For EXPANSION OF EXISTING DISTILLERY (From 60 …20 2.3 Alcohol Processing - Eco Management - Flow...

ENVIRONMENTAL IMPACT ASSESSMENT REPORT

(With Environmental Management Plan)

For

EXPANSION OF EXISTING DISTILLERY (From 60 KLPD to 150 KLPD)

Project Proponent

BANNARI AMMAN SUGARS LIMITED (Unit-II) Alaganchi Village, Nanjangud Taluk

Mysore District, Karnataka State – 571119

Consultants

M/s. ULTRA-TECH Environmental Consultancy & Laboratory Unit No. 206, 224-225, Jai Commercial Complex,

Eastern Express Highway, Opp.Cadbury Factory, Khopat,

Thane (West)-400 601

Accreditation of Consultant: (NABET Accreditation):

Sl.No. 93 of List A of MoEF –O.M. No.J-11013/77/2004/IA II(I) Dated 30th September,2011

Sl.No. 156 of List of Consultants with Provisional Accreditation/Rev.22A/dated 10th Sep, 2014

HON’BLE CHIEF MINISTER OF KARNATAKA, SRI.D.V.SADANANDHA GOWDA

PRESENTS

ENVIRONMENT EXCELLENCE AWARD – 2011

under the category of "Sugar with Distillery" to M/s Bannari Amman Sugars Ltd, Nanjangud, Mysore

on the occasion of

"Karnataka State Pollution Control Board – Foundation Day "

held on 21st September 2011, Bangalore. TO

DR.S.V.BALASUBRAMANIAM, CHAIRMAN, BANNARI AMMAN GROUP OF COMPANIES

i

CONTENTS

Chapter No.

Particulars Pg. no.

1.0 Introduction 1-13

1.1 Background of Project 1

1.2 Background of the Project Proponent 1

1.3 Purpose of Environmental Impact Assessment 2

1.4 Status of Proposed Project 3

1.5 Brief Description of Nature, Size & Location of Project 4

1.6 Need of project & its importance to country & region 7

1.7 Objective and scope of EIA studies 8

1.8 Methodology of EIA studies 9

1.9 Terms of References (TOR) from MoEF and their compliances 13

2.0 Project Description 14-51

2.1 Type of project 14

2.2 Need for the project 15

2.3 Highlights of the proposed distillery technology 16

2.4 Site location 17

2.5 Size and magnitude of operation 22

2.6 Project investment 25

2.7 Schedule for approval & implementation of project 26

2.8 Process Technology 26

2.9 Raw material and products 29

2.10 Sources of molasses and its transportation 31

2.11 Power and steam requirement 31

2.12 Source and requirement of fuel and their transportation 33

2.13 Source and utilization of water

33

2.14 Sources of pollution 37

2.15 Waste water management 37

2.16 G Gaseous emissions and air pollution control measures

48

2.17 Noise source and control measures 50

2.18 Source and management of solid waste 51

3.0 Description of Environment 52-94

3.1 Study area, period, Components & methodology 52

3.2 Establishment of Baseline data 55

ii

3.3 Base Maps of all Environmental components 90

4.0 Anticipated Environmental Impacts & Mitigation Measures 95-138

4.1 Introduction 95

4.2 Identification & characterization of impacts 96

4.3 Impact during construction phase 102

4.4 Operational phase impact 104

4.5 Mitigation measures against environmental impacts 123

5.0 Analysis of Alternatives 139-145

5.1 Sitting of project 139

5.2 Technology process 141

5.3 Benefit of Proposed expansion 145

6.0 Environment Monitoring Program 146-152

6.1 Introduction 146

6.2 Monitoring plan 147

6.3 Sampling schedule and locations 148

6.4 Laboratory facilities 149

6.5 Compliances to environmental statutes 150

6.6 Monitoring of compliances to statutory conditions 151

6.7 Environmental Management Committee 151

6.8 Success indicators 151

7.0 Additional Studies

159-177

7.1 Public hearing and consultation 153

7.2 Risk assessment 153

7.3 Disaster management plan (DMP) 172

7.4 Social impact assessment, R & R action plan 176

8.0 Project Benefits 178-179

8.1 Improvements In Physical Infrastructure

178

8.2 Improvements In The Social Infrastructure 178

8.3 Employment Potential – Skilled, Semi-Skilled And Unskilled

179

8.4 Other Tangible Benefits 179

9.0 Environmental Cost Benefit Analysis 180

10.0 Environmental Management Plan 181-203

10.1 Introduction 181

10.2 Need

181

10.3 Objectives 182

10.4 Environment Components

182

10.5 Environment management Hierarchy

186

iii

10.6 Checklist Of Statutory Obligations 186

10.7 Records Of Waste Generation To Be Maintained As Per Following:

190

10.8 Environmental Organization 191

10.9 Environmental Monitoring Schedule 197

10.10 Schedules 198

10.11 Socio-welfare activity 200

11.0 Summary and Conclusions 204-213

12.0 Disclosure of consultants 214-216

12.1 The Names Of The Consultants Engaged With Their Brief Resume & Nature Of Consultancy Rendered

214

ANNEXURES

ANNEXURE NO.

PARTICULARS

1 Executive Summary

2 Terms Of Reference

3 Terms Of Reference & Compliances

4 (4) – Copy of Environmental Clearance ; (4A) - Copy of Consent order for operations (4B) – Compliances for the Consent for Operations; (4C) – Compliances for the Environmental Clearance

5 Permission letter for drawal of water from Kabini River

6 Plant lay out

7 Monitored data

8 Bag filter specifications

iv

FIGURES

Figure No.

Particulars Pg. no.

1.1 Location of Project Site in District map of Mysore 06

2.1 Location of Project Site in District map of Mysore 19

2.2 The Google Map Showing the Project Boundary and Site Location

20

2.3 Alcohol Processing - Eco Management - Flow Chart For Proposed

Expansion (Zero Discharge System) 28

2.4 Material balance 30

2.5A Water balance for Increased Capacity of 150 KLPD, in m3/d 36

2.6 Process flow diagram for the operation of spent wash evaporation cum boiler

47

3.1 Topo Map of Project Site 53

3.1A Topo map showing 10 km radius around the project site 54

3.2 Wind rose diagram 59-62

3.3 Wind Rose Diagram 68

3.4 Topo Map Showing Sampling Locations 82

3.5 Google map showing connectivity 91

3.6 Google map showing land-use pattern 92

3.7 Google Map Covering 5 Km Aerial Distance From the Project Site 93

3.8 Google Map Covering 10 Km Aerial Distance From the Project Site 94

4.1 Suspended Particulate Matter (PM10) isopleths for proposed

project 111

4.2 Sulphur di-oxide (SO2) isopleths for proposed project 112

4.3 Oxides of nitrogen (NOx) isopleths for proposed project 113

4.4 Carbon monoxide (CO) isopleths for proposed project 114

10.1 Structures of Environment Management Plan 185

10.2 Environment hierarchy 186

v

TABLES

Table No.

Particulars Pg. no.

1.1 Salient Features of the Industry 04

1.2 Environmental attributes and frequency of monitoring 12

2.1 Location features of the site 18

2.2 Schedule for Approval & Implementation of Project 26

2.3 Raw materials & other products used in proposed distillery 29

2.4 Sources of Molasses 31

2.5 Generation & utilization of steam & power 32

2.6 Utilization of water for Distillery 35

2.7 Characteristics of spent wash 38

2.8 Characteristics of effluents 39

2.9 Treatment & disposal of Effluent 41

2.10 Operating parameters for spent wash evaporator 43

2.11 Salient features of the Proposed boiler 44

2.12 Performance of the boilers at 150 KLPD Production 45

2.13 Characteristics of fuels 49

2.14 Sources of the flue gases & APC measures 49

2.15 Source & disposal of solid waste 51

3.1 Meteorological data of Mysore for the year 2013 56

3.2 Techniques adopted/Protocols for ambient air quality monitoring 63

3.3 Protocol for Surface Water Quality Monitoring

64

3.4 Protocol for ground water quality monitoring 65

3.5 Ambient Air Sampling Stations 67

3.6 Air Quality Data at the Project Site 69

3.7 Air quality data at Kirugunda village (downwind direction) 70

3.8 Air quality data at other locations 71

3.9 Ambient air quality standards – MoEF as per the notification dated 16th November 2009 for industrial, residential & rural areas

72

3.10 The monitored values observed at the project site & Kirugunda (downwind direction)

73

3.11 Noise Level Monitoring Stations 74

vi

3.12 Summary of Noise Level 75

3.13 Limits as per Environmental Protection Rules 75

3.14 Water sampling stations 76

3.15 Surface Water Quality (Kabini River Water Quantity 1Lts).

78

3.16 Ground Water Quality 79

3.17 Soil Sampling Stations 81

3.18 Physico-Chemical Characteristics of Soil 81

3.19 Location of sampling stations 83

3.20 Flora and Fauna Study 84

3.21 Distribution of Population

86

3.22 Distribution of Literates And Literacy Levels In The Study Area 87

3.23 List of Infrastructural Facilities in the Surroundings 88

3.24 Connectivity from the Project Site 89

3.25 Industries Surrounding the Project Site 89

3.26 Existing Land-Use Pattern 90

4.1 Impact Identification Matrix 99

4.2A Characteristics of Environmental Impacts from Construction Phase 100

4.2B Characteristics of Environmental Impacts from Operational Phase 101

4.3 Sources of air pollution & pollutants 104

4.4 Data on Boiler Flue Gases 105

4.5 Sources of Fugitive dust 106

4.6 Data considered for calculation of GLC 108

4.7 Predicted incremental short-term concentrations due to the proposed project

110

4.8 Resultant maximum 24 hourly concentrations 115

4.8.A Ambient air sampling stations 116

4.9 Treatment and Utilization of Waste Water 118

6.1 Post Project Monitoring Schedule 148

7.1 Organization Chart 173

10.1 Cost estimates of EMP in distillery project 195

10.2 Budget for Environmental Management Plan

196

vii

10.3 Monitoring Schedule 197

10.4 Consent Compliance 199

10.5 Proposed Socio Welfare Activity. 203

12.1 List of Functional Area Experts

215

12.2 Laboratory Details 216

Chapter-1

INTRODUCTION

1

Chapter-1

INTRODUCTION

1.1 BACKGROUND OF THE PROJECT

M/s. Bannari Amman Sugars Ltd., have established and operating

a 60 Kilo Litres Per Day (KLPD) Distillery located at Alaganchi Village, Nanjangud

Taluk, Mysore District, Karnataka State from the year 2005. The distillery is operating in

the existing Sugar Complex having 7500 TCD Sugar Mill and 36 MW Cogen units.

Considering the demand for the Alcohol in the country and availability of raw materials in

the region, the unit has proposed to expand the capacity of the existing Distillery from

60 KLPD (RS/ENA) to 150 KLPD Alcohol [RS/ENA/Ethanol (AA)].

1.2 B AC K G R O U N D O F P R O P O N E N T S

Bannari Amman Group is one of the largest Industrial Conglomerates in South India

with wide spectrum of manufacturing, trading, distribution and financing activities.

Manufacturing and trading includes Sugar, Alcohol, Generation & Distribution of Power,

Granite etc. The service sector has Education, Health care etc., Group’s net-worth

exceeds Rs.1, 200 Crores with turnover of Rs.2, 500 Crores.

Bannari Amman Sugars Limited (BASL) is the flag ship company of the group engaged in

the manufacture of Sugar, Alcohol, Bio-compost, Granite products and Generation &

Distribution of Power. BASL has five operating sugar units, three situated in Tamil Nadu

State and two situated in Karnataka State.

BASL is rated as the most efficient sugar manufacturer in India and is the first company in

South India to obtain ISO-9001 accreditation. In its core business of sugar, the

company is very well positioned in the market and is confident of further

strengthening its competitive position. The company’s future plans are primarily

catered upon with further expansion of its sugar manufacturing & cogeneration

power operations.

2

The company is managed by the Chairman Dr. S.V. Balasubramaniam B.Com.,

A.C.A, A.C.S under the guidance of competent Board of Directors. The

management with three decades of its expertise in the field of Sugar and Alcohol

Industry is well organized to run the industry in a scientific and efficient manner. The

distillery plant is looked after by qualified and experienced technical Executives.

1.3 PURPOSE OF THE ENVIRONMENTAL IMPACT ASSESSMENT (EIA)

Every developmental activity invariably has some impact and more often adverse

consequence to the environment. Mankind as it is developed today cannot live without

taking up these developmental activities for its food, security or other needs.

Consequently, there is a need for harmonious developmental activities with

environmental concern. EIA is one of the tools available with the planners to achieve the

above goal. It is desirable to ensure that the developmental options under consideration

are sustainable. Hence, the environmental consequence must be characterized early in

the project cycle and accounted for in the project design. The objective of EIA is to

foresee the potential environmental problems that would arise out of the proposed

development and address them in the project planning and design stage. This can often

prevent future liabilities and expensive consequences of the project activity. .The EIA

process should allow for communication of the information to:

1. Project proponent

2. The regulatory agencies

3. All stake holders and interest groups

EIA study is in particular essential for the industries causing significant environmental

impacts. Ministry of Environment and Forests (MoEF), Government of India has issued

EIA Notification dated 14-09-2006 in which guidelines are given for conduct of EIA study

and also the list of industries attracting the said notification.

The proposed industry is listed under EIA Notification dated 14-09-2006 and as

amended in December 2009 of Ministry of Environment and Forests (MoEF),

Government of India. As per this notification the industry is categorized under Schedule

3

5(g), Category-A for molasses based distillery. As per the notification, prior

Environmental Clearance (EC) from MoEF is mandatory before establishment of this

industry. Hence, the industry has to follow due course of procedure to secure EC by

application to MoEF for terms of references for conduct of EIA studies, public

hearing/consultations and deliberation of project at Expert Appraisal Committee of

MoEF. Accordingly, the project proponents have submitted prescribed application along

with Pre-feasibility report to the MoEF New Delhi seeking Terms of references (TOR) to

conduct of EIA studies. MoEF New Delhi has deliberated the project during the 7th

Reconstituted EAC (Industry) meeting held on 4-5th April, 2013, and specified the Terms

of Reference(TOR) for conduct of EIA studies and preparation of EIA/EMP report.TOR

communicated to the project proponent vide MoEF letter F.No.J-11011/71/2013-IA II (I)

Dated 7th June 2013. Accordingly, EIA studies were conducted and the report is

prepared for submission to authorities with other documents of the industry to approach

KSPCB to conduct public consultations.

Final EIA/EMP report is to be prepared based on Draft EIA/EMP report accommodating

the compliances to the observations made during public hearing/consultations. The

report will then be submitted to MoEF New Delhi for final Environmental Clearance.

1.4 STATUS OF PROPOSED PROJECT

Status of the existing project and permissions available for the proposed project is given below.

1 EC from MoEF

Letter No. J-11011/4/2004-IA II (I) dated 13.05.2004, & J- 11011/4/2004-IA II(I) dated 13th Nov 2007. (Annexure–4) – for 60 KLPD(RS/ENA) Distillery

2

CFO for existing distillery from KSPCB for 2014-15.

Letter KSPCB/RO (Mys-Rural) /LR/Consent/ 2014-15/198 dated 05.06.2014 (Annexure-4 A)

3 TOR for proposed expansion project

TOR received (Annexure- 2)

4 Water drawl permission from State Government

Water drawal permission already obtained. (Annexure – 5)

4

1.5 BRIEF DESCRIPTION OF NATURE, SIZE & LOCATION OF PROJECT

Proposed project is the Expansion of Existing Distillery of 60 KLPD (RS/ENA) to

150 KLPD RS/ENA/Ethanol (AA). Distillery unit is located in the Existing Sugar

industrial complex consisting of 7500 TCD sugar unit and 36 MW Cogen Unit. The

molasses, by- product of sugar unit is utilized as raw material in the Distillery.

Distillery is basically a Bio-chemical industry where in molasses is converted by bio-

process in fermenters into alcohol. The aqueous alcohol mixture from fermenter is

distilled in series of multi pressure distillation columns to produce pure alcohol of

desired quality. Salient features of the project are given in Table-1.1. The location of the

proposed project is given in Figure-1.1

Table-1.1 - Salient Features of the Industry

Sl

No Feature Particulars

1 Name and Address of the

Company

M/s Bannari Amman Sugars Limited

(Registered Office)

No.1212, Trichy Road

Coimbatore - 641 018, Tamil Nadu

BANGALORE OFFICE:

Flat No.202, II Block, “Royal Residency”

No.8, Brunton Road

Bangalore – 560 025, Karnataka.

2 Project Site

Bannari Amman Sugars Limited ( Unit-II)

Alaganchi Village, Nanjangud Taluk,

Mysore District, Karnataka State

3 Proposed Project

Expansion of the existing Distillery from

60 KLPD to 150 KLPD alcohol of

RS/ENA/Ethanol (AA).

5

Project Parameters Existing Capacity After proposed

expansion - Capacity 4

Products: A lcohol of RS/ENA/

Ethanol(AA)

60 KLPD

(RS/ENA grades)

150 KLPD

(RS/ENA/AA grades). 5 Working days per year 300 330

6 Raw Material (Molasses) , T/d 240 594

7 Man power in the industry 60 90

Land area (Hectare.)

Total area 20.66

.

20.66

. Built up area 6.16 6.50

Green Belt area 6.02 6.82

8

Vacant area for future use 8.48 7.34

9 Boiler & Capacity, TPH 23.4 TPH 2 x 23.4TPH

10

Boiler Fuel, T/d

a. Conc. S.W. 60% Solids

b. Coal

c. Bagasse (alternative to Coal)

148

45

-

361

124

236

11 Steam Turbine capacity, 2.0 MW

2 x 2.0 MW

12 Power Requirement 1300 KW 3200 KW

13 Fresh Water requirement,

m3/day

599 1350

14 Fresh Water source (*) River Kabini River Kabini

15

Total investment on project

-- Rs. 85.00 Crore

16 Investment on EMP -- Rs. 45.00 Crore

17 Spent wash Management

Concentration of spent wash in multiple effect

Evaporators a n d concentrated spent wash is

burnt as fuel in a specially designed boiler

along with support subsidiary fuels.

18 APC facility to boiler Bag Filter Bag Filter

6

Figure- 1.1 Location Of Project Site In the District Map of Mysore M/s Bannari Amman Sugars Ltd Nanjangud.

Bannari Amman Sugars.

7

1.6 NEED OF PROJECT & ITS IMPORTANCE TO COUNTRY & REGION

Alcohol has assumed a very important place in the economy of the country. It

is used as a raw material for number of chemicals, as a potential fuel in the form of

Ethanol blended with petrol and as an ingredient in Alcoholic Beverages. Use of

alcohol as a main ingredient in beverages is well known. Further, it is a major

source of revenue by way of excise duty to the State Governments. The

importance and utility of alcohol as an industrial raw material for manufacture of

variety of chemicals is now being increasingly appreciated all over the world. This is

partly due to the escalating costs of these chemicals produced through petrochemical

route and abnormal increase in crude oil prices. Crude oil which was sold at 3 dollars

per barrel in 1969 is more than 100 dollars. The price is predicted to increase further

depending upon international situation and with depletion/exhaustion of petroleum

resources of the world. The location of the distillery slated for expansion is at

rural, agro-based and economically backward region. The proposed expansion

programme wi l l fetch better realization to the molasses and in turn to sugar cane

grown in the region.

Alcohol is an eco-friendly product . As a substitute to petroleum, the distillery

helps to reduce the dependency on petroleum and has potential to save foreign

exchange. Petroleum is a scarce, non-renewable and fastly depleting product. Under

the National Ethanol Programme, there is a mandate to blend 5 % ethanol, in petrol

in nine sugar producing states. This programme was started on 1st October 2003.

This amounts to a demand of 360 million litres of ethanol per year. In addition, the

Government of India has directed for introduction of gasoline and diesel confirming to

Euro-3 fuel standards in India. The Euro-3 standard specifies the presence of an

oxidant in the fuel, which minimizes the emissions due to the combustions o f these

fuels. Alcohol being one of the most viable additives available, the oil companies

has to use alcohol for blending with petrol. With this, the demand for ethanol would

be more than doubled.

8

The Indian sugar industry is passing through a difficult period. The sugar price in the

Indian market is low, and even the world market price is low. On the other hand, the

cost of the raw material, the sugar cane, keeps increasing every year and so is the

production cost. With high inventories and the prices low and with the raw material and

production costs increasing every year, survival has become a major problem for the

Indian sugar industry. The sugar industry can hope to come out of this situation by best

utilization of the existing resources. Hence, it is proposed to expand the capacity of the

existing distillery.

1.7 OBJECTIVE AND SCOPE OF EIA STUDIES

The overall objective of any EIA studies is to identify and assess the adverse and

beneficial impacts of the project in the planning stage itself, so that necessary mitigation

measures to prevent or minimize these adverse impacts could be planned early and

cost effectively. In view of this objective, the scope of EIA study broadly includes:

I. Introduction along with scope and methodologies for EIA study (Chapter-1).

II. Preliminary details of project including type, need and location of project and also

the magnitude of project activities (Chapter-2).

III. Project description of project including process, resource required and products

formed along with sources of pollution and built in mitigation measures with

respect to waste water, gaseous emissions and Solid wastes (Chapter-2).

IV. Existing baseline status of the relevant environmental parameters in the specified

study area through primary and secondary source. The environmental

parameters include meteorology, air, water, land, soil, noise, ecology and socio

economics (Chapter-3).

V. Anticipated environmental impacts of the proposed project on environment and

measures for mitigation of the predicted adverse impacts (Chapter-4).

VI. Sitting of project and selection of Process and Technology .( Chapter- 5)

VII. Technical aspects of monitoring the effectiveness of mitigation measures. It

includes laboratory and other facilities monitoring facilities, environmental

parameters to be monitored, data to be analyzed and sampling location and

9

schedule. It also includes budgetary provision and procurement schedule for the

monitoring facilities (Chapter-6).

VIII. Additional studies relevant to the project such as public consultation, risk

assessment and social impact assessment with R.R. action plan (Chapter-7).

IX. Project benefits in terms of improvement in social and physical infrastructures in

the region of the proposed project (Chapter-8).

X. Environmental benefit analysis of the project (Chapter-9).

XI. Administrative aspects of environmental management plan to ensure that the

mitigation measures implemented and their effectiveness monitored

(Chapter-10).

XII. Summary and conclusion consisting of overall justification of project. It also

includes the summary of significant adverse effects along with the measures to

overcome the same (Chapter-11).

XIII. Preparation of EIA document as per MoEF guidelines. It includes all the above

information of items from I to XII.

1.8 METHODOLOGY OF STUDIES

1.8.1 EXISTING ENVIRONMENTAL STATUS

The environmental influence due to the project is likely to cover a radial distance of

about 10 km around the factory premises. Therefore, the study area for monitoring of

environmental parameters covers 10 km distance from the project site.

The environmental parameters, which are likely to be affected by the activities of the

project, were identified. They include air, noise, water, soil, land use, ecology,

socio- economic etc. The existing status of these environmental parameters for study

area is collected from both primary and secondary sources. Primary source data were

collected through environmental monitoring survey of representative locations of the

study area during the post monsoon period from December 21st 2013 to March 21st

2014. The reconnaissance survey was conducted and the sampling locations were

identified based on:

10

I. Existing topography and location of surface water bodies like ponds and streams.

II. Meteorological conditions (predominant wind directions).

III. Location of towns, villages and other sensitive areas present in the vicinity of the

proposed project site.

IV. Representative areas for baseline conditions

V. Accessibility, power availability and security to the monitoring equipment.

Secondary data were collected from various organizations to substantiate the primary

data. The data thus collected was compared with the standards prescribed for the

respective environmental parameters. The environmental parameters monitored and the

frequency of monitoring is given in Table-1.2. The methodologies adopted for studying

individual components of environment are briefly described below.

1. MICRO METEOROLOGY

A temporary automatic weather monitoring station was installed to record

meteorological parameters at plant site. The parameters like Wind speed, Wind

direction, maximum and minimum temperatures, relative humidity and cloud cover were

recorded on hourly basis continuously during the study period. Wind speed and wind

direction data recorded were used for computation of relative percentage frequencies at

different wind directions. The meteorological data thus collected has been used for

interpretation of the existing Ambient Air Quality status, and the same data has been

used for prediction of impacts on future scenario due to the activities of the project.

2. AMBIENT AIR QUALITY

The status of the existing ambient air quality in the study region has been assessed

through a network of 6 air monitoring locations with one AAQMS in down wind direction

during the study period within a radial distance of 10 km distance from the project site.

The monitoring network was so designed that a representative baseline scenario is

obtained in upwind, downwind and crosswind directions. These monitoring sites have

been established keeping in view the available data on predominant wind direction and

wind speed of this particular region. The existing ambient air quality status (AAQ) has

11

been monitored for PM10, PM2.5, SO2 and NOx at each station on 24 hourly basis. The

monitoring was done as per the approved methods of Central Pollution Control Board

(CPCB). Maximum, minimum and average values have been computed from the data

collected at all individual sampling stations to represent the Ambient Air quality status.

3. NOISE ENVIRONMENT

Noise monitoring has been carried out at 6 different locations to identify the impact of

project activities on the surroundings in the study area. Noise levels were recorded at

an interval of one hour for 24 hours during the day and night times to compute the day

equivalent, night equivalent and day-night equivalent level.

4. WATER ENVIRONMENT

The existing sources of surface and ground water in and around the plant site were

monitored for assessment of their quality. Surface water sample collected from the

nearby river (60 m upstream and 60 m downstream). Ground water samples were

collected from 4 locations. The quality parameters of the water samples thus collected

were compared with BIS standards. The activities around the source during sampling

were taken into consideration in interpretation of the water quality of the particular

source.

5. LAND ENVIRONMENT

Field surveys were conducted to delineate classification of land use pattern, cropping

pattern, vegetation cover in the study area. Representative soil samples were collected

from 3 different sampling locations within an area of 10 km radius around the plant site.

They were analyzed to assess their Physico-chemical characteristics. Standard

procedures were followed for sampling and analysis. The samples collected were

assessed for their suitability for the growth of plant species and crops.

12

6. SOCIO-ECONOMIC ENVIRONMENT

Socioeconomic data including demographic pattern, population density, education and

medical facilities, livelihood, economic and health status, transport facility were collected

for the study area from primary and secondary sources for the study area and analyzed.

Table1.2 Environmental Attributes and Frequency of Monitoring

Sl. No

Attribute Parameters Frequency of Monitoring

1 Micro meteorology

Wind speed (hourly) & direction, temperature, relative humidity and rainfall

At project site continuous for 3 months hourly recording.

2 Ambient air quality

As per NAAQS at 6 locations 24 hours continuous monitoring

3 Gaseous emissions

Stack Monitoring Once in a month

4 Surface (river) water quality

Physical, chemical & bacteriological parameters.

Grab samples have been collected once during the study period.

5 Ground water quality

Physical, chemical & bacteriological parameters for 4 locations.

Grab samples have been collected once during the study period

6 Ecology Terrestrial and aquatic flora and fauna in the region.

Secondary data.

7 Noise levels Noise levels in dB (A) at 6 locations Recording at hourly interval for 24 hrs, once a month per location during study period.

8 Soil characteristics

Parameters related to agriculture potential at 3 locations.

Once during the study period.

9 Land use Trend of land use change for different categories.

Based on data published in district census handbook.

10 Socio– economic aspects

Socio-economic characteristics. Based on the data collected from the secondary source.

11 Geology Geological history Based on the data collected from the secondary source.

12 Hydrology Drainage area and pattern nature of streams. Aquifer characteristics recharge and discharge areas.

Based on the data collected from the secondary source.

13 Risk assessment

To identify areas where disaster can occur due to fire & explosives & release of toxic substance.

Identification of possible risks at the proposed project, quantification of risk through modeling.

13

1.8.2 IDENTIFICATION OF IMPACTS AND MITIGATION MEASURES

The likely impacts of various activities of the proposed project on the environment were

identified. These impacts were assessed for their significance based on the background

environmental quality in the area and the magnitude of the impact. All components of

the environment were considered and wherever possible impacts were evaluated in

quantitative / qualitative terms. Estimated impacts have been superimposed over the

baseline (pre-project) status of environmental quality. The resultant (post-project) quality

of environmental parameters is reviewed with respect to the permissible limits. Thereby,

the preventive and mitigation measures were formulated and incorporated in the

environmental plan.

1.9 TERMS OF REFERENCES (TOR) FROM MOEF AND THEIR COMPLIANCES

Terms of References (TOR) for conduct of EIA studies were specified to this industry by

7th Reconstituted Environmental Appraisal Committee (Industry), MOEF New Delhi vide

their letter No. F.No. J-11011/71/2013-IA II (I) dated 07.06.2013 (Annexure-2). The EIA

studies were conducted based on these TOR from December 21st -2013 to March 21st

2014 and accordingly the EIA report is prepared. The list of TOR and their compliances

is given in Annexure-3.

CHAPTER-2

PROJECT DESCRIPTION

14

Chapter-2

PROJECT DESCRIPTION

2.1 TYPE OF PROJECT

M/s Bannari Amman Sugars Ltd have already established and operating Sugar industry

complex with 7500 TCD Sugar Mill, 36 MW co-gen power plant and 60 KLPD Distillery.

The Existing 60 KLPD distillery unit located in the sugar complex at Alaganchi

Village, Nanjangud Taluk, Mysore District, Karnataka State was commissioned in the

year 2005 is operating now with latest Zero Discharge Environmental Management

system of Concentration and Incineration. To make use of the available resources, the

industry has now proposed to expand the capacity of the existing Distillery from the 60

KLPD Alcohol (RS/ENA) to 150 KLPD Alcohol [RS/ENA/Ethanol (AA)].

2.1.1 PRESENT PROPOSAL

1. To enhance the capacity of the distillery from 60 KLPD to 150 KLPD,

addition of equipments in Production and Environmental facility will be made.

2. In the Environmental Management Section, Multiple effect evaporators for

concentration of spent wash from about 18% to 60% solids and a specially

designed multi fuel Boiler to burn the concentrated spent wash as a fuel is now

in operation to handle 60 KLPD Alcohol production. The 2.0 MW steam turbo

generator is now in operation to take care of the power requirement.

3. Already the company is operating one boiler of 23.4T/h, multi fuel. In view of

expansion to 150 KLPD, one additional 23.4 T/h multi fuel Boiler capable to

handle fuels like concentrated spent wash as main fuel along with bagasse/

biomass & coal (Indian/Imported) will be installed.

4. One additional 2 MW turbo generator will be installed, to take care of the

expansion to 150 KL Alcohol/day.

15

2.2 NEED FOR THE PROJECT

The integrated sugar industry with sugar and alcohol as main products along with

exportable power and bio-manure as co-products has proved to be an economical

proposal. The Government of Karnataka envisaged the policy to encourage integrated

Sugar industries consisting of Sugar, co-generation of power and molasses based

Distillery in the state.

Bagasse, press mud and molasses are the by- products of the sugar industry. Once

thought as an unwanted waste product, these by-products are now advantageously

utilized as a valuable resource for profitable applications.

The importance and utility of Ethanol is well known as an industrial raw material for

manufacture of a variety of organic chemicals including pharmaceuticals, cosmetics,

potable Alcohol, fuel Ethanol etc. Further, it is a potential fuel in the form of power

ethanol when blended with petrol. Alcohol is substitute to the imported petroleum.

Petroleum is a scarce, non-renewable.

On the contrary, the ethanol being produced from renewable source and is an

environmental friendly product. Large demand is also anticipated for its use as fuel.

The Euro-3 standard specifies the presence of an oxidant in the fuel, which minimizes

the emissions due to the combustions of these fuels. Ethanol being one of the most

viable additives available, the oil companies has to use ethanol for blending with petrol.

Alcohol is being used as an ingredient in alcoholic Beverages. It is a potential source of

revenue by way of Excise Duty levied by State Government. The Distillery helps to

reduce the dependency on petroleum and has potential to save foreign exchange Press

mud contains organic and inorganic plant nutrients and therefore it is used for

composting it as a bio-manure for agriculture use.

The sugar industry along with Power and Distillery will thus meet the national interest of

economical power and food. Further it helps to uplift the rural mass. The proposed

project will create additional indirect employment opportunities for more than 500

16

personnel in terms of factory employment, transportation, vehicle maintenance, petty

shops etc.

2.3 HIGHLIGHTS OF THE PROPOSED DISTILLERY TECHNOLOGY

1. The unit adopts latest technologies in fermentation and distillation system

(Multi pressure distillation).

2. Re-boilers incorporated in the existing distillation system have resulted in reduction

of effluent generation to 8 litre/ litre of alcohol.

3. Spent wash is concentrated from 18 % to 60 % in multi effect evaporators.

4. Evaporators are self cleaning type (Praj – Flubex). Frequent cleaning not required.

5. The condensate water generated from integrated evaporators is utilized in the

plant process section, after Biological treatment and final polishing it in RO filtration

system.

