the primary goal of Parliament in

enacting Environmental Policy Act 1986 to establish national policy in favor of protecting and

restoring the environmental.

The primary purpose for preparing environmental impact assessment is to disclose the

environmental consequences of a proposed action, there by alerting the agencies, decision

makers and the public to the environmental risks that are involved in a proposal. An important

intended consequence of this disclosure is to build in to the concerned decision making process,

a continuous consciousness of environmental consideration.

The spirit of the law is founded on the premises, that to utilize resources in an environmentally

compatible way and to protect and enhance the environment. It is necessary to know how



activities of the proposed project will affect the environment and to consider these effects early

enough so that changes in plan can be made if the potential impacts warrant them.

Environmental impact assessment provides a vehicle to record impacts of activities so that

knowledge of what adverse changes may occur can be collected and maintained. The purpose of

inventory is to ensure discloser of the impacts on the proposed projects so that concern

institutions or individuals will be aware of possible repercussions of the subject activities.

Another valuable use for the inventory of impacts is to identify the potential cumulative effects

of a group or series of activities in an area. Any single activity might not cause serious changes

in the environmental but when its effects are added to those of other projects, the impacts on the

environment might be severe. The potential for cumulative impacts must be identified and in

some cases, this may be possible only at the intra agency level. A preliminary assessment will

indicate the possible impact areas on which detailed data should be monitored for presenting the

results of the preliminary assessment. This will attempt to answer the impacts on physical or

health hazard, economic interest of the existing communities, impact on infrastructure, and

future growth pattern in the region.

5.1 MATRIX METHOD

The major use of matrices is to indicate cause and effect by listing activities along horizontal axis

and environmental parameters along the vertical axis. In this way the impacts of both individual

components of projects as well as major alternatives can be compared. The simplest matrices use

a single mark to show whether an impact is predicted or not. However, it is easy to increase the

information level by changing the size of the mark to indicate scale. The greatest drawback of

matrices is that they can effectively illustrate only the primary impacts.

A matrix having rows as environmental attributes or impact areas and columns having proposed

project activities is constructed. Each action having an impact on environmental attributes is

given a weight or Parameter Importance Unit (PIU) viewed by experts. Weights given are on

following conception.

Weight 1 is given for insignificant low impact, which is not injurious to environment in case of

its adverse nature.

Weight 3 is given in case of measurable impact, which is not injurious to environment with

proper planning and building in case of its adverse nature.



Weight 7 is given in case of high impact on environment, which can be curbed by taking

precautionary measures in case of its adverse nature.

Weight 10 is given in case of very high impact on environment.

The predicted environmental impact rated on a scale of environmental scores multiplied by the

corresponding weight then gives the weighted impact. All weighted impacts added together give

the overall weighted impact of proposed project on environment. Negative sign in impact matrix

indicates that the impact is of adverse nature.

The environmental matrix for the proposed cogeneration power plant after plan after and during

its implementation is shown in table No. 3

Environmental Impact Matrix for the Proposed Distillery during Construction Phase

Sr. No. Environmental

Attribute

Environmental Score Due to Activities

I II III

1 Air Quality -1 3 1 3 -1 3

2 Noise Levels -1 5 1 3 -1 3

3 Land Use 0 5 1 3 -1 3

4 Soil Chemistry -1 3 1 3 -1 3

5 Crop Yield -2 3 0 3 -1 3

6 Occupational

Structure

3 5 1 5 2 5

7 Flora & Fauna 0 3 1 3 1 3

8 Social Interactions 2 3 2 3 3 5

9 Transportation 2 5 1 3 1 3

10 Economy 3 5 2 3 1 7

LEGEND

I Erection of mechanical equipments



II Plantation/landscaping

III Infrastructural activities

Environmental Impact Matrix for the proposed distillery During Construction Phase

(Contd…)

Sr.

No.

Environmental Attribute Environmental Impact Due to Activities

I II

1 Air Quality -2 7 2 5

2 Noise Levels -2 5 2 3

3 Land Use - - 2 5

4 Soil Chemistry -1 5 1 5

5 Crop Yield -2 5 1 3

6 Occupational Structure 5 7 1 3

7 Flora & Fauna -1 3 2 5

8 Social Interactions 3 5 1 3

9 Transportation 3 5 1 3

10 Economy 3 7 1 3

LEGEND

I Power Generation

II Plantation / Landscaping



5.2 CHECK LIST METHOD

The detailed impact analysis and from the course of the environmental impact assessment one

has to use a checklist method for identifying the possible impact during and after the completion

of the proposed plant. The check list include modification of regime, land transformation and

construction, resource extraction, processing, land alternation, resource renewal, changes in

traffic, waste replacement and treatment, chemical treatment and accident risk involved have to

be assessed. This comprehensive and user friendly checklist is invaluable aid for several

activities of EIA, particularly in scoping and defining baseline studies. The check list has been

prepared for non-specialist and enables much time consuming work to be carried out in advance

of expert input. It includes extensive data collection sheets. The collected data can then be used

to answer a series of questions to identify major impacts and identify shortage of data. The result

sheet from the checklist is reproduced in the following table.

Result Sheet for Assessing Checklist

Parameter Positive

Impact

Very

Positive

Impact

Possible

No

Impact

Negative

Impact

Possible

Negative

Impact

Very

No

Judgment

Possible

Comm-

ents

Alteration of

ground water

hydrology

No No Yes No No -- --

Irrigation No No Yes No No -- --

Noise and

vibration

No No Yes No No -- --

Urbanization Yes -- -- -- -- -- --

Highways No No Yes No No -- --

Dams No No Yes No No -- --

Surface

Excavation

No Yes No No -- -- --



Well drilling Yes -- -- -- -- -- --

Farming Yes -- -- -- -- -- --

Pairing Yes -- -- -- -- -- --

Energy

Generation

Yes -- -- -- -- -- -

Erosion

Control &

Terracing

Yes -- -- -- -- -- --

Ground water

Recharge

No No Yes -- -- -- --

Result Sheet for Assessing Checklist

Parameter Positive

Impact

Very

Positive

Impact

Possible

No

Impact

Negative

Impact

Possible

Negative

Impact

Very

No

Judgment

Possible

Comments

Waste

Recycling

Yes -- -- -- -- -- --

Fertilizer

Application

Yes -- -- -- -- -- --

Trucking Yes -- -- -- -- -- --

Communicati

on

Yes -- -- -- -- -- --

Land Fill -- -- Yes -- - --

Cooling

water

Discharge

Yes -- -- -- -- -- --



Liquid

Effluent

Discharge

No -- Yes -- -- -- -

Stack and

Exhaust

Emission

No -- Yes -- -- -- --

Weed

Control

Yes -- -- -- -- -- --

Insect

Control

No -- Yes -- -- -- --

Explosion -- -- -- Yes -- -- --

Operational

Failure

-- -- -- Yes -- -- --

The very simple layout of the table enables an overview of impacts to be presented clearly which

is enormous value for the scoping of proposed cogeneration power activities.

5.3 EXPERT ADVICE

Expert advice should be sought for predictions, which are inherently non-numeric and is

particularly suitable for estimating social and cultural impacts. It shall be preferably taken in the

form of a consensus of expert opinion for example, it is necessary to find out whether there is

impact on wetland or not. The reduction in the wetland productivity may result in to the fall of

grain yield. As a consequence the quantity of grain required for producing alcohol shall be

severally affected. In order to mitigate these problems it is very much necessary to continuously

monitor the production of grain. It is also necessary to make available the other type of biomass

for producing power with the use of boiler.

CHAPTER 6

ENVIRONMENTAL MANAGEMENT PLAN

6.0 ENVIRONMENT MANAGEMENT PLAN (EMP) (ToR Point. 25, 26)

Environmental impact analysis carried out in previous chapter indicates that Molasses based

proposed distillery project of KSPL would not have any adverse effects on any of the

environmental attributes. The EMP has been designed in such a fashion that all the affected

components have been covered and analysed separately. Main goal of Environment

Management Plan is to conserve the resources, minimize the waste generation, treatment of

waste to within acceptable norms, recovery of by products and recycling of material. It also

incorporates preserving flora and fauna of the region and landscaping of open area.

Post project monitoring is essential part of EMP in order to assess effectiveness of mitigation and

other conservation methods suggested.

6.1 DURING CONSTRUCTION PHASE

6.1.1 WATER ENVIRONMENT

During construction water will be needed mainly for cement concrete mixing purpose, slab

watering, and tank preparation. PP plans to use existing building hence no major building

construction work is involved for the project. Most of civil construction will be limited to

foundations and structural work for plant and machinery.

