Chapter 1 Introduction

Transcription

1 Limited Unit II Chapter 1 Introduction 1.0 Purpose of the Report Limited (JSL) is proposed to enhancethe Sugar Unit with a capacity from 2500 TCD to 3500 TCD along with Cogeneration power plant from 15 MW to 27 MW capacity at village Nad KD, Taluka Indi, District- Bijapur, State- Karnataka. The purpose of this report is to present the environmental related issues of the enhanced project from 2500 TCD to 3500 TCD of sugar unit and 15 MW to 27 MW cogeneration of power plant in an area of acres at NAD KD village, Indi Taluka, Bijapur District of Karnataka. This project requires environmental clearance as per EIA Notification dated 14 th September The Terms of References issued by MoEFvide Letter no. J-13012/38/ IA. II (T) dated October 29, 2012for carrying out the Environmental Impact Assessment study. 1.1 Identification of Project The salient features of the study area covering 10 km radius from the project site are described below in Table 1.1. Table 1.1 Salient Features of the Project Site Enhanced Capacity from 2500 TCD to 3500 TCD Name of the Project of Sugar Plant and 15 MW to 27 MW of Cogeneration Power Plant Location of Project Village Nad KD Taluka Indi District Bijapur State Karnataka 17 o N, 76 o E Coordinates of the plant site 17 o N, 76 o E 17 o N, 76 o E 17 o N, 76 o E Elevation 458 m above Mean Sea Level General Climatic Conditions Bhagavathi Ana Labs Ltd., Hyderabad. 1

2 Limited Unit II Maximum Temperature ( C) 45 C Minimum Temperature ( C) 20 C Relative Humidity (Maximum) (%) 55% Annual average Rainfall (mm) 595 mm Dominant wind direction (during study period) North-East (NE) Accessibility Road Connectivity National Highway (NH-13) km State Highway(SH-34) of Indi-Afazalpur 2.0 km Rail Connectivity Railway station Indi 24km Airport Belgaum 300km Environmental Sensitivity Sattanalnadi 1.5 km Water bodies DoddaNalla- 5.2 km Bhima river 9.0 km Forest Area None within the 10 km radius of the proposed plant site Sanctuaries / National Parks None within the 10 km radius of the proposed plant site Archaeological/Historically Important Site None within the 10 km radius of the proposed plant site Seismic zone Seismic Zone II as per IS: , GOI The location and topographical mapsof 10 km radius study area of project site is shown in Fig 1.1 and Fig 1.2 respectively. 1.2 Project Proponent Limited is managed under the leadership of its Chairman Shri S.B. Nyamagouda, who is an Ex- member of Karnataka State Legislative Council and Ex- Union Minister.The Managing Director is Shri S. Dhayanandhan.Both the Chairman and the Managing Director are highly experienced and successfully managing various industries including the existing sugar unit I at Jamkhandiand allied co-generation unit. It is under the leadership of these two that the Ltd., was received awards of Best Performance Sugar Factory and Best Cane Development Third Place in Karnataka for the Crushing Season , Best Performance Sugar Factory and best Cane Bhagavathi Ana Labs Ltd., Hyderabad. 2

3 Limited Unit II Development second place in Karnataka for the Crushing Season from the South Indian Sugarcane & Sugar Technologists Association (SISSTA )and second place for Best Cogeneration Award ( ). 1.3 Brief Description of Project site JSL is located in the Bhima river belt, which is ideal basin for growing rich varieties of sugar cane to achieve highest yield. In view of the cane availability at NAD KD, JSL has establishedsugar unit and proposed to enhance from 2500 TCD to3500 TCD capacity with cogeneration of 27 MW. The site is centrally located in the area of operation and is in heart of sugarcane area. The project site is well connected to the village roads for transportation of sugar cane by carts/trucks. An adequate skilled, semi-skilled and unskilled labourforce is available in the study area.theinfrastructure facilities like power, road, communication facilities, and banks are available around the project site. 1.4 Project Importance to the Country & Region The sugar industry scenario in Karnataka and in Nation is very bright as India being the second largest producer of sugarcane in the world and the second largest producer of sugar next to Brazil. There is a very good scope for export of quality sugar. Present Status of Demand and Availability The existing Sugar factories could not crush all available cane from the areas of operation and hence, rest of the sugarcane is being taken to the sugar factories in neighbouring districts of Karnataka and Maharashtra.Presently, the cane grown by farmers are diverting to the sugar factories located in Maharashtra, in this connection farmers are suffering like delay in disposal, less price, less payment etc., Thus, the farmers are facing problems of disposal of sugarcane in 3-4 seasons. This situation has demanded to need Sugar units at this area. The demand for electrical power has been increasing at a faster pace after the country s economic development the pace speeded up, especially in Karnataka which has been the hub of software services. The effective generation of power has not been meeting the demand and the same trend is expected to continue, especially during the peak hours and summer seasons. Hence, there is good scope for exporting power to the third parties using the state grid through power traders / purchasers. Bhagavathi Ana Labs Ltd., Hyderabad. 3

4 Limited Unit II 1.5 Scope of the Study M/s Limitedhas entrusted to M/s Bhagavathi Ana Labs Ltd, Hyderabad, so as to carryout Environmental Impact Assessment (EIA) studies and to prepare an effective Environmental Management Plan for implementation during the operation of the project. Scope of this study is to identify environmental impacts and to provide mitigation measures as per Ministry of Environment & Forests (MoEF)/ Central Pollution Control Board (CPCB) guidelines. The report is prepared based on TORs issued by MoEF reference no. F. No J /38/ IA. II (T) dated October 29, The TORs issued by MOEF Expert Appraisal Committee are given as under:- i) Vision document specifying prospective long term plan of the site, if any, shall be formulated and submitted. ii) Status of compliance to the conditions stipulated for environmental and CRZ clearances of the previous phase(s), as applicable, shall be submitted. iii) Status of compliance to the conditions stipulated in the environmental clearances accorded for sugar plant shall be submitted as applicable. iv) Executive summary of the project indicating relevant details along with recent photographs of the approved site shall be provided. Response to the issues raised during Public Hearing and to the written representations (if any), along with a time bound Action Plan and budgetary allocations to address the same, shall be provided in a tabular form, against each action proposed. v) Harnessing solar power within the premises of the plant particularly at available roof tops and other available areas shall be formulated and status of implementation shall be submitted to the Ministry. vi) The coordinates of the approved site including location of ash pond shall be submitted along with topo sheet (1:50,000 scale) and confirmed GPS readings of plant boundary and NRS satellite map of the area, shall be submitted. Elevation of plant site and ash pond with respect to HFL of water body/nallah/river shall be specified, if the site is located in proximity to them. vii) Layout plan indicating break-up of plant area, ash pond, area for green belt, infrastructure, roads etc. shall be provided. viii) Land requirement for the project shall be optimized and in any case not more than what has been specified by CEA from time to time. Item wise break up of land requirement and revised layout (as modified by the EAC) shall be provided. Bhagavathi Ana Labs Ltd., Hyderabad. 4

5 Limited Unit II ix) Present land use as per the revenue records (free of all encumbrances of the proposed site, shall be furnished. Information on land to be acquired) if any, for coal transportation system as well as for laying of pipeline including ROW shall be specifically stated. x) The issues relating to land acquisition and R&R scheme with a time bound Action Plan should be formulated and clearly spelt out in the EIA report. xi) CWC clearance for drawl of water from the river for the proposed TPP shall be submitted. xii) Satellite imagery or authenticated toposheet indicating drainage, cropping pattern, water bodies (wetland, river system, stream, nallahs, ponds etc.), location of nearest villages, creeks, mangroves, rivers, reservoirs etc. in the study area shall be provided. xiii) Location of any National Park, Sanctuary, Elephant/Tiger Reserve (existing as well as proposed), migratory routes / wildlife corridor, if any, within 10 km of the project site shall be specified and marked on the map duly authenticated by the Office of the Chief Wildlife Warden of the area concerned. xiv) Topography of the study area supported by toposheet on 1:50,000 scale of Survey of India, alongwith a large scale map preferably of 1:25,000 scale and the specific information whether the site requires any filling shall be provided. In that case, details of filling, quantity of fill material required; its source, transportation etc. shall be submitted. xv) A detailed study on land use pattern in the study area shall be carried out including identification of common property resources (such as grazing and community land, water resources etc.) available and Action Plan for its protection and management shall be formulated. If acquisition of grazing land is involved, it shall be ensured that an equal area of grazing land to be acquired is developed alternatively and details plan shall be submitted. xvi) A mineralogical map of the proposed site (including soil type) and information (if available) that the site is not located on economically feasible mineable mineral deposit shall be submitted. xvii) Details of 100% fly ash utilization plan as per latest fly ash Utilization Notification of GOI along with firm agreements / MoU with contracting parties including other usages etc. shall be submitted. The plan shall also include disposal method / mechanism of bottom ash. xviii) Water requirement, calculated as per norms stipulated by CEA from time to time, shall be submitted along with water balance diagram. Details of water balance calculated shall take into account reuse and re-circulation of effluents which shall be explicitly specified. xix) Water body/nallah (if any) passing across the site should not be disturbed as far as possible. In case any nallah / drain have to be diverted, it shall be ensured that the diversion does not disturb the natural drainage pattern of the area. Details of diversion required shall be furnished which shall be duly approved by the concerned department. Bhagavathi Ana Labs Ltd., Hyderabad. 5

6 Limited Unit II xx) It shall also be ensured that a minimum of 500 m distance of plant boundary is kept from the HFL of river system / streams etc. xxi) Hydro-geological study of the area shall be carried out through an institute/ organisation of repute to assess the impact on ground and surface water regimes. Specific mitigation measures shall be spelt out and time bound Action Plan for its implementation shall be submitted. xxii) Detailed Studies on the impacts of the ecology including fisheries of the river/estuary/sea due to the proposed withdrawal of water / discharge of treated wastewater into the river/creek/ sea etc shall be carried out and submitted along with the EIA Report. In case of requirement of marine impact assessment study, the location of intake and outfall shall be clearly specified along with depth of water drawl and discharge into open sea. xxiii) Source of water and its sustainability even in lean season shall be provided along with details of ecological impacts arising out of withdrawal of water and taking into account interstate shares (if any). Information on other competing sources downstream of the proposed project. Commitment regarding availability of requisite quantity of water from the Competent Authority shall be provided along with letter / document stating firm allocation of water. xxiv) Detailed plan for carrying out rainwater harvesting and its proposed utilisation in the plant shall be furnished. xxv) Feasibility of zero discharge concept shall be critically examined and its details submitted. xxvi) Optimization of COC along with other water conservation measures in the project shall be specified. xxvii) Plan for recirculation of ash pond water and its implementation shall be submitted. xxviii) Detailed plan for conducting monitoring of water quality regularly with proper maintenance of records shall be formulated. Detail of methodology and identification of monitoring points (between the plant and drainage in the direction of flow of surface / ground water) shall be submitted. It shall be ensured that parameter to be monitored also include heavy metals. xxix) Socio-economic study of the study area comprising of 10 km from the plant site shall be carried out by a reputed institute / agency which shall consist of detail assessment of the impact on livelihood of local communities. xxx) Action Plan for identification of local employable youth for training in skills, relevant to the project, for eventual employment in the project itself shall be formulated and numbers specified during construction & operation phases of the Project. Bhagavathi Ana Labs Ltd., Hyderabad. 6

7 Limited Unit II xxxi) If the area has tribal population it shall be ensured that the rights of tribals are well protected. The project proponent shall accordingly identify tribal issues under various provisions of the law of the land. xxxii) A detailed CSR plan along with activities wise break up of financial commitment shall be prepared. CSR component shall be identified considering need based assessment study. Sustainable income generating measures which can help in upliftment of poor section of society, which is consistent with the traditional skills of the people, shall be identified. Separate budget for community development activities and income generating programmes shall be specified. xxxiii) While formulating CSR schemes it shall be ensured that an in-built monitoring mechanism for the schemes identified are in place and mechanism for conducting annual social audit from the nearest government institute of repute in the region shall be prepared. The project proponent shall also provide Action Plan for the status of implementation of the scheme from time to time and dovetail the same with any Govt. scheme(s). CSR details done in the past should be clearly spelt out in case of expansion projects. xxxiv) R&R plan, as applicable, shall be formulated wherein mechanism for protecting the rights and livelihood of the people in the region who are likely to be impacted, is taken into consideration. R&R plan shall be formulated after a detailed census of population based on socio economic surveys who were dependant on land falling in the project, as well as, population who were dependant on land not owned by them. xxxv) Assessment of occupational health as endemic diseases of environmental origin shall be carried out and Action Plan to mitigate the same shall be prepared. xxxvi) Occupational health and safety measures for the workers including identification of work related health hazards shall be formulated. The company shall engage full time qualified doctors who are trained in occupational health. Health monitoring of the workers shall be conducted at periodic intervals and health records maintained. Awareness programme for workers due to likely adverse impact on their health due to working in nonconducive environment shall be carried out and precautionary measures like use of personal equipments etc. shall be provided. Review of impact of various health measures undertaken at intervals of two years shall be conducted with an excellent follow up plan of action wherever required. xxxvii) One complete season site specific meteorological and AAQ data (except monsoon season) as per MoEF Notification dated shall be collected and the dates of monitoring recorded. The parameters to be covered for AAQ shall include SPM, RSPM (PM10, PM2.5), SO 2, NO x, Hg and O 3 (ground level). The location of the monitoring stations Bhagavathi Ana Labs Ltd., Hyderabad. 7