6. Currently the Concentrated spent wash is burnt as fuel along with the coal as

support fuel in a Boiler (23.4T/h) specifically designed to handle spent wash

material.

7. The sludge generated from fermentation section and spent wash storage

section are utilized in Bio-composting process along with sugar factory press mud

to produce valuable Bio-compost manure. The modern composting facility with

concrete yard established during the commissioning of the existing 60 KLPD

distillery in the year 2005, handles the composting.

8. Spent wash fired Boiler ash contains plant nutrients such as potash, phosphate

etc., It is being utilized as an enrichment in composting and also given to farmers

as manure.

9. Spent wash management scheme implemented here results into “Zero Discharge

of Spent Wash”. Entire spent wash is used as a fuel in the Boiler.

10. The expansion of 60 KLPD Distillery to 150 KLPD will adopt the latest

methodologies in process & Environmental Management to meet the

Environmental Norms.

11. In this regard additional Evaporation cum Boiler (spent wash burning) will be

installed.

17

2.4 SITE LOCATION

2.4.1 LOCATION FEATURE

M/s Bannari Amman Sugars Limited (Unit- II) Distillery i s located at Alaganchi

Village, Nanjangud Taluk, Mysore District, Karnataka State. The site is situated on

longitude 760 45’29” E, latitude 120 06’ 14”N at an altitude of 692 metre. The nearest

Railway Station is Nanjangud at 11 KM on South Central Railway. The nearest Airport

is at Mysore, 27 KM from the site. Location feature of the site is given in Figure 2.1.

The surrounding area of the project site is rural and agrarian. Annual rainfall is in the

range of 580 mm to 840 mm. The perennial river, Kabini is flowing from west to east

is located at about 6 km north from the site. The small streams present in the region

carry water during rainy period and dries up during summer. There are small hillocks of

50 – 100 m height at a distance of 5 – 10 Km located on south side of the site. The

lands in the region are rain fed and irrigated through bore well and Kabini dam

channels. The crops are mainly sugarcane, paddy, and maize. Few sectors of

horticultural land with banana, coconut, mango and other plantations are found within

the region.

The maximum temperature is in the range of 28 0C to 36 0C and the maximum is in the

month of May. The minimum temperature ranges from 15 0C to 22 0C and the minimum

is in the month of December and January.

The wind speed is low to moderate and predominantly in the range of 5 to 7 km/hr. In

general the wind direction is towards North-East during the months of October to

December and towards South – West during the months of May to September.

18

Table-2.1 Location Features of the Site

Sl.

No. Feature Particulars

1. Location

M/s Bannari Amman Sugars Ltd. Alaganchi Village, Nanjangud Taluk, Mysore District, Karnataka

2. Latitude / Longitude

Altitude

Latitude: 120 06' 14"N;

Longitude: 760 45'29"E;

Altitude : 692 m above MSL

3 Present use of land Rain fed dry agriculture land

4 Monthly temp. in 0C Max.: 36 min.:15

5 Average Relative humidity The monthly mean of maximum and minimum

Relative Humidity are 64 and 78 respectively

6 Annual rain fall in mm

Annual rain fall is in the range of 580 mm to

840 mm with an average of average rainfall of

650 mm.

7 Predominant wind directions

Wind direction is towards south west during

months of May to September and towards North

east during the months of October to December.

This region is characterized by moderate wind

velocities and especially high during monsoon.

The wind speed varies from 5-7 km/hr.

8 Soil type

The major soil types in the region are red

sandy, clay and shallow black. The red soils

are characterized by neutral pH, low salinity

and low water retention capacity.

10 Nearest highway NH-212, Mysore- Ooty Road is at 12 km

from site

11 Nearest railway station Nanjangud Railway Station, 11km

12 Nearest airport Mysore airport, 27 km

13 Nearest village Alaganchi Village, 2.0 Km

14 Nearest City Mysore at 36 km

15 Nearest industry Gemini Distilleries, Nestle India, Zenith Textiles

16 Nearest water body Kabini river,6 km from the site (North Side)

17

Hill, protected forests, monuments, religious, national park, zoo or other sensitive locations.

None with in 10 km from the site

19

Figure-2.1 Location of Project Site on the District Map of Mysore For M/s Bannari Amman Sugars Ltd , Alaganchi

Location of Project Site

20

Figure ‐2.2 Google Map Showing the Project Boundary and Site Location

For M/s Bannari Amman Sugars Ltd, Alaganchi

Site location

21

2.4.2 BASIS FOR SELECTION OF SITE

The proposed project is for expansion of the distillery from 60KLPD to 150 KLPD.

The distillery is in the premises of the existing sugar industrial complex located at

Alaganchi Village, Nanjangud Taluk, Mysore District, Karnataka State. The land is

already acquired through Karnataka State Industrial Area Development Board .The

proposed expansion will utilize molasses and fuels available in the sugar plant and

also from our Kollegal sugar unit M/s Bannari Amman Sugars Limited (Unit – III), 4500

TCD at a distance of 40 KM. One more sugar unit is proposed to be established in

this region shortly. Hence, major requirement of molasses will be met by these group

units. The land, water and other infrastructural facility are already available in the

existing industry. Hence, the expansion is planned in the same premise of the existing

distillery.

The location confers several advantages, which are summarized below.

1. The site is well connected by roadways.

2. Water requirement for the expansion is met from River Kabini located at 6 km from

the site for which permission already obtained.

3. No incidence of cyclones, earthquake, floods or landslides in the region has been

reported.

4. There are no eco-sensitive locations such as national park, wild life sanctuary,

bio- sphere reserve within 10 km radius around the proposed project site.

5. Already 60 KLPD Distillery is in full fledged operation with Zero Discharge

Environmental Management System of Concentration and Incineration.

6. The infrastructure facilities already available at this site and ease for installing

additional equipments and machineries for expansion make this site, a highly

suitable.

22

2.5 SIZE AND /MAGNITUDE OF OPERATION

2.5.1 PLANT FACILITIES

Existing facility for 60 KLPD Distillery plant

1. 60 KLPD alcohol plant with Distillation and Fermentation units.

2. 23.4 T/h boiler fired with coal and concentrated spent wash (CSW) as fuel

3. 2.0 MW T.G set

4. Multiple Effect Evaporators to concentrate spent wash from 18% - 60%

5. Bulk storage facilities for molasses and alcohol

6. Bio compost facility to utilize sludge materials and RO concentrate of

Evaporator condensate water.

7. Condensate water treatment system for reuse

8. WTP, ETP, cooling tower, fuel storage yard etc.

Proposed Facilities for 150 KLPD Distillery Plant

1. Distillation and fermentation units for enhanced capacity.

2. Additional 23.4 T/h boiler fired with concentrated spent wash (CSW) and

supplementary fuels such as, Bagasse, Bio-mass & coal.

3. Additional 2.0 MW T.G set

4. Multiple Effect Evaporators to concentrate spent wash from 18% - 60%

5. Additional Bulk storage facilities for molasses and alcohol

6. Additional Condensate water treatment system for reuse

7. Additional WTP, RO, ETP, cooling tower, fuel storage yard etc

2.5.2 LAND AREA

Total land area already available with distillery is 51 Acres. The existing land area is

adequate for expansion of the distillery capacity. Utilization for the project is given

below.

23

Utilization of Land at Distillery

2.5.3 MAN POWER REQUIREMENT

The man power utilized in the existing 60 KLPD capacity distillery is having a total of 60

employees including office staff, skilled & unskilled workers. However, additional man

power of 30 persons will be needed after expansion up to 150 KLPD. More than 85%

of the man power requirement will be met from local source.

2.5.4. RESOURCE REQUIREMENT

Sl No Item For existing

60KLPD After expansion to

150 KLPD

1 Molasses, T/d 240 594

2 Water , m3/d 599 1350

3 Power 1.3 MW 3.2 MW

4 Steam 19.0 T/h 46.8 T/h

Fuel

Coal (fuel) 45T/d 124 T/d

CSW (fuel) 148 T/d 361 T/d 5

Bagasse (fuel) as alternate to coal

- 236 T/d

Land Utilization (in Acres) Present 60 KLPD After Expansion to

150 KLPD

Built up area 15 16

Green belt Area 15 17

Open vacant area for future development

21

18

Total 51 51

24

2.5.5 TRANSPORTATION (After proposed expansion of the distillery)

1. Personnel

A maximum of 75 persons will be engaged during proposed construction works.

Construction period is about 6 months. They use company vehicle facilities, public

transportation and own vehicles.

During operation of the expanded unit maximum of about 90 persons will be visiting to

the industry including employees & visitors. Daily a total of about 2 visits by four

wheelers, 40 visits by two wheelers and 4 visits by bus is the transportation of

personnel.

2. Material

During Construction period material including gravel, sand, stone and bricks transported

per day will be about 25 Lorrie’s loads per day.

During operation, of the expanded unit a maximum of about 31 loads per day of material

will be transported to or from the factory as below.

a. After expansion, a total of 594 T/d of molasses will be consumed in the unit.

Balance of the molasses is transported by 12 tankers Lorry per day

b. Alcohol 150 KLPD, 9 tankers Lorry per day

c. Others (fuel, boiler ash etc) 10 lorry loads per day

2.5.6 BULK STORAGE FACILITIES

Bulk storage facility will be provided for raw material molasses and product ethanol of

different grades is given below molasses is stored in closed MS tank as per CPCB

guide lines. It is provided with external cooling arrangement with water spray. Alcohol

25

also stored in closed MS/SS tanks as per guide lines for storage of flammable solvent

storage tanks.

Bulk Storage Capacity for Molasses and Alcohol (Existing)

Product Particulars Storage Capacity

No. of tanks

Alcohol bulk storage 525 KL each 9 Nos.

Alcohol Alcohol day receivers

87 KL,108 KL , 18 KL & 16 KL

14 Nos. (7+4+2+1)

Molasses tank Steel storage tank 6160 M.Tonnes -

Each 2 Nos

Additional required tanks will be installed to take care of 150 KLPD Alcohol productions.

2.5.7 SPENT WASH STORAGE TANK

2 Nos of spent wash storage tank of capacity 6000 m3 tank is constructed above ground

level for the existing plant. The above two nos. of impervious tanks are constructed with

150 mm PCC and 230 mm RCC and 250 micron HMHD black colour UV sheet in

bottom area to avoid ground water pollution. The side wall is constructed with size stone

masonry of 1500 mm in bottom and 1000 mm in top with concrete lining reinforcement.

Particulars Capacity Nos.

Spent wash tank 6000 m3 2

The above existing tanks will take care of the 150 KLPD Alcohol production.

2.6 PROJECT INVESTMENT

Total investment for expansion of the Distillery project is Rs.8500 Lakhs Investment on

EMP facility will be is Rs. 4500 Lakhs.

26

2.7 SCHEDULE FOR APROVAL AND IMPLEMENTATION OF PROJECT

Schedule for approval and Implementation of project is given in Table-2.2.

Table-2.2 Schedule for Approval and Implementation of Project

Sl.

No.

Project activity Proposed time

schedule

Revised time schedule

1 Application to MOEF New

Delhi for TOR February 2013 --

2 Approval of TOR from

MoEF New Delhi June, 2013

TOR received on

07.06.2013

3

Submission of draft EIA

report & TOR to KSPCB for

conduct of PC

September 2014 October 2014

4

Submission of final EIA

report to MoEF for EC

clearance

November 2014 December 2014

5 EC clearance from MoEF March 2015 March 2015

2.8 PROCESS TECHNOLOGY

2.8.1 PROCESS DESCRIPTION

The existing distillery unit has a capacity to manufacture 60 KLPD of Alcohol of Rectified

spirit (RS), neutral alcohol (ENA) grades based on molasses as raw material. Expansion of

this Distillery from 60 KLPD to 150 KLPD (RS/ENA/Ethanol(AA)) will involve addition

of equipments for fermentation, distillation, evaporation of spent wash and burning of

concentrated spent wash in a Boiler. The process for Alcohol production is based

on advanced fermentation system with multi pressure Distillation. Fermentation is

27

carried out in the presence of yeast culture and nutrients. Yeast present in fermented

wash is separated and utilized in composting. The wash contains about 10 % alcohol is

distilled out in multi pressure distillation columns to produce various grades of alcohol. A

typical comprehensive flow diagram for manufacture of alcohol from molasses is given

in Figure-2.3. Material balance in the process is given in Figure-2.4.

2.8.2 PROCESS DETAILS

Molasses is diluted with water and mixed with small quantity of specified yeast culture

and nutrients and then subjected to fermentation in large fermentation tanks. The

product mixture (referred as fermented wash) containing about 10 % alcohol is clarified

in settling tank. The bottom sludge from clarifier is further clarified. Thick sludge is sent

for utilization in composting. Clear wash is sent to primary distillation column where in,

the distillate with 35 to 45 % alcohol is recovered from top. Alcohol free aqueous

solution referred as spent wash is discharged from the bottom. The distillate from

primary column is further purified in multi pressure distillation columns to obtain alcohol

of desired quality and grades.

28

Figure-2.3 Alcohol Processing - Eco Management - Flow Chart For Proposed Expansion (Zero Discharge System)

Bannari Amman Sugars Limited, (Unit- II) Distillery Unit

Alaganchi Village, Nanjangud Taluk, Mysore District

MOLASSES

( Raw material for Alcohol production )

Yeast &

Enzymes Water Nutrient

FERMENTATION PROCESS

( For 24 hours – to get about 10 % alcohol )

DISTILLATION PROCESS

( For separating alcohol in the fermented wash )

YEAST SLUDGE

For Composting

Steam for

distillation

of alcohol

Steam

ALCOHOL

(RS/ENA/ETHANOL)

(FOR SALE)

Steam for Spentwash Concentration

SPENTWASH ( 8 Ltr per Ltr of Alcohol)

EVAPORATION

Sludge

Turbo

Generator

Steam INCINERATION

BOILER

CONCENTRATED

SPENTWASH

(Used as Fuel)

CONDENSATE WATER

BIOLOGICAL TREATMENT 2.0 MW Power

( utilised in

process )

ASH

Coal/Bagasse

(as Supportive Fuel)

REJECT WATER

REVERSE OSMOSIS (R.O)

USED AS FARM

LAND MANURE

PRESSMUD

From Sugar Unit

SPECIAL MICRO-ORGANISMS

FOR COMPOSTING

(CONCENTRATE)

BIOCOMPOSTING

ON CONCRETED YARD

PULVERIZER, SCREENING

AND PACKING OF

COMPOST IN 50KG BAGS

PERMEATE WATER

( RE-USED IN THE PROCESS )

Sludges from process

COMPOST MANURE

SOLD TO FARMERS

29

2.8.3 IN HOUSE GENERATION OF POWER

The existing 60 KLPD distillery has 23.4 T/h boiler and 2.0 MW steam turbo generator

(STG) to generate power. An Additional 23.4 T/h boiler and a 2.0 MW turbo

generator will be installed to handle the proposed expansion to 150 KLPD Alcohol.

High pressure steam from the boiler is passed through turbine to generate electric

power. Back pressure steam at 4.0 kg/cm2 is used in distillation and evaporation

section. The generated power is used in the plant to meet the captive needs.

2.9 RAW MATERIAL AND PRODUCTS

The list and quantity of raw materials and products including consumables, chemicals,

by products and waste products is given in Table-2.3 the flow diagram of manufacturing

process with material balance is given in Figure-2.4.

Table-2.3 Raw Materials and other Products use in Proposed Distillery (Existing 60 KLPD & After expansion to 150 KLPD)

Quantity

Item Existing 60 KLPD

After expansion

to 150 KLPD

Transportation Storage

1.0 Raw material 1.1 Molasses

240 T/d

594 T/d

Lorry tanker/ Pipe line

MS Tank

2.0 Nutrients/Consumables

2.1 DAP 0.030 T/d 0.050 T/d Lorry 50 Kg Bags

2.2 Antifoam oil 0.075T/d 0.100 T/d Lorry Drums

3.0 Product/ By-product

3.1 Alcohol, KL/d

60 (RS/ENA grades)

150 (RS/ENA/ Ethanol(AA)

Lorry tanker

MS/SS Tank

3.2 Yeast sludge, dry 2T/d (Dry) 5 T/d (Dry) Tractor Utilized in Bio-

composting

3.3 Boiler ash 31.5 T/d 80 T/d Tractor Constructed

Yard

30

Figure-2.4 Material Balance for Distillery, T/d

(For Proposed 150 KLPD Unit) 161, Scrubber CO2 & Vapour

Molasses, 594 Scrubber - 21

Fresh water, 384 978

RO permeate,179

Fermenter CIP -60

146 998-0

Alcohol, 120

Fresh water, 498

Fermenter wash, 1457

PRC/FO Lees - 405

Spent wash, 1216

RC lees to cooling tower, 360

1216

361, Concentrated spent wash

With 60% solids

Cooling tower blow down -155 Vapour condensate, 855

RO reject for compost, 152 With 2% solids

566, cooling tower make up

SCRUBBER Molasses

dilution

FERMENTER

1643

Yeast cake, -25

Fermentation wash

1457-

ED column,

scrubber,

decanter

DISTILLATION

Spent wash tank

EVAPORATOR

Plant washings, 30

ETP/ RO, 1010

Scrubber,decanter-146

31

2.10 SOURCES OF MOLASSES AND ITS TRANSPORTATION

Total requirement of molasses after expansion will be 594 T/d and 196020 T/a

(330 days of operation). The major requirement of the molasses is met from the own

sugar industries located in the vicinity of the distillery (144000 T/a). The capacity of

these sugar units and availability of molasses from them is given in Table 2.4

Table- 2.4 Sources of Molasses

Sl.

No. Sugar unit Location

Cane Crushing

capacity

Availability of

molasses

1

M/s Bannari Amman

Sugars Limited Unit-II,

Alaganchi

Adjacent to the

distillery

(7500 T/d)

2000000 T/a 90 000 T/a

2

M/s Bannari Amman

Sugars Limited Unit-III,

Kollegal

40 km from the

distillery site

(4500 T/d)

1200000 T/a 54000 T/a

Total 144000 T/a

The balance requirement of 52020 T/a molasses will be met from the other sugar

industries located in the area. These sugar units do not have their own distilleries.

Presently, the existing distilleries in the states are having assured supply of molasses

from the sugar industries. During the years of favorable sugar cane in the country, there

is a glut in molasses market. During such period the sugar industries face serious

problem of marketing and storage of molasses. The establishment of molasses based

distillery is advantage to the sugar industry to maintain the price of molasses and to get

higher returns to their molasses.

2.11 POWER AND STEAM REQUIREMENT

Steam economy is achieved by employing multi pressure distillation, multiple effect

evaporators and heat recovery systems in the plant. The distillery is equipped with

power plant at the spent wash concentration and incineration section. High pressure

32

steam from the boiler runs back pressure turbine to produce electric power for captive

use. Exhaust steam from the turbine is utilized in distillation and evaporation plants.

The existing 60 KLPD distillery is provided with 23.4T/Hr multi fuel spent wash fired

boiler and 2.0 MW co-gen power plant to meet its requirement of steam and power. During

the proposed expansion, an additional co-gen power plant consisting of 23.4T/Hr boiler

and 2.0 MW steam turbine will be installed to meet the requirement of additional steam

and power. The proposed boiler will be fired with concentrated spent wash (CSW) along

with supportive fuels like coal /bagasse/bio mass. High pressure steam from the boiler

will run the back pressure turbines to produce electric power. The details of steam and

power in the industry are given in Table 2.5

Table-2.5 Generation and Utilization of Steam and Power

Sl. No Parameters Existing 60 KLPD

After proposed expansion to 150

KLPD

1. Boiler Capacity, TPH 23.4 23.4 + 23.4

2. Steam generation from boilers, TPH 19.0 23.4 + 23.4

Steam utilization in industry, T/h

Steam utilization in boiler for de-aerator 2.5 5.0

Steam utilization in distillation 8.5 20.0

Steam utilization in evaporation 8.0 21.0

3.

Total steam utilization 19.0 46.0

Boiler Fuel, T/d

a. Conc. Spent Wash, T/d 148

361

b. Coal as support fuel

45

124 4.

c. Bagasse (as an alternative to Coal) - 236

5. Steam Turbine Capacity, MW

2.0

2.0 + 2.0

6. Power utilization in plant, KW 1300 3200

33

2.12 SOURCE AND REQUIREMENT OF FUEL AND THEIR TRANSPORTATION

Existing distillery is having a boiler of 23.4 T/h capacity fired with spent wash along with

coal as support fuel. After enhancement of distillery capacity to 150 KLPD there will be

two boilers, each of 23.4 T/h capacity. The boilers are designed to operate on multi

fuels such as concentrated spent wash as main fuel and, coal/ bagasse and bio-mass

as supportive fuel. The bagasse is available from the sugar complex as captive source.

The Indian Coal/imported coal will be used. Bagasse within the factory premise

transferred through enclosed belt conveyors. Coal and external bio-mass will be

transported through lorries. Bagasse and coal are stored in the covered storage

yards.

Major requirement of fuel to the boilers is met from the concentrated spent wash

(CSW) generated from the evaporator. The balance requirement of fuel is met from

coal and/or bagasse as support fuel in the incineration boiler. The requirement of these

fuels is worked given in Table-2.5 and characteristics of fuels is given in

Table- 2.13.

2.13 SOURCE AND UTILIZATION OF WATER

2.13.1 SOURCE OF WATER

Fresh water requirement to the industry will be met from the Kabini River located at

about 6 km from the site. The industry is already having permission for drawal of water

from the river (Annexure – 5). The condensate water generated during evaporation is

biologically treated and polished in R.O, helps to reduce the intake of fresh water.

The requirement of fresh water to the existing distillery of 60 KLPD is 599 m3/d and

after expansion to 150 KLPD it will be 1350 m3/d. The expansion scheme will integrate

all water conservation measures.

2.13.2 UTILIZATION OF WATER IN DISTILLERY UNIT

The distillery is basically a bio- process based industry and utilizes large quantity of

water for dilution of molasses in fermenter, dilution in re-distillation and purification of

alcohol, scrubbing of alcohol vapors, cooling tower make up, washing and sterilization

34

of fermenters, boiler feed water make up, pump and compressor sealing etc. The water

consumption in the distillery is minimized by adoption of various conservation

measures like Recycle, Reuse and Reduce as presented below.

1. Technology improvement such as multi pressure distillation, use of re-boilers in

distillation columns, use of spent lees water /spent wash for dilution of molasses,

evaporation of spent wash for turning it into Boiler fuel.

2. The evaporator condensate water and cooling tower blow down water are

collected and treated in effluent treatment plant consisting of anaerobic and

aerobic and RO. The treated permeate water from RO is reused for Process use,

cooling tower make up, pump sealing, vapor scrubbers and in plant washings.

Fresh water is mainly required for dilution of molasses, boiler feed water make up, and

domestic applications as indicated in Table 2.6. The water balance for 150 KLPD

distillery unit including freshwater, recycled water and effluent generated is

given in Figure-2.5

35

Application Quantity, m3/d

FRESH WATER Existing 60KLPD Unit After expansion to

150 KLPD

Process water for Dilution 244 384

Vacuum pump & compressor sealing water 80 137

ED column dilution, scrubber & decanter 199 644

Incineration Boiler 72 179

Domestic 4 6

Total fresh water 599 1350

RECYCLED WATER

Pre-Rec. column lees to fermentation 162 405

Rectifier lees to cooling tower 144 360

RO permeate water for cooling tower makeup

376 566

RO permeate water for fermentation

72 179

RO permeate water to fermenter through CO2 scrubber & fermenter CIP

32 81

RO permeate water for miscellaneous use (floor wash & ash quenching)

12 30

Total

798

1621

Table-2.6 Utilization of Water in Distillery

36

384m3 137m3 146 m3 498m

3 179m3 6 m

3

644 m3

1118

244m3 PRC,FO lees,405m3

137m3

FIGURE – 2.5 WATER BALANCE FOR INCREASED CAPACITY OF 150 KLPD ALCOHOL PER DAY (PROPOSED) m3 per day

Total water required – 1350 m3/d Water from molasses, 89

m3

Process water for dilution in

fermentation section

Water for Cooling

Tower makeup in

utility section and for

vacuum pump sealing

Water for ED column

dilution, Scrubber, FO

decanters in

Distillation section

Incineration boiler

make up, 179 m3

Water for

Domestic Use

Cooling

Tower

Fermentation

Process

Distillation Section, Incineration

Boiler

Rectifier

lees, 360m3

179 Cu.M/Day

Spent wash 997 m3-

(1216 MT)

Evaporation Section,

997 m3

Concentrated

spentwash, 144 m3

Process condensate

853 m3

Effluent Treatment Plant/RO 1008 m3

Reject to Composting,

152 m3

Permeate

water 856 m3 To Co2 scrubber & Fermentation CIP, 81 m3

Fermentation dilution, 179 m3

Cooling

Towers Make up

566 m3

Other miscellaneous use like floor wash, Ash

quenching, 30 m3

Cooling

Towers Blowdown

155 m3

Yeast

sludge-

20 m3

To cooling tower-

566 m3

Blow Down

17 m3

37

2.14 SOURCES OF POLLUTION

Liquid, gaseous and solid wastes generated from distillery are likely to cause

environmental pollution. A suitable waste management system including reduce,

recycle and reprocess techniques is adopted in the industry to control pollution on the

environment as discussed in process details. The waste generation and inbuilt pollution

control measures are presented in subsequent sections.

2.15 WASTE WATER MANAGEMENT

2.15.1 SOURCE AND QUANTITY OF EFFLUENTS

The distillery is known to be a water intensive process industry, wherein large quantity

of water is consumed and effluent is generated. However in the present distillery,

measures is incorporated in the plant with reduce, recycle and reuse methodologies to

conserve water.

Spent wash is the main effluent in Distillery industry. Fermenter wash containing about

10 % alcohol is distilled and aqueous alcohol is recovered from top of the primary

distillation column. The alcohol free aqueous solution containing organic and inorganic

impurities is discharged as spent wash from bottom of the column. The miscellaneous

effluents from distillery are cooling tower blow down and condensate water collected

from spent wash evaporator. These are combined and treated by Anaerobic, Aerobic

and RO polishing unit. The permeate water from RO is recycled for use in the plant.

Effluent water from the distillery consists of floor and plant washings and RO reject is

utilized in Bio composting. Apart from the above, domestic effluents are generated

from rest rooms and wash rooms located at different locations is treated in septic tank &

soak pit.

Effluents from different sources are segregated as shown in Table-2.9 for the

convenience of treatment and utilization. The effluent generated from different sources

and the water balance in the distillery is given in Figure-2.5.

38

2.15.2 CHARACTERISTICS OF EFFLUENT

STREAM-A: SPENT WASH

Molasses which is used as a main raw material in distillery contains large quantity of

in-organic salts and non-fermentable organic matter as impurities. Major portion of

these ingredients will end up in spent wash. Spent wash contains about 18 % solids and

is rich in organic matter. The characteristics of the spent wash are given Table- 2.7.

STREAM-B: MICELLENEOUS EFFLUENTS

Miscellaneous effluents in distillery include evaporator condensate water and cooling

water blow down. These effluents have low values of TDS, and high values of BOD and

COD. The characteristics of miscellaneous effluents are given in Table-2.8.

STREAM-C: RO EFFLUENTS

RO reject is having high values of TDS and moderate values of BOD and COD. The

characteristics of plant effluents are given in Table-2.8.

STREAM-D: DOMESTIC EFFLUENTS

Domestic effluents are having less BOD and COD and easily bio-degradable. The

characteristics of domestic effluent is given in Table- 2.8

Table-2.7 Characteristics of Raw Spent Wash

Sl.No. Parameter Value

1 pH 4.0 –4.5

2 Total solids, mg/l 116000–132000

3 Volatile acids, mg/l 66000-73000

4 Ash, mg/l 21200–24500

5 BOD, mg/l 51800– 62100

6 COD, mg/l 125000–130000

39

Table-2.8 Characteristics of Effluents

Sl. No.

Parameter Miscellaneous

effluent, (Stream–B)

RO effluent (Stream–C)

Domestic effluent

(Stream–D)

1 pH 6.5-6.8 7.0- 7.4 7.2-8.0

2 Total dissolved solids,

mg/l 820-966 385-442 488

3 Suspended solids, mg/l 155-178 68-76 176

4 COD, mg/l 830-910 180-220 360

5 BOD, mg/l 510 60-80 260

6 Chloride(Cl), mg/l 68 180-212 75

7 Sulphate (SO4),mg/l 26 56-68 25

2.15.3 TREATMENT AND DISPOSAL OF WASTEWATER

STREAM- A: SPENTWASH

Quantity: Proposed expansion 150 KLPD unit: 997 m3/d /

Existing 60 KLPD unit: 480 m3/d

Spent wash Storage tank of about 10 day’s capacity is provided to store the spentwash.

The spentwash is rich in organic matter and inorganic salts. The spentwash of

18%solids is concentrated in multiple effect evaporators to about 60% solids.

Concentrated spent wash and vapor condensate water are generated from the

evaporator. Concentrated spent wash will be burnt in the specially designed multi fuel

7 Total nitrogen as N, mg/l 2500–3000

8 Potassium as K2O, mg/l 9000–11000

9 Sodium as Na, mg/l 240–280

10 Phosphorus as P2O5, mg/l 900–1100

11 Sulphate as SO4,mg/l 2800-3200

12 Chloride Cl ,mg/l 5700–6100

40

boiler. Ash from the boiler plant contains nutrients such as potash and phosphate. It is

sent to farmers for use as soil nutrient and also utilized in composting for enrichment of

soil. The condensate water generated from evaporator is further treated as

miscellaneous effluent for use it as reusable water. Source and treatment of effluent

further the distillery is given in Table 2.9.

STREAM-B: MICELLENEOUS EFFLUENTS

Quantity: Proposed expansion to 150 KLPD unit: 1008 m3/d

Existing, 60 KLPD unit: 493 m3/d

The miscellaneous effluents consist of evaporator condensate water; plant washings

and cooling water blow down. These effluents have relatively low values of TDS, BOD

and COD. They are combined and treated in tertiary effluent treatment plant consisting

of bio process, sand filter, carbon filter and chlorine disinfectants. The treated effluent

further polished in RO plant, and then recycled for use in the plant. The RO reject

with high TDS and moderate BOD & COD is utilized in the compost process along with

press mud to produce bio-manure.

STREAM-C: R.O. EFFLUENTS

Quantity: Proposed expansion to 150 KLPD unit: 152 m3/d


RO concentrate water has high TDS and moderate BOD and COD. These effluents are

collected in a sump and then utilized for composting along with press mud available

from the sugar unit.

STREAM-D: DOMESTIC EFFLUENT,

Quantity: Proposed, 150 KLPD unit: 6 m3/d


Domestic effluent is relatively less in quantity and has moderate values of TDS, BOD

and COD. It is treated in septic tank and dissipated using soak pit.

41

Table-2.9 Treatment and Disposal of Effluent,

(After proposed expansion to 150 KLPD & Existing unit of 60 KLPD)

Effluent Quality Treatment & Disposal/utilization

1. Spent wash

After proposed expansion

to 150 KLPD : 997 m3/d

Existing unit : 480 m3/d

Contains 18 %

solids with organic &

in-organic matter.

Spent wash is concentrated in the

multiple effect evaporator.

Concentrated Spent Wash (CSW) and

vapor condensate water will be

generated from the evaporator.

CSW is utilized as fuel in the boiler.

Vapor condensate water is further

treated in ETP consisting of bio-

process and RO.

Concentrated

spent wash


to 150 KLPD : 361 T/Day

Existing unit : 148 T/Day

Contains 60 %

solids with high

organic and

inorganic matter and

with GCV of 1800

kcal/kg.

It will be burnt as fuel along with

support fuel such as coal and/or

bagasse. Resulted boiler ash

containing plant nutrients such as

potash and phosphate is used as

manure.

2.Miscellaneous

Effluent :


to 150 KLPD unit: 1008

m3/d

Existing unit: 493 m3/d

Low TDS with

moderate BOD &

COD.

Treated in ETP consisting of bio

process. It is further treated (polishing)

in RO unit and then recycled for use as

cooling water make and other plant

needs.

3. RO concentrate water


to 150 KLPD unit: 152

m3/d

Existing, unit: 76 m3/d

High TDS with low

BOD and COD

Utilized along with press mud in

preparation of bio compost.

42

4.Domestic effluent,


to 150 KLPD unit: 6 m3/d

Existing unit: 4 m3/d

Moderate TDS,

BOD and COD.

Stabilized in septic tanks and sent to

soak pits.

2.15.4 SPENT WASH EVAPORATION UNIT

Molasses is fermented and distilled to produce alcohol in which spent wash is

generated as waste water from the process. Spent wash has a solid content of about

18%. For the existing distillery operation the company has installed a specially

designed spent wash Concentration Evaporators of self cleaning model supplied by

M/s. Praj Industries Limited, Pune. The evaporation system consists of 5-Effect

Evaporator (Flubex) system including finisher.