Waste water is not generated during construction activity hence, no formation or discharge

of waste water during construction will occur.

Being existing factory sanitation and drinking water provision for construction workers is

existing.

6.1.2 AIR ENVIRONMENT

As no building construction is involved use of cement, gravel and sand etc is limited to

foundation of new equipments, hence expected to be insignificant factor in air pollution.

RMC will be used mostly in construction. No mixing of cement, sand, gravel required at

site.

Environment Impact Assessment Chapter-6 New 100 KLPD Molasses based distiller

Karan Sugars Pvt Ltd 2 Herwad Taluka Shirol, Dist Kolahapur

All vehicles entering the factory premises will be maintained regularly.

All the vehicles will follow the vehicular pollution regulation of PUC.

6.1.3 NOISE ENVIRONMENT

As no building construction is involved use of heavy duty construction machinery is not

required, hence noise impact will be insignificant.

Preventive and periodic maintenance, lubrication of all equipment will be regularly

serviced.

Ear plugs and air muffs will be provided to construction workers working near the noise

generating activities like pneumatic excavation, concrete mixers, compressors etc.

Sufficient Plantation is already carried out in the premises to absorb noise levels partly.

6.1.4 SOCIOECONOMIC & OCCUPATIONAL IMPACT

Generally local people will be employed for construction work.

Facilities of sanitation are already existing

Potable water supplies to construction workers. Is available at site.

Canteen facilities are available at site.

Safety equipments for workers like provision of safety belts, helmets, goggles, aprons,

hand gloves, rain coats, and shoes will be provided.

6.2 DURING OPERATION PHASE

Generation of waste water, gaseous emission, solid waste and other discharges due to the project

operational phase will be reduced to insignificance or below the tolerable limits as per action

plan as detailed below:.

6.2.1 AIR ENVIRONNENT

AIR POLLUTION CONTROL SYSTEM



The only likely source of air pollution from the KSPL proposed molasses based distillery & co-

generation process is emission from the stack attached to boiler using agricultural waste/dried

spent wash/ coal for steam generation and power co-generation. A chimney of 0.3 m diameter

and the stack height of 35 meter are proposed on the basis of CPCB guidelines to ensure proper

gaseous dispersion after initial arresting of fly ash in fly ash arrester and a bag filter separator. It

is recommended to undertake following mitigation measures for air pollution control to fulfill

CPCB norms.

Air pollution control equipment like Bag-filter shall be installed to reduce particulate

emission in air.

It will be ensured that all vehicles used in transportation have PUC certificate.

KSPL will ensure all internal roads are tar roads and regular water sprinkling shall be carried

out on all the other roads to prevent fugitive dust emissions.

Tree plantation to the extent of 33% of open area in approximately 8 acres of land is planned

to absorb environmental impacts due to gases, dust and noise. Green belt development

program has been prepared and a budget of Rs 25 lakhs is allocated for this purpose for

initial years. Initially plantation shall be carried out along the boundary wall of the plant.

6.2.2. FLY ASH HANDLING

Capacity of proposed boiler is 25 TPH and it will consume agri residue / coal / bagasse and

concentrated spent wash. Bagasse consumption is proposed to be reduced from @ 270

MT/day to 142 MT/day by use of biogas and spent wash burning.

Gaseous emission from the boiler will be passed through cyclone separator to control the

emission level of pollutants SPM within the stipulated limits. SO2 emission will be low as

bagasse Sulphur content is low. NOx formation will be negligible as burning temperatures

are low. The flue gases would be discharged into atmosphere through 35 m high stack.

Dust collector will be installed on flue gas path before I D fan to mitigate excessive

emissions in air.



Ash from the dust collector hoppers, the air-heater hoppers and the ash collected from the

furnace bottom hoppers will be collected in a common silo the total fly

ash will be picked up by brick manufacturers.

6.2.3. WATER ENVIRONMENT

A network of planned storm water drainage will be provided and maintained. Rain water

harvesting will be carried out to recharge the ground water. It will help in increasing ground

water table around the villages.

Heavily polluted waste water generation in form of spent wash will be nil as it will be

incinerated along with other fuels in boiler. Other waste water due to washings/ boiler and

cooling water blow down shall be used for gardening after primary treatment.

6.2.3.1. EFFLUENT TREATMENT SYSTEM :

Effluent treatment Plant Facilities for 100 KLPD Distillery

Zero Discharge System for spent wash as it will be 100% burnt in the incineration boiler

has been detailed in chapter-4

6.2.4. SOLID WASTE MANAGEMENT (TOR POINT.21)

Solid wastes generated from the process are:

Ash - 5 %.

Yeast sludge - 2 M3/day

Bottom ash - 3.2 MT/day

The part of ash is distributed to the member farmers for use as manure. The ash generated is used

for brick manufacturing and yeast sludge is selling as farm manure. Thus it can be seen that the

Management of Karan Sugar Pvt. Ltd. is committed towards environmental protection and have

taken necessary measures to counter the pollution generated out of the distillery.



6.2.5 NOISE & VIBRATION CONTROL

All the equipments produce continuous noise. As deliberated in chapter -IV, noise level impacts

of KSPL operations are significant only on the operators of machinery and are negligible within

buffer zone. This is because the noise produced by machinery gets dissipated due to wave

divergence, atmospheric absorption and absorption by noise barriers before being even felt in the

buffer zone.

Following measures are proposed to lessen noise level impacts on machinery operators and

within core and buffer zone of KSPL:

Proper lubrication and regular maintenance of all the machinery used.

Development of greenery / barriers / landscaping of trees/ bushes and shrubs.

Reduced noise exposure to the operators of machinery by work scheduling and by providing

ear protective equipment.

Use rubber sheets in packing in the foundations of machineries to prevent noise transmission

to the surrounding.

Proper isolation & due covering with noise absorbing screens in noise creating areas to make

them noise proof.

6.2.6 LAND ENVIRONMENT

This molasses based distillery project is aimed at zero discharge as its goal. Maximum water

conservation is proposed. The fly ash generated will be used for brick making. Hence it will

contribute to saving of soil which otherwise would have been lost in brick making.

6.2.7 GREEN BELT DEVELOPMENT ( TOR POINT. 24)

Development of green belt in and around an industrial complex is an effective way to check the

dispersion of pollutants to the surrounding areas. The degree of pollution attenuation by a green

belt depends on its height, width, foliage, surface area, density of the leaf, etc. Various plant

species like Banyan trees, Mango, Neem, etc is proposed to be planted in green belt of distillery.

The main objectives of the green belt development in and around the proposed distillery will be

A curtain to absorb sound waves and a barrier



Act as windbreakers.

Mitigate impact due to fugitive emissions.

Create an aesthetic environment.

Create a complex bio-diverse ecology.

Restore the water balance

Prevent soil erosion & surface run off.

6.2.8 OCCUPATIONAL HEALTH AND SAFETY (ToR Point.28)

The occupational health surveillance program is to address pre employment health examination

and periodic health examination. Every employee on his appointment for factory the pre-

employment medical examination will be done. Scheme for health surveillance shall include

exposure data at each pertinent work place, periodical examination of workers, X-ray

examination, lung function test for digestive disorder and clinical examination for early detection

of signs of asbestosis. These tests are to be recorded for pre-employment, periodic surveillance

and at cessation of employment as per the concerned state government regulations. Occupational

health surveillance is to be carried out by occupational physician or chest physician trained in

occupational medicine. The occupational health surveillance program is to be drawn for all the

employees potentially exposed.

The medical records is to be maintained and stored for period of 15 years following the

termination of employment or for 40 years after first day of employment, whichever is later. The

medical records is to be maintained covering the details of pre-employment examination, the

periodical medical examinations, medical examination done at other times, if any and the

medical examinations conducted at cessation of employment and further follow-up

examinations, where done. The records shall also be maintained of the individual employee’s

occupational exposure profile to asbestos, specific work practices, and preventive measures

prescribed, if any.

The occupational health surveillance program is to address the following aspects

Pre-employment medical examination

Periodic medical examination

Medical employment at cessation of employment



Maintenance of medical records and

Health education

Scheme for occupational health monitoring is to be prepared in detail [BIS code of practices IS:

11451-1986 (Reaffirmed 2005) (Recommendations for safety health requirements relating to

occupational exposure to asbestos)]

OCCUPATIONAL HEALTH SURVEILLANCE

Assessment This is a

proposed unit.

The

recommendations

of health

surveillance are

expected to be

followed after

project is

implemented.

Does the occupational health professional of the plant responsible for

counting of fibre take part in national or international training?

Are new or re-employed workers submitted to medical exams prior to

working in the plant?

Are temporary workers submitted to medical screening?

