M/s. Bhima Sahakari Sakhar Karkhana Limited. Takali-Sikander ...

Draft Environmental Impact Assessment Report

M/s. Bhima Sahakari Sakhar Karkhana Limited. Takali-Sikander.

EXECUTIVE SUMMERY

1.0 Introduction:-

The promoters of ' Bhima Sahakari Sakhar Karkhana Limited have

planned to go for expansion of existing Sugar Factory from 2500 to 5000

TCD (increased by 2500 TCD) & Cogeneration Plant 25 MW establish

located at Gat No. 209,211 At Post: Takali-Sikander, Tal.:Mohol; Dist.:

Solapur.

The above proposed expansion project attracts the condition of

Environmental Clearance procurement as per the Ministry Of

Environment, Forest and Climate Change Notification No. DL.33004/99

dated 25.06.2014; amendments thereat. Accordingly, it has been listed

under Category – B1. The proposed project was considered by the State

Expert Appraisal Committee (SEAC) on 22.12.2014 for grant of Terms of

Reference (ToRs).

Total capital investment towards proposed expansion projects of Sugar

Factory and Co-gen Plant is Rs. 199.5877 Crores while that of existing

manufacturing set-up is Rs. 40.92Crores. Sugar Factory Registred as a

Co-Operative Societies Act- 1960 vide Registration No. S.U.R. /P.R.G. (A)

dated 09/08/1974.It is one of the progressive sugar factory in the South-

East Maharashtra. The first crushing season of Sugar Factory was

commenced in the year 1981.

2.0 PROJECT DETAILS:- The management of Bhima Sahakari Sakhar Karkhana Limited.

Propose production capacity of sugar plant from 2500 TCD to

5000 TCD & co-generation 25 MW. at Takali-Sikander, Tal- Mohol,

Dist- Solapur. Chairman is Shri. DhananjayBhimaraoMahadik. & Shri.

SatishNarsinhJagtap is Vice-Chairman of K.K.S.S.K.L.

Location Site Map:



1 Director Body of B.S.S.K.L:-

Table No.-1.1: List of Board of Directors.

Sr.

No. Name Designation

1. Shri. DhananjayBhimaraoMahadik. Chairman

2. Shri. SatishNarsinhJagtap Vice-Chairman

3. Shri. Prakash SambhajiBachute Director

4. Shri. Shivaji Namdev Chavan. Director

5. Shri. Bibhishan Baba Wagh. Director

6. Shri. Dinkar Shivajirao Deshmukh. Director

7. Shri. Ramhari Ananta Randive. Director

8. Shri. Babasaheb Baliram Kahirsagar. Director

9. Shri. Uttam Yeshwant Mule. Director

10. Shri. Dattatraya Vithoba Kadam. Director

11. Shri. Anil Agatao Gavali. Director

12. Shri. Arun Rajaram Madane. Director

13. Shri. VinayakRayappaSarvade. Director

14. Shri. Suresh AppaShivpuje. Director

15. Shri.SudhakarRamchandraParicharak. Society

Representative

16. Sau. SindhuChendrasenJadhav. Director

17. Smt. Chaya AchutraoChavan Director

18. Shri. VijaysinhShankarraoMohite-Patil M.S.C.Ban

Representative

19. Shri. Regional Deputy Director of Sugar Govt.

Representative.

20. Shri. E. G. Sadand Managing Director

Table No.-1.2: Location Details

Sr. No.

Particulars Details



1 Name and Address of the Industry

Bhima Sahakari Sakhar Karkhana Ltd. At Takali Sikandar, Tal- Mohol, Dist- Solapur, Maharashtra.

2 Land acquired for the plant 36219.3SQ. M. 3 Elevation 461 Meter above sea level 4 Nearest habitation Takali-Sikander 5 Nearest city Mohol -20 Km 6 Nearest highway Solapur -Pune NH-9 - 20 Km 7 Nearest railway track from Project

site Pandharpur station -30 Km

8 Nearest airport Solapur Airport -60 Km 9 Nearest tourist places Pandharpur - 30 Km 10 Defense installations Nil within 10 Km radius 11 Archaeological important Nil within 10 Km radius 12 Ecological sensitive zones Nil within 10 Km radius 13 Reserved /Protected forest /

National Parks/ WildlifeSanctuary (from Project Site)

Nil within 10 Km radius

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

Bhima River- 4.0 Km

Table: 2.3 List of Products

Industrial

Unit

Products &

By Product

Quantity

Existing Total (Proposed

+Existing Unit)

Sugar Unit

Crushing

Capacity 2,500 TCD 5,000 TCD

Sugar 9900

MT/M 18150 MT/M

By Product

Molasses 3500 MT/M 6600 MT/M

Bagasse 28,500

MT/M 49500 MT/M

Press Mud 3200 MT/M 5770 MT/M



Co-gen Electricity - 25MW

2.4 Process Description

The flow diagram of sugar co-gen power plant is given in below figure.

2.7.1 Water Requirement:

Irrigation department of state of Maharashtra has sanctioned water supply

i.e. 950m3/day and it is sufficient for existing as well as proposed sugar

and co-generation unit.

Table No. 2.5: Table No. 2.10: Water Balance & Effluent Generation after Expansion Project (5000 TCD & 25 MW)

Sr.No.

Station Input Cum/day

Effluent Cum/day

1. Boiler 480 30

2. Industrial Process , washing and Laboratory

660 380



3. Cooling water for mill & turbine bearing (Recirculation)

480 50

4. Domestic 50 40

Total 1670 700

2.7.6 Fuel:

Fuel requirement is mainly for generation of steam in the boiler.

Bagasse generated from the Sugar Plant i.e. 52.76TPH will be

used as fuel for operation of the boiler. The fuel characteristics

are given as under:-

Table No. 2.7: Characteristics of Bagasse

2.7 Raw Material Requirement

Table No. 2.8: Raw Material Requirement

List of row material

to be used

Quantity

(MT/Month)

Existing Proposed

Sugarcane 90000 165000

Lime 0.14 % 0.14 %

Sulphar 0.05 % 0.05%

Oil& grease 11 15.4

Name of Existing Proposed activity

S.No. Particulars Value

1 Fuel consumption 52.02MT/ Hr

2 Calorific value 2200 Kcal/Kg

3 Ash content % 5%

4 Sulphur content % Nil

5 Other (specify) --



products & By

products

Main Products :

a) Sugar

b) Electrici ty

9900 MT/M

-

18150 MT/M

25 MW

By-Products:

a) Molasses

b) Bagasse

c) Pressmud

3500 MT/M

28,500 MT/M

3200 MT/M

6600 MT/M

49500 MT/M

5770 MT/M

3.0 Baseline Environment

The climate of this district is on the whole agreeable and is

characterised by general dryness in the major part of the year.

The cold season is from December to about the middle of

February. The hot season which follows, lasts till the end of

May. June to September is the south-west monsoon season and

the two months, October and November, constitute the post-

monsoon or retreating monsoon season

A detailed survey of the quality of environment with

relation to water, air, soil, noise, meteorology, land-use, flora,

fauna, socio-economic and demographic pattern is carried out.

EIA needs a datum on which the evaluation can be done.

Therefore through baseline studies on present quality of the

environment has been done.

3.1 Micro-Meteorology:-

The climate of this district is on the whole agreeable and is

characterised by general dryness in the major part of the year.

The cold season is from December to about the middle of

February. The hot season which follows, lasts till the end of

May. June to September is the south-west monsoon season and



the two months, October and November, constitute the post-

monsoon or retreating monsoon season.

The climate of Solapur district is, by and large, a temperate climate,

characterized by hot summer. The year is usually divided into four

seasons. The period from March to May is reckoned as the summer

season, June to September monsoon and October to February as winter.

3.2 Air Environment:-

In general air quality is expressed in amount of pollutants

present in air at respective time like Particulate Matter, Sulphur

Dioxide and Oxides of Nitrogen. Many sources add to

concentrations of these agents in ambient air like vehicular

movement, venting of gases from industrial processes,

construction and erection activity, units in the vicinity, dust

storms, high speed winds etc.

The ambient air quality i.e. Suspended Particulate Matter (SPM), Sulphur

Dioxide (SO2) and Oxides of Nitrogen (NOX) levels in the area are well

within the limits prescribed by National Ambient Air Quality Standards.

Air quality was monitored and reported at surrounding villages

like Yevaluj, Khupire, Sangrul, Mharul & Ganeshwadi at

K.K.S.S.K.L, ambient air monitoring is performed each year and

always observed well in limits prescribed by MPCB.

3.3 Noise Environment

A preliminary reconnaissance survey has been undertaken to

identify the major noise generating sources in the area. Noise

at different noise generating sources has been identified based

on the activities in the village area, ambient noise due to

industries and traffic and the noise at sensitive areas like

hospitals and schools. The noise monitoring has been conducted

for determination of noise levels at select locations in the study



area. Except for occasional time noise levels have been

generally within limits.

3.4 Water Environment

The main source of water in the study area is Bhima River.The water

samples from wells in the field where effluent is applied and also other

wells bore wells in the study area were collected for detailed analysis and

the results are given in Annexure II. All the bore well waters examined

are found to be fit for irrigation purpose. The ground water is good and it

can be used for drinking after filtration and disinfection.

3.5 Land Environment

The land in the surrounding area of the industry is fertile and irrigated

with surface water, bore well and well Water. Geologically the depth of

hard strata is after 9 meters with a ground water level is 30-35 meter.

Soil is derived from the Latin word solium, which means upper layer. The

physical properties of soil are important to be considered from

engineering point of view.

3.6 Biological Environment

The important features of environment are flora and fauna.

They have countless life cycle modes, forms and activities that

are important to be considered in EIA.

The facet of the natural environment includes vegetation and

animals, flora & fauna. Human activity should not disturb the

biological habitat, because then the man-kind itself will be

harmed in turn. It will be necessary to know the natural

existing environment as a background inventory. In the study

area of 10 km radius of B.S.S.K.L, the Biological survey

conducted and the list of flora and fauna given in the EIA

report.



3.7 Socio –Economic Environment

Socio-economic environment forms an integral part of an EIA

study. As regards to baseline environmental data in respect of

Demography, Occupational Structure, Community Services such

as Post Offices, Post & Telegraph Offices, Telephone,

Educational and Health Care Facilities, Banks and Co –

Operative institutes, social and Cultural Institutions present

Buffer zone were collected from Department of Census

operations, Government of India, Department of Statistics and

Economics of the Government of Maharashtra, Village for

preparation of existing environmental scenario in respect of

these parameters. The amenities available in the villages under

the study area denote the economic well being of the region.

The study area as a whole possesses poor to moderate level of

infrastructural facilities. The above data is obtained from

Census 2001

4.0 Environmental Impact Prediction 4.1 Impacts during Construction & operation Phase and Mitigation Measures

Probable environmental impacts during construction phase are

typically due to activities related to clearing of vegetation,

leveling of site, civil constructions erection of structures and

installation of equipment. During the Operation Phase the

establishment of the project, results in emissions, generation of

wastewater and solid waste.

i) Impact on Air Quality

The main sources for impact of air quality during construction

period is due to movement of vehicles and construction



equipment at site, dust emitted during leveling, grading,

earthmoving, foundation works, transportation of construction

material etc. Major sources of air pollution in Sugar & co-

generation plant are boiler, and crushers.

Air Pollution Mitigation Measures

The dust generated will also be fugitive in nature, which can be

controlled by sprinkling of water. Frequent water sprinkling in

the vicinity of the construction sites would be undertaken and

will be continued after the completion of plant construction as

there is scope for heavy truck mobility. It will be ensured that

diesel powered vehicles will be properly maintained to comply

with exhaust emission requirements.

ii) Impact on Noise Levels

The major sources of noise during the construction phase are

vehicles and construction. The operation of the equipment can

generate noise in the range 85-90 dB (A) near the source.

Noise Levels Mitigation Measures

The noise control measures during the construction phase

include provision of caps on the construction equipment and

regular maintenance of the equipment. High noise producing

construction activities will be restricted to daytime only.

iii) Impact on Water Resources and Quality

Impact on water quality during construction phase is due to

non-point discharges of sewage generated from the construction

work force stationed at the site. Runoffs from the construction



yards and worker camps during monsoon could affect the

quality of water bodies in the project area.

Water Pollution Mitigation Measures

Toilets with septic tanks will be constructed at site for workers.

Construction yards will be constructed properly.

iv) Impact on Land use

Preparatory activities like construction of access roads,

temporary offices, and go-downs, piling, storage of construction

materials etc. will be confined within the project area. No

forestland is involved. Therefore, impact will be negligible.

v) Impact on Topography

Most of the area forms plain land covered with mixed soil.

Adequate storm water drains will be provided to collect and

carry the surface runoff during monsoon to the natural drainage

system of the project area.

vI) Socio-economic Environment

The socio-economic impacts during the construction phase of

the proposed Enhancement Sugar plant with Cogeneration Plant

could result due to migrant workers, worker camps, induced

development etc. The local population will have employment

opportunities in related service activities.

4.2 Facilities to be provided by Labour Contractor

The contractor will be made to provide the following facilities to

construction work force:

First Aid



At work place, first aid facilities will be maintained at a readily

accessible place where necessary appliances including sterilized

cotton wool etc. Ambulance will be kept at the site and made

available at workplace to take injured person to the nearest

hospital.

Potable Water

Sufficient supply of water fit for drinking will be provided at

suitable places.

Sanitary Facility

Sanitary facilities will be provided at accessible place within the

work zone and kept in a good condition. The contractor will

conform to requirement of local medical and health authorities

at all times.

Canteen

The canteen will be provided for the benefit of workers.

Security

K.K.S.S.K.L. will provide necessary security to work force in co-

ordination with State authorities.

4.3 Waste water generation

The total waste water generation from the Sugar plant along with the Cogeneration Plant of

existing unit will be 380 M3/day & waste water generation from proposed unit will be 360

M3/day. The generated wastewater will be sent to Effluent Treatment Plant (ETP) and the

treated wastewater will be used for cane irrigation and green belt development.

4.4 Dry fly ash and Furnace bottom ash



Fly ash collected from the ESP hoppers and the airheaters hoppers and

the ash collected from the furnace bottom hoppers can be used as landfill.

The ash content in bagasse is less than 2%. The total fly ash 40 TPD will

be used as manure. The high potash content in the bagasse ash makes

the ash as good manure.

4.5 Impact on Ecology

The enhanced project will not have any significant impact on

ecology as there are no reserve forests in the study area and in

addition to that the project will implement an effective

environmental management plan to control the emissions from

the project.

4.6 Green belt development

The total project area acquired for plant is 7,15,500M2, and 33% of it 2,36,115 M2 will be

used for green belt development. Local species will be preferred for green belt development.

4.7 Impact on Health

Adequate air pollution and noise control measures will be

provided. The environmental management and emergency

preparedness plans will be prepared to ensure that the

probability of undesired events and consequences would be

reduced, and adequate mitigation measures will be provided in

case of an emergency. The overall impact on Human health is

negligible during operation of plant.

5.0 Environmental Monitoring Program

Pollution Monitoring and Surveillance Systems for Proposed

Enhanced Sugar Plant and Cogeneration power plant, the Indian

Emission Regulations stipulate the limits for particulate matter

emissions and appropriate stack heights will be maintained for



keeping the emission levels in the ambient within the air quality

standards.

5.1 Air Quality monitoring programme

It is proposed to monitor particulate emission qualitatively and

quantitatively in the stack and with the aid of a continuous

particulate stack monitoring system. The stack monitoring data

would be utilized to keep a continuous check on the

performance of wet scrubber. Further it is proposed to monitor

and record the weather parameters such as temperature

(maximum & minimum), Relative humidity, wind direction, wind

speed, rainfall etc. on daily basis, for this purpose, it is

proposed to install Weather Monitoring Station with necessary

gadgets.

5.2 Post Project Environmental Monitoring

Environmental monitoring will be conducted on regular basis to

assess the pollution level in the plant as well in the surrounding

area.

6.0 Risk Assessment and Disaster Management Plan

An emergency occurring in the proposed Enhancement plant is

one that may affect several sections within it and/ or may cause

serious injuries, loss of lives, extensive damage to environment

or property or serious disruption outside the plant. It will

require the best use of internal resources and the use of

outside resources to handle it effectively. . It is imperative to

conduct risk analysis for all the projects where hazardous

materials, fuels are handled.

6.1 Methodology



The Risk Analysis Study carried out under the following task

heads:-

v System Study

The system description covers the plant description, storage & handling of fuels /

chemicals, etc.

v Hazard Identification

The hazards associated with the proposed Enhancement Project have been discussed

in terms of material hazards due to fuel storage.

v Frequency of Hazard Occurrence

Based on the available international statistics and in-house risk database, the

frequencies of occurrence for the different accident scenarios were determined. The

frequencies derived from the historical database have been checked with the possible

hazard scenario identified during hazard identification.

v Consequence Analysis

Based on the identified hazards, accident scenarios and the frequency of occurrence,

consequence calculations were done for spreading distances (zone of influence) or

risk distance for Pool fires.

v Risk Reducing Measures

Necessary risk reducing measures have been suggested based on the consequence

scenarios.

6.2 Remedial measures:

ü Storage in tightly closed containers in a cool, well-ventilated area

away from WATER, HEAT, COMBUSTIBLES (such as WOOD, PAPER

and OIL) and LIGHT.

ü Storage away from incompatible materials such as flammable

materials, oxidizing materials, reducing materials, strong bases.

ü Use of corrosion-resistant structural materials and lighting and

ventilation systems in the storage area.

ü Wood and other organic/combustible materials will not be used on

floors, structural materials and ventilation systems in the storage

area.



ü Use of airtight containers, kept well sealed, securely labelled and

protected from damage

ü Use of suitable, approved storage cabinets, tanks, rooms and

buildings.

ü Suitable storage will include glass bottles and containers.

ü Storage tanks will be above ground and surrounded with dikes

capable of holding entire contents.

ü Limit quantity of material in storage. Restrict access to storage

area.

ü Post warning signs when appropriate. Keep storage area separate

from populated work areas. Inspect periodically for deficiencies such

as damage or leaks.

ü Have appropriate fire extinguishers available in and near the

storage area.

The following measures are adopted for reducing the risk involved in pipeline systems. 7.0 Project Benefits This project development will give rise to social and economic development measures in the

study area.

7.1 Improvement in Physical Infrastructure

Ø Road Transport facilities

Ø Educational facilities

Ø Water supply and sanitation

7.2 Improvement in Social Infrastructure

ü Education facilities

ü Banking facilities

ü Post offices and Communication facilities

ü Medical facilities

ü Recreation facilities

ü Business establishments



Community facilities

8.0 Environmental Management Plan The Environmental Management Plan (EMP) of the Expansion plant with

respect to noise, air quality, water quality, solid waste, ecology, landscape

socio-economic measures.

8.1 Air Environment

Ø All sources of dust generation in the Sugar Plant with Cogeneration Plant shall be

well designed for producing minimum dust and shall be provided with high efficiency

Bag filters and Wet Scrubber.

Ø Particulate Matter emission level from the stack chimney will be less

than 50 mg/Nm3 and the stack height is 30m, 30m, 35m

Ø SO2 concentration will be negligible as the bagasse will be used as

fuel for boiler.

Ø The periodic evaluation for the efficiency performance of Wet

Scrubber will be carried out.

Ø For controlling fugitive dust, in hopper, reclaimer, conveyors, silos

etc. bag filters shall be installed.

Ø Fugitive emissions due to storage, transportation, etc. and the

leakages and spillages shall be continuously monitored and

controlled.

Ø Water conservation measures shall be undertaken for effective

implementation. Cooling water is put into closed circuit to minimize

the evaporation losses.

Ø Thermal insulation will be provided wherever necessary to minimize

heat radiation from the equipment, piping etc., to ensure protection

of personnel.

8.2 Noise Environment

ü The design features of machineries shall be provided to ensure low

noise levels in the working areas.



ü Extensive vibration monitoring system will be provided to check and

reduce vibrations. Allfans, compressors etc., are provided with

vibration isolators to reduce vibration and noise.

ü Provision for silencers wherever possible.

ü Green belt development will be done and it will act as noise

reducers.

ü Requisite enclosures will also be provided on the working

platform/areas to provide local protection in high noise level areas.

ü All heavy earthmoving equipment will be kept in a well maintained

condition.

ü Proper lubrication and house equipment will be kept in better

condition.

8.3 Waste water Management v No trade effluent shall be discharged from the Plants

v Cooling water is put into closed circuit to minimize the evaporation losses

v The domestic sewages from the Plants, Sugar Plant with Cogeneration Unit and

Township shall be treated in the Sewage Treatment Plant.

v No percolation of treated water to deep ground water table is done.

v Periodical monitoring for specific parameters shall be done regularly.

v Rainwater harvesting structures shall also be developed.

8.4 Rain Water harvesting System

The rain (storm) water from the building roofs, non-process area and

grade level surfaces will be directed through the rain water harvesting

structures and excess water will be directed through open drains to the

storm drainage system. The storm water from the storm drainage system

will be discharged outside the plant boundary.

8.5 Occupational Health & Safety



During operation stage, dust causes the main health hazard. Other health

hazards are due to gas cutting, welding, noise and high temperature and

micro ambient conditions especially near the boiler and platforms, which

may lead to adverse effects (Heat cramps, heat exhaustion and heat

stress reaction) leading to local and systemic disorders.

8.6 Design of Green Belt

The Area Calculation for Green Belt Plan

Table No. 8.2 Area Details

Description Area

Total plot area (Sugar &

Co-gen)

9,20000 Sq.

M.

Built up area 36837 Sq.

M.

Total Open space 883163 Sq.

M.

For Detailed Area break up of industrial unit refer Table.

9.0 Conclusion

The potential environmental, social and economic impacts have been

assessed. The proposed Sugar Unit and Cogeneration Plant will have

certain levels of marginal impacts on the local environment.

Implementation of the project will have beneficial impact in terms of

providing direct and indirect employment opportunities. There will be a

positive socio-economic development in the region. Quality of life of the

people will be improved. Recommendations made in the CREP for Sugar

Plant will be implemented. B.S.S.K.L will also undertake various

community welfare measures for the upliftment of the villages of the

study area

******



CHAPTER 1

INTRODUCTION

1 INTRODUCTION

1.1 THE PROJECT

The promoters of ' Bhima Sahakari Sakhar Karkhana Limited have planned to go for

expansion of existing Sugar Factory from 2500 to 5000 TCD (increased by 2500 TCD) &

Cogeneration Plant 25 MW establish located at Gat No. 209,211 At Post: Takali-Sikander,

Tal.:Mohol; Dist.: Solapur.



The above proposed expansion project attracts the condition of Environmental

Clearance procurement as per the Ministry Of Environment, Forest and Climate Change

Notification No. DL.33004/99 dated 25.06.2014; amendments thereat. Accordingly, it has

been listed under Category – B1. The proposed project was considered by the State Expert

Appraisal Committee (SEAC) on 22.12.2014 for grant of Terms of Reference (ToRs).

Total capital investment towards proposed expansion projects of Sugar Factory and

Co-gen Plant is Rs. 199.5877 Crores while that of existing manufacturing set-up is Rs.

40.92Crores. Sugar Factory Registred as a Co-Operative Societies Act- 1960 vide

Registration No. S.U.R. /P.R.G. (A) dated 09/08/1974.It is one of the progressive sugar

factory in the South- East Maharashtra. The first crushing season of Sugar Factory was

commenced in the year 1981.

1.2 PURPOSE OF THE REPORT

· Describe a pre-project baseline condition with respect to Environmental

Indicators.

· Identify Environmental Impacts and Risks associated with the expansion project

and to suggest suitable mitigation measures for alleviating the impacts to the

extent possible, and

· Suggest Environmental / Risk Management Plans for implementing the mitigation

measures.

1.3 IDENTIFICATION OF PROJECT

The discovery of sugarcane, from which sugar as it is known today, is derived dates

backunknown thousands of years. It is thought to have originated in New Guinea, and was

spread along routes to Southeast Asia and India. The process known for creating sugar, by

pressing out the juice and then boiling it into crystals, was developed in India around 500 BC.

Although India is the largest producer of sugarcane and sugar, the sugar factories in

India are facing problems. Sugar factories cannot survive in healthy condition on a single

product i.e. sugar. It has become now a necessity to develop sugar factory into an affiliated

chemical complex so as to utilize the valuable by-products more profitably.



Bagasse is a by-product of sugar cane that is used as fuel in boilers to produce process

steam. National level potential of power generation through bagasse co-generation as per

MNRE, Govt. of India study is about 3500 MW, whereas the potential in Maharashtra is 1250

MW. The promotion of bagasse co-generation in sugar mills for surplus power generation is

one of the important schemes of MEDA.

Molasses is a very important by-product of the sugar industry. The profits earned by

conversion of molasses into alcohol are much higher than that of resale of molasses alone.

Moreover, there is a good demand for alcohol in the country as production and consumption

of alcohol in India are quite balanced. Also, there is a good export potential, out of the

country, for the alcohol. India is on the ethanol growth wave.

With a due consideration to all the above facts, availability of sugarcane in its area

ofoperation, the management of BSSKL has planned to go for expansion of existing

sugarfactory (2500 to 5000 TCD) & Establish of new co-gen plant (25 MW) capacity.

Following table reflects the details about products and by- product manufactured /to

be manufactured under existing and expansion activities.