In this Evaporator, the spent wash is fed from an inlet nozzle into the lower section by a

specially designed distributor plate. The liquid along with solid wire bits is then

distributed through the tubes. The solid bits are maintained in a fluidized state during

operation by the velocity of the flowing spent wash. The solids wire bits impart a gentle

scouring effect on the inside of the tube walls while moving upward through the tubes.

While keeping the tubes clean, this also enhances the heat transfer co-efficient without

damage to the tube material.

The Evaporation System proposed for the expansion is 5-Effect system including

finisher for concentrating the spentwash from 18% solids to 60 % solids. The

spentwash at 25° C from spentwash storage tank is first taken into the feed tank and

then feed to Evaporation System. The feed is concentrated from the initial concentration

of 18% solids to about 50 % solids in 4 effects of Evaporation. These concentrated

spent wash with 50 % solids is fed to finisher for further concentration to about 60%

solids.

The concentrated spent wash having calorific value of 1800-Kcal/Kg. is burnt in a

specially designed boiler as a fuel along with coal/bagasse, biomass as a support fuel.

43

The condensate water generated from the Evaporators is treated in ETP consists of

Anaerobic and Aerobic system. It is further treated (polishing) in RO.unit and then

recycled for process use.

The existing evaporators in operation are capable to handle the raw spent wash

generated from the existing 60 KLPD unit. To expand the distillery to 150 KLPD

production, additional evaporators will be installed. Operating parameters of the

evaporators are given in Table-2.10.

TABLE- 2.10 Operating Parameters for Spent Wash Evaporator

NOTE: The existing evaporator section will be in operation and in addition adequate

capacity evaporators will be installed to handle the additional effluent generated, for

achieving maximum total production of 150 KLPD.

2.15.5 MULTI FUEL SPENT WASH BOILER

In the spent wash fired boiler, the concentrated spent wash is used as main fuel with

Coal/bagasse, biomass as a supportive fuel to generate steam. The proposed boiler

consists of combustion chamber, super heater coil, economizer, bag filter and

chimney. The existing boiler has capacity to burn concentrated spent wash generated

Evaporator particulars Sl.

No Particulars

Existing,

for 60 KLPD Unit

For proposed,

Expansion to 150 KLPD

1 Type of Evaporator

Multiple effect Evaporator

-5 effects (self cleaning)

Multiple effect

Evaporator -5 effects

2 Raw Spent wash at inlet

514 T/d or 480 m3 with

18 % solids

1216 T/d or 997 m3 with

18 % solids

3 Concentrated Spent wash

(CSW) at outlet of Evaporator

148 T/d with

60 % solids

361 T/d with

60 % solids

4 Total water evaporated 366 m3/d

853 m3/d

44

from the existing 60 KLPD distillery unit.

The heat generated by burning the concentrated spent wash along with

coal/bagasse, biomass is passed through the heat transfer zones and generates

steam. The flue gas passes through the convective heat recovery zones and finally

passed to the bag Filter section. The flue gas which contains fine dust particles are

removed at the bag Filters to the PCB norms and let out through the chimney. The ash

generated from the boiler is rich in Potash nutrient and finds use as farm land manure /

bio compost enrichment.

The feed water that enters the unit at the economizer inlet flows through economizer and

evaporator banks in the convection pass to recover the heat from the flue gas. The

steam passes through the primary and secondary super heater and discharge to the

outlet of Main Stream Stop Valve. Salient features of the boiler are

given in Table-2.11.

To achieve the expansion to 150KLPD Alcohol/day, one additional boiler of 23.4T/hr

capacity is proposed with multi fuel burning of concentrated spent wash/coal/bagasse,

biomass.

Concentrated Spent wash (CSW) with about 60 % solids is rich in organic matter with

a gross calorific value of 1800 kcal/kg is admixed with coal/bagasse and used as fuel in

Table-2.11 Salient Features of the Proposed Boiler

1 The construction of the boiler is such that the fouling potential is minimized through suitable design.

2 The boiler is to be designed in such a way that it is easily maintainable.

3 The convective section of the main boiler is of vertical tubes.

4 The total assembly is of gas tight construction.

5

The furnace design with economizer and super heater will be designed keeping it in mind of spent wash characteristics having high fouling potash content.

6 HP dosing line from Dosing system to Steam drum is of SS-304.

7 To keep the Boiler Emission level in norm, Bag filter Assembly is incorporated

45

the boiler. High pressure steam from the boiler is fed to back pressure turbine

to generate electric power for captive use in the industry. The exhaust steam from the

boiler utilized in distillation and spent wash evaporation sections. The process flow

diagram for the operation of evaporation cum boiler is given in Figure-2.3.

Operating parameters for the boiler are given in Table-2.12.

Table - 2.12 Performances of the Boilers at 150 KLPD production.

Sl. No. Parameter Existing 60 KLPD capacity

Proposed 150 KLPD Capacity

1

Boiler capacity, T/h 23.4 T/h

23.4 T/Hr

Quantity of fuel

Concentrated Spent Wash(60 % solids) 180.5 T/d 180.5 T/d

Coal, T/d 62 62

2

Bagasse( as alternative to coal) 118 118

4 Flue gas temp. at stack °C 200 200

5 Flue gas velocity through chimney, m/s 15 15

6 SPM in flue gas (max.), mg/Nm3 <150 <150

7 Boiler Ash, T/d 33 33

8 Chimney, ht 58m 58 m

9 APC device in boiler Bag filter Bag filter

10 Flue gas flow rate, Nm3/h 66,200 66,200

Note: The existing and proposed boiler will in combine handle the total concentrated

spent wash of 361 T/d as fuel.

2.15.6 CONDENSATE WATER POLISHING UNIT ALONG WITH RO SYSTEM

The condensate water generated during evaporation of spent wash is having volatile

organics. The condensate water is pretreated in anaerobic and aerobic system and

then fed to the RO system. The RO system is based on cross-flow membrane filtration

technique and is designed for removal of organics.

46

The condensate water treated by such system is reused back in to the Distillery

process, cooling water make-up and other uses thereby reduces the requirement of

fresh water. System typically recovers around 90 % of the condensate as clean

reusable water and has about 10 % reject which finds utilization in bio-composting of

press mud to produce bio-manure. Additional R.O facility will be made to handle

150 KL/Day Alcohol production level.

2.15.7 BIO COMPOST PROCESS – FOR SLUDGE AND RO REJECT WATERS.

In the bio-composting system, the process is carried out on a concrete floor yard

(10.5 Acres) by aerobic windrow technology using special aerobic microbial culture.

The sugar industry Press mud, yeast sludge of distillery fermentation and ETP sludge

are mixed suitably and bio-activated using microbial culture on the concrete floor. The

reaction is an exothermic one which helps to evaporate the water content. The

necessary moisture in the composting windrow i s maintained by spraying the R.O.

Reject water and washings from process section, on the composting windrows. Aero

tiller machine is used on the windrows to turn the material uniformly and spray the bio

degradable residues and keep the process in aerobic condition. To enrich the Bio

compost, the boiler ash rich in potash received from spent wash incineration boiler is

used. The bio-composting process would take about 60 to 75 days for completion and

the ready Bio compost manure is utilized as farmland manure.

All the above treatment methodologies adopted in the Environmental Management Plan

are of “Zero Discharge Environmental Concept” of Pollution Control Board.

The existing compost unit established in the year 2005 could take care of the additional

sludge’s and reject water generated in the expanded production capacity of 150 KLPD

Alcohol/day.

Thus, the Distillery Spent wash Management programme, the Concentration and

Incineration System of spent wash– Reverse Osmosis System – Biocomposting System

all could be efficiently integrated to achieve the Zero Discharge concept.

48

2.16 GASEOUS EMISSIONS AND AIR POLLUTION CONTROL MEASURES

Gaseous emission in this industry is mainly the flue gas from the boilers. Other fugitive

emissions are due to Coal, and Bagasse fuels, Boiler ash handling and movement of

vehicles.

1. Flue gas from boilers dealt through bag filter and 58 Metre chimney.

2. Process emissions from fermenter vent gases containing traces of alcohol vapors

dealt by water scrubber.

3. Fugitive emissions due to coal, bagasse, ash handling will be dealt by handling

it in closed conveyors and water mist spray.

2.16.1 FLUE GASES FROM BOILERS

1. SOURCES OF FLUE GASES

The sources of flue gases from the industry will be,

EXISTING

23.4 T/h multi fuel boiler i s a l r e a d y p r e s e n t in the exis t ing 60 KLPD

distillery. The boiler is currently operated on concentrated s pent wash and coal.

PROPOSED

23.4 T/h bo i le r is proposed to be operated with concentrated spent wash/bagasse

biomass/ coal.

The characteristics of fuels are given in Table-2.13

49

Table-2.13 Characteristics of Fuels

Sl.

No. Parameter

CSW

(Conc. Spent wash)

Coal Bagasse

1 Heat value, GCV,

(Average) 1800, cal/kg 3800, kcal/kg 2200, kcal/kg

2 Sulphur content 2.5kg/T 5 kg/T 0.1 kg/T

3 Ash 180 kg/T 300 kg/T 10 kg/T

4 Steam/fuel ratio 1.8 kg/kg 3.8 kg/kg 2.0 kg/kg

The information on stack and sources of emissions are given in Table- 2.14

Table- 2.14 Sources of Flue Gases and APC Measures

2. AIR POLLUTION CONTROL MEASURES FOR THE BOILER

Boiler will be fired with concentrated spent wash (CSW) along with the support fuel such

as coal and/or bagasse. Characteristics of these fuels are given in Table-2.13. Flue gas

is expected to contain suspended particulate matter (SPM) and sulphur dioxide (SO2)

as pollutants. Chimney height is designed based on sulphur in fuel. Bag filter

(Specifications of bag filter Annexure-8) is provided with the boiler to reduce the

SL

No.

Source of Flue

gases Fuel consumption

Flue

gas

Stack

Height

APC

measure

i. CSW (Concentrated

Spent wash), 148 T/d

1

Existing boiler,

23.4 T/h in 60

KLPD

distillery unit

ii. Coal (as support fuel),

45 T/d

66.200

Nm3/h

58 m,

AGL

Bag filter &

Stack

i. CSW (Concentrated

spent wash), 361 T/d

ii. Coal, (as support fuel),

124 T/d

2

Proposed

a d d i t i o n a l

boiler,

23.4T/hr for 150

KLPD distillery

unit

iii. Bagasse (as alternative

coal), 236 T/d

66.200

Nm3/h

58 m,

AGL

Bag filter

& Stack

50

concentration of suspended matter in the flue gas to allowable limits of less than 100

mg/Nm3. The information on gaseous emissions from boiler and the measures for air

pollution control is given in Table-2.14

2.16.2 PROCESS EMISSIONS

Carbon dioxide generated in the fermentor carries traces of alcohol vapors. The vapors

are scrubbed with water and then vented to atmosphere through a stack of 3 m height

above roof level. The scrubbed solution containing alcohol is returned to the fermenter.

2.17 NOISE SOURCE AND CONTRL MEASURES

1. SOURCES OF NOISE

The source and quality of noise in the distillery are given below.

i. Steam turbines : 85-90 dB (A)

ii. Fans and blowers : 80-85 dB (A)

Water sealed vacuum pump and air blowers are used in fermentation, distillation and

evaporator plants. Fans and blowers are used at boiler house and fermentor house. In

addition steam turbine 2.0. MW is present in Incineration power plant.

The sound intensity appears to be at moderate level in distillery plants. In general, at

the locations of turbines, compressors, fans etc, the sound intensity generally exceeds

the limit. Necessary measures as indicated below are taken to reduce the sound

intensity below the allowable limits at the source itself. The workers engaged in such

locations are provided with ear muffs to have additional safety against noise nuisance.

2. NOISE CONTROL MEASURES

Noise generating units such as steam turbine, blowers and fans are manufactured to

meet the noise level standards as per MOEF/ CPCB guide lines.

51

Workers operating these equipments are provided with ear muff and ear plug as

personnel protective appliances against noise. Steam turbines are located in isolated

and acoustic building.

2.18 SOURCE AND MANAGEMENT OF SOLID WASTE

The solid wastes produced from the alcohol plant are ash from boilers and yeast sludge

from fermenters. These are produced mainly from agro source and are non hazardous

type.

Fermenter Sludge

Fermenter wash contains yeast as a solid bio-product. This is clarified in settling

tank. Yeast sludge separated from the clarifier is used in Bio composing using sugar

industry press mud.

Boiler Ash

Proposed boiler will be operated using multi fuels (say bagasse) with concentrated

spent wash as prime fuel, and the potash rich ash generated is used as farm land

manure and also to blend in bio compost manure.

Table-2.15 Source and Disposal of Solid Waste for Proposed Unit

Parameters Quantity, T/d Utilization/disposal

60

KLPD

After expansion

to 150 KLPD

Boiler Ash, T/d 31.5 80.0

Used in Bio composing and also

supplied to farmers for use as soil

conditioner and soil nutrient.

Yeast sludge from

molasses based

process.(Dry basis), T/d

2.0 5.0 Utilization in bio composting

CHAPTER 3

DESCRIPTION OF ENVIRONMENT

52

Chapter-3

DESCRIPTION OF ENVIRONMENT

3.1 STUDY AREA, PERIOD, COMPONENTS & METHODOLOGY

STUDY AREA: An area, covering 10 km radial distance around the project site is

considered as the study area for conducting baseline studies.

PERIOD: Baseline study in this Environmental Impact Assessment report was

conducted for a period of three months during December 21st 2013 to March 21st 2014.

COMPONENTS: Air, noise, water & soil analysis studies were carried out. Survey of the

flora & fauna in the surroundings & demographic pattern of the survey area were also

studied.

METHODOLOGY: The data was collected from both primary and secondary sources.

Primary data sources include the data collected through environmental monitoring/

survey of the study area. The studies involved conducting field studies and analyzing

various parameters that might be affected due to the industry and conducting

socio-economic survey among the people.

For reconnaissance survey the sampling locations were identified based on:

1. Existing topography and meteorological conditions

2. Locations of water intake and waste disposal points

3. Location of human habilitation and other sensitive areas present in the vicinity of

the proposed project site

4. Representative areas for baseline conditions

5. Accessibility for sampling

Secondary data was collected from various organizations to substantiate the primary

data. The data thus collected was compared with the standards prescribed for the

respective environmental parameters.

53

Figure-3.1 Topo Map of Project Site (Bannari Amman Sugars Ltd.,)

Source: Survey of India; Scale: 1:50000

54

Figure-3.1 A Topo map showing 10 km radius around the project site

55

3.2 ESTABLISHMENT OF BASELINE DATA

3.2.1 METEOROLOGICAL DATA

Assessment of the micro and macro meteorology is important from the standpoint of

understanding the nature and extent of air pollution in the study area. Climate has an

important role in the build-up of pollution levels. The climatic condition of the area may

be classified as moderately or seasonally dry, tropical or temperate savanna climate

with four seasons in a year. Winter is critical for air pollution build-up because of

frequent calm conditions with temperature inversions resulting in poor atmospheric

mixing, natural ventilation and high emission loads.

The classification of months according to the seasons is given in the following

table

Season Period

Summer March to May

Monsoon June to September

Post monsoon October to November

Winter December to February

The metrological data for various parameters from both primary & secondary sources

are detailed subsequently.

Sources of meteorological data

The meteorological data for Mysore District was obtained from U.S. EPA

AERMOD

Modeling studies carried out using U.S. EPA AERMOD dispersion model,

1996 – 2013 Lakes Environmental Software, version 6.2.0. (secondary source).

56

a. Meteorological data from modeling studies carried out using U.S. EPA aermod dispersion model, 1996 – 2013

Lakes Environmental Software, version 6.2.0.

The metrological data reflecting minimum, maximum temperature in 0C, relative humidity in %, rainfall in mm/hr, wind

speed in m/s, mixing height in m, cloud cover in tenths and atmospheric pressure in mb for the year 2013 obtained

from modeling studies carried out using U.S. EPA AERMOD dispersion model, 1996 – 2013 Lakes Environmental

Software, Version 7.1.0 has been appended as Table-3.1.

Table- 3.1 Meteorological data of Mysore for the year 2013

Temperature 0C Relative humidity %

Precipitation

rate (mm/hr)

Atmospheric

pressure (mb)

Wind

speed

(m/s)

Inversion /

mixing height

(m)

Cloud cover

(tenths) Month

Min Max Max Min Min Max Min Max Min Max Day Night Min Max

Jan 14 26.3 76.3 33.9 0 1.52 926 936 0 6.2 2,064 2,192 2 10

Feb 13.8 29.1 75.6 21.0 0 1.78 925 933 0 5.7 2,321 1,969 2 6

Mar 17.7 30.1 76.4 24.4 0 1.02 924 934 0 6.7 2,785 2,345 2 8

Apr 21 31.8 74.7 29.0 0 3.56 925 932 0 6.7 2,809 2,282 2 6

May 19.1 32.5 69.8 37.5 0 5.84 922 930 0 7.2 2,936 2,812 2 10

June 18.1 31.7 68.6 45.6 0 4.57 922 930 0 9.3 2,787 3,962 2 10

July 18.4 30.1 67.6 53.1 0 3.56 922 930 0 9.8 2,224 4,000 2 10

Aug 17.8 29.1 69.6 44.0 0 2.79 921 930 0 7.7 2,448 3,031 3 10

Sept 17.8 29.8 70.6 47.3 0 6.6 923 930 0 7.7 2,329 3,046 2 10

Oct 16.7 29.5 72.6 45.4 0 3.3 922 931 0 7.2 2,239 2,743 2 10

Nov 16.4 27.1 71.6 46.8 0 25.91 922 932 0 5.7 1,851 2,037 3 10

Dec 13.4 25.1 72.3 33.5 0 2.29 923 932 0 7.7 1,700 3,019 2 10

57

2. TEMPERATURE

The mean maximum temperature is observed at 32.5 0C in the month of May and the

mean minimum temperature at 13.4 0C is observed in the month of December. In the

summer season the mean minimum temperature is observed during the month of

Mar (17.7 0C). During the monsoon the mean maximum temperature is observed to be

31.7 0C in the month of June with the mean minimum temperature at 17.8 0C during

August. By the end of September with the onset of post monsoon season (October -

November), day temperatures drop slightly with the mean maximum temperature at

29.5 0C in October and mean minimum temperature is observed at 16.4 0C in

November. The values are presented in Table- 3.1.

3. RELATIVE HUMIDITY

Minimum and maximum values of relative humidity have been recorded. The minimum

humidity is observed to be at 21.0% in the month of Feb and the maximum is 76.3% in

the month of January. The mean minimum values of humidity during summer, monsoon,

post-monsoon and rainy seasons are 24.4%, 44.0%, 45.4% & 21.0% during the months

of March, Aug, October and February respectively. Similarly the maximum values are

69.8%, 70.6%, 72.6%, 72.3% in the months of May, September, October & December

during the summer, monsoon, post monsoon & winter seasons. The values are

presented in Table- 3.1.

4. RAINFALL

The monsoon in this region usually occurs twice in a year i.e. from June to September

and from October to November. The maximum annual rate of precipitation over this

region is 776.7 mm.

58

5. ATMOSPHERIC PRESSURE

The maximum and the minimum atmospheric pressures are recorded during all

seasons. In the summer season, the mean maximum and minimum pressure values are

observed to be 932 & 925 mb in the month of April and 930 & 922 mb in the month of

May respectively. During monsoon season, the maximum pressure is 923 mb and

minimum 921 mb. The maximum and miminum pressure during the post-monsoon

season is observed to be 922 mb. During the winter season the minimum atmospheric

pressure is 923 mb in December and the maximum is 936 mb in the month of January.

The values are presented in Table-3.1.

6. INVERSION HEIGHT

The maximum inversion heights at the project site during the day time & night time for

all the months of the year is as given in the table 3.1. The maximum mixing height of

2,936 m is observed during the month of May during the day time and 4,000 m during

the month of July during the night time. The minimum inversion heights are 1,851 m

during the day in November & 1,969 m during the night in the month of February.

7. CLOUD COVER

The minimum cover measured in the unit of tenths is 2 and the maximum observed

cloud cover is 10.

8. WIND

The data on wind patterns are pictorially represented by means of wind rose diagrams

for the entire year as Figure-3.2 (for different seasons).

Predominant wind directions

Season Period Wind directionSummer March to May North East

Monsoon June to September East

Post monsoon October to November North East

Winter December to February South West

59

Figure- 3.2 Wind rose diagrams

1) March to May (summer season)

M/s. ULTRA-TECH

60

2) June to September (monsoon season)

M?s. ULTRA-TECH

61

3) October to November (post monsoon season)

M?s. ULTRA-TECH

62

4) December to February (winter season)

63

3.2.2 BASELINE MONITORING

1. SAMPLING AND ANALYTICAL TECHNIQUES & TIME SCHEDULE CHART FOR

BASELINE MONITORING

i. AIR QUALITY

PM10 and PM2.5 have been estimated by gravimetric method. Modified West and Gaeke

Method (IS: 5182 Part – II, 1969) has been adopted for estimation of SO2. Jacobs –

Hochheiser Method (IS: 5182 Part-VI, 1975) has been adopted for the estimation of

NOx. NDIRS (Non-Dispersive Infra Red Spectroscopic) Method (IS: 5182 Part-X, 1999)

has been adopted for the estimation of CO and Electrochem sensor method has been

adopted for the estimation of Ozone. Spectrophotometric method for ammonia, AAS

(Atomic Absorption Spectrophotometry) method for lead. Summary of the analytical

techniques and their references are appended in Tables 3.2 – 3.4.

Table-3.2 Techniques Adopted/Protocols for Ambient Air Quality Monitoring

SL. No

Parameters Techniques Technical Protocol

Minimum detectable limits as

provided by lab

1 Sulphur Dioxide (SO2) West & Gaeke IS:5182 (P2) 4 mcg

2 Nitrogen Dioxide (NO2) Jacob &

Hochheiser IS:5182 (P6) 1 mcg

3 Particulate Matter

PM10 Gravimetric IS:5182 (P15) 5 mcg

4 Particulate Matter

PM 2.5 Gravimetric IS:5182 (P15) 5 mcg

5 Ozone (O3) Electrochem sensor - NIL

6 Ammonia as NH3 Spectrophotometric Handbook of air

pollution analysis

NIL

7 Carbon monoxide as

CO NDIR IS: 5182 (P-10) 10 mcg

8 Lead as Pb AAS IS:5182 (P22) 0.01 mcg

64

ii. WATER QUALITY

Table- 3.3 Protocol for Surface Water Quality Monitoring

Sl.

No. Parameter/Test Protocol

Physical parameters

1 pH IS: 3025 (P 11)

2 Suspended solids IS: 3025 (P 17)

3 Color & odor IS: 3025 (P 4&5)

4 Oil & grease IS: 3025 (P 39)

Chemicals parameters

5 Total dissolved solids IS: 3025 (P 16)

6 Ammoniacal nitrogen, as N IS: 3025 (P 34)

7 Total kjeldahl nitrogen, as N IS: 3025 (P 34)

8 Biochemical Oxygen Demand

at 270 C for 3 days IS: 3025 (P 44)

9 Chemical Oxygen Demand APHA

10 Chlorides, as Cl IS: 3025 (P 32)

11 Sulphates , as SO4 IS: 3025 (P 24)

12 Nitrates, as NO3 IS: 3025 (P 34)

13 Phosphates, as PO4 IS: 3025 (P 31)

14 Phenolic compounds, as

C6H5OH IS: 3025 (P 43)

15 Total hardness, as CaCO3 IS: 3025 (P 21)

16 Calcium, as Ca IS: 3025 (P 40)

17 Magnesium, as Mg IS: 3025 (P 46)

18 Nitrates, as NO2 IS: 3025 (P 34)

19 Alkalinity, as CaCO3 IS: 3025 (P 23)

20 Fluoride, as F IS: 3025 (P 60)

21 Electrical conductivity APHA

22 Dissolved oxygen, mg/L -

65

Table- 3.4 Protocol for ground water quality monitoring

Sl.

No. Parameter/Test Unit Protocol

1 Color True color units IS: 3025 (P 4)

2 Odor - IS: 3025 (P 5)

3 Taste - IS: 3025 (P 8)

4 Turbidity NTU IS: 3025 (P 10)

5 pH - IS: 3025 (P 11)

6 Chlorides as Cl mg/L AN-S-003

7 Total hardness as CaCO3 mg/L IS: 3025 (P 21)

8 Calcium as Ca mg/L IS: 3025 (P 40)

9 Magnesium as Mg mg/L IS: 3025 (P 46)

10 Total dissolved solids mg/L IS: 3025 (P 16)

11 Sulphates as SO4 mg/L AN-S-003

12 Copper as Cu mg/L IS: 3025 (P 42)

13 Iron as Fe mg/L IS: 3025 (P 53)

14 Manganese as Mn mg/L IS: 3025 (P 59)

15 Nitrate as NO3 mg/L AN-S-003

16 Fluoride as F mg/L AN-S-003

17 Phenolic compounds as C6H5OH mg/L IS: 3025 (P 43)

18 Mercury as Hg mg/L IS: 3025 (P 48)

19 Cadmium as Cd mg/L IS: 3025 (P 41)

20 Selenium as Se mg/L IS: 3025 (P 56)

21 Arsenic as As mg/L IS: 3025 (P 37)

22 Cyanide as CN mg/L APHA

23 Lead as Pb mg/L IS: 3025 (P 47)

24 Zinc as Zn mg/L IS: 3025 (P 49)

25 Anionic detergents as MBAS mg/L Annex K of

IS:13428

26 Chromium as Cr+6 mg/L IS: 3025 (P 52)

27 Residual free chlorine mg/L IS: 3025 (P 26)

28 Alkalinity as CaCO3 mg/L IS: 3025 (P 23)

29 Aluminum as Al mg/L IS: 3025 (P 55)

30 Boron as B mg/L APHA

66

iii. NOISE & SOIL MONITORING

Noise levels were measured using integrated sound level meter & soil quality using pH

meter, Conductivity meter, Turbidity Meter, Flame Photometer, Spectro photometer,

Mercury Analyzer, Oven & Electronic Balance.

2. AIR QUALITY

The baseline air quality was established by monitoring major air pollutants like

suspended particulate matter, oxides of sulfur, nitrogen etc. at various locations near

the project site.

High volume samplers were used for ambient air sampling. Samples were collected

continuously from all the stations for 24 hours. Samples thus collected were analyzed

for various pollutants.

Baseline data for ambient air quality was collected during the months of December 21st

2013 to March 21st 2014. The sampling stations along with their distance and direction

from the project site, ambient air quality monitoring stations, wind rose diagram showing

the direction of the blowing wind during the analysis period, ambient air quality analysis

data for various parameters, National Ambient Air Quality Standards specified by MoEF

are detailed subsequently.

To study the existing ambient air quality, monitoring was done by Bangalore Test

House, Bangalore, NABL Accredited lab with the frequency of two days/week for the

project site and weekly for other locations.

The observations made during the study period are presented under the forthcoming

sub-sections.

67

Methodology adopted for the study

The baseline status of the ambient air has been established through a scientifically

designed ambient air quality monitoring network. The following criteria were taken into

account during selection of the sampling stations:

Topography of the area

Human settlements within the study area

Safety, accessibility and non-interference with general routine of the people

residing near the station

Prediction of maximum concentration of the air pollutants through dispersion

modeling for the proposed source details using prevailing meteorological

conditions in the region

Table- 3.5 Ambient Air Sampling Stations

Sl. No. Code no. Name of the station Direction from

the site

Distance from

site (km)

1 A 1 Project site - -

2 A 2 Kirugunda (downwind

direction) East 1.70

3 A 3 Alaganchi South East 2.0

4 A 4 Bendagahalli South West 3.88

5 A 5 Haniyamballi North 3.68

6 A 6 Saragooru North West 3.09

68

Figure-3.3 Wind Rose Diagram– December 21st 2013 to March 21st 2014

(sampling period)

69

A. Air quality at the project site: Ambient air quality analysis was conducted at the project site by-weekly for 3 months from December 21st 2013 to March 21st 2014. The analysis reports are appended in the Table below.

Table-3.6 Air Quality Data at the Project Site

PM2.5 PM10 SO2 NOx NH3 Pb O3 C6H6

Benzo(a) pyrene in

particulate phase

As Ni CO HC -

methane HC – non methane

Sample no.

µg/m3 ng/m

3 mg/m

3 ppm

A1.1 7.7 38 3.1 4.8 <0.5 0.01 –0.1 Nil ND <1.0 ND ND ND ND ND A1.2 8.2 37 3 4.7 <0.5 0.01 –0.1 Nil ND <1.0 ND ND ND ND ND A1.3 10.3 35 2.9 4.5 <0.5 0.01 –0.1 Nil ND <1.0 ND ND ND ND ND A1.4 9.6 35 2.8 4.5 <0.5 0.01 –0.1 Nil ND <1.0 ND ND ND ND ND A1.5 12.5 40 3.5 5.4 <0.5 0.01 –0.1 Nil ND <1.0 ND ND ND ND ND A1.6 10.3 41 2.9 5.1 <0.5 0.01 –0.1 Nil ND <1.0 ND ND ND ND ND A1.7 15.6 43 3.1 5.3 <0.5 0.01 –0.1 Nil ND <1.0 ND ND ND ND ND A1.8 14.5 41 3 5.4 <0.5 0.01 –0.1 Nil ND <1.0 ND ND ND ND ND A1.9 18.9 44 3.4 5.8 <0.5 0.01 –0.1 Nil ND <1.0 ND ND ND ND ND

A1.10 18.5 45 3.2 5.7 <0.5 0.01 –0.1 Nil ND <1.0 ND ND ND ND ND A1.11 18.6 45 3.1 5.5 <0.5 0.01 –0.1 Nil ND <1.0 ND ND ND ND ND A1.12 18.6 45 3.4 5.4 <0.5 0.01 –0.1 Nil ND <1.0 ND ND ND ND ND A1.13 14.6 44 3.8 5.6 <0.5 0.01 –0.1 Nil ND <1.0 ND ND ND ND ND A1.14 17.9 45 3.3 5.1 <0.5 0.01 –0.1 Nil ND <1.0 ND ND ND ND ND A1.15 16.5 44 3.4 5.4 <0.5 0.01 –0.1 Nil ND <1.0 ND ND ND ND ND A1.16 13.6 41 3.7 5.2 <0.5 0.01 –0.1 Nil ND <1.0 ND ND ND ND ND A1.17 14.5 45 4 6.2 <0.5 0.01 –0.1 Nil ND <1.0 ND ND ND ND ND A1.18 15.2 44 3.8 6.1 <0.5 0.01 –0.1 Nil ND <1.0 ND ND ND ND ND A1.19 15.6 45 3.9 6 <0.5 0.01 –0.1 Nil ND <1.0 ND ND ND ND ND

A1.20 12.3 43 3.7 5.8

<0.5 0.01 –0.1 Nil ND <1.0 ND ND ND ND ND

A1.21 12.9 41 3.4 5.7 <0.5 0.01 –0.1 Nil ND <1.0 ND ND ND ND ND A1.22 13.2 42 3.1 6 <0.5 0.01 –0.1 Nil ND <1.0 ND ND ND ND ND A1.23 14.5 45 3.5 5.8 <0.5 0.01 –0.1 Nil ND <1.0 ND ND ND ND ND A1.24 13.1 41 3.1 5.7 <0.5 0.01 –0.1 Nil ND <1.0 ND ND ND ND ND

70

Note:

PM10 & PM2.5 - Particulate matter; SO2 – Sulphur dioxide; NOx – Oxides of nitrogen; NH3 – Ammonia ; C6H6 –

Benzene; As – Arsenic; Ni – Nickel; Pb – Lead; O3 – Ozone; CO – Carbon monoxide; ND – not detected

Air quality data analysis reports are for 24 hourly average

B. Air quality in the downwind direction (Kirugunda): Ambient air quality analysis was conducted at

Kirugunda weekly for 3 months from 21st December 2013 to March 21st 2014. The analysis reports are

appended in the Table below

Table-3.7 Air quality data at Kirugunda village (downwind direction)

PM2.

5 PM10 SO2 NOx NH3 Pb O3 C6H6

Benzo(a) pyrene in

particulate phase

As Ni CO HC -

methane

HC – non

methane Sample

no.