Is there a register of individual health records (subject to professional

confidentiality)?

Are the workers made aware of the results from their own medical

examinations?

Are the occupational health services of the plant made aware of the workers

dust exposure results? Do they carry out regular visit of the plant?

6.2.9. SOCIO-ECONOMIC BENEFITS

Industry will help the farmers in various ways i.e. educational, social institutions, cultural

institutions.

Create direct & indirect employment opportunities.

During the construction, employment will be generated for the local villagers.

The sale of alcohol will generate large amount of revenue to state government by way of

excise and octroi for local bodies

The distillery will also generate direct employment to local skilled, semiskilled and

unskilled workers.



The distillery can also generate revenue for local population by the services that they render

to the industry.

6.2.10. BUDGET PROVISION FOR ENVIRONMENTAL MANAGEMENT PLAN

KSPL has proposed required budget for EMP in its annual budget to fulfill the stated objectives

of the environmental policy. For environmental management capital equipment includes Air

Pollution Control System, effluent treatment plant for zero discharge, green belt development

and the environment laboratory.

Table 6.1:

Budget provision for Environmental Management plan

SL

No Item

Recurring Cost per

annum

(Lac)

Capital Cost

(Lac)

1 Air Pollution Control 12.5 70.00

2 Water Pollution Control 5.0 400.00

3 Noise Pollution Control ---- 03.00


Management 0.45 03.00

5 Occupational Health 1.00 12.00

6 Green Belt 1.00 25.00

7 Salary of EMP staff 6.8 ----

8 Safety management. 12.00

9 Laboratory and chemicals 05.0 28.00

10 Maintenance of ETP and wages of

workers. 15.0 22.00

Total 46.75 575.00

KSPL management has separately assigned fund of Rs 5.75 crores for an effective technology to

ensure all pollution norms are adhered in letter and spirit. Such kind of investment has been done



by very few industries and management assures water pollution problem will be totally solved by

the technology of zero discharge for proposed 100 KLPD molasses based distillery.

CORPORATE SOCIAL RESPONSIBILITY (CSR)

CSR program shall under take by company as notification published by ministry of corporate

affairs dated 27th Febuary, 2014. KSPL has divided all over CSR program into three categories,

namely those are as follows.

GREEN INITIATIVES

EDUCATIONAL DEVELOPMENT

SOCIAL WELFARE

GREEN INITIATIVES: The ‘Green Initiative’ has become a critical focal point around the world. With the increasing

competitive environment, limited resources and increased focus on preserving the environment

for future generations, the green benefits of resource conservation are no longer a secondary

consideration. KSPL has planned program for initiating green initiatives around its premises.

EDUCATIONAL DEVELOPMENT: Development of education in India will have to attain a new level of importance considering

today’s scenario. To develop education in India, compulsory education should be provided to all

the children up to age of 14. From such schemes KSPL has planned to extend helping hand to

existing institutes.

SOCIAL WELFARE: Basic objective of the social welfare is to support and improve the standard of living of the

people and provide them equal opportunities. Government of India and state government already

takes action and proposes several schemes. On this node KSPL also has planned few programs to

improve quality of life people of surrounding villages.



I. GREEN INITIATIVES:

1. GREEN BELT DEVELOPMENT KSPL will develop a green belt within the plant up to 33% of the in plant area. In addition KSPL

will develop additional green belt all round the factory, about 10 m wide, in order to ensure

sound effects and air emissions are absorbed within factory and are not transmitted to nearby

residential places. About 1600 trees are planned for plantation. Plantation drive has already been

initiated and about 300 trees have been planted

Plantation produces green canopy over land and is helpful in controlling land erosion, land

stabilization, and provides windbreaks. It is also helpful in enriching local biodiversity.

KSPL will develop greeneries in the periphery of the factory and surrounding villages This

plantation will be established within plant as well as outside plant boundary . The tree species

used in a plantation is also an important factor. Various local specious has been selected for

plantation to avoid disturbance in micro level ecological balance. Following table shows name

of various tree species and their number which will be planted during plantation program.

KSPL expects to spend about Rs 25 lacs in establishing green belt as detailed above.

2. DRIP IRRIGATION : Drip irrigation is known as micro irrigation or localized irrigation. It is a method to save water,

to increase the productivity and production per unit of land and water. This technique allows

water to drip slowly to the roots of plant, either onto the soil surface or directly onto the root

zone, through a network of valves, pipes, tubing, and emitters. It is done through narrow tubes

that deliver water directly to the base of the plant. Keeping in view to minimum use of water the

Factory will encourage the farmer to adopt this drip irrigation system. KSPL will encourage

optimum use of water resource. Education program will be run for farmers of surrounding

villages. The factory shall provide demo plants in select areas for active demonstration.

KSPL expects to spend about Rs 30 lacs in establishing green belt as detailed above.



3. FERTILIZER SUBSIDY:

Ash produced by burning of bagasse and spent wash is very well known fertilizer. It has several

micronutrients. By mixing with other additives like biomass, press mud, soil a proper additive

is made which can be used in the agricultural field for crop production.

KSPL has planned to distribute ash as farm manure to the farmer. For this purpose factory will

install a wet conveying system to collect bottom ash from boiler and the bag filter in a separate

silo. The company will develop soil nutrient mixture which if dozed in specific amounts will

replenish basic elements of soil and increase productivity.

The factory expects an expenditure of about Rs 15 lacs for above activity.

4. RAIN WATER HARVESTING Rainwater harvesting is the accumulation and deposition of rainwater for reuse before it reaches

the aquifer. It is among the one of the method to reduced water bill effectively. This project

covers the roof of administrative building Distillery and co-generation building, paved areas as

well as unpaved areas. The rain water shall collect through storm water drain lines and will be

stored either in pond or dug well. This stored water is excellent source of water for landscape

irrigation, with no chemicals such as fluoride and chlorine, and any dissolved salts and minerals

from the soil. This stored water will use for greeneries and seed nurseries in factory premises.

The factory expects an expenditure of about Rs 15 lacs for above activity.

II. EDUCATIONAL DEVELOPMENT

1. SCHOOL BUILDING: School building is the Basic requirement for awareness the importance of enhancement of

education. KLPL will ensure proper sanitation is available for school children

KSPL will help to improve the basic infrastructure and dilapidated school building of

surrounding villages. In village KSPL will provide the furniture to them KSPL also plans to

distribute computers to the schools.

2. LIBRARY: The library will be build to organized and collect the sources of information and similar

resources, made accessible to local community. KSPL will build up one room of 20’X .The daily



news papers such as Lokmat, sakal, Zunjarneta, Times of India, and agro one are available in the

library. The books on Agriculture developments, Novels and National personalities will be

available in the library.

3. COMMUNICATION INTERNET CENTER: The Internet is a global system of interconnected computer networks that use the

standard Internet protocol suite (TCP/IP) to serve several billion users worldwide. It is a network

of networks that consists of millions of private, public, academic, business, and government

networks, of local to global scope, that are linked by a broad array of electronic, wireless, and

optical networking technologies. KSPL is appreciated the importance the Internet. A

communication internet center will be build by KSPL along with the library

4. SELF HELP GROUP: Self help group played an important to overall well being of micro-level economics. A group of

local people can produced economically important homemade product to earn their own bread

and butter. Those local groups sometime face problem relating to initial capital and find out

potential market.

The KSPL encourage and provided the funds to the Mohila Bachat Guts formed in the nearby

village The product of Mohila bachat Guts purchased by factory and supplied to workers of

factory.

5. SCHOLERSHIP FOR HIGHER EDUCATION: A scholarship is an award of financial aid for a student to further his or her education.

The ksplfactory aims to give the scholarship to the students these who are coming in Merit.

Minimum 10 students are selected per year and provided the facility.

A scholarship is an award of financial aid for a student to further his or her education.

Scholarships are awarded based upon various criteria, which usually reflect the values and

purposes of the donor or founder of the award. Scholarship money is not required to be repaid

The mamangement expects to spend about Rs 25 lacs for completing above social benefits



III. SOCIAL WELFARE

1. COMMUNITY HALL: Surrounding villagers are faces problem while they are arrange of marriage ceremony of their

own family member. KSPL has felt their problem and planned to build up one Marriage hall

where the people of surrounding area could arrange the marriage ceremony. The minimum

capacity of the hall will be 1000 people. KSPL believe it will give benefit to the local people.

2. HEALTH CHECK UP CAMPS: To improve the health of the surrounding village’s people, KSPL will arrange heath check-up

camp twice in a year. This camp will be organized in the premises of the factory. Specialist

doctor from various fields along with general physician will be invited in the health check-up

camp. People are lived surrounding village can attain this camp and examine their heath at free

of cost. Factory will be taking all the responsibilities regarding payment of Doctors’ fees.