8 Limited Unit II should be so decided so as to take into consideration the pre-dominant downwind direction, population zone, villages in the vicinity and sensitive receptors including reserved forests. There should be at least one monitoring station each in the upwind and in the pre - dominant downwind direction at a location where maximum ground level concentration is likely to occur. xxxviii) A list of industries existing and proposed in the study area shall be furnished. xxxix) Cumulative impact of all sources of emissions (including transportation) on the AAQ of the area shall be well assessed. Details of the model used and the input data used for modelling shall also be provided. The air quality contours should be plotted on a location map showing the location of project site, habitation nearby, sensitive receptors, if any. The wind roses should also be shown on the location map as well. xl) Composition of fuels and its ratio (as applicable) to be explicitly stated. xli)fuel analysis shall be provided. Details of auxiliary fuel, if any, including its quantity, quality, storage etc. should also be furnished. xlii) Quantity of fuel required, its source and characteristics and documentary evidence to substantiate confirmed fuel linkage shall be furnished. xliii) Details of transportation of fuel from the source (including port handling) to the proposed plant and its impact on ambient AAQ shall be suitably assessed and submitted. If transportation entails a long distance it shall be ensured that rail transportation to the site shall be first assessed. Wagon loading at source shall preferably be through silo/conveyor belt. xliv) For proposals based on imported coal, inland transportation and port handling and rolling stocks /rail movement bottle necks shall be critically examined and details furnished. xlv) Details regarding infrastructure facilities such as sanitation, fuel, restrooms, medical facilities, safety during construction phase etc. to be provided to the labour force during construction as well as to the casual workers including truck drivers during operation phase should be adequately catered for and details furnished. xlvi)emp to mitigate the adverse impacts due to the project along with item - wise cost of its implementation in a time bound manner shall be specified. xlvii) A Disaster Management Plan (DMP) along with risk assessment study including fire and explosion issues due to storage and use of fuel should be carried out. It should take into account the maximum inventory of storage at site at any point of time. The risk contours should be plotted on the plant layout map clearly showing which of the proposed activities would be affected in case of an accident taking place. Based on the same, proposed Bhagavathi Ana Labs Ltd., Hyderabad. 8

9 Limited Unit II safeguard measures should be provided. Measures to guard against fire hazards should also be invariably provided. xlviii) The DMP so formulated shall include measures against likely Tsunami/Cyclones/Storm Surges/Earthquakes etc, as applicable. It shall be ensured that DMP consists of both on-site and off-site plan, complete with details of containing likely disaster and shall specifically mention personnel identified for the task. Smaller version of the plan shall be prepared both in English and local languages. xlix) Detailed plan for raising green belt of native species of appropriate width (50 to 100 m) and consisting of at least 3 tiers around plant boundary (except in areas not possible) with tree density of 2000 to 2500 trees per ha with a good survival rate of about 80% shall be submitted. Photographic evidence must be created and submitted periodically including NRSA reports. l) Status of development of green belt shall also be submitted along with photographic details. li) Over and above the green belt, as carbon sink, additional plantation shall be carried out in identified blocks of degraded forests, in close consultation with the District Forests Department. In pursuance to this the project proponent shall formulate time bound Action Plans along with financial allocation and shall submit status of implementation to the Ministry every six months. lii) Corporate Environment Policy i. Does the company has a well laid down Environment Policy approved by its Board of Directors? If so, it may be detailed in the EIA report. ii. Does the Environment Policy prescribe for standard operating process / procedures to bring into focus any infringement / deviation / violation of the environmental or forest norms / conditions? If so, it may be detailed in 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 clearance conditions. Details of this system may be given. iv. Does the company has 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 should be detailed in the EIA report. All the above details should be adequately brought out in the EIA report and in the presentation to the Committee. Bhagavathi Ana Labs Ltd., Hyderabad. 9

10 Limited Unit II liii) Details of litigation pending or otherwise with respect to project in any court, tribunal etc. shall invariably be furnished. Bhagavathi Ana Labs Ltd., Hyderabad. 10

11 EIA/EMP of 3500 TCD Sugar Plant and 27 MW Cogeneration Power Plant M/s Limited Unit II Chapter 2 Project Description 2.0 Type of Project Ltd., (JSL) proposesto enhance from 2500 TCD to 3500 TCD of sugar unit and 15 MW to 27 MW of cogeneration power plant in an area of acres at Nad KD village, Indi Taluka, Bijapur district of Karnataka. The raw material sugar cane is available in the vicinity of the project site and the bagasse will be used as fuel for cogeneration power plant. The project developments of the Ltd.,are listed below: Ltd., obtained Environmental Clearance vide letter no. SEIAA A:29:IND:2007 Dated: 29 th December 2009,for 2500 TCD of Sugar Unit along with 15 MW of Co-generation Power Plant by State Level Environment Impact Assessment Authority, Karnataka. Consent order for Establishment (CFE) for 2500 TCD of Sugar unit from KSPCB Vide No. CFE-CELL/JSL-U-IL/EIA-726/ /110 Dated: Need for the Project JSL is located in the Bhima river belt, which is ideal basin for growing rich varieties of sugar cane to achieve highest yield. In view of the cane availability at NAD KD, JSL has establishedsugar unit and proposed to enhance from 2500 TCD to3500 TCD capacity with cogeneration of 27 MW. The area of Bhima river belt and UKP irrigation in the Indi Taluka is the most ideal belt for growing rich varieties of sugar cane to achieve highest recovery. Due to continuous water availability and UKP irrigation facilities, the sugar cane area under cultivation has increased substantially in Bijapur District than required for the existing sugar factory crushing capacity. The site is centrally located in the area of operation and is in heart of sugarcane area. The site of Ltd., possess the following advantages:- Bhagavathi Ana Labs Ltd., Hyderabad. 11

12 EIA/EMP of 3500 TCD Sugar Plant and 27 MW Cogeneration Power Plant M/s Limited Unit II The project site is well connected to the village roads for supply of raw material sugar cane. The adequate skilled, semi-skilled and unskilled labour forceis available in the vicinity of project area. All the infrastructure facilities like power, road, communication facilities, banks are available in the vicinity of the project area. 2.2 Location This project of Enhancement from 2500 TCD to 3500 TCD capacity Sugar Plant with Cogeneration of 15 MW to 27 MW Power Plant is located at Nad KD village,indi Taluka, BijapurDistrict, Karnataka state. The plant layout ofthe project site is shown in Fig Technical Details The technical features of 3500 TCD Sugar Unit and 27 MW Cogeneration Plant areprovided in Table 2.1. Table 2.1 Technical Information of Sugar Unit and Cogeneration Plant Parameter Description Production Capacity 3500 TCD Sugar Unit and 27 MW Cogeneration Plant a. Sugar Plant:-Sugar Cane:3500 T/day Raw Materials Requirement b. Bagasse: T/day c. Agro Waste: 547 T/day 2600m 3 /day and will be sourced from Bhima River through pipeline. The intake point of water is at a distance of 9.0 km from the project site. Water drawl permission obtained for 400 KLD Water source and Requirement LrNo.KNNL/IPZ/CEG/TA-1/AE-1/ /4100 Dated: Revised application submitted for 3000 KLD of water drawl. Boiler Capacity Power Generation 120 TPH Capacity, 110 ata pressure, 540C Cane Crushing Season:14,540 (KW) Off Season :21,400 (KW) 2.4 Basic Requirements for the Proposed Project Land Requirement The project is identified in a non-agricultural revenue land of acres.the Land Use break up is given in the following Table 2.3. Bhagavathi Ana Labs Ltd., Hyderabad. 12

13 EIA/EMP of 3500 TCD Sugar Plant and 27 MW Cogeneration Power Plant M/s Limited Unit II S. No. Table 2.3 Land Use Break up of Project Area Description Area in Acres ha 1. Built Up Area Water Storage Facility Area for Green Belt (33%) Future Expansion Total Area Water Requirement The total water requirement for the project is 2600m 3 /day during the crushing and during the slack season. Water will be met from Bhima River through pipeline and the water intake point is at a distance of 9.0 km from the project site. The total water requirement is given in Table 2.4. Details Table 2.4 Water for proposed plant No. of Capacity working days Standard water required KL/Annum M 3 /day Manufacturing Details Sugar Unit 3500 TCD 260 Co-generation Staff Quarters and Man Power MW 27x 24 Hrs 120ltr per ton KL/MW 32, Staff Quarters 108 persons Ltr/day Employees Regular Employees 250 persons Ltr/day Employees during crushing season 250 persons Ltr/day Indirect Employees Farmers, visitors, drivers, claners, cart drivers, bullock carts etc 3000 persons Approx Ltr/day Canteen Total ~2600 Cycle of concentration (COC) is considered for the project is 1.5Water balance diagram is given in Figure Bhagavathi Ana Labs Ltd., Hyderabad. 13

14 EIA/EMP of 3500 TCD Sugar Plant and 27 MW Cogeneration Power Plant M/s Limited Unit II Figure-2.3 Water balance diagram (m 3 /hr) Bhagavathi Ana Labs Ltd., Hyderabad. 14

15 Limited Unit II Raw Material Requirement The raw materials requirementis given in Table-2.5. Table- 2.5 Raw Material Requirement S.No. Item Quantity TPD 1 Raw Material Sugarcane Consumables ( Chemicals) 3 Products Lime 3.5 Caustic soda (100%) 0.1 Sulphur 0.7 Hydrochloric acid (30%) 0.1 Sodium Chloride 0.1 Phosphoric Acid 0.05 Oils& grease 0.02 Filter aid (Bagasse,50% moisture) 28 Sugar 350 Bagasse,(50% moisture) 1085 Press mud (75% moisture) 140 Molasses (25% moisture) Utilities Utilitieswill be provided for smooth and efficient functioning of the enhancedproject of 3500 TCD Sugar Unit and 27 MW Cogeneration Plant. These include the following: Water The total water requirement for the proposed project is 2600 KLPDduring crushing season and slack season. There will be masonry underground reservoir to store water in the plant premises. Bhagavathi Ana Labs Ltd., Hyderabad. 1

16 Limited Unit II There will be an overhead RCC tank to supply drinking water to the colony and the factory. Nearly, 15 m head should be available from this tank. Arrangement for pumping water from the underground water reservoir to the M.S. tank to the pan floor directly should also be made Power The plant requires 500 KVA at 415 V. Three phase electric supply from the State Electricity Board for initial erection activity and after completion of project, by erection of Cogeneration Plant which would meet the demand of the plant.500 KVA transformer with necessary switch gear will be installed. Standby Power One set of 500 KW 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 Fuel Fuel requirement is mainly for generation of steam in the boiler. Bagasse generated from the Sugar Plant i.e TPD will be used as fuel for operation of the boiler. The fuel characteristics is given as under:- Table 2.6 Characteristics of Bagasse S.No. Particulars Value 1 Calorific Value 4400 Kcal/kg (dry) 2250 Kcal/kg (wet) 2 Moisture content 45 55% 3 Ash Content 2 10 % 4 In sugar mill the crushed cane forms bagasse 30-35% Bhagavathi Ana Labs Ltd., Hyderabad. 2

17 Limited Unit II Table 2.7 Characteristics of Diesel Fuel (IS: 1448) S. No. Parameter Value 1. Acidity Nil 2. Ash%, by mass Carbon residue %, by mass Pour point, Max 03C for winter, 15C for summer 5. Flash point 35C 6. Kinematic Viscosity, cst at 40C Sediment %, by mass (max) Sulphur content by mass (max.) 0.05% 9. Water content, % by volume, Max Details of Machinery Sugar Plant Table 2.8 Mill Section S.No. Description of Equipment Qty.(in numbers) 1 Cane loader 2 2 Cane unloader 1 3 Feeder table 2 4 First cane carrier 1 5 Cane chopper 1 6 Cane leveller 1 7 Swing Hammer Fibrizer 1 8 Rake type carrier 1 9 Belt conveyor with tramp iron separator 1 10 Cane equalizer 1 11 Intermediate Rake carrier 3 12 Milling Plant 4 13 Mill house Crane 1 14 Belt Conveyor 1 15 Rake type bagasse elevator 1 Bhagavathi Ana Labs Ltd., Hyderabad. 3