µg/m3 ng/m

3 mg/m

3 ppm

A2.1 10.5 36.1 3.9 1.9 <0.5 <0.01 Nil ND <1.0 ND ND ND ND ND A2.2 9.6 34.0 3.6 1.7 <0.5 <0.01 Nil ND <1.0 ND ND ND ND ND A2.3 11.2 34.5 4.1 1.8 <0.5 <0.01 Nil ND <1.0 ND ND ND ND ND A2.4 12.5 20.8 4.2 1.7 <0.5 <0.01 Nil ND <1.0 ND ND ND ND ND A2.5 12.9 35.7 4.6 1.6 <0.5 <0.01 Nil ND <1.0 ND ND ND ND ND A2.6 11.9 38.4 4.3 1.9 <0.5 <0.01 Nil ND <1.0 ND ND ND ND ND A2.7 11.2 37.2 4.1 2.1 <0.5 <0.01 Nil ND <1.0 ND ND ND ND ND A2.8 14.5 35.9 4.7 2.5 <0.5 <0.01 Nil ND <1.0 ND ND ND ND ND A2.9 13.4 42.5 5.3 3.1 <0.5 <0.01 Nil ND <1.0 ND ND ND ND ND A2.10 10.8 41.4 4.9 2.9 <0.5 <0.01 Nil ND <1.0 ND ND ND ND ND A2.11 10.2 41.6 4.9 2.5 <0.5 <0.01 Nil ND <1.0 ND ND ND ND ND A2.12 16.5 40.5 5.1 2.6 <0.5 <0.01 Nil ND <1.0 ND ND ND ND ND

71

C. AIR QUALITY AT OTHER LOCATIONS

Table-3.8 Air Quality Data at other Locations

24 Hrs concentration (µg/m3)

Monitoring station Sl.

No. Parameter

A 3 A 4 A 5

A 6

1 PM2.5, µg/m3 15.2 12.6 20.1 22.1

2 PM10, µg/m3 35.5 28.5 40.5 42

3 SO2, µg/m3 2.7 2 3.3 4.1

4 NOx, µg/m3 3.9 3.5 4.7 5

5 NH3, µg/m3

6 Pb, µg/m3 ND ND ND ND

7 O3, µg/m3 Nil Nil Nil Nil

8 C6H6, µg/m3

9 Benzo(a) pyrene in

particulate phase, ng/m3

<1.0 <1.0 <1.0 <1.0

10 As, ng/m3

11 Ni, ng/m3 ND ND ND ND

12 CO, mg/m3 ND ND ND ND

13 HC - methane, ppm ND ND ND ND

14 HC – non methane, ppm ND ND ND ND

72

Table-3.9 Ambient Air Quality Standards – MoEF as per the Notification dated 16th

November 2009 for Industrial, Residential & Rural Areas

Concentration Air Quality Parameter

24 hrs Annual

1 Particulate matter (size less

than 10 µm), PM10, µg/m3

100 60

2 Particulate matter (size less

than 2.5 µm), PM2.5 ,µg/m3

60 40

3 Sulphur-di-oxide, µg/m3 80 50

4 Nitrogen dioxide, µg/m3 80 40

5 Ammonia (NH3), µg/m3 400 100

6 Benzene (C6H6), µg/m3 - 5

7 Benzo(a) pyrene in particulate

phase, ng/m3 - 1

8 Arsenic (As), ng/m3 - 6

9 Nickel (Ni), ng/m3 - 20

10 Lead (Pb), µg/m3 1 0.5

11 Ozone (O3), µg/m3 180 – 1 hr 100 – 8 hrs

12 Carbon monoxide, mg/m3 4 – 1 hr 2 – 8 hrs

Note:

8 hourly or hourly monitored values, as applicable, shall be complied with 98% of the

time in a year. 2% of the time, they may exceed the limits but not on two consecutive

days of monitoring.

Whenever and wherever monitoring results on two constitutive days of monitoring

exceed the limits specified above for the respective category, it shall be considered

adequate reason to institute regular or continuous monitoring and further

investigation.

73

D. OBSERVATIONS

Table-3.10: The Monitored Values Observed at the Project Site & Kirugunda

(Downwind Direction)

24 Hrs concentration (µg/m3)

Monitoring station Sl.

No. Parameter

Project site Kirugunda Other

locations 1 PM2.5, µg/m3 7.7-18.5 9.6-16.5 12.6-22.1

2 PM10, µg/m3 35 - 45 20.8 – 42.5 26 – 43

3 SO2, µg/m3 2.8 – 4 1.6 – 3.1 1.8 – 4.5

4 NOx, µg/m3 4.5 – 6.2 3.6 – 5.3 3.1 – 5.4

5 NH3, µg/m3 <0.5 <0.5 ND

6 Pb, µg/m3 <0.01 <0.01 ND

7 O3, µg/m3 Nil Nil Nil

8 C6H6, µg/m3 ND ND ND

9 Benzo(a) pyrene in particulate

phase, ng/ m3 <1.0 <1.0 <1.0

10 As, ng/ m3 ND ND ND

11 Ni, ng/ m3 ND ND ND

12 CO, mg/ m3 ND ND ND

13 HC - methane, ppm ND ND ND

14 HC – non methane, ppm ND ND ND

The monitored values are within the limits specified by MoEF (as per the notification

dated 16th November 2009 for industrial, residential & rural areas).

3. NOISE ENVIRONMENT

The proposed project is an expansion of existing distillery (from 60 KLPD to 150 KLPD)

industry and hence requires movement of raw materials, chemicals, fuels, tools &

tackles required for its manufacturing process and also transportation of finished

74

products to its destination. The movement of personnel from their residence to industry

would also result in a moderate increase in the traffic, which would not result in any

drastic change in either the existing traffic pattern or noise levels of the area as

accommodation facilities are proposed within the project site for most of the employees.

Background noise levels were measured in 6 locations (Table-3.12), monitoring

locations depicted in map attached (Figure-3.4) in human settlements within the study

area. A sound level meter was used for measuring the noise level at one-hour interval

continuously for 24 hrs at 1.5 m above ground level, about 3 m from walls, buildings or

other sound reflecting sources.

The measurements were carried out in such a way that the monitoring locations were

1 m away from the sources and 1 m away from the edge of the roads. The lowest and

highest noise levels are presented in table 3.12 and the limits as per Environmental

Protection Rules, 1986 for industrial, commercial & residential areas are presented in

Table-3.13 as under.

Table-3.11 Noise Level Monitoring Stations

Sl.

No.

Code

no.

Name of the station

Direction

from the site

Distance from

site (km)

1 N 1 Project site - -

2 N 2 Kirugunda (downwind direction) East 1.70

3 N 3 Alaganchi South East 2.0

4 N 4 Bendagahalli South West 3.88

5 N 5 Haniyamballi North 3.68

6 N 6 Saragooru North West 3.09

75

Table - 3.12 Summary of Noise Level

Sl.

No. Code No. Name of the station

Lowest

dB (A)

Highest

dB (A)

1 N 1 Project site 52 64

2 N 2 Kirugunda (downwind

direction) 40.9 44.8

3 N 3 Alaganchi 38.5 44

4 N 4 Bendagahalli 41 44.2

5 N 5 Haniyamballi 36.8 39.5

6 N 6 Saragooru 32.5 37.4

Table - 3.13 Limits as per Environmental Protection Rules

Limits as per Env. Protection Rules, 1986 in dB(A)Leq

Industrial area Commercial area Residential area Silent Zone

Day Night Day Night Day Night Day Night

75 70 65 55 55 45 50 40

OBSERVATIONS

The baseline noise levels have been monitored at different locations as indicated in the

table above. The noise levels in the study area varies between 32.5 – 64. It has been

observed that the maximum noise levels at all the locations are within the limits

specified for industrial/residential areas.

76

4. WATER ENVIRONMENT

A. RECONNAISSANCE SURVEY

The impact has been assessed on randomly selected surface and ground water

sources falling within the impact zone.

In order to assess the existing water quality, the water samples were collected from 5

different locations within the study area (fig 3.4) and analyzed as per the procedure

specified in standard methods for examination of water and wastewater published by

American Public Health Association and Bureau of Indian Standards (APHA/BIS).

Samples for the analysis were collected in polyethylene containers. Samples collected

for metal content were acidified with 1 ml HNO3. Samples for biological analysis were

collected in sterilized glass bottles. Selected Physico-chemical and biological

parameters have been analyzed for projecting the existing water quality status in the

study area. Parameters like temperature, Dissolved Oxygen (DO), and pH were

analyzed at the time of sample collection. Name of the locations, orientation with

respect to the project site are listed in the Table 3.14 along with the type of source. The

analytical data for surface water quality has been tabulated in Table- 3.15 & 3.16.

Table - 3.14 Water Sampling Stations

Sl. No.

Code No.

Name of the Station

Direction from site

Distance From site (km)

Source/ Type

1 SW1 Kabini river North 3.52 River

2 GW 1 Project site - - Bore Well

3 GW2 Kirugunda East 1.70 Borewell

4 GW3 Alaganchipura South – East 0.60 Borewell

5 GW4 Chinnadagudi

Hundi South west 2.91 Borewell

77

B. SURFACE WATER

The major fresh water source within the study zone is Kabini River. The water

requirement for the proposed project will be sourced from Kabini River. The supply of

water to the industry will be metered for its quantification.

The results of the analysis of surface water sample are appended as Table- 3.15.

C. GROUND WATER

Ground water occurs under water table conditions in the weathered mantle of granite

gneisses and in the joints, cracks and crevices of the basement rock. The depth of

water is also dependent on topography and varies depending on the depth of

weathering.

The results of the analysis of ground water samples are appended as Table- 3.16.

78

Table 3.15 Surface Water Quality (Kabini River Water Quantity 1Lts)

Sl. no.

Characteristics Unit Results (SW1)

Maximum Acceptable

Limits As per IS:10500-1991

Maximum Permissible Limits in the Absence of Alternate

Source As Per IS:10500-1991

1 Color, Hazen Unit Pt-Co units

6 5 25

2 Odor - Un-

objectionable Un-

objectionable Un-objectionable

3 Taste - Agreeable Agreeable Agreeable 4 Turbidity NTU 1.7 5 10 5 pH - 8.1 6.5 – 8.5 No relaxation

6 Total hardness as CaCO3

mg/L 120 300 600

7 Iron as Fe mg/L 0.06 0.3 1.0 8 Chlorides as Cl mg/L 13.9 250 1000 9 Residual free chlorine mg/L <0.05 0.2 min - 10 Total dissolved solids mg/L 122.0 500 2000 11 Calcium as Ca mg/L 21.1 75 200 12 Copper as Cu mg/L < 0.05 0.05 1.5 13 Manganese as Mn mg/L < 0.1 0.1 0.3 14 Sulphates as SO4 mg/L 3.4 200 400 15 Nitrate as NO3 mg/L 1.5 45 No relaxation 16 Fluoride as F mg/L 0.08 1.0 1.5 17 Phenolic compounds mg/L Absent 0.001 No relaxation 18 Mercury as Hg mg/L < 0.001 0.001 No relaxation 19 Cadmium as Cd mg/L < 0.01 0.01 No relaxation 20 Selenium as Se mg/L < 0.001 0.01 No relaxation 21 Arsenic as As mg/L < 0.01 0.05 No relaxation 22 Cyanide as CN mg/L Absent 0.05 No relaxation 23 Lead as Pb mg/L <0.01 0.05 No relaxation 24 Zinc as Zn mg/L <0.01 5.0 15 25 Anionic surfactants mg/L <0.2 0.2 1.0 26 Chromium as Cr+6 mg/L <0.01 0.05 No relaxation

27 Polycyclic aromatic hydrocarbon

mg/L Absent - -

28 Mineral Oil mg/L <0.01 0.01 0.03 29 Pesticides mg/L Absent Absent 0.001 30 Alkalinity as CaCO3 mg/L 200 200 600 31 Aluminum as Al mg/L 0.02 0.03 0.2 32 Boron as B mg/L 1.00 1.0 1.5 33 Magnesium as Mg mg/L 2.3 30 100

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

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

79

Note: A-Agreeable ; NA- NotAgreeable ; UO – Un-objectionable

Results Sl. No

Tests GW 1 GW 2 GW3 GW 4

Maximum Acceptable Limits As per IS:10500-

1991

Maximum Permissible Limits in the Absence of Alternate

Source As Per IS:10500-1991

1 Color (True color units) <2.0 0.3 0.9 1.5 5 25 2 Odour Agreeable Agreeable Agreeable Agreeable UO - 3 Taste agreeable agreeable Agreeable agreeable A - 4 Turbidity, NTU 0.8 0.3 0.2 1.5 5 10 5 pH 6.79 7.16 7.98 8.1 6.50-8.50 No relaxation 6 Chlorides, as Cl ,mg/L 117.9 48.7 85.1 115 250 1000 7 Total hardness as CaCO3, mg/L 298.9 297.6 295.2 251.3 300 600 8 Calcium, as Ca, mg/L 166.7 90.5 85.3 79.6 75 200 9 Magnesium, as Mg, mg/L 65.0 26.0 12.6 16.5 30 100

10 Total Dissolved Solids, mg/L 495.3 498.9 496.2 495.3 500 2000

11 Sulphates, as SO4, mg/L 295.6 68.8 52.6 53.8 200 400

12 Copper as Cu, mg/L <0.05 <0.05 <0.05 <0.05 0.05 1.5

13 Iron, as Fe, mg/L 0.09 0.07 0.19 0.24 0.30 1.0

14 Manganese as Mn, mg/L <0.1 <0.1 <0.1 <0.1 0.1 0.3

15 Nitrates, as NO3 , mg/L 10.6 5.6 4.4 7.2 45 No relaxation

16 Fluorides, as F, mg/L 0.4 0.6 0.19 0.26 1.0 1.5

17 Phenolic Compounds as C6H5OH, mg/L

Absent Absent Absent Absent 0.001 0.002

18 Mercury as Hg, mg/L <0.001 <0.001 <0.001 <0.001 0.001 No relaxation 19 Cadmium ad Cd, mg/L <0.003 <0.003 <0.01 <0.01 0.01 No relaxation 20 Selenium as Se, mg/L <0.01 <0.01 <0.01 <0.01 0.01 No relaxation 21 Arsenic as As, mg/L <0.01 <0.01 <0.01 <0.01 0.01 No relaxation 22 Cyanide as CN, mg/L Absent Absent Absent Absent 0.05 No relaxation 23 Lead as Pb, mg/L <0.01 <0.01 <0.01 <0.01 0.05 No relaxation 24 Zinc as Zn, mg/L 0.02 0.06 0.1 0.35 5 15 25 Anionic detergents (as MBAS) <0.2 <0.2 <0.2 <0.2 0.20 1.0

26 Total Chromium as Cr

6+,mg/L

<0.01 <0.01 <0.01 <0.01 0.05 No relaxation

27 Residual free chlorine, mg/L <0.05 <0.05 <0.05 <0.05 Min 0.2 -

28 Alkalinity, as CaCO3, mg/L 198.4 195.6 51.2 89.2 200 600 29 Aluminum as Al, mg/L 0.03 0.01 0.02 <0.01 0.03 0.2 30 Boron as B, mg/L <0.1 <0.1 <0.1 <0.1 1.00 5.0

Table-3.16 Ground Water Quality

80

D. OBSERVATIONS

The physicochemical quality of the ground water sources at and around the plant site

has been analyzed, which indicates that almost all the parameters analyzed are within

“Maximum Acceptable Limits As per IS: 10500-1991.

The analysis of samples collected from rivers for various parameters also reveals that

the quality of water is fairly potable to meet the quality requirement for human use.

The Observations made are Tabulated Below

Ground water Sl. no.

Parameter Surface water Project site

Other locations

1 pH 8.1 6.79 7.16-8.1

2 Total dissolved solids, mg/L 122.0 495.3 495.3-498.9

3 Total hardness, mg/L 120 298.9 251.3 -297.6

4 Fluoride, mg/L 0.08 0.4 0.19 – 0.6

5 Nitrates, as NO3 , mg/L 1.5 10.6 4.4-7.2

5. SOIL AND GEOLOGY

Soil characteristics, erosion aspects, soil fertility etc., have direct bearing on the

environment. Knowledge of soil parameters is essential for the planning and

implementation of green-belt. Hence it becomes important to study the soil

characteristics. Baseline data for land environment was collected at two locations in

order to assess the soil quality of the study area. Soil samples at a depth of one and

half feet were collected using sampling augers, spades and field capacity apparatus.

The list of locations and the orientation with reference to the project site are listed in

Table-3.17. Soil sampling locations are shown in the map appended as Figure-3.4. Soil

samples were analyzed for physical and chemical parameters the results of which are

given in Table-3.18.

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Table-3.17 Soil Sampling Stations

Sl. No.

Code No.

Name of the Station

Direction from site

Distance from site (km)

1 S 1 Project site - -

2 S 2 Kirugunda East 1.70

3 S 3 Bendagahalli South West 3.88

Table-3.18 Physico-Chemical Characteristics of Soil

Sampling station Sl. No.

Parameter S 1 S 2 S 3

1 Texture Greenish Brown Colored Moist

Soil

Grey colored moist soil

Grayish brown colored soil

2 pH(20% Suspension) 8.46@ 24 0C 8.21@ 24 0C 7.9@ 24 0C

3 Organic solids, % 4.8 7.3 6.5

4 Chlorides, as Cl, % 0.005 0.005 0.002

5 Phosphorous, as P,% 0.01 0.01 0.024

6 Nitrogen, as N, % 0.10 0.14 0.21

7 Potassium, as K, % 0.15 0.14 0.023

8 Iron, as Fe, % 3.1 2.1 2.8

9 Sulphates, as SO4, % 0.02 0.07 0.016

10 Calcium, as Ca, % 1.7 3.0 0.65

11 Magnesium as Mg % 0.07 0.09 0.19

12 Conductivity microomhos/cm (20% suspension)

95.8@24 0C 199.3@24 0C 69

13 Moisture, % 4.0 6.4 5.6

14 Inorganic solids, % 95.2 92.7 84.6

The results of the analysis show that the nature of the soil is neutral.

mailto:95.8@24

82

Figure- 3.4 Topo Map Showing Sampling Locations

83

Table- 3.19 Location of Sampling Stations

Sl. No.

Name of the Station

Direction from site

Distance from site (km)

Sampling location code

1 Project site - - A1, N1, GW 1,S1

2 Kirugunda (downwind direction)

East 1.70 A2,N2, GW 2,S2

3 Alaganchi SE 2.0 A3,N3,

4 Bendagahalli SW 3.88 A4,N4,S3

5 Haniyamballi North 3.68 A5,N5,

6 Saragooru NW 3.09 A6,N6,

7 Alaganchipura SE 0.60 GW3

8 Chinnadagudi

Hundi SW 2.91 GW4

9 Kabini river North 3.52 River

Note: All distances mentioned are aerial.

6. BIOLOGICAL ENVIRONMENT:

A biological system comprises of both plant and animal communities. Natural flora and

fauna are important feature of the environment. Ecological systems show complex

interrelationship between biotic and abiotic components including dependence,

competition and mutualism. Biotic component comprises of both plant and animal

communities, which interact not only within and between them but also with the abiotic

components viz., physical and chemical components, of the environment.

Several variables like temperature, humidity, rainfall, soil characteristics. Topography

etc., are responsible for maintaining the homeostasis of the environment. A change in

any one of these variables may lead to stress on the ecosystem. The animal and plant

communities exist in their natural habitat in a well-organized manner. Any ecological

system normally undergoes evolution process through their natural settings of

constituent communities. These settings can be disturbed by any externally induced

anthropogenic activities or by naturally induced calamities or disasters also. So, once

84

the natural setting is disturbed it becomes practically impossible or takes a very long

time to come to its original state. Plants and animals are more susceptible to

environmental stress. Thus study of biological environment is one of the most important

aspects of environmental impact assessment, in view of the need for conservation of

biodiversity/ ecology through environmental protection.

6. ECOLOGY

A. FLORA

Natural flora and fauna are important features of the environment. They are organized

into natural communities with mutual dependencies among their members and show

various responses and sensitivities to physical innocence. The integrated ecological

thinking and planning process is an urgent need in the context of natural environment's

deterioration which has a direct bearing on socio-economic development. Ecology of the

study area includes the flora and fauna studies within the study zone. The investigation

included field observations, discussions with local people, forest officials etc. The area

does not have any hiding place for wild life and hence they are not spotted in the area.

The flora and fauna existing in the study area is presented below.

Table - 3.20 Flora and Fauna Study

Botanical Name Local Name Zoological Name Common Name

Abutilon indicum Thubbergida Bubulus bubalus Buffalo

Acacia ferrugenia Banni Ratus ratus House Rat

Acacia leucophloe Hillijali Canis familiaris Dog

Acacia arabica Gobli Equus cabalu Donkey

Asgle americana Kathale Ovis sp. Sheep

Alangium lamarkii Ankole Naja naja Cobra

Santalum album Sandal Ptyas mucosus Rat Snake

Mangifera indica Maavu Bos indicus Cow

Climbers: Alsi, Gunj, Kusari, Uksi, Watwel, Gulvel etc Grasses: Bhuti, Boru, Hanyali, Marvel, Kolsa, Rosha, Phulia, Kusali etc

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B. FAUNA

However, as this area is not a dense forest area, these animals are not often seen in

the vicinity. During the survey and discussions with the local forest government

authorities, it has been noted that endangered species like Lion, Tiger, etc. are not

found within the vicinity.

Domestic animals in the vicinity include Bullock, Cow, Buffaloes, Cat, Dogs, Goats, etc.

The bullocks are mainly used for farming.

The birds in the vicinity includes:

1. Common myna (Acridotherus tristis)

2. Common green pigeon (Treron phoenicoptera)

3. House crow (Corvus splendens)

4. Common quail (Coturnix coturnix)

5. Common king fisher (Alcedo atthis)

However, migratory birds are not found within vicinity.

C. FISHERIES:

There is only a limited scope for fishing in the district. As the district does not have a

coastline only fresh water fishing can be carried out in river and tanks. The rivers and

streams of mysore district are only moderately stocked with fish. The fishing is done by

cast nets, gill nets and drag nets and also by hook and lines.

7. SOCIO-ECONOMIC ENVIRONMENT

The baseline data referring to the socio-economic environment is collected by way of

secondary sources such as census records, statistical hand book and relevant official

records with the government agencies and primary sources such as the socio-economic

surveys conducted by different Govt. & Non Govt. Agencies.

86

The growth of industrial sectors and infrastructure development in and around the

agricultural area i.e. villages and semi-urban settings and towns is bound to create

certain socio-economic impacts on the local population. The impacts may be either

positive or negative depending on the nature of development. To assess such impact it

is necessary to know the existing socio-economic order of the study area, which will be

helpful in improving the overall quality of life.

A. Demographic structure

The information collected from the secondary sources are from the district census

statistical hand books and the records of the National Informatics Center, New Delhi in

respect of the population, infrastructure facilities available and the occupational

structures of the study area. The socio-ecological aspect of the study include the agro

based economy, industry based economy and occupational structure of the workers.

The distributions of population in the study area as per the census record of the 2001

are presented as table 3.21 below.

Table- 3.21 Distribution of Population Alaganchi

Particulars 2001 2011

Total residential houses 473 536 Total population 2258

2560

Population male 1153 1307 Population female 1105

1253

Schedule caste male 456

517

Schedule caste female 439

498

Schedule tribe male 272 308 Schedule tribe female 259

294

Literates male 502

569

Literates female 327

371

Main workers male 759

861

Main workers female 269

305

Marginal workers male 11 13

Marginal workers female 28 32 Non workers male 383 434 Non workers female 808 915

87

Source: District census handbook

Note: The percentage decadal growth rate for Mysore during 2001 – 2011 is 13.39 %

(from http://censuskarnataka.gov.in/)

Male population – 51.05 %

Female population – 48.94 %

Literacy levels

The literacy level in the study area is appended as table 3.22 below

Table-3.22 Distribution of Literates and Literacy Levels in the Study Area

Alaganchi Particulars

2001 2011

Total population 2258 2560

Total literate 829 940

Literate male 502 569

Total % of literates 36.71

% of male literate 60.53

Literate female 327 371

% of female literate 39.46

Source: District census hand book

B. Social infrastructure available

Infrastructure is the basic physical and organizational structures needed for the

operation of a society or enterprise or the services and facilities necessary for an

economy to function.

The term typically refers to the technical structures that support a society, such as

roads, water supply, sewers, electrical grids, telecommunications and so forth and can

be defined as "the physical components of interrelated systems providing commodities

and services essential to enable, sustain or enhance societal living conditions.

88

Viewed functionally, infrastructure facilitates for example, roads enable the transport of

raw materials to a factory. The basic social services such as schools and hospitals are

also very essential.

The list of hospitals & other infrastructural facilities available in the vicinity of the

proposed industry is tabulated below

Table- 3.23 List of Infrastructural Facilities in the Surroundings

Sl. No. Hospital Dist. & Dir. from the

industry (km)

1 JSS primary health center, Sutturu

7.59, NE

2 Sushrutha Ortho Clinic, Nanjanagudu

7.39, W

3 Arogyashrama, Nanjanagudu

8.82, W

4 Government Hospital, Nanjanagudu

8.38, NW

5 ESI Hospital 8.99, NW

6 Chinnadagudi Hundi railway station

3.50, SW

7 Badanavalu railway station 2.90, S

8 Nanjanagudu railway station 7.89, NW

9 Mysore Airport 17.43, NW


C. Connectivity

Connectivity to the project site is detailed in the following table. Google map showing

the same is appended subsequently.

89

Table-3.24 Connectivity from the Project Site

Sl. No.

Road Dist. & Dir. from the

project site (km)

1 SH- 84 2.25, N

2 SH – 80 3.96, SW

3 NH-212 9.00, W

4 Chinnadagudi Hundi railway station 3.50, SW

5 Badanavalu railway station 2.90, S

6 Nanjanagudu railway station 7.89, NW

7 Mysore Airport 17.43, NW

8 Karnataka Tamilnadu border 36.67, SE


D. Surrounding industries

The details of the major industries in the surrounding are tabulated below.

Table-3.25 Industries Surrounding the Project Site

Sl. No.

Industry Dist. & Dir. from the

project site (km)

1 Gemini Distilleries 4.45, W

2 Nanjangud industrial area 10.50, NW

3 UB industry 7.49,NW

Note: - All distances mentioned are aerial

90

3.3 BASE MAPS OF ALL ENVIRONMENTAL COMPONENTS

Table-3.26 Existing Land-Use Pattern

Sl. No.

Particulars Details Dist.& Dir. from the

project site (km) Direction w.r.t. project site

1 Agriculture Scattered - -

2 National park,

forest Sri Chamarajendra Zoological Gardens

22.98 NW

3 Water bodies Kabini river 3.52 North


91

Figure-3.5 Google map showing connectivity

92

Figure-3.6 Google map showing land-use pattern

93

Figure-3.7 Google Map Covering 5 Km Aerial Distance From the Project Site

94

Figure-3.8 Google Map Covering 10 Km Aerial Distance From the Project Site

Chapter - 4

ANTICIPATED ENVIRONMENTAL IMPACTS

AND MITIGATION MEASURES

95

Chapter – 4

ANTICIPATED ENVIRONMENTAL IMPACTS AND MITIGATION MEASURES

4.1 INTRODUCTION

Environmental impact in the study area is any alteration of environmental conditions or

creation of new set of environmental conditions, adverse or beneficial, caused or

induced by the impact of project. Prediction involving identification and assessment of

potential impacts of the project on surrounding environment is a significant component

of REIA studies. The likely Impacts of various activities of the proposed project on the

environment were identified. These impacts were assessed for their significance based

on the background environmental quality in the area and the magnitude of the impact.

All components of the environment were considered and wherever possible impacts

were evaluated in quantitative/qualitative terms. Several scientific methods are

available to qualify and predict the impact of project on environmental factors such as

water, air, noise, land ecological socio economic. Such predictions are superimposed,

over base line environmental status to derive post project scenario of the environmental

conditions. The resultant (post-project) quality of environmental parameters is reviewed

with respect to the permissible limits. Based on the impacts thus predicted preventive

and mitigation measures were formulated and incorporated in the environmental

management plan to minimize adverse impacts on environmental quality during and

after project execution.

The environmental impacts can be categorized as primary and secondary. Primary are

those which are directly attributed to the project and secondary impacts are those which

are indirectly induced due to primary impacts and include those associated with

investment & socio-economic status. The project impact may be broadly divided into

two phases.

96

During construction phase: These may be regarded as temporary or short term

and ceases with implementation of the project.

During operation phase: These impacts are continuous warranting built in

permanent measures for mitigation and monitoring.

Construction and operation phase of the project comprises of various activities, each of

which will have an impact on some or other environmental parameters. Impacts on

environmental parameters during construction and operational phase have been studied

to estimate the impacts on environment. The impacts have been predicted for the

proposed industrial project assuming that the pollution due to the existing activities has

already been covered under baseline environmental monitoring.

4.2 IDENTIFICATION & CHARACTERIZATION OF IMPACTS

The wastes and pollutants generated due to various activities of the project cause

impacts on different environmental attributes. The major project activities and the

affected environmental parameters are given below.

4.2.1 CONSTRUCTION PHASE

Construction activity includes foundation works, fabrication of storage tanks and

erection of plant-machineries. The construction phase is expected to be about three

months. The major activities during construction phase include,

1. Site preparation and development

2. Civil construction work

3. Vehicular movement

4. Loading and unloading civil items and plant machineries

5. On site storage of civil items & plant machineries.

6. Erection of plant and civil structures

7. Power supply

8. Maintenance of construction machinery

9. Disposal of solid wastes

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4.2.2 OPERATION PHASE

The major activities M/S Bannari Amman Sugars Ltd site in the operational phase

involves storage & handling of Molasses, bagasse & associated raw materials, etc.

These activities may affect the environment in varying degrees through natural

resources depletion viz. water consumption, release of particulates and

gaseous emissions, contamination of water body, run-off from waste storage area

etc. During working life of plant, air, water and noise may be affected due to material

usage and processing of alcohol and associated activities in general. The sources of

pollution during operational is given in Table 4.2. Allied operations, e.g. transportation

of materials, operations of workshop and garage, canteen etc., may also affect air,

water and noise environment. Green belt development will have a positive impact not

only on flora and fauna but also on air quality, noise and soil characteristics. Positive

impacts on socio- economic environment are expected due to employment, further

infrastructure development and also due to socio-economic welfare developmental

activities to be taken up. The major project activities and the affected environmental

parameters are given below.

Project Activities:

i. Manufacture of alcohol

ii. Operation of power plant with boiler and turbine

iii. Water treatment

iv. Spent wash treatment through evaporation and Incineration by utilizing it as fuel

in boiler along with supportive fuel such as bagasse, biomass & Coal.

v. Storage of molasses and alcohol, fuel, boiler ash and bio-manure.

vi. Transportation of raw materials, products and personnel.

Pollution Sources:

i. Spent wash and other waste water from the distillery

ii. Flue gases from boiler and diesel generators

iii. Solid wastes (boiler ash, press mud, ETP sludge)

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iv. Noise from turbine, D.G. set, fans, and vehicular movement.

Affected Environmental Parameters

1. Air quality

2. Water resources & quality

3. Noise level

4. Soil quality

5. Biological

6. Socio-economics

Impact Matrix

Environmental impacts could be positive or negative, direct or indirect, local or regional

and also reversible or irreversible. The primary function of an environment impact

assessment study is to predict and quantify the magnitude of these impacts, evaluate

and assess the importance of the identified changes, present information and monitor

actual changes. The activities of the proposed project are studied. The impacts of

various activities of the proposed project are identified and presented as matrix in

Table-4.1. Further the characteristics of these impacts have been evaluated and they

are presented as matrix in Table- 4.2A 4.2B,

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Table-4.1 Impact Identification Matrix

Environmental Attribute

Activities Air Noise

Surface Water

Ground Water

Climate Land &

soil Ecology

Socio Economics

Aesthetics

Construction Phase

Site Clearing

Quarrying (indirect)

Ready-mix concrete preparation

Transportation of raw materials

Construction activities on land

Laying of roads

Operational phase

Operation of DGs

Solid waste disposal (indirect)

Wastewater disposal

Buildings

Storage and handling of Raw

materials

Processing of Alcohol

Vehicular Movement

Air Emissions from Stack and

other Unit processes

100

Table-4.2A Characteristics of Environmental Impacts from Construction Phase

Impact characteristics

Activity

Environmental

Attributes

Cause Nature Duration Reversibility Significance

Air Quality (SPM,PM10

SO2, NOx, And CO

Dislodging of particles from the

ground

Direct

Negative

Short Term

Reversible

Low, if Personnel Protective

Equipment (PPE) are used

Noise levels

Noise generation from earth excavating equipment

Direct

Negative

Short Term

Reversible

Low, if PPE are used by workers

Land Use

Industrial land use Direct

Negative

Long Term

Irreversible

Low.

Site clearing

Ecology

Removal of vegetation and loss of flora and fauna

Direct

Negative

Long Term

Reversible

Low. No cutting of

trees.

Air Quality

(SPM, PM10

SO2, NOx, CO)

Transport of construction

material in trucks & Exhaust

emission from vehicles

Direct

Negative

Short Term

Reversible

Medium if regular emission checks are performed

Noise levels Noise generation

from vehicles

Direct

Negative

Short Term

Reversible

Low if regular vehicle

maintenance is done.