3. BLOOD DONATION CAMPS: Blood donation camp has a huge social importance. Nothing is comparable to the preciousness of

human blood. In spite of the rapid and remarkable conquests of medical science today, At the

same time during health check up blood camp will be arrange. KSPL encourage the public to

donate the blood, bank helps to the needed patients at critical time.

4. AMBULANCE: A transportation of sick or injured people to, from or between places of treatment for

an illness or injury and in some instances will also provide out of hospital medical care to the

patient. The KSPL purchase one Ambulance in the services of people from the area of operation.

The ambulance is being provided free of cost to the needed persons.

Management expects a budget of Rs 40 lacs in order to extend above social benefits.

CHAPTER 7

ENVIRONMENT MONITORING PROGRAM

7.1 MONITORING SYSTEM

7.1.1 FORMATION OF ENVIRONMENTAL MANAGEMENT CELL (EMC)

Monitoring of pollution parameters and analysis of results are the tools to verify the anticipated

pollution and effectiveness of measures of mitigation planned for environmental protection. It is

possible to estimate measures are performing efficiently or not on a particular day but throughout

the year. To achieve this objective an environmental management cell consisting of senior

officials will be constituted. EMC will perform following functions:

Monthly review of environmental problems and monitoring of installation / performance /

maintenance of pollution control measures.

Enforcement of latest acts, rules and regulations under relevant Environmental protection

Acts.

Preparation of budgetary estimates to seek sanctions for new pollution control measures if

required and / or for up-gradation of existing one based on new technologies.

Emergency planning.

EMC shall meet at least once in a month and take stock of progress of work relating to decisions

taken and targets set in the previous meeting.

7.1.2 FORMATION OF TASK FORCE

A task force comprising KSPL staff of various grades shall be constituted. The task force will

ensure following tasks:

Monitoring activities within core and buffer zone of KSPL.

Monitoring of efficiency of pollution control schemes.

Preparation of maintenances schedule of pollution control equipment and effluent

treatment plants and strict adherence to the same.



Implementation of shut down jobs, cleaning & testing of settling tanks, vessel jackets,

heat exchangers, cooling towers, drainage system, HT supply to Grid etc.

Green –belt development and its proper implementation

Water and energy conservation

Good housekeeping

Appraising & updating EMC on regular basis.

7.1.3 MONITORING PROGRAM (TOR POINT. 26)

Monitoring schedule given by CPCB / MPCB will be strictly followed to ensure the full proof

system of environmental protection activities.

In general, the monitoring schedule shall be as follows:

AMBIENT AIR

Monitoring of ambient air quality within 10 km radius of KSPL at 5 stations, once in six

months or as directed by compliance monitoring agency.

Pollutants monitored shall be for Suspended Particulate Matter, Sulphur Dioxide and Oxides

of Nitrogen. Monitoring shall be carried out generally once in three months or as may be

deemed necessary

Air monitoring will be outsourced to approved agency.

WATER

SURFACE WATER SOURCES

Sampling of Panchganga river water located within 10 km radius of KSPL shall be carried out

once in 6 months. Three grab samples shall be collected at the rate of one sample each on 3

different days.



GROUND WATER SOURCES

Sampling of ground water from hand pump area, open-wells and bore wills located within 5 km

buffer zone of KSPL, especially downstream, shall be carried out once in 3 months.

Analysis of samples collected from effluent, surface and ground water sources shall be carried

out for parameters stated in the consent issued by Maharashtra State Pollution Control Board.

SOIL TESTING

Soil samples from various farms /agriculture fields in the down contour side area shall be

collected. Soil testing will be carried out once in six months or as required. Soil pollution is not

expected as spent wash is not to be stored or bio-composted instead it will be burnt in

incineration boiler.

This job will also be outsourced.

NOISE

Hourly noise levels shall be monitored near all the noise making equipment for a period of 8

hours. Hourly noise level shall also be monitored for 8 hours in situated near boundary of KSPL

site. Monitoring may be done along with air monitoring or separately if required.

7.1.4 LABORATORY FACILITIES AND MONITORING PLAN

1. MONITORING FACILITY

It is proposed to get the monitoring work done from the laboratory of MPCB initially. In due

course of time KSPL may acquire-monitoring equipments namely High Volume Samplers, Stack

Monitoring Kit, Automatic recording Weather Monitoring Station, Noise Monitoring

Equipments etc. to carry out environmental monitoring work. However KSPL will prefer an

outside agency to carryout air monitoring.

2. MONITORING PLAN

A comprehensive monitoring program is suggested. Environmental attributes will be monitored

as described below:



AIR POLLUTION AND METEOROLOGY ASPECTS

Both ambient air quality and stack emissions shall be monitored. The ambient air quality shall be

monitored to ensure compliance of Central Pollution Control Board / MPCB guidelines.

WATER AND WASTE WATER QUALITY

All the effluent streams from the plant shall be monitored for their physico-chemical

characteristics and heavy metals. In addition ground water samples surrounding the waste

storage area will be monitored so as to check for any seepage and take preventive action.

NOISE LEVELS

Noise levels in the work zone environment shall be monitored. The frequency should be once in

three months in the work zone.

II. LABORATORY FACILITY

A full fledge laboratory will be provided with man power and facilities for self monitoring of

pollutants generated in the complex and also it effects on the receiving soil, water body and

atmosphere.

The laboratory will be equipped with instruments and chemicals required for monitoring

following pollution parameters.

A. FOR WATER

pH, Temperature, TS, TSS, TDS, BOD, COD. CI, SO4, PO4 N, Na, K, D.O. etc

B. FOR GASES

Velocity, temperature, SPM, SO2, NOx, CO and CO2 from the stack. SPM, SO2, NOx, RSPM,

TSPM from Ambient air. An outsourced agency may be assigned for such jobs.

C. METEOROLOGY

Wind speed and direction temperature, relative humidity and rainfall.

An outsourced agency may be assigned for such jobs.



III RECORDS TO BE MAINTAINED

Following records will be maintained by the environmental department in respect of operation of

pollution control facilities

Log sheet to record spent wash generation, concentration and amount burnt in boiler.

Log sheet for to record daily plant Operation.

Instruction manual for standard operation and maintenance of spent wash treatment, multiple

effect evaporator, dried spent wash burnt in boiler etc.

Instruction manual for monitoring of water, solid and gaseous parameter discharged from the

factory and also for various parameters of pollution control facilities.

Statutory records as per the Environmental Acts.

Yearly Environment statement.

IV SAMPLING SCHEDULES AND LOCATIONS (Post project environmental

monitoring)

Post project monitoring schedule for various environmental parameters is given in Table

Particulars Location Frequency

Ambient Air Quality 2 samples down wind direction at

500m and 1000m

1 sample at up wind direction at

500m

24 hr sample half

yearly

Flue gas from Chimney

for flow rate SPM,

RSPM, SO2, NOX

Sampling port of chimney Six Monthly

Ground Water 1 Km from distillery

2 location on downward drainage

pattern

1 on upward drainage

Half Yearly



River water 1 sample each down and upstream Quarterly

Soil In 10 km radius representative

samples

Pre and post

Monsoon

Waste Water (lean

effluent)

At site after treatment for use in

gardening

Daily

Spent wash Inlet to bio digestor Daily or as per

generation

7.2 ENVIRONMENT MANAGEMENT CELL

Environment Management Cell will be established to look after the Effluent Treatment Facility

and to monitor and control the environmental quality. This cell would comprise of following

members: Environmental Engineer 1

Environmental Chemist 1

Laboratory Attendants 2

Safety Officer 3

Plant Operator 4

Supporting Staff 2

Members of the Environmental Cell would be well qualified and experienced in the concerned

field. Some of the routine tests of wastewater such as pH, solids, temperature, etc. will be carried

out in the laboratory of distillery. However, for special tests if required, of water, wastewater,

soil, air etc. services of reputed laboratories as well as that of a consultant would be hired.

CHAPTER 8

DISASTER CONTROL PLAN

8.0 DISASTER OR EMERGENCY CONTROL PLAN

KSPL management has planned policy in environmental protection, ensuring safety and health of

all employees as well as well being of the people in the surrounding areas. It is likely that any

activity of the plant can create threat / danger / hazard due to storage of alcohol. Proposed

captive power generation plant also can cause fire, electrocution and explosion hazards. Karan

Sugar Pvt. Ltd. is already covered under Factories Act 1948 & Maharashtra Factories Rules 1963

with all amendments till today and all directives from Director Safety, Health & Environment

[SHE] are binding on KSPL. KSPL management is bound to appoint a qualified Safety Officer.