Table No. 1.1 List of Products and By- products

IndustrialUnit Product

Quantity

Existing

(2500 TCD)

Total

(5000 TCD)

Sugar Unit Sugar 9900MT/M 18150 MT/M

By

Product

Molasses 3500MT/M 6600 MT/M

Bagasse 28500MT/M 49500 MT/M

Press Mud 3200MT/M 5770MT/M

Cogeneration Electricity - 25MW

1.4 IDENTIFICATION OF PROJECT PROPONENT

Table No.-1.2: List of List of Promoters



Sr. No. Name Designation

1. Shri. DhananjayBhimaraoMahadik. Chairman

2. Shri. SatishNarsinhJagtap Vice-Chairman

3. Shri. Prakash SambhajiBachute Director

4. Shri. Shivaji Namdev Chavan. Director

5. Shri. Bibhishan Baba Wagh. Director

6. Shri. Dinkar Shivajirao Deshmukh. Director

7. Shri. Ramhari Ananta Randive. Director

8. Shri. Babasaheb Baliram Kahirsagar. Director

9. Shri. Uttam Yeshwant Mule. Director

10. Shri. Dattatraya Vithoba Kadam. Director

11. Shri. Anil Agatao Gavali. Director

12. Shri. Arun Rajaram Madane. Director

13. Shri. VinayakRayappaSarvade. Director

14. Shri. Suresh AppaShivpuje. Director

15. Shri.SudhakarRamchandraParicharak. Society Representative

16. Sau. SindhuChendrasenJadhav. Director

17. Smt. Chaya AchutraoChavan Director

18. Shri. VijaysinhShankarraoMohite-Patil M.S.C.Ban

Representative

19. Shri. Regional Deputy Director of Sugar Govt. Representative.

20. Shri. E. G. Sadand Managing Director

The proposed expansion would be implemented by the management of Bhima

Sahakari Sakhar Karkhana Limited (BSSKL). The promoters are well experienced in relevant

fields & have made a thorough study of entire project planning as well as implementation

schedule.

1.5 PROJECT IMPORTANCE TO THE COUNTRY/REGION

The Sugar Industry in India is well maintained and is growing at a steady pace,

boasting of aconsumer base of over billions of people. India is the second largest producer of



sugar in the world. With more than 45 millions of sugarcane growers in the country, the bulk

of rural population in India depends on this industry. One of the agro-based enterprises in

India, sugar manufacturing is the second largest agricultural industry, after the textile sector.

Sugar manufacturing in Maharashtra is one of the most notable sectors in the country.

The pace of growth of this industry has been massive over the past few years. Most of the

sugar units have by-product utilization plants, based on bagasse and molasses. Ethanol,

power and paper projects have tremendous scope for development in India. In near future,

about 10-15% ethanol may be allowed to be blended with petrol. Thus, alcohol production

from molasses has the most promising prospects. Bagasse based power generation projects,

installed in the premises of sugar factory, not only fulfill captive need of the industry but also

make available surplus power which could be exported in the grid thereby providing value

addition.

Co-generation is the concept of producing two forms of energy from one fuel. One of

the forms of energy must always be heat and the other may be electricity or mechanical

energy. In a conventional power plant, fuel is burnt in a boiler to generate high-pressure

steam. This steam is used to drive a turbine, which in turn drives an alternator through a

steam turbine to produce electric power. The exhaust steam is generally condensed to water

that goes back to the boiler.

As the low-pressure steam has a large quantum of heat, which is lost in the process of

condensing, the efficiency of conventional power plants is only around 35%. In a

cogeneration plant, very high efficiency levels, in the range of 75%-90%, can be reached.This

is so, because the low-pressure exhaust steam coming out of the turbine is notcondensed, but

used for heating purposes in factories or houses.

Since co-generation can meet both power and heat needs, it has other advantages as

well inthe form of significant cost savings for the plant and reduction in emissions of

pollutants dueto reduced fuel consumption.

Large cogeneration systems provide heating water and power for an industrial site or

anentire town. Common CHP plant types are:

• Gas turbine CHP plants using the waste heat in the flue gas of gas turbines

• Combined cycle power plants adapted for CHP

• Steam turbine CHP plants that use the heating system as the steam condenser for the

steam turbine.

• Molten-carbonate fuel cells have a hot exhaust, very suitable for heating.



Smaller cogeneration units may use a reciprocating engine or Sterling engine. The heat is

removed from the exhaust and the radiator. These systems are popular in small sizes because

small gas and diesel engines are less expensive than small gas- or oil-fired steam electric

plants. Some cogeneration plants are fired by biomass.

1.6 Nature, size and location of the project

The existing sugar & co-gen project by BSSKL is set up at Gat No. 209,211 At-Post

Takali-Sikander, Tal.:Mohol, Dist.: Solapur.

The total land acquired by the industry is 9,20,000 Sq. M. The built-uparea of

existingset-up is of 36219.3 Sq. M. No Objection Permission for the proposed project activity

has been obtained from the Grampanchayat of Takali-Sikander, Tal.:Mohol, Dist.: Solapur.

Refer the Grampanchayat NOC in certificate and other documents.

Table No.-1.3: Location Details

Sr. No.

Particulars Details

1 Name and Address of the Industry

Bhima Sahakari Sakhar Karkhana Ltd. At Takali Sikandar, Tal- Mohol, Dist- Solapur, Maharashtra.

2 Land acquired for the plant 36219.3SQ. M. 3 Elevation 461 Meter above sea level 4 Nearest habitation Takali-Sikander 5 Nearest city Mohol -20 Km 6 Nearest highway Solapur -Pune NH-9 - 20 Km 7 Nearest railway track from Project site Pandharpur station -30 Km 8 Nearest airport Solapur Airport -60 Km 9 Nearest tourist places Pandharpur - 30 Km 10 Defense installations Nil within 10 Km radius 11 Archaeological important Nil within 10 Km radius 12 Ecological sensitive zones Nil within 10 Km radius 13 Reserved /Protected forest / National Parks/

WildlifeSanctuary (from Project Site) Nil within 10 Km radius

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

Bhima River- 4.0 Km

Figure No.-1.1: Location: Site map

Location Map showing 10 Km. radius from proposed plant site



Following aspects are taken into consideration while planning proposed expansion

project -

• Availability of raw material.

• Adequate land for the expansion activity.

• Avoiding likely odor nuisance to the nearby residential areas and public in general.

• The availability of utilities such as water and electricity.

Figure No.-1.2: Google Image:

1.7 SCOPE OF THE STUDY (AS PER TERMS OF REFERENCE)

This EIA report has been complied with the Terms of Reference (TORs) issued by

Dept. of Environment Govt. of Maharashtra and summarized details of the same are provided

hereunder



Table



No.

1.3: Table No. 1.4Summary of Terms of Reference

Above points shall be adequately addressed in the EIA report in addition to the contents

given in the reporting structure as below:

Sr.

No. LIST OF TOR'S COMPLIANCE

1

Executive Summary of the project along with

justification Refer for the project.

Chapter -1

2 Photographs of the proposed and existing (if

application) plant site.

Refer Appendix - 2.2 of

Chapter-2

3 A line diagram 1 flow sheet for the process and

EMP. Refer Chapter – 2

4 In case of existing project seeking expansion , (i)

A certified copy of the Monitoring Report of the

Regional Office of the Ministry of Environment

and Forest as per circular dated so" May,2012 on

the status of the status of compliance of the

conditions stipulated in the environmental

clearance and (ii) Status of compliance of

Consent to Operate for the ongoing / existing

operation of the project and SPCB and SPCB ,

which shall include data on AAQ , water quality,

solid waste etc. shall be submitted.

Refer Appendix - 2.2

Chapter - 2



5 A toposheet of the study area and site location

map on Indian map of 1:10,00,000 scale followed

by 1:50,000/1:25,000 scale on an A3/A2sheet

with at least next 10kms of terrains i.e. circle of

10kms and further 10kms on A3/A2 sheet with

proper longitude/latitude/heights

withmin.100/200 m. contours shall be included.3-

D view i.e. DEM(Digital Elevation Model) for the

area in 10km radius from the proposal site.MRL

details of project site and RL of nearby sources of

water shall be indicated.

Refer Chapter - 3

6 Present land use shall be prepared based on

satellite imagery. High-resolution satellite image

data having 1m-5m spatial resolution like

quickbird, lkonos, IRS P-6 pan sharpened etc. for

the 10km radius area from proposed site. The

same shall be used for land used/ land –cover

mapping of the area.

Refer Chapter - 3

7 Topography of the area shall be given clearly

indicating whether the site requires any filling. If

so, details of filling, quantity of fill material

required, its sources, transportation etc. shall be

given. In case the site is located on a hilly terrain,

a 3-dimensional view of the location vis-a-vis

major land use features and locations such as

Critically Polluted Area(s) and Eco-sensitive

Area(s) found within the study area, indicating

shortest distance from the site shall be provided.

Refer Chapter - 3

8 Map showing location of national parks/ wildlife

sanctuary /reserve forests within 10km, radius

shall specifically be mentioned. A map showing

land use /land cover, reserved forests, wildlife

No any National Park/

Wildlife Sanctuary/ National

parks, tiger reserve in 10km

of the project site.



sanctuaries, national parks, tiger reserve etc. in

10km of the project site and shortest (aerial)

distance from critically/severely polluted area(s)

and Eco-sensitive Areas.

9 Project site layout plan to scale using Auto CAD

showing raw materials, fly ash and other storage

plans, bore well or water storage, aquifers (within

1km) dumping ,waste disposal ,green areas, water

bodies ,river/drainage passing through the project

site shall be included.

Refer Appendix-2.2 of

Chapter -2 for Plot layout

plan.

10 Co-ordinate of the plant site as well as ash pond

with topo sheet co-ordinates shall also be

included.

Refer Chapter - 3

11 Details and classification of total land (identified

andacquired) shall be included. Refer Chapter - 3

12 A copy of the mutual agreement for land

acquisition signed with land oustees. -

13 Proposed shall be submitted to the Ministry for

environment clearance only after acquiring total

land. Necessary documents indicating acquisition

of land shall be included.

-

14 Permission and approval for the use of forest land

(forestry clearance), if any, and recommendations

of the State Forest Department.

There would be no use of

forest land

15 If the project falls within 10km of an eco-

sensitive area, present status / approval from the

Standing Committee on Wildlife of the NBWL

shall be furnished.

No any eco-sensitive area

within 10 Km radius

16 Rehabilitation & Resettlement (R&R) shall be as

per policy of the State Govt. and a detailed action

plan shall be included.

Not Applicable

17 A list of major industries with name and type No any industry located



within study area (1Okm radius) shall be

incorporated.

within 10 Km radius

18 List of raw material required, analysis of all the

raw materials and source along with mode of

transportation shall be included. All the trucks for

raw material and finished product transportation

must be "EnvironmentallyCompliant”.

Refer Chaper-2

19 Action plan for excavation and muck disposal

during construction phase. -

20 Studies for fly ash, muck. Slurry, sludge material

disposal and solid waste generated from the plant

operations and processes and environmental

control measures. If the raw materials used have

trace elements, an environment management plan

shall also be included.

For plant operations and

processes and environmental

control measures Refer

Chaper-2&for environment

management plan

referChapter- 9

21 Manufacturing process details shall be included. Refer Chaper-2

22 Mass balance for the raw material and products

shall be included.

Refer Chaper-2

23 Energy balance data for all the components of

steel plant including proposed power plant shall

be incorporated.

-

24 One season site-specific micro-meteorological

data usingtemperature, relative humidity, hourly

wind speed anddirection and rainfall and AAQ

data (except monsoon) shall be collected. The

monitoring stations shall take into account the pre

-dominant wind direction, population zone and

sensitive receptors including reserved forests.

Refer Annexure-2

25 One season data for gaseous emissions other than

monsoon season is necessary. Refer Annexure-2

26 Ambient air quality monitoring at 8 locations

within the study area of 1Okm, aerial coverage Refer Annexure-2



from project site with one AQMS in downwind

direction shall be carried out.

27 Suspended particulate matter present in the

ambient air must be analysed for source analysis

– natural dust/generated from plant operations

(for eg.Cement dust)/flyash/etc. The SPM shall

also be analysed for presence of poly-aromatic

hydrocarbons (PHA), i.e. Benzene soluble

fraction, where applicable. Chemical

characterization of RSPM and incorporating of

RSPMdata.

Refer Annexure-2

28 Determination of atmospheric inversion level at

the project site and assessment of ground level

concentration of pollutants from the stack

emission based on site -specific meteorological

features. In case the project is located on a hilly

terrain, the AQIP Modeling shall be done using

inputs of the specific terraincharacteristic for

determining the potential impacts of theproject on

the AAQ.

-

29 Action plan to implement National Ambient Air

Quality Emission Standards issued by the

Ministry vide G.S.R.No.826 (E) dated 16th

November, 2009 shall be included.

Refer Annexure-2

30 Ambient air quality modeling along with

cumulative impact shall be included for the day

(24 hrs) for maximum GLC along with following:

i) Emissions (g/second) with and without the air

pollution control measures

ii) Meteorological inputs (wind speed, m/s), wind

direction,ambient air temperature, cloud cover,

relative humidity &nixing height on hourly basis.

-



iii) Model input options for terrain, plume rise,

deposition etc.

iv) Print -out of model input and output on hourly

anddaily average basis.

v) A graph of daily averaged concentration

(MGLC scenario) with downwind distances at

every 500m interval covering the exact location

of GLC.

vi) Details of air pollution control methods used

with percentage efficiency that are used for

emission rate estimation with respect to each

pollutant.

vii) Applicable air quality standards as per LULC

covered in the study area and % contribution of

the proposed plant to the applicable Air quality

standards. In case of expansion project, the

contribution shall be inclusive of both existing

and expanded capacity.

viii) No. I-VII are to be repeated roe fugitive

emission s and any other source type relevant and

used for industry.

ix) Graphs of monthly average daily

concentration withdown-wind distances.

x) Specify when and where the ambient air

qualitystandards are exceeded either due to the

proposed plantalone or when the plant

contribution is added to thebackground air

quality.

xi) Fugitive dust protection or dust reduction

technologyfor works within 30m of the plant

active areas.

31 A plan for the utilization of waste /fuel gases in

the WHRB (if applicable) for generating power -



shall be presented.

32 Impact of the transport of the raw materials and

end products on the surrounding environment

shall be assessed and provided. The alternate

method of raw material and end product

transportation also be studiedand details included

Refer Chaper-4

33 An action plan to control and monitor secondary

fugitive emissions from all the sources as per the

latest permissible limits issued by the Ministry

vide G.S.R. 414(E) dated 30th May, 2008.

Refer Chaper-6

34 Presence of aquifer(s) within 1 km of the project

boundaries and management plan for recharging

the within aquifer shall be included.

No any presence of aquifer

10 Km radius

35 If the site is within 1 km radius of any major

river, Flood Hazard Zonation Mapping is required

at 1:5000 to 1:10,000 scale indicating the peak

and lean River discharge as well as flood

occurrence frequency.

No any major river, Flood

No any major river, Flood

Km radius

36 Details of water requirement, water balance chart

for new unit or for existing unit as well as

proposed expansion (if expansion). Measures for

conservation water by recycling and reuse to

minimize the fresh water requirement.

Refer Chaper-2

37 Source of water supply and permission of

withdrawal of water from Competent Authority. Refer Chaper-2

38 Water balance data including quantity of effluent

generated, recycled and reused and discharged is

to be provided. Methods adopted/to be adopted

for the water conservation shall be included. Zero

discharge effluent concepts to be adopted.

Refer Chaper-2

39 Source of surface/ground water level, site (GPS),

chemical analysis for water to be used. If surface Refer Chaper-3



water is used from river, rainfall, discharge rate,

quantity, 1drainage and distance from project site

shall also be included. Information regarding

surface hydrology and water regime shall be

included.

40 Ground water analysis with bore well data, litho-

logs, drawdown and recovery tests to quantify the

area andvolume of aquifer and its management.

Refer Chaper-3

41 Ground water monitoring minimum at 8 locations

and near solid waste dump zone, Geological

features and Geo-hydrological status of the study

area are essential as also. Ecological status

(Terrestrial and Aquatic) is vital.

Refer Chaper-3

42 Ground water modelling showing the pathways of

the pollutants shall be included -

43 Column leachate study for all types of stockpiles

or wastedisposal sites at 200C-500C shall be

conducted and included, if the project is of

metallurgy industry/involves use/production of

metals and the pH of the soil in the project and

impact zone is acidic in nature.

-

44 Action plan for rainwater harvesting measures at

plant site shall be submitted to harvest rainwater

from the roof tops and storm water drains to

recharge the ground water and also to use for the

various activities at the project site to conserve

fresh water and reduce the water requirement

from other sources. Rain water harvesting and

groundwater recharge structures may also be

constructed outside the plant premises in

consultation with local Grampanchayat and

Village Heads to augment the ground water level.

Refer Chaper-4



Incorporation of water harvesting plan for the

project is necessary, if source of water is bore

well.

45 A note on the impact of drawl of water on the

nearby River during lean season. Permission of

competentauthority for withdrawal of river and /

or groundwater.

Refer Chaper-2

46 Surface water quality of nearby River (60 m

upstream and downstream) and other surface

drains at eight locations to be provided.

Refer Chaper-3

47 A note on treatment of wastewater from different

plants, recycle and reuse for different purposes

shall be included. Complete scheme of effluent

treatment. Characteristics of untreated and treated

effluent to meet the prescribed standards.

Refer Chaper-2

48 Provision of traps and treatment plants are to be

made, if water is getting mixed with oil, grease

and cleaning agents.

Refer Chaper-2 & 6

49 If the water is mixed with solid particulates,

proposal for sediment pond before further

transport shall be included. The sediment pond

capacity shall be 100 times the transport capacity.

-

50 Wastewater characteristics from all shall be

included. Refer Chaper-2

51 The pathways for pollution via seepages,

evaporation, residual remains are to be studied for

surface water (drainage, rivers, ponds, and lakes),

sub-surface and ground water with a monitoring

and management plans

Refer Chaper-2

52 Action plan for solid/hazardous waste generation,

storage, utilization and disposal from all the

sources including fly ash. Copies of MOU

Refer Chaper-2 & 9



regarding utilization of ash shall also be included.

EMP shall include the concept of waste-

minimization, recycle/reuse/recover techniques,

Energy conservation, and natural resource

conservation.

53 Details of evacuation of ash, details regarding ash

pond impermeability and whether it would be

lined, if so detailsof the lining etc. need to be

addressed.

-

54 End use of solid waste and its composition shall

be covered. Toxic metal content in the waste

material and its composition shall also be

incorporated particularly of slag.

Refer Chaper-2

55 All stock piles will have to be on top of a stable

liner to avoid leaching of materials to around

water.

Refer Chaper-2

56 Action plan for the green belt development plan

in 33 % area i.e. land with not less than 1,500

trees per ha.Giving details of species, width of

plantation, planning schedule etc. shall be

included. The green belt shall be around the

project boundary and a scheme for greening of

the roads used for the project shall also be

incorporated. All rooftops/terraces shall have

some green cover.

Refer Chaper-4

57 Detailed description on flora and fauna (terrestrial

and aquatic) exists in the study area shall be given

with special reference to rare, endemic and

endangered species. If Schedule-l fauna are found

within the study area, a Wildlife Conservation

Plan shall be prepared and furnished.

Refer Chaper-3

58 Disaster Preparedness and Management Plan Refer Chaper-7



including Risk Assessment and damage control

needs to be addressed and included.

59 Occupational health:

a) Details of existing Occupational & Safety

Hazards. What are the exposure levels of

abovementioned hazards and whether they are

within Permissible Exposure level (PEL). If

theseare not within PEL, what measures the

company has adopted to keep them within PEL

sothat health of the workers can be preserved,

b) Details of exposure specific health status

evaluation of worker. If the workers' health is

being evaluated by pre designed format, chest x

rays, Audiometry, Spirometry Vision testing (Far

& Near vision, colour vision and any other ocular

defect) ECG, during pre placement and periodical

examinations give the details of the same. Details

regarding last month analyzed data of

abovementioned parameters as per age, sex,

duration of exposure and department wise.

c) Annual report of health status of workers with

specialreference to Occupational Health and

Safety.

d) Action plan for the implementation of OHS

standardsas per OSHAS/USEPA.

e) Plan and fund allocation to ensure the

occupationalhealth & safety of all contract and

subcontract workers.

Refer Chaper-7

60 Corporate Environment Policy

i. Does the company have a well laid down

EnvironmentPolicy approved by its Board of

Directors? If so, it may bedetailed in the EIA

report.

Refer Chaper-2



ii. Does the Environment Policy prescribe for

standardoperating process / procedures to bring

into focus anyinfringement / deviation / violation

of the environmental orforest norms / conditions?

If so, it may be detailed in the EIA.

iii. What is the hierarchical system or

Administrative order of the company to deal with

the environmental issues and for ensuring

compliance with the environmental

clearanceconditions? Details of this system may

be given.

iv. Does the company have system of reporting of

non-compliances / violations of environmental

norms to the Board of Directors of the company

and / or shareholders or stakeholders at large?

This reporting mechanism shall be detailed in the

EIA report

61 Details regarding infrastructure facilities such as

sanitation, fuel, restroom etc. to be provided to

the labour force during construction as well as to

the casual workers including truck drivers during

operation phase.

Refer Chaper-6

62 Impact of the project on local infrastructure of the

area such as road network and whether any

additional infrastructure needs to be constructed

and the agency responsible for the same with time

frame.

Refer Chaper-6

63 Environment Management Plan (EMP) to

mitigate theadverse impacts due to the project

along with item wisecost of its implementation.

Total capital cost andrecurring cost/annum for

environmental pollution controlmeasures shall be

Refer Chaper-9



included.

64 Plan for the implementation of the

recommendations made for the Sector in the

CREP guidelines must be prepared.

Refer Chaper-9

65 At least 5 % of the total cost of the project shall

beearmarked towards the Enterprise Social

Commitmentbased on public hearing issues and

item-wise detailsalong with time bound action

plan shall be included.Socio-economic

development activities need to beelaborated upon.

Refer Chaper-6 & 8

66 A note on identification and implementation of

CarbonCredit project shall be included. Not Applicable

67 Any litigation pending against the project and/or

any direction/order passed by any Court of Law

against the project, if so, details thereof shall also

be included. Has the unit received any notice

under the Section 5 of Environment (Protection)

Act, 1986 or relevant Sections of Air and Water

Acts? If so, details thereof and compliance/ATR

to the notice(s) and present status of the case.

Not Applicable

68 A tabular chart with index for point wise

compliance of above TORs.

Refer Chaper-1 of Table No-

1.3

69 The questionnaire for industry sector (available

on MOEFwebsite) shall be submitted while

submitting EIA-EMP.

Refer questionnaire of page

No.1-18

The EIA study includes determination of baseline conditions, assessment of the Impacts on

the environment due to the construction and operation of the proposed project and making

recommendations on the preventive measures to be taken, to minimize the impact on the

environment to acceptable levels. A suitable post-study monitoring program will be outlined.

Preparation of Environment Management Plan will be given based on the emissions and

feasibility report. The scope of work is prepared based on above mentioned ToR given by

MoEF and guidelines given as per below given scope of work.



The Generic structure of EIA is given in EIA notification dated 14th September, 2006 is

maintained. The EIA plan and procedure are summarized in below given chart:

The baseline data generated were analyzed and compared with applicable standards for each

environmental attribute so that the critical environmental areas and also attributes of concern

were identified. The short-term and long-term impacts particularly on sensitive targets such

as endangered species, crops and historically important monuments were identified.

Economic and social factors are recognized and assessed while siting an industry.

Environmental factors must be taken into consideration in industrial siting. Proximity of

water sources, highway, major settlements, markets for products and raw material resources



were desired for economy of production. Industries are, therefore, required to be sited,

striking a balance between economic and environmental considerations.

* * * * *



Chapter 2

Project Description

2.1 Introduction

M/s. Bhima Sahakari Sakhar Karkhana Ltd have proposed to expansion of sugar &

co-generation project ,for expansion of changing in production capacity of

sugar plant from 2500 TCD to 5000 TCD & co-generation 25 MW . Regd. No. of

factory: DL.33004/99 dated 25.06.2014.

The site is well connected by Road, so that both the raw materials and

finished goods can be conventionally handled. land available is much more than

actual requirement. Bagasse would be used as fuel in boilers installed in existing as well

under expansion.

The project developments of the BSSKL are listed below:

Table.2.1: Regulatory Clearance

Regulatory Clearances Competent Authority Status

A) Sugar Factory Environmental Clearance MoEF, Govt. of India Applied

Consent to Establish Maharashtra pollution Control

Board (MPCB)

Obtained

IEM license for sugar Ministry of Commerce Obtained

B) Cogeneration Plant Consent to Establish Maharashtra pollution Control

Board (MPCB) Obtained

Approval for Project

Installation

Commissioner of Sugar, Govt.

of Maharashtra Obtained

Site NOC Grampanchayat Kuditre Obtained

Power Purchase Agreement

Maharashtra State Electricity

Board

Yes

2 .2 TYPE OF PROJECT

The proposed project by ' Bhima Sahakari Sakhar Karkhana Ltdwill be an expansion

of its existing sugar factory from 2500 TCD to 5000 TCD and establish of co-gen plant 25

MW.As per the Ministry Of Environment, Forest And Climate Change Notification No.