Transportation of construction

materials

Risk Risk of accidents

during transit

Direct

Negative

Long

Term

Irreversible

Low, if safety measures are

taken to prevent accidents

Air Quality (SPM, SO2, NOx, CO)

Operation of construction

machinery, welding activities and

others

Direct

Negative

Short Term

Reversible



from use of machinery

Direct

Negative

Short Term

Reversible


Land use Setting up of

Project

Direct

Negative

Long Term

Irreversible The area is

designated as Industrial area

Construction activities

/ Laying of roads

Ecology Loss of vegetation

Direct

Negative

Long Term

Reversible

Low. No cutting of

trees and green

belt development

is envisaged

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Table-4.2B Characteristics of Environmental Impacts from Operational Phase

Impact characteristics

Activity

Environmental

Attributes

Cause Nature Duration Reversibility Significance

Afforestation / Green belt development

Ecology Planting of trees Direct

Positive Long Term

Reversible High positive impact

Air Quality (SPM, SO2,

NOx, CO, HC)

Unit operations Vehicle operation

and fuel combustion

Direct Negative

Long Term

Reversible

Low as Ambient and Stack Monitoring,

vehicle maintenance will be performed.

Emissions from various unit processes and Vehicular traffic


from vehicles Direct

Negative Short term

Reversible Low, with periodical

maintenance of vehicles

Employment

generation

Direct and

indirect

employment

Direct

Positive

Long

Term Irreversible

High, new

opportunities of

steady income for

many families Socio-

economic

Quality of life

In-flow of funds

in the

region/nation

Direct

Positive

Long

Term Irreversible

High, the project will

generate

employment

Solid waste

disposal Land and soil

Generation of

solid wastes

Direct

Negative

Short

Term Reversible

Low, proper

collection and

disposal

Wastewater

discharge Water quality

Generation of

waste water

Direct

Negative

Short

term Reversible

Low, as Septic Tank

and soak pit will be

provided

Air quality Exhaust

emissions

Direct

Negative

Short

term Reversible

Medium (DG set is

only a standby).

DG set,

operation Noise levels Noise generation

Direct

Negative

Short

term Reversible

Low due to noise

protection measures

(enclosures, PPE

etc.)

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4.3 IMPACTS DURING CONSTRUCTION PHASE

4.3.1 LAND ENVIRONMENT

With land development and leveling, the site may have better landscape. However this

is restricted only to the factory boundary. There are no major trees or crops in the site.

Hence there will be no change in land use pattern or soil quality.

4.3.2 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 will be avoided

during rainy days to mitigate the small impacts on soil quality caused due to

construction activity. With segregation of construction area and proper drainages

provided prevents the contamination of water due to soil erosion. As there are no water

bodies in the vicinity of the project site, the impact of construction activities on water

environment is insignificant.

4.3.3 IMPACT ON AIR ENVIRONMENT

During construction phase, suspended particulate matter will be the main pollutant,

which could be generated from site development activities and movement of vehicles.

Concentration of PM10, SO2, NOX and CO may slightly increase due to increased

vehicular traffic. The approach roads will be paved or tarred and vehicles will be kept in

good order to minimize the pollution due to vehicular traffic. The impact of such

activities would be temporary and restricted to the constructed phase. The impact will

be confined within the project boundary and is expected to be negligible outside the

plant boundaries. Proper upkeep and maintenance of vehicles, sprinkling of water on

roads and construction site, providing sufficient vegetation all-around are some of the

measure that would greatly reduce the impacts during the construction phase.

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4.3.4 IMPACT ON NOISE LEVEL

The major source of noise generation during the construction phase are vehicular traffic,

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). The noise produced during the construction will have

significant impact on the existing ambient noise levels. The construction equipments

have high noise levels which can affect the personnel, operating the machines. Major

construction work will be carried during the daytime. Use of protective equipments like

mufflers will reduce noise generated by such equipments. Personnel protective such as

earplugs shall be used by the operators of these machineries.

4.3.5 IMPACT ON BIOLOGICAL ENVIRONMENT

Sound due to construction activities at the site involving human and vehicular

movement will disturb aril and wild animals in the area. Terrestrial micro flora and fauna

at the site are also affected. However, the adverse effect are reduced by shortening the

construction phase period and development of greenery in the site. No effect on

aquatic environment is expected as there are no water bodies in the vicinity of the site.

Further, there are no sensitive locations within the study area. Hence, no significant

adverse impacts are expected on biological environment.

4.3.6 IMPACT ON SOCIO-ECONOMIC STATUS

The construction phase induces employment opportunities for the local people. Up to

75 persons will be employed during peak construction phase. In addition to the

opportunity of getting employment in construction work, the local population would also

have employment opportunities in related activities like petty commercial

establishments, small contracts and supply of construction materials etc.

The dwelling of construction workers at the site may cause sanitation and other

problems. As the villages are nearby and staying facilities are readily available in these

104

villages. The construction and other workers will not be permitted to reside at the

project site.

Safety and health care of workers is also an important factor to be considered during

construction phase. Hazards expected are electrocution, vehicular accident, fall of

personnel from overhead works, high level noise due to construction machinery,

centering failure and exposure of eyes to dust and welding rays. Constructional and

occupational safety measures will be adopted during construction phase of the industry.

4.4 OPERATIONAL PHASE IMPACT

4.4.1 IMPACT ON AIR QUALITY

1 SOURCES OF AIR POLLUTION

The air quality of the region will be affected by the gaseous and fugitive emissions.

Emissions are generated from boiler and D.G. set. The information on emissions from

project activities is furnished in Chapter-2.

TABLE 4.3 SOURCES OF AIR POLLUTION & POLLUTANTS

Sl. No. Source Pollutants

1 Flue gases from 23.4 T/hr boiler SPM, SO2 and NOx

2 Smoke from 750 KVA D.G. Set SO2, NOx

3 Fugitive emissions SPM

i. GASEOUS EMISSIONS FROM DIESEL GENERATOR

For use in case of power failure, a diesel generator of 750 KVA will be provided in the

unit. The sulphur content in the diesel is about 0.1 %. The height of stack is estimated

as per CPCB guidelines. The diesel generator is operated only during power failure and

other emergency to operate essential services. Hence its impact on environment is not

significant.

105

ii. GASEOUS EMISSIONS FROM BOILER

The boiler will be fired with spent wash concentrate, bio-mass such as bagasse,

biomass & coal. The information on fuels and emissions are given in Table-2.13. The

air pollutants emitted from boiler would be SPM, PM10 , SO2 and NOx. The nitrogen

content in fuels is small. The boiler will be provided with Bag filter to control SPM

concentration in flue gases. The Bag filter is designed to operate with high efficiency

and to reduce SPM below 150 mg/Nm3 in the flue gases. BAG filter specifications are

given in Annexure-8. Height of chimney is designed for the worst scenario of boiler

operation. The height of chimneys will be such that the ground level concentrations of

pollutants including SPM,PM10 SO2 and NOx due to the operation of these boilers will

be within the permissible limits. The information on boiler flue gas is given in Table-4.4.

iii. FUGITIVE EMISSIONS

Fugitive emissions are generated mainly due to fuel and ash handling and vehicular

movement. Table – 4.4 Data on Proposed Boiler Flue Gases

Particulars Boiler -A – (Existing) 23.4 T/Hr

Boiler -B – (Proposed) 23.4 T/Hr

Capacity of boiler 23.4 T/hr 23.4 T/hr

Spent wash concentrate - MT 180.5 180.5

Coal - MT 62 62

Bagasse - MT 118 118

SPM controller for flue gases Bag filter Bag filter

SPM in flue gas (at chimney exit) < 150 mg / Nm3 < 150 mg / Nm3

Flue gas temperature in chimney 200 0C 200 0C

SPM concentration in flue gas 2.80 g/s 2.80 g/s

SO2 concentration in flue gas 18.22 g/s 18.22 g/s

Height of chimney 58 m 58 m

Stack dia. In Metre 1.8 m 1.8

Velocity of flue gas at chimney exit 15.0 m/s 15.0 m/s

Fugitive Emissions arise from the following areas:

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Table 4.5: Sources of Fugitive dust

Sl. No Area Monitoring Location

1 Raw Material Handling area Tripper, Screen area, transfer points, stock bin area

2 Crusher area Crusher plant, vibrating screen , transfer points

3 Raw material feed area Feeder area, mixing area, transfer points

4 Product processing area

Intermediate stock bin area, screening plant, separation unit, transfer points, discharge area, product separation

area, bagging area

iv. FUGITIVE EMISSIONS AND ITS IMPACT

Handling boiler fuel (bio-mass) and boiler ash and the movement vehicles is the source

of fugitive emission in the plant premises. Water sprinkling is practiced on roads and

other locations of dust source to control fugitive emissions. Green belts and plantations

are developed around solid storage yards, manufacturing plants, road sides to reduce

the adverse impact of fugitive emissions. The impact of fugitive emissions in the

industry are controlled by following measures

Green belt and greenery development around storage yards, around plants,

either side of roads and around the periphery of the industry.

Water spray and sprinkling is practiced at roads and near loading & unloading

locations. The roads will be sprayed with water through tractor tankers.

The conveyors of fuel are suitably covered with hood or enclosures to control

fugitive emissions.

All internal roads in the premise will be paved /tarred.

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2 PRE-PROJECT AIR QUALITY

The ambient air quality monitoring data for the study area of 10 km around project site is

furnished in Chapter-3. The air quality monitoring data for stack emission, fugitive

emission in the plant premise is enclosed in Annexure-7. The ambient air quality with

in the project premise and around the premise is within the permissible limits.

3. GROUND LEVEL CONCENTRATION (GLC) OF POLLUTANTS

The prediction of impact due to project activities on air environment was based on

1. Source, quantity and quality of emissions

2. Pre project ambient air quality

3. Air quality modeling

The impact on air quality from the proposed industry is discussed below.

4. AIR POLLUTION DISPERSION MODELING STUDIES

Introduction

Atmospheric dispersion modeling is the mathematical simulation of how air pollutants

disperse in the ambient atmosphere. It is performed with computer programs that solve

the mathematical equations and algorithms which simulate the pollutant dispersion. The

dispersion models are used to estimate or to predict the downwind concentration of air

pollutants emitted from sources such as industrial plants and vehicular traffic. Such

models are important to governmental agencies tasked with protecting and managing

the ambient air quality. The models are typically employed to determine whether

existing or proposed new industrial facilities are or will be in compliance with the

National Ambient Air Quality Standards (NAAQS). The models also serve to assist in

the design of effective control strategies to reduce emissions of harmful air pollutants.

In the present study prediction of impacts on the air environment has been carried out

employing U.S. EPA AERMOD dispersion model, 1996 – 2011 Lakes Environmental

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Software, Version 6.2.0 and designed for multiple sources for predicting the maximum

ground level concentration (GLC).

Model input data

The major air emissions at the site of M/s Bannari Amman Sugars ltd. are SPM, PM10,

SO2 and NOx from boilers & DG Set. The Proponents have proposed to install Bag filter

to the stack of the boiler to control the dust emission in the flue gas. The site specific

and monitored details considered for input data for the software AERMOD view by

Lakes Environmental for prediction of impact on the air environment are given in the

following table

Table 4.6: Data considered for calculation of GLC

Particulars Existing Boiler - 23.4 T/hr Proposed Boiler – 23.4

T/Hr

Stack height 58 m, AGL 58 m, AGL

Stack diameter 1.8m 1.8 m

Flue gas flow 66,200 Nm3/h 66,200 Nm3/h

Gas exit velocity 15 m/s 15 m/s

Flue gas temp. 200°c 200°c

Emission rate,

Emission load, g/s

PM10 1.84 1.84

SO2 36.43 36.43

NOx 8.88 8.88

CO 3.24 3.24

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Emission load Calculations

23.4 TPH boiler x 2 Boilers

SO2 EMISSIONS

Coal

Sulphur content in coal = 5 kg/T = 0.5 %

Fuel consumption = 5.17 TPH

Sulphur content in coal = 5 x 5.17=25.85 kg/h

SO2 emissions from coal = 25.85 x 2.0 = 51.7 kg/Hr = 14.36 g/s

Spent wash

Sulphur content in CSW = 2.5 kg/T


Sulphur content in CSW = 38.0 kg/hr

SO2 emissions = 38.0 x 2.0 = 76.0 kg/h =21.11 g/s

SO2 emissions = 14.36 + 21.11 = 35.47 g/s

CO EMISSIONS -

Coal

Emission factor = 2.5 kg/Mg

Fuel consumption = 5.17 TPH = 5170 kg/h

Emission rate = 2.5 x 5170

= 12.93 kg/h = 3.59 g/s

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NOx EMISSIONS

Coal

Emission factor = 6.85 kg/Mg


Emission rate = 6.85 x 5.17 = 35.41 kg/hr = 9.84 g/s

Meteorological data

Data recorded at the site for one year period (January 1st 2013 to December 31st 2013)

for wind speed, direction, temperature etc. has been used for computations. In order to

conduct a refined air dispersion modeling short term air quality dispersion models, the

site specific hourly meteorological data measured at the site is pre-processed using

U.S. EPA AERMET program.

Presentation of results

The simulations were made to evaluate incremental short-term concentrations due to

proposed project. In the short-term simulations, the incremental concentrations were

estimated to obtain an optimum description of variations in concentrations within study

area of 10 km radius. The predicted (maximum) concentration levels & the incremental

concentrations at various locations due to the proposed industry are tabulated in the

following tables.

Table- 4.7 Predicted Incremental Short-Term Concentrations due to the Proposed Project

Time Maximum predicted

concentrations, µg/m3 Direction and distance of occurrence

PM10 0.84616 0.2 km – East

SO2 12.48999 9.6 km- E, 4.5 km-W, 2.1 km - S &

0.9 km -N

NOx 4.08362 2.2 km - East & West, 1.1km - South

CO 1.48997

1 hr – 0.9 km – East & West 8 hrs –4.0 km – East &West

1.6 km –South, 0.6 km - North

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Figure- 4.1 Incremental concentration (PM10) Isopleths for the Proposed Project, 24 hours (Bannari Amman Sugars Ltd.,)

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Figure-4.2 Incremental concentration (SO2) Isopleths for Proposed Project, 24 hours (Bannari Amman Sugars Ltd.,)

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Figure-4.3 Incremental Concentration (NOx) Isopleths for Proposed Project, 24 h (Bannari Amman Sugars Ltd.,)

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Figure- 4.4: Incremental Concentration (CO) Isopleths for Proposed Project, 1h (Bannari Amman Sugars Ltd.,)

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Comments

The maximum short-term incremental ground-level concentrations are superimposed on

the baseline data to get the likely resultant levels after the establishment of the

proposed project as tabulated below.

Table 4.8: Resultant Maximum 24 Hourly Concentrations

Pollutant Incremental concentrations, µg/m3

Max. Baseline concentrations, µg/m3

Resultant concentrations, µg/m3

Limits as per MoEF, µg/m3 for industrial areas (24 hrs)

PROJECT SITE (A1) PM10 0.84616 45 45.846 100 SO2 12.48999 4 16.489 80 NOx 4.08362 6.2 10.283 80

CO 1.48997 – 8 hrs 3.22331– 1 hr

ND 1.48997 – 1 hr 3.22331– 8 hrs

4,000 – 1 hr 2,000 –8 hr

KIRUGUNDA (DOWNWIND DIRECTION) (A2) PM10 0.84616 42.5 43.346 100 SO2 12.48999 3.1 15.899 80 NOx 4.08362 5.3 9.383 80

CO 1.48997 – 8 hrs 3.22331– 1 hr

ND 1.48997 – 1 hr 3.22331– 8 hrs

4,000 – 1 hr 2,000 – 8 hrs

ALAGANCHI (A3) PM10 0.84616 35.5 36.346 100 SO2 12.48999 2.7 15.189 80 NOx 4.08362 3.9 7.9836 80

CO 1.48997 – 8 hrs 3.22331– 1 hr

ND 1.48997 – 1 hr 3.22331– 8 hrs

4,000 – 1 hr 2,000 – 8 hrs

BENDAGAHALLI (A4) PM10 0.84616 28.5 29.346 100 SO2 12.48999 2 14.489 80 NOx 4.08362 3.5 7.5836 80

CO 1.48997 – 8 hrs 3.22331– 1 hr

ND 1.48997 – 1 hr 3.22331– 8 hrs

4,000 – 1 hr 2,000 – 8 hrs

HANIYAMBALLI (A5) PM10 0.84616 40.5 41.34 100 SO2 12.48999 3.3 15.789 80 NOx 4.08362 4.7 8.783 80

CO 1.48997 – 8 hrs 3.22331– 1 hr

ND 1.48997 – 1 hr 3.22331– 8 hrs

4,000 – 1 hr 2,000 – 8 hrs

SARAGOORU (A6) PM10 0.84616 42 42.846 100 SO2 12.48999 4.1 16.589 80 NOx 4.08362 5 9.0836 80 CO 1.48997 – 8 hrs

3.22331– 1 hr ND

1.48997 – 1 hr 3.22331– 8 hrs

4,000 – 1 hr 2,000 – 8 hrs

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Table- 4.8 A Ambient Air Sampling Stations

Sl. No.

Code no.

Name of the station

Dist. & Dir from the site

1 A 1 Project site -

2 A 2 Kirugunda (downwind

direction) 1.70 km, E

3 A 3 Alaganchi, School 2.0 km, SE

4 A 4 Bendagahalli, Tea shop 3.88 km SW

5 A 5 Haniyamballi, Bus stand 3.68km, N

6 A 6 Saragooru, School 3.09km, NW

According to MoEF air quality standards (as per the notification dated 16th November

2009 for industrial, residential & rural areas) 24 hourly or 8 hourly or 1 hourly monitored

values, as applicable, shall be complied with 98% of the time in a year; 2% of the time,

they may exceed the limits but not on two consecutive days of monitoring.

Therefore the 98% values are considered for estimation of the incremental

concentration.

The above table indicates that the cumulative resultant ambient air quality after

proposed project operation will be within the ambient air quality limits specified by MoEF

as per the notification dated 16th November 2009 for industrial, residential & rural areas.

4.4.2 WATER ENVIRONMENT

Potential impacts of withdrawal of water and wastewater discharges from the proposed

industry on land or water body is an important factor in EIA Studies. The quantitative

and qualitative information on water utilization and waste water generation in the

proposed industry is presented in Chapter - 2. The information also includes the built in

facilities and measures for treatment and disposal of waste water proposed to be

incorporated in the project. The impacts expected from withdrawal of water from river

and disposal of waste water on land is discussed in this section.

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i. WATER USAGE

Fresh water requirement to the industry will be met from the Kabini River located at

about 6 km from the site. The industry is already having permission for drawal of water

from the river. Storm water storage tank is available to hold the rain water for its use

during lean season period. Various water conservation measures including reduce,

reuse and recycle are practiced in the industry. Large quantity of water present in sugar

cane is recovered and utilized as source of water to the industry. Water utilization and

management details are given in Chapter- 2

ii. WASTE WATER TREATMENT AND DISPOSAL

Water conservation measures such as re-boilers to distillation column, reuse of spent

lees water good housekeeping etc. will be introduced in the distillery to reduce the

generation of waste water

Waste water generated from the proposed project will consist of 1205 m3/d spent wash,

highly contaminated with organic and inorganic matter and 185 m3/d of combined

factory effluent with moderate organic and inorganic matter. Spent wash generated from

distillery is concentrated and Incinerated in boiler as fuel. Concentrated spent wash will

be used as fuel in the boiler to generate steam. The ash produced from the boiler is

valuable soil nutrient as it contains high percentage of potash and phosphates. It is

utilized in bio-composting and also supplied to farmers and others for using it as soil

conditioner on agriculture lands.

Domestic effluent stabilized and then disposed to soak pit. The miscellaneous effluents

generated in distillery and power plant are treated to irrigation standards in Effluent

Treatment Plant and then utilized for development of greenery and sugar cane

cultivation.

In view of the measures taken as above there is no adverse effect of spent wash or

other effluents on environment.

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The details of water and effluent management in the industry are given in Chapter-2.8.

The summary of waste water treatment scheme is given in Table-4.6.

Table-4.9. Treatment and Utilization of Waste Water

IV. Surface water hydrology

According to the data available, the study region shows all the features of semi-arid

erosion, the drainage channels are short and discontinuous and remain dry except

during short period of rainfall. The amount of rainfall in the study area is the main factor

causing changes in water level of the streams, which will affect their water quality.

During rainy days water in streams is turbid. Off rainy days the water is of good quality.

The project site is at elevated location and no natural steams in the area. During

construction period, loose soil and gravel is likely to be washed out. Potential impacts

on surface water quality during construction could arise from dust emissions due to

vehicular movement and disturbance of soil cover. It causes high suspended solids in

storm water runoff. Bund and embankments will be provided avoid wash out of loose

soil and gravel. Dust emissions will be controlled by periodic spraying with water.

Suspended solids will be controlled by using the construction pits to allow the particles

to settle down prior to discharge. Further, construction work during rainy period will be

curtailed. These measures will reduce surface water quality impacts during construction

to insignificant levels.

Sl. No.

Source Quantity

m3/d Disposal

1 Spent wash from

distillery plant. 997 or

1216 T/d

Concentrated in evaporator and then used as fuel in boiler. Condensate water from evaporator will be treated and preused in distillery process and for cooling tower water make up.

2 Factory effluent from boiler, cooling tower,

plant washings 1008

Treated in anaerobic, aerobic process and treated effluent is used for irrigation purpose.

3 Domestic 06 Septic tank and soak pit

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The proposed unit being a process industry generates utilize water and generate

effluent. The industry is adopting the best available technology to reduce the utilization

of fresh water. Further the effluents are suitably treated to confirm to the standards set

by the pollution control board. Further treated effluents shall be utilized for irrigation

purposes. No serious surface water pollution is expected.

4.4.3 NOISE LEVEL

The permissible occupational noise level and exposer time is given below.

Standards for Occupational Noise Exposure

Total Time of Exposure per day in hours (continuous or short term Exposure)

Sound pressure level in dB (A)

8 90 6 92 4 95 3 97 2 100

3/2 102 1 105 ¾ 107 ½ 110

1/4 115 NEVER 115

Note: No exposure in excess of 115 of dB (A) is to be permitted. For any period of

exposure falling in between any figure and the next higher or lower figure or indicated in

column (1). The permissible level is to be determined by extrapolation on a

proportionate scale. Similarly, the standards for ambient noise level are given below.

Category of area dB (A) Day dB (A) Night

Industrial Area 75 70

Commercial Area 65 55

Residential Area 55 45

Silence Zone 50 40

Day Time : 6 am to 9 pm Night time : 9 pm to 6 am

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To meet these limits, noise abaterment measures as indicated in EMP will be

incorporated with the project.

The principle source of noise from industry are from fans, centrifuge, turbine, sugar

dryer, steam traps, steam vents etc., the observed noise level of these machineries in

existing sugar factories is given below.

i. Steam turbine - 90 – 95 dB (A)

ii. Fans, compressors and blowers - 85-90 dB (A)

Most of these generate higher noise. The movement of vehicles like trucks & tractors

have noise level of 70-80 dB (A).

Steam turbine is located in separate buildings and acoustic treated premise. Workers at

these equipments are provided with noise control appliances. The noise impact of the

industrial activity is insignificant at the boundary level of the industry. The noise level

due to project activity is limited to the project site only and little impact on surrounding

area. However, movement of vehicles will increase noise levels on the roads and their

near by vicinity.

4.4.4 IMPACT ON SOIL QUALITY

The soil characteristics in the study area are given in Chapter-3 It is seen that the soil

quality is of moderate fertility. Waste water and solid waste if discharged without control

on land are likely to affect soil quality. Miscellaneous effluent, 185m3 /d is treated to

irrigation standards and then utilized on land. Spent wash and solid waste are not

discharged from the plant. Boiler ash contains soil nutrient such as potash and

phosphate. Utilization of Boiler ash on agriculture land improves the soil quality.

4.4.5 BIOLOGICAL ENVIRONMENT :

The study area is mainly agricultural land. There are no forests and no significant water

bodies in the vicinity of the site except the river Kabini which is at 6.0 km north from the

site. There are no endangered flora and fauna species in the region. The project

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activities are restricted to the factory site except the transportation of raw material and

products. There is no discharge of solid or liquid wastes to the environment. No impact

of project on biological environment is expected.

4.4.6 SOCIO-ECONOMIC IMPACT

Establishment of project will enhance the transportation activity. This will create

opportunities to the localites to start vehicle garages. With development of the industry

the roads and communicatiun facilities will be enhanced. The distillery will also create

job opportunities to the local peoples.

Presently the educational facilities in the study area are limited to primary and high

school. With establishment of this industry the transportation, public mobility and job

opportunity along with associated activities in the region may increase. These activities

will improve economic condition of the local population. The presence of the industry

will enhance commercial activities, which inturn will improve the economic conditions of

the population. Service infrastructure like transportation, health care, education,

communication facilities may improve considerably. The availability of power from the

industry will help to reduce the power scarcity and frequent power failures in the region

by stabilization of the power in the grid, which will improve power supply to irrigation

pump sets and house hold requirements.

4.4.7 TRAFFIC DENSITY AND ITS IMPACT

Bagasse and molasses are the main inputs to the proposed project and they are

available from the captive source and transported through pipe line and covered

mechanical conveyor. Shortage of these materials will be met from external source.

Raw materials (molasses), fuels (Bagasse/coal/Other biomass) will be procured from

various locations of Mysore and adjacent districts in Karnataka state and transported to

the factory through lorry transport. Similarly alcohol produced in the factory is

transported to various consumers in and out of the state through lorry tankers. The

vehicles will move mainly through State and National high ways. District roads are

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tarred. Presently, the traffic on these roads is meagre. The additional traffic due to the

proposed activity is not likely to affect the environment.

TRAFFIC DUE TO PROJECT ACTIVITIES

Personnel

During operation a maximum of about 90 persons (inclusive of employees and others)

are attending the industry. A total of about 2 visits by four wheelers and 40 visits by two

wheelers and 4 by bus will be made to the industry for transportation of personnel. In

addition 10 night duty vehicles provided for movement miscellaneous material such as

stores, ash etc.

Material

Movement of heavy vehicles due to transportation of material and personnel during

operation is given below.

Molasses - 12 tanker lorries per day

Alcohol - 9 tanker lorries per day

Others (Fuel & Boiler ash)) - 10 lorries per day

3. TRAFFIC IMPACTS AND MITIGATION MEASURES

The transportation density on the road is likely to increases by about 20 %. The road is

a tarred wide road and has adequate capacity to take the additional vehicular load. The

road passes through villages and adjacent to agriculture lands. Lorries carrying solid

material and Bagasse will be covered with tarpaulin. The industry will take measures to

additional plantation on road sides. Bell mouth shape geometry will be provided at entry

and gates to the industry. Considering the facilities as above the impact of additional

transportation on road will be insignificant.

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4.5 MITIGATION MEASURES AGAINST ENVIRONMENTAL IMPACTS

The main objective of mitigation measures is to conserve the resources, minimise the

waste generation, treatment of wastes, recovery of by products and recycling of

material. It also incorporates greenery development and landscape of open area and

also the post project monitoring of environmental quality. The measures under

mitigation plan are classified as,

Measures built in the process

Measures during construction phase

Measures during operation phase.

4.5.1 MEASURES BUILT IN THE PROCESS

Built in measures for resource conservation and pollution control in the industry are

discussed along with project details in Chapter-2. The main objective is to follow

environmental friendly process, with efficient utilisation of resources, minimum waste

generation and built in waste treatment and operation safety. The measures adopted

are,

DISTILLERY UNIT

i. Continuous fermentation to improve alcohol yield and recovery and thereby

molasses consumption reduced.

ii. Separation, recovery and recycle of yeast present in fermenter wash for reuse in

fermenter. This reduces the use of fresh culture and nutrients in the fermenter and

also improves ethanol yield.

iii. Use of live steam is avoided by installing re-boiler in distillation columns. This

reduces the generation of wastewater.

iv. Multi pressure distillation system is used to reduce the consumption of steam and

quantity of effluent.

v. Use of pumps with mechanical seals to avoid liquid leakages.

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vi. Scrubbing of fermenter vent gases containing CO2 to recover traces of alcohol

present in it.

vii. Water utilization reduced by 1. Evaporation of spent wash with recovery of

condensate water for use in Distillery process & cooling tower make up,

2. Re-boiler reduces water utilization, and 3. Recycle of spent lees water for

dilution of molasses.

viii. Concentrated spent wash is used as fuel in boiler.

4.5.2 CONSTRUCTION PHASE MITIGATION MEASURES

1. WATER MANAGEMENT

Construction equipment requiring minimum water for cooling and other operations will

be chosen.

i. High pressure hoses will be used for cleaning and dust suppression purpose.

ii. If water from local well is to be extracted, the rate of extraction would always be kept

below the safe yield level.

iii. Monsoon season would be avoided for the construction activity, particularly the

excavation work.

iv. Wherever required check dams and dykes will be provided for control of soil erosion.

v. Fast growing soil holding/binding vegetation e.g. grass will grown around the

construction site before commencement of construction activity to reduce soil

erosion and dust suppression.

vi. Appropriate sanitation facilities will be provided for the workers to reduce impact on

surface water quality.

vii. Construction wastes will not be discharged to surface or ground water bodies.

2. AIR QUALITY

i. All vehicles and construction equipment with internal combustion engines being

used will be maintained for effective combustion to reduce vehicular emissions.

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ii. Vehicles and all internal combustion engines will meet the prescribed emission

standards of CPCB.

iii. Unleaded petrol will be used for vehicles in use.

iv. Vehicles being allowed within the construction site and for the construction activity

will be meeting the vehicular pollution regulations.

v. Good quality diesel from authorized dealers will be used. Good combustion and

there by reduced gaseous emission from vehicles and diesel generator is ensured.

vi. Water will be sprayed through high pressure water hoses during dust generating

construction activities e.g. excavation, crushing, concrete mixing, material handling

etc. for dust suppression.

vii. Measures will be taken not to use asbestos in the construction work.

3. NOISE

i. Construction equipment generating minimum noise and vibrations will be chosen.

ii. Ear plugs and/or ear muffs will be used by construction workers working near the

noise generating activities.

iii. Vehicles and construction equipment with internal combustion engines will be

provided with silencers and mufflers in order to reduce noise levels.

iv. Green belt will be developed to attenuate noise impacts and to reduce noise

pollution.

4. LAND

i. Check bunds shall be built in the construction area to prevent soil erosion due to rain

water.

ii. Measures will be taken to minimize waste soiled generation. Constructional waste

material will be recycled.

iii. Designation and demarcation of construction site with due provision for

infrastructure.

iv. Appropriate measures are adopted for slope stabilization to reduce land erosions.

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5. ECOLOGY

The measures indicated below will be practiced in maintaining ecology.

i. Plantation of dust absorbing trees near dust emission areas.

ii. Plantation of soil holding/ binding and fast growing plants e.g. grass to avoid soil

erosion.

iii. Plantation of noise attenuating species to reduce noise pollution both during the

construction as well as in the operational phase.

iv. Stabilization of all disturbed slopes before the onset of monsoon to avoided soil

erosion.

v. Avoiding felling of existing trees / vegetation as far as possible. If necessary, the

number of trees felled to be replaced with double the number of trees in the form of

green belt development.

vi. Reuse of wastewater generated out of construction activity for irrigation of green

belt.

vii. Avoiding use of high noise producing equipment during night time to avoid impact on

fauna present in the region.

viii. Use on best available construction technology to minimize impacts on flora and

fauna of study area.

6. SOCIO-ECONOMIC FACTORS

i. Marking use of local people for construction work to the maximum extent possible.

ii. Providing proper facilities for domestic supply, sanitation, domestic fuel, education,

transportation, etc. for the construction workers.

iii. Protection of company employees and equipment from construction hazards such as

open excavations, falling objects, welding operations. dust, dirt, temporary wring,

and temporary overhead electrical lines.

iv. Barricades, fences and necessary personnel protective equipment such as safety

helmet, shoes, goggles, harness etc. will be provided to the workers and employees.

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4.5.3 OPERATIONAL PHASE MITIGATION MEASURES

The generation of pollutants such as waste water, gaseous emissions, waste solid and

noise and also the other activities of the project during operational phase are likely

cause adverse impacts and stress on various environment parameters. The

management plan for mitigation of such adverse impacts and for enhancement of

beneficial impacts is discussed below.

1. WATER MANAGEMENT

Water Resources

i. Fresh water need to the industries will be minimized by taking appropriates reuse

and recycle measures as discussed in chapter-2.

ii. A net work of planned storm water drainages will be provided and maintained to

avoid contamination of rain water with factory waste water and other waste

materials.

iii. Rain harvesting plan will be implemented to collect, and store rain water to replenish

the underground water. The rain water thus collected can be used for irrigation and

greenery development in the premises. This water can also be used to supplement

the fresh water requirement in the industry.

Waste Water

The quantity and quality of waste water in the plant will be controlled by following

measures.

i. Recycle of process water including vapour condensate and hot water.

ii. Control of water taps, hose pipe washings, leakages from pump glands and flanged

joints and overflow of vessels are monitored and controlled.

iii. Floor cleaning with hose pipe waster is replaced with dry cleanings using bagasse.

iv. Leakages & spillages at pumps & vessels is collected in small pits near the

respective locations and recycled.