18 Limited Unit II 16 Lubrication System 1 17 Juice Tray 1 18 Donnelly Chute 4 19 Pumps 4 20 Lubricants for Mill House Package 4 21 Rotary screen juice 1 Boiling House Machinery Table 2.9 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 vacuum pan 13 Crystallizers 14 Condensor and injection pump station 15 Sugar melter 16 Sugar drying 17 Mild steel fabricated vapour pipe 18 Insulation Bhagavathi Ana Labs Ltd., Hyderabad. 4

19 Limited Unit II Power Generating Unit Table 2.10 (i) One TG set of 27 MW rating will be used for the export of power during season and off season. (ii) The TG set of 27 MW will be Extraction cum Condensing type having Inlet steam pressure 110 ata& temperature 40 degcelcius with all its accessories. Brief Technical Specification of Turbo Alternator Particulars Units Value Turbo generator 1 Type Double Extrn cum condensing Rated output (continuous) KW Steam pressure before emergency stop valve ata 108 Rated pressure at extraction ata 2.5 Rated pressure at exhaust ata Efficiency Parameters The plant and machinery shall be of proper design and capacity to have following efficiency parameters:- Preparatory Index- +85 % RME- +95 % Boiler efficiency- 71 % Steam Consumption- less than 42% on cane Reduced Boiling house efficiency- +80 % Recovery % cane to 12.5 Bhagavathi Ana Labs Ltd., Hyderabad. 5

20 Limited Unit II 2.5.6Employment The employment requirement is estimated about 91 personnel. The list of employment is given below the Table Table Manpower Requirement Sugar Plant Employment Number of personnel Managers 6 Mechanical Engineer 4 Sugar Technologies 4 Lab Assistance 4 Electrical Engineer 1 Electrical Supervisor 4 Cogeneration Plant Manager 1 Instrumentation Engineer 1 Mechanical Engineer 4 Electrical Engineer 3 Instrumentation Technicians 4 Electrical supervisor 1 Fuel/ash handling supervisor 4 Working floor staff 50 TOTAL Process Description Sugar Plant Brief Description Of Process To Manufacture White Sugar By Double Sulphitation Process The process of manufacturing involves the following steps: i) Extraction of cane juice from cane ii) Purification of cane juice iii) Evaporation of cane juice to facilitates crystallisation Bhagavathi Ana Labs Ltd., Hyderabad. 6

21 Limited Unit II iv) Crystallisation of Sugar v) Separation of sugar and liquid by Centrifugal force vi) Re-Boiling of Liquid vii) Drying Brief Description Of The Above Process Steps Are Given Below:- I. Extraction of Cane Juice From Cane The cane which is brought from fields by carts/trucks/tractors, weighed and unloaded in the cane carrier for extraction of juice from sugarcane. The unloaded cane will pass through preparatory devices (Chopper, leveller and fibrizer). The preparatory devices will cut the cane stalks into pieces. The prepared cane enters mills consist of multiple units of three roller combination through which the prepared cane.to aid in the extraction of juice spraying thin juice from previous mills and water before last mill, directed on the blanket of Bagasse as it emerges from each mill help to leach out the sugar. Use of Bagasse The residue that leaves the last mill is called bagasse contains un-extracted sugar, woody fibre and water. The bagasse will be used as fuel to produce steam and power as cogeneration. The generated steam will be used to run turbines for power generation. The outlet of the turbine i.e., low pressure steam will be used for mill juice processing. The condensed water will be sent back to boiler for steam generation during off crushing season. II. Purification of Cane Juice Clarification The extracted juice from mills is strained to remove bagasse particles before sending for process. This juice will be sent through a mass flow meter and the quantity automatically recorded. The dark green juice from mills is acidic and turbid. The universal process employed to remove both soluble and insoluble impurities is called Sulphitation process. The juice will be heated up to 70C to 75C to avoid inversion. In sugar plant as a measure of Bhagavathi Ana Labs Ltd., Hyderabad. 7

22 Limited Unit II steam economy primary heating will be done by plate type heat exchanger using heat energy available from the condensates of evaporators and pans. Liming and Sulphitation The process in whichmilk of lime(ca(oh) 2 ) is added to the juice simultaneously in juice sulphiter, thereby ph of juice will be increased to 6.9 to 7.2. CaO+H 2 O Ca(OH) 2 + Colour The aim of this neutralization is to remove colourants from the juice, and to neutralize organic acids. The formation of tri-calcium phosphate and sulphate, which are products on sedimentation and carry impurities present in the liquid. Lime consumption (Cao) ranges from 0.18 to 0.25 % on cane according to the treatment strength required. The absorption of the SO 2 gas (sulphurdioxide) by the juice takes place in juice sulphitor.the SO 2 gas is produced in the unit by burning sulphur in the presence of air, in special furnace and the reaction is given below. S+O 2 SO 2 The main objectives of Sulphitation are; Sulphitation is the practice of adding sulphur dioxide (SO 2 ) to process streams in a sugar factory. This is done for one of three reasons : 1. ph control - the SO 2 in aqueous solution forms sulphurous acid H 2 SO 3 (aq) which reduces the ph of the process stream. An example of this would control of diffusion water ph in a beet factory, where keeping the ph below 5.5 reduces the extraction of pectin from the beet cell walls which helps pulp pressing. 2. Biocide - used in sufficient quantities the SO 2 inhibits the life cycle of bacteria, reducing the quantity of sugar lost by bacterial degradation to lactic acid. This is similar to the use of sodium metabisulphite for sterilising home brewing equipment. The efficiency of SO 2 as a biocide is sometimes challenged in the literature. Bhagavathi Ana Labs Ltd., Hyderabad. 8

23 Limited Unit II 3. Colour blocking - SO 2 reacts with the carboxyl groups of invert sugars (glucose and fructose) to inhibit their participation in the colour forming Maillard reaction with amino compounds. By adding SO 2 to juice before evaporation the increase in colour through the evaporators is kept to a minimum, protecting the juice from excessive colour formation at high temperature in the evaporators. Decreasing the viscosity of the juice and consequently of the syrup, to reduce viscosity and remove the colouring matters present in the juice. This ultimately facilitates better evaporation and crystal development. Average consumption of Sulphur can be estimated in between 0.05% to 0.06% on cane. The sulphited juice is heated to approximately 101 to C to accelerate and facilitate the coagulation and flocculation of colloids and non sugar proteins, emulsify fats and waxes, or in other words accelerate the chemical process, increasing decanting efficiency and also enabling removal of gas from the juice. The juice purification by removing the flocculated impurities from the previous treatments. This process is carried out continuously in equipment called a claifier. The clarified juice is removed from the upper part of Solids Recycle Type Clarifiers (SRTC) and sent to the evaporation section for concentration. The mud will be withdrawn from the bottom of the SRTC and sent to rotary vacuum filter. In rotary vacuum filters, juice and filter cake will be separated by vacuum. The cake that is discharged are applied to fields as fertilizer and in some countries cane wax is extracted from this cake. III. Evaporation The clarified juice obtained in the clarifiers constitutes 75% water. The first stage of concentration is carried out in equipment called the evaporator, which operates continuously. The evaporator consists of five bodies, connected in series so that the juice undergoes progressive concentration from the first effect to the last effect to evaporate 75% of water which is present in the juice we require steam. Henceexhaust steam from turbines at a pressure of 1.5 kg/cm 2 at 133Cwill be fed to the effect of evaporator. Subsequently due to the evaporation of the water in the first effect will yield the same Bhagavathi Ana Labs Ltd., Hyderabad. 9

24 Limited Unit II amount of vapour, which will be fed to the succeeding bodies. Due to the difference in the pressure and the vacuum in the bodies the evaporation of juice will takes place in all the evaporators. Initially clarified juice will have a brix of C, reaching C Brix from the outlet of the V body. This syrup is passed through a tower consists of absorption of the SO 2 (Sulphurdioxide) by the syrup, lowering its original ph from to The water vapour generated from 1 st evaporator will be used in subsequent bodies and the generated condensate will be utilised for cane juice extraction at mills, muddy juice filtration at vacuum filters, milk of lime preparation, pan washing and centrifuge. The excess condensate will be cooled and used for plant utilities and on land irrigation. IV.Crystalisation Crystallisation takes place in single effect vacuum pan. The syrup obtained from the evaporator will be boiled until saturated with sugar. At this point seed grain is added to serve as nuclei for the sugar crystals and more syrup is added as the water evaporates. Continuing the above process the pans are filled up till the desire size crystals are built up and dropped in mixers called crystallisers. The sugar and syrup forms a dense mass known as Massecuite. V. Separation of sugar and liquid by centrifugal force From the crystallizers, the massecuite will be cured in the centrifugal machines. In centrifugals the sugar and molasses will be separated. In centrifugals there are two types of machines I. Continuous centrifugal Machines II. Batch Type centrifugal machine The continuous centrifugal machines will be used for low grade massecuites like B and C Massecuites. The separated molasses will be taken back to the process for extracting the dissolved sugar which is present in molasses. The separated sugar having low purity is made as a magma minglers and it will be melted in the sugar melter and will be taken back to the A massecuite boiling.high grade massecuite i.e., A- Massecuite will be cured Bhagavathi Ana Labs Ltd., Hyderabad. 10

25 Limited Unit II in the batchtype centrifugals. The sugar discharged from the batch centrifugal has a high moisture level with temperature of around 60 to 65 degree centigrade. VI. Re-boiling of Liquid The aim of sugar boiling is to recover more sugar and send less purity of molasses ( Final Molasses) as by product. A Massecuite From Syrup and second grade used as seed nuclei and high purity washings from high grade sugar (AL Molasses) high grade or A Massecuite is boiled. From this A Massecuite we get white sugar, A Heavy Molasses and AL molasses. This AL light molasses will be sent back for A Massecuite boiling. The AH molasses is being sent for A Massecuite boiling. The AH molasses is being sent for B Massecuite B Massecuite The AH Molasses is taken in to batch pan and boil till the super saturation stage. At this point seed slurry is added to serve as nuclei for the sugar crystals. Continuing the boiling by feeding AH till the crystals size reaches to 160 to 180 µm. The grain will be transferred to vacuum crystallisers, futher boiling takes place in continuous vacuum pans. The continuous pan outlet massecuite size will be 250 to 300 microns.the B grade Massecuite separation we will get B seed and B heavy molasses. The part of B seed will be sent for A graining and balance for melting. B heavy molasses sent for C Boiling. C Massecuite or Low Grade Massecuite As this is the important massecuite from which mother liquor goes out as Final Molasses must be of low purity. Hence, more number of small crystals must be present to have larger area to deposit or de-sugar the mother liquor. Here the crystals are smallest to achieve our aim. Graining is done using C light and AH molasses in batch pan and boiled till the super saturation stage. At this point seed slurry of 3 to 4 microns is added to serve as nuclei for the sugar crystals. Continuing the boiling by feeding C light and BH molasses till the crystals size reaches to 70 to 90 microns. The grain will be transferred to C vacuum Bhagavathi Ana Labs Ltd., Hyderabad. 11

26 Limited Unit II crystalliser. Further boiling takes place in continuous pans by feeding BH molasses. The crystals size of pan outlet is 150 to 180 microns. The massecuite dropped to Mono Vertical crystalliser for cooling. During cooling of the massecuite the temperature bring down to 42 to 43 degree centigrade to achieve maximum sugar recovery. The cooled massecuite fed to continuous centrifugals for separation. The separated mother liquor termed Final Molasses will sent to distillery industry. The sugar separated from first curing is mixed with water and sent for second curing. During second curing we will get C seed and C light molasses. C seed will be sent for A Boiling and C light molasses sent for C boiling. VII. Drying The separated sugar from A centrifugals cooling and drying of the sugar is carried out in a multi tray hopper, in the hopper the cold and hot air will be pass in co-current direction to bring down the moisture and temperature of the marketable sugar. From the drier, the sugar passes through grader where the separation of sugar of various grades depending on the size and colour like: L-30, M-30, S-30 and SS-31 will takes place. The graded sugar will be collected in bins. The sugar from the bins will be weighed in automatic weighing scale, stitched and will be sent to the sugar godown. Sugar is stored in 50 kg PP bags and 100kg A twill gunny bags in sugar godown. 2.7 Cogeneration Power Plant JSL proposes to implement the Cogeneration of 27 MW power plant by installation of 120 TPH boiler of 110 ata pressure and 540C temperature and single T.G. set of 27 MW extraction cum condensing. The scheme of Co-generation is designed to operate plant at the rated capacity of 3500 TCD (160 TCH) Selection of Pressure and Temperature for the proposed Cogeneration Power Cycle While going for Sugar Unit of 3500 TCD, the factory has proposed 110 ata and 540C Boiler of 120 TPH.The adaptation of pressure and temperature are very suitable for obtaining the maximum power generation for proved technology available for bagasse based cogeneration. Therefore, while implementation of the cogeneration project; the parameters Bhagavathi Ana Labs Ltd., Hyderabad. 12