DL.33004/99 dated 25.06.2014; amendments thereat. Accordingly, it has been listed under

Category – B1. The proposed project was considered by the State Expert Appraisal

Committee (SEAC) on 22.12.2014 for grant of Terms of Reference (ToRs). Thereafter, TORs



were issued to the expansion project and directions were given to proceed for EIA

preparation including conducting Public Hearing.

a. Sugar Unit

Ø Modernization of Sugar unit to 5000 TCD by capacity addition

2500TCD in existing 2500 TCD sugar mill

Ø Double Sulphitation process with 3 massecuite boiling scheme shall be

adopted for production of plantation white sugar.

Ø Number of days of operation of sugar factory is 160 days (Season) &

69 (off Season)

Ø Capacity utilization of sugar factory considered for first year 90% and

second year onwards 100%.

Ø 100% of total sugar produced as free sale

Ø Recovery of sugar considered for sugar production is Average 13% and

recovery of molasses sent to Distillery is 4%

b. Co-Gen Power Plant

Ø Existing total boiler capacity 75 TPH with pressure 21 Kg

Ø Existing D.G.Set 320 KVA and 1000 KVA

Ø The boiler will be fired with agro waste bio-mass fuel such as Bagasse

and cane trash.

Ø Existing boilers are provided with ESP system and 52.0mtr, 35mtr &

45 mtr heights of total 3 stacks as pollution control facili ty.

Ø Proposed units Boilers are provided with ESP and Wet scrubber system

with 52.0mtr & 35mtr height of total 2 stacks as pollution control

facili ty.

Ø Surplus power available from the industry will be exported to public

grid.

2.3 NEED FOR THE PROJECT

In India, sugarcane is the major raw material for production of sugar. The major sugar

cane producing states in tropical parts of India are Maharashtra, Andhra Pradesh, Tamil Nadu

and Gujarat.



Sugar Factories are backbone of Maharashtra State. There are about 226 installed

(Co- operative as well as non-operative) sugar factories in Maharashtra State. Majority of

these factories are in co-operative sector. Solapur district has been ranked in Maharashtra for

sugar production due to availability of sugar cane in sufficient or in excess quantity. Bagasse

is a byproduct of sugarcane that is used as fuel in boilers to produce process steam.

National level potential of power generation through bagasse co-generation as per

MNRE, Govt. of India study is about 3500 MW, whereas the potential in Maharashtra is 1250

MW. The promotion of bagasse co-generation in sugar mills for surplus power generation is

one of the important schemes of MEDA. There are nearly 202 sugar factories registered in

Maharashtra. For encouraging sugar factories in developing the Cogeneration power project

an attractive policy has been declared by GoM vide G.R. dated 14.10.2008.

In light of above facts and In order to cater to the demand of suppliers and also due to

sugar cane availability within 10 to 15 Km radius area. The management of Bhima Sahakari

Sakhar Karkhana Ltd. decided to establish a 25 MW Co-generation unit and sugar unit of

2500 TCD expandable to 5000 TCD based on latest technology, at Village – Takali Sikandar,

Tal.: Mohol, Dist.: Solapur.

2.2.1 Employment Generation Potential

Main products of economically importance & secondary products for value addition

are manufactured that include; Sugar, Molasses, Bagasse, Alcohol, Power etc. The economy

&developments as a result of projects such as sugar factory, distillery, power, etc. help in

improving standard of living of the local people & assist towards social development of the

region. The improved employment potential & development of infrastructure are direct

benefits resulting out of the projects.

The activities in industry would improve the socio-economic status of people in the

study area in terms of local labor employment and contract basis jobs. The proposed activity

might provide employment opportunities to the local populace, especially in business and

other services.

2.4 LOCATION OF THE PROJECT

The project site shall be undertake is located at post Takali-Sikander, Tal.: Mohol,

Dist.: Solapur, Maharashtra. Geographical location of site is 170 41' 57.72" N Longitude, 75°

32' 17.76" E Latitude.



The area is well connected by mettled and unmettled roads as well as rail networks.

The Pandharpur railway station is situated around 30 Km from the project site. Solapur city is

located at about 60 Km from the project site.

2.4.1 SITE SELECTION

The expansion would be undertaken in existing sugar factory premises. The favorable

aspects of proposed expansion projects are-

• Availability of all basic facilities like water, power, man power etc. and other

alliedfacilities.

• The district has rail and road links to every destination so that procurement of

rawmaterial as well as marketing of finished product will be easier and economical.

• Good communication facilities are available in parent Sugar Factory.

• No Rehabilitation and Resettlement shall be required.

• No National Park or Wildlife Habitats fall within 10 Km radial distance from project

site. Refer Appendix - 2.1 for 10 Km Google image of the project site & Site location

mapsof the Study Region.

Fig. No. 2.1 Satellite Image of Project Location

Fig. No. 2.2Location Map of Site

The salient features of project site are given in table no. 2.2.

Table- 2.2 Salient features of site location

Sr.

No. Particulars Details

1 Name and Address of the

Industry

Bhima Sahakari Sakhar Karkhana

Ltd. At Takali Sikandar, Tal- Mohol,

Dist- Solapur, Maharashtra.

2 Land acquired for the plant 36219.3SQ. M.

3 Elevation 461 Meter above sea level

4 Nearest habitation Takali-Sikander

5 Nearest city Mohol -20 Km

6 Nearest highway Solapur -Pune NH-9 - 20 Km



7 Nearest railway track from Project site Pandharpur station -30 Km

8 Nearest airport Solapur Airport -60 Km

9 Nearest tourist places Pandharpur - 30 Km

10 Defense installations Nil within 10 Km radius

11 Archaeological important Nil within 10 Km radius

12 Ecological sensitive zones Nil within 10 Km radius

13 Reserved /Protected forest / National Parks/

WildlifeSanctuary (from Project Site)

Nil within 10 Km radius

14 Nearest streams / Rivers / water bodies (from

Project Site)

Bhima River- 4.0 Km

The proposed co-gen power unit will be associated activity of the existing sugar unit. The

proposed plant will utilize bagasse available in the sugar plant. The land, water and other

infrastructural facility is available in the existing sugar industry. Hence, the project is

essentially to be located in the premise of the existing sugar industry.

The selection of site location for the industry depends mainly on the availability of resources

such as raw materials, fuel, power, water, manpower, connectivity for transportation of man

and material, market for the product and more important is environmental compatibility and

sustainability.

2.5 Technical Details

2.5.1Product

The details of products that are being manufactured under existing Sugar Factory and

Co-gen Plant as well as that would be manufactured under expansion are presented in

following table-

Table No. 2.3 List of Products

Industrial Unit Products & By

Product

Quantity

Existing Total (Proposed +Existing

Unit)

Sugar Unit

Crushing

Capacity 2,500 TCD 5,000 TCD

Sugar 9900 MT/M 18150 MT/M

By Product



Molasses 3500 MT/M 6600 MT/M

Bagasse 28,500 MT/M 49500 MT/M

Press Mud 3200 MT/M 5770 MT/M

Co-gen Electricity - 25MW

Table No. 2.4 Working Pattern Details

Sr. No.

Type of Activity

Days of Operation

Season Off- Season

1 Sugar Factory 160 Days Nil 2 Co-generation Plant 160 Days 69.8

Sugarcane as raw material for sugar factory shall be made available from nearby farms in 25Km area of the factory. During cultivation of sugarcane in farms, farmers inform the field man of Karkhana which are appointed region wise, regarding the start of cultivation. Lateran, the field man submits the information to Karkhana office. Accordingly, days of maturation of sugarcane cultivation is calculated and labors as well as vehicles are forwarded by factory to the farms for its harvesting. Further, this harvested cane is brought to Karkhana site and immediately consumed for processing within 24 hrs. The vehicles filled with cane wait in parking lot for their turn. Hence, no any bulk storage of sugarcane is done on site. Ample parking space is provided for the bullock carts, trucks and trolleys.

Table No 2.5 Cane Availability Sr. No. Description Details

1 No. of share holders 20500 2 Total shareholders land under cane crop (Acers) 22855 3 Avg. yield MT per Acer 43 4 Total cane available from shareholders land (MT) 995000 5 Cane available from Non-shareholders land (MT) 507000 6 Total cane available (MT) 1502000 7 Avg. distance from sugar factory (Km.) 20 Km

Table No. 2.6 Products and By-products Storage Details

Sr. No. Product and By-product Mode of Storage Details of Storage Area

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

There are 02 Nos. of existing RCC Godowns of following dimensions 1) 40 M X 70 M 2) 30 M X 70 M.

2 Bagasse Bagasse is bailed and stored in dedicated separate yard in own premises

Yard Area - 10000 Sq. M

3 Pressmud Pressmud is stored in dedicated Pressmud is sold to



separate yard in own premises nearby farmers for agricultural use Total 18000 Sq.M and is allocated for storage of same.

4 Molasses Steel Tanks Two tanks of 4000 MT each are provided for 30 Days storage.

Sugarcane shall be transported to site through various means of transportation viz. Bullock Carts, Trucks and Tractor Trolleys.

Table No. 2.7 Details of Sugarcane Transport to Sugar Factory

Sr. No. Type of Vehicle Avg. wt (MT) / vehicle

Daily No. of Vehicles

Quantity of Cane %

1 Bullock Carts 3 825 2475 MT 46.5 2 Tractor Trolleys 14 130 1820MT 35 3 Trucks 12 60 720 MT 28.5

Total 29 1015 5015 MT 100

Figure 2.3 Flow Diagram of Sugar & Co-Gen. power Plant Process

2.5.2 Manufacturing Process for Sugar

1. Cane Preparation



In order to facilitate easy operation of juice extraction, cane preparation is a

prerequisite.During same, first cane is cut into small pieces and then passed through

shredder or other cane preparation devices.

2. Juice Extraction

Prepared cane is fed to 15t mill for primary extraction where same is ruptured

and juice is extracted. In order to extract further residual juice, rupturing operation is

repeated for 3 to 5 times in multiple mills tandum. This juice obtained is termed as

secondary juice.

3. Juice Clarification

Extracted juice is weighed and analyzed for P205, CaO. Phosphate level is

made up, then juice is heated up to 75°C in the juice heater. Heated juice is limed up

to pH 9.5 to 9.8 by milk of lime addition and neutralized with blowing 802 gas up to

7.00 pH. Treated juice is heated further up to boiling point and sent to clarifier for

setting. Analysis of clear juice for, pH CaO, colour transmitted is done to understand

effectiveness of clarification. The clear juice obtained after settling is sent for

evaporation and muddy juice is forwarded for filtration.

4. Muddy Juice Filtration

Muddy juice drawn from clarifier is mixed with bagacillo and sent for

filtration into vaccum filter.The filtrate obtained is treated separately in conventional

liming and sulphitation process whereas the solid waste in the form of pressmud is

disposed as manure.

5. Evaporation

The clear juice obtained from clarifier is thin of about 15 to 16 brix. To

concentrate this juice, the process of evaporation is carried out in multiple effects

evaporator bodies under the vaccum to obtain thick juice syrup of about 60 to 62 brix.

The syrup is bleached in to sulphitation tower by blowing 802 gas up to pH 5.1 to 5.2.

Waste gases recovered in gas absorption tower.

6. Crystallization

Crystallization is process of taking out liquid sugar from syrup and

transforming it into uniform granule form. The crystallization process is carried out in

three to four boiling step called as there boiling system consisting of four massecuite

viz. A, B1, B2 & C. All massecuite system carried out under vaccum in single



evaporator body. Each massecuite boiling consist of concentration, seeding, washing

and then growing of the crystals.

From A massecuite final sugar and AH & AL re-circulated in to process for

B1 masseuite boiling. From B massecuite B1 sugar and used for B2 boiling, B2

massecuite product B2 sugar and B2H molasses B2 sugar melted and used for C

massecuite boiling C massecuite produced C and final molasses C sugar melted and

used for A boiling and final molasses spent for alcohol production.

7. Sugar Formation & Grading

Sugar crystals are separated from mother liquor of massecuites by centrifugal

machines. Four types of centrifugal machines are used for 4 various massecuite. From

A massecuite final sugar is taken out from B1, B2 & C massecuites sugar is melted

and reused in process for Amassecuites. Boiling sugar obtained from A massecuite is

dried, cooled and packed in jute bags after weighment. The bags are then stitched and

sent to godown for stacking.

8. Steam and Power Generation:

In addition to above, steam and power required for manufacturing process are

generated in the process. The steam is generated in boiler by using bagasse as fuel.

This steam is used for power generation and exhaust obtained is used for process. The

excess bagasse is bailed and sent for sale or paper mill. Presently the power is

generated according to actual consumption in sugar unit.

9. Co-product Management

Sugar cane is main raw material for cane sugar production. Bagasse, Press

Mud and final molasses are the by-products manufactured. Bagasse is used as fuel for

steam generation. Excess bagasse is stored for use in off-season whereas the loose

excess is sold in open market. Press mud (filter cake) is used as a manure. The

molasses is stored in steel tanks. Excess molasses, if any, is sold in open market.

10. Solid and Liquid Waste Management

Boiler ash and dust sugar are the solid waste. Boiler ash is collected, store in

separate yard in the 38 Karkhana premises and supplied directly as manure or

incorporated as filler material during spentwash bio-composting process. Dust sugar

is collected by wet scrubber systems and recycles in process.

Excess hot water (condensate) is collected in centralized M.S. tank, cooled in

mini spray pond and reused as raw water. Cold waste water (effluent) is treated in



Effluent Treatment Plant (ETP), polished and given to share holder farmers for their

irrigation need. Also, the same is recycled in spray pond as make up water.

2.5.3 Manufacturing Process for Co-generation Power Plant

The existing co-generation power plant has one high pressure boiler of 75 TPH (S.S

Engineers make), with 72 kg/cm2g working pressure & 51O°C+ /-5°C superheated steam

temperature configuration is employed, with one matching 12 MW Double Extraction

Condensing (DEC) type Turbine of working pressure configuration of 70 kq/cm" &

temperature 500 'C. The Boiler is two drum water tube membrane wall having total heat

surface of 4254 M2 along with RO plant of 25 M3/hr, deaerator, fans, Boiler feed water

pump, wet scrubber, transfer pump, bagasse feeding system, ash handling system etc.

Under expansion project, additional high pressure boiler of 75 TPH (S.S Engineers

make), with72 kg/cm2g working pressure & 510°C+ /-5°C superheated steam temperature

configuration shall be employed, with one matching 14 MW Back Pressure type Turbine.

The auxiliary steam consumption for the power plant will be for soot blowing and

other auxiliaryconsumptions like Steam Jet Air Ejector (SJAE) & Gland steam condenser

(GSC) at high pressure, for de-aerator at low pressure. The auxiliary power consumption for

the power plant will be about 7% to 10% of generation during season & off season periods

respectively.

The brief design parameters for the cogeneration power plant will be as follows:

Table No. 2.8 Boiler Details

Sr. No. Description Details

1 Boiler Capacity, TPH • Existing: 75 TPH

• Proposed: 130 TPH

2 Pressure kg/cm" E= 21 Kg/cm2 P=87 Kg/cm2

3 Temperature oC 515oC

4 Turbine Capacity, MW 25 MW

5 Turbine Type

Double Condensing & Back

Pressure



6 Season Operation, Days 160 Days

7 Off Season Operation, Days 69

8 Fuels used for Season Operation Mill Bagasse

9 Fuels used for Off -Season Operation Saved Bagasse

10 Boiler Efficiency % 71

11 On Bagasse/Cane Trash 70.00 ± 2.0-

12 Feed Water Temperature oC 165 0 c with H.P water

13 Captive Power consumption % of

generation in Season & Off Season

Sugar=7943 KW & 2159

Co-gen= 1763 kw & 1700 Kw

14 Turbo-Generator Efficiency % 80%

15 Utilization Level % 90%

Table No. 2.9 Bagasse Mass Balance

Sr. No. Description Quantity

1 Sugar Cane Crushing 5000 TCD

2 Working Days of Sugar Factory 160 Days

3 Total Crushing 800000MT /Season

4 Bagasse Quantity generated @ 30% of cane

crushed

240000 MT/Season

5 Total Bagasse quantity generated during Season 2,40,000 MT/Season

6 Daily Bagasse required for Co-gen boilers (130

TPH; )

52.02 MT/Hr

7 Bagasse for Co-gen during Season(180 days) 199780 MT/Season

8 Total saved Bagasse during Season 50713 MT /Season

9 Bagasse for Co-gen during off -season(69.8 days) 87143.904 MT /Season

The colony power requirement will be met by the co-generation power plant, during

season & off season periods.



Fig. No. 2.5 Process Flow Chart Co-gen

2.5.4 Selection of Pressure and Temperature for the proposed Cogeneration Power

Cycle

While going for Sugar Unit of 5000 TCD, the factory has proposed two boilers of 100TPH at

87 Kg/cm2 pressure & 540°c & 16 TPH at 15.6 Kg/cm2 pressure & 310°c temperature. The

adaptation of pressure and temperature are very suitable for obtaining the maximum power

generation for proved technology available for bagasse based cogeneration. Further, various

parameters viz. optimum cycle efficiency, metallurgy of pressure parts, standard range of

turbine, operability, maintainability and working performance of similar bagasse based

cogeneration plants recently commissioned have been taken into account.

2.5.5 Design parameters for the proposed Cogeneration plant following design

parameters for the expansion project will be taken into account

Ø Actual crushing capacity of Sugar Plant will be 5000 TCD on 24 hrs

Ø Production of bagasse will be 2,40,000 MT/Season.

Ø The gross season will be of 160 days

Ø Captive steam consumption:

· Sugar factory process (2.5 ata) :43 % on cane(98.90 TPH)

· Steam for distillery (8.0 ata) :4.5 to 5.0 TPH

Ø Captive Power consumption % of generation in Season & Off Season Sugar plant :22

KW/TCH

· Sugar=7943 KW & 2159

· Co-gen= 1763 kw & 1700 Kw



2.5.6 Air Conditioning System

Ø The main plant control room housing the controls for boiler, TG Sets and balance of

plant accessories shall be air conditioned with ductable package air conditions which

will be located in an AC room.

Ø The condensers shall be located above the plant ac rooms.

Ø A temperature shall be maintained at 220C with relative humidity of 55In the AC

room

Ø Compressor shall be hermetically sealed; condensers shall be air cooled type.

Ø Refrigeration piping shall be of hard copper pipe of minimum 10 SWG thickness.

Ø Thermal insulation of ducting shall be 25 mm thick aluminum foil faced glass wool.

2.5.7 Ventilation System

This consists of positive supply ventilation system and exhaust ventilation system. Positive

supply ventilation system is required for the area of 11 KV switch gear room, MCC rooms

etc. which needs positive pressure to avoid outside air infiltration which is to be achieved by

continuous fresh air supply. Two centrifugal fans of each 0 % capacity to supply air shall be

provided. These fans shall draw air through a bank of coarse filters and then through a bank

of 10 microns filters. Separate branches for each area shall be supplied. Exhaust ventilation

system is required for the area of compressors room, cable gallery, TG Hall , battery room.

Exhaust fans shall be installed in these areas.

2.5.8 Fire Protection System

The fire protection system shall comprise of:-

Ø Hydrant system for all areas in the plant

Ø High velocity water spray system for transformer

Ø Automatic fire detection and alarm system

Ø Portable fire extinguishers

2.5.9 Raw Water system

The raw water will be stored for the Cogeneration Plant and sugar unit is in existing storage

tank.Health and Sanitation Facilities to ensure optimum hygienic conditions in the plant area,

proper drainage network will be provided to avoid water logging and outflow. Adequate



health related measures and a well be equipped Safety and Environment Cell will be

established as a part of Environmental Management Plan.

2.6 Resources Utilization / Consumption

2.6.1 Water Requirement:

Irrigation department of state of Maharashtra has sanctioned water supply i.e 950m3/day and

it is sufficient for existing as well as proposed sugar and co-generation unit.

Table No. 2.8: Water Balance & Effluent Generation after Expansion Project (5000 TCD & 25 MW)

Sr.No. Station Input

Cum/day Effluent Cum/day

1. Boiler 480 30

2. Industrial Process , washing and Laboratory

660 380

3. Cooling water for mill & turbine bearing (Recirculation)

480 50

4. Domestic 50 40

Total 1670 700

2.6.2 Land Requirement

The project is identified in a non-agricultural revenue land. The Land Use break up is given in

the following:

The detailed layout plant is given as figure 2.6

Fig 2.6 Plant layout



Fig 2.7 Layout of Expansion

Fig 2.8 Layout of 25 M.W. Co-Generation Plant

The proposed expansion will be carried out in existing premises of sugar industry having total

area of 36219.3SQ. M.

Table No. 2.9 Land Use Break up of Project Area

Sr

No.

Description Built Up Area Open Space Total Area

A Administration Block --- B

M

12439 Sq. M 700

B Residential Colony 30450Sq. 1887 Sq.

C Sugar Factory &Oo-gen

1 Mill House 1500 Sq. M 600

2 Power House 1100.0 Sq. M 400

3 Clarification House 563 Sq. M 175

4 Evaporation House 473 Sq. M 135

5 Suqar House 110 Sq. M 75

6 Cane Yard 14000 Sq. M 14000 Sq. M

7 Store 843 Sq. M 523

8 Boiler House 460 Sq. M 325 Sq. M

9 Cooling Tower 788.14Sq.M 123



10 Ash Yard 375 Sq. M 187

11 Switch Yard 1387 Sq. M 918

12 Sugar Godown No.1 5600.0Sq. M 2351

13 Sugar Godown No.1 10500.0Sq. M 873

14 Bacasse Yard 29075Sq. M 29075 Sq. M

15 Molasses Tank 904Sq. M 378

16 ETP Area 1575 Sq. M 763 Sq. M

17 Water Reservoir 1764 Sq. M 600

18 Spray Pond 3000 Sq. M 475

19 Near SuqarGodown -- Sq. M

20 Near Switch Yard --

Total 46,407.3 Sq. M

D Area under Roads 40491 Sq. M --

Total (A+B+C+D) 422354.74 Sq.

M

6422282 Sq. M 920000 Sq. M

Green Belt Area is 44 % of

Open

27,207 Sq. M

Table No. 2.10: Raw Material Requirement

List of row material

to be used

Quantity

(MT/Month)

Existing Proposed

Sugarcane 90000 165000

Lime 0.14 % 0.14 %

Sulphar 0.05 % 0.05%

Oil& grease 11 15.4

Name of products &

By products

Existing Proposed activity

Main Products :

a) Sugar

b) Electrici ty

9900 MT/M

-

18150 MT/M

25 MW



By-Products:

a) Molasses

b) Bagasse

c) Pressmud

3500 MT/M

28,500 MT/M

3200 MT/M

6600 MT/M

49500 MT/M

5770 MT/M

2.6.3 Util ities:

Utilities will be provided for smooth and efficient functioning of the

enhanced project of 5000 TCD Sugar Unit and 25 MW Cogeneration Plant.

2.6.4 Power:

Two set of 320and 1000 KVA capacity DG set will be installed in the initial

stages of construction to supply standby electric power during power

cuts/break downs in grid supply. During crushing season, all electric

requirements, of the plant and machinery and residential complex shall be met

from the Cogeneration plant. JSL will install the DG set as a standby power

supply system unit to meet emergency requirement.

2.6.5 Fuel:

Fuel requirement is mainly for generation of steam in the boiler. Bagasse

generated from the Sugar Plant i .e70 MT/hr will be used as fuel for operation

of the boiler. The fuel characteristics are given as under:-

Table No. 2.11: Characteristics of Bagasse

2.6.7 Details of Machinery

Table No. 2.12: List of Equipments in Existing Manufacturing Set-up

S.No. Particulars Value

1 Fuel consumption 52.02MT/ Hr

2 Calorific value 2200 Kcal/Kg

3 Ash content % 5%

4 Sulphur content % Nil

5 Other (specify) --



Sr.

No.