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v. Effluent treatment plant (ETP) facilities as envisaged in chapter 2 including

spentwash concentrating evaporators will be provided.

vi. Effluent treatment plants will be operated scientifically to treat to the waste

water to irrigation standards.

vii. Treated waste water from sugar plant ETP will be completely utilised for irrigation of

agricultural land. The quality of soil and ground water of the land is to be monitored

regularly. Agriculture management plan for the scientific utilization of treated effluent

will be practiced.

viii. A storage reservoir of adequate capacity is provided to hold treated effluent during

un favorable climatic condition as discussed in chapter-2.

2. AIR ENVIRONMENT

Gaseous emissions in the industry include boiler flue gases, fugitive emissions and D.G.

set emissions. Fugitive emissions are originated mainly in bagasse yard and in roads

due to vehicular movement. The main pollutants are suspended matter in boiler flue gas

and sulphur dioxide in D.G set emissions. The following measures are adopted to

manage gaseous emissions to prevent their adverse impact on the environment.

Fugitive Emission

Fugitive emissions within the factory are prevented by good housekeeping.

i. Spillage of fuel and ash are avoided and the floor is kept clean.

ii. Tree plantation in 3 to 5 rows is developed all around the fuel yard, ash yard, spent

wash and ETP premises.

iii. All internal roads are properly paved or tarred so as avoid to fugitive emissions. A

tree plantation in 2 to 3 rows is developed on both sides of the roads.

iv. Water spaying will be practiced on roads and dusty yards.

129

Flue Gases

i. Stacks of adequate height shall be provided for boilers and diesel generator.

ii. Bag filter of proven make shall be provided to the boilers to reduce SPM in flue gas

to the permissible levels.

iii. Arrangements will be made for periodical monitoring of stack gas and ambient air

quality. The sampling points will be located based on metrological conditions of the

region.

iv. Boiler model and make to be provided with assured performance of low pollution

load.

v. Ladder, port hole, power supply points will be provided to the boiler chimney.

3. SOLID WASTES

Boiler ash and ETP sludge are the main solid wastes produced in the industry. Quality

and quantitative details and their disposals are discussed in chapter-2. The measures

for control, storage, handling and disposal of these solid wastes are presented below.

i. Fuel/Bagasse yard is isolated with compacted and prepared flooring and garland

channels are provided to prevent entry and exit of storm water.

ii. Green belt of 6-10 m is maintained all around the bagasse yards.

iii. Molasses is stored in top covered M. S. tank. Dyke wall shall be constructed to hold

the tank contents in case of leakage.

iv. Boiler ash would be supplied to the farmers for its use as soil conditioner in

cultivation of sugar cane and other crops.

v. Composting of press-mud is carried out scientifically and the quality of composted

manure is regularly checked.

4 NOISE ENVIRONMENT:

Necessary measures as indicated below are taken to reduce the sound intensity below

the allowable limits at the source itself in the present sugar industry. In general at the

locations of turbines, compressors, fans etc, the sound intensity generally exceeds the

130

limit. The workers engaged in such locations are provided with earmuffs to have

additional safety against noise nuisance.

i. Adoption of noise reduction measures in the construction of the industry as per the

I.S. 3408-1965.

ii. Specifying the noise standards to the manufacturing of machineries

iii. Acoustic barriers or shields to the machineries.

iv. Heavy foundations and vibration absorption systems provided to steam turbines.

v. Acoustic walls roofs to building where such machineries are installed.

vi. Segregation of machineries having high noise level in separate buildings.

vii. Incorporation of sound absorbers to blowers and compressors.

viii. Sound control measures to steam vents.

ix. Proper maintenance of machineries especially oiling and greasing of bearing and

gears etc.

x. Avoiding vibration of machineries with proper design of machineries such as speed,

balancing etc.

xi. Use of personnel protective equipments to persons working in such locations.

xii. Plantation of green trees around the factory building and premises to control the

intensity of noise to the surrounding area.

With above noise abatement measures the noise level in the premise will be maintained

with the desired limits. It will be ensured that the workers in high noise areas use ear

muffs / ear plugs provided to them. Further, ambient noise level inside the work area will

confirm to the standards of industrial area and noise level outside project premise will

confirm standards of residential areas.

5. BIOLOGICAL ENVIRONMENT

Following measures are taken to preserve biological environment in the area:

i. It is proposed to develop green belt all around the project site.

ii. Conservation of existing vegetation.

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iii. Taking up a forestation work in the vicinity of factory in co-operation with village

authorities as a community service.

iv. Plantation program shall be taken in all vacant lands including plantation in the

proposed plant premises, along the internal and external roads and also along the

administrative buildings.

6. GREEN BELT DEVELOPMENT

Development of greenbelt in and around industrial activity is an effective way to control

pollutants and their dispersion in to surrounding areas. The degree of pollution

attenuation by a green belt depends on its height and width, foliage surface area,

density, dry deposition, velocity of pollutants and the average wind speed through the

green belt. The main objective of green belt around the factory is:

i. Mitigation of impacts due to fugitive emissions

ii. Attenuation of noise levels

iii. Ecological restoration

iv. Improvement in aesthetic environment quality

v. Waste water reuse.

vi. Soil erosion prevention

Keeping in view of the soil and water quality available in and around the project site and

the topography of land, following criteria are considered while selection of species for

green belt development.

Criteria for Selection of Species for Green belt

i. Rapid growth and evergreen type of species.

ii. Tolerance to water stress and extreme climatic conditions.

iii. Difference in height and growth habits

iv. Aesthetic and pleasing appearance

v. Large bio-mass to provide fodder and fuel

vi. Ability to efficiently fixing carbon and nitrogen.

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vii. Improving waste land

viii. To suit specific climate and soil characteristics.

ix. Sustainability with minimum maintenance.

Plant species recommended by CPCB and as suited to the local environment will be

used in green belt and greenery development. The width of green belts and type of

plant species to be developed in the premise will include the following.

i. 30% of the total industrial land area is covered with greenery and green belt. An

average of about 1250 plants will be maintained per hectare of the greenery area.

ii. 10 m width green belt all along the border of the site

iii. 10 m width green belt all along the border of fuel yard

iv. Tree plantation on both sides of interior roads in the premise.

v. Lawn with aesthetic plants in open space of buildings and other places

7. STORM WATER MANAGEMENT AND RAIN WATER HARVESTING

Large quantity of storm water is generated during rainy days. Rain water collection and

harvesting plan will be implemented to conserve the water resources and to improve the

underground water table. Total land area of the project is 20.66 hectares, of which

factory area is about 6.16 hectares. Strom water gutters are designed and constructed

based on contour data of the premises and rainfall data of the region. The rainwater

thus collected will be used for greenery development in the factory or let out to near by

agricultural land for irrigation application. The storm water thus collected can also be

used as a source of water for the industry.

iii. RAIN HARVESTING

Rain harvesting provisions will be constructed along rain water gutters at a distance of

about 60 m. A total of about 20 pits will be constructed as per practice. Each pit will be

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of size 3.0 m X 2.0 m X 3.0 M. They are filled with small boulders, pebbles, and coarse

sand.

STORM WATER RESERVOIR

The annual rainfall in the region is about 776.7 mm and is spread from May to October.

Annual rainy days are about 53. Strom water gutters are constructed in the premise as

per the standards. The storm water drains are lead to rain water reservoirs constructed

at the lowest level of the premises as shown in the layout plan. The rain water thus

collected is used for greenery development in the industry. The storm water thus

collected can also be used as a source of water for the industry. The storm water

collected from different locations of the factory premises is given below.

Sl no

Location Area

Hectares Average

Run-off Factor Rain fall

m/yr Quantity

m3/yr

1. Factory built up area 6.16 (24640) 0.50 0.77 56918.4

Storm water storage capacity is provided for about 20 % of the annual storm water

collected from the factory premises. Thus, the total capacity of the reservoirs shall be

15000 m3. Rain water reservoir (1 no.) of following specifications is available in earthen

work as per standard practices.

Reservoirs Capacity in

m3 Average ht in m

Area of reservoir, m2

Size in m

Water Reservoir – I

15000 3 5625 75 X 75

8. AGRICULTURAL MANAGEMENT PLAN (Irrigation application of treated effluent)

The industrial effluent is treated in an effluent treatment plant to the standards

prescribed for land applications. Treated effluent of 185 m3/d will be discharged from the

industry, which is to be applied on land for irrigation. The land has a sandy loam

structure. The soil at the site is suitable for crops such as sugar cane, maize and plants

such as neam, pungemia, acacia etc. Plantation can be grown on the land at a rate of

about 400-600 plants per acre. The plantation requires irrigation throughout the year.

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However in the present industry the treated effluent is mainly used for cultivation of

sugar cane. Sugar cane requires water throughout the year. Hydraulic loading of

25-30 m3/day can be allowed per acre based on climatic conditions. A total of about 10

acres will be provided for utilization of treated effluent for irrigation.

Sugar cane crop requires a total of 3 m of water for the cropping period of 12 months.

Water is supplied to the crops in a total of 20 irrigations each of about 0.15 m with an

interval of 15-20 days. During rainy period the requirement of water by the crops is

partially or fully met by the rain.

9. INDUSTRIAL HAZARDS AND SAFETY

i. HAZARD IDENTIFICATION

Safety Audit will be conducted by qualified technical personnel to study the installation

and activities of the industry and to suggest measures to protect personnel and property

against the risks. The areas of possible hazardous incident are given for follow up

action:

Fire in Bagasse storage yard, alcohol storage tanks and diesel storage tanks.

Fire and explosion at alcohol storage tanks.

Electric Short circuit and consequent fire accident.

Puncture of Boiler and boiler tubes.

Possibility of any gas leakage.

Bursting of pipeline joints.

Fall from high level structures

ii. FIRE FIGHTING FACILITIES

Fire Hydrants

Fire hydrant system with hose pipe of 8 kg/cm2 pressure with single hydrants are

located in bagasse yard, boiler house and sugar godown.

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Water tank at elevated place : 60 m3 capacity

Water pump at 10 kg/cm2 pressure : 20 m3/hr

Fire Extinguishers

Foam water : 2 each at main office and store.

CO2 type : 6 nos. one each at departmental office.

DCP type : 9 nos. each at Distillery plant, sugar plant and power

plant.

Fire Protective Appliances

Three sets of fire safety appliances each consisting of fire mask (6), face shield (6), fire

gloves (12) fire helmet (12), safety belts (6), located at store, power plant office and

Distillery plant office respectively.

Fire Brigade

Fire brigade facilities available at Nanjangud & Mysore shall be utilized whenever need

arises.

iii. SAFETY EQUIPMENTS AND APPLIANCES

These equipment and facilities listed below are kept at administrative building/stores

building and are under the control of emergency Co-ordinator

First AID medical units of one unit in each department, 4 units at store

and 4 units at ECR

Safety belts

Ear muffs, masks against dusts, aprons against chemical spillage.

Shock proof gloves and mats.

Leather Aprons.

Safety items of gum shoes, hand gloves, helmets, goggles.

Safety ladder.

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Face masks & gas masks Leather gloves.

Breathing apparatus.

Stretchers and oxygen cylinder.

Flame proof battery and lighting.

Emergency lighting facilities,

Air life line for working in vessels and tanks.

iv. EMERGENCY TRANSPORT VEHICLE

One vehicle along with driver is always made available at the factory premises for

emergency needs.

v. AMBULANCE

Ambulance facilities are available in factory and also at general hospitals of Nanjangud

& Mysore. The facilities will be used whenever necessary.

10. OCCUPATIONAL HEALTH CARE

Safety officer is available in the industry. He will co-ordinate and manage occupational

health management. A medical facility with qualified doctor and clinical facilities will be

created in the industry to meet the factory and residential colony requirement of the

health services. Higher medical services shall be availed from the hospitals present in

Nanjangud, Mysore. Health care aspects to be practiced in the industry are indicated

below.

i. Health and safety related displays will be exhibited at strategic locations in the

industry.

ii. Workers will be educated and trained in occupational health safety.

iii. Regular health check up of the workers will be carried out once in 6 months and

health records of individual workers will be maintained.

iv. Utility rooms will be provided with facilities and properly maintained.

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v. First aid facilities will be provided at different locations. Further first aiders will be

trained.

Housekeeping in the industry, sanitation in utility rooms, canteen, Rest rooms and other

places will be given top priority.

1. HEALTH AND SAFETY MEASURES FOR THE WORKERS

a. Buildings and structures: No walls, Chimneys, Galleries, Stairways, Floor,

Platform, Staging or structure whether of a permanent or temporary character will be

constructed in such manner as to cause risk or bodily injury.

b. Provision of crawling boards etc: No person will be required to stand to pass

over or work on or near by any roof of ceiling cover with fragile material through

which he is liable to fall, in case it breaks or gives away the distance for more than

3 meters without use of sufficient number of suitable ladders, duck ladders or

crawling boards which are securely support.

c. Service platforms: Whenever practicable and demanded service

platforms and gangways will be provided for overhead shafting, and where

required by him these will be securely fence with guardrails and toe boards.

d. Belts, etc: All belts will be regularly examined to ensure that the joints are safe and

the belts are proper tension.

e. Helmets: Helmets will be provided to the workers for safe guarding

themselves against any head injuries.

f. Machinery: No machineries are equipments will be Situated, Operated or

maintained in such a manner as to cause risk of bodily injury.

g. Methods of work: No process of work will be carried out in such a manner as to

cause risk of bodily injury.

h. Electricity: No electricity installation will be provided during construction so as to be

dangers to human life or safety.

i. Medical Check-up: Medical examination for every employee will be examined by

certified surgeon at least once in 6 months of a calendar.

j. Inspection and maintenance of pollution control systems only after getting official

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shutdown or with permission of authorized officer.

k. Regular cleaning of floors, road, rooftops, conveyer galleries and any other dusty

place.

l. All pollution control systems will be interlocked with operation of process equipment.

m. The workers exposed to noisy equipment will be provided with ear plugs.

If necessary, the duty hours will be rotated, so that noise exposure time is kept

within specified limits.

Chapter - 5

ANALYSIS OF ALTERNATIVES

(TECHNOLOGY & SITE)

139

Chapter – 5

ANALYSIS OF ALTERNATIVES (TECHNOLOGY & SITE)

5.1 SITING OF PROJECT

5.1.1 ENVIRONMENTAL GUIDELINES

Setting restrictions for the project depend on the sensitivity of the surrounding

environment. Sensitivity of the project site should be assessed in relation to its proximity

to the ecologically sensitive places. As per MoEF guidelines, following aspects are to be

considered while selecting the site. The project site meets these guidelines.

i. Land procured should be minimum but sufficient to provide greenbelt.

ii. If treated effluent is to be utilized for irrigation, additional agricultural land is to be

made available.

iii. Enough space for storing solid waste.

iv. Layout and form of the project must confirm to the landscape of the area without

affecting the existing scenic features.

v. If associated township of the project is to be created, it must provide space for

phyto-graphic barrier between project and township and also should take into

account of wind direction.

vi. The site should not be in migration route.

vii. It should not interfere with the natural water course

viii. Forest, agriculture, and fertile and other specified lands to be avoided.

ix. The following distances maintained between the project and specified location

Estuaries: 200 m

Flood plains of riverian systems: 500M

Highways and Railways: 500M

Streams and rivers used for drinking water supply: 1500 m

Ecological and/or otherwise sensitive areas: 15 km

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5.1.2 GENERAL CRITERION FOR SELECTION OF LOCATION

The general criterion for site selection is:

Accessibility for easy disposal of effluents.

Proximity to availability of perennial water supply, raw materials, skilled and

unskilled man power.

Access to power supply from HESCOM/ own captive generation.

Further important details to be checked up about the site are:

Soil conditions.

Contour Survey.

Rainfall in the area.

Ground water resources / potential.

Weather conditions, maximum and minimum temperature, humidity etc.,

Seismographic soundness of the place.

5.1.3 PROJECT SITE AND LOCATION

The present distillery of 60 KLPD is located adjacent to the existing sugar industrial

complex located at Alaganchi village, Nanjangud Taluk, Mysore District, Karnataka

State. The expansion of distillery from 60 KLPD (RS/ENA) to 150 KLPD

[RS/ENA/Ethanol (AA)] is proposed in the premise of the existing distillery. The distillery

site of 51 acres is situated on longitude 76°45’ 29’’ E latitude 12°06’ 14’’ N at an

altitude of 692 metre. The site is adjacent to the road joining Nanjangud & Mysore. It is

2 km from the nearest village Alaganchi and 10 km from Nanjangud town. Nearest

water body is river Kabini at 6 km from the site.

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i. RAW MATERIAL AVAILABILITY

In the proposed industry is based on sugar industry for its inputs viz. Molasses &

bagasse .

ii. AVILABILITY OF WATER SUPPLY

Water requirement to the industry is 1350 m3/d. Water supply to the industry is obtained

from river. The water source is found to be adequate to meet the requirement of the

industry. The quality of water is suitable for the industrial applications.

iii. EFFLUENT DISPOSAL

The effluent with high organic matter (spent wash) will be concentrated and burnt in the

boiler as fuel. The water table is 30-40 m below the ground level. Infiltration rate of soil

in the region is moderate to poor. The location of the site is suitable for effluent

treatment and utilization under Zero Discharge Environmental management program.

iv. PROXIMITY TO COMMUNITY FACILITIES

Accessibility to urban facilities such as higher education, medical, fire station, cultural

entertainment and market are advantage to the growth of industry.

V. ENVIRONMENTAL FEATURES OF SITE

There are no eco- sensitive locations such as bio-sphere, Mangrove, protected forest,

National parks etc or environmental sensitive locations such as protected monuments,

historical places within 10 km from the site. River Kabini a perennial river is present at 6

km from the site.

5.2 TECHNOLOGY/ PROCESS

The process selection is done based on the following considerations:

i. Least stress on resources including raw materials and utilities.

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ii. Reduce, Recycle and Reuse of wastes.

iii. Least or no pollution from the industry.

iv. Least or no risk to human and property.

v. Least or no adverse impacts on environment

The technology options for the proposed expansion of existing 60 KLPD Distillery to 150

KLPD is considered based on raw material, process and waste water generation.

1. PROCESS BACKGROUND

The manufacture of alcohol basically involves fermentation of substrate containing

sugar material such as molasses and sugar cane juice.

2. SELECTION OF PROCESS

i. Hi-ferm Fermentation

The fermentation process is engineered to operate in fed batch as well as continuous

mode. The purpose of fermentation is to convert the fermentable sugars into alcohol.

During fermentation, sugars are broken down into alcohol and Carbon-di-oxide.

Significant heat release takes place during fermentation the fermentation temperature is

maintained at around 32 º C by forced recirculation flow through plate heat exchangers.

CO2 evolved during fermentation carries along with it some entrained alcohol. This CO2

is taken to a CO2 scrubber where it is washed with water to recover the entrained

alcohol. The scrubbed CO2 is vented out. Fermented wash is sent to yeast settling tank

for separation of yeast under gravity.

Spent wash from vacuum distillation is re-circulated to fermentor depending on solids

concentration in fermented wash and molasses composition.

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ii. Multi Pressure Distillation

Fermented wash is distilled through a number of distillation columns and the alcohol

present in it is separated. In conventional process distillation was carried out at

atmospheric pressure. In recent process, the distillation is carried out under vacuum

and at different pressures. Thereby, the saving in Steam and Power consumption and

also reduction in Spent wash volume is achieved in Multi pressure Distillation.

iii. Molecular Sieve Dehydration

The Ethanol (AA) having 99.8% Alcohol is manufactured using latest molecular sieve

dehydration methodology.

3. FEATURES OF SELECTED PROCESS

M/s BASL have selected modern technology with Hi-ferm fermentation and multi

pressure vacuum distillation for production of high quality ethanol of

Industrial/ENA/Ethanol(AA) grades. The distillation plant is designed as an

INTEGRATED MODEL with Zero Pollution option having no discharge of spent wash

from the unit. It has incorporated an advanced technology by concentration and

incineration in boiler for treatment and utilization of spent wash. The boiler ash is rich in

potash and phosphorus and therefore it can be used as a soil nutrient in agricultural

lands. The main features of selected INTEGRATED MODEL are,

i. Captive generation of fuel.

ii. Spent wash management, concentration by evaporation and incineration. Hence,

pollution from spent wash will not be there.

iii. Employment of improved culture and Hi-ferm fermentation system, whereby,

fermentation period is reduced from 36 hrs to 26 hours.

iv. Multi pressure vacuum distillation system helps to economize the steam

consumption. This has reduced the steam consumption to a level of 70% of the

conventional atmospheric distillation.

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v. Provision of Re-boiler, which has resulted in reduction of effluent volume and

fresh water requirement. This has dispensed with the requirement of live steam

to the distillation column and resulted in further reduction of effluent quantity and

requirement of fresh water.

4. SPENT WASH MANAGEMENT DEVELOPMENTS

In earlier days the spent wash treatment at Distilleries was by primary and secondary

biological treatment processes to reduce its BOD content and then utilized on

agriculture land as liquid manure to the crops. Also the treated spent wash is being

utilized in Bio compost process using sugar factory press mud to produce compost

manure for agriculture.

CONCENTRATION AND INCINERATION

Spent wash is concentrated in multiple effect evaporators. The concentrated spent

wash rich in organic matter has a high heat value. Hence, this may be used as fuel in

the boiler. The ash produced in the boiler contains mainly potassium and phosphate

salts and therefore, it can be used as plant nutrient in agriculture.

5. CHOICE OF SPENT WASH TREATMENT METHOD

The company is already operating concentration and incineration system for its 60

KLPD alcohol production and also proposed to incorporate the same concentration and

incineration system to achieve the proposed 150 KLPD alcohol production. The

proposed 150 KLPD production will result in 997 m3/d (1216 T/d) of raw spent wash

(18% solids). The spent wash will be concentrated to 60% solids in multi effect

evaporators (self cleaning type). The concentrated spent wash with GCV of about

1800 kcal/kg will be burnt as prime fuel along with support fuel, coal/bagasse &

biomass. The resultant as generated after burning is rich in potash and phosphate. It

will be utilized as soil nutrient and also blended with compost manure. Thus the

expansion program of existing distillery to 150 KLPD will also adopted Zero Discharge

Environmental management system.

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5.3 BENEFIT OF THE PROPOSED EXPANSION

The project is proposed mainly for the purpose of best utilization of waste product such

as molasses produced in the sugar industry to produce ethanol. This project will be

environmental friendly. Alcohol is an essential product for use in Alcoholic beverages,

as raw material for various organic products and as a liquid fuel for use in automobiles.

Alcohol is useful as a substitute to the petroleum source and basically an environmental

friendly product. It is a major source of revenue to the government. The production of

alcohol has a potential in saving foreign exchange and export earnings. Being an agro-

based unit the distillery will help farmers to improve their economic conditions.

The proposed project will not cause depletion of natural resources or the significant

adverse impacts on environment. On the contrary, it will produce value added resources

such as alcohol, agro-manure and bio energy.

Chapter - 6

ENVIRONMENTAL MONITORING

PROGRAMME

146

Chapter – 6

ENVIRONMENTAL MONITORING PROGRAMME

6. 1 INTRODUCTION

The Objective of this Study is to minimize or off-set the adverse impacts that might be

created due to this project. Various mitigation measures are designed and described. In

operation phase we have to check continuously as to (1) whether our measures are

being operated as per design and (2) whether the resultant impacts are coming

inside the tolerance limits. This can happen only if we have a specialized cell, higher

management support for the cell, adequate funding, support of library- laboratory,

open dialogue corridor with all the stakeholders and authorities, and if the success

indicators are in agreement with our findings. Documentation is necessary along with

periodic Reporting to factory management and statutory authorities such as MoEF,

SPCB, Factory inspectorate etc.

It is proposed to frame an Environmental Monitoring programme both in

Construction and Operational stages to monitor the effectiveness of the mitigation

measures by judging the impact on environment. A separate budget is proposed for

the same as also a dedicated Cell. A transparent approach will be kept with

documentation and Reporting with statistical treatment to the data. Checklist of

statutory obligations will be maintained and compliance with it will be monitored.

A chemical or process industry in general produces solid, liquid and gaseous wastes,

which are discharged to the environment. These discharges pollute receiving media

such as air, water and land which in turn harm living beings and property. The waste

product may contain one or more chemical constituents. It is the responsibility of the

industries to prevent or minimize the discharges of waste products by adopting suitable

control measures in the factory to avoid harm to the environment. The effectiveness of

such measures is ascertained by systematic monitoring of discharges at factory level

and at receiving level. Systematic monitoring of various environmental parameters is to

be carried out on regular basis to ascertain the following.

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i. Pollution status within the plant and in its vicinity.

ii. Generate data for predictive or corrective purpose in respect of pollution.

iii. Effectiveness of pollution control measures and control facilities.

iv. To assess environmental impacts.

v. To follow the trend of parameters which have been identified as critical.

6.2 MONITORING PLAN

The routine monitoring program as indicated below is already practiced in the existing

industry. The same facility and system is adequate even after expansion of the

proposed distillery plant. However additional monitoring facility will be provided for

stack emissions of the proposed 23.4 T/h boiler.

Regular monitoring of important and crucial environmental parameters is of immense

importance to assess the status of environment during plant operation. The knowledge

of baseline status and monitored data is an indicator to ascertain for any deterioration in

environmental conditions due to operation of the plant. Based on these data, suitable

mitigation steps could be taken in time to safeguard the environment. Monitoring is as

important as that of pollution control since the efficiency of control measures can only

be determined by monitoring. A comprehensive monitoring system in the industry is

parented below.

Air Pollution and Metrological Aspects

Both ambient air quality and stack emissions are monitored. The parameters monitored

are PM10 , NOx and SO2. The ambient air is monitored as per the guidelines of Central

Pollution Control Board.

Water and Waste water Quality

All the effluents emanating from the plant are monitored for their physico-chemical

characteristics and heavy metals. In addition ground water samples surrounding the

hazardous waste storage area are monitored.

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Noise Levels

Noise levels in the work zone environment are monitored once a month in the work

zone.

6.3 SAMPLING SCHEDULE AND LOCATIONS

The solid, liquid or gases discharges from the factory are analyzed at the sampling

points indicated below by the factory as self monitoring system. Post Project Monitoring

Plan with environmental attributes and schedule of monitoring is given in Table-6.1.

Table 6.1: Post Project Monitoring Schedule

Sl. No.

Particulars Location Frequency &

Duration Parameters

1 Meteorology 1 No. at site Daily

Max. & Min. Temp., Rain Fall, Rel.

Humidity, Atm. Pr., Wind Dir. & Speed,

2 AIR QUALITY

2.1 Ambient air quality

6 nos. including downwind direction

and one each in upward and

crosswind direction.

24 hr., 2 consecutive

working days in a week.

PM10, SO2, NOX,

2.2 Stack emission Sampling port of

Stack Once in a

Month

PM10, SO2, NOX , HC (methane & non

methane), Temp. Velocity, Temp.

2.3 Fugitive emissions At specified locations

(crusher, screen, loading, unloading)

Once in a Month

SPM

3 WATER QUALITY

3.1 Ground water 6 Locations Quarterly Physico- chemical,

3.2 Ground water near solid storage area

Specified Locations Quarterly Physico- chemical with heavy metals,

3.3 Surface water 2 location at each

source Monthly

Physico-chemical, Org., Bacteriologic.

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3.4

Surface water (susceptible to contamination)

At each source Quarterly

Physico-chemical, Org.,&

Bacteriologic

6 Effluent water At inlet and out let of

ETP Daily

Physico-chemical, Org. and as specified by

KSPCB

5 Soil 6 Locations at & around premise

Pre & post monsoon

Physico-chemical, Org & Heavy

metals

7 Noise level, work

zone (hourly)

12 specified locations (Crusher, screen, Turbine house, At

fans & compressors, Rolling mill.)

Once in a month

Day & Night noise level

8 Water utilization,

m3/d

For process, domestic, cooling

and boiler Daily m3

9 Power utilization For air pollution

control facility (Bag filter) and for ETP

Daily KWH

10 Health Check All plant personnel Yearly As specified by

authorities

11 Ecological Green belt Seasonal Survival rate

6.4 LABORATORY FACILITIES

Laboratory is already provided with man power and facilities for self monitoring of

pollutants generated in the industry and also its effects on the receiving soil, water body

and atmosphere. The laboratory is equipped with instruments and chemicals required

for monitoring following pollution parameters.

Air quality and Meteorology

High volume samplers, Stack monitoring kit, Respirable Dust sampler, Central Weather

Monitoring Station, Spectrophotometer (Visible range), Single pan balance, Flame

photometer & Relevant chemicals as per IS:5182.

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Water and Wastewater Quality

The sampling shall be done as per the standard procedures laid down by IS: 2488. The

equipments and consumables required are:

BOD incubator, COD reflex set-up, Refrigerator, Oven, Stop watch, Thermometer, pH

meter, Distilled water plant, pipette sets, Titration set, Dissolved Oxygen Analyzer &

Relevant chemicals.

Noise Levels

Noise monitoring shall be done utilizing an integrating sound level meter to record noise

levels in different scales like A-weighing with slow and fast response options.

6.5 COMPLIANCES TO ENVIRONMENTAL STATUS

This industry is law-abiding and especially the Environmental Status is observed very

minutely with letter and spirit.

1. Carrying out “Environmental Audit Statement” of various environmental

aspects, review the environmental policies with the help of experts and make

the up gradation /changes accordingly.

2. Submission of the “Environmental Statement” to the State Pollution Control

Board in Form V under Rule 14 of the Environment (Protection) Second

Amendment Rules 1992 of the Environment (Protection) Act, 1986.

3. Renewal of Consent to Operate under the Water and Air Acts.

4. File the Cess returns to the State PCB under the Water (Prevention and

Control of Pollution) Cess Act, 1977.

5. Renew the Hazardous Waste Authorization under sub-rule 3 of the

Hazardous Waste (Management and Handling) Rules, 1989.

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6.6 MONITORING OF COMPLIANCES TO STATUTORY CONDITIONS

Environmental clearances from KSPCB AND MoEF are always accompanied by the

specified terms and conditions. Necessary measures are taken to comply with these

conditions. Environmental Cell and the associated staff monitor the compliances

regularly.

6.7 ENVIRONMENTAL MONITORING COMMITTEE

EMC will constitute an environmental monitoring committee consisting of two

environmental experts drawn from professional organization. They will make periodical

and surprise visit to the industry and monitor the performance of the environmental

system and report the observations to the environmental management cell. The scope of

committee includes monitoring & reviewing of

1. Construction activities

2. Treatment & disposal of effluent, gaseous emissions & solid wastes.

3. Documentation related to operation & maintenance of pollution control facilities.

4. Monitored data w.r.t effluents, emissions (stack, fugitive & ambient), ground &

surface water source around the factory, solid waste etc.

5. Greenery & green belt, storm water management, water harvesting.

6. Enforcement of laws and rules including maintaining records, filing returns to

authorities etc.

7. Safety & health care facilities.

6.8 SUCCESS INDICATORS

The success of the sincere and honest efforts the Project Proponent is putting in,

will be judged by various indicators, such as –

1. There is no complaint of the villagers regarding transfer of lands

2. There is no complaint of the customers regarding quality of product and

delivery schedule.

3. No complaints from Government or Non Government Authorities and Public.

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4. Statistics of Health, Safety and Environment is an indicator of the successful

Management and Pollution Control.

5. Other Promoters come to seek our advice.

6. Demonstration to others for Rainwater harvesting, Environmental Status

Report, Environmental Statements (annually), Cess Returns (monthly),

Groundwater Recharging, sand-substitute ash, plastic-free packing, care for

disabled etc.

Chapter - 7

ADDITIONAL STUDIES

153

CHAPTER - 7

ADDITIONAL STUDIES

7.1 PUBLIC HEARING AND CONSULTATION

The project is to enhance the capacity of the distillery from 60 KLPD to 150 KLPD.

Addition of equipments in Production and Environmental facility will be made. The

project attracts EIA notification and therefore needs Public Hearing and Public

Consultation. Public hearing will be conducted as per the EIA guidelines.

Expert Appraisal Committee(Industry), MoEF, GOI, New Delhi during their meeting

held during 4th- 5th April, 2013, has specified TOR and scoping for EIA studies and

preparation of EIA report (vide F.No J-11011/71/2013- IA II (I)) dated 07.06.2013

Further, they have advised the company to approach KSPCB along with Draft EIA

Report for conduct of Public Hearing. Accordingly, the company has conducted EIA

studies and draft EIA report prepared and approached KSPCB, Bangalore with a

request to arrange the Public Hearing.

The Company will participate in the public hearing and make presentation of the

proposed project. The observations made by the public will be attended and

incorporating the same final EIA Report will be prepared for submission to MoEF, GOI

New Delhi.

7.2 RISK ASSESSMENT

An industry with its complex nature of activities involving various plant machineries, raw

materials, products, operations, intermediates and environmental discharge has a

number of associated hazards. A minor failure can lead to major failure resulting into a

disaster causing heavy losses to life, property and environmental. Risk assessment

studies are being conducted to ensure safety and reliability of any new plant, through a

systematic and scientific methods to identify possible failures and prevent their

occurrences before they actually cause disasters and production loss.