On site and off site disaster control plans, their perfect implementation will be part and parcel of

the project & duty of safety officer. To lessen the probability of hazard to materialize & avoid

the consequent damage, a disaster management and control plan has been worked out for whole

complex.

8.1. TYPE OF DISASTER AT KSPL COMPLEX

Disaster can occur at site or off site i.e. disaster on campus or disaster in nearby area causing

indirect damage to site area and the complex.

Disaster is classified into two categories such as, Natural and Manmade calamities:

Natural calamities :- Flood, Storm / typhoon, Earthquake, Tsunami, Heavy mist, fog, hail

storm, eruption of volcano, Land slide

Man made calamities involve:- Fire & Explosion, All types of leakages & spillage,

Electrocution, Accidents during excavation, construction activities, erection, or sabotage, rail

& road accidents, mass agitation, looting, morcha, mass agitation, war etc.

The identified Dangerous areas in the complex are:-

1. Boiler area - Explosion



2. Oil tanks - Fire and spillage

3. Turbine section - Explosion

4. Electrical rooms - Fire and electrocution

5. Transformer area - Fire and electrocution

6. Cable - Fire and electrocution

7. Storage facilities – Fire / spillage for fuel and alcohol

Considering various probabilities the management & safety department will create safety

awareness & preparedness in all employees and people in vicinity area in case of any emergency

& a chalk out plan to overcome the disaster in time. This includes preparation of onsite and

offsite disaster control plans, impart training to staff and employees, conducting regular mock

drills at least 2 times in a calendar year, reports schemes to DISH & take their guidance for the

perfect implementation.

8.2. LEVEL OF ACCIDENT

If there is any disaster in any part of plant/work place due to any reason the level of accidents

from damage point of view may vary. Accordingly accident prevention program will have to be

initiated by safety department simultaneously.

8.3. CRITICAL TARGETS DURING EMERGENCY

Level I Accidents

Under this level disaster may happen due to electrocution, fire explosion, oil spillage and

spontaneous ignition of combustible material. This level has probability of occurrence affecting

persons inside the plant.

Level II Accidents

In second level cases of sabotage and compete failure of all automatic control/warning systems,

and also if the start up fuel oil stored in tank and covered by tank bunds leaks out. However,

probability of occurrence of Level II Accidents reduces due to the proposed adequate security

training, and education level of plant personnel for the captive power plant.



8.4. SITE EMERGENCY CONTROL ROOM (SECR) & SITE MAIN CONTROLLER

In each segment of work from domestic level to war fighting team level approach always helps.

If concerned man is aware of his duty at his place & need of the time he can complement to huge

task of containing the damage of the disaster. To overcome the emergency in its occurrence it is

the strategy to get prepared in advance, plan for the team effort, educate others and reduce all

effects of disaster.

In case of any disaster main responsibility lies with the Chairman and Board of Directors, where

they nominate one person as responsible who will be Chief incidence controller. In case of

disaster key person like Chief engineer, Chief chemist, Distillery manager, Safety officer will be

appointed as the site main incidence controller and will commence respective duties in that

capacity to curtail the emergency & minimize the losses may be occurring.

People in all departments can render assistance in form of contacting external persons or

agencies, district, state and central authorities, hospital & ambulance contact, police department

for evacuation if needed for people in the vicinity with assistance of state transport buses. People

from maintenance department are to rectify the fault in system as early as possible. Security

persons have to assist in fire fighting & segregation of material to avoid losses. All situations

should be visualized and plan safety operations involving all staff in factory to get any sort of

external help / assistance in time to lessen all sorts of damage.

To ensure disaster is controlled effectively a site emergency control room (SECR) will be

established at the plant site. The SECR shall keep following information and accessories ready

and prominently displayed and start to act as detailed if the emergency occurs:

List of telephone numbers of Chairman & Directors KSPL, Chief Engineer, Chief Chemist,

Distillery Manager, Administration Manager.

Telephone numbers of Sarpanch and members of Panchayat of Harwad village, members of

city council of Shirol town, Collector, Kolhapur district, Shirol regional State road transport

depot office, Kolhapur District & local fire brigade station, home guard, civil defense, N.C.C.

unit, State crisis group, Shirol, crisis group.

All material handling & incoming vehicle traffic to be stopped or diverted



All out going lines to be used to contact above authorities.

Captive power plant layout with details of inventories and locations of fuel storage areas

Oil / furnace oil storage tanks, bagasse, rice husk, coal storage yard etc.

Hazard identification chart, maximum number of people working at a time, assembly points

etc

List of village and their population in the vicinity of proposed plant

Public address system like loud speaker, battery operated speaker, sirens,

Whistles, batteries, signaling flags etc.

Rechargeable and battery operated torch lights and invertors.

Tie up with nearest hospital for medical assistance and facility for stretchers, chairs etc.

List of registered medical practitioners in vicinity.

Study map showing various villages and towns in the vicinity of plant.

Muster Roll of all present employees.

Note pads and ball pens to record message received and instructions to be passed to

concerned persons

The blow up copy of Layout plan showing areas where accident could occur.

Accident mock drill for at least 2 times in a calendar year is to be a part of

Routine exercise. The report before such drill has to be submitted to DISH for information

and approval.

8.5. DISASTER PREVENTIVE MEASURES

The proposed plant will have following preventive measures to avoid occurrence of disasters:

I. Specification & marking of safe area to gather in emergency.



II. Design, manufacture and construction of plant, machineries and buildings will be as per

national and international codes as applicable in specific cases and laid down by statutory

authorities.

III. Provision of adequate access ways for movement of equipment and personnel.

IV. Minimum two numbers of gates to escape during disaster shall be provided.

V. Fuel oil storage shall be in protected and fenced. The tank will be housed in a dyke wall.

As per regulations of Chief Controller of Explosives, it’s testing & certification will be

performed each 5 years regularly.

VI. Proper color coding for all process water, air & steam lines will be done.

VII. Proper insulation for all steam & condensate, hot water lines will be done.

VIII. Provision of circuit brakers, isolation switches, signals will be provided as per electricity

act & rules.

IX. Proper & rigid bonding and earthing to all equipment will be arranged.

X. Meger value of earthing connections will be checked each 6 months and the same record

will be available.

XI. System of fire hydrants comprising, of electrical motor driven fire pumps is planned. The

fire hydrant system will have electrical motor and a generator driven jockey pump to keep

the fire hydrant system properly pressurized.

XII. Automatic water sprinkling system is planned for all transformers.

8.6. FIRE FIGHTING SYSTEM AS PER (TAC) NORMS: (TOR POINT.23)

The fire detection and protection system has been planned to meet the above objective according

to Tariff Advisory Committee (TAC) of India. The complete fire protection system will

comprise of the following



(a) Sprinkler system

Automatic with manual switchover sprinkler system will be installed for fire detection & alarm

system followed by initiation of water spays in area with likelihood of fire hazards.

(b) Fire Hydrant

Fire hydrants are provided at all around in the plant at specific distance as per TAC Norms. The

system shall be complete with electrical fire pump, diesel engine driven pump, jokey pump,

control panel capable of starting system from safety alarms, A pressurized hydrant pipe will run

through the areas of storage and manufacturing system to ensure immediate water supply is

available in case of any emergency.

A dedicated fire water tank of 20,000 liter capacity will be available for fire protection.

(c) Portable fire extinguishers

Various areas of the plant have one or more of the above system depending upon the particular

nature of risk involved in that area.

(d) Portable Chemical Fire Extinguishers

These are intended as a first line of defense, and hence are stationed at strategic locations in

different buildings and also for outdoor facilities. Portable fire extinguishers are foam type;

carbon dioxide type and multipurpose dry chemical (MPDC) type.

(e) Fire Detection and Alarm System

This system comprises fire alarm panels, automatic fire detectors, manual call points and fire

siren (hooter).

The main fire alarm panel provides both visual and audible alarm of fire in any protected

areas of the plant.

Manual break glass type fire alarms are provided at strategic locations where high hazards

exits.

Automatic fire detectors are provided for coal handling areas and in plant areas such as

control rooms, switchgear rooms, cable galleries etc.



(f) Foam type fire extinguishers will be installed in alcohol storage area. These will

help in discharging foam and preventing oxygen supply to material catching fire.

FIRST AID

A first aid centre with adequate facilities is provided. An Ambulance is provided at site to carry

affected people to hospital.

SECURITY

The security requirements of the company premises are taken care by CSO assisted by a Fire In

charge.

SAFETY

The required safety appliances are distributed at different locations of the plant to meet any

eventualities.