Particulars No. of Plant and

Machinery

1 Juice Flow Meter 1 No.

2 Juice Heaters 6 Nos.

3 Clear Juice Heaters 1 No.

4 Juice Sulphitation And Liming Equipment 1 No.

5 Clarifier 1 No.

6 Sulphur Gas Plants 3 No.

7 Quintuple Effect Evaporator Bodies 8 Nos.

8 Syrup Storage & Molasses Storage Tanks. 15 Nos.

9 Molasses Conditioning Tanks 2 Nos.

10 Vacuum Pans For A & BAnd C 8 Nos.

11 Condensation Plants. 4 Nos.

12 Injection Water Pumps 5 Nos.

13 Spray Pumps 2 Nos.

14 Spray Ponds 1 No.

15 Vacuum Crystallizers 3 Nos.

16 Seed Crystallizers 2 No.

17 Continuous Centrifugal Machines 7 Nos.

18 Batch Type CF m/c 5 No.

19 Magma And Molasses Pumps 8 No.

20 Sugar Melter 2 No.

21 Sugar Grass Hoppers 3 Nos.

22 Sugar Grader 2 No.

23 Sugar Elevator 2 No.

24 Sugar Weighing Machine 3 Nos.

Table No. 2.13 List of Equipments to be Installed under Proposed Expansion Activity

Sr. No. Particulars No. of Plant and

Machinery

1 Weigh Bridge 50 MT 1 No

2 Weigh Bridge 10 MT 1 No



3 Cane Carrier Modifications 1 No

4 Cane Kicker replacement 1 No

5 Cane Leveler replacement 1 No

6 Cane Fiberizer modifications with motor 1 No

7 De-hooking system for unloader 1 No

8 Bagasse handling system modifications 1 No

9 Addition in mill house crane of 30Ton trolley and

strengthening 1 No

10 Unscreen juice pumps 2 Nos.

11 Screen juice pumps 2 Nos.

12 Rake carrier for first mill with Donnelly chute 1 No

13 Rotary juice screen 1 No

14 Mass Flow meter 1 No

15 Pumps for Raw Juice 2 Nos.

16 Pumps for Clear Juice 2 Nos.

17 Pumps for Sulphur Juice 2 Nos.

18 Pumps for Syrup 2 Nos.

19 Clarifier 1 No

20 Juice Sulphiter 300 HL 1 No

21 Syrup Sulphiter 120 HL 1 No

22 Sulphur Burner 1 No

23 Vibro Screen for MOL & Dry Seed ---

24 Sugar Melter 1 No

25 sugar Silos with elevator 1 No

26 Sugar weighing machines stitching m/c with slat

conveyors 1 No

27 Sugar Bag Bbelt Conveyors 1 No

28 Molasses storage tank ---

29 Juice Heater 350 sq.mtr. 2 No

30 Sulphur juice heater 450sq.mtr. 2 No

31 Pan 80 ton 2 No

32 Vertical crystallizer 500 MT for C massecuite 1 No



33 Continuous pan 30 MT 1 No

34 Batch type centrifugal machines 1750/charge 2 Nos.

35 continuous centrifugal machines 4 No

36 Sugar hopper 2000 mm width. 3 Nos.

37. Sugar elevator 35 MT/hr 1 No

38. Spray pond modification Caustic storage tank, unloading

/ metering pumps, HCL Tank, etc. 1 No

39. Vacuum filter 14 x 28feet 1 No

40 Miscellaneous 1 No

41.

New Boiler (1 x 130 TPH ,87 kg/cm2, 515 DC)&

auxiliaries, viz. ESP, fans, pumps, de aerator etc.,

incl. E&C

1 No

42.

Steam Turbine and auxiliaries (1 x 17 MW capacity

double effect condensing type, and8 MW back

pressure87 kg/cm" pressure, 505 DC)

1 No

43. Electrical distribution for sugar expansion, including

switchyard, tie line & metering 1 No

44. DCS & plant automation 1 No

45. OM water plant, tank & pumps, De aerator tank, 1 No

Table No. 2.13: Boiling House Machinery:

S.No. Particulars

1. Raw juice

2 Juice heaters

3 Juice sulphitor

4 Sulphur burner

5 Air blowers

6 Milk of lime preparation

7 Juice clarifier

8 Vacuum filter

9 Evaporator Quintuple

10 Syrup sulphitor



11 Syrup & molasses storage tanks

12 Batch type & continuous vacuum pan

13 Crystallizers

14 Condensor and injection pump station

15 Sugar melter

16 Sugar drying

17 Mild steel fabricated vapour pipe

18 Insulation

Table No. 2.14: Power Generating Unit

(i) Two TG sets of19.5 MW (2 +17.5 MW) rating will be used for the export

of power during season.

2.7 Responsible Care for Wastes

2.7.1 WATER

Mitigation measures during construction phase:

There will not be any significant pollution during the construction phase as

the development will take place in existing building structure. Adequate

provisions will be made available to collect the runoff from the site, so that

runoff will not be allowed to stand or enter into the roadside or nearby drain.

Raw Water

The water used for the BSSKL plant will be supplied by Irrigation

department. The water will be treated fully to standard characterist ics. The

samples will be tested & confirmed.

Disposal

The waste water generated in the collective activity thus will be the

Domestic, sludge and sewage. The treatment through well-designed septic

tank is adequate for the purpose.



Total effluent generated during the operation will be about 360 M3/day (As

per CREP norms). An effluent treatment plant has been provided which is

continuously in operation and the results obtained will be within the

permissible limits as prescribed by MPCB. The various treatment methods of

the Effluent Treatment Plant (ETP) are given below in the flow sheet.

The disposal will be for greenery in absorbing at root zone by sub surface

irrigation. There will be no discharge of effluent outside.

Figure 2.9 :Flow diagram of ETP

Domestic Effluent:

The quantity of domestic effluent from existing activities is to the tune of 20 M3/Day

is presentlytreated separately in septic tanks followed by soak pits provided in a decentralized

manner. Overflow shall be used for gardening. And after expansion the quantity of domestic

effluent generated would be treated in STP unit

Industrial Effluent:

Industrial effluent would be generated from the various industrial operations &

processes in the factory.

The effluent generated from the existing and expansion activities would be 280

M3/day. The same shall be generated from various operations such as process, cooling &

boiler blow downs, as well as lab & washing. Following tables gives detailed information

regarding the effluents generated from existing and proposed expansion operations in sugar

and co-gen plant.

The entire effluent from existing and expansion activities would be treated in existing

Effluent Treatment Plant (ETP) which shall be upgraded accordingly. The existing ETP

comprises of Primary, Secondary and Tertiary Treatment unit operations viz. Oil & Grease

Chamber, Equalization Tank, Screen Chamber, Primary Settling Tank, Secondary Clarifier,

Treated Water Sump, Pressure Sand Filter and Sludge Drying Beds. Additional units that

would be provided under up-gradation plan of ETP would be Reaction Tanks, Aeration Tank,

Activated Carbon Filter, Sludge Drying Beds and Primary Settling Tank.

Table No. 2.15 Water Balance & Effluent Generation after Expansion Project (5000

TCD & 25 MW)



Sr.No. Station Input

Cum/day

Effluent

Cum/day

1. Boiler 480 30

2. Industrial Process , washing

and Laboratory

660 380

3. Cooling water for mill &

turbine bearing

(Recirculation)

480 50

4. Domestic 50 40

Total 1670 700

1. Process units involved in the treatment:

A. Preliminary Treatment:

· Screening:

Coarse screen or rack is used for removal of large pieces of gunny bags, plastics,

branches, rubbers, packing materials, gaskets, cotton waste and other floatable. It is used

as protecting devices so that large suspended solids and floating material do not damage

pumps, agitators, mixers and aerators. Coarse screens have openings ranging from 75mm

to 150 mm and racks are set at an angle of 450 – 600. The cleaning of screens is done

either manually.

· Oil & Grease Skimmer:

Oil being is lighter than water, floats. This property is used to separate it out.

However, if there is more turbulence or if the travel distance is high, gradient slop is

more, or if boiler blow down, excess condensate, stream trap, cooling purging co-enters,

the oil gets emulsified and then does not float out easily. It has to avoid such situations to

the maximum extent possible by either providing the traps very near to the source, or by

segregating the sub-streams. If the oil does not float and a thick film does not develop,

the physical removal by big spoon becomes difficult. In such case, the oil & grease

escapes out to further downstream units of the ETP to spoil the situation. In aeration tank

the contents are further churned and the oil may cover the bacterial cell wall, stopping

their work of adsorbing and absorbing the food (BOD) and utilizing the same in turn for



their life and growth cycle. The BOD will not get utilized for removal, and the shining

oil will escape out from the secondary clarifier to the disposal site.

Removal of oil and grease is necessary to increase treat ability. In an industry oil

and grease traps are situated close to the source of oil and grease. Various patterns are

available for oil and grease trap. The most common is the one in which inlet is below the

surface and outlet is at the bottom with sufficient retention period (10-30min). The

floating material rises and remains on the surface of the wastewater. The oil & grease will

be collected in a separate sump, by manually.

· V-Notch:

The triangular or V-notch sharp-crested consist of an angular notch cut into a

bulkhead in the flow channel. The apex of the notch is at the bottom, and the sides are set

equally on either side of a vertical line from the apex. The angle of the notch most

commonly used is 90o .The discharge equation of a free flowing triangular weir takes the

form.

· Equalization Tank:

Equalization is often used for smoothening out individual wastewater stream flow

variations so that a composite stream of relatively constant flow rate is fed to the

treatment plant and, also to even out variations in effluent feed BOD to the treatment

facility. This will avoid shock loading and process upsets of the treatment plant. Effluent

after passing though the oil & grease separator shall enter equalization tank. The

equalization tank is well equipped with the aeration system for the equalization as well as

increasing dissolved oxygen of the effluent which enhances the flocculation reaction.

The equalization tank should not work as settling tank. The solids should be kept

is suspension. For this, the water must be in motion. Diffused air is employed.

· Lime Dosing Tank:

Tankis provided with 1 HP mixer of 300 rpm. Here 10% lime slurry is prepared

and used for neutralization in reaction tank.

· Nutrient Dosing Tank:

Nutrient Dosing Tank is provided with air line for mixing purpose. Solution is

prepared which is used for in biotower and areation tank.

· Primary Clarifier-:

Purpose of this process is to reduce settlable suspended solids content of the

wastewaters. When a liquid containing such solids is detained without disturbances for a



time, particles of higher specific gravity will settle and those with lower specific gravity

will float. About 50-65 % removal of suspended solids and 20-40 % of the BOD removal

can be achieved in a properly designed and operated primary clarifier. Common retention

time is 90-150 minutes based on average rate of flow. Sugar factory effluent contains

bagacillo particles as a suspended particle. These should to be separated out before the

biological treatment.

Primary sludge generated during neutralization process gets settled in primary

clarifier. In this clarifier flocks get mattered and down leaving clear supernatant to

overflow from weir of the clarifier into bio-tower. The settled sludge is send to the sludge

drying beds.

B. Primary Biological Treatment:

· Bio-Tower:

The supernatant from primary clarifier is further subjected to Bio-tower. Bio-

Tower is provided with plastic media for attachment of bacteria, which increases contact

time to bacteria and food (BOD). This plastic media have large surface area and high

voidage ratio. Effluent will be re-circulate to the Bio-tower to maintain wetting rate of

plastic media and part of effluent passed to settling tank, where the settled particles are

taken out from the bottom in the form of sludge. The Biological sludge is sent to sludge

drying beds for dewatering. Reduction in BOD is 60%.

C. Secondary Biological treatment:

The clarified effluent from Bio-tower settling tank is further subjected to aeration

tank. The biological treatment of effluent by aeration process with sludge culture is very

sensitive. The efficiency depends on pH, temperature, air contact, suspended solids,

culture growth, and concentration of floc that is optimum mixed liquor suspended solids

concentration (MLSS). The microbial culture concentration is to be maintained in the

range of 1500 to 4000 mg/l. Hence initial culture development and maintaining of

activated sludge rate by re-circulation of sludge and addition of cow dung, urea, DAP and

their mixing are essential. The nutrients are to be in liquid form. The ratio of BOD: N: P

is 100:5:1 will be maintained. Care is to be taken not to destabilize the microbial culture.

Reduction in BOD is 95%.

· Secondary Clarifier:



It is a cylindrical concrete tank with conical bottom. There is a central well to

which water is fed to avoid short-circuiting of water into the overflows. The central

stirrer is rotated at 2 RPH. Sludge will be collected at the bottom from where it re-

circulated to aeration tank and excess sludge is taken on sludge drying beds by pumping.

There is circumferential overflow from which treated effluent is collected and sent for

chlorination and filtration.

D. Tertiary Treatment:

· Chlorine contact Tank:

The treated wastewater is further subjected to chlorination for disinfection.

Chlorine solution is added to treated wastewater. A baffled wall channel constructed in

RCC M-20 is provided. Chlorine dose is adjusted to maintain the residual chlorine

concentration of 0.5 ppm.

· De- Chlorine Tank:

The treated wastewater is further be subjected to de-chlorination SMBS solution is

added to treated wastewater. A baffled wall channel constructed in RCC M-20 is

provided.

· Multi Grade Filter:

The treated water is then be pumped to Multi Grade filter for removal of

suspended solids. Multi Grade filter consist of a cylindrical mild steel vessel with dished

ends. Filter media in the form of sand and gravel is provided.

· Activated Carbon Filer:

Wastewater is then pumped from multi Grade Filter to activated carbon filter for

removal of suspended solids, color, odor, chlorides etc. Activated Carbon filter consist of

a cylindrical mild steel vessel with dished ends filter media in the form of activated

carbon is provided.

Treated water is taken into treated water tank and send 15 days storage tank. From

15 days storage tank treated water is used for irrigation purpose and achieved zero

discharge in inland surface water.

E. Sludge Treatment:

· Sludge dewatering system:



The sludge from Primary Clarifies, Settling tank and Secondary clarifier is sent to

sludge drying beds. Sludge is dried in natural heat of sunlight. The dried cakes are

scrapped off periodically and utilized for as manure.

Table No. 2.16 Dimensions of ETP Unit

Sr. No. Unit Size Volume,

in m3

1. Neutralisation tank 5.0M x 5.0 x 2.00 M SWD + 0.3 M

free board 50.00

2. a Screening chamber 1.00 m x 1.50 m x 1.50 m -SWD

(0.3 m –free board) 2.25

2.b Oil Skimmer, Tank 7.00m x 1.50m x 1.50 m -SWD

(0.3 m- free board) 15.75

3. Surge Tank

(19.5 M x 8.0 M) Top x (10.5 M x

4.0 M) Bottom x 2.50 M SWD

+ 0.5 M free board

225.00

4. Equalization Tank

(19.5 M x 6.0 M) Top x (10.5 M x

6.0 M) Bottom x 2.50 M SWD

+ 0.5 M free board

225.00

5. Primary Clarifier 4.00 m x 4.00 m x 3.50m Ht 36.60

6. Primary clarified water

sump

(6.0 x 3.0)Top x (2.5 x 1.25)

Bottom x2.0m SWD + 0.5 M free

board

18.06

7. Sludge sump

(6.0 x 3.0)Top x (2.5 x 1.25)

Bottom x2.0m SWD + 0.5 M free

board

18.06

8. Bio-tower 6.00m x 6.00 m x 6.00m Ht 216.00

9. Bio-tower sump 9.00m x 9.00 m x 1.50m SWD

+ 0.5 M free board 121.50

10. Settling Tank 4.00 m x 4.00 m x 3.50m Ht 36.60



11. Aeration tank

(19.5 M x 20.5 M) Top x (10.5 M x

15.5M) Bottom x 2.50 M SWD

+ 0.5 M free board

675.00

12. Secondary Clarifier 7.00 m dia and 3.0 m SWD

(0.3 m free board) 115.40

13. Chlorination &

de-chlorination 4.0x 2.0 x 2.0m SWD -2 Nos. 16.0

14. Sludge Drying beds 7.1m x 7.1m x 0.725m Ht

– 4 Nos -

15. Multimedia filter 2000 mm dia x 2400 mm ht -

16. Activated

Carbon filter 2000 mm dia x 2400 mm ht -

17. Air blower Capacity- 700 m3/hr -

Effluent from co-generation plant

Effluent water from cooling tower and clarifier is collected in the neutralization tank where in

ph is maintained between 7.0 to7.5 and after neutralization it is taken for treatment in ETP

plant.

Wastewater from a power plant does not have any significant BOD, COD level. All

wastewater is neutralized prior to discharge. An effluent treatment plant for sugar factory is

already in operation which meets the norms prescribed by MPCB.

Sewage

Sewage from various buildings in the plant area is conveyed through separate drains of septic

tank followed by soak pit. Sludge is removed occasionally and disposed of as land fill at

suitable places.

Mitigation

As additional mitigation measures, BSSKL proposes to take-up following measures:

Ø To spread awareness to the workers about the importance of water quantity

measurements and resource conservation.

Ø The treated domestic waste water will be applied judiciously on land for gardening so

that there will not be any flooding of excess water either to migrate to ground water

table or get away as runoff to join surface water drains.



Ø The industrial waste water is subjected to thermal treatment resulting in hazardous

solid waste being sent to CHWTSDF & evaporating the moisture.

Summary

From the foregoing it may be seen that the industry doesn’t discharge any such effluent

which is hazardous, poisonous or non-biodegradable. It is not likely to create pollution from

the point-of-view of water phase of environment.

This is a zero Discharge Industry.

2.7.2 AIR

Air Pollution can be defined as the presence in the outdoor atmosphere, of one or

more air contaminants (i.e. dust, fumes, gas, mist, odour, smoke or vapour) in sufficient

quantities, of such characteristics and of such duration so as to threaten or to be injurious to

human, plant or animal life or to property, or which reasonably interferes with the

comfortable enjoyment of life or property.

Under expansion activity, an additional high pressure boiler of 130 TPH shall be

installed. Fuel for same shall be bagasse to the tune of 52.02MT /Hr. This proposed boiler

shall be provided with Electrostatic Precipitator (ESP) preceding the RCC stack of 85 M

height as Air Pollution Control Equipment (APC). Efficiency of proposed Electro static

Precipitator (ESP) would be 98 - 99%.

In existing factory, a high pressure boiler of 75 TPH is already installed. Bagasse to

the tune of 816 MT /day is used as fuel for same. Dust Collector as APC equipment followed

by stack of 60 M is provided. After expansion, the existing boiler exhaust shall be connected

to ESP proposed under expansion replacing the existing Dust Collector.

Under expansion activity, two D.G. Sets 320 KVA & 1000 KVA capacity shall be

installed. The same would be provided with common stack with height of 18 M. The D.G.

Sets would be used only during power failure.

Table No 2.17 Details of Stacks

Sr. No. Details Name of Stacks

A Attached to Boiler D.G. Set - I D.G. Set - II

B Capacity 130 TPH

320 KVA 1000 KVA



C Fuel type Bagasse Diesel/HSD Diesel/HSD

D Fuel quantity 52.02

MT/Hr.

35 Lit /Hr 45 Lit! Hr

E Material of

construction

RCC MS

F Shape

(round/rectangular)

Round --

G Height, M (from

ground level)

85 M 18 M

H Diameter/size, in

meters

4.2 M 0.2 M

I Control equipment

preceding the stack

ESP ---

J Nature of pollutants

likely to present in the

stack gases

SPM S02, NOx

Mitigation measure during construction phase:

Air quality around the project site will not be impacted during construction

phase as the proposed project will be developed in the existing building

structure. Small construction work is proposed.

Further to minimize any impact following measures shall be taken:

Ø The raw material handling will be located as per the predominant wind

direction, in such a way that the fugit ive dust generated from the site

will be primarily contained within the construction site only.

Ø The raw material handling yard will be suitably enclosed so as to

generate minimum air born dust.

Ø All the loose material ei ther stacked or transport will be provided with

suitable covering such as tarpaulin, etc.

Ø Water sprinkling will be done at the locations where dust generation is

anticipated.



Ø To minimize the occupational health hazard, proper personal protective

gears i .e. mask will be provided to the workers who are engaged in dust

generation activity.

Emission Control Equipments (ECE)

The air pollution caused by this industry is mainly from dust as suspended

particulate matter (SPM) from Cogeneration power plant – boilers and fuel of

diesel generating set (DG set).

BSSKL knows from which unit operation or process, air pollutants are

expected. For the purpose of arresting and capturing the pollutants, measures

are proposed and designed.

ESP Details:

Details Electro Static Precipitator (ESP)

Table No 2.18 Details of Boiler & Electro Static Precipitator (ESP)

Sr. No. Description Details

Boiler Details

1 Boiler Capacity 130 T/Hr

2 Gas Flow Rate 60 m3 / Sec

3 Gas Temp 160 oC

4 Peak Load for half an hour 82.5 T/Hr

5 Working Pressure at Stack Height

outlet heade

72 Kg/cm2A

6 Temp at Stack Height outlet header 510 + 50C

ESP Details

7 ESP Make Unicon Engineers,

Coimbatore

8 Gas Flow Inlet / Sec 68.1 m3

9 Temp Inlet 160 oC

10 Mechanical Design Temp 250 oC



11 Velocity of Gas 10 m/Sec

12 Inlet Dust Conc. 6.1 gms/ Nm3

13 Outlet Dust Conc. Below 100 mg/Nm3

14 Overall Dust Collection Efficiency

with all fields

98-99%

15 Specific Collection Area 50 m2/m3/Sec

16 Treatment Time 9.99/sec

A suitable ESP so that the fly ash contents of flue gases leaving the chimney confirm to the rules and

regulations of the pollution act as applicable to the factory (below 100 Mg/Nm3).

It shall be the responsibility of the steam generator manufacturer/ Supplier to provide all technical

documents to pollution control authority. Obtaining pollution clearance shall be in purchaser’s scope.

The ESP shall be installed on the suction side of the I.D fan and shall be complete with rotary airlock valve

with drive provide with local and remote push button control, and a side manual gate. The minimum

elevation of discharge flange of the rotary airlock valve shall be at + 2500 mm.

Suitable platform, ladder, inspection and poking holes etc. shall be provided to facilitate regular inspection

and cleaning of the ESP.

Even with one field of ESP out of service the ESP must remain in operation. Manufacture/supplier to

specify the emission level with only one field in service at 100% boiler MCR with bagasse as fuel.

All electrical including MCC, rectifiers, panels, electrical & control cables, earthling etc. in Suppliers

scope. ESP MCC & Controller shall be located power house.

The manufacture is to design & supply suitable flue gas cleaning system to ensure that the flue gases

entering the chimney do not contain SPM in excess of 115 mg/Nm3 for 100% Bagasse firing.

DETAILED SPECIFICATION FOR THE ELECTROSTATIC PRECIPITATOR

Detailed Scope of Supply for ESP

The scope of supplies shall include, but not limited to the following:

The electrostatic precipitator complete including all components and accessories stated in this section.

Complete structural steel required for supporting the ESP with all associated beams cross ties, foot plates,

foundation materials (bolts, anchor channels, sleeves, etc).



Required Stairways and walkways with handrails for the ESP.

All sliding supports for thermal expansion of cas Precipitator housing (all walls and roof, with required

columns, stiffeners, access door, etc).

Thermal insulation complete with lagging, wire mesh fixing cleats and outer aluminum cladding.

Inlet and outlet funnels with gas distribution devices, defector plates, flow splitters and necessary gas flow control

devices.

Ash hopper complete with required thermostatically controlled heating elements, inspection doors, level

monitoring and indicators, outlet flanges, poke holes, manually operated gates, rotary air lock valves, speed

switches for air lock valves, junction boxes for field instruments and heaters etc.,

Each hopper heater and thermostat shall be provided with IP 55 junction box on the hopper itself, so that the

termination of the hopper heaters and thermostat can be made in the junction box itself The heater type shall be

of tubular. All interconnection from junction boxes to individual instrument and equipment.

High voltage emitting system with required frame work, support arrangement and support insulators emitting

electrodes, etc.

Collecting electrode complete.

The ESP shall have Two fields in operation and space for one as a provision for future.

Rapping mechanism complete with structural supporting frame, drives, geared motor and automatic rapping

control panels, etc.

Required number of high voltage transformer — rectifier sets, accessories and controll cubicle, with automatic

voltage control system for the ESP system

Required sets of insulators, heating system for the support and shaft insulator complete with thermostats.

Junction boxes to supply power for the heater units and control supplies, as required. Each insulator

heater and thermostat shall be provided with IP 55 junction box on the insulator itself, so that the

termination of the insulator heater and thermostat can be made in the junction box itself.

Electronic controller unit for TR sets, in a cubicle.

High voltage bus duct connection (between the transformer rectifier and high voltage emitting

system) including insulator, HV disconnecting switches, for isolating bus section with earthing

position.



Complete lifting and handling arrangement for the transformer, rectifier sets.

Mechanical interlock system and electrical interlocks for personnel protection.

Complete cabling arrangements to and from the ESP control panel located in the near to ESP.

Provision for water washing system for the precipitator and hoppers along with all piping, valves nozzles,

etc.

External annunciation system for indication of faults in central control room.

All instrument test connections (pressure, temperature, velocity, dust concentration measurement, etc.)

Matching flanges along with all bolts, nut, gaskets etc, required for connecting to matching ducting /

components.

Metallic expansion bellows of stainless steel material of 1.6.mm thk, at the inlet and outlet funnels.

All ash hoppers shall with motor operated air lock ash discharge valves, and with manually operated isolation

gates upstream of the air lock valves.

Electromagnetic vibrators with control panel shall be provided for the free evacuation of ash from the hopper.

Temperature indication of the inner parts of the hopper shall be provided at local and also in the control room.

Rapper controller complete with timer and accessories, as a part of TR set control panel or in a separate floor

mounted control panel.

Equipment and System Description.

Design considerations

The ESP shall be designed to provide an outlet dust concentration level of 100 mg/Nm3, with

the boiler operating with bagasse The ESP design and the layout of the equipment shall take care of

the above requirements.

The ESP shall be designed with required number of independent electrical fields with all associated

electrical, controls, cables, panels, hoppers, etc.

The aspect ratio of the ESP (electrode zone) shall be optimally selected, so as to minimize re-

entrainment and carry over of the collected dust, and for assured ESP performance.

The gas velocity should preferably be between 1.0 to 1.2 M/sec.

Flow Model Study (Not required)



Housing

ESP housing shall be gas tight, weather proof, all welded steel envelope suitably stiffened. The housing

shall be designed to withstand 250 Deg.0 and a pressure of ± 400 mmwc. Necessary sealing arrangement

to prevent moisture and air ingress into the casing shall be provided. Air ingress shall not exceed 1% of design

gas flow. The casing shall be provided with required number of gas tight access door for inspection and

maintenance. The casing steel plates shall be of adequate thickness. The precipitator casing and hopper shall

form a common structure suitably reinforced to withstand the wind load (in accordance with IS:875),

load due to dust in collecting hoppers, etc. The housing shall be supported on suitable bearings to allow the

movement due to thermal expansion. The ESP housing shall be kept at an elevation which will permit the

easy removal and introduction of the collecting electrodes.