27 Limited Unit II adopted shall be based on minimum 110 ata pressure and 540Ctemperature of the boilers. 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 Design Parameters for the proposed Cogeneration Plant Following design parameters for the Expansion project will be taken into account:- Actual crushing capacity of Sugar Plant will be 160 TCH on 22 hrs, basis (3840 TCD /24 hrs.) Average production of bagasse will be 29.5 % on cane. Bagasse used for vacuum filter will be 0.6 % on cane and reserved for start-up to stoppages and wind age losses will be o.2 % on cane. Thus, the bagasse available for the steam generation will be % The gross season will be of 180 days Captive power consumption for the sugar unit is 24 KW/TCH ie 3840 KW Captive steam consumption: Sugar factory process (2.5 ata) :44 % on cane Sugar factory misc. (8.0 ata) :1 % on cane Captive power consumption: Boiler of 120 TPH and 110 ata pressure and matching TG set of 27 MW will be used as captive power for Sugar Plant Surplus power will be exported during season (180 days) and during off season (80 days) to KSEDCL grid of 110 KV level at Almal sub station located at 8 km away from the cogeneration plant. GCV of mill wet bagasse: 220 kcal /kg Thermal efficiency of boiler on GCV of bagasse: 71 % Steam to bagasse ratio (120 TPH, 110 ata boiler) : 2.61 Actual steam rating (ASR ):27 MW, DEC T.G. Set (110 ata ata extraction :8.5 ata extraction:6.5 ata extraction:5.3 ata condensing stage:3.4 kg/kwh Bhagavathi Ana Labs Ltd., Hyderabad. 13

28 Limited Unit II Operation of the Cogeneration Plant during Crushing Season The 120 TPH, 110 ata boiler with matching 27 MW condensing & extraction TG set will work to cater the demand for process steam and power of sugar unit and power for auxiliary units of Cogeneration plant and balance power will be exported to the state grid. The steam balance, Bagasse balance and Power balance during the season operation of the Cogeneration Plant are described as below i)steam Balance 120 TPH, 110 ata boiler Steam generated from 120 TPH, 110 ata boiler are TPH and is passed through 27 MW Extraction and condensing TG set from which, 8.4 TPH is extracted at ata& used for ejector and HP Heater -2, 8.0 TPH is extracted at 8.4 ata& used for sugar processing and HP Heater 1, 75.0 TPH is extracted at 3.0 ata and after desuper heating it is used for sugar processing and Deaerator and balance TPH is led to condensing stage thus totalling 10.4 TPH steam. Steam Consumption *at ata (Extracted steam 8.40 TPH) Ejector : 0.40 TPH HP Heater 2 :8.00 TPH TOTAL : 8.40 TPH The steam consumption at ata is 8.40 TPH. *AT 8.4 ata (extracted steam 8.0 tph) SF Process : 1.0 TPH HP Heater TOTAL : 1.50 TPH : 8.10 TPH Considering Desuper water of 0.1 TPH, the steam consumption is 8.0 TPH. *AT 2.5 ATA (Extracted steam TPH ) Bhagavathi Ana Labs Ltd., Hyderabad. 14

29 Limited Unit II SF Process :70.40 TPH Deaerator:5.10 TPH Total :75.60 TPH Considering Desuper water of 0.6 TPH, the steam consumption is 75.0 TPH *at ata condensing stage (15.00 TPH) The TPH steam is passed to the condensing stage of 27 MW EC TG set. It is to be noted that steam demand at 2.5 ata level for SF process is met through the steam extracted from 27 MW EC TG set 70.4 TPH ) thus totalling 70.4 TPH which comes to be 44.0 % on cane. Similarly steam demand at 8.0 ata level for SF misc. is met through the steam extracted at 8.4 ata after desuper (1.6 TPH ) which comes to be about 1.00 % on cane. Bagasse Balance Bagasse production (29.50 % cane ) :47.20 TPH Bagasse used for vacuum filter and Reserved for start up& stoppages(0.625% cane ) : 1.00 tph Bagasse available for boilers:46.20 TPH Bagasse utilization:120 TPH, 110 ata boiler having TPH load (@steam to bagasse ratio having 2.61 ) :40.77 TPH Saved bagasse : =5.43 TPH (3.33% cane) Thus, the total bagasse saved will be about 21, 110 tonnes during the season which will be used for operating the cogeneration plant in off- season. Similarly, 3100 tonnes of trash farm will be collected and burnt in the boiler during season and about same amount of bagasse will be saved. Power Balance Power generation: from 27 MW EC TG set 8.40 TPH stem at ata /KWH :988 KW Bhagavathi Ana Labs Ltd., Hyderabad. 15

30 Limited Unit II 8.00 TPH stem at 8.0 ata kg /KWH:1230 KW TPH Stem at 2.5 ata kg/kwh:14151kw TPH stem at 0.07 ata 3. 4 Kg/KWH:4411 KW TOTAL :20780 KW Thus the total power generation from TG sets 27 MW will be KW. Captive power consumption Sugar factory(24.0 KW /TCH) :3840 KW Work shop(season off season) :25 KW Office lighting & Colony :50 KW ETP (Season off season ) :50 KW 120 TPH, 110 ata boiler and auxiliaries :2275 KW TOTAL :6240 KW Thus the total captive power consumption will be 6240 KW. Power export Total power generation:20780 KW Total power consumption :6240 KW Surplus exportable power :14540 KW Power export in season: MWH Thus the Cogeneration plant will export the power of 1540 KW amounting to Million units during the season Operation of the Cogeneration Plant during Off season Operation of the Cogeneration plant during off season has been shown in the Steam & Power Cycle. Only 120 TPH, 110 ata boiler with matching 27 MW ECTG set will be in operation. The Steam balance, bagasse balance and power balance during off season operation of the Cogeneration plant are outlined as below:- i)steam Balance Steam generated from 120 TPH, 110 ata boiler is TPH and is passed through 27 MW ECTG set from which, 7.15 TPH is extracted at ata& used for ejector and HP Heater - Bhagavathi Ana Labs Ltd., Hyderabad. 16

31 Limited Unit II 2, 4.80 TPH is extracted at 8.4 ata& used for HP Heater -1, 7.20TPH is extracted at 3.0 ata and after desuper heating it used for Deaerator and balance TPH is led to condensing stage thus totalling TPH steam. Steam Consumption *at ata (Extracted steam 7.15 TPH) Ejector : 0.40 TPH HP Heater:6.75 TPH TOTAL: 7.15 TPH The steam consumption at ata is 7.15 TPH. *at 8.4 ata (Extracted steam 4.8 TPH ) SF Process :0.00tph HP Heater -1: 4.80 TPH TOTAL: 4.80 TPH The steam consumption is 4.80 TPH. * at 3.0 ATA (Extracted steam 7.2 TPH ) SF PROCESS :0.00 TPH Deaerator:7.20 TPH TOTAL:7.20 TPH Considering Desuper water of 0.0 TPH, the steam consumption is 7.20 TPH. *at 0.1 ata condensing stage (69.00 TPH) The TPH steam is passed to the condensing stage of 27 MW EC TG set. ii)bagasse balance Available bagasse saved in season and procured from JSL I :64910 T Bagasse used for 120 TPH, 110 ata boiler:33.77 TPH having TPH to bagasse ratio of 2.61 Bhagavathi Ana Labs Ltd., Hyderabad. 17

32 Limited Unit II Operational days: 80 days Thus the Cogeneration plant will be in operation for 80 days during the off season period. iii)power Balance *From 27 MW EC TG set 7.15 TPH steam at ata kg /KWH: 840 KW 4.80 TPH steam at 8.0 kg/kwh: 738 KW 7.20 TPH steam at 2.5 ata kg/kwh : 358 KW TPH steam at 0.75 ata kg/kwh : KW TOTAL: KW Thus, the total power generation from 27 MW EC TG set will be KW. *Captive power consumption: Cogeneration & auxiliary (Boiler and TG set) :2340 KW Workshop: 25 KW Office and Lighting: 25 KW ETP: 50 KW TOTAL: 2440 KW Thus, the total captive power consumption will be 2440 KW. *Power Export Total power generation:23840 KW Total power consumption:2440 KW Surplus exportable power:21,400kw Power export in off season:36.97 M KWH Thus, the cogeneration plant will export the power of KW amounting to Million units during the off season. Bhagavathi Ana Labs Ltd., Hyderabad. 18

33 Limited Unit II 2.8 Air Conditioning System 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. The condensers shall be located above the plant ac rooms. A temperature shall b maintained at 22 degcelsius with relative humidity of 55In the AC room Compressor shall be hermetically sealed,condensors shall be air cooled type. Refrigeration piping shall be of hard copper pipe of minimum 10 SWG thickness Thermal insulation of ducting shall be 25 mm thick aluminium foil faced glass wool. 2.9 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 Fire Protection System The fire protection system shall comprise of:- Hydrant system for all areas in the plant High velocity water spray system for transformer Automatic fire detection and alarm system Portable fire extinguishers Bhagavathi Ana Labs Ltd., Hyderabad. 19

34 Limited Unit II 2.11 Raw Water system The raw water will be stored for the Cogeneration Plant is MCFT in Season and MCFT in Off season 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. Bhagavathi Ana Labs Ltd., Hyderabad. 20

35 Limited Unit II Chapter 3 Description of the Environment 3.0 Introduction Baseline environmental status in and around enhanced project depicts the existing environmental conditions of air, noise, water, and soil, biological and socio-economic environment. With this project as the centre, a radial distance of 10 km is considered as study area for baseline data collection and environmental monitoring. Baseline data was collected for various environmental attributes so as to compute the impacts that are likely to arise due to proposed developmental activity. The main aim of the impact assessment study is to find out the impact of the project on the environment. This study is carried out during the project planning stage itself, so that the proponent can implement the project in a technically, financially and environmentally viable way. Existing environmental conditions are enumerated by collecting baseline data. The estimated impact due to the enhanced project is superimposed over the existing conditions to arrive at the post project scenario. The scope of the baseline studies includes detailed characterization of various environmental components, which are most likely to be influenced by setting up an industry. Meteorological conditions Ambient Air Quality Noise Levels Water Quality (Surface and Ground water) Soil Quality Socio Economic studies and Land use The baseline data generation for the EIA was carried out during the study period post monsoon season 2012 (October November). The data is generated with respect to meteorological conditions, air pollution levels, noise levels, water quality, soil quality and socio economic conditions were carried out during the study period.secondary Bhagavathi Ana Labs Ltd., Hyderabad. 21

36 Limited Unit II meteorological data collected for reference from the nearest IMD station Bijapurat a distance of 35 km 3.1 Meteorology The study of meteorological conditions forms an intrinsic part of the environment impact assessment study. The meteorological conditions of an area and the industrial process are both intertwined and each has a definite influence over the other. Regional meteorological scenario helps to understand the trends of the climatic factors. It also helps in determining the sampling stations in predicting the post project environmental scenario. Meteorological Scenario exerts a critical influence on Air Quality as the pollution arises from the interaction of atmospheric contaminants with adverse meteorological conditions such as temperature inversions. Atmospheric stability and topographical features like hills, canyons and valleys. The critical weather elements that influence air pollution are wind speed, wind direction, temperature, which together determines atmosphere stability. Hence it is an indispensable part of any air pollution studies and required for interpretation of base line information. An automatic weather station was installed in the plant area to study the meteorological conditions of the study area. It was placed at a height of about 10 m above the ground level ensuring that there is no obstruction to the free flow of wind. Apart from the wind speed and direction, temperature, relative humidity and rainfall were also measured. On site monitoring was undertaken for various meteorological variables in order to generate site-specific data. Hourly average, maximum and minimum values of wind speed, direction, relative humidity and temperature were recorded continuously for the study period. The meteorological data recorded and used for interpretation of the baseline information as well as for prediction analysis. Hourly wind speed and direction recorded during the study period to identify the influence of meteorology on the air quality of the area. Wind rose on sixteen - sector basis i.e., N, NNE, NE, ENE, E, ESE, SE, SSE, S, SSW, SW, WSW, W, WNW, NW and NNW is prepared. During the study period the maximum and minimum temperature, relative humidity and rainfall recorded and wind speeds and pre dominant wind directions observed are given in Table 3.1. Bhagavathi Ana Labs Ltd., Hyderabad. 22

37 Limited Unit II Period Temperature ( o C) Table -3.1 Observed Meteorological Data Relative Humidity (%) Wind Pattern 2012 Min Max Min Max Direction Average Wind Speed (m/s) October November ENE 1.2 The frequency of occurrence of wind in various speed categories was calculated on the basis of total number of observations recorded. The average 24 hour wind rose diagram during October-November 2012 reveals that the predominant wind direction during the study period is from East of North-East (ENE). The wind pattern during 00 to 23 hours is shown in Figure-3.1. Figure 3.0: Windrose Diagram for Post Monsoon 2012 (October & November) 3.2 Ambient Air Quality The baseline status of the ambient air quality was assessed through a scientifically designed ambient air quality network. The design of monitoring network in the air quality surveillance program is based on the following considerations: Meteorological parameters Bhagavathi Ana Labs Ltd., Hyderabad. 23