EVACUATION PROCEDURE

As the major hazard is due to fire, which has more or less localized impact no mass evacuation,

procedures are required. Evacuation would involve only of the people working very close to the

fire area.

EMERGENCY CONTROL CENTER

Provision is made to establish an Emergency Control Centre (ECC) from which

emergency operations are directed and coordinated.

The ECC consists of one room, located in an area that offers minimal risk being directly

exposed to possible accidents.

The ECC is always ready for operation and provided with the equipment and supplies

necessary during the emergency such as:

Updated copies of the On–site Disaster Management Plan.

Emergency telephone numbers.

The names, phone number, and address of external agencies, response

Organizations and neighboring facilities.



The adequate number of telephone (more than two).

Emergency lights.

List of fire extinguishers with their type no. and location, capacity, etc.

Personal protective equipment.

Safety helmets – List of quantity & location.

Clock.

Status boards/message board.

Material safety data sheets for chemicals handled at the facility.

Fire is one of the main causes to initiate an emergency situation. It always pays in time if due

attention is given to all materials and combustibles present on site and their quantities in time. It

can occur any time and hence one aught to be vigilant and cautious nature of management and all

staff always helps to lessen the cases of fire accidents.

To meet any sort of challenges in case of fires, BIS 2190 provides Indian standards for

firefighting equipment. All firefighting equipment and extinguishers have to be planned

according to this standard as explained in the table below.

There are 4 classes of fire extinguishers:

Class Materials Extinguisher

A Cotton, Cloth, paper, wood Water type

B Oils, Hydrocarbons, Alcohol, Greases CO2 type

C Gases, CNG, LPG, Acetylene, Foam type

D Electrical & metals Foam



RECOMMENDATION

The fire tender, which will be part of project with following minimum fire fighting

arrangements, shall be procured:

Water tank - 5000 liters

CO2 - 2700 liters

Foam tank - 45 liters

CO2 type fire extinguishers - 6 nos. of 4.5 kg each

8.7. LOCATION TYPE OF FIRE EXTINGUISHERS

Turbo-generator area CO2 Type, Foam Type Dry chemical powder.

Cable galleries CO2 Type, Foam Type Dry chemical powder

High voltage panel CO2 Type, Foam Type Dry chemical powder.

Control rooms CO2 Type, Foam Type Dry chemical powder.

MCC rooms CO2 Type, Foam Type Dry chemical powder.

Pump houses CO2 Type, Foam type dry chemical powder.

Fuel tank Area CO2 type, Foam Type Dry chemical powder Sand Basket.

Offices & Godowns Foam or Dry chemical powder Type.

Crushers house CO2 Type, Foam Type dry chemical powder.

Alcohol storage tank area, foam type dry chemical powder and sand basket.

8.8. ALARM SYSTEM TO BE FOLLOWED DURING DISASTER

On the receiving of message of ‘Disaster from Site Main Controller, fire station control room

attendant will crash Siren ‘WAVING TYPE’ for 5 minutes. Incident controller will arrange to

broad cast disaster message through public address system.



On receiving the message of “Emergency Over” from incident Controller the fire station control

room attendant will give “All Clear Signal” by sounding alarm straight for two minutes. The

features of alarm system will be explained to one and all to avoid panic or misunderstanding

during disaster.

It is necessary to take one trial for perfect functioning of the siren at least once in one week with

prior intimation to Kolhapur District Collector.

8.9 PRECAUTIONS TO BE TAKEN IN HANDLING AND STORAGE OF ALCOHOL:

(TOR POINT.22)

Storage in tightly closed containers in cool, dark, well-ventilated area. Protect containers from

physical damage. Keep heat, fire and flame away. Outside building or underground storage is

recommended.

8.10 RISK ASSESSMENT: ENVIRONMENT

8.10.1 GENERAL ASSESSMENT:

The environment is at risk of exposure during transportation, storage, disposal, or destruction of

ethyl alcohol. In almost every scenario, the threat of environmental exposure is contingent upon

the proper handling of the chemical substance. Accidental spills, large or small, can result in fire,

explosion, and possible contamination of the surrounding environmental mediums (water, soil,

and air).

8.10.2 RECOMMENDED RISK-REDUCTION MEASURES:

Proper training of all transporters will reduce the likelihood of an accident resulting in a leak or

spill to the environment. The correct use of DOT labeling (per the MSDS) on all containers,

trucks, and rail cars will enable emergency responders to react properly and quickly to any

disaster thereby reducing the potential risk to the environment and to personnel.

Storage of ethyl alcohol shall be segregated from incompatible chemicals to minimize the risk of

cross contamination or contact. Buildings designated for storage shall be equipped with

appropriate fire protection systems (alarms, sprinklers, emergency lighting, and portable

extinguishers). Equipment shall be designed to meet explosion-proof standards.



If a spill or leak to the environment has occurred, fire department, emergency response, and/or

hazardous materials spill person should be notified immediately. Cleanup should be attempted

only by those trained in proper spill containment procedures. Contaminated soils should be

removed for incineration and replaced with clean soil. If ethyl alcohol should contact the water

table, aquifer, or navigable waterway, time is: of the essence. It is highly soluble in water and,

therefore, total containment and remediation may not be entirely possible. When such spills

occur, the local and/or state emergency response authorities must be notified. A comprehensive

emergency response of disaster awareness/recovery plan should be in place prior to any

operations involving the use, transportation, storage, or disposal of ethyl alcohol. If ethyl alcohol

is spilled or leaked, the following specific steps are recommended:

Restrict persons not wearing protective clothing from area of spill or leak until cleanup is

complete and area can be opened for normal work.

Ventilate area and remove ignition sources.

Absorb liquids in vermiculite, dry sand, earth, or a similar material and deposit in sealed

containers. Use non-sparking tools.

It may be necessary to dispose of ethyl alcohol as a hazardous waste. The responsible

state agency or the regional office of the federal Environmental Protection Agency

(EPA) should be contacted for specific recommendations.

CHAPTER 9

PROJECT BENEFITS

Karan Sugars Pvt Ltd manufacturing unit situated at Village – Harwad Taluka - Shirol, of

Kolhapur district in Western Maharashtra, propose to install a new molasses based distillery of

100 KLPD capacity. The company has procured land belonging to Shetmal Sahakari Prakriya

Sansthann Ltd who had 30 KLPD cane juice based distillery. The distillery was non operational

due to continual losses. KSPL decided to scrap the existing cane juice based distillery and install

new 100% molasses based distillery of 100 KLPD capacity.

The pros and cons of the proposal are discussed below:

Cane juice based manufacturing involves crushing of sugarcane followed by processing

of cane juice, fermentation to produce alcohol. It required crushing of cane upto 12000

MT/month. It created unhealthy competition in cane procurement because of presence of large

capacity sugar mills in an area of 30 km with Karan Sugars site as center.

As the prices as well as availability of sugarcane fluctuated, profitability of company was

affected in a negative manner. Cascading effect of low profit and / or non receipt of timely

payment reflected in form of overall financial crunch down the line extending up to the farmers

involved in producing and supplying cane.

Competition in getting sugar cane is a threat to survival of existing unit there is an

opportunity in form of availability of molasses as many of sugar mill do not have own distillery.

A list of sugar factories in the vicinity of project, their crushing capacity, amount of cane crushed

and status vis a vis having own distillery or not -is as below:


TCD

Last year

Crushing

MTA

Distillery

Capacity

KLPD

Shree Datta Sahakari Sakhar Karkhana

Ltd Sirod, dist- kolhapur

18 km 7000 91800 60

Shree Gurudutta Sucrose Ltd 8 km 2500 670000 Nil



Takrewadi Sirod dist- Kolhapur

Shree Jawahar Shetkari Sahakari

Sakhar Karkhana Ltd Hupari tal-

Hatkanangale dist- Kolhapur

23 km 9000 1428000 Nil

Shri sharad sahakari sakhar karkhana

Ltd Narande Tal- tal- Hatkanangale

dist- Kolhapur

45 km 2500 589000 Nil

Shree Panchganga Sahakari Sakhar

Karkhana Ltd Ganganagar Ichalkaranji

tal- Hatkanangale dist- Kolhapur

23 km 5000 740000 Nil

Shri Chhatrapati Rajaram Sahakari

Sakhar Karkhana Ltd, kasba bawda,

Dist Kolhapur

49 km 2200 410000 Nil

Shree Chattrapati Shahu SSKL Kagal

Tal-Kagal Dist- Kolhapur

36 km 3500 731000 45

Vasantdada SSKL Madhavnagar

Sangali tal Miraj Dist -

Sangli

34 Km 5000 530000 Nil

Shree Guppy Sugar Works Ltd,

Kagwad, Tal – chikkodi Dist –

Belgaon Karnataka

30 Km 5000 46600 Nil

Shree Shiv Shakti sugar ltd yadrav

ankali tal- chikodi dist Belgaum

Karnataka

41 Km 2500 390000 Nil

Dudhganga- Krushna SSKL Nanandi,

tal-Chikkodi dist Belgaum Karnataka

32 Km 60000 836000 Nil

Venkateshwara power project bedkihal

tal-Chikodi dist- Belgaum Karnataka

18 Km 3500 707000 Nil

Ugar Sugar ltd, Ugar khurd Tal- 48 Km 10,000 1156000 30 KLPD



Chikodi dist- Belgaum karnataka OLD

45 KLPD

NEW

It is obvious several tons of bagasse and molasses is available in excess and needs suitable

treatment for profit generation. KSPL decision will help farmers of region as well as sugar

mills who do not have their own distillery and have problem of molasses disposal.