Funnels

The inlet to and outlet from the precipitator shall be provided with suitable flanged transition funnel equipped

with access doors and shall be completely seal welded on the inlet and outside after assembling.

Necessary guide vanes, deflector plates, flow split and any other flow control devices warranted by the

results of flow model study shall be provided. The funnels shall be complete with supports, stiffeners,

bracings, brackets, expansion bellow etc.

Ash Hoppers

All ash hoppers shall be of pyramidal type, identical size and capacity with flanged outlet connection,

rotary air lock valves to connect it with dry ash removal system to be provided by the PURCHASER.

Combined Ash storage capacity shall be minimum 4 hours with the rated conditions specified in this

specification. A margin of 10% shall be provided in the hopper capacity over the calculated values.

Specific weight of ash may be taken as 150 Kg/cu.m for calculating storage capacity and 1100 Kg/Cu.m for

structural design.Hoppers shall be of welded steel plate of 6.mm thickness suitably stiffened.

Each hopper shall be complete with an access door.

Hopper valley angle shall not be less than 60 Deg. For free flow of ash to dust removal system.

Each hoppers shall be provided with adequate number of poke holes with screw caps. Adequate number of

electromagnetic vibrators shall be provided in each of the hopper to enable the free discharge of the ash

from the hoppers.



The internal surface of the hopper shall be free from ridges. The outlet of the hopper shall be provided

with a thermostatically controlled hopper heating system of adequate capacity to ensure free flow of

dust from the hopper and close them at present with a suitable leak proof door to be manually operated.

Each hopper shal l be provided with sui table dust level monitor ing system incorporating all the

necessary accessories including level transmitters, level switch, local and remote signaling lamps and

high level alarm. A timer shall also be provided for de- energizing the affected elected electrical section.

Thermal Insulation

All exposed parts which will operate at temperature above the maximum ambient temperature of 50 Deg.C

shall be provided with external thermal insulation and cladding. Insulation shall be mineral wool / ceramic

blanket of adequate thickness such that the skin temperature does not exceed 20 Deg. C from the ambient

temperature at 1 m/s wind velocity. The insulation shall be kept in place by means of adequate number of

pins spot welded to the cover panel. The insulation shall be covered with wire mesh of adequate size. The

outer casing shall be of plain aluminum sheet with a minimum thickness of 22 SWG.

Gas Distribution Screens

For uniform gas flow and distribution throughout the ESP cross section area gas distribution screen shall be

provided at inlet and outlet section of the ESP. the distribution system shall be designed to minimize local

velocity regions and re-entrainment of dust and shall not cause undue resistance to the passage of gases. The

distribution screens shall be of modular design with suitable cleaning system.

Emitting electrodes

The high tension emitting electrodes shall be made of durable and corrosion resistant material. They shall be

accurately centered between the collecting electrodes, duly supported to prevent swinging and shall be

properly insulated from the precipitator casing.

The emitting electrode design, geometry, size, arrangement and material shall be of well proven type,

considering the duty conditions for achieving uniform corona effect, reliable operation, performance and

long life.



Provisions made to maintain alignment of electrodes during normal operation, including rapping and

thermal transients shall be clearly brought out in the offer.

Collecting electrodes.

The collecting electrodes shall be designed on concept of dimensional stability and

maintain the collecting efficiency at desired level. The profile of the collecting plates shall be such as to

minimize the re-entrainment of thc collected dust at the time of rapping.

Each plate shall be shaped in one piece by roll forming and shall be stiff enough to carry the rapping intensity.

The swinging tendencies of plates shall be prevented by suitable means. These means shall be clearly brought

out in the proposal.

Rapping systems

Independent rapping system shall be provided for discharge and collecting electrodes with independent

control systems. The rapping mechanism shall be of either electric impact type or tumbling hammer type. This

shall be adjustable in frequency to provide an efficient cleaning rate. Separate rapping equipment shall be

provided for each field so that each mechanism can be suitably adjusted when required. It shall be so

arranged that the rapping frequency can be independently set from the control room ( without requiring any

opening up of the panel) in accordance with the dust build up, inlet dust loading and changing gas volumes.

Sufficient number of rappers and rapper drives shall be provided so that maximum collection area and

discharge electrode lengths are rapped at any instant. In case any special features are added to meet this

stipulation, the same should be clearly brought out in the offer.

The rapping system shall be designed for continuous sequential rapping to prevent puffing under any

conditions of precipitator operation.

All internal parts of the rapping mechanism shall be accessible for inspection and they shall be placed on wide

access passages. Major part of the rapping mechanism shall be located external to the precipitator. Necessary

lubrication system shall be provided for the rapping mechanism.

The gas distribution screen system shall also be provided with rapping systems.

· Electric Equipment



· Power supply

Power supply for the precipitator is needed for the following functions:

I. To produce high voltage DC corona.

II. To actuate electrical auxiliary components.

The necessary power for the high voltage Dc corona is obtained by providing a thyristor controlled rectifier

transformer unit

Transformer — Rectifier Units.

The transformer-rectifier unit essentially consists of a high voltage transformer, SCR bridge, high

frequency choke all contained in a common tank filled with power transformer oil. Necessary controls

and other protective device are to be incorporated in control cubicle, which shall be kept in the

control room. Automatic constant current regulations and spark rate regulation is to be achieved by

controlling the input to the transformer rectifier unit through SCR's connected in anti parallel fashion.

Protection should include the following.

ii) Arc suppression unit

iii) Under Voltage protection

iv. Protection against excessive temperature rise of oil and internal short

circuit on transformer winding.

v. Over load p ro t ec t ion .

Sources of Air Pollutants

1. Boiler

The industry proposes to continue the efforts of air pollution control and

remain inside the limits.

Ø Stack Heights of proposed two boilers – will be 30Mtr & 70Mtr.



v Wet Scrubber & Electrostatic precipitator shall be installed to

maintain the air emission within the norms to comply the norms

of MoEF.

2. Burning of fuel in standby DG set:

Table No.2.18: Emission of pollutants From DG set

S.No Source Pollutant In-plant

Measures

Control Equipment

1 Standby

DG set

SO2 Feed low

Sulphur diesel

–

2 Process HCl Close container Fume hood vents are

provided with

scrubber system

Fugitive

A number of mitigation measures will be taken to control fugitive emissions,

the presence of which will be noticeable by plain vision if not controlled.

The measures are thus taken seriously and continuously such as:

Ø Rubber wheel carts / trucks to bring in raw materials will not be fi lled

high, side’s cladded, slow speed travel , avoiding vibrations en-route.

Ø Engineering the plant layout will be in such a way so as to virtually

eliminate need of using heavy equipment for material handling.

Ø Tree plantation on surrounding available area.

Ø The industry proposes to continue the efforts of air pollution control

and remain inside the limits.

2.7.3 Solid Waste:

Introduction:



Solid Wastes from the Industries are categorized as hazardous and non-hazardous. Wastes

that pose a substantial danger immediately or over a period of time to human, plant, or animal

life are classified as hazardous wastes.

Non- hazardous waste is defined as the waste that contributes no damage to human or animal

life. However, it only adds to the quantity of waste.

Following table gives details of solid waste in form of ETP sludge and boiler ash generated

from bagasse burning in boiler in existing as well as proposed expansion project.

Table No. 2.19 Solid Waste Details

Sr. No. Non-Hazardous

Solid Waste

Quantity Disposal

Existing Expansion

1 Boiler ash 15 MT/Day 15 MT/Day Sale to farmers as

manure or sale to

brick manufacturers

for secondary use.

2 ETP Sludge

0.3 MT/Day 0.5 MT/Day Used as manure in

own factory

premises.

An agreement has been executed with nearby brick manufacturers for utilization of ash for

brickmanufacturing as per the MoEF Notification S.O. 763 (E) dated 14.09.1999

amendments dated27.08.2003 and 03.11.2009

Waste management during construction phase:

Minimum amount of solid waste will be generated as there will be small

construction work which will be confined within the existing building

structure.

Following mitigation practice is the policy for future:

Ø Minimization at all levels need be attempted for discarded products,

empty containers, packing surpluses, incoming raw material unloading

spillages and fugitives.

Ø The solid in process generate only as Ash from cogeneration plant, ETP

sludge and domestic waste.

Ø Other will be empty drums which can be used for refill or may be

disposed to original vendors



a) Non Hazardous Solid Waste

Based on above working, the summary is

ü Ash generation will be about 15 MT/Day.

ü This ash will be mixed with the press mud, being sold to the

farmers during season.

ü Municipal solid waste generated during construction & operation

will be Composted and used for Gardening

ü The collected ash will be given / sold to cement industries &

brick making.

b) Hazardous Waste

The different types of hazardous wastes being generated from existing operations as

well asthose to be generated from proposed activities and their disposal methods are

presented infollowing table

Table No. 2.20 Hazardous Wastes

Sr. No.

Hazardous Wastes (Management,

Handling and Transboundary

Movement Fourth Amendment

Rules, 2010

Quantity

Disposal Existing Expansion

1 Cat. No. 5.1 Spent oil 0.3

MT/M

0.6 MT/M Burnt along

with bagasse

in co-can

boiler.

2.7.4 NOISE

Noise is normally defined as objectionable or unwanted sound, which is without agreeable

quality and essentially non-euphonious. The concern on noise depends upon the noise level

near the source, on the work environment and near the residential zone. Earlier, noise was

summarized to be exclusively an occupational problem. But, since the effects are found also



on people who are not directly involved, it has acquired wider dimension. Hence it is

necessary to know the noise levels near the sources as well as near the residential colonies.

Sources of Noise Pollution

The source of noise generation would be the cane carrier, mills, pumps, compressors,

and boiler house as well as stand by D.G.Set.

At the tendering stage itself the limit of noise levels, as measured at various points

near the equipment in the boiler house, is identified as not more than 85 dB(A) as observed in

existing unit. The equipments are designed to meet these conditions.

The noise would be created by movement of trucks/ tractor trolleys for material

transportation. However, this would not be of a continuous nature and would not have much

impact on the workenvironment of the project site.

Insulation also helps in limiting noise levels. The workers entering inside the plant are

protectedby earmuffs, which would give the reduction of 30 dB (A). Further, people working

in close vicinity of the high noise generating equipments and sources in the sugar factory &

co-gen are provided with Personal Protective Equipments (PPE) such as ear plugs, ear muffs

etc. so as to attenuate the noise levels and minimize bad effects of exposure to high sound.

Two D.G. Sets 320 KVA & 1000 KVA capacity shall be installed on site. However,

this would not be the continuous source. Only in case of electricity failure, D.G. Set would be

operated. D.G. Sets shall be enclosed in a separate canopy to reduce the noise levels.

Mitigation measures during construction phase:

During the construction stage, expected noise levels shall be in the range of

75-80 dB. All the construction activities shall be carried out during the

daytime. To prevent any occupational hazard, ear muff / ear plug will be

given to the workers working around or operating plant and machinery

emitting high noise levels. Use of such plant or machinery will not be

allowed during night hour. Careful planning of machinery operation and

scheduling of operations shall be done to minimize such impact.

Mitigation measures during operation phase:

No significant amount of noise will be generated during the operation phase.

2.7.5 Green belt development



Adequate green belt will be developed within the premise of the proposed

establishment which comprises of local varieties of trees, shrubs, climbers

and grass cover.

The management has also initiated tree plantation along the existing approach

road and surrounding areas to make the vicinity greener and ecologically

aesthetic. More than 1000 nos of trees have been planted till date with

survival rate of around 80%.

2.7.6 Waste Recycling

This being sugar and Cogeneration power plant, quality is very important .

This may involve use of water in the different stages of sugar production and

co-generation power plant steps. It may be possible to reuse such water

again.

The treated sewage/effluent will be put to a secondary use of greening or

agriculture purpose and that too as sub-surface irrigation. However, rain

water harvesting will be done and used for groundwater recharge.

2.8 Safety

Safety and occupational health will be dealt carefully. A disciplined approach

is natural to this industry. Safety policy will be in place. The unit will be

registered under factory act and are bound by state factory rules. Thus, first

aid trained and fire-fighting trained person will be available in every shift .

Implant safety will be controlled& monitored by qualified person& also the

competent person retained. Where necessary, provisions of other Acts, where

required like Petroleum act, Explosive Act, etc. will be obeyed. Fire fighting

system is kept as per norms of insurance company and CIF.

DMP (Disaster Management Plan) and off-site emergency plan will be in

place. Accordingly, Personal protection equipment will be given and use will

be insisted. Consulting Physician is retained to visit the factory.

Prediction of impacts is the most important component in the environmental

impact assessment studies. Several scientific techniques and methodologies



are available to predict impacts of project developmental activit ies on

environment. Such predictions are superimposed over the baseline (proposed

project) status of environmental quality to derive the ultimate (post-project)

scenario of environmental conditions. The prediction of impacts helps to

prepare the Environmental Management Plan (EMP) required to be executed

during the on-going activities for the proposed project to minimize the

adverse impacts on environmental quality

* * * * *

Chapter – 4

Anticipated Environmental Impacts & Mitigation Measures

4.0 Identification of Impacts

This chapter presents identification and appraisal of various impacts due to the proposed

Enhanced Sugar Plant with Cogeneration Unit. The environmental impacts can be

categorized as either primary or secondary. Primary impacts are those, which are attributed

directly to the project and secondary impacts are those, which are indirectly induced and

typically include associated investment and changed pattern of social and economic activities

due to the project. The impacts have been assessed during the construction and operation

phase of the Sugar Plant with Cogeneration power plant on different environmental

components:-

4.1 Impacts during Construction Phase and Mitigation Measures



Probable environmental impacts during construction phase are typically due to activities

related to clearing of vegetation, leveling of site, civil constructions erection of structures and

installation of equipment.

4.2 Air Environment

4.2.1 Impact on Air Quality

The main sources for impact of air quality during construction period is due to movement of

vehicles and construction equipment at site, dust emitted during leveling, grading,

earthmoving, foundation works, transportation of construction material etc. Hence, during the

construction phase, particulate matter (PM10& PM2.5) would be the main pollutants. The

emissions from vehicles and construction equipment could also be of some concern on a local

level.

Air Pollution Mitigation Measures

The dust generated will also be fugitive in nature, which can be controlled by sprinkling of

water. The impacts will be localized in nature and the areas outside the project boundary are

not likely to have any major impact with respect to ambient air quality.

The construction of proposed units would result in the increase of SPM concentrations due to

fugitive dust. Frequent water sprinkling in the vicinity of the construction sites would be

undertaken and will be continued after the completion of plant construction as there is scope

for heavy truck mobility. It will be ensured that diesel powered vehicles will be properly

maintained to comply with exhaust emission requirements.

4.2.2 Noise Environment

Impact on Noise Levels

The major sources of noise during the construction phase are vehicles and construction .The

operation of the equipment can generate noise in the range 85-90 dB (A) near the source. The

noise will be generated within the plant boundary and will be temporary in nature.

Noise Levels Mitigation Measures

The noise control measures during the construction phase include provision of caps on the

construction equipment and regular maintenance of the equipment. Equipment will be

maintained appropriately to keep the noise level within 75 dB (A). Wherever possible,

equipment will be provided with silencers and mufflers. High noise producing construction

activities will be restricted to daytime only. Further, workers deployed in high noise areas



will be provided with necessary protective devices such as ear plug, ear-muffs etc. Overall,

the impact due to increase in noise on the environment would be insignificant, localized and

confined to the day hours.

4.2.3 Water Environment

Impact on Water Resources and Quality

Impact on water quality during construction phase is due to non-point discharges of sewage

generated from the construction work force stationed at the site. Plant sanitation facilities

(septic tanks) will be utilized for treatment and disposal of sanitary sewage generated by the

work force. Runoffs from the construction yards and worker camps during monsoon could

affect the quality of water bodies in the project area. Further there is possibility of water

stagnation in ponds and ditches which can create an environment conducive to disease

carrying vectors.

Water Pollution Mitigation Measures

Toilets with septic tanks will be constructed at site for workers and it will be ensured that

domestic wastewater generated in worker colonies does not flow to water bodies. The overall

impact on water environment during construction phase due to expansion activities is likely

to be short term and insignificant. By adopting necessary mitigation measures the overall

impact on water environment during construction phase of the project will be temporary and

insignificant.

4.2.4 Land Environment

Impact on Land use

Preparatory activities like construction of access roads, temporary offices, and go-downs,

piling, storage of construction materials etc. will be confined within the project area. These

will not exercise any significant impact except altering the land use pattern of the existing

site. The impact will be insignificant on the adjoining land. No forestland is involved.

Therefore, impact will be negligible.

Impact on Topography

Topographically, the area forms slightly elevated land and general elevation is from North to

South. Most of the area forms plain land covered with mixed soil. Adequate storm water

drains will be provided to collect and carry the surface runoff during monsoon to the natural

drainage system of the project area.



4.2.5 Socio-economic Environment

The socio-economic impacts during the construction phase of the proposed Enhancement

Sugar plant with Cogeneration Plant could result due to migrant workers, worker camps,

induced development etc. Increase in floating population. The local population will have

employment opportunities in related service activities like petty commercial establishments,

small contracts/sub-contracts and supply of construction materials for buildings and ancillary

infrastructures etc. consequently, this will contribute to economic up liftment of the area.

Normally, the construction activity will benefit the local population in a number of ways,

which include the increase in requirement of construction skilled, semi-skilled and un-skilled

workers, tertiary sector employment and provision of goods and services for daily needs

including transport.

Ø Local people will be given preference for employment depending on their suitability;

Ø All the applicable guidelines under the relevant Acts and Rules related to labour

welfare and safety will be implemented during the construction phase;

Ø The contractor has been advised to provide fire wood/kerosene/LPG to the workers to

prevent cutting of nearby trees for firewood; and

Ø The construction site will be secured with fencing and is having guarded entry points.

4.2.6 Storage of Hazardous Material

The hazardous materials used during construction may include diesel and lubricating oils.

These materials will be stored and handled carefully under applicable safety guidelines. Some

of the precautions of storage include the following:-

Ø Dyked enclosures will be provided so as to contain complete contents of the largest

tank;

Ø Diesel and other fuels will be stored in separate dyke enclosures;

Ø Tanks having large storage capacity for will be separated by fire insulating walls from

other storage tanks; and

Ø The distance between the storage tanks will be maintained half their height.

4.2.7 Facilities to be provided by Labour Contractor

The contractor will be made to provide the following facilities to construction work force:

First Aid



At work place, first aid facilities will be maintained at a readily accessible place where

necessary appliances including sterilized cotton wool etc. Ambulance will be kept at the site

and made available at workplace to take injured person to the nearest hospital.

Potable Water

Sufficient supply of water fit for drinking will be provided at suitable places.

Sanitary Facility

Sanitary facilities will be provided at accessible place within the work zone and kept in a

good condition. The contractor will conform to requirement of local medical and health

authorities at all times.

Canteen

The canteen will be provided for the benefit of workers.

Security

BSSKL will provide necessary security to work force in co-ordination with State authorities.

4.3 Impacts during Operation Phase During the Operation Phase the establishment of the

project, results in emissions, generation of wastewater and solid waste.

4.3.1 Air Pollution Major sources of air pollution in power plant are boiler, and crushers.

Fugitive dust emissions are also inevitable from raw material handling system as well as

transportation. The standby DG sets will be provided with adequate stacks as per CPCB

norm.

Transportation of Raw Material & Finished Goods

The emissions from transportation of Raw Material and Finished Goods within the plant area

have been considered as line source emissions all along the road. The stack emissions of

other industries are reflected on existing baseline concentrations of the study area.

Table – 4.1: Stack & Emission Details

Stack & Emission Details with Pollution control Equipment Parameters

Number of Stacks 1

Common Stack with no. of flues One flue

Stack Height from ground level (m) 85

Stack Dia. (m) (internal) 4.2



Exhaust Gas Temperature (0C) 210

Exit Gas Velocity (m/s) 6.90

Volumetric Flow Rate (Nm3/hr) 147280

APCE Proposed ESP with outlet concentration PM <50

mg/Nm3

Emission Rate of PM (mg/m3) 30

Emission Rate of SO2 (mg/m3) 8.66

In order to estimate the ground level concentrations due to the emission from the proposed

project, EPA approved Industrial Source Complex AERMOD View Model has been

employed. The mathematical model used for predictions on air quality impact in the present

study is ISC-AERMOD View. It is the next generation air dispersion model, which

incorporates planetary boundary layer concepts. The AERMOD is actually a modelling

system with three separate components: AERMOD (AERMIC Dispersion Model), AERMAP

(AERMOD Terrain Pre-processor), and AERMET (AERMOD Meteorological Pre-

processor). Special features of AERMOD include its ability to treat the vertical in

homogeneity of the planetary boundary layer special treatment of surface releases,

irregularly-shaped area sources, a plume model for the convective boundary layer, limitation

of vertical mixing in the stable boundary layer, and fixing the reflecting surface at the stack

base. The AERMET is the meteorological pre-processor for the AERMOD. Input data can

come from hourly cloud cover observations, surface meteorological observations and twice-

a-day upper air soundings. Output includes surface meteorological observations and

parameters and vertical profiles of several atmospheric parameters. The AERMAP is a terrain

pre-processor designed to simplify and standardize the input of terrain data for the

AERMOD. Input data include receptor terrain elevation data. Output includes, for each

receptor, location and height scale, which are elevations used for the calculation of airflow

around hills.

4.3.3 Post Project Scenario

Predicted maximum ground level concentrations considering micro meteorological data of

winter (Oct. – Dec.) 2014 are superimposed on the maximum baseline concentrations

obtained during the study period to estimate the post project scenario, which would prevail at

the post operational phase. The overall scenario with predicted concentrations over the



maximum baseline concentrations is shown in the Table 4.2 along with isopleths shown in

Figures 4.1 to 4.2.

4.5 Impact on Water Quality Effluent from water treatment plant

Hydrochloric acid and sodium hydroxide will be used as regenerants in the proposed

demineralising water plant. The acid and alkali effluents generated during the regeneration

process of the ion-exchangers would be drained into an epoxy lined underground neutralizing

pit. Theseeffluents are self-neutralizing.However, provisions will be made such that the

effluents will be neutralized by addition of either acid or alkali to achieve neutral pH of

7.0.The effluent will then be pumped into the effluent treatment plant for treatment.

Chlorine in cooling water

In the auxiliary cooling water, residual chlorine of about 0.2 ppm

Boiler Blow down

The salient features of blow down water from the point of view of pollution are, the pH and

temperature of water since suspended solids are negligible. The pH would be in the range of

9.8 to 10.3 and the temperature of blow down water will be 1000C. The quantity of about 1.8

tonnes/hour of blow down is very small and hence, it is proposed to pull the blow down into

the trench and leave it in the effluent ponds.

Waste Water treatment

Waste water treatment for the plant will be based on discharges of the various waste water to

ponds for clarification and filtration. Oily water will be treated separately to remove

oil/grease before discharge into effluent ponds. The oily water collection in the plant is

basically due to floor cleaning, leaky oil filters, etc.

4.5.1 Waste water generation

The total waste water generation from the Sugar plant along with the Cogeneration Plant will

be 700 m3/day. The generated wastewater will be sent to Effluent Treatment Plant (ETP) and

the treated wastewater will be used for cane irrigation and green belt development.

4.6 Solid Waste

4.6.1 Dry fly ash and Furnace bottom ash



Fly ash collected from the ESP hoppers and the airheaters hoppers and the ash collected from

the furnace bottom hoppers can be used as landfill. The ash content in bagasse is less than

2%. The total fly ash 21.7 TPD will be used as manure. The high potash content in the

bagasse ash makes the ash as good manure.

Press mud of 140 TPD will be sold to farmers as manure. The liquid molasses 140 TPD will

be sent to distillery for manufacture of alcohol.

4.6.2 Sewage from various buildings in the plant

Sewage from various buildings in the plant area will be conveyed through separate drains of

the septic tank followed by soak pit. Sludge will be removed occasionally and disposed off as

a land fill at suitable places.

4.8 Impact on Ecology

The enhanced project will not have any significant impact on ecology as there are no reserve

forests in the study area and in addition to that the project will implement an effective

environmental management plan to control the emissions from the project.

Green belt development

The total project area acquired for plant is 98.04 acres, and 33% of it,32.35 acres will be used

for green belt development. Local species will be preferred for green belt development.

4.9 Demography and Socio-economics

The impacts due to enhanced project on demography and socio economic condition are as

follows:-

Ø Increase in employment opportunities and Reduction in migrants to outside for

employment.

Ø Increase in literacy rate.

Ø Growth in service sectors

Ø Increase in consumer prices of indigenous produce and services, land prices, house

rent rates and Labour prices.

Ø Improvement in socio cultural environment of the study area.

Ø Improvement in transport, communication, health and educational services.

Ø Increase in employment due to increased business, trade commerce and service sector.



Ø The overall impact on the socio economic environment will be beneficial.

4.10 Impact on Health

Adequate air pollution and noise control measures will be provided. The environmental

management and emergency preparedness plans will be prepared to ensure that the

probability of undesired events and consequences would be reduced, and adequate mitigation

measures will be provided in case of an emergency. The overall impact on Human health is

negligible during operation of plant.