38 Limited Unit II Major human settlements Topography of the study area Representatives of regional background air quality for obtaining baseline status Representatives of likely impact areas Ambient Air Quality Monitoring (AAQM) stations were set up at 8 locations with due consideration to the above mentioned points. AAQ locations were selected in upwind, downwind, and cross wind directionswith reference to the project site. Ambient Air Quality Monitoring stations Location map is shown in Figure-3.1.The details of the monitoring stations are given in Table At each sampling station monitoring was carried for a frequency of twice a week for 4 weeks in a month during study period. The air pollutants are suspended particulate matter (SPM), fine particulate matter (PM 10 & PM 2.5 ),Sulphur dioxide (SO 2 ),Oxides of Nitrogen (NO x ), Carbon Monoxide (CO), Mercury (Hg) and Ozone (O 3 ) were monitored,analysed and compared with the NAAQ standards stipulated by CPCB. Table 3.2 Ambient Air Quality Monitoring Stations Station Name of the Station Direction w.r.t. Distance Wind Pattern Code plant site w.r.t. plant w.r.t. wind rose site A1 Plant site A2 Nad KD 2.7 WSW Downwind A3 Golsara 3.6 N Crosswind A4 Hanchina 4.0 ENE Upwind A5 Arjunagi 4.0 E Crosswind A6 Marsanahalli 4.5 SE Crosswind A7 Vibuthihalli 5.0 ESE Crosswind A8 Shrisara 5.2 SSW Crosswind Analysis of baseline concentrations The monitored levels of air pollutants are presented in Table-3.3. Various statistical parameters like minimum, maximum, Average, Standard deviation and 98 percentiles have been computed from the observed raw data for all sampling stations and the details are provided in Annexure II. These are compared with the NAAQ standards prescribed by Central Pollution Control Board (CPCB). Bhagavathi Ana Labs Ltd., Hyderabad. 24

39 Limited Unit II Table -3.3 Ambient Air Quality in the Study Area (All values are in g/m 3 ) Air Quality Station Plant site Nad KD Golsara Hanchina Arjunagi Marsanahalli Vibuthihalli Shrisara O Code Particulars SPM PM 10 PM 2.5 SO 2 NO x CO Hg mg/m 3 ng/m 3 3 A1 Minimum NT 20.0 Maximum NT 23.1 A2 Minimum NT 20.0 Maximum NT 22.6 A3 Minimum NT 20 Maximum NT 23.1 A4 Minimum NT 21.0 Maximum NT 24.1 A5 Minimum NT 21.0 Maximum NT 24.5 A6 Minimum NT 21 Maximum NT 23.1 A7 Minimum NT 21 Maximum NT 23.1 A8 Minimum NT 21 Maximum NT Regional Scenario The results obtained are processed for finding out the percentiles, minimum, and maximum. Close observation of the processed values reveals the following: Particulate Matter Particulate Matter or dust in general terms is the particulate matter in suspension in ambient air. It includes dust, smoke, carbonaceous matter, trace metals like lead, cadmium, mercury, etc. Sources: The following sources of suspended particulate matter in the study area are identified: Emissions due to vehicular movement, Bhagavathi Ana Labs Ltd., Hyderabad. 25

40 Limited Unit II Air born dust generation from ground and Fire wood, garbage and garden waste burning. Particulate Matter Levels in the study area: The minimum level of SPM recorded in the study area was 101 µg/m 3 at project siteand the maximum level recorded was 121 µg/m 3 at Shrisara. The minimum level of PM 10 recorded in the study area was 30.3 µg/m 3 at project siteand the maximum level recorded was 36.3 µg/m 3 at Hanchina&Shrisara. The minimum level of PM 2.5 recorded in the study area was 8.0µg/m 3 at project siteand the maximum level recorded was 12.0µg/m 3 at Mavanahalli. Sulphur Dioxide levels Sulphur dioxide gas is an inorganic gaseous pollutant. Sulphur dioxide emissions are expected to emit wherever combustion of any fuel containing elemental sulphur takes place. The sulphur in the fuel will combine with oxygen to form sulphur dioxide. Sulphur trioxide and sulphuric acid mist are the other important pollutants in the sulphur group. Sources: In general some of the important sources of sulphur dioxide are from nearby industries and domestic use of fuel. The following sources of Sulphur dioxide in the study area are identified: Emissions from domestic burning of fuel (wood, kerosene, etc.) Emissions from nearby transportation of vehicles. SO 2 Levels in the study area: The minimum level of SO 2 recorded in the study area was 7.5 µg/m 3 at Plant siteand the maximum level recorded was 8.8 µg/m 3 at Shrisara&Hanchina. Bhagavathi Ana Labs Ltd., Hyderabad. 26

41 Limited Unit II Oxides of Nitrogen Like Sulphur dioxide, oxides of nitrogen are also an inorganic gaseous pollutant. Oxides of nitrogen are expected to emit wherever combustion at high temperatures takes place. Nitrous oxide and nitric acid mist are the other important pollutants in the inorganic nitrogen group. Sources: In general some of the important sources of oxides of nitrogen are acid manufacture, Boilers in utilities in any industry and Auto exhaust. The following sources of oxides of nitrogen in the study area are identified: Emissions from domestic burning of fuels. Emissions from automobiles. NO x Levels in the study area: The minimum level of NO x recorded in the study area was 9.1 µg/m 3 at project siteand the maximum level recorded was 10.6 µg/m 3 at Shrisara. HC and COLevels in the study area: Sources Emissions from domestic burning of fuels, & wood. Emissions from automobiles. HC values in the study area were found to be less <0.1 ppm at all locations. CO values in the study area were in the range of 1.01 to 1.21 mg/m 3. Ozone (O 3 ) Ozone values in the study area were in the range of µg/m 3. The air quality contours along with wind rose diagram for SPM, PM 10, PM 2.5, SO 2 and NO x are shown in Figures 3.1a, 3.1b, 3.1c, 3.1d, & 3.1e respectively. Bhagavathi Ana Labs Ltd., Hyderabad. 27

42 Limited Unit II 3.5 Noise Environment The impact of industrial noise on surrounding community depends on Characteristics of noise sources (instantaneous or continuous in nature). It is well known that a steady noise is not as annoying as one that is continuously varying in loudness. Time of the day at which noise occurs, for example loud noises at night in residential areas are not acceptable because of sleep disturbance. The location of noise source with respect to noise sensitive areas determines the loudness and period of noise exposure. Thebaseline data survey for noise levels in the study area has been carried out by selecting 8 noise-monitoring locations. The noise quality monitoring locations are shown in table below and are shown in the topographical map Figure-3.2. Table 3.4 Noise Monitoring Locations Direction w.r.t S. No. Location Code Location Name plant site Distance w.r.t. plant site in km 1 N1 Plant site N2 Nad KD WSW N3 Golsara N N4 Hanchina ENE N5 Arjunagi E N6 Marsanahalli SE N7 Vibuthihalli ESE N8 Shrisara SSW 5.2 Bhagavathi Ana Labs Ltd., Hyderabad. 28

43 Limited Unit II Table 3.5 Noise Levels db (A) Time N1 N2 N3 N4 N5 N6 N7 N8 6: : : : : : : : : : : : : : : : : : : : : : : : Min Max Ld Ln Study area Scenario The minimum noise level during day time L d 49.7 db (A) at project site and maximum L d was recorded 54.2 db(a) at NAD KD while the minimum noise level during night time Ln db(a) at Golsaraand maximum L n 43.0 db (A) was recorded at Shrisara. Bhagavathi Ana Labs Ltd., Hyderabad. 29

44 Limited Unit II 3.6 Water Environment The water quality parameters as per IS: for water resources within 10 km of the study area have been used for describing the water environment and assessing the impacts on it. Based on the water sources in the project area sixground water samples, plant water andsix surface water samples were collected and analyzed. The details of the locations and distances from the study area shown in topographical map, in Figure 3.3. Surface water sampling was carried out inbhimariver (upstream and downstream), Sattanal river and Doddanalla present in the study area. The Surface water Sampling locations are given Table 3.6 and the Characteristics of Surface Water are given in Table-3.8. Location Code SW1 Table -3.6 Surface Water Quality Sampling Locations Sampling Station Distance w.r.t. Remarks plant site in km Bhima River Upstream 10.0 Surface water(river) SW2 Bhima RiverDownstream 8.5 Surface water(river) SW3 Sattanal river 3.0 Surface water(river) SW4 DoddaNalla 4.0 Surface water(stream) Table 3.7 Ground Water Quality Sampling Locations Location Sampling Station Distance w.r.t. plant Code site in km GW1 Project site 0.0 GW2 Mavanahalli 4.5 GW3 Vibuthihalli 5.0 GW4 Hanchina 4.0 GW5 Arjunagi 4.0 GW6 Shrisara 5.2 GW7 Nad KD 2.7 GW8 Golsara 3.6 Bhagavathi Ana Labs Ltd., Hyderabad. 30

45 Limited Unit II S.No. Parameters Table 3.8 Surface water Quality Data Bhima River Upstream Bhima River Downstream Sattanal river DoddaNalla I. Essential Characteristics 1. Colour (Hazen Units) <5 <5 <5 <5 2. Odour Un - Objectionable 3. Taste Agreeable Agreeable Agreeable Agreeable 4. Turbidity, NTU Dissolved Oxygen, mg/l ph Total Hardness as CaCO 3, mg/l 8. Iron as Fe, mg/l Chlorides as Cl, mg/l Residual free, Chlorine, Nil Nil Nil Nil mg/l II. Desirable Characteristics 1. Total Dissolved Solids, mg/l 2. Calcium as Ca, mg/l Magnesium as Mg, mg/l Copper as Cu, mg/l <0.01 <0.01 <0.01 < Manganese as Mn, mg/l <0.01 <0.01 <0.01 < Sulphate as SO 4, mg/l Nitrate as NO 3, mg/l Fluoride as F, mg/l Phenolic Compounds as <0.001 <0.001 <0.001 <0.001 C 6H 5OH, mg/l 10. Mercury as Hg, mg/l <0.001 <0.001 <0.001 < Cadmium as Cd, mg/l <0.01 <0.01 <0.01 < Selenium as Se, mg/l <0.01 <0.01 <0.01 < Arsenic as As, mg/l <0.01 <0.01 <0.01 < Cyanide as CN, mg/l <0.01 <0.01 <0.01 < Lead as Pb, mg/l <0.01 <0.01 <0.01 < Zinc as Zn, mg/l <0.01 <0.01 <0.01 < Anionic detergents as <0.02 <0.02 <0.02 <0.02 MBAS, mg/l 18. Chromium as Cr6 +, mg/l <0.01 <0.01 <0.01 < Mineral Oil, mg/l Absent Absent Absent Absent 20. Alkalinity CaCO 3, mg/l Aluminium as Al, mg/l <0.01 <0.01 <0.01 < Boron as B, mg/l <0.1 <0.1 <0.1 < Total Coliform, MPN/ ml Un - Objectionable Un - Objectionable Un - Objectionable Bhagavathi Ana Labs Ltd., Hyderabad. 31

46 Limited Unit II S.No. Parameters Table 3.9 Ground Water Quality Data Results Obtained Project Mavanahalli Vibuthihalli Hanchinahalli Arjunagi Shrisada Nad KD Golsara I. Essential Characteristics 1. Colour (Hazen < 5 < 5 < 5 < 5 < 5 < 5 < 5 < 5 2. Units) Odour Un - Objectionable Un - Objectionable Un Objectionable Un - Objectionable Un - Objectionabl e Un Objectionable Un - Objectionable Un Objectionable 3. Taste Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable 4. Turbidity, NTU < 1 < 1 < 1 < 1 2 < 1 < 1 < 1 5. ph Total Hardness as CaCO 3, mg/l 7. Iron as Fe, mg/l Chlorides as Cl, Residual free, Nil Nil Nil Nil Nil Nil Nil Nil Chlorine, mg/l II. Desirable Characteristics 1. Dissolved Solids, mg/l 2. Calcium as Ca, mg/l 3. Magnesium as Mg, mg/l 4. Copper as Cu, mg/l <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 < Manganese as Mn, < 0.01 <0.01 < 0.01 < 0.01 < 0.01 < 0.01 <0.01 <0.01 mg/l 6. Sulphate as SO 4, mg/l 7. Nitrate as NO 3, mg/l Fluoride as F, mg/l Phenolic Compounds as C 6H 5OH, mg/l 10 Mercury as Hg, mg/l 11 Cadmium as Cd, mg/l 12 Selenium as Se, mg/l <0.001 <0.001 <0.001 <0.001 <0.001 <0.001 <0.001 <0.001 <0.001 <0.001 <0.001 <0.001 <0.001 <0.001 <0.001 <0.001 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 < Arsenic as As, mg/l <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 < Cyanide as CN, <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 mg/l 15 Lead as Pb, mg/l <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 < Zinc as Zn, mg/l < 0.01 < 0.01 < 0.01 < 0.01 < 0.01 < 0.01 < 0.01 < Anionic detergents <0.02 <0.02 <0.02 <0.02 <0.02 <0.02 <0.02 <0.02 as MBAS, mg/l 18 Chromium as Cr6 +, <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 mg/l 19 Mineral Oil, mg/l Absent Absent Absent Absent Absent Absent Absent Absent 20 Alkalinity CaCO 3, mg/l Aluminium as Al, < 0.01 < 0.01 < 0.01 < 0.01 < 0.01 < 0.01 < 0.01 < 0.01 mg/l 22 Boron as B, mg/l < 0.1 < 0.1 < 0.1 < 0.1 < 0.1 < 0.1 < 0.1 < 0.1 Bhagavathi Ana Labs Ltd., Hyderabad. 32