Implementation of proposal will change the situation for better. Sugar cane farmers will be

free to supply sugar cane to sugar factories and can have long term purchase agreements.

Sugar factories need not search market for the molasses generated due to their operations.

Sugar factories will have ready market, price realization not only for molasses but also for

bagasse, both being byproducts of sugar industry will generate additional revenues. The

additional benefits will obviously percolate and provide long term benefits to farmers not

only in Shirol taluka but in Kolhapur district as whole.

This will raise funds to pay good price to farmers. This industry will provide revenue to

State and Central Government. Overall prosperity of region will go up.

It will be a nucleus for forecasted accelerated growth in the region near Harwad village. As

cash money will be available to the farmers’ cooperative supplementary units to farms like

poultry, cattle growing and milk products and other food items, silkworm growing and silk

weaving, Edible seeds crushing to yield oils, handmade paper units can be initiated.

Both direct and indirect employment opportunities will be generated. About 70 persons will

be in direct employment. May others will find self employment as transporters, mechanics,

traders, small time merchants, tax consultants, hotel owners, printing and stationary

suppliers etc.

The project will not need power from MSEB which is already facing problems in meeting

power demands of consumers in Maharashtra. Earlier as process was cane juice based

bagasse was available as by product. Company needed only 750 KW/hr power and were

generating by using steam required for process though a turbo generator first then used in



process. Required steam was produced in a bagasse fired boiler of 14 TPH capacity. Now

factory will need 2200 KW/hr power. The existing boiler will be kept as stand by and a new

incineration boiler will be provided which will not only generate steam for power generation

and plant use but also destroy spent wash generated to implement zero discharge.

Hence present proposal will ensure self sufficiency in electrical power requirement. There

will be no load on state grid for power supply.

There will be remarkable reduction in the waste from the complex. The proposal is unique

as it not only promises total destruction of spent wash but plans to generate energy from it

and save water. Spent wash will be concentrated in multiple effect evaporator combination.

Water will be recovered and reused to reduce fresh water consumption. Spent wash will be

concentrated and then burnt in boiler and generate steam required for power generation and

in process.

Thus in one master stroke KSPL will eliminate problem of disposal of most hazardous

distillery waste ”Spent wash” and its associated problems of soil pollution, ground water

contamination, surface water pollution, malicious odor generation etc and at same time

avoid storing of spent wash,

KSPL plans to produce alcohol and its variety like anhydrous ethanol, rectified spirit

absolute alcohol

These find extensive use in the industry as ethanol is starting raw material for many

pharmaceutical industries, dyes and intermediate industries, paint, bulk drug industries etc.

Government has policy to promote 5% mixing of extra neutral alcohol in petrol.

Implementation of such policy opens up huge market for alcohol. As manufacture of alcohol

is agro based it can be done indigenously saving considerable foreign exchange at same time

providing employment to several unskilled workers.

Present Government wills is considering 10% mixing of ethanol in petrol which will

increase market potential multifold and lead to shortage of ethanol. The new government is

indicating to implement proposal of mixing ethanol in petrol to the extent of 10% and this

will create huge demand for ethanol.



Hence the proposed project will assume important part in national goal of self reliance,

saving in foreign exchange and economic development by renewable resources. At the

national and the state levels the benefits include decentralized power generation, reduction

in waste treatment & disposal loss, reduced emissions, reduction in the imports of petroleum

products, increased tax revenues and reduction in the transportation cost. The project will

have excellent multiplier effect and will become truly a win-win situation for all the

stakeholders and for local people.

With so many advantages and latest techniques of waste reduction, water conservation,

generation of energy by burning of waste, total destruction of spent wash, the project merits

environmental clearance.

CHAPTER 10

CONSULTANT

Mantras Resources was a registered partnership organization established in 2005, it is ISO

9001:2008 certified organization providing complete range of consultancy services for

Engineering & Environmental project services since 2007.

The constitution of the company has changed. Now it is a public limited company and the name

is changed to Mantras Green Resources Ltd. from 9th May 2013

Mantras Green Resources Ltd. is a well-knit family of highly qualified personnel dedicated to

provide excellent service to the industry. Well defined working philosophy, is the backbone of

Mantras’ growth.

10.1 Working philosophy:

Services

Identification of industrial pollution problems in air, water and solid disposal, the

environmental concerns and providing precise solutions, forms the core of our activities.

Quality

Results oriented services intended to suit customer requirement. Getting clear documents

that require no corrections and impose minimum conditions to be on right side of law.

Integrity

Not letting down customer in the hour of crisis, clarifications and repeated explanations

called upon authorities. Provide answers with patience.

Customer satisfaction

Strive consciously to exceed customer expectations.

Self Reliance



Practice self reliance in all the aspects of management skills, technical competence,

application of sophisticated tools in project execution and report presentation, to provide

one stop solution

10.2 Firm's experience:

Since inception, MGRL have successfully completed several diverse projects for different type

of industries and are regarded as a leading environmental management firm. Mantras have served

as consultants to industries, institutions and government for projects executed in India. Mantras

have acquired firsthand experience for the environmental problems of diverse industrial units

such as Distilleries, Sugar industry, Building & Construction projects, Thermal Power Plants,

Pesticide Industry, Synthetic Organic Chemical Industry, Metallurgical industries, Townships

and Area development projects etc, for Government, Private and Co-operative organizations. An

important aspect of Mantras capabilities is the multi-disciplinary expertise and approach.

Mantras employ about fifty qualified technical personnel from various disciplines and offers

services that integrate different dimensions of environmental engineering & technology.

Capabilities and services provided by Mantras Resources include;

Environmental Management

Preparing Environment Impact Assessment (EIA)reports

Obtaining compliance certification to EC, preparing EC compliance and six monthly

compliance.

Selecting, Designing and executing Pollution Control Systems.

Obtaining Consent from State Pollution Control Board

Obtaining compliance to consent conditions

Preparation of Detailed Project Report (DPR)

Groundwater and Surface Water Investigations

Soil Analysis & Testing

Solid waste management (Industry and construction projects)

Operation and maintenance of Effluent Treatment Systems (Industry)

Green Building certification

Social Impact Assessment (SIA)



Rain Water Harvesting

Conducting Energy Audit

Conducting Environmental Audit

Preparing Environmental Statement reports

Obtaining Renewable Energy Certificate

A detailed customer list is attached for ready reference.

Infrastructure:

Over the years MGRL has acquired an operational infrastructure which provides a strong base to

the services rendered by the organization Outline of the infrastructure which is specifically

developed to meet services oriented work is summarized below:

10.4 Technical expertise:

MGRL considers their employees as human resources as they are obviously at the heart of any

successful organization. The organization has result-oriented, experienced people with adequate

qualification. MGRL employs and has associated technical people to suit services provided, apart

from the administration, accounts and other support staff.

10.5 Office:

MGRL have a comfortable, centrally located office in Nashik. The office is equipped with all

modern amenities and gadgets to complete any design, drafting, and publishing work in-house.

In addition the state-of-art communication system facilitates immediate contact, interactions and

data communication either from field to office or with any client around the globe.

10.6 Laboratory:

Laboratory services are outsourced for monitoring ambient air quality, meteorology data, noise,

water quality (surface and ground water) and soil quality.

The EIA coordinator visits the Laboratory for verifying the facilities. The exercise is conducted

once in a year. Evaluation is carried out to assess the capabilities of the laboratory. Also



inspections and audits are conducted at suppliers end to have better control on the processes.

The data collected during the process is analyzed and improvements are carried out on the same.

Records of the evaluation are maintained by EIA coordinator.

The evaluation is supported by the storage facilities for samples available at the laboratory for

carrying out the above-mentioned monitoring including the competence of the employees. Work

contract is prepared with the laboratory for carrying out the above monitoring. During collection

of samples, our FAE accompanies the laboratory Field Operation Team.