* * * *

CHAPTER– 5

Environmental Monitoring Program

Pollution Monitoring and Surveillance Systems

For Proposed Enhanced Sugar Plant and Cogeneration power plant, the Indian Emission

Regulations stipulate the limits for particulate matter emissions and appropriate stack heights

will be maintained for keeping the emission levels in the ambient within the air quality

standards. The characteristics of the effluent from the plant would be maintained so as to

meet the requirements of the State Pollution Control Board and the National Standards for

Sugar Plant stipulated by the Central Board for Prevention and Control of Water Pollution.



Air Quality monitoring programme

The purpose of air quality monitoring is acquisition of data for comparison against prescribed

standards, thereby ensuring that the quality of air is maintained within the permissible levels.

It is proposed to monitor the following from the stack emissions:-

v Particulate Matter (SPM, PM10& PM2.5)

v Sulphur dioxide

v Oxides of Nitrogen

It is proposed to monitor particulate emission qualitatively and quantitatively in the stack and

with the aid of a continuous particulate stack monitoring system. The stack monitoring data

would be utilized to keep a continuous check on the performance of wet scrubber. Further it

is proposed to monitor and record the weather parameters such as temperature (maximum &

minimum), Relative humidity, wind direction, wind speed, rainfall etc. on daily basis, for this

purpose, it is proposed to install Weather Monitoring Station with necessary gadgets.

5.0 Post Project Environmental Monitoring

Environmental monitoring will be conducted on regular basis to assess the pollution level in

the plant as well in the surrounding area. Therefore, regular monitoring program of the

environmental parameters is essential to take into account the changes in the environment.

The objectives of monitoring are:-

Ø To verify the result of the impact assessment study in particular with regards to new

developments;

Ø To follow the trend of parameters which have been identified as critical;

Ø To check or assess the efficacy of the controlling measures;

Ø To ensure that new parameters, other than those identified in the impact assessment

study, do not become critical through the commissioning of new installations or

through the modification in the operation of existing facilities;

Ø To check assumptions made with regard to the development and to detect deviations

in order to initiate necessary measures; and

Ø To establish a database for future Impact Assessment Studies for expansion projects.

The attributes, which merit regular monitoring, are specified below:-

v Air quality;

v Water and wastewater quality;



v Noise levels;

v Soil quality;

v Ecological preservation and afforestation; and

v Socio Economic aspects and community development

The post project monitoring will be carried out at the industry level is discussed below:

5.1 Monitoring and Reporting Procedure

Regular monitoring of important and crucial environmental parameters has an immense

importance to assess the status of environment during plant operation. With the knowledge of

baseline conditions, the monitoring programme can serve as an indicator for any deterioration

in environmental conditions due to operation of the plant and suitable mitigation steps could

be taken in time to safeguard the environment. Monitoring is as important as that of control

of pollution since the efficiency of control measures can only be determined by monitoring.

The following routine monitoring programme would therefore be implemented. A

comprehensive monitoring program will be implemented is given in the Table 5.2.

Table 5.1 Post Project Monitoring Source

Source Location Parameters to

be monitored

Frequency Responsibility

Meteorology At the project site Wind speed,

direction,

temperature,

relative

humidity

,rainfall

Hourly M/s BSSKL

Ambient Air

Quality

Within plant and

surrounding 10km

radial zone.

PM10, PM2.5

SO2, NOx

Monthly M/s BSSKL

Water Quality Within the plant

and surrounding

As per IS:

10500

Monthly M/s BSSKL



10km radial zone

Surface Water As

well as Ground

Water

Noise Levels Within the plant

and surrounding

10km radial zone.

Noise levels Monthly M/s BSSKL

Soil quality Within the plant

and 10 km radial

zone

Soil parameters Monthly M/s BSSKL

Boilers Individual Units Particulate

matter, SO2,

NOx

Monthly M/s KKSSKL

Wastewater Inlet and outlet of

ETP Steam–

Generator Blow

down Cooling

Tower

pH, TDS, COD,

SS and others .

pH, SS, Oil,

Grease, Cu, Iron

Phosphates

Monthly

Weekly Weekly

M/s KKSSKL

5.2 Environmental Laboratory Equipment

The plant will have an in-house environmental laboratory for the online monitoring of air,

noise, water and soil. For all non-routine analysis, the plant may utilize the services of

external accredited laboratory facilities. The laboratory equipment required for monitoring

and analysis are given below:

Table-5.2 List of Equipments in Existing Manufacturing Set-up

Sr. No.

Particulars No. of Plant and Machinery

1 Juice Flow Meter 1 No. 2 Juice Heaters 6 Nos. 3 Clear Juice Heaters 1 No. 4 Juice Sulphitation And Liming Equipment 1 No. 5 Clarifier 1 No. 6 Sulphur Gas Plants 3 No.



7 Quintuple Effect Evaporator Bodies 8 Nos. 8 Syrup Storage & Molasses Storage Tanks. 15 Nos. 9 Molasses Conditioning Tanks 2 Nos. 10 Vacuum Pans For A & BAnd C 8 Nos. 11 Condensation Plants. 4 Nos. 12 Injection Water Pumps 5 Nos. 13 Spray Pumps 2 Nos. 14 Spray Ponds 1 No. 15 Vacuum Crystallizers 3 Nos. 16 Seed Crystallizers 2 No. 17 Continuous Centrifugal Machines 7 Nos. 18 Batch Type CF m/c 5 No. 19 Magma And Molasses Pumps 8 No. 20 Sugar Melter 2 No. 21 Sugar Grass Hoppers 3 Nos. 22 Sugar Grader 2 No. 23 Sugar Elevator 2 No. 24 Sugar Weighing Machine 3 Nos.

Table No. 5.3 List of Equipments to be Installed under Proposed Expansion Activity

Sr. No. Particulars No. of Plant and Machinery

1 Weigh Bridge 50 MT 1 No 2 Weigh Bridge 10 MT 1 No 3 Cane Carrier Modifications 1 No 4 Cane Kicker replacement 1 No 5 Cane Leveler replacement 1 No 6 Cane Fiberizer modifications with motor 1 No 7 De-hooking system for unloader 1 No 8 Bagasse handling system modifications 1 No

9 Addition in mill house crane of 30Ton trolley and strengthening

1 No

10 Unscreen juice pumps 2 Nos. 11 Screen juice pumps 2 Nos. 12 Rake carrier for first mill with Donnelly chute 1 No 13 Rotary juice screen 1 No 14 Mass Flow meter 1 No 15 Pumps for Raw Juice 2 Nos. 16 Pumps for Clear Juice 2 Nos. 17 Pumps for Sulphur Juice 2 Nos. 18 Pumps for Syrup 2 Nos. 19 Clarifier 1 No 20 Juice Sulphiter 300 HL 1 No 21 Syrup Sulphiter 120 HL 1 No 22 Sulphur Burner 1 No 23 Vibro Screen for MOL & Dry Seed ---



24 Sugar Melter 1 No 25 sugar Silos with elevator 1 No

26 Sugar weighing machines stitching m/c with slat conveyors 1 No

27 Sugar Bag Bbelt Conveyors 1 No 28 Molasses storage tank --- 29 Juice Heater 350 sq.mtr. 2 No 30 Sulphur juice heater 450sq.mtr. 2 No 31 Pan 80 ton 2 No 32 Vertical crystallizer 500 MT for C massecuite 1 No 33 Continuous pan 30 MT 1 No 34 Batch type centrifugal machines 1750/charge 2 Nos. 35 continuous centrifugal machines 4 No 36 Sugar hopper 2000 mm width. 3 Nos. 37. Sugar elevator 35 MT/hr 1 No

38. Spray pond modification Caustic storage tank, unloading / metering pumps, HCL Tank, etc. 1 No

39. Vacuum filter 14 x 28feet 1 No 40 Miscellaneous 1 No

41. New Boiler (1 x 130 TPH ,87 kg/cm2, 515 DC)& auxiliaries, viz. ESP, fans, pumps, de aerator etc., incl. E&C

1 No

42. Steam Turbine and auxiliaries (1 x 17 MW capacity double effect condensing type, and8 MW back pressure87 kg/cm" pressure, 505 DC)

1 No

43. Electrical distribution for sugar expansion, including switchyard, tie line & metering 1 No

44. DCS & plant automation 1 No 45. OM water plant, tank & pumps, De aerator tank, 1 No

5.3 Environmental Management Group

A separate environmental management group will be established to implement the

management plan. The group will be headed by a Superintending Engineer. The group will

ensure the suitability, adequacy and effectiveness of the Environment Management Program.

The management review process will ensure that the necessary information is collected to

allow management to carry out its evaluation. This review will be documented. Functions of

Environmental Management Group (EMG) at Site will be:-

Ø Obtaining consent order from State Pollution Control Board.

Ø Environmental monitoring.

Ø Analysis of environmental data, reports, preparations and transmission of report to

statutory authorities, Corporate Centre etc.



Ø Co-ordinate with statutory bodies, functional groups of the station, head office etc.

Ø Interactions for evolving and implementation of modification programs to improve

the availability / efficiency of pollution control devices / systems.

Ø Environmental Appraisal (Internal) and Environmental Audit.

* * * * *

Chapter– 6

Additional Studies

(Risk Assessment and Disaster Management Plan)

Risk Assessment

6.1 Introduction

The word 'disaster' is synonymous with 'emergency' as defined by the Ministry of

Environment and Forests (MoEF). An emergency occurring in the proposed Enhancement

plant is one that may affect several sections within it and/ or may cause serious injuries, loss

of lives, extensive damage to environment or property or serious disruption outside the plant.

It will require the best use of internal resources and the use of outside resources to handle it



effectively. It may happen usually as the result of a malfunction of the normal operating

procedures. It is imperative to conduct risk analysis for all the projects where hazardous

materials, fuels are handled.

The following have been addressed as part of the risk analysis.

ü Introduction

ü Hazard Identification and Risk Analysis

ü Risk Reducing Measures

The Introduction deals with the objective and methodology of carrying out the risk analysis.

Hazard Identification and Risk Analysis discusses about the various types of hazards

associated with the operation of the Plant due to process, storage & handling, human errors,

electric failures and natural calamities. It also presents the calculated frequencies of

occurrence of different accident scenarios for the identified potential hazard occurrence in the

proposed plant and the details of consequence modelling/ analysis for the identified potential

accidents/disaster scenarios in the plant. Risk Reducing Measures based on the calculated

frequencies and consequences.

6.2 Objective

The principal objective of the study is to identify the potential hazards from the proposed

Enhancement Project and estimate the effects of the hazards to people and property within the

plant premises. The consequences resulting due to accidental release of toxic & flammable

liquids and leakage of fuels will provide data for developing strategies to prevent accidents

right from design to operational phase. This will also generate information for formulating a

meaningful Disaster Management Plan (DMP). A risk analysis is defined as an assessment of

the likelihood of a release of HAZMAT (hazardous materials) and the consequences that may

result, based on information gathered during the hazard identification and vulnerability

analyses. Risk analysis requires evaluation of existing base and local community plans,

response capabilities, and previous incidents. In order to determine the risk factor at each

facility on the base, the following information was evaluated:-

v Procedures for storing, handling, shipping, and transferring of HAZMAT;

v Facility information including: physical features and location of storm and sanitary

sewer systems;



v Site measures for managing and controlling HAZMAT releases; and,

v Base emergency response and preparedness programs.

6.3 Methodology

The Risk Analysis Study carried out under the following task heads:-

v System Study

The system description covers the plant description, storage & handling of fuels /

chemicals, etc.

v Hazard Identification

The hazards associated with the proposed Enhancement Project have been discussed

in terms of material hazards due to fuel storage.

v Frequency of Hazard Occurrence

Based on the available international statistics and in-house risk database, the

frequencies of occurrence for the different accident scenarios were determined. The

frequencies derived from the historical database have been checked with the possible

hazard scenario identified during hazard identification.

v Consequence Analysis

Based on the identified hazards, accident scenarios and the frequency of occurrence,

consequence calculations were done for spreading distances (zone of influence) or

risk distance for Pool fires.

v Risk Reducing Measures

Necessary risk reducing measures have been suggested based on the consequence

scenarios.

6.4 Hazard Identification and Risk Analysis (HIRA)

The main hazard potentials in the Proposed Plant are categorized as below:-

· Material hazards; Diesel Oil as an auxiliary fuel to start-up and flame stabilization

of the boiler.

· Process hazards due to loss of containment during handling of hazardous materials

or processes resulting in fire, explosion, etc.

· Mechanical hazards due to "mechanical" operations such as welding, maintenance,

falling objects etc. - basically those NOT connected to hazardous materials.



· Electrical hazards: electrocution, high voltage levels, short circuit, etc.

Out of these, the material and process hazards are the one with a much wider damage

potential as compared to the mechanical and electrical hazards, which are by and large

limited to very small local pockets.

6.4.1 Material Hazards

Diesel Oil is used as an auxiliary fuel, which is inflammable.

6.4.2 Process Hazards

No process hazards are assessed.

6.4.3 Hazard Intensity Classification

The hazard intensities of the chemicals that are to be handled in the proposed Enhancement

plant (as per NFPA codes) are presented below.

Table -6.1 Hazard Intensity Classification



Remedial measures:

ü Storage in tightly closed containers in a cool, well-ventilated area away from

WATER, HEAT, COMBUSTIBLES (such as WOOD, PAPER and OIL) and LIGHT.

ü Storage away from incompatible materials such as flammable materials, oxidizing

materials, reducing materials, strong bases.

ü Use of corrosion-resistant structural materials and lighting and ventilation systems in

the storage area.

ü Wood and other organic/combustible materials will not be used on floors, structural

materials and ventilation systems in the storage area.

ü Use of airtight containers, kept well sealed, securely labelled and protected from

damage

ü Use of suitable, approved storage cabinets, tanks, rooms and buildings.

ü Suitable storage will include glass bottles and containers.



ü Storage tanks will be above ground and surrounded with dikes capable of holding

entire contents.

ü Limit quantity of material in storage. Restrict access to storage area.

ü Post warning signs when appropriate. Keep storage area separate from populated

work areas. Inspect periodically for deficiencies such as damage or leaks.

ü Have appropriate fire extinguishers available in and near the storage area.

The following measures are adopted for reducing the risk involved in pipeline systems.

Preventive Maintenance:

Routine inspection and preventive maintenance of equipment / facilities at the unit.

Instruments:

All the instruments like pressure, temperature transmitters/gauges and alarms switches and

safety interlocks will be tested for their intended application as per the preventive

maintenance schedule. Similarly, the emergency shutdown system will be tested as per the

preventive maintenance schedule.

6.6 Risk Mitigation Measures

The materials handled at the proposed installation are non-inflammable and non-reactive

substances and based on the consequence analysis; the following measures are adopted as

risk mitigation measures.

Ø The storage area, process area as well as road tankers loading/unloading areas where

there is maximum possibility of presence of flammable hydrocarbons such as diesel in

small quantities, it will be ensured that combustible materials are not placed here such

as oil filled cloth, wooden supports, oil buckets etc. to reduce the probability of

secondary fires in case of release.

Ø Hydrocarbon, smoke and fire detectors will be suitably located and linked to fire

fighting system to reduce the response time and ensure safe dispersal of vapours

before ignition can occur.

Ø Emergency procedures will be well rehearsed and state of readiness will be achieved.

6.6.1 Possibilities, Nature and Effects of Emergency



Leaving aside earthquake, cyclone, flood, arson and sabotage, the possible emergencies that

can arise in the plant due to storage and handling of the above materials are:

Ø Explosion in boilers, turbo generators, and transformers.

Ø Accidental release of huge ash slurry

Ø Chlorine leakage in the water treatment plant

Ø Accidental fire due to some other reasons

6.7 Disaster Management Plan

This DMP has been designed based on the range, scales and effects of "Major Generic

Hazards" described in the Risk Assessment Report just mentioned and on their typical

behaviours predicted therein. The DMP addresses the range of thermal and mechanical

impacts of these major hazards so that potential harm to people onsite and off-site, plant and

environment can be reduced to a practicable minimum. The scenarios of loss of containment

are credible worst cases to which this DMP is linked. The project is in its formative stage and

detail engineering is yet to be done, so the elements of the DMP are based on concepts.

6.7.1 Capabilities of DMP

The emergency plan envisaged will be designed to intercept full range of hazards specific 'to

Cogeneration power plant such as fire, explosion, major spill etc. In particular, the DMP will

be designed and conducted to mitigate those losses of containment situations, which have

potentials to escalate into major perils. Another measure of the DMP's capability will be to

combat small and large fire due to ignition of flammable materials, either from storage or

from process streams and evacuate people from the affected areas speedily to safe locations

to prevent irreversible injury. Emergency medical aid to those who might be affected by

incident heat radiation flux, shock wave overpressures and toxic exposure will be inherent in

the basic capabilities. The most important capability of this DMP will be the required speed

of response to intercept a developing emergency in good time so that disasters such as

explosion, major fire etc. are never allowed to happen.

6.7.2 Disaster Control Philosophy



The emergency control philosophy of the plant is in line with its normal operational controls.

The emergency control room will be the plant's Central Control Room, which will employ

Distributed Control System (DCS). All emergency operations, which may involve shutdown

of the plant, will be controlled from the Central Control Room by the same operator(s) using

dedicated "Shut-Down Consoles". The consoles will send commands to initiate the shutdown

procedure. Plant shutdown system will be performed by DCS.

The principal strategy of DMP of the plant is "Prevention" of identified major hazards. The

"Identification" of the hazards will employ one or more of the techniques [e.g. Hazard and

Operability Study (HAZOP), accident consequence analysis etc.]. Since these hazards can

occur only in the event of loss of containment one of the key objectives of technology

selection, project engineering, construction, commissioning and operation is "Total and

Consistent Quality Assurance". The Project Authority will

be committed to this strategy right from the conceptual stage of the plant so that the objective

of prevention can have ample opportunities to mature and be realized in practice The DMP or

Emergency Preparedness Plan (EPP) will consist of:-

v On-site Emergency Plan

v Off-site Emergency Plan

Disaster Management Plan preparation under the headlines of On-site Emergency Plan and

Off-site Emergency Plan is in consonance with the guidelines laid by the Ministry of

Environment and Forests (MOEF), Govt of India. "Occupier" of the facility is responsible for

the development of the On-site Emergency Plan as per the guidelines given by the

Government; The Off-site Emergency Plan will be developed by the Government (District

Authorities).

6.8 On-Site Emergency Plan

6.8.1 Objectives

The objective of the On-site Emergency Plan should be to make maximum use of the

combined resources of the plant and the outside service to

ü To locate the emergency and if possible eliminate the same.

ü To minimize the effects of accidents on people ,property and environment.



ü To command,coordination & response organization structure along with efficient

trained personnel.

ü The availability of resource for handeling emergencies.

ü Appropriate emergency response action.

ü Regular review and updating of emergency plan.

ü Proper training of the concerned personnel.

6.8.2 Action Plans

The Action Plan consists of:

ü Identification of Key Personnel

ü Defining responsibilities of Key Personnel

ü Designating Emergency Control Centres and Assembly Points

ü Declaration of Emergency

ü Sending All Clear Signal

ü Defining action’s to be taken by non-key personnel during emergency

6.8.3 Key Personnel

The actions necessary in an emergency will clearly depend upon the surrounding

circumstances. Nevertheless, it is imperative that the required actions are initiated and

directed by nominated people, each having specified responsibilities as part of co-ordinated

plan. Such nominated personnel are known as Key Personnel. The Key Personnel are:-

ü Site Controller (SC)

ü Incidental Controller (IC)

ü Liaison and Communication Officer (LCO)

ü Fire and Security Officer (FSO)

ü Team Leaders (TL)

Site Controller (SC)

In the emergency situation, decisions have to be taken which may affect the whole or a

substantial part of the plant and even places outside. Many of these decisions will be taken in

collaboration with the other officers at the plant and the staff. It is essential that the authority

to make decision be invested in one individual. In this plan, he is referred to as the 'Site

Controller'. The Plant Manager (however called) or his nominated deputy will assume

responsibility as SC.



Incident Controller (IC)

In the emergency situation, someone has to direct the operations in the plant area and co-

ordinate the actions of outside emergency services at the scene of incident. The one who will

shoulder this responsibility is known as 'Incident Controller' in this plan. A Senior Operations

Officer or an officer of similar rank of the unit may be nominated to act as the IC.

Liaison and Communication Officer (LCO)

Operations Officer or any other officer of deputy rank will work as LCO and will be stationed

at the main entrance during emergency to handle Police, Press and other enquiries. He will

maintain communication with the IC.

Fire and Safety officer (FSO)

The Fire and Safety Officer will be responsible for fire fighting. On hearing the fire alarm he

shall contact the fire station immediately and advise the security staff in the plant and cancel

the alarm. He will also announce on PAS (public Address System) or convey through

telephones or messengers to the SC, IC and LCO about the incident zone. He will open the

gates nearest to the incident and stand by to direct the emergency services. He will also be

responsible for isolation of equipment from the affected zone.

Team Leaders (TL)

A number of special activities may have to be carried out by specified personnel to control as

well as minimize the damage and loss. For this purpose designated teams would be available.

Each team will be headed by a Team Leader (TL). Following teams are suggested:

· Repair Team

· Fire Fighting Team

· Communication Team

· Security Team

· Safety Team

· Medical Team

6.8.4 Responsibilities of Key Personnel



Site Controller (SC)

v On getting information about emergency, proceed to Main Control Centre

v Call in outside emergency services

v Take control of areas outside the plant, which are affected

v Maintain continuous communication, review situation and assess possible course of

events

v Direct evacuation of nearby settlements, if necessary

v Ensure that casualties are getting enough help

v Arrange for additional medical help and inform relatives

v Liaison with Fire and Police Services and Provide advice on possible effects on

outside areas

v Arrange for chronological recording of the emergency

v Where emergency is prolonged, arrange for relieving personnel, their catering needs

etc.

v Inform higher officials in head office

v Ensure preservation of evidence

v Direct rehabilitation work on termination of emergency

Incident Controller (IC)

v On getting emergency information, proceed to Main Control Centre

v Activate emergency procedure such as calling in various teams

v Direct all operations within plant with following priorities:

a) Control and contain emergency

b) Secure safety of personnel

c) Minimise damage to plant, property and the environment

d) Minimise loss of material

v Direct rescue and repair activities

v Guide fire-fighting teams

v Arrange to search affected area and rescue trapped persons

v Arrange to evacuate non-essential personnel to safe area/assembly point

v Set up communications network and establish communication with SC

v Arrange for additional help/equipment to key personnel of various teams

v Consider need for preserving all records, information for subsequent enquiries



Liaison and Communications Officer

Ø To ensure that casualties receive adequate attention, arrange additional help if

required and inform relatives

Ø To control traffic movements into the plant and ensure that alternative transport is

available when need arises

Ø When emergency is prolonged, arrange for the relief of personnel and organize

refreshments/catering facility

Ø Advise the Site Controller of the situation, recommending (if necessary) evacuation of

staff from assembly points

Ø Recruit suitable staff to act as runners between the Incident Controller and himself if

the telephone and other system of communication fail. -Maintain contact with

congregation points

Ø Maintain prior agreed inventory in the Control Room

Ø Maintain a log of the incident on tape

Ø In case of a prolonged emergency involving risk to outside areas by windblown

materials - contact local meteorological office to receive early notification of changes

in weather conditions

Fire and Safety Officer

v Announce over the PAS in which zone the incident has occurred and on the advice of

the Shift Officer informs the staff to evacuate the assembly

v Inform the Shift Officer In-charge, if there is any large escape of fumes.

v Call out in the following order:

1. Incident Controller or his nominated deputy

2. Maintenance Officer

3. Personnel and Administrative Officer

4. Departmental Head in whose area the incident occurred

5. Team Leaders (TL)

6.8.5 Responsibilities of Teams

1. Repair Team



They will identify source of leak and arrest it, take steps to keep rest of the plant in safe

condition, arrange safe shutdown of operations if necessary, attend to all repair jobs which

are needed from emergency point of view, take steps to contain or reduce the intensity of

emergency, arrange for additional equipment and give temporary connections as needed.

2. Fire Fighting Team

They will rush to the incident spot and start fighting the fire, maintain adequate water

pressure in the fire hydrant system, arrange first aid fire extinguishers where needed and

guide and direct outside fire fighting agencies.

3. Communication Team

They will maintain the communication network inside the terminal, attend urgent repairs in

the communication system, and arrange messengers for conveying urgent messages when

needed so, help SC, IC, LCO and FSO in their communication activities.

4. Security Team

They will man all gates, with minimum delay permit the entry of authorized personnel and

outside agencies, vehicles etc. who have come to help, bar entry of unauthorized persons,

allow the ambulance etc. to go through the gates without normal checks.

5. Safety Team

They will rescue the casualties on priority basis, transport casualties to first aid post, safe

places, or medical centres, account the personnel, search for missing

personnel and pass information to the kith and kin of fatal or serious casualties, arrange

required safety equipment, report of status to their leader, record of accidents, collect and

preserve evidences in connection with accident cases, arrange for transport of casualties,

arrange for transport of materials, attend to vehicle breakdowns, arrange petrol and diesel

supply and withdraw and transport materials from stores.

6. Medical Team

They will arrange for first aid, arrange for stretchers, arrange for immediate medical

attention, arrange for sending the casualties to various hospitals and nursing homes and

arrange for medicines.