47 Limited Unit II RegionalScenario The ph values for all the samples collected in the study area during study period were from 7.54 to 8.22 which were well within the limits. The TDS of all the samples were between 52 to 2080 mg/l. The Chloride levels in the ground water samples collected in the study area were ranging from 178 mg/l to a maximum of 255 mg/l except one sample, all are within the desirable limits. In the ground water samples collected from the study area, the hardness is varying from 195 mg/l to 1050 mg/l. In the ground water samples of study area the fluoride value were in the range of 0.50 mg/l to 1.30 mg/l. Overall all the ground water samples collected from the study area were found to be fit for human consumption, however the hardness, dissolved solids most of ground water samples seem to be above desirable limit but well within the permissible limits. The heavy metals in all samples are below detectable limits. 3.5 Soil Quality The present study on soil quality establishes the baseline characteristics in the study area surrounding the project site. The study has been addressed with the following objectives. To determine the base line characteristics To determine the existing soil characteristics around proposed project To determine the impact of industrialization/urbanization on soil characteristics To determine the impacts on soils from agricultural productivity point of view Criteria Adopted For Selection of Sampling Locations For studying the soil types and soil characteristics, 7 sampling locations were selected to assess the existing soil conditions representing various land use conditions and geological features Methodology of Sampling The homogenized soil samples collected at different locations were packed in a polyethylene plastic bag and sealed. The sealed samples were sent to laboratory for analysis. The physical, chemical parameter concentrations were determined from all samples. Bhagavathi Ana Labs Ltd., Hyderabad. 33

48 Limited Unit II Soil Sampling Locations Details of the soil sampling locations are given in Table Soil sampling location map is shown in Figure 3.6. The soil analysis results are shown in Table The rating chart of soil data is given in Table Table-3.10 Soil Sampling Locations Location Sampling Station Distance w.r.t. plant Code site in km S1 Project site 0.0 S2 Marsanahalli 4.5 S3 Vibuthihalli 5.0 S4 Arjunagi 4.0 S5 Shrisara 5.2 S6 Nad KD 2.7 S7 Golsara 3.6 Table 3.11 Soil Quality Data S.No Parameters Results Project site Marsanahalli Vibuthihalli Arjunagi Village Village Village 1. ph (1.2 Soil Water Extract) E.C ( mhos) (1:2 Soil water Extract) 3. Available Nitrogen, Kg/Hec Available Phosphorous as P 2 O 5, Kg/Hec 5. Available Potassium as K 2 O, Kg/Hec Ex. Sodium as Na, ppm Ex. Calcium as Ca, ppm Ex. Magnesium as Mg, ppm Sodium Absorption Ratio (SAR) 10. Water soluble Chloride as Cl, ppm Organic Carbon,% Texture Sandy Sandy Clay Sandy Loam Clay Loam a) Sand, % b) Silt, % c) Clay, % Bhagavathi Ana Labs Ltd., Hyderabad. 34

49 Limited Unit II S.No Parameters Results Project site Marsanahalli Shrisada Nada Golsara Village Village KD Village 1. ph (1.2 Soil Water Extract) Villag E.C ( mhos) (1:2 Soil water Extract) 3. Available Nitrogen, Kg/Hec Available Phosphorous as P 2 O 5, Kg/Hec 5. Available Potassium as K 2 O, Kg/Hec Ex. Sodium as Na, ppm Ex. Calcium as Ca, ppm Ex. Magnesium as Mg, ppm Sodium Absorption Ratio (SAR) 10. Water soluble Chloride as Cl, ppm Organic Carbon,% Texture Sandy Sandy Clay Sandy Sandy Clay Loam loam Clay a) Sand, % b) Silt, % c) Clay, % Table-3.12 RatingChart of the Soil Test Data (Indian Council of Agricultural Research, New Delhi) Nutrient Units Low Medium High Organic Carbon (as measure of available Nitrogen) % Below Above 0.75 Available Nitrogen (N) Kg/ha Below Above 560 Available Phosphorus (P) Kg/ha Below Above 25 Available Potassium (K) Kg/ha Below Above 280 Acidic Normal to saline Tending to become alkaline Alkaline Below Above 9.0 Normal PH Total Soluble salts (Conductivity in Millimhos/cm) Critical for germination Critical for growth of the sensitive crops Injurious to most crops Below Above 4.0 Bhagavathi Ana Labs Ltd., Hyderabad. 35

50 Limited Unit II Regional Scenario The analytical results of the soil samples collected during the study period are summarized below. The ph values in the study area are varying from 7.96 to 8.44 indicating that the soils are falling in normal to saline class. The electrical conductivity in the study area is varying from 98 to 150 umhos/cm indicating that soils falling under Normal category. The organic carbon in the study area is varying from 0.28 to 0.68 %, The Nitrates as N value in the study area is varying from 120 kg/ha to 380 kg/ha indicating that it requires addition of nitrates for proper growth. In the study area Phosphorus is varying from 10 kg/ha to 45 kg/ha. The Available Potassium in the study area is varying between 190 kg/ha to 390 kg/ha. 3.6 Biological Environment An ecological survey of the study area was conducted particularly with reference to listing of flora and fauna. Assessment of area, surrounding the project site in respect of plant species and animals were carried out by collecting field data and collating available information from the forest department. The flora and fauna details are presented in Table 3.13 and Table3.14 respectively. Flora The cropping pattern in the district reveals that food crops like jowar, maize, bajra and wheat among cereals, red gram, Bengal gram and green gram among pulses are major crops cultivated in the district. The major oilseed crops are sunflower, groundnut and safflower. Horticulture crops like grapes, pomegranate, ber, guavasapota, lime are also grown. Recent trend shows that there is a low shift towards fruit crops like Pomegranate and grapes of the total area of 8.61 lakh ha. Covered during cereals occupy about 55.2% by oilseeds 24.5% pulse 15.6% and other commercial crops like cotton and sugarcane about 4.8% There is slight shift towards commercial crops like cotton and sugarcane over last 2 years. Bhagavathi Ana Labs Ltd., Hyderabad. 36

51 Limited Unit II Table 3.13 List Of Flora In The Study Area S.No. Local Name Botanical Name 1 Amla,Nelli Emblicaofficinalis 2 Bur, Ala Ficusbengalensis 3 Arali,Aswatha Ficusreligiosa 4 Ari basavanapada Bauhiniracemosa 5 Babul, karijali,gobli Acacia nilotica 6 Neem,Bevu Azadirachtaindica 7 Gulmohar Delonixregia 8 Wood apple Feronialimonia 9 Sausage tree Kigeliapinnata 10 Channangi Lagerstroemia parviflora 11 Mango, Aam, Mavu Mangiferaindica 12 Rain tree Samaniasaman 13 Chinch, Hunse Tamarindusindica 14 Jamun, Nerale Syzygiumcumini 15 Woodi, oddi Delechandronfaicata 16 Bija-sal, Honne Pterecarpusmarsupium 17 Gotti,Gotte Zizyphusxylopyra 18 Hanmanki Flacourtiaramontchi 19 Ippi, mari Bassialatifolia 20 Khair, Katinamara Acacia catechu 21 Kari Randiadumetorum 22 Kakki, Bava Capparis species 23 Mulmuttal, Pangara Erythrinaindica 24 Muttal, Palas Buteafrondosa 25 Mashwal Chloroxylonswietenia 26 Nekri Ximenaamericana 27 Siris, Bage Albizialebbek 28 Niral, Jambul Eugenia jambolana 29 Sitaphal Anonasquamosa 30 Tugli Albizzi 31 Tapasi Holopteliaintegrifolia 32 Gajag Ceasalptinabonduce Shrubs 1 Shisha, kammari Lantana camara 2 Honnambri, Tarwad Cassia auriculata 3 Henkal Gymnosporiamontana 4 Kalli, Sher Eupnorbiatirucalli Bhagavathi Ana Labs Ltd., Hyderabad. 37

52 Limited Unit II Fauna 5 Karunda Carissa carandas 6 Lekki, Nirgudi Vitexnegundo 7 Pargi Toddaliaaculata 8 Revdi Capparisdivaricata Herbs 1 Anantmul (Indian sarsaparila) Hemidusmusindicus 2 Nachikemullu Mimosa pudica Climbers 1 Bondwel Lettsomiaelliptica 2 Gulganj Abrusprecatorius 3 Kusri, Wildjasmin, Advimallige Jasminum species 4 Palaswel Buteasuperba 5 Wagati Wageteaspicata Table 3.14 List of Fauna In The Study Area S.No. Local Name Botanical Name Schedule 1 Common Jackal Canis - aureus Schedule-II Part-II 2 Common Wolf Canis-lypuspallipes Schedule -I 3 Common Mongoose Herpestes-edwardsi Schedule -IV 4 Indian Hare Lepur-Nigricollis Schedule -IV 5 Pangolin Manis- crassicaudata Schedule -I 6 Wild pig Sus-screfa Schedule -I 7 Cobra Naja -naja Schedule-II Part-II 8 Rat snakes PtyasMucosus Schedule-II Part-II 9 Viper Viperarusselli Schedule-II Part-II Avifauna (Birds) 1 Baya weaver Bird Ploceusphilppinus Schedule -IV 2 Small -Barbets Capitomidae Schedule -IV 3 Bulbuls Pycnonotidae Schedule -IV 4 Bustard Qualis Turnicidae Schedule -IV 5 Cuckoos Cuculidae Schedule -IV 6 Common Myna Acridotherestristis Schedule -IV 7 Doves Columbidae Schedule -IV 8 Magpies Corvidae Schedule -IV 9 Munias Estrildinae Schedule -IV 10 Parakeets Psittacidae Schedule -IV 11 Pigeons Columbidae Schedule -IV 12 Sun birds Nectarinidae Schedule -IV 13 Koel Eudynamysscolopocea 14 Peacock Pavociristatus Schedule-I Part-III 15 Yellow throated sparrow Passezdomesticus 16 Tailor Bird Orthotomus 17 White Backed vulture Gyps-bengalensis Schedule-IV Bhagavathi Ana Labs Ltd., Hyderabad. 38

53 Limited Unit II 3.7 Socio Economic Environment The study area consists of 15 villages. Total population of the study area is with males and females. The sex ratio of the district as per 2001 census is 950. The total literacy rate is 44.2 %.Relatively high level of literate population in the locality is an indicator of the development of the area. The total percent of main and marginalworkers is out of which % is marginal workers and 27.7 % is main workers and % is non workers. The demographic, literacy details of the study area are given as under:- Table-3.15 Demographic details of the study area Description 2011 Actual Population 2,175,102 Male 1,112,953 Female 1,062,149 Population Growth 20.38% Area Sq. Km 10,517 Density/km2 207 Proportion to Karnataka Population 3.56% Sex Ratio (Per 1000) 954 Child Sex Ratio (0-6 Age) 930 Average Literacy 67.2 Male Literacy Female Literacy Total Child Population (0-6 Age) 303,480 Male Population (0-6 Age) 157,212 Female Population (0-6 Age) 146,268 Literates 1,257,742 Male Literates 739,873 Female Literates 517,869 Child Proportion (0-6 Age) 13.95% Boys Proportion (0-6 Age) 14.13% Girls Proportion (0-6 Age) 13.77% Infrastructural Facilities Education Facilities In the 10 km radius buffer zone comprises 32 primary schools and 22 Middle schools are. Here is need to focus on Vocational and Degree college and infrastructure in govt. Bhagavathi Ana Labs Ltd., Hyderabad. 39