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7.2.1 OBJECTIVITES OF THE STUDY

The distillery involves storage and handling of large quantity of alcohol which is

flammable under unfavorable situations. To ensure safe operation of the plant, it is

proposed to carry out the Risk Analysis Study with the following objectives,

1. To identify the major hazards relating to fire, explosion and toxicity due to

storage and handling of Alcohol.

2. To visualize maximum credible accident scenarios

3. To analyze and quantify primary and secondary effects and damage

potentials of the identified maximum credible accident scenarios using

standard procedure.

4. To study the nature of exposures, pathways and consequences of maximum

credible accident scenarios and characteristics of risk levels.

5. To provide guidelines for disaster management plan.

Risk assessment studies have been carried out to assess the worst case scenarios of

the plant operations to formulate an emergency management plan.

7.2.2 PRELIMINARY HAZARD ANALYSIS

Technical information on project including plant, process, and material is given in

Chapter-2.

Preliminary Hazard analysis is used to identify typical and often relatively apparent risk

sources and damage events in a system. Hazards of significant nature whose

consequence potential is of worth consideration, where in a specified area or where,

more number of personnel likely to be present etc, is considered in identifying hazards.

Alcohol being an organic solvent is flammable. Based on the preliminary hazard

identification, the storage and handling facilities of alcohol has been recognized as

distinctive and relatively evidential risk source. Loading and unloading from storage and

forwarding of alcohol may lead to containment failure for various reasons. Such

situation can cause fire or explosions depending upon the situation.

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1. Characteristics of alcohol

Rectified spirit (RS), Absolute Alcohol and Extra Neutral Alcohol (ENA) are basically

ethanol of different grades and have the same hazard characteristics. Hence, all these

products are considered as ethanol in hazard analysis. Alcohol is a clear, colorless and

flammable liquid. It has the boiling point of 78 0C, ignition point of 365 0C and explosive

limits of 3.3 % - 19.0 % by volume. The characteristics of ethanol are given

General Characteristics of Alcohol

Physical State Liquid

Appearance Clear

Color Colorless

Physical Form Volatile Liquid

Odour Alcohol odour

Taste Burning taste

Molecular Weight 46.07

Molecular Formula CH3 CH2OH

Boiling Point 173.07 0F ( 78.37 0C)

Freezing point -173 0F (-78.33 0C)

Vapor Pressure 40 mm Hg @ 19 ºC

Vapor Density 1.59 kg/m³

Specific Gravity 0.789 g/cm3 (at 25 0C)

Water Solubility Soluble

Volatility 100 %

Odour Threshold 5 – 10 ppm

Viscosity 1.22 – 1.41 cp @ 20 0C

Solvent Solubility

Benzene, ether, acetone, chloroform, methanol, organic solvents

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2. Fire Hazard of Alcohol

Alcohol falls under flammable category of high intensity. The probable fire hazard in the

plant is in the areas of alcohol storage and handling. In case of leaks, invisible vapours

spread easily and are set on fire by ignition sources. Therefore, it is important to control

or eliminate all potential ignition sources in areas that might lead to ignition of vapour.

All forms and types of energy can be considered a potential ignition source. The

management will exert close control over the storage and handling of the ethanol. This

is best done by proper training of personnel, confinement of the liquids and associated

vapors to selected areas, ventilation to prevent vapor build up, control of potential

ignition sources, and protection of the area with an extinguishing system.

3. Potential Sources of Ignition

The potential sources of ignition are:

Open flames

Electrical wiring / devices

Smoking

Heat sources / Hot surfaces

Welding and cutting

Friction

Sparks and Arcs

Static sparks

Gas Compression.

Lightning effect

Precaution against Ignition

Following are some of the precautions that will be taken to minimize the probability of

ignition:

Electrical equipment and wiring should be suitable to avoid hazard.

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If a heating operation is necessary, use only indirect heating methods.

Do not allow any open flames.

Provide grounding and bonding for all equipment handling using these liquids.

Maintenance program will be established to assure that all equipment and safety

controls are functioning satisfactorily.

4. Health Hazards of Alcohol

The following acute health effects may occur

Can affect when breathed in and by passing through skin

May cause mutations

Can irritate the skin. Repeated contact can dry the skin with cracking, peeling

and itching

Exposure can cause headache, nausea, a feeling if heat and drowsiness, Higher

exposure can cause unconsciousness

Exposure can irritate the eyes, nose, mouth and throat

Breathing of alcohol can irritate the lungs causing coughing and/or shortness of

breath.

Threshold limit value for Alcohol

The Threshold limit value of the alcohol is 30 to 50 ppm it is well within the permissible

exposure level as per ACGIH recommendation

Alcohol OSHA NIOSH ACGIH

8 – hour exposure 1000 ppm 1000 ppm 1000 ppm

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5. Alcohol Storage Details

Details of storage conditions and hazardous nature of alcohol are given below.

Storage Conditions and Nature of Hazard

Hazardous Chemical

Physical State

Material of Construction

Storage Pressure

Hazardous Nature

Alcohol Liquid MS/SS Atmospheric. Flammable & Toxic

Hazard Rating of Alcohol

The rating of large number of chemicals based on flammability, reactivity and toxicity

have been given in National Fire Protection Association codes 49 and 345 M. The

NFPA rating for the ethanol is given below,

NFPA Hazard Rating

CHEMICAL NH (Health Factor) NF (Fire Factor) NR (Reactivity)

Alcohol 2 3 0

(Least-0, Slight-1, Moderate-2, High-3, Extreme-4)

7.2.3 IDENTIFICATION OF POSSIBLE HAZARDS

In order to identify hazards the following two methods have been used.

Identification based on storage and handling of Alcohol.

Identification involving relative rating technique through Fire Explosion and

Toxicity Index

i. IDENTIFICATION (Based On Manufacture, Storage and Import of Hazardous

Chemical Rules, GOI Rules 1989)

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In order to determine applicability of GOI Rules 1989 to the notified threshold quantities,

analysis of products and quantities of storage in the plant has been carried out.

Threshold Quantity Product

Listed In Schedule

Total Quantity

Rules 5,7-9 and 13-15

Rule 10-12 Applicable

Rule

Alcohol 1 (2) 6000 KL (4800 T)

1000 t 50000 t Rule 5, 7-9 and

13-15

Based on the above, it is noted that ethanol produced and stored in the plant attract the

rules of GOI 1989.

ii. IDENTIFICATION INVOLVING RELATIVE RATING TECHNIQUE

(Through Fire Explosion and Toxicity Index.)

Fire Explosion & Toxicity Indexing (FETI) is a rapid ranking method for identifying the

degree of hazard. The basic objectives that characterize Fire Explosion and Toxicity

Index are,

Identification of equipment within the plant that would contribute to the initiation

or escalation of accidents.

Quantification and classification of the expected damage potential of fire

explosion and toxicity index in relative terms.

Determination of area of exposure.

In preliminary hazard analysis, alcohol is considered to have Toxic and Fire hazards.

The application of FETI would help to make a quick assessment of the nature and

quantification of the hazard in these areas. Before hazards index is applied, the

installation in question is sub divided into logical, independent elements or units. The

unit is logically characterized by the nature of the process that takes place in it.

Fire explosion and Toxicity Index is a product of Material Factor and Hazard Factor.

Material factor represents the flammability and reactivity of the chemicals. The hazards

factor itself is a product of general process and special process hazard.

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Respective Material Factor (MF), General Hazard Factors (GHF), Special Process

Hazard factors (SPH) are computed using standard procedure of awarding penalties

based on storage, handling and reaction parameters. Material factor is a measure of

intrinsic rate of potential energy release from fire and explosion produced by

combustion or other chemical reaction. General factor is a measure of intrinsic rate of

potential energy release from fire and explosion produced by combustion or other

chemical reaction.

General Process Hazard

The plant activities, which contribute to a significant enhancement of potential for Fire

and Explosion, have been identified. The measured values of penalties have been

added to obtain the value of General Process Hazard as given IN DOW’s Fire &

Explosion Index Hazard classification guide.

Special Process Hazard

The Special Process Hazard includes the factor that contributes the probability and

occurrence of accident. They are:

Process temperature

Low pressure

Operation in or near flammable range

Operation pressure

Low temperature

Quantity of Flammable and toxic material

Corrosion and erosion

Leakage, Joints

FEI (Fire Explosion Index) = MF x (1 + GPH) x (1 + SPH)

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Classification of Hazards into Categories

By comparing the indices Fire and/or Toxicity to the criteria in the following table the unit

in the question classified in one of the three categories established for this purpose.

Dows Fire and Explosion Index Hazard Classification, Degree of Hazard for F & E I

F & EI Range Degree of Hazard

01-60 Light

61-96 Moderate

97-127 Intermediate

128-158 Heavy

159 and more Severe

Based on the above, the degree of potential hazard based on DOW’s classification for

alcohol is given below.

Section Material Factor

General Process Hazard

Special Process Hazard

Fire & Explosion

Index

Radius of Explosure M

Category of Potential Hazard

Alcohol 16 2.85 2.6 118.56 30 Intermediate

Toxicity Index

Toxicity index is primarily based on the index figures for health hazards established by

the NFPA in codes NFPA 704, NFPA 4 n and NFPA 325 m. NFPA Index figures of

toxicity factor for Health Hazard index Nh are given below:

NFPA Index Toxicity Factor

0 0

1 50

2 125

3 250

4 325

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NFPA Health hazard index of ethanol is 2, which give toxicity factor of 125. In addition,

the toxicity factor has to be corrected for the Maximum Allowable Concentration (MAC)

values of the toxic substance by adding a penalty Ts. Ts values are arranged according

to the following Criteria.

MAC (ppm) Penalty Ts

< 5 125

5-50 75

> 50 50

MAC value for ethanol is 1000 ppm. Toxicity index is evaluated suing the following

equation

Th +Ts (1+GPH+SPH) Toxicity Index = 100

By comparing the indices of FEI and Toxicity index, the unit under consideration is

classified into one of the following three categories,

Classification of FEI and Toxicity Index

Category Fire Explosion Index Toxicity Index

Light <65 <6

Moderate 65-95 6-10

Severe > 95 >10

Fire Explosion and Toxicity Index for Storage Facility

Fire explosion and Toxicity Index values obtained for rectified Spirit and ENA both

combined through FETI are given below:

Fire Explosion and Toxicity Index for Storage Facility

Section Quantity

Processed

Material

Factor

Fire Explosion

Index Toxicity Index

Alcohol 6000 KL 16 118.56 3.6

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Degree of Hazard based on Fire explosion and Toxicity indices computed for the

storage units is categorized as below:

Degree of Hazard

Minimum Preventive and Protective Measures for Fire and Explosion

Based on the categorization of Degree of Hazard, the following minimum preventive and

protective measures are recommended.

FE & I Rating Features Light Moderate

Intermediate Heavy Severe

Fire Proofing 2 2 3 4 4

Water Spray Directional 2 3 3 4 4

Area 2 3 3 4 4

Curtain Special Instr. 1 2 2 2 4

Temperature 2 3 3 4 4

Pressure 2 3 3 4 4

Flow Control 2 3 4 4 4

Blow down-spill 1 2 3 3 4

Internal Explosion 2 3 3 4 4

Combustible gas Monitors 1 2 3 3 4

Remote Operation 1 2 2 3 4

Dyking 4 4 4 4 4

Blast and Barrier wall

separation 1 2 3 4 4

1= Optional 2=Suggested 3=Recommended 4= Required

Section Fire Explosion Toxicity

Alcohol Intermediate Light

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7.2.4 HAZARD ANALYSIS

1. MAXIMUM CREDIABLE ACCIDENT ANALYSIS

Maximum Credible Accident Analysis (MCA Analysis) is one of methodologies evolved

to identify worst credible accident with maximum damage distance which is still believed

to be probable. The analysis does not include quantification of probability. The

following is an attempt in that direction.

Hazardous substance may be released as a result of failures or catastrophes, causing

damage to the surrounding area. The physical effects resulting from the release of

hazardous substances can be calculated by means of models. The results thus

obtained through modeling are used to translate the physical effects in terms of injuries

and damage to exposed population and environment.

The probable fire hazard in the plant is in the area of ethanol and is due to storage and

handling. It is proposed to store about 60 day’s production of both the products within a

common dyke of 40x55 m. As a worst case it is assumed that the entire contents are

leaked out. In the event of spilling its contents through a small leakage or due to

rupture of the pipeline connecting the tank and on ignition fire will eventually forming

pool of fire. In order to assess the radiation levels, Heat Radiation model has been

used the algorithm of the models is based on the formulae published in the yellow book

by the TNO, Netherlands. Details of the model are given below:

2. Heat Radiation Model – Pool Fire

The heat load on objects outside the burning pool of liquid can be calculated with the

heat radiation model. This model uses an average radiation intensity which is

dependent on the liquid. Account is also taken of the diameter to height ratio of the fire,

which depends on the burning liquid. In addition, the heat load is also influences by the

following factors:

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3. Distance from the fire

The relative humidity of the air (water vapour has a relatively high heat absorbing

capacity)

4. Visualization and Simulation of Maximum Accidental Scenarios

The worst case scenario which is considered for MCA analysis is Pool fire due to failure

of storage of alcohol storage tanks in the farm area. The proposed industry will provide

10 days storage of the final product within the plant premises.

As a worst case it is assumed that the entire contents are leaked out. In the event of

spilling its contents through a small leakage or due to rupture of the pipeline connecting

the tank and on ignition fire will eventuate forming pool fire. As the tanks are provided

within the dyke the fire will be confined within the dyke wall.

Fires affect surroundings primarily through radiated heat, which is emitted. If the level

of heat radiation is sufficiently high, other objects, which are inflammable, can be

ignited. In addition, any living organism may be burned by heat radiation. The damage

caused by heat radiation can be calculated from the dose of radiation received, a

measure of dose is the energy per unit area of surface exposed to radiation over the

duration of exposure.

5. Effects of Pool Fire

Pool fire may result when bulk storage tanks will leak/burst, and the material released is

ignited. As these tanks are provided with dyke walls to contain the leak and avoid

spreading of flammable material, the pool fire will be confined to the dyke area only.

However, the effects of radiation may be felt to larger area depending upon the size of

the plant and quantity of material involved.

Thermal radiation due to pool fire may cause various degrees of burns of human

bodies. Moreever, their effects on objects like piping, equipment are severe depending

upon the intensity. The heat radiation intensities due to the pool fire of the above tank

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farms are computed using the pool fire model. The results obtained are presented in

the following Table.

Pool Fire Scenarios and Radiation Distances

Quantity of Storage : 4700 KL Alcohol Storage Tanks Farm

Dyke area : 40 m x 50 m

Damage Criteria Damage Distance

100 % Lethality (35.5 kW/m2) 5.0

50% Lethality (25.0 kW/m2) 25.0

1 % Lethality (12.5 kW/m2) 65.0

First Degree burns ( 4.5 kW/m2) 140

Normal Intensity with no discomfort (1.6 kW/m2) 170

6. Damage Criteria for Heat Radiation

The following table indicates likely damage level for different levels of heat radiations:

Sl. No.

Type of Damage Incident Radiation Intensity (kW/m2)

1 i. Spontaneous ignition of wood 62.0

2 ii. Sufficient to cause damage to process equipment. 37.5

3 iii. Minimum energy required to ignite wood at infinitely long exposure(non piloted)

25

4 iv. Minimum energy required for piloted ignition of wood, melting plastic tubing

12.5

5 v. Sufficient to cause pain to personnel if unable to reach cover within 20 seconds; however blistering of skin (1st degree burns) is likely.

4.5

6 vi. Will cause no discomfort to long exposure 1.6

7 vii. Equivalent to solar radiation 0.7

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7. Critical Radiations of Interest on Human Body

Un protected skin continuous 1.5 kW/m2

Blisters in skin at 30 sec 5 kW/m2

Protected skin 5 kW/m2

Special protection 8 kW/m2

For continuous presence of persons, thermal radiation intensity levels of 4.5 kW /m2 for

plant operators and 1.6 kW/m2 for outside population are usually assumed. These

criteria are followed where peak load conditions may occur for a short time but mostly

without warning. If the operators are properly trained and clothed, they are expected to

run to shelter very quickly. For the secondary fires, a thermal incident radiation of

12.5 kW / m2 is adopted as minimum criteria.

8. Physiological Effect of Threshold Thermal Doses

The effects of heat radiation depend upon the intensity and duration of exposure.

Intensity and duration put together is the thermal dose. The consequences on human

body for different thermal doses are tabulated here:

Dose Threshold (kW/m2) Effects

37.5 3rd degree burns

25.0 2nd degree burns

4.5 1st degree burns

7.2.5 CONSEQUENCE ANALYSIS

Consequence analysis is a part of hazard analysis and it provides a relative measure of

likelihood and severity of various possible hazardous events and enables those

responsible to focus on the potential hazards. For practical purposes, the risk analysis

may be based on subjective common-sense evaluation. Thus, this study concerns itself

with the adverse effects of accidental and short-term release of hazardous materials on

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people in the surrounding area. The long-term effects of continuous pollutants are not

dealt with.

1. Failure Frequencies

Failure rates for various critical equipments are very important in risk assessment. Very

limited data in this regard is available in our country. However, Safety and Reliability

Directorate of UK and IEEE of USA have certain data in this regard. Relevant data are

extracted and used in estimating failure rates leading to release of chemical. This data

has different norms such as per hour, per vessel year, failures per year, errors per

million operations etc.

2. Failure Data

Process Control Failure 3.0 e (-) 5 per hour

Process Control Valve 2.4 e (-) 6 per hour

Alarm 4.6 e (-) 5 per hour

Leakage at largest Storage tank 3.0 e (-) 5 per year

Leakage of pipeline (150 mm dia) Full Bore 8.0e (-) 8 per meter per year

Leakage of pipeline (150 mm dia.) 20 % rupture 2.6 e (-) 8 per meter per year

Human failure 1.8 e (-) 3 demand

3. Probability of Occurrence of Identified Hazards

The probability and consequence for each identified hazard event considering the

method and procedure of plant operation and existing infrastructure for hazard control is

evaluated.

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The following criterion is adopted related to ignition probabilities:

For instantaneous releases, immediate ignition may occur 0.25 times. There could be

delayed vapour cloud explosions for such releases, towards residential areas 0.9 times.

Flash fire probability is 0.5.

When the release, continuous, the chance of immediate ignition is 0.1 and delayed

ignition is 0.75. A directional probability of 0.2 is considered with regards to wave

propagation direction in case of explosions.

4. Ignition Sources of Major Fires

Electrical Wiring 23%

Smoking 18%

Friction-bearings/broken parts 10%

Overheated materials 08%

Hot surfaces-boilers-lamps 07%

Burner flame-torch 07%

Combustion sparks 05%

Spontaneous ignition 04%

Cutting, Welding 04%

Exposure fires 03%

Incendiaries 02%

Mechanical sparks 02%

Molten substances 01%

Chemical action 01%

Static charge 01%

Lightning 01%

Miscellaneous 01%

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5. Site Specific Consequences

In order to assess the site-specific consequences, information pertaining to the site

such as nearest habitation, nearest industry etc was collected. The nearest village to

the plant site is Alaganchi village with a population of about 2000 located at distance of

2.0 km from the plant site in the West direction. Site specific consequence analysis of

failure cases are carried out with the objective to study how many persons are involved

in an accident and are likely to get killed or injured, or how large is the area which is

likely to be destroyed or rendered unusable so that a true assessment of the safety of

the plant can be made.

6. Consequences of Heat Radiation – Alcohol Storage Tanks Failure

Failure of alcohol storage tanks showed 100%, 50% and 1% lethality upto a distance of

less than 85m due to radiation intensity of 37.5 kW/m2, 25.5 kW / m2, and 12.5 kW /m2.

Radiation of this intensity will cause damage to process equipment.

Radiation intensity of 4.5 kW/m2 which cause first degree burns when exposed for 20

seconds will extend to a maximum distance of 160 m from the edge of the pool.

Nearest Habitation is located at a distance of 2.0 km from the plant site. Therefore the

pool fire scenario of storage tank farm does not call for offsite damage. However the

major effect will be on the onsite personnel. The employees located with the 4.5

kW/m2, contour will get affected. As the project is located for away from any human

habitation and surrounded by dry lands & hillocks with scrubs the offsite damage to the

general public and property is negligible.

7.2.6 FIRE FIGHTING FACILITIES IN ALCOHOL PLANT

1. POSSIBLE FIRE HAZARDS

i. Fire in fuel/bio-mass storage yard

ii. Fire in Alcohol storage tanks Electric static electricity and consequent fire

accident.

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2. FIRE FIGHTING FACILITIES

a. Water Hydrant System

Fire hydrant system with hose pipe of 7 kg/cm2 pressure with hydrants are located

at in bio-mass yard, distillery house, ethanol storage area

A jockey pump and accessories. 50 m3/hr at 90 m head

Corrosion protected M.S. underground piping 150 mm dia. and 100 mm and

around the plant as closed loop

8 nos. single headed hydrants distributed around the plant at about 30 m

spacing to supply pressurized water for fire fighting.

10nos. MS hydrant hose cabinet adjacent to each section.

b. Fire Extinguishers

Foam water : 2 each at main office and store.

CO2 type : 6 nos. one each at departmental office and electrical installations.

DCP type : 8 nos. each at distillery plant and power plant.

Sand buckets: At different locations

c. Fire Protective Appliances

Two sets of fire safety appliances each consisting of following units are located

at store and alcohol storage, respectively.

Face masks & gas masks (2),

Face shield (2),

Helmet (6),

Safety belts (2),

Safety ladder (1)

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d. Fire Brigade

Fire brigade facilities available at Nanjangud and Mysore will be utilized whenever

need arises.

7.3 DISASTER MANAGEMENT PLAN (DMP)

The project includes the existing sugar unit and power and proposed expansion of

distillery unit. A comprehensive DMP will be implemented in the industry as presented

below.

7.3.1 OBJECTIVES

Even though all safety measures are adopted, the hazards leading to emergency

situations are likely occur in the industries under unforeseen circumstances. The

project proponents are therefore prepared an “Emergency Management Plan” (EMP) for

the proposed industry with the main objective to keep the organization in a state of

readiness to contain the emergency and its cascading effect and to bring the incident

under control with priority to saving of life, preventing injury and loss of property and

also to bring back the plant to normality and working condition. EMP is the systematic

information along with a set of instructions and preparatory details to meet such

eventualities with a view to contain it to be minimum in terms of damage or loss to

health, life, property within the industry or outside the industry. In the distillery, the

eventualities are likely to cause emergency situation confined to the industry itself, and

therefore, on-site emergency management plan is prepared for the proposed industry.

Before starting to prepare the EMP it is ensured that all the necessary standards and

codes of safety including electrical, insurance etc., are followed from the design stage

itself in the industry. For convenience of planning the emergencies are classified in to

on-site and off-site emergencies.

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1. ON-SITE EMERGENCY:

It consists of those situations affecting one or more plants of the industrial facility and

manageable by a planned resources of the industry itself.

2. OFF-SITE EMERGENCY:

It consists of more serious situations affecting several plants of the industry, even

spreading outside and requiring outside assistance including state or national level

resources mobilization to manage them.

In the distillery, the eventualities are likely to cause emergency situation confined to the

industry itself, and therefore, on-site emergency management plan is prepared for the

proposed industry.

3. PROJECT FEATURES

Knowledge of manufacturing process, plant, machineries and layout plan of plant and

site are required for planning emergency management and these are given in

Chapter-2.

4. RISK ASSESSEMENT:

To work out EMP, it is necessary to assess the risk involved in and around the

proposed industry. The detailed information on risk assessment is furnished in

Chapter-7.2.

7.3.2 ORGANIZATION

TABLE 7.1 Organization Chart

Chief Controller of Disasters (Factory General Manager) Team-1 Team-2 Team-3 Team-4 Team-5 Team-6

Area Co-Ordinator

Medical Co-Ordinator

Material Co-Ordinator

Fire-Safety Co-Ordinator

PR Co-Odinator

Security Co-Ordinator

Distillery Manager

Chemist Civil Engineer

Power plant

Manager HR

Manager Security Officer

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7.3.3 DUTY ALLOCATION

1. Chief Disaster Controller (General Manager)

Take control and declare emergency

Be there

Contact Authorities

2. Area Co-ordinator

Take steps. Make Emergency shut-down of activities. Put everything in Safe

condition.

Evacuate.

Commence initial fire-fighting, till Fire Department comes to take up.

Identify materials requirements and call Material Manager.

3. Medical Co-Ordinator

Establish Emergency Center, Treat affected persons, Transfer/Remove Patients

Assign and Deploy staff

Contact Authorities

4. Material Co-Ordinator

Dispatch necessary Supplies

Arrange Purchases

5. Fire & Safety Co-Ordinator

Be Overall incharge for Fire and Safety.

Coordinate with Area Coordinator and Direct the Operations

Coordinate with City and Other Fire-tenderers.

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6. PR & Security Co-Ordinator

Remove Crowd

Arrange Gate security

Contact Police

Arrange evacuation

Contact outside Agencies if asked.

Handle news media

Mobilize vehicles

Arrange Food, clothing’s to Officers inside.

7. Emergency Control Center

Adequate Internal phones

Adequate external phones

Workers Tally

Map showing hazardous storages, Fire safety equ ipments , Gates and side

gates, Assembly points, List of persons.

8. Action on Site

Evacuate. Non-essential people first at Assembly point

Persons Accounting

Record of Next-of-kins

Public Relation

9. Post Disaster Analysis.

Why happened

Whether on-site operations failed? In what respect?

How to avoid such failure in future

Report to be submitted in detail to Authorities

Compensation arrangements if any, commenced?

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Call suggestions on shortfalls observed.

Give rewards openly, pull defaulters individually

7.4 SOCIAL IMPACT ASSESSMENT, R & R ACTION PLAN

SOCIETY STATUS

It is proposed to describe first the existing social status in detail as to demography,

amenities, public health, agriculture, land-use pattern, employment and industries. The

need of developmental efforts will be arrived and on that background, this Project will be

seen.

POPULATION

As of 2001 India census, Nanjangud had a population of 48,220. Males constitute 51%

of the population and females 49%. Nanjangud has an average literacy rate of 68%,

higher than the national average of 59.5%: male literacy is 74%, and female literacy is

63%. In Nanjangud, 11% of the population is under 6 years of age.

TRANSPORTATION & COMMUNICATION

All villages in the study zone are connected by road network. However, surfacing

facilities needs to be improved. The establishment of this industry is catalytic to the road

development.

PUBLIC HEALTH

The villages in the study zone facilities are scanty. Few have some resemblance of

health centre, in others visiting practitioners visit. A Government Hospital is present is

Nanjangud, about 10 km from the project site.

AMENITIES IN STUDY AREA

It is peculiar that all the villages are in habitated. The information compiled by record

and interviews is as follows:

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Sugarcane is grown in all the villages & the villagers will be benefitted by the

establishment of this industry.

Primary school education is available in all the villages.

Drinking water is available to all the villages, the source being bore wells.

It is encouraging to find that all the villages are connected by road network,

though it needs good surfacing. This is a good infrastructure for bringing cane

from the villagers and they will get benefited.

ECONOMIC STATUS IN THE REGION:

Most population lives in rural areas mostly dependent on agriculture and associated

activities. The industrial activity is mainly based on the sugar industrial complex of the

present proponents. A significant person are directly or indirectly associated and

benefitted due to this industry.

Chapter - 8

PROJECT BENEFITS

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Chapter- 8

PROJECT BENEFITS

8.1 IMPROVEMENTS IN PHYSICAL INFRASTRUCTURE

The proposed project is expansion of the distillery capacity from 60 KLPD to 150 KLPD

at the existing sugar industrial complex consisting of sugar, co gen power and distillery

units. The unit is located at Alaganchi village, Nanjangud taluk, Mysore district in

Karnataka state. The Alcohol industry was established in the year 2005. Before

establishment of the sugar industry, the location was more backward and under

developed with respect to transportation, roads, communication facility, banking facility,

school, lively hood opportunities, job opportunities. During last 22 years, after

establishment of the sugar industrial complex the region around the project site has

improved significantly in physical and social infrastructure facility, job opportunities.

Agriculture activities, greenery development and road development are very significant.

With expansion of the proposed project the infrastructure facility already provided will be

further improved

Vehicular movement for raw materials and products and also for the movement of

personnel in the roads of this area will considerably increase. This will result in

development and maintenance of roads. Automobile related activity such as vehicle

repair and maintenance garages, workshops and shops are started.

The location is rural and economically backward. The industry will lead to creation of

new job opportunities and scope for transport and other petty business activity.

8.2 IMPROVEMENTS IN THE SOCIAL INFRASTRUCTURE

The location is rural and economically backward. Creation of job opportunity and scope

for transport and other petty business activity will improve the economy and attitude of

the public towards education and health. This may result in the creation of additional

education and health care facilities in this rural area.

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In rural areas much of the time and energy is wasted in reaching from one place to

another. This is due to lack of swift mode of transport. By the expansion of this industry,

movement of vehicles in this area will generally improve (both private and public-

owned).

Society of farmers and this Industry are interdependent. Industry gets raw material from

the farmers. Better and purer the raw material quality better is the finished product of

the industry and sophisticated market. Both of them can get better pricing.

8.3 EMPLOYMENT POTENTIAL – SKILLED, SEMI-SKILLED AND UNSKILLED

The industry and its supporting activities need people from manual to managerial

strength, in a pyramid. The overall potential including the garages, loading-unloading

actions, eateries, small shop owners is substantial. The local people can get a good

share out of this.

After the expansion of this industry, it will create direct employment to 30 people and

indirect employment opportunities to 150 people in terms of factory general work,

transportation, vehicle maintenance, petty shops etc.

8.4 OTHER TANGIBLE BENEFITS

Both tangible and non-tangible benefits will result from this activity and many of those

are described above. Apart from direct employment, other benefits are listed below

Ground water level harvesting will be practiced

Aesthetics improvement by general greening with emphasis on biodiversity

Availability of compost fertilizer facilitates for raising crops and grass

Developed economy will improve living standards.

Developed economy brings with it literacy and healthy living.

Improved safety-security in surrounding with better Law and Order.

Symbiosis and sustainable development will be the ultimate objective.

All these social benefits will become a reality by the expansion of this industry.

Chapter - 9

ENVIRONMENTAL COST BENEFIT

ANALYSIS

180

Chapter - 9

ENVIRONMENTAL COST BENEFIT ANALYSIS

The benefits of the integrated sugar industry with bio-mass based Co-gen power unit

and molasses based distillery unit are well established and they have proved to be

economical attractive. Distilleries are agro based and located in rural area and they

have contributed significantly in socio-economic development of the rural region of the

country. During scoping stage the authorities have not specified the requirement of

environmental cost benefit analysis. Hence, the environmental cost benefit analysis was

not considered in the report. However the main benefits of the proposed distillery units

associated with sugar industry is presented in Chapter-1.

Chapter - 10

ENVIRONMENTAL MANAGEMENT PLAN

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Chapter - 10

ENVIRONMENTAL MANAGEMENT PLAN

10.1 INTRODUCTION

Environmental management plan (EMP) describes the administrative aspects of

ensuring that mitigation measures are implemented and their effectiveness monitored,

after approval of EIA. It consists of various policies, control measures etc. for abatement

of critical environmental impacts arising out of the proposed project. Based on the

impacts identified, mitigation measures are proposed and these will be incorporated

with the plant. Further a suitable environment management plan will be introduced in

the project to implement and practice measures to protect and enhance the quality of

environment. The EMP is only as effective as its implementation. An appropriate

environmental management strategy is developed and presented in the form of an

EMS.

The proposed project involves utilization of natural resources and generation of waste

and polluting substances. Depletion of natural resources will affect the competitive

users. The waste and polluting materials if discharged without control and treatment is

likely to have adverse consequence to the environment parameters including water, air,

soil, flora and fauna. Further, it may exert stress to the existing infrastructural and other

facilities and also to the existing socio economic status of the region. It is the

responsibility of the project proponents to control the utilization of resources and

discharges of waste products by adopting suitable control measures in the factory to

avoid adverse consequence of industrial activities on the environment and in turn to

enhance the quality of the existing environment.

10.2 NEED

Environmental management is a crucial segment of Industrial Project. Management

of project, in view of the global concept of sustainable development will do their

best. Therefore, preparation of Environmental Management Plan is a must to fulfill

bifocal aspect of the statutory compliance as well as that of social concern. Water

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needs of project may be reasonable, but generally this resource is dwindling. Thus, on

hand one should use it less and on the other source should not be left polluted for

others. Air environment needs to be continuously managed, because man needs

inhalation every moment, so also is Flora and Fauna dependent on it. The biological

aspects, soil and ground water are all interdependent. Thus a proper environmental

management and a conscious plan are needed.