6.8.6 Emergency Control Centre

The Emergency Control Centre will be the focal point in case of an emergency from where

the operations to handle the emergency are directed and co-ordinated. It will control site

activities. Emergency management measures in this case will be carried out from single

control Centre designated as Main Control Centre (MCC) MCC is the place from which

messages to outside agencies will be sent and mutual aids and other helps for the

management of emergency will be arranged. It will be located in the safe area. It will be

equipped with every facility for external and internal communication, with relevant data,

personal protective equipment to assist hose manning the centre to enable them to co-ordinate

emergency control activities. CC will be attended by SC.

Proposed Location:-

Office of the DGM (Maintenance) located in Administrative Building.

Following facilities would be available in the MCC:-

Ø P&T phones, mobile phones, intercoms, and wireless

Ø Fax and telex

Ø Emergency manuals

Ø Blown up area maps

Ø Internal telephone directories

Ø District telephone directories

Ø Emergency lights

Ø Wind direction and speed indicator

Ø Requisite sets of personal protective equipment such as gloves, gumboots and aprons

Ø MCC will be furnished with call out

MCC will be furnished with call out list of key persons, fire, safety, first aid, medical,

security, police and district administrative authorities. MCC will also contain safety data

pertaining to all hazardous materials likely to cause emergency and well-defined procedures

of fire fighting, rescue operations, first aid etc.

6.8.7 Assembly Point

In an emergency, it will certainly be necessary to evacuate personnel from affected areas and

as precautionary measure, to further evacuate non-essential workers, in the first instance,



from areas likely to be affected, should the emergency escalate. The evacuation will be

effected on getting necessary message from i.e. On evacuation; employees would be directed

to a predetermined safe place called Assembly Point. Proposed Location: Area opposite to

service building will be the Assembly Point where all non-key personnel would assemble on

getting direction over Public-Address System. Outdoor assembly points, predetermined and

premarked, will also be provided to accommodate evacuees from affected plant area(s). Roll

call of personnel collected at these assembly points, indoor and outdoor will be carried out by

roll call crew of safety team to account for any missing person(s) and to initiate search and

rescue operations if necessary.

6.8.8 Declaration of Emergency

An emergency may arise in the terminal due to major leakage of oil or major outbreak of fire.

In case of major leak or major outbreak of fire the state of emergency has to be declared by

the concerned by sounding Emergency Siren. Upon manual or sensor detection of a major

loss of containment of volatile hazardous substance, the DMP is activated by raising an

audible and visual alarm through a network of geographically dispersed gas/vapour and heat

detectors and also "break glass" type fire alarm call points with telephone handsets to inform

the Central Control Room.

A separate siren audible to a distance of 5 km range will be available for this purpose. The

alarm is coded such that the nature of emergency can be distinguished as a leakage or major

fire. The Control Centre and Assembly point have been located at an area of the minimum

risk or vulnerability in the premises concerned, taking into account the wind direction, areas

which might be affected by fire/explosion, leakage etc. After cessation of emergency, FSO

will communicate to IC. After verification of status, IC will communicate with SC and then

announce the "All Clear" by instructing the Time Office to sound the "All Clear Signal".

Alarms would be followed by an announcement over Public Address System (PAS). In case

of failure of alarm system, communication would be' by telephone operator who will make

announcement in the complex through PAS. Walkie-talkie system is very useful for

communication during emergency with predetermined codes of communication. If everything

fails, a messenger could be used for sending the information. Two 5 km, range variable pitch

electric sirens (one in service and the other standby) will generate the main alarm for the

entire site as well as for the district fire brigade. The alarm is coded such that the nature of



emergency can be distinguished as a leakage or major fire. Fire and Gas alarm matrices are

provided at the Central Control room, security gate, on-site fire station and main

administrative office corridor to indicate location of the site of emergency and its nature.

6.8.9 Mutual Aid

Procedure All factories may not be equipped with an exhaustive stock of

equipment/materials required during an emergency. Further, there may be a need to augment

supplies if an emergency is prolonged. It would be ideal to pool all resources available in the

and nearby outside agencies especially factories during an emergency, for which a formal

Mutual Aid scheme should be made among industries in the region.

6.8.10 Essential Elements

Essential elements of this scheme are given below:-

ü Mutual aid must be a written document, signed by Location In-charge of all the

industries concerned

ü It should specify available quantity of materials/ equipment that can be spared (not

that which is in stock)

ü Mode of requisition during an emergency.

ü It should authorize the shift-in-charge to quickly deploy available material/equipment

without waiting for formalities like gate pass etc.

ü It should spell out mode of payment/replacement of material given during an

emergency

ü It should specify key personnel who are authorized to requisition materials from other

industries or who can send materials to other industries

ü It should state clearly mode of receipt of materials at the affected unit without waiting

for quantity/quality verification etc.

ü Revision number and validity of agreement should be mentioned

ü This may be updated from time to time based on experience gained

6.8.11 Emergency Management Training



The Key Personnel would undergo special courses on disaster management. This may

preferably be in-plant training. The Managers, Senior Officers and Staff would undergo a

course on the use of personal protective equipment. The Key Personnel belonging to various

Teams would undergo special courses as per their expected nature of work at the time of

emergency. The plant management should conduct special courses to outside agencies like

district fire services to make them familiar with the plant layout and other aspects, which will

be helpful to them during an emergency.

6.8.12 Mock Drills

It is imperative that the procedures laid in this Plan are put to the test by conducting Mock

Drills. To avoid any lethality, the emergency response time would be clocked below 2

minutes during the mock drill.

1st Step: Test the effectiveness of communication system

2nd Step: Test the speed of mobilisation of the plant emergency teams

3rd Step: Test the effectiveness of search, rescue and treatment of casualties

4th Step: Test emergency isolation and shut down and remedial measures taken on the

system

5th Step: Conduct a full rehearsal of all the actions to be taken during an emergency

The Disaster Management Plan would be periodically revised based on experiences gained

from the mock drills.

6.9 Proposed Communication System

The instrument and control system will take care of the following operating philosophy of the

plant:

ü The project will be provided with a control system located in a central control room.

ü The shift engineer will operate the plant from his console panel.

ü All operations will be represented in a graphic panel on the console and every

operation will be depicted as operating sequences.

ü All operating parameters will be displayed in digital format.

ü Alarms will be provided for all parameters, when they exceed set values.

ü High-High/Low-Low alarms and trip functions will be provided to trip

ü Pumps/compressors to bring the entire system to a safe shutdown.



6.10 Proposed Fire Fighting System

Elaborate fire fighting system will be available for fighting fires in any comer of the plant. A

comprehensive fire detection and protection system is envisaged for the complete power

station.

ü Fire water storage tanks of adequate capacity.

ü Fire water pump house containing combination of diesel and electrically driven

pumps.

ü Hydrant system complete with suitable size piping, valves, instrumentation, hoses,

nozzles, hose boxes/stations, monitors etc.

ü Foam injection system for fuel oil/storage tanks consisting of foam concentrate tanks,

foam pumps, in-line inductors, valves, piping and instrumentation etc.

ü Automatic high velocity water spray system consisting of detectors, deluge valves

projectors, valves, piping and instrumentation.

ü Automatic medium velocity water spray system consisting of QB

ü Detectors/smoke detectors, linear heat sensing cable detectors, deluge valves,

isolation valves, nozzles, piping, instrumentation etc.

ü Suitable "Halon Substitutes" such as INERGEN or FM: 200 or AGGONITE for

protection of control room, equipment room, computer room and other electric and

electronic equipment rooms.

ü Computerized analogue, addressable, early warning type fire detection and alarm

system consisting various types of fire detection such as ionisation type smoke

detection system, photo electric type smoke detection system, linear heat sensing

cable detector, quartzoid bulb (QB) heat detection system, infrared heat detectors and

spot type electrical heat detectors.

ü Portable and mobile extinguishers, such as pressurized water type, carbon dioxide

type, foam type, dry chemical powder (DCP) type located at strategic locations

throughout the plant.

ü Fire tenders/engines of water type, DCP type/foam type, trailer pump with fire jeep

etc. provided in the fire station.

ü Complete instrumentation and control system for the entire fire detection and

protection system for safe operation of the complete system.



6.11 Other safety Measures

Considering that fire and explosion is the most likely hazard in such installations, the plant is

being provided with systems to guard against such hazards. Salient among these are:-

Ø A proper layout to prevent and minimize the effects of any hazardous situation

Ø Design of storage vessels and all components to codes and standards to withstand the

rigorous duty

Ø Provision of operating systems to conduct the process through well-established safe

operating procedures

Ø A control system, which monitors all plant parameters and give alarms

Ø Control system, which has trip provisions to prevent hazard conditions escalating

Ø A gas detection system which will provide early warning of any leaks

Ø Provision of a fire protection system to control fire

Ø Provision of flame-proof lighting system in the fire prone areas

6.12 Proposed First Aid And medical Facilities

The First Aid Medical Centre has been proposed. It will be fully equipped with emergency

facilities. It will be open round the clock. A Medical Officer with Compounder will always

be available in the centre. Emergency cars will be available in all the shifts. Adequate number

of first aid boxes will be kept at strategic locations. Required stock of first aid medicines will

be maintained. Trained first aiders will be available in all departments. Facilities to be kept in

the Medical Room along with others will include: Oxygen Cylinders, Injection Corarnine,

Glucose Saline, LV. Sets, Syringes, Injection Needles, Stretchers and medicines.

6.13 Proposed Emergency Power Supply

Strategic areas will be provided with emergency lights fed through station battery system.

Portable emergency lamps will be also available at required points. A Diesel Driven

Generator of adequate capacity will be available to keep the operations running in case of

power failure. Diesel Engine operated fire pumps will be available.



6.14 Off Site Emergency Plan Objective

If the effects of the accident or disaster inside the plant are felt outside its premises, it calls

for an off-site emergency plan, which should be prepared and documented in advance in

consultation with the District Authorities.

Key Personnel

The ultimate responsibility for the management of the off-site emergencies rests on the

Collector / District Magistrate / Deputy Commissioner. He will be assisted by representatives

from all concerned organisations, departments and services at the District level. This core

group of officers would be called the District Crisis Management Group (CMG). The

members of the group will include:

v Collector/District Magistrate Deputy Commissioner

v Commissioner of Police

v Municipal Commissioner, if municipalities are involved

v Deputy Director, Health

v Pollution Control Board Representative

An Operation Response Group (ORG) will then have to be constituted to implement the

directives of the CMG. The various government departments, some or all of which will be

concerned, depending on the nature of the emergency, could include:

Ø Police

Ø Health & Family Welfare

Ø Medical

Ø Revenue

Ø Fire Service

Ø Transport

Ø Electricity

Ø Animal Husbandry

Ø Agriculture

Ø Civil Defence

Ø PWD

Ø Civil Supplies

Ø Panchayats



The SC and IC, of the on-site emergency team, will also be responsible for communications

with the CMG during the off-site emergency.

Education to Public

People living within the influence zone should be educated on the emergency in a suitable

manner. This can be achieved only through the Local and District Authorities. However, the

Project Authority will extend necessary information to the Authorities.

* * * * *



CHAPTER – 7

Project Benefits

7.0 Benefits

Any industrial activity helps in improving the social status of the locality. The

proposedexpansion project will result in improvement of infrastructure and social structure in

the studyarea that will lead to sustainable development. The community that inhabit in the

nearbyareas will be benefited directly or indirectly by this project. Following benefits due to

theproposed expansion project are as follows

7.1 Improvement in Physical Infrastructure

· The industry shall construct tar roads for easy access to the workers. It will also help

in transportation of raw materials and products from the industry. This will

improvethe transportation facilities and road connectivity in the area.

· The industry shall adopt the rain water harvesting systems that will improve the

ground water table. As no any groundwater is utilized for the proposed project it

willbe indeed useful to the surrounding farmers in their fields.

· Plantation of trees in the industrial area and its surrounding shall help in improving

the aesthetic beauty of the surrounding environment giving a pleasant look and

improvising the air quality. Also green belt will help in arresting dust emissions

aswell as noise. Treated wastewater will be used for the growth of the plants.

7.2 Improvement in Social Infrastructure

· Upliftment of the sector: Due to the presence of the industry there is availability of

various amenities and facilities viz. various shops, banking facilities and Post Office.

This will help in boosting the standard of the area and the living.

· The people residing in the nearby areas will be benefited by the educational facility

that will help in enhancing the literacy rate and safety in that area.

· The industry shall organize various campaigns regarding the medical and health

checkup for the workers/labours and also for the local people. This will help improve

good sanitation practice as well as health awareness among the people. Ambulance

service will be made available for everyone.



· Due to expansion, the frequency of the local transportation will increase in this area.

This will help shorten the time reaching destination and utilize it for some fruitful

productive work.

· BSSKL will undertake implementation of amenities like street lights, school

infrastructure, community sanitation & waste management in command area.

· BSSKL will increase the yield in its command area up to 80-90 MT/ha by availing the

agricultural loan advances from local banks for drip irrigation, seed cane, fertilizers,

etc. whereby the factory will identify the beneficiary farmers and will also issue

suitable guarantees for recovery of bank loans.

· BSSKL will develop its own nursery which can be used for growing newer and better

varieties of cane and the seeds of these newer varieties can be provided to the farmers

to assure continuous and assured supply of cane from them.

· BSSKL will increase the ratoon yields by adopting proper ratoon management

practices and by providing chemical fertilizers, bio-fertilizers and micronutrients to

farmers on subsidized rate.

· BSSKL will provide free soil testing facility to its farmers for efficient use of

chemical fertilizers through its own testing laboratory.

· BSSKL will provide various training programs with help of VSI Sugar

ResearchInstitute to motivate cane farmers to adopt modern sugar cane cultivation

methods.

7.3 Employment potential- Skilled, Semi- skilled and Unskilled:

In any industrial activity all three types i.e. skilled, semi-skilled and unskilled people

are required. Preference is given for employment to local people based on qualification and

requirement. The existing sugar factory has provided Direct & Indirect Employment to local

people. When the production of sugar, alcohol and power manufacturing becomes stable

expansion may become possible further and then employment availability may further

enhance. Hence, it can be stated that by this activity employment potential is certainly

increasing in all walks of life - skilled, semi-skilled and unskilled.

7.4 Other Tangible Benefits



After execution of the project the above mentioned benefits shall accrue. Apart from

this other tangible benefits are mentioned below

· After establishment of the industry, the industry will meet the national interest of

economical growth through sustainable development, as sugar and alcohol has been a

great source of revenue through excise duty levied by the Government.

· First Aid Training and fire safety training will be given to all the workers.

· Insurance Policies for the workers will be made available.

· Improvement in the aesthetic through green belt development.

· The ground water recharging shall be done by arresting rain water.

* * * * *



Chapter – 8

Environmental Management Plan

8.0 Introduction

Environment Management Plan is required for ensuring sustainable development. It

should not affect the surrounding environment adversely. The management plan presented in

this chapter needs to be implemented by the proposed expansion of sugar and co-gen unit.

The Environment Management Plan aims at controlling pollution at source with

available and affordable technology followed by treatment measures. Waste minimization

and waste recycling measures are emphasized. In addition to the Industry specific control

measures, the proposed industry should adopt following guidelines.

They are:

• Application of Low and Non Waste Technology in the production process;

• Adoption of reuse and recycling technologies to reduce generation of wastes

and to optimize the production cost of the industry.

The recycling and reuse of industrial waste not only reduces the waste generation but

also can be an economic gain to the industry.

Further, the management of the BSSKL will take all the necessary steps to control and

mitigate the environmental pollution in the designing stage of the project. While

implementing the project the management will follow guidelines issued by CPCB.

The EMP is prepared based on the existing environmental status of the project

location and the anticipated impacts of the project activities on environment.

8.1 Environmental Management Plan during Construction Phase

8.1.1 Air Environment

The setting up of enhanced project from 2500 to 5000 TCD of Sugar Plant and 25 MW of

Cogeneration power plant would result in increase of dust concentrations due to fugitive dust.

Frequent water sprinkling in the vicinity of the construction sites would be undertaken and

will be continued after the completion of plant construction, as there is scope for heavy truck

mobility. It will be ensured that both petrol and diesel powered vehicles are properly

maintained to comply with exhaust emission requirements.



8.1.2 Noise Environment There will be marginal increase in noise levels during construction

phase, which is temporary and intermittent.

8.1.3 Water Environment

During construction, provision for infra-structural services including water supply, sewage,

drainage facilities and electrification will be made.

8.1.4 Land Environment

Any hazardous material required for constructional activity will be stored as per safety

norms. Further construction site will be provided with suitable toilet and treatment facilities

etc for maintaining hygienic conditions.

8.1.5 Socio-economic Environment

Any construction activity will benefit the local population in a number of ways. The company

management will give preference to local eligible people through both direct and indirect

employment. It will provide ample opportunity to the locals to up-lift their living standards

by organizing events that propagate mutual benefits to all, such as health camps, awareness

campaigns, donations to poorer sections of society and down-trodden.

8.1.6 Safety and Health

Adequate space will be provided for construction of temporary sheds for construction

workers mobilized by the contractors. M/s BSSKL will take care of supply of potable water

for the construction workers. The safety department will supervise the safe working of the

contractor and their employees. Work spots will be maintained clean, provided with optimum

lighting and enough ventilation to eliminate dust/fumes. A comprehensive Occupational

Health and Safety management plan is put in place to address any sort of eventuality.

8.2 Environmental Management Plan during Operations Phase

8.2.1 Air Environment

The major pollutants emerged due to Sugar Plant and Cogeneration Plant operations are

suspended particulate matter (SPM), fine particulate matter (PM10& PM2.5), Sulphur

dioxide (SO2) and Oxides of Nitrogen (NOx).



Ø All sources of dust generation in the Sugar Plant with Cogeneration Plant shall be

well designed for producing minimum dust and shall be provided with high efficiency

Bag filters and Wet Scrubber.

Ø Particulate Matter emission level from the stack chimney will be less than 50

mg/Nm3 and the stack height is 30m, 30m, 35m

Ø SO2 concentration will be negligible as the bagasse will be used as fuel for boiler.

Ø The periodic evaluation for the efficiency performance of Wet Scrubber will be

carried out.

Ø For controlling fugitive dust, in hopper, reclaimer, conveyors, silos etc. bag filters

shall be installed.

Ø Fugitive emissions due to storage, transportation, etc. and the leakages and spillages

shall be continuously monitored and controlled.

Ø Water conservation measures shall be undertaken for effective implementation.

Cooling water is put into closed circuit to minimize the evaporation losses.

Ø Thermal insulation will be provided wherever necessary to minimize heat radiation

from the equipment, piping etc., to ensure protection of personnel.

8.2.2 Noise Environment

ü All rotating items are well lubricated and provided with enclosures as far as possible

to reduce noise.

ü The design features of machineries shall be provided to ensure low noise levels in the

working areas.

ü Extensive vibration monitoring system will be provided to check and reduce

vibrations. Allfans, compressors etc., are provided with vibration isolators to reduce

vibration and noise.

ü Noise generating equipment including fans, blowers, pumps, motors etc.,will be

running with speed less than 1500 rpm and reduce noise levels.

ü Provision for silencers wherever possible.

ü Green belt development will be done and it will act as noise reducers.

ü Requisite enclosures will also be provided on the working platform/areas to provide

local protection in high noise level areas.

ü All heavy earthmoving equipment will be kept in a well maintained condition.

ü Proper lubrication and house equipment will be kept in better condition

ü Necessary PPE will be provided such as ear plugs, ear muffs etc.



By these measures, it is anticipated that noise levels in the plant will be maintained within the

permissible limits at the boundary of the plant premises. Plantation on the periphery of the

plant would further attenuate noise levels.

8.2.3 Solid Waste Management

Dry fly ash and furnace bottom ash

The trouble with dust in work zone and ambient atmospheres shall be controlled by

certain dedicated measures. An action plan has been prepared in the industry that includes

following.

a. Installation of appropriate, adequate and efficient exhaust and ventilation system to

remove and control dust from work zone areas.

b. The efficiencies of dust control equipment in the industry such as ESP shall be

monitored regularly (at least once a month).

c. Dust collected from the APC equipment e.g. fly ash from co-gen boilers will be

properly handled and disposed off by supply to farmers for use as manure.

d. Inlet and outlet of pollution control equipment shall be provided with necessary

sampling arrangements as per guidelines of CPCB.

e. Air pollution control equipment would be interlocked with the process as per the

guidelines of CPCB.

f. Personal protective equipment such as masks, aprons, gloves, goggles etc. shall be

provided to the workers.

g. Implementation of green belt of adequate density and type shall be made to control

and attenuate dust transfer in the premises.

h. Provision of properly surfaced internal roads and work premises (tarred and concrete)

shall be made to curb dust generation and its suspension due to vehicular movement.

Sewage from various buildings in the plant

Sewage from various buildings in the plant area will be conveyed though separate drains to

the septic tank. The effluent from septic tank will be disposed in soil by providing disposing



trenches. There will be no ground pollution because of leaching due to this. Sludge will be

used as manure for green belt development.

8.2.4 Water and Wastewater Management

Continuous efforts would be made to reduce the water consumption and thereby to reduce the

wastewater generation. Flow meters would be installed for all major water inlet and the flow

rates would be continuously monitored. Periodic water audits would be conducted to explore

the possibilities for minimization of water consumption. Water will be drawn from Krishna

River to meet the plant consumptive water requirement. Considering the quality of water, the

Cycle of Concentration (COC) of the cooling tower is considered as 1.5.

Waste water Management

The treated water quantity will be used for dust suppression. Water Pollution control

measures to be undertaken are given as under:-

v No trade effluent shall be discharged from the Plants

v Cooling water is put into closed circuit to minimize the evaporation losses

v The domestic sewages from the Plants, Sugar Plant with Cogeneration Unit and

Township shall be treated in the Sewage Treatment Plant to meet the Statutory

scharge Norms and the treated sewage shall be used for Green Belt;

v No percolation of treated water to deep ground water table is done.

v Periodical monitoring for specific parameters shall be done regularly.

v Rainwater harvesting structures shall also be developed as proposed from the roof

tops of Plants as well as Township areas to supplement the water supply from the

river.

Wastewater treatment

Waste water treatment for the plant will be based on discharges of the various effluents to

ponds for clarification and filtration. Oily water will be treated separately to remove

oil/grease before discharge into effluent ponds. The oily water collection in the plant is

basically due to floor cleaning, leaky oil filters, etc. Clarification is used to settle out large

suspended particles and condition smaller colloidal particles to make them settle. A pond,



reservoir tank or tank is used to allow larger particles to settle in a matter of hours. The finer

particles overflow and are made to settle more quickly by the addition of chemical agents,

coagulants and polymers that cause agglomeration to sizes large enough to settle out of

suspension. As required and with approvals from appropriate regulating bodies, final waste

stream pH is controlled by combining various plant streams to provide a neutral pH product.

Where needed, acid or alkali addition will be used to achieve the final pH.

Final Disposal of the wastewater

The treated effluent from the effluent tank will be used for horticulture and green belt

development within the plant.

Monitoring of Wastewater Treatment

The treated effluent would be monitored regularly for the flow rate and quality to identify any

deviations in performance of Effluent treatment plant.

Thermal Pollution Management

A closed circuit cooling water system with cooling towers is present in the existing area. This

eliminates the letting out of high temperature water into the canals and prevents thermal

pollution. Blow down from the cooling tower will be trenched out and ultimately conveyed to

the effluent ponds. Hence, there is no separate pollution on account of blow down from

cooling water system.

8.4 Rain Water harvesting System

8.4.1 Rainwater Harvesting

Rains are the sources of all waters. It is an outcome of the thermal process between land mass

and oceanic part. This process is everlasting and therefore rains are bound to be available as

per long terms averages fixed, excess over averages and deficit too.

Rainwater stored across the terrain as surface water and across subsurface as groundwater. It

is reassuring to have rains in India of an average annual rainfall of 117 cm. But this rainwater

during heavy spells runs off.

Moreover, rains in India are seasonal. More than 80 percent of the annual rainfall occurs

during monsoon period of June to September. This rainfall occurs within a period of 30 to 60

days. Besides, these seasonal rains have variations. Some of the region is getting heavy rain



while some of the region is seen drought prone area. As well as the total rainfall in any region

varies from one year to another.

Hence to avoid the wastage of rainfall as run-off and to meet the scarcity of water,

management of rainwater is essential.

Scientific studies revealed that rainfall run-off, if managed carefully, it can result in higher

groundwater availability.

4.8.2 Rooftop Rainwater Harvesting

Large urban centers are the single largest users of freshwater for domestic purposes.

They also happen to be one of the prime factors contributing towards the freshwater crisis. In

urban areas, the surface run-off generated during storms gathers considerable amount of point

and diffused sources pollutants in the form of chemicals, organic and mineral matters and

microorganisms, impairing the quality of surface water bodies. Low water quality reduces the

availability of water resources for specific uses. Further, ill-planned and uncontrolled urban

sprawl leads to loss of catchment areas and permeable open surfaces, which serve as

groundwater recharge areas, affecting thereby the groundwater potential.

A majority of cities and towns in India face acute scarcity of water in terms of both

quantity and quality. Local governments often tackle water scarcity by identifying new and

deeper aquifers or supplying through tankers and pipelines brought from distant sources.