54 Limited Unit II educational institutionsi.e. furniture, toilets, drinking water and RCC building for all schools, library facilities, Girl child and Adult education. Health Facilities In the buffer zone of 10 km area Health facilities comprise 1 Public Health Centre is here, 1 Maternity & Child Welfare Centre, 1 Family Welfare Centre and here is need to focus on Health Care infrastructure facilities. Animal Husbandry The study area is provided with veterinary services with Dispensary and local centers for the livestocks. Drinking Water Supply Adequate facilities are available for tapping drinking water in all of the villages and towns. Most of the villagers depend on underground water resources such as from well, tank etc. 3.8 Land Use Pattern As per the 2001 census data the land use pattern is like this hectors comprises in the buffer zone among that Irrigated land is hectors, un irrigated land is hectors, cultivable waste hectors, forest area is nil and area not available land for Cultivation is hectors. Land use of the study area around the project site as per census 2001 is given below. Table-3.17 Land Use Pattern of the Study Area S. No. Particulars Land Use pattern (In Ha) 1 Irrigated Area Un-irrigated area Cultivable Waste Forest Area 0 5 Area Not Available for Cultivation Total Area Seismicity The study area fall under seismic zone II as per IS: ,BIS, GOI,Seismic zoning map of India Meteorological Department shown in Figure 3.7. Bhagavathi Ana Labs Ltd., Hyderabad. 40

55 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 EnhancedSugar 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 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 (PM 10 & PM 2.5 ) 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 Bhagavathi Ana Labs Ltd., Hyderabad. 41

56 forheavy truck mobility. It will be ensured that diesel powered vehicles will be properly maintained to comply with exhaust emission requirements 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 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 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. Plantsanitation 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. Bhagavathi Ana Labs Ltd., Hyderabad. 42

57 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 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. Local people will be given preference for employment depending on their suitability; All the applicable guidelines under the relevant Acts and Rules related to labour welfare and safety will be implemented during the construction phase; The contractor has been advised to provide fire wood/kerosene/lpg to the workers to prevent cutting of nearby trees for firewood; and The construction site will be secured with fencing and is having guarded entry points. Bhagavathi Ana Labs Ltd., Hyderabad. 43

58 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:- Dyked enclosures will be provided so as to contain complete contents of the largest tank; Diesel and other fuels will be stored in separate dyke enclosures; Tanks having large storage capacity for will be separated by fire insulating walls from other storage tanks; and The distance between the storage tanks will be maintained half their height 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 JSL 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. Bhagavathi Ana Labs Ltd., Hyderabad. 44

59 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 with Pollution control Equipment Parameters Number of Stacks 1 Common Stack with no. of flues One flue Stack Height from ground level (m) 90 Stack Dia. (m) (internal) 1.2 Exhaust Gas Temperature ( 0 C) 140 Exit Gas Velocity (m/s) 13.5 Volumetric Flow Rate (m 3 /s) 140 APCE Proposed ESP with outlet concentration PM <50 mg/nm 3 Emission Rate of PM (gm/sec 0.55 Emission Rate of SO 2 (gm/sec) Emission Rate of NO x (gm/sec) Input Data for Ground Level Concentrations (GLCs) Predictions Meteorological Data The meteorological data recorded continuously during the study period on hourly basis on wind speed, wind direction and temperature has been processed for application of ISC AERMOD View model. Simulation Model for Prediction using Industrial Source Complex AERMOD View The pollutants released into the atmosphere will disperse in the down wind direction and finally reach the ground at farther distance from the source. The concentration of ground level concentrations mainly depends upon the strength of the emission source and micrometeorology of the study area. Bhagavathi Ana Labs Ltd., Hyderabad. 45

60 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 Post Project Scenario Predicted maximum ground level concentrations considering micro meteorological data of Post Monsoon (Oct- Nov) 2012 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 4.2along with isopleths shown in Figures 4.1 to 4.3. Bhagavathi Ana Labs Ltd., Hyderabad. 46

61 Season Post Monsoon (October & November) Year Table 4.2 Over all Scenario Maximum Incremental Levels (g/m 3 ) PM 10 SO 2 NO x Distance km Direction WSW The predicted ground level concentrations obtained when superimposed on the baseline concentrations are well within the prescribed NAAQ Standards. Mitigation Measures The power plant operates during cane crushing season and off season by using bagasse as a fuel. Electrostatic precipitator is proposed for the boiler. The height of the stack is fixed at 90 m as per CPCB guidelines. Fugitive emissions at transfer points will be controlled by water sprinklers. 4.4 Impact on Noise Levels The equipment in the plant would be designed for noise levels not exceeding 90 db(a). Proper encasement of noise generating sources will be done to control the noise levels below 75 db(a) at plant boundary. The steam turbine generator is provided with acoustic enclosures and silencers in the exhaust. The steam turbine is housed in a closed building which considerably reduces the noise. In case of maintenance, the persons working near the steam turbine generator building are provided with ear muffs. Green belt in an area of acres will be developed all around the plant which will act as a noise barrier. In general the following methods will be adopted to control the noise pollution from the proposed Enhancement Project units:- The use of concrete and masonry walls and barriers keeping in view the benefits of stiffness weight and cavity construction and the need to provide well sealed sound attenuating doors and windows. The use of complete or partial enclosures Attenuation by use of sound absorbents on walls and fixed or suspended ceilings Introduction of control and monitoring rooms having good sound insulation properties The use of vibration insulation techniques Bhagavathi Ana Labs Ltd., Hyderabad. 47

62 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 100C. 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 wastewater 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 Waste water generation The total waste water generation from the Sugar plant along with the Cogeneration Plant will be432 m 3 /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 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. Bhagavathi Ana Labs Ltd., Hyderabad. 48

63 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 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 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:- Increase in employment opportunities and Reduction in migrants to outside for employment. Increase in literacy rate. Growth in service sectors Increase in consumer prices of indigenous produce and services, land prices, house rent rates and Labour prices. Improvement in socio cultural environment of the study area. Improvement in transport, communication, health and educational services. Increase in employment due to increased business, trade commerce and service sector. The overall impact on the socio economic environment will be beneficial 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. Bhagavathi Ana Labs Ltd., Hyderabad. 49

64 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:- Particulate Matter (SPM, PM 10 & PM 2.5 ) Sulphur dioxide 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 ESPs. 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. Bhagavathi Ana Labs Ltd., Hyderabad. 50

65 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:- To verify the result of the impact assessment study in particular with regards to new developments; To follow the trend of parameters which have been identified as critical; To check or assess the efficacy of the controlling measures; 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; To check assumptions made with regard to the development and to detect deviations in order to initiate necessary measures; and To establish a database for future Impact Assessment Studies for expansion projects. The attributes, which merit regular monitoring, are specified below:- Air quality; Water and wastewater quality; Noise levels; Soil quality; Ecological preservation and afforestation; and 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 Bhagavathi Ana Labs Ltd., Hyderabad. 51

66 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 5.2 Post Project Monitoring Parameters to Source Location be monitored Frequency Responsibility Wind speed, Meteorology At the project site direction, M/s Jamkhandi temperature, Hourly Sugars Limited relative humidity rainfall Ambient Air Quality Within plant and surrounding 10km radial zone. PM 10, PM 2.5 SO 2, NO x Monthly M/s Jamkhandi Sugars Limited Within the plant and surrounding 10km Water Quality radial zone Surface Water As per IS: Monthly M/s Jamkhandi Sugars Limited As well as Ground Water Noise Levels Within the plant and surrounding 10km radial zone. Noise levels Monthly M/s Jamkhandi Sugars Limited Soil quality Within the plant and 10 km radial zone Soil parameters Boilers Individual Units Particulate matter, SO 2, NO x Monthly Monthly M/s Jamkhandi Sugars Limited M/s Jamkhandi Sugars Limited Bhagavathi Ana Labs Ltd., Hyderabad. 52

67 Source Wastewater Location Inlet and outlet of Parameters to be monitored ph, TDS, COD, Frequency Monthly Responsibility ETP SS and others. Steam Generator Blow down ph, SS, Oil, Grease, Cu, Iron Weekly M/s Jamkhandi Sugars Limited Cooling Tower Phosphates Weekly 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-5.3 List of Equipment Proposed for Environmental Laboratory Name of the Equipment Automatic Weather Station, which can record wind speed, wind direction temperature, relative humidity, rainfall, Solar radiation Sunshine a) Online Automatic gaseous stack monitoring kit for SO 2, NO x, O 2, Flue gas volume, Temperature etc. b) On line dust monitor Fine Particulate Matter samplers with PM 10 & PM 2.5 provision 5 Portable Flue Gas Combustion Analyser 1 Atomic Absorption Spectrophotometer 1 Mercury analyzer 1 Portable Noise level meter (Dosimeter) 2 Portable Waste Water Analysis Kit 1 BOD Incubator 1 COD Digester 2 Electronic Balance 1 Calorimeter 1 Conductivity Meter 2 Different micron sieves (set) Dissolved Oxygen Meter Brief case size 2 Electronic colony counter 1 Flask Shaker 1 Nos. 1 Bhagavathi Ana Labs Ltd., Hyderabad set

68 Hot Air Oven 2 Laboratory Water Distillation and demineralisation (DM) unit 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:- Obtaining consent order from State Pollution Control Board. Environmental monitoring. Analysis of environmental data, reports, preparations and transmission of report to statutory authorities, Corporate Centre etc. Co-ordinate with statutory bodies, functional groups of the station, head office etc. Interactions for evolving and implementation of modification programs to improve the availability / efficiency of pollution control devices / systems. Environmental Appraisal (Internal) and Environmental Audit. 5.4 Expenditure and Environmental Measures The budget for Environmental Protection Measures in Lakhs is given as under:- Table-5.4 Budget for Environmental Measures S. No. Particulars Capital cost (Rs.Lakhs) Recurring cost (Rs.Lakhs) 1. Air Pollution & Noise Control Septic tanks & Soak pits Wastewater Treatment Environment Monitoring and Management Occupational Health & Safety Green Belt TOTAL Bhagavathi Ana Labs Ltd., Hyderabad. 54

69 Chapter 6 Additional Studies (Risk Assessment & Disaster Management Plan) 6.0 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. Introduction Hazard Identification and Risk Analysis 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. Bhagavathi Ana Labs Ltd., Hyderabad. 55

70 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:- Procedures for storing, handling, shipping, and transferring of HAZMAT; Facility information including: physical features and location of storm and sanitary sewer systems; Site measures for managing and controlling HAZMAT releases; and, Base emergency response and preparedness programs. 6.3 Methodology The Risk Analysis Study carried out under the following task heads:- System Study The system description covers the plant description, storage & handling of fuels / chemicals, etc. Hazard Identification The hazards associated with the proposed Enhancement Project have been discussed in terms of material hazards due to fuel storage. Frequency of Hazard Occurrence Bhagavathi Ana Labs Ltd., Hyderabad. 56

71 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. 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. 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 Material Hazards Diesel Oil is used as an auxiliary fuel, which is inflammable Process Hazards No process hazards are assessed 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. Bhagavathi Ana Labs Ltd., Hyderabad. 57

72 Table -6.3 Hazard Intensity Classification Remedial measures: Bhagavathi Ana Labs Ltd., Hyderabad. 58

73 Storage in tightly closed containers in a cool, well-ventilated area away from WATER, HEAT, COMBUSTIBLES (such as WOOD, PAPER and OIL) and LIGHT. Storage away from incompatible materials such as flammable materials, oxidizing materials, reducing materials, strong bases. Use of corrosion-resistant structural materials and lighting and ventilation systems in the storage area. Wood and other organic/combustible materials will not be used on floors, structural materials and ventilation systems in the storage area. Use of airtight containers, kept well sealed, securely labelled and protected from damage Use of suitable, approved storage cabinets, tanks, rooms and buildings. Suitable storage will include glass bottles and containers. Storage tanks will be above ground and surrounded with dikes capable of holding entire contents. Limit quantity of material in storage. Restrict access to storage area. Post warning signs when appropriate. Keep storage area separate from populated work areas. Inspect periodically for deficiencies such as damage or leaks. 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. Bhagavathi Ana Labs Ltd., Hyderabad. 59

74 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. 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. Emergency procedures will be well rehearsed and state of readiness will be achieved 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: Explosion in boilers, turbo generators, and transformers. Accidental release of huge ash slurry Chlorine leakage in the water treatment plant 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. Bhagavathi Ana Labs Ltd., Hyderabad. 60

75 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 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 Bhagavathi Ana Labs Ltd., Hyderabad. 61

76 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:- On-site Emergency Plan 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 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 Effect the rescue and treatment of casualties Safeguard other personnel in the premises Minimise damage to property and environment Initially contain and ultimately bring the incident under control Identify any dead Provide for the needs of relatives Provide authoritative information to the news media Secure the safe rehabilitation of affected areas Preserve relevant records and equipment for the subsequent enquiry into the cause and circumstances of emergency Action Plans The Action Plan consists of: Identification of Key Personnel Defining responsibilities of Key Personnel Designating Emergency Control Centres and Assembly Points Declaration of Emergency Sending All Clear Signal Bhagavathi Ana Labs Ltd., Hyderabad. 62