10.3 OBJECTIVES

1. To define the components of environmental management..

2. To prepare an environmental hierarchy.

3. To prepare a checklist for statutory compliance.

4. To prepare environmental organization.

5. To prepare a schedule for monitoring and compliance.

6. To establish a watchdog committee voluntarily with an ultimate aim to get ISO

14001 certification.

10.4 ENVIRONMENT COMPONENTS

10.4.1 Air Environment

1. Monitor the consented parameters at ambient air quality stations, regularly.

2. Monitor the work zone at various stations to satisfy the corporate requirements

for health and environment.

3. Monitor the stack.

4. 8 hourly average concentration of total suspended particulate matter in ambient

air shall be monitored at 40 meter distance from the primary vibratory / rotary

/screen or the site boundary whichever lesser using high volume sampler

instrument.

5. Use of low Sulphur coal

6. Covered storage for coal, wherever necessary

7. Water sprinklers

8. Smooth Roads. Trucks Covered

9. Green Belt around

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10.4.2 Water Environment

1. Keep record of input water every day for quantity and quality.

2. Measures are taken to segregate the sub-streams of effluent as per their

characterization.

3. Water conservation is accorded high priority in every section of the activity.

4. Captive power plant Boiler blow down & cooling purging water reused after

treatment through PCT (Physico Chemical Treatment).

5. Keep record of wastewater returned back to boiler make up and process

for both the quantity and quality details.

10.4.3 Solid waste

1. Monitor solid waste disposal zone environment. (Water, groundwater, leachates,

air, soil, up-gradient to down-gradient, upwind to downwind) Monitor garden

sweepings and dry leaves)

2. Stored on raised platform

3. Non hazardous material

10.4.4 Aesthetic (Noise & Odour) Environment

The Project will generate noise from various locations like

1. Steam Generator

2. Rotary equipments like fans, blowers and compressors

3. Combustion Chamber, Steam traps and leaking points the proponent note that

the project will have the following facilities, which will reduce the overall impact

of noise pollution

4. Use of better acoustic systems to minimize noise generated by the

equipments

5. Regular maintenance of equipments to minimize noise pollution

6. Monitor the ambient noise level and work zone noise level to conform the

stipulated norms.

7. Creation of awareness for noise attenuation and mitigation program.

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8. Monitor the ambient Odour level and work zone Odour level by sensing.

9. Creation of awareness for Odour attenuation and mitigation program

10.4.5 Biological Environment

1. Special attention is planned to maintain green belt in and around the

Amenities premises.

2. Adequate provisions are made to facilitate daily watering of all plants and

lawns.

3. Special attention provided during summer to ensure that the green belt does

not suffer from water shortage.

4. Development & maintenance of green belt to be considered as a priority issue.

5. Return water collection, treatment and reuse under watch.

10.4.6 Work-zone Comfort Environment

1. Monitor the work zone temperature levels.

2. Monitor the work zone humidity.

3. Examine the health of staff workers and keep record.

10.4.7 Socio-Economic Environment

1. The operators and workers are trained in various aspects of ESH

(Environment, Safety and Health).

2. The managers and officers involved in Environment Management Cell shall

undergo refresher workshop and up gradation of information on various

environmental issues.

3. The industrial authority shall help in promoting the activities related to

environmental awareness in nearby villages and visitors.

4. The industrial authority shall help in promoting local people for livelihood

5. Commensurate with their will, skill and abilities

6. Health Statistics will be assembled, compiled and displayed.

7. Environmental status will be displayed.

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Figure 10.1: Structures for EMP

186

10.5 ENVIRONMENT MANAGEMENT HIERARCHY

Developer is aware that environmental management is not a job, which can be handled without a careful planning. The success lies if three components are simultaneously present

viz. (1) management support, (2) efficiency of the environment management cell and (3) acceptability of resulting environmental quality, both by SPCB and by public. A structure of this plan and hierarchy of process flow for environmental management is prepared and enclosed as logics, which is self-explanatory. Developers will adopt this structure and hierarchy, which is akin to principles and practice.

10.6 CHECKLIST OF STATUTORY OBLIGATIONS

There are a number of environmental statutes required to be attended to by the

industries or projects. Industry has prepared a checklist of these obligations, which

facilitates the obedience of the laws of land. These are advised to industry as follows:

1. The Consents, whether under the Water Act or under the Air Act, are normally

issued for a fixed validity period. Please check whether the Consent is valid. If

the same is expiring, it is better to apply for a fresh renewal at least 120 days

prior to the expiry date.

2. The Consent normally describes the items of manufactured products with

Figure10.2 Environment Hierarchy

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quantity. One should see that, the described framework is not overstepped. In

case, there is any likely hood of such increase, it will be worthwhile to obtain

permission for the same. At least a letter to that effect is posted to the relevant

board officer.

3. The Consent lays down a condition as to the volume and rate of discharge of

effluents both for domestic as well as the industrial activity. By routine checks at

the measuring devices, this can be ascertained.

4. For this purpose, STP is already provided by the industry. There should be a

continuous performance evaluation of the treatment units, so as to always

remain inside tolerance limits Following measures can be adopted,

a. Characterization of raw effluents/emissions.

b. Attempting in-plant controls.

c. Operation, maintenance, repairs and replacement of the ETP,

d. Retrofit equipment to the existing plant.

5. Disposal is the last ditch battle. Disposal, dispersion, dilution, diversion,

therefore, has to be planned very methodically and operated efficiently. This is a

place where more reliable staff is required to be deployed. Any untoward

incidence be reported.

6. The drainage network has been planned in such a way that, storm water and

effluents do not get mixed. Keep the terminal manhole clean and always

hospitable to facilitate taking of sample by the Board officials. Also check that no

effluent is admitted in the channel down-stream of the terminal manhole, which

means all the effluent, finally should pass via the terminal manhole only.

7. Monitoring aspects are always very crucial for operating the plant, certain

parameters be constantly checked. However, it will be a good practice to check

monthly all the parameters through standard and approved laboratories. In case

there is a water body in the vicinity, it is advised to take periodically samples from

it. This applies both to the surface water as well as ground water. The findings

will either give you a confident satisfaction or may give you a timely warning for

improvement in the treatment or more so in the disposal system.

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8. The environmental audit statement is required to be submitted on annual basis,.

9. The industry should device their own format for a daily log book recording of the

running of their ETP. A printed format shows your conscious efforts towards the

goal of pollution control, whenever any inspection takes place.

10. An inspection book to note observations made by the visiting KSPCB field officer

is maintained.. The compliance of the unsatisfactory remarks are shown during

next inspection.

11. In case, there is an unfortunate accident, unforeseen act or event by which

pollutants are excessively released into the environment, the same be brought

immediately to the notice of the board and other concerned agencies. This will

enable you to get experienced timely help from them. Your burden gets shared.

Synergistic effects can be predicted by an overview.

12. In case, you feel aggrieved by any conditions imposed in the Consent, approach

the board immediately for discussion, or thereafter prefer an appeal timely.

Therefore, read the Consent carefully as soon as you receive the same.

13. The Water Cess Act, 1977, is applicable to certain specified industries. In case

your industry is covered, the regular returns be submitted. Water meters be

installed, whether the industry is covered or not under the Cess Act. Also check

from time to time whether the class of your industry, which may not be presently

specified, has since got covered under the Cess Act.

14. The Cess amount be paid as per assessment orders and record maintained.

15. In case you feel aggrieved by excessive cess assessment or non-sanction of

rebate, the appeal is preferred in time that is within 30 days. And in case, you are

late in doing this, at last submit with reasons for the delay.

16. The Government or Board while giving site clearance or Consent normally puts a

condition of plantation of trees. Otherwise also, planting trees within the

compound gives a good demonstration of your plant performance. A better

practice is to select about three varieties and species selected be tough and

tolerant for existing type of environment.

17. An unsafe working and the environmental pollution generally goes hand-in-hand.

Therefore, the obligations under the Factories Act be scrupulously followed and

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record maintained.

18. There are certain responsibilities regarding the hazardous waste. These can be

summarized as follows: a) Identification of quantity, constituents and compatibility

of hazardous waste, being generated during the activity.

a. Proper labeling and marking of containers, which are used for store,

transport, or disposal of hazardous waste.

b. Use of appropriate containers for storage and transport.

c. Furnishing of information regarding the waste, its nature, its hazards,

antidotes, and non-compatibility etc. to the persons who either transport,

treat, store or dispose off the waste.

d. Use of authorized operator agency system to ensure the proper

disposal of hazardous wastes and to streamline the treatment and

disposal.

e. Training of personnel for handling and proper storage of such categorized

waste.

f. Identify a transporter specialized in such wastes, and the practice of

explicate Manifest (gate-pass) be followed.

g. Submission of reports to MoEF and KSPCB.

h. To provide safety measures for handling of hazardous waste.

i. In case of an unforeseen act or event in transit occurs, the transporter

should immediately report to the nearest police station about the accident,

and The clean- up measures.

j. He should also report to SPCB on the Form prescribed by the Hazardous

Waste (Management and Handling) Rules, 2008 and the guidelines issued

by the Central Government.

k. A container be opened for a short duration while receiving the hazardous

material in it and while removing out from it, or otherwise it must always be

kept closed in storage yard.

l. A container be opened or handled so carefully and slowly as not to

rupture/damage the container. Always keep in spare some empty, clean

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and sturdy containers handy and immediately available.

m. Inspect the filled and stored containers every day and if any found in bad

conditions transfer the contents to a good container immediately but

carefully.

n. Keep a daily record of your custody.

o. Documentation is always a matter of evidential value. No job is complete

unless paper work is complete. Occupier/generator should carefully note

this, and following be developed.

p. Gate-pass when waste leaves the factory by a transport towards the

treatment facility. Keep the receipts.

q. A receipt of material as signed by the facility Operator as a manifested

colour coded copy is preserved for three years.

r. Analyze the out-going waste and keep the results for three years from the

date of dispatch.

10.7 Records of Waste generation to be maintained as per following:

1. Quantity and points of generation.

2. Physical state and chemical constituents.

3. Hazardous waste category as per E. P. Rules of 2008.

4. Hazardous waste class, as per Motor Vehicle Rules of 1989.

5. Certify internally, the limit of 90 days and storage of ten tons.

Under the Manufacture, Storage and Import of Hazardous Chemicals Rules,

1989, the immediate duties can be summarized as:

a. To forecast the possible situations of major accidents.

b. To design steps in advance to avoid accidents and its consequences

including cascading effect.

c. To educate the related workers to stand to such occurrence.

1. The occupier should not merely do the above job, but also make a show of his

work. Occupier is best advised to inform the concerned authorities and agencies,

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as to his preparing documents like risk analysis, emergency plan, safety training,

avoidance of major accidents, health plan, etc.

2. Under the Public Liability Insurance Act, 1991 the industrial manager is advised

to check some important activities, such as:

a. Owner should take out one or more insurance policies.

b. He should take out such policies before he starts handling any

hazardous substances.

c. The policies should always be kept renewed and alive.

d. The amount insured shall not be less than the paid capital. Check this from

time to time by taking a review of your position.

e. General Insurance Corporation or similar agencies may be able to throw more

light, if approached.”

10.8 ENVIRONMENTAL ORGANIZATION

Environmental organization will have an environmental cell responsible for pollution

control and also for self-examination through monitoring.

10.8.1 ENVIRONMENTAL POLICY

To attend the environmental concerns, Environmental Cell and Environmental

Department are created in the industry. Company has adopted Corporate

Environmental Policy as presented below. The policy is to be implemented through the

Environmental Management System such as ISO 14001.

CORPORATE ENVIRONMENTAL POLICY (CEP)

We at Bannari Amman Sugar industry Nanjangud taluk commit to improve in our

Environmental Management System and minimize the impact of our manufacturing

activity on the environment, on continual basis, by Complying with applicable

environmental Laws and Regulations. Establishing the systems and processes which

minimize, and prevents pollution and foster conservation of resources.

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Improving efficiency of all the operations through our proactive efforts in environmental

management and incorporating Cleaner technologies in the projects.

Establishing objectives and targets and the review of policy.

Enhancing the skills and competence of our employees to ensure sound environmental

management

10.8.2 ENVIRONMENTAL CELL

Structure of Environmental Cell

Environmental cell is constituted in the industry for effective management of

environmental protection and pollution control. It consists of following members drawn

out of the factory senior staff.

ENVIRONMENTAL CELL

Sl. No. Designation Member

1 Chairman Managing Director

2 Executive Officer General Manager

3 Convener Environmental Officer

Asst. General Manager –Distillery

Sr. Manager Process – Sugar

Manager-Cogen

Deputy Manger

Chemist

H. R. Manager

Security Officer

Dy. Manager - Cane

Environmental Engineer

4 Members

Civil Engineer

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AIM

The main aim of environmental cell is to plan, implement and monitor the measures

related to:

i. Pollution control and Environmental protection

ii. Sustainable development through Cleaner Technology

iii. Conservation of natural resources

iv. Statutory provisions

ACTIVITIES

i. Collection of information regarding

Industrial activities causing adverse impacts on environment

Generation of waste substances including liquid, gaseous and solid from

the factory and their adverse effects to environment.

Measures to prevent or reduce the wastes at the source itself in the

factory

Pollution control measures to avoid the adverse impact of industrial

activities on environment.

ii. Financial provisions for installation of pollution control and environmental

protection facilities

iii. To provide staff and labour for management of environment and also for the

operation and maintenance of pollution control facilities and self monitor

system.

iv. Monitoring the program of,

Performance of environmental department.

Monitor the implementation of various acts and rules related to

Environmental acts.

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Storm water management and rain water harvesting.

Green belt and greenery development in the premise.

10.8.3 ENVIRONMENTAL DEPARTMENT AIM

Environmental department will be formed under environmental engineer to implement

the activities of environmental management plan. It has overall responsibility of

environmental protection and pollution control, including the maintenance of pollution

control facilities, laboratories, self monitoring and also to maintain statutory records.

STRUCTURE

Sl. No. Designation Responsibility

1 Environmental Officer

In charge of environmental management, Liaison with Environmental Cell, responsible for statutory compliances, maintenance of records for interaction other departments of the industry and guidance to environmental staff.

2 Environmental Engineer In charge of Operation and maintenance of pollution control facilities.

3 Environmental Chemist Maintaining lab facilities, monitoring of discharges, P.C. operation, and ambient environmental parameters etc.

4 ETP supervisors

5 APC supervisors

To assist the smooth operations of ETP & Stack

6 Officer-green development

To help greenery development

7 Safety Officer Safety of the workmen

8 Medical Officer Health of the workmen

9 Workers To assist all the above activities

10.8.4 RECORDS TO BE MAINTAINED

Following records will be maintained by the environmental department in respect of

operation of pollution control facilities.

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Log sheet for operating ETP for waste water

Log Sheet for Operation of A.P.C plant

Instruction manual for operation and maintenance of ETP, APC, etc,

Log sheets for self monitoring of ETP& APC etc.

Manual for monitoring of Air, Water and soil for Ambient conditions

Instruction manual for monitoring of water, solid and gaseous parameters

discharged from the factory, and also for various parameters of pollution control

facilities.

Statutory records as per the Environmental Acts.

Monthly and annual progress reports.

10.1 COST ESTIMATES OF EMP IN DISTILLERY PROJECT

SL. NO.

PARTICULARS

EXISTING INVESTMENT

ALREADY MADE (Rs. In LAKHS)

(60KLPD ALCOHOL)

PROPOSED INVESTMENT IN EXPANSION (Rs. In

LAKHS) (150 KLPD ALCOHOL)

Total project investment (Alcohol unit & Environmental facility)

8320 8500

i Investment in Alcohol Unit 3650 4000

1

ii. Environmental facility •Spent wash Evaporation & Incineration Boiler

•Bio Compost unit & Condensate Polishing RO facility established

•Miscellaneous & other development activities

4670 4500

2 Annual Recurring cost (Maintenance)

90 250(Estimated)

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10.8.5 BUDGET FOR ENVIRONMENTAL MANAGEMENT PLAN

The total investment on the project and towards EMP is given below.

Table-10.2 Budget for Environmental Management Plan

Budget, Rs. Lakhs

Sl.

No. Application of funds

Implemented in

existing sugar

industry

During

implementation

of proposed project

1.0 Total investment on the project 8320 8500

2.0 Investment towards EMP

2.1 Air pollution control facilities

(Bagfilter, Chimney and ash 880 850

2.2 Waste water treatment facilities 3500 3400

2.3 Green belt, Land scaping etc 15 20

2.4 Laboratory and monitoring facilities 25 30

2.5 CSR Scheme 250 200

Sub total 4670 4500

3.0 Recurring Cost of Operation and Maintenance

3.1 Air pollution control 25 50

3.2 Water pollution control 25 80

3.3 Monitoring cost 15 30

3.4 Maintenance of greenery, socio

activities etc 25 90

Sub total 90 250

4.0 Investment on Alcohol unit 3650 4000

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10.9 Environmental Monitoring Schedule

To measure the success of the cell, monitoring is a useful tool. The monitoring

schedule is decided as under:

TABLE 10.3 Monitoring Schedules

Legend : W=Weekly, M=Monthly, Y= Yearly

It is being considered to have a full-fledged laboratory, allotted to these facilities of

analysis. It is felt that, this arrangement will be adequate enough for Environmental

Protection. Monitoring is a technique of drawing a sample and understanding from it the

universe. The sampling station, the parameters and frequency is of extreme importance

as also the careful analysis, reporting and interpretation.

Subject From Frequency Parameters

Water Drinking M Standard

Raw M Waste water

Treated M

pH, BOD,COD,TSS,TDS,

N, P,SS,TDS

Raw Y

Treated Y BOD,N,P, SS, TDS

Storm Water

Stack M

Air Ambient Air M SPM, SO2, NOx, CO

Noise Ambient M dB(A)

Soil Y C, N, P, K

Aesthetics

Odour, comfort,

visual,

Housekeeping,

Roads

W Marks: Severe, Tolerable,

Average, Excellent

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10.10 SCHEDULES

There will be three facets to design and follow the schedules viz.: (A) for compliance of

responsibilities, (B) for day-to-day operation and management of WTP and ECE, and

(C) for routine environmental monitoring, to assess the impact and take timely warning.

The schedule:

10.10.1 Daily Compliance

1. Take the meter readings -initial and final, for checking the water consumption.

2. Maintain the electricity consumption record for pollution control.

3. Monitor wastewater generation, treatment system & reuse of treated

water.

10.10.2 Monthly Compliance

1. Monitor the emission sources through the competent authority and submit

the analysis reports to the board.

2. Monitor ambient/work zone noise levels & ensure conformance to standards.

10.10.3 Quarterly Compliance

1. Monitor the ambient air quality at upwind and downwind locations of the factory.

2. Review the Water Reuse performance.

3. Monitor ambient air per quarterly.

10.10.4 Yearly Compliance

1. Carryout “Environmental Audit Statement” of various environmental aspects,

review the environmental policies with the help of experts and make the up

gradation/changes accordingly.

2. Submit the “Environmental Statement” to the State Pollution Control Board in

Form V under Rule 14 of the Environment (Protection) Second Amendment

Rules 1992 of the Environment (Protection) Act, 1986.

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3. Renew the Consent to Operate under the Water and Air Acts.

4. File the Cess returns to the State PCB under the Water (Prevention and Control

of Pollution) Cess Act, 1977.

5. Renew the Hazardous Waste Authorization under sub-rule 3 of the Hazardous

Waste (Management and Handling) Rules, 2008.

10.10.5 Consent Compliance

Project undertakes to comply the conditions prescribed by the Consent. In this

direction, the following discipline will be followed:

TABLE – 10.4: CONSENT COMPLIANCE

CONDITION REGARDING MODE OF COMPLIANCE

Quantity of Effluent To be measured daily and in-plant control. Not to exceed

any time

Quantity of Sewage To be measured periodically. Not to exceed the

consent conditions.

Total water input

To be measured daily. Repair meters. Not to exceed.

Make breakup as per usages. Fill monthly Cess returns.

Pay as per

Quality of Effluents By running ETP in correct fashion. Monitor. Report

Disposal Not over application. No percolation, no spillages.

Monitor.

Ambient Air Regular monitoring.

Noise levels Check foundation for vibrations, Tree plantation

Solid Waste Quantity to be measured & record kept..

Environ. Audit To be complied every year before 30th Sept., as also

the ESR Environmental status report

Inspections Inspection Book to be opened. Instructions given by

KSPCB visiting officer to be complied and reported.

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10.11 SOCIO-WELFARE ACTIVITY

The Company has adopted a management policy to involve in Socio Economic

Activities. The co-gen sugar industry is basically agro based and directly associated

with farmers and other inhabitants of the region.

10.11.1 PRESENT ACTIVITIES (CORPORATE ENDOWNMENT IN SOCIAL SERVICE)

The contribution made by Bannari Amman Group through its Chairman

Dr. S.V.Balasubramaniam as Chairman of Siruthuli Trust, Coimbatore, in conserving

the water sources around Coimbatore city by renovating the age-old ponds

and make it fit for harvesting the rainwater to ensure assured supply of ground

water throughout the year to the city of Coimbatore, is a highly successful and laudable

project. Dr.A.P.J.Abdul Kalam, the Former President of India, admired this

magnificent service to the humanity and now he himself is propagating this model at

various places across the nation. The noble work done has made the ground water

available at 40 feet depth itself, against the previous level of 400 feet.

The active role of the Bannari Amman Group in agro development, industry and

education has been widely recognised. The Chairman, Sri S V Balasubramaniam was

honoured with Doctorate of Science (Honoris Causa) by the well-reputed, a century

heritage, Tamil Nadu Agricultural University, Coimbatore, for his contribution to Agro

industry and Education service by Sri Surjit Singh Barnala, Governor of Tamil Nadu in

presence of Dr. A.P.J.Abdul Kalam, Former President of India.

PARTICIPATION OF THE FORMER PRESIDENT DR. A.P.J. ABDUL KALAM IN SIRUTHULI

PROJECT

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Annamalai University, Chidambaram, Tamil Nadu also conferred Doctor of Letters

(Honoris Causa) for his contribution to Industrial and Educational service and the

award was conferred by Sri Surjit Singh Barnala, Governor of Tamil Nadu.

Bannari Amman Sugars have provided resources, infrastructure, motivation and

direction in the establishment of the following facilities benefiting the rural public in

the command area. The social responsibility activities that are executed by Bannari

Rural Foundation with the assistance provided by the Company are as under :

65 eye camps benefiting 2520 patients

Special medical camps for physically challenged in rural areas

Construction of building and providing equipment at hospitals and rehabilitation

centers

Providing toilet facilities in schools and rural house holdings

Supply of furniture and other essentials to schools in rural areas

Rain water harvesting and Tree planting programmes

Developing green nurturing program in school near to our industry. The industry

spent around 1 lakh rupees for this program.

The sustainable environmental friendly technologies adopted at our Sugar complex

add values to the environmental aspects.

CFL bulbs worth Rs. 50000 provided to nearby villages to promote power saving

bulb usage

Honorary Degree of ‘Doctor of Science

(Honoris Causa)’ was conferred by Tamil

Nadu Agricultural University, Coimbatore

Honorary Degree of ‘Doctor of Letters (Honoris

Causa)’ was conferred by Annamalai University,

Chidambaram

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DISTRIBUTION OF BOOKS & STATIONERIES TO NEAR BY SCHOOLS

DONATION FOR VILLAGE DEVELOPMENT PAINTING OF TEMPLE

DISTRIBUTION OF ENVIRONMENTAL

CHARTS, CFL BULBS & FIRST AID BOX

TO NEAR BY SCHOOLS

DRUMS DONATED TO NEAR BY SCHOOLS

FOR STORAGE OF WATER

(KITCHEN & TOILETS USE)

CSR ACTIVITIES - BANNARI AMMAN SUGARS LTD, ALAGANCHI

203

10.11.2 PROPOSED SOCIO WELFARE ACTIVITIES

The industry has proposed to take up socio-welfare activities as below over a period of

3 years.

Table-10.5 Proposed Socio Welfare Activity.

Sl. No.

Particulars of acivity Budget,

Rs. Lakhs

1 Drinking water facility with bore well, water storage tank and pump at isolated locations at 10 locations

20.00

2 Assisting the village panchayat or local N.G.O.s for cultural activities

20.00

3 Adopting school/students for development of quality education 50.00

4 Assisting local youths in development of technical skill and/vocational training, about 50 candidates

30.00

5 Assisting the village panchayat or local N.G.O.s for development of greenery including medicinal and oil plants. 10 locations

20.00

6 Assisting the village panchayat or local N.G.O.s for development Library facility, 10 locations

20.00

7 Need based assistance for benefit of the region 40.00

Total 200.00

CHAPTER - 11

SUMMARY AND CONCLUSIONS

204

Chapter - 11

SUMMARY AND CONCLUSIONS

M/s Bannari Amman S u g a rs Limited i s an agro based company engaged in the

manufacture of Sugar, Cogen power, Alcohol etc. The company has already

established and running a fully integrated sugar complex of 7500 TCD sugar

unit, 36 MW co-gen unit and a distillery of 60 KLPD with Spentwash

concentration and Incineration plant at Alaganchi village, Nanjangud taluk, Mysore

district in Karnataka State.

Now the company has proposed to expand the distillery of 60 KLPD (RS/ENA) to

150 KLPD (RS/ENA/Ethanol(AA). The existing 60 KLPD distillery was

established in the year 2005, with Biocomposting facility as the Environmental

Management Programme. During the year 2008 the company has installed

Spentwash concentration system with burning it as fuel in a specially designed Boiler.

The Evaporator and Boiler system was designed in such a way to handle the spent

wash generated up to the level of 732 m3/day at 18% concentration and boiler with

210 T/d concentrated spent wash (60%) burning capacity.

The expansion of 60 KLPD Alcohol to 150 KLPD Alcohol is proposed to be carried out

will involve addition and alteration of equipments, machineries, building etc.

The above expansion programmes will be integrated with latest Zero Discharge

Environmental Management Systems in line with MoEF/CPCB/PCB guidelines.

1. The spent wash will be concentrated from 18% solids to around 60% solids and

burnt as fuel in a specially designed boiler with support fuels like coal, bagasse &

Biomass etc. All the sludge materials generated at Distillery Fermentation

section and spentwash storage sections, and RO reject water are currently

utilised in Biocomposting process, using sugar unit’s press mud, potash rich

boiler ash material and valuable compost manure produced in an Eco Friendly

way finds use as valuable manure to the farm lands. The full fledged concreted

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compost yard in 10.50 acres area established during the year 2005 with

modern composting machines, compost pulverizer, Auto bagging section with

monitoring lab are in operation. The additional sludge etc., generated in the

proposed expansion to 150 KLPD Alcohol will be utilized in the Biocomposting.

This will minimize the loading to evaporators and boiler and ultimately

reduce scaling impact and fuel requirement of the boiler.

2. The condensate water generated from spent wash evaporation process etc., is

currently treated in ETP and polished in RO to reuse the water back in processing

sections and cooling towers. Required additional facility will be established to deal

with the expansion to 150 KLPD.

3. To keep the zone green, all round efforts are being taken with continuous

programme of tree planting.

4. In the vicinity of the factory there are no protected forests, sanctuary,

archaeological important structures and sensitive locations. Therefore, the

proposed expansion will not have any adverse effect on the environment or the

eco system.

5. The project is an example to sustainable development, as the resources used from

the nature are sent back to the earth by recycling process. The concept of Recycle,

Reuse and Reduce is practiced in the unit in line with the eco-policy of Govt. of

India.

6. This industry does not produce any toxic products and does not have

significant adverse effect on the quality of land, water and air. The industry has

taken all the necessary preventive measures to mitigate even the small effects

which may be caused by industrial activities.

7. The industry adopted an effective environment management system and

environment management plan to protect the environment. Due priority is given for

greenery development and rain harvesting in the factory premises and around.

Environmental management plan and suggested measures for pollution control are

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adequate for protection of environment and to seek environmental clearance to the

project.

8. The industry will adhere to all the mitigation measures to safeguard the

environment and operate the proposed expansion of 60 KLPD to 150 KLPD

effectively.

9. We submit the details for the earliest Environmental Clearance (EC) from the

MoEF to expand the capacity of the distillery from 60 KLPD to 150 KLPD.

207

View of Distillery Unit- Installed In the Year 2005

View of Concentration and Incineration Plant

Installed In the End of the Year 2008

208

View of Turbo Generator section & Evaporator section

View of Spent wash Incineration Boiler

209

View of Bio compost Yard

View of Bio Compost Yard - A Waste To Wealth Programme

210

View of Boiler Ash Handling System

Boiler Ash rich in POTASH as K (10%)

About 25 Tonnes of Potash rich Ash available per day.

Blended with compost to increase the manural value at about 5 - 10% level.

Potash fertilizer is animported item.

We are working on to value add thePotash rich ASH.

211

View of Bag Filter and Chimney

View of Reverse Osmosis Unit

212

Intensive Tree Plantation near Bio Compost Yard

Intensive Tree Plantation around Distillery Unit

213

Tree Plantation at ETP Area

CHAPTER - 12

CONSULTANTS ENGAGED

214

Chapter 12

DISCLOSURE OF CONSULTANTS ENGAGED

12.1 The Names of the Consultants Engaged With Their Brief Resume & Nature of

Consultancy Rendered

This EIA report is prepared on behalf of the proponents, taking inputs from proponent’s

office staff, their R & D wing, Architects, Project Management Professionals etc. by

Environmental Consultants M/s. Ultra-Tech Environmental Consultancy & Laboratory,

Thane, Mumbai , who have been accredited by QCI-NABET vide official memorandum

of MoEF S.N. 93 of LIST ‘A’ of MoEF - O.M. No. J 11013/77/2004/IA II(I) dated

September 30, 2011. Sl.No. of 156 of list of Consultants with provisional

Accreditation/Rev/22A/Sep 10th, 2014.

M/s Ultra-Tech Environmental Consultancy & Laboratory:

Ultra-Tech Environmental Consultancy & Laboratory [Lab Gazetted by MoEF – Govt. of

India] not only give environmental solutions for sustainable development, but make sure

that they are economically feasible. With innovative ideas and impact mitigation

measures offered, make them distinguished in environmental consulting business. The

completion of tasks in record time is the key feature of Ultra-Tech. A team of more than

hundred environmental brigadiers consists of engineers, experts, ecologists,

hydrologists, geologists, socio-economic experts, solid waste and hazard waste experts

apart from environmental media sampling and monitoring experts and management

experts , strive hard to serve clients with up to mark and best services.

Ultra-Tech offers environmental consultancy services to assist its clients to obtain

environmental clearance for their large buildings, construction, CRZ, SEZ, high rise

buildings, township projects and industries covering sugar and distilleries from

respective authorities. Ultra-Tech is in the process of getting QCI-NABET final

accreditation for its EIA organization.

Ultra-Tech also provide STP/ETP /WTP project consultancy on turn-key basis apart

from Operation and Maintenance of these projects on annual contract basis. Also,

having MoEF approved environmental laboratory, Ultra-Tech provide laboratory

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services for monitoring and analysis of various environmental media like air, water,

waste water, stack, noise and meteorological data to its clients all over India and

abroad.

Functional area experts and assistance to FAE involved in the EIA study for “M/s.

Bannari Amman Sugars Ltd. Alaganchi Village, Nanjangud Taluk Mysore District in

Karnataka State is as follows:

Table No. 12.1: List of Functional Area Experts

FUNCTIONAL AREA EXPERTS INVOLVED IN THE EIA:

FUNCTIONAL AREA EXPERTS INVOLVED #

Name Of Sector

Name Of Project

Name Of Client

Name Of EIA Coordinator

FA NAME/S

AP Mr. Shekhar Tamhane Team member: Ms. Annapurna.D

WP

Mrs. Deepa Tamhane – Karnik Team member: Ms. Anushka.M

EB Dr. T. K. Ghosh Team member: Ms. Bharti Khairnar

SE

Dr. V.G. Panwalkar Team member: Mr. Shrikrishna Kulkarni Ms. Harshada Borawke

SHW Mrs. Santosh Gupta Team member: Dr.S.S.Hotanahalli

Mr. Swapnil. Awagnade

LU Team member: Mr.Ajay Kadam

1. Distilleries

Sector: (22), 5(g)

Industrial Project

M/s. Bannari Amman

Sugars Ltd, Alaganchi.

Dr.S.S.Hotanahalli

RH Dr. Ravindra Kode

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Table No. 12.2: Laboratory Details

LABORATORY FOR ANALYSIS:

NAME OF LABORATORY SCOPE OF SERVICES ACCREDITATION STATUS

M/s. Bangalore Test House #65, 20th Main,, Marenahalli, Vijaynagar, Bangalore – 560 040

Monitoring and Analysis of: 1. Ambient Air Quality

Monitoring 2. Ground and Surface Water

Quality Monitoring 3. Noise Level Monitoring and 4. Soil Quality Monitoring 5. Metrological data collection

M/s. Bangalore Test House is a NABL certified laboratory

For EXPANSION OF EXISTING DISTILLERY (From 60 …20 2.3 Alcohol Processing - Eco Management - Flow...

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