After examination, analysis reports containing reports on monitoring ambient air quality,

meteorology data, noise, water quality (surface and ground water) and soil quality are obtained

from the Laboratory.

Control exercised on the laboratories is as below:

MoEF approval is obtained from Laboratory in the form of Certificate and validity of the

certificate.

Calibration record of the equipments/instruments is obtained yearly.

List of laboratory’s staffs with qualification, experience is obtained.

Sample storage facilities and duration of storing the samples.

10.7 Computer Center

MGRL computer center attached with various gadgets cans rapidly process and store data.

Computer is equipped with latest and custom-built software for designing and detailing

equipments, Process flow diagrams. Layout drawings etc. Word processors and printing devices

ensure quality production of any document or report.

Internet facility is provided to all of employees in order to let them upgrade their knowledge and

self search answer to their queries.



10.8 Reference Library

MGRL maintains a library consisting of reference books, journals, papers, articles, publishers,

reports and other such comprehensive study material. Continuous up-gradation of knowledge in

the chosen area of business is a regular activity and every employee is trained and encouraged to

do so.

Latest edition of Handbooks on environmental, chemical, civil, mechanical, electrical

engineering have been made available. Additional reference books on legal, management,

communication and computers are also available here. Copies of environment protection act,

notifications issued by MoEF are carefully preserved and referred.

In addition books on specialized knowledge of functional areas as specified by QCI / NABET for

example Air pollution, water pollution, land use, ecology and biodiversity, solid waste

management etc are provided.

10.9 List of the Experts:

Complete list of experts (ECs and FAEs & AFAEs)

In- house experts

Sr.

No.

Name of the expert Approved Sectors Approved Functional

Areas

1. K. N. Sharma 4,8,21,22,38 AP,WP,RH,SHW

(Industrial and

Hazardous waste )

2. Mrs. Julee Kamble Nil WP

3. Mrs. Chandrani Bhattacharjee Nil SE

4. Ms. Meena Charbhe Nil MSW

5. Ms. Dhanashree Powar Nil WP,AP

6. Ms. Manjusha Patil Nil SHW



Empanelled experts-

Sr. No. Name of the experts Approved Sectors Approved

Functional Areas

1. Dr. S. S. Patil 25 EB

2. Partho Mukherjee Nil AQ,AP,N

3. Dr. A.N. Dongre Nil HG, GEO

4. Mr. S. L. Bonde Nil RH

5. Ms Chandrani Bhattacharjee Nil SE

6. Mr. Manoj Kumar Nil SC

7. G.V.A. Ramakrishna Nil LU

10.10 List of our Valuable Customers till date:-

Sr.

No

Name of the customer Project Status Date

1.

Lokmangal Mauli

Industries Ltd.

Osmanabad

New project of environmental

clearance for sugar mill of 6000 TCD

and cogeneration of 30 MW.

EC granted 25/02/2014

2.

Lokmangal Sugar

Ethanol and cogeneration

Industries Ltd.

Solapur

Expansion project of sugar mill from

2500 TCD to 6000 TCD and

cogeneration unit from 15 MW to 31.5

MW.

Final MoEF

presentation

completed

22.02.2014

3.

Lokmangal Agro

Industries Ltd.

Solapur.

Expansion from 80 KLPD to 160

KLPD molasses based distillery EC awaited 22/09/2014



4.

KGS Sugar and Infra

Corporation Ltd.

Nashik.

New project of environmental

clearance for grain based 50 KLPD

distillery unit with 1.5 cogeneration

unit.

Applied for EC 06.12.2013

5.

M/S S.V. Distilleries (P)

Ltd.

Malchapur, Bidar.

Expansion to 100 KLPD molasses

based distillery unit and 4.5 MW

captive cogeneration power plant

Applied for EC 21.02.2014

6. Jogeshwari Breweries

Pvt. Ltd

Environmental Clearance

New 25 KLPD grain based distillery

unit

Project cleared

by SEAC 06/03/2014

7. Majalgaon Sahakari

sakhar Karkhana Ltd.


New 22 MW cogen with sugar plant

modernization cum expansion 3500

TCD to 5000TCD

EC granted 19/12/2013

8. Zenith realty Construction Project at Satpur, Nasik

Compliance to

SEAC being

done.

25/03/2013

9. Ruchi Soya Industries Environmental Clearance

Coal based 4.42 MW Power Plant

Project cleared

by SEIAA for

EC

26/08/2014

10. Tantia Agrochemicals

Pvt. Ltd.


New 90 KLPD distillery

Public hearing

completed 23-07-2014

11. Kukadi SSK Ltd. Environmental Clearance

New 30 KLPD distillery

Final EC

presentation 29/09/2014

12.

Rajsthan State

Ganganagar Sugar Mills

Ltd. Sri Ganganagar

Government of Rajasthan

Enterprise

Expansion, modernization and

relocation of 1500 TCD sugar mill,

4.9 MW cogen plant and

30 KLPD multifeed distillery

EC received 11/01/2013



13. Bhagylaxmi Rolling

Mills Pvt.Ltd.


Expansion 350 to 750 MTD of steel

plant

ToR approved 24/8/2012

14. Kalika Steel & Alloys

Pvt. Ltd.


Expansion 300 to 800MTD of steel

plant

ToR approved 24/08/2012

15.

Kadwa Goda Khore

Sugar Manufacturing

karkhana Ltd.

Environmental Clearance 4000 TCD

and 14 MW cogen.

Exemption for

EC received

from

SEAC(MAH)

04/04/2012

16. Karan Distillery Pvt. Ltd,

Bhandara


expansion 22 KLPD to 29 KLPD EC granted 14-06-2011

17. Kishanganj Jute Mills

Ltd.


New 60 KLPD Grain Based Distillery.

EC Granted 01-03-2011

18. Tasgaonkar Industries


New 3500 TCD Sugar unit and 06

MW Cogeneration power plants.

Exemption

received

15-02-2011

19. Kukadi SSK Ltd. Environmental Clearance

New 16 MW Power Plant

EC Granted 31-01-2011

20. Aditya Petrochemicals

Pvt. Ltd., Nasik. Consent to Operate

Renewal

obtained 26-10-2010

21. Bhairavnath Sugar works

Ltd.,


New distillery 30 KLPD EC granted 05-10-2010

22. Good deal Industries

LLP. Ltd.


New 60 KLPD Grain Based Distillery.

TOR approved 27-10-2010

23. Chhattisgarh Distilleries

Pvt. Ltd.

Revamping of UASB Bio - Digester

Into CSTR Technology Completed 26.06.2010

24.

Dharni Sugar &

Chemicals Ltd.,

Tamilnadu

Revamping of 750m3 Bio-digester Completed 01-04-2010



25. Adlers Bio-Energy Pvt.

Ltd.



26. Saswad Mali Sugar

Factory Ltd.



27. Sona Sati Organics Pvt.

Ltd.


Installation of Grain based Distillery

Unit (45 KLPD) in the existing

Distillery Unit (Molasses based 45

KLPD)

ToR approved 26-08-2011

Sr.

No

Name of the customer Project Status Date

28. Vitthal Sugar Mfg. Ltd., Environmental Clearance


29. Rena SSK Pvt. Ltd.


New 30 KLPD molasses based

Distillery

EC granted 04-02-2009

30. Excel Krishi Prakriya

Pvt. Ltd.



31.

Padmashree Dr.

Vitthalrao Vikhe Patil

SSK Ltd.


New distillery 30 KLPD TOR approved 02-09-2008

32. Aditya Bio-Energy Pvt.

Ltd.


New distillery 30 KLPD TOR approved 02-09-2008

33. Aurangabad Distilleries

Pvt. Ltd.


Expansion 30 KLPD to 90 KLPD EC granted 19-08-2008

34. Pioneer Industries

Limited 50 KLPD Grain based distillery EC granted 31-01-2005



35. Mahalaxmi Mining Pvt.

Ltd., Kolhapur.


Bauxite Mine In process --

36. Deswal Industries Pvt.

Ltd.


New 6 MW Cogen Project In Process --

37. Sewda Transenergy Pvt.

Ltd.

Project proposal, DPR and EC. For 6

MW Cogen and 25 KLPD Grain

Based Distillery

In Process --

38. Nasik Municipal

Corporation (NMC)

Municipal solid waste conversion to

energy In process --

39. Deogaon farms LLP Consent to establish CTE granted 07-05-2012

40. Deogaon farms LLP Providing effluent treatment plant Completed

FINAL ENVIRONMENT IMPACT ASSESSMENT...

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