Such solutions are both unsustainable as well as expensive. Instead, rainwater of reasonable

quality can be collected using the roof top areas that can be stored to provide individual

building with adequate supplies in water scarce rural areas. Harvesting rainwater for human

use would be the most appropriate technology in areas that do not have adequate water

supply to serve the community with continuous and reliable service. Properly and maintained

roofs are the best choice as a collection surface, because their location protects the water from

pollution, which is typical in ground-level collection surfaces. With rooftop rainwater

collection, pollutants can be reduced by 80-90%. Rainwater from the roofs of buildings can

be easily collected also in cities and towns as well, and not just in rural areas. Thus, in large

cities and towns, it is possible to replace substantial portion of freshwater requirement by

harvesting rainwater.

A number of rooftop RWH systems have been developed and adopted in India and

abroad. In water-scarce regions more often than not, the harvested rainwater is stored and

used for domestic purposes, either directly or after preliminary treatment (such as screening).

However, costs of storage tanks often become a constraint for adopting this type of usage.



Plastic storage tanks are generally too expensive for countries, it has been reported that their

cost is 2 or 3 times that of brick or ferro-cement tanks of similar capacity. Another

disadvantage posed by plastic tanks is that they have a low proportion of their cost in the

form of local labour contribution, which may be an important feature of subsidized

propagation of RWH in rural areas.

In case of storage and domestic uses, a common question that arises in about the

quality of stored water. It has been reported that water could and is being stored cleanly for

months or years in RW tanks. Experimental verifications in India showed good quality water

even after 180 days of storage, as did in South Africa after 2 years. However, such long

storage time will require regular cleaning of RW tanks, roof surfaces and of maintaining

tanks dark and sealed.

Apart from the storage tanks, collection gutters, down pipes and filters constitute

about 20% of the cost of normal rooftop RWH systems. These components are often poorly

made or not maintained, and therefore constitute the main form of early system failure, in

countries like East Africa and Sri Lanka.

4.8.3 Issues

A number of issues may affect the widespread adoption of rooftop RWH systems in

India. These include:

A. Economics and Technology- research and design needs to improve the cost-

effectiveness of RWH, for example for:

• Economically optimizing the size of system components.

• Minimizing the quantity and/or quality of materials needed to create any given

volume of water storage.

• Developing new designs for tanks, guttering and catchments.

• Developing measuring instruments to assist RWH system management.

• Establishing the environmental and economic benefits of reducing extraction of

domestic water from distant point sources.

B. Water quality and Health: the impact of RWH on health such as:

• The likely causes of low RW quality (physical, chemical, biological) and

assessing its impact on health.

• Actual RW quality as a function of user behavior, system design and

environmental conditions.



• Devising new techniques for reducing turbidity and pathogens, and improving the

taste.

• Understanding the links between RWH and the prevalence of disease vectors like

mosquitoes and identifying cost-effective and sustainable vector control measures.

C. Water policies, Regulations and Attitudes:

That affect taking-up of RWH projects on wider scales, including:

• Current policies, priorities, rules and concern of key stakeholders.

• RWH popularization and dissemination techniques the optimal role of RWH

alongside other water supplies in different regions of the country.

4.5.4 Artificial Recharge (Ar) For Utilization Of Harvested Rainwater:

In tropical semi-arid country like India, one of the main issues of rainwater harvesting arises

as a result of rainfall patterns. India has short but intense rainy period followed by long dry

periods. Most of the annual rainfall occurs in four monsoon months. This will pose serious

constraints on the type of usage the rainwater can be put to. Constructing large local storage

facilities with adequate capacities for water supply to last throughout the year may cause both

space and financial constraints. Additionally, protecting the quality of harvested rainwater

during storage from extraneous contamination also will be an issue to be adequately taken

care of. In urban areas that already have substantial population covered by organized water

supply, people may not be motivated to install rainwater harvesting systems, firstly due to the

lack of space for constructing storage facilities; secondly, due to the financial requirements

involved; and lastly to avoid the hassles of operating and maintaining the rainwater utilization

systems.

Utilization of harvested rainwater for livestock and irrigation purposes will also involve

proper maintenance of collection area (micro basins) and piping/canal systems with

permanent vegetation cover to filter sediment and refuse. The storage reservoir should be

drained with the first rainfall to eliminate summer concentrations and should be kept clean

and weeded. All these require high level of user involvement with continuous efforts for the

upkeep of the system.

A cost-effective way of storing the harvested rainwater would be to use it to replenish the

groundwater adopting what are called artificial recharge (AR) methods. Groundwater

recharge, in general refers to natural replenishment of an aquifer by percolation of surface

run-off, stream flows, or melting snow into the ground. Rainwater harvesting and AR



promises to be a potential solution for effectively increasing the utilization of surface run-off

and hence, to augment the freshwater supplies in urban areas at lower costs. Artificial

recharge of rainwater will also help to qualitatively improve contaminated groundwater

aquifers by reducing the concentration of pollutants through dilution effects.

Artificial recharge is a process in which water is introduced into groundwater aquifers by

anthropogenic means. For decades now, AR has been adopted in many arid and semi-arid

countries, where the evaporation rate is high, and hence need for alternative water storage

methods to surface storage. Israel and the United States (Particularly California) have been

world leaders in large-scale AR operations. Other countries where AR is extensively adopted

are Australia, South Africa, Japan, Germany, Switzerland, Netherlands, Canada, Great

Britain and Jamaica. In Sweden, about 25% of the drinking water supply is obtained from

water storage underground using artificial recharge methods.

4.8.5 Simple Methods For Rain Water Harvesting System

Adoption of rooftop rainwater harvesting followed by its storage through artificial

recharge methods at building level could be a viable strategy to locally tackle the growing

water scarcity problem that is prevalent in most of the towns and cities of India. Artificial

groundwater recharge methods can be adopted in urban areas where;

• Groundwater level occurs at a depth of 5m or more.

• Permeable strata’s available at shallow or moderate depth

• Groundwater quality needs improvement

• There are possibilities of saline water intrusion in coastal areas and

• Evaporation rate from surface storage will be very high.

The AR techniques described in the previous section are more suitable for large scale RWH

projects with huge catchment area. They may also be appropriate for institutional campuses

with large rooftop as well as open surface area. Many simple and low cost AR techniques

have been developed and practiced to encourage adopting RWH practice. The methods

prescribed for adoption at building levels are mostly the simplified forms of the AR

techniques described earlier. These include:

1. Use of recharge trenches

2. Recharge the Ground water Dug Wells/Open Well

4.8.6 Recharge Trenches



Recharge trenches can be adopted when permeable soil strata is available at shallow

depths (less than 1.5m). These are trenches of shallow depths and adequate width. As in

recharge pits, the trenches also are filled with coarse gravel, pebbles and boulders. Recharge

trenches are constructed along the boundary walls of building, or across the landscape where

open space is available (fig. 1)

Fig. 4.1: Recharge Trenches

4.8.7 Calculations:

Average annual rain fall: 545.4 mms.

Total Built up Area of the karkhana: 36219.3 Sq. M

Roof Top: 36219.3 Sq. M



Maximum Intensity of Rain Fall: 37.85 mm/hr

The capacity of recharge tank will be calculated to retain runoff from

At least 15 min rainfall of peak intensity

For 15 Min it is 9.5 mm/ 15 min

The total run off is calculated using this intensity of rainfall.

= Total terrace area x Co. eff of Runoff x 15 min rainfall peak intensity

= 36219.3 x 0.8 x 9.5

= 27.52 Cu. m = 27526 lit

Recharge Trench –

A factor of loose density of the media ( Void Ratio) of the filler material varies with the

material used, commonly use are brickbat, pebbles and gravel, a void ratio of 0.5 is assumed

27.52 x 2= 55.04 cu.m say 55 Cu.m

Tank dimensions- length 5 m x wide 4 m x depth 1.5 m = 30 cu.m

4.8.8 Conclusion:

• Provide one recharge tank of dimension 4m (wide) X 1.5m (depth) X 5m (length).

• Total capacity of trench and tank after filter material is 30.0 M3.

• Cover the tank with plastic sheet min.12” below ground level to avoid chocking of

filter material with ground soil.

• Extent the plastic sheet minimum 1’ outside the tank width and length.

Recharge tanks or trenches are used to store rain water for percolation. The optimum

capacity of tanks or trenches is calculated from guidelines provided by center for science and

environment. Which are based on size of catchment intensity of rain fall and rate of recharge.

The capacity of the recharge trench can be designed to retain runoff from atleast 15

minutes rainfall of peak intensity. The peak rainfall for Pune city is 55 mm/hr. therefore for

15 minutes it is 13.75 mm/15 minutes. The total runoff is calculate using this intensity of

rainfall.

Runoff Calculation:

Total terrace area x co. off of runoff x 15 min rainfall peak intensity

= 12844 x 0.80 x 0.01375

= 141.28 cu. m

8.5 Housekeeping

Salient features of housekeeping will be adopted are as follows:-



v Mechanized cleaning of roads and floor area inside the plant premises by using road

sweeper and mobile vacuum cleaner on regular basis;

v Training on regular basis to all workers and staff about the importance of cleanliness;

v Careful garbage transportation to dumping site and disinfection of transport vehicles

body;

v Decorative plantation and gardening to improve aesthetics of the plant; and

v Construction of suitably designed drains all along the roads and boundary of the plant

premises.

8.6 Occupational Health & Safety

The following measures are taken up by the existing unit -

• As per the requirement of Factory Act, there is provision of Occupational Health

Center.There under, a qualified visiting doctor has been appointed.

• An ambulance is available all the time i.e. 24X7.

• Regular medical checkup of employees is carried out and records are maintained.

• Workmen Compensation Policy as well as Mediclaim Health Policy has been done for

all the workers (temporary and permanent) in the Industry and which is renewed

every year.

The following measures shall be taken after expansion activity -

• The existing Occupational Health Center services shall also be extended to workers

under expansion. The health center shall be well equipped with following equipments-

• The existing ambulance which is available all the time i.e. 24X7 will be used.

• Regular medical checkup of employees for additional workers under expansion shall

also be carried out and record shall be maintained.

• Workmen Compensation Policy as well as Mediclaim Health Policy shall also be

done for the workers under expansion (temporary and permanent) and shall be

renewed every year.

Following equipments are provided/ to be provided in Health Care Cen

Table – 8.1Health Care Facility Equipment

Sr. No. Instrument Use

1. Stethoscope Used to hear sounds from movements



within the body, like heart beats, intestinal

movement, breath sounds,etc.

2. Reflex testing hammer To test motor reflexs of the body

3. Sphygmomanometer (Blood

pressure meter)

To record the patient's blood pressure

4. A thin beam electric torch To see into the eye, body's natural orifices,

etc., and to test for pupillary light reflex,

etc.

5. A watch / stopwatch

Used in recording rates like heart rate,

respiratory rate, etc.; for certain tests of

hearing

6. A measuring tape For size measurements

7. A weighing machine To record the weight

8. Tuning forks To test for deafness and to categorize it

9. Kidney dish As a tray for instruments, gauze, tissue,

etc.

10. Thermometer To record the body temperature

11. Gas cylinders. Supply of oxygen, nitrous oxide, carbon

dioxide, etc.

12. Oxygen mask or tubes

Delivering gases up to the nostrils to assist

in oxygen intake or to administer

aerosolized or casings drugs

13.

Vaporizer To produce vapors

14. Instrument sterilizers

Used to sterilize instruments in absence of

an autoclave

15. Dressing drums Storage of gowns, cotton, linen, etc.

16. Syringe of different sizes and

needles

.

For injections and aspiration of blood or

fluid from the body

17. Otoscope To look into the external ear cavity



Ø All workers engaged in material handling system will be regularly examined for lung

diseases such as PFT (Pulmonary Function Test) tests;

8.7 Design of Green Belt

The Area Calculation for Green Belt Plan

Table No. 8.2 Area Details

Description Area

Total plot area (Sugar & Co-gen) 9,20000 Sq. M.

Built up area 36837 Sq. M.

Total Open space 883163 Sq. M.

For Detailed Area break up of industrial unit refer Table. No. 2.2 of Chapter 2.

Refer Appendix 4.1 for photographs of existing green belt.

8.7.1 Proposed Tree Plantation

A comprehensive 'Green Belt Development Programme' would be implemented in a

phase wise manner under the proposed project. Features of proposed green belt development

programme.

• Trees would be planted in the proposed project's premises along roads as well as

along the fence.

• A thick barrier of trees would be created along the entire periphery of the plot.

• Trees of commercial importance would be planted.

• In the immediate vicinity of ash storage sections /godowns, the trees tolerant to dust

would be planted.

• As per the recommendations by Central Pollution Control Board (CPCB) and

Ministry of Environment & Forests (MoEF), the green belt would cover more than 33

% of open land available with the industry. Based on the above assumption, the green

belt development plan has been designed.

The trees along periphery would be planted in the setback margin in three rows with a

distance between adjacent trees to the tune of 2 M c/c. Moreover, plantation along the

internal roads would be done in single row on either side ofthe road. Here also the distance

between adjacent trees is considered as 2 M c/c, and area covered by a single tree is taken as

4 Sq.M.

8.7.2 The Criteria for Green Belt Development Plan



Emission of SPM, S02 is the main criteria for consideration of green belt development. The green belt development is provided to abate effects of the emissions of SPM & S02.Moreover, there would also be control on noise from the industry to surrounding localities as considerable attenuation would occur due to the barrier of trees in proposed green belt. From a glance at Table 4.9, it could be seen that the green belt under unit of "BSSKL", would cover an area of 27,207 M2. Further about 6802 trees would be planted under green belt development plan in a phase wise manner. The species of trees that would be planted under the proposed Green Belt Development Plan, based on SPM, S02 and Noise consideration, are as follows-

Sr. No. Vernacular name

01. Silver Oak 02. Bottle Palm 03. Ashok 04. Coconut 05. Amba 06. Morpankhi 07. Jasmine 08. Raintree 09. Kanchan 10. Gulmohor 11.

Badam 12. Kashid 13. Karanja 14. Sisu 15. Nilmohor 16. Limbu 17. Suru 18. Nilgiri 19. Sitaphal 20. Kanheri 21. Stikoma 22. Bongalwelia

8.8 Measures to Improve Socio-Economic Conditions

For the benefit of the community in the vicinity of the project, BSSKL will take several

measures to develop various amenities in an effort to improve standard of living, some of

which are; Capital budget of Rs.9.00 crores will be allotted for the following works in

consultation with local administration.

ü Providing drinking water

ü Construction of schools



ü Construction of community centres

ü Construction of roads and drainage

ü Construction of health centres

8.9 Landscaping

The various service I utility areas within the plant will be suitably graded to different

elevations. Natural features of the plant site will be retained as far as possible to integrate

with the buildings to form pleasant environment. Areas in front of various buildings and the

entrance of Sugar Plant with Cogeneration Unit will be landscaped with ground cover, plants,

trees based on factors like climate, adaptability, etc. The green belt will consist of native

perennial green and fast growing trees. Trees will also be planted around the plant boundary

to minimize the dust pollution. Adequate afforestation will be carried out as per the

guidelines of MoEF.

8.10 Fire Fighting & Protection System

Safety Policy and Regulations

Keeping in view of the safety requirement during construction, operation and maintenance

phase, M/s BSSKL has formulated safety policy with the following regulations:-

v Creating awareness in all employees & service providers about the safty & health.

v Understanding the organization’s responsibilities to create suitable arrangements for

informing, education, &training to it’s own employees at different levels.

v Create suitable organization to maintain safe & healthy environment at work place.

v Provide all necessary resources, latest technology and process for safety.

v Harmonious work environment for career growth of our employees and to achieve the

organizational goals of productivity, quality and zero accidents.

v Ensure responsibilities regarding safety of contractor, sub- contractor, instructors and

other organizes entering the premises.

v Assess our safety status from time to time to decide directions for improvement.

v Complying with applicable rules, statutory, regulatory and other requirements.

Fire Protection System

v The plant has proposed adequate number of wall/column mounted type portable fire

extinguishers in various strategic areas of the plant including the control room,



administration building, stores, pump house etc. These portable fire extinguishers are

basically of carbon dioxide and dry powder type.

v Fire hydrants at suitable locations for TG building, boiler area, & storage area.

v Medium velocity water spray system for the cable gallery

v Necessary electric driven, Jockey pumps with piping valves & instrumentation for

safe operation.

8.11 Corporate Environment Policy Corporate Responsibility for Environmental

Management

Ø The plant has an Environmental Management Committee headed by the Director &

Chief Operating Officer and comprises of key personnel in the plant. The Committee

meets regularly to review the status of various aspects of pollution control measures

will be implemented in the plant.

Ø The unit has also initiated improvement measures to get ISO14001 certification.

Ø Suggestion scheme has been launched and various suggestions given by the workers

and employees have been implemented in order to improve safety and protect

environment.

Ø The unit has resolved to become a zero waste integrated agro business sugar complex

and in its commitment to ensure zero discharge. Measures will be implemented to

recycle and reuse waste water to avoid effluent discharge into the environment.

Ø The unit complies with the various requirements and standards stipulated by Ministry

of Environment & Forests, Central Pollution Control Board and Maharashtra

Pollution Control Board.

Ø The unit recently commissioned a new mist cooling system with automation for

cooling the evaporator and pan condenser water.

Ø Involvement of workmen in Safety Management through the Safety Committee which

is empowered to review accidents and initiate corrective and preventive action.

Ø Ensuring high standards of housekeeping in the factory premises, resulting in a Safe

Shop floor,

Ø All personnel are trained on First Aid and basics of Safety Management.

* * * * *



CHAPTER –9

Summary and Conclusions

10.1 INTRODUCTION

This EIA report has been prepared for project by ' M/s. Bhima Sahakari Sakhar

Karkhana Ltd., Takali Sikandar,Tal – Mohol, Dist – Solapur, Maharashtra. . The existing

cane crushing capacity of the sugar factory is about 2500 TCD . The first crushing season of

Sugar Factory was commenced in the year 1981. By taking into consideration the raw

material availability in the command area and demand of the products (Sugar and Power) in

the market, BSSK have planned to go for proposed expansion of existing sugar factory from

2500 to 5000 TCD (increased by 2500 TCD) &estsblishment of Co-gen Plant of 25 MW in

existing premises.

The above proposed expansion project attracts the condition of Environmental

Clearance procurement as per the Environmental Impact Assessment (EIA) Notification No.

S. O. 1533 (E) dated 14.09.2006; amendments thereat. Accordingly, it has been listed under

Category – B. The proposed expansion project was considered by the Expert Appraisal

Committee (EAC) on 22.12.2014 for grant of Terms of Reference (ToRs).

Total capital investment towards proposed projects of Sugar Factory and Co-gen

Plant is Rs. 199.5877Crores while that of existing manufacturing set-up is Rs11 0 Crores.

Sugar Factory is registered under the Maharashtra Co-Operative Societies Act, 1960 vide

Registration No. S.U.R./P.R.G dated 09/08/1974.

Salient Features of the project

Table No.1 0.1

Project at a Glance

Sr.

No.

Particulars Details

1 Name and

Address of the

Industry

M/s. Bhima Sahakari Sakhar Karkhana Ltd., Takali

Sikandar,Tal – Mohol, Dist – Solapur, Maharashtra..

2 Type and capacity

Project

Expansion cum Modernization of 2500 TCD To 5000 TCD

Sugar & 25 MW Cogeneration Plant



3 Latitude

,Longitude, and

Elevation

170 41’57.72’’N

750 32’ 17.76’’E

461 Meter above sea level

4 Land area and

break up

· Total Plot Area –9,20,000Sqm.

· Built - Up Area – 36919.3 Sqm

· Open Space Available - Ha

· Green Belt Area: - Ha

5 Nearest habitation Takali-Sikander

6 Nearest city Mohol -20 Km

7 Nearest highway Pun-Solapur NH-09

8 Nearest railway

track

Pandharpur station -30 Km

from Project site

9 Nearest airport Solapur Airport -60 Km

10 Nearest streams

/Rivers /water

bodies(from

Project Site)

Bhima River- 5 Km

11 Capital &

RecurringCost

towards EMP

No Description Cost Component (Crores)

Capital 0&M / Year

1 Air Pollution Control

Equipment ESP for

Cogen Boiler, UP-

gradation of existing

set-up

Rs.1.85 Rs.0.35

2 Water Pollution

Control- ETP

upgradation

Rs.1.50 Rs.0.20

3 Noise Pollution

Control

Rs. 0.10 Rs.0.05

4 Environment

Monitoring

Management

-- Rs.0.15



5 Occupational Health

& Safety

-- Rs.0.15

6 Green Belt & Rain

Water Harvesting

-- Rs.0.20

7 CSR Activities Rs.5.27 --

Total Rs.8.27 Rs.1.10

.

CONCLUSION

· The proposed expansion activity of Sugar and Co-gen plant by BSSKL will help to

elevate the economic growth at the local level as well as national level. It will also

generate the employment in the study region, thereby improving the standard of living

in the region. The expansion activity shall not disturb the land use pattern in the study

region of 10 Km. No Rehabilitation is involved under this project since expansion is

to be done in the existing unit.

· While undertaking this expansion activity the farmers shall also be partially

benefitted; as their farm lands will be irrigated by the treated water from sugar ETP.

· The bagasse based power generation projects not only fulfil the captive needs of the

industry but also the surplus power is exported to grid.

· The expansion project is further beneficial for society without hampering the

environment and thereby accomplishing the aim of sustainable development.

* * * * *



Chapter –10

Disclosure of Consultant

Green Circle Inc.

Table No. 10.1: General information

Name of organization : Green Circle Inc.

Address : Green Empire (Anupushpam Habitat Centre)

Above Axis bank, Near Yash Complex,

Gotri Road,

Vadodara - 390021 (Gujarat)

Telephone Nos : +91-265-2371269

+91-265-2371028

+91-9998036028

Fax : +91-265-2371269

Email : [email protected] , [email protected]

VISION

We shall ensure quality, reliability and continuous technology up gradation thereby

enhancing the value of stakeholders. We should inspire others to create pollution free

world in order to achieve sustainable growth.

MISSION

Our mission is to become one stop consultancy for all kind of services in the field of

environment, health, Safety and risk by providing optimal solutions and to strengthen our

position by adopting and evolving best practices and principles. We strive to give our

customer highest level of satisfaction based upon a commitment to serve, an

understanding of their needs and goals, and a demonstrated ability to produce results.

APPROVALS & ACCREDATATIONS

Ø MoEF (Ministry of Environment & Forest) Recognized & Gazetted Laboratory with

Field Monitoring Facility.

Ø Recognized by Ministry of Environment & Forest, New Delhi under EPA 1986



Ø GPCB Approved Schedule II Environmental Auditor.

Ø ISO 9001:2008, 14001: 2004 & OHSAS 18001 Certified organization. Currently

NABL, ISO 17025 & BIS system implementation &certification process is in

progress.

Ø Gujarat High court Stay order for NABET - No. C/SCA/10311/2012 dated

24/01/2013

ACTIVITIES:-

Figure No.10.1: ACTIVITIES

EIA TEAM

The EIA team engaged in the preparation of EIA report consists of professionals with

multidisciplinary skills and experience required for undertaking this project. The EIA

involved in various stages of planning to final report preparation is given below in table

7.1.



Table 10.2: EIA TEAM MEMBERS S/No. Person Name Qualification Key Responsibility

Area Experience (Years)

1 Mr. Pradeep Joshi M.Sc. (Env. Sc) Industrial Engineer

Team leader 26

2 Dr. Prashant Banne M.Sc. (Env. Sc), Ph.D. EIA Coordinator 12 3 Mrs. Jassica Caria M.Sc., PhD (GIS & RS) Land use preparation 9 4 Mr. Anand Shirsat BE (Chemical Eng.) Report finalization 8 5 Dr. Sandeep Sohani M.Sc. Ph.D

(Environmental Sc. ) Ecology Biodiversity 7

6 Mr. Pravin Shinde M.Sc. (Marine Sc.) Report preparation 6 7 Mr. Raghav Soni M.Sc. (Env. Sc) Report Preparation &

Monitoring 5

8 Ms. Priyanka Pandey

M.Sc. (Biochemistry) Laboratory analysis 5

9 Mr. Shailendra Singh

M.Sc. M.Phil. (Env. Sc) Air and Noise Monitoring

5

10 Mr. Kuldeep Gurav M.Sc. (Env) Ecology and Biodiversity

4

11 Mr. Chandrakant Patil

M.Sc. (Env. Sc) Report Preparation & Monitoring

8

12 Mr. Sandeep Patil M.Sc. M.Tech. Air pollution and Noise 3 13 Ms. Dipali Chavan M.Sc. (Env. Sc) Report Preparation Air

and Noise 5

14 Mr. Ranjit Kalita M.Sc. M. Phil. (Env. Sc) Report Preparation 4 15 Ms. Stuti Patel M.Sc. (Env. Sc & Tech.) Report Preparation 2 16 Mr. Vikash Bhagat M.Sc (Chem), M.Tech

(Energy & Env. Eng) Report Preparation 2

17 Ms. Riddhi Mehta BE (Chemical Eng.) Report preparation 2 18 Ms. Nidhi Trivedi M.Sc. (Env. Sc.) Report preparation 2 19 Mr. Amit Das BE (Env. Eng.) Baseline report

preparation 0.2

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M/s. Bhima Sahakari Sakhar Karkhana Limited. Takali-Sikander ...

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