77 Defining action s to be taken by non-key personnel during emergency 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:- Site Controller (SC) Incidental Controller (IC) Liaison and Communication Officer (LCO) Fire and Security Officer (FSO) 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 Bhagavathi Ana Labs Ltd., Hyderabad. 63

78 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 Responsibilities of Key Personnel Site Controller (SC) On getting information about emergency, proceed to Main Control Centre Call in outside emergency services Take control of areas outside the plant, which are affected Maintain continuous communication, review situation and assess possible course of events Direct evacuation of nearby settlements, if necessary Ensure that casualties are getting enough help Arrange for additional medical help and inform relatives Liaison with Fire and Police Services and Provide advice on possible effects on outside areas Arrange for chronological recording of the emergency Where emergency is prolonged, arrange for relieving personnel, their catering needs etc. Inform higher officials in head office Ensure preservation of evidence Direct rehabilitation work on termination of emergency Bhagavathi Ana Labs Ltd., Hyderabad. 64

79 Incident Controller (IC) On getting emergency information, proceed to Main Control Centre Activate emergency procedure such as calling in various teams 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 Direct rescue and repair activities Guide fire-fighting teams Arrange to search affected area and rescue trapped persons Arrange to evacuate non-essential personnel to safe area/assembly point Set up communications network and establish communication with SC Arrange for additional help/equipment to key personnel of various teams Consider need for preserving all records, information for subsequent enquiries Liaison and Communications Officer To ensure that casualties receive adequate attention, arrange additional help if required and inform relatives To control traffic movements into the plant and ensure that alternative transport is available when need arises When emergency is prolonged, arrange for the relief of personnel and organize refreshments/catering facility Advise the Site Controller of the situation, recommending (if necessary) evacuation of staff from assembly points 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 Maintain prior agreed inventory in the Control Room Maintain a log of the incident on tape 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 Bhagavathi Ana Labs Ltd., Hyderabad. 65

80 Fire and Safety Officer 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 Inform the Shift Officer In-charge, if there is any large escape of fumes. 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) 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 Bhagavathi Ana Labs Ltd., Hyderabad. 66

81 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 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:- P&T phones, mobile phones, intercoms, and wireless Fax and telex Emergency manuals Blown up area maps Internal telephone directories District telephone directories Emergency lights Wind direction and speed indicator Bhagavathi Ana Labs Ltd., Hyderabad. 67

82 Requisite sets of personal protective equipment such as gloves, gumboots and aprons 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 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 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. Bhagavathi Ana Labs Ltd., Hyderabad. 68

83 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 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 Essential Elements Essential elements of this scheme are given below:- Mutual aid must be a written document, signed by Location In-charge of all the industries concerned Bhagavathi Ana Labs Ltd., Hyderabad. 69

84 It should specify available quantity of materials/ equipment that can be spared (not that which is in stock) Mode of requisition during an emergency. It should authorize the shift-in-charge to quickly deploy available material/equipment without waiting for formalities like gate pass etc. It should spell out mode of payment/replacement of material given during an emergency It should specify key personnel who are authorized to requisition materials from other industries or who can send materials to other industries It should state clearly mode of receipt of materials at the affected unit without waiting for quantity/quality verification etc. Revision number and validity of agreement should be mentioned This may be updated from time to time based on experience gained 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 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 Bhagavathi Ana Labs Ltd., Hyderabad. 70

85 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: The project will be provided with a control system located in a central control room. The shift engineer will operate the plant from his console panel. All operations will be represented in a graphic panel on the console and every operation will be depicted as operating sequences. All operating parameters will be displayed in digital format. Alarms will be provided for all parameters, when they exceed set values. High-High/Low-Low alarms and trip functions will be provided to trip Pumps/compressors to bring the entire system to a safe shutdown 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. Fire water storage tanks of adequate capacity. Fire water pump house containing combination of diesel and electrically driven pumps. Hydrant system complete with suitable size piping, valves, instrumentation, hoses, nozzles, hose boxes/stations, monitors etc. Foam injection system for fuel oil/storage tanks consisting of foam concentrate tanks, foam pumps, in-line inductors, valves, piping and instrumentation etc. Automatic high velocity water spray system consisting of detectors, deluge valves projectors, valves, piping and instrumentation. Bhagavathi Ana Labs Ltd., Hyderabad. 71

86 Automatic medium velocity water spray system consisting of QB Detectors/smoke detectors, linear heat sensing cable detectors, deluge valves, isolation valves, nozzles, piping, instrumentation etc. 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. 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. 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. Fire tenders/engines of water type, DCP type/foam type, trailer pump with fire jeep etc. provided in the fire station. Complete instrumentation and control system for the entire fire detection and protection system for safe operation of the complete system 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:- A proper layout to prevent and minimize the effects of any hazardous situation Design of storage vessels and all components to codes and standards to withstand the rigorous duty Provision of operating systems to conduct the process through wellestablished safe operating procedures A control system, which monitors all plant parameters and give alarms Control system, which has trip provisions to prevent hazard conditions escalating A gas detection system which will provide early warning of any leaks Bhagavathi Ana Labs Ltd., Hyderabad. 72

87 Provision of a fire protection system to control fire 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 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 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: Collector/District Magistrate Deputy Commissioner Bhagavathi Ana Labs Ltd., Hyderabad. 73

88 Commissioner of Police Municipal Commissioner, if municipalities are involved Deputy Director, Health 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: Police Health & Family Welfare Medical Revenue Fire Service Transport Electricity Animal Husbandry Agriculture Civil Defence PWD Civil Supplies 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. Bhagavathi Ana Labs Ltd., Hyderabad. 74

89 Chapter 7 Project Benefits 7.0 Benefits Limited,has proposed Enhancement from 2500 TCD to 3500 TCD Sugar Plant and 15 MW to 27 MW Cogeneration Unit at Nad KD village, Indi Taluk, Bijapur district, Karnataka state. This project development will give rise to social and economic development measures in the study area. 7.1 Improvement in Physical Infrastructure The Enhancement project is expected to yield a positive impact on the socio-economic environment. It helps in sustainable development of this area including further development of physical Infrastructural facilities. The following physical infrastructure facilities will improve due to proposed project:- Road Transport facilities Educational facilities Water supply and sanitation 7.2 Improvement in Social Infrastructure The Enhancement project will lead to direct and indirect employment opportunity. Employment is expected during civil construction period, in trade, garbage lifting, sanitation, plantation works and other ancillary services. Employment in these sectors will be primarily temporary or contractual and involvement of unskilled labour will be more. This will enhance their income and lead to overall economic growth of the area. The following changes in socio-economic status are expected to take place with this project. The project will have a strong positive employment and income effect, both direct as well as indirect because of better indirect employment opportunities due to this project. The project is going to have positive impact on consumption behavior by way of raising average consumption and income through multiplier effect. The project is going to bring about Bhagavathi Ana Labs Ltd., Hyderabad. 75

90 changes in the pattern of demand from food to non-food items and sufficient income is generated. Following development of social infrastructures will be carried out:-. Education facilities Banking facilities Post offices and Communication facilities Medical facilities Recreation facilities Business establishments Community facilities 7.3 Places of Historical Importance There is no historical or archaeological monument within 10 km of the area. Industrial development and consequent economic development will lead to improvement in the living standards of the people and enhanced social awareness. On the other hand, the Enhancement project is likely to have several benefits like improvement in indirect employment generation and economic growth of the area, by way of improved infrastructure facilities and better socio-economic conditions. 7.4 Other Tangible Benefits The Expansion project is likely to have other tangible benefits as given below:- Indirect employment opportunities to local people in contractual works like housing construction, transportations, sanitation, for supply of goods and services to the project and other community services; Additional housing demand for rental accommodation will be increased; Market and business establishment facilities will be alsoincreased; Cultural, recreation and aesthetic facilities will be improved; Improvement in communication, transport, education, community development and medical facilities. Bhagavathi Ana Labs Ltd., Hyderabad. 76

91 Chapter 8 Environmental Management Plan 8.0 Introduction The Environment Management Plan describes both generic good practice measures and site-specific measures so as to mitigate potential impacts associated with the proposed activities. The Environmental Management Plan (EMP) of the Expansion plant with respect to noise, air quality, water quality, solid waste, ecology, landscape socio-economic measure are summarized below:- The EMP provides a delivery mechanism to address potential adverse impacts and to introduce standards of good practice to be adopted for all project works. For each stage of the program, the EMP lists all the requirements to ensure effective mitigation of every potential environmental attribute and socio-economic impacts. For each impact type during construction and operation the following information is presented:- A comprehensive listing of the mitigation measures (actions) that are needed to implement; The parameters that will be monitored to ensure effective implementation of the action; The timing for implementation of the action to ensure that the objectives of mitigation are fully met. 8.1 Environmental Management Plan during Construction Phase Air Environment The setting up of enhanced project from 2500 to 3500 TCDof Sugar Plant and 15 MW to 27 MW of Cogeneration power plantwould 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 Noise Environment There will be marginal increase in noise levels during construction phase, which is temporary and intermittent. Bhagavathi Ana Labs Ltd., Hyderabad. 77

92 8.1.3 Water Environment During construction, provision for infra-structural services including water supply, sewage, drainage facilities and electrification will be made 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 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 Safety and Health Adequate space will be provided for construction of temporary sheds for construction workers mobilized by the contractors. M/s Limited 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 Air Environment The major pollutants emerged due to Sugar Plant and Cogeneration Plant operations are suspended particulate matter(spm), fine particulate matter (PM 10 & PM 2.5 ), Sulphur dioxide (SO 2 ) and Oxides of Nitrogen (NO x ). 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 ESP. Bhagavathi Ana Labs Ltd., Hyderabad. 78

93 Particulate Matter emission level from the stack chimney will be less than 50 mg/nm 3 and the stack height is proposed to 90 m. SO 2 concentration will be negligible as the bagasse will be used as fuel for boiler. The periodic evaluation for the efficiency performance of ESP will be carried out. For controlling fugitive dust, in hopper, reclaimer, conveyors, silos etc. bag filters shall be installed. Fugitive emissions due to storage, transportation, etc. and the leakages and spillages shall be continuously monitored and controlled. Water conservation measures shall be undertaken for effective implementation. Cooling water is put into closed circuit to minimize the evaporation losses. Thermal insulation will be provided wherever necessary to minimize heat radiation from the equipment, piping etc., to ensure protection of personnel Noise Environment All rotating items are well lubricated and provided with enclosures as far as possible to reduce noise. The design features of machineries shall be provided to ensure low noise levels in the working areas. 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. Noise generating equipment including fans, blowers, pumps, motors etc.,will be running with speed less than 1500 rpm and reduce noise levels. Provision for silencers wherever possible. Green belt development will be done and it will act as noise reducers. Requisite enclosures will also be provided on the working platform/areas to provide local protection in high noise level areas. All heavy earthmoving equipment will be kept in a well maintained condition. Proper lubrication and house equipment will be kept in better condition 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. Bhagavathi Ana Labs Ltd., Hyderabad. 79

94 8.2.3 Solid Waste Management 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 a landfill. 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. 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 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 Bhima 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:- No trade effluent shall be discharged from the Plants Cooling water is put into closed circuit to minimize the evaporation losses The domestic sewages from the Plants, Sugar Plant with Cogeneration Unit and Township shall be treated in the Sewage Treatment Plant to meet the Statutory Discharge Norms and the treated sewage shall be used for Green Belt; No percolation of treated water to deep ground water table is done. Periodical monitoring for specific parameters shall be done regularly. Bhagavathi Ana Labs Ltd., Hyderabad. 80

95 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 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 Bhagavathi Ana Labs Ltd., Hyderabad. 81

96 drainage system will be discharged outside the plant boundary. All drains will be lined and will be arranged to provide the shortest possible drainage path for efficient drainage. Rainwater Harvesting System (RWHS) designs and construction details are given below. Figure :8.1 Rainwater Harvesting Structure The plant may have an in-house environmental laboratory for the routine monitoring of air, water, soil and noise. For all non-routine analysis, the plant may utilize the services of external laboratories and facilities. Surface Area Rainwater Harvesting The unit is proposed rain water harvesting by way of surface run-off. Surface area = m 2 Annual rainfall = 595mm Considering Runoff co-efficient as 0.6 Total water recharged by harvesting = (Area X Annual Rainfall X Runoff coefficient for surface) = x 0.595m x 0.6 Total water recharged by harvesting = m 3 Bhagavathi Ana Labs Ltd., Hyderabad. 82

97 Roof top Rainwater Harvesting Rainwater Harvesting scheme is proposed and will be sought for suitable place within the premises. The unit is proposed to rain water harvesting by way of capturing run-off from rooftops. The basic concept of harvesting rainwater is simple. Rainwater is mostly collected from the roofs of buildings. It flows by gravity through gutters and downspouts into a storage tank. Roof top area = m 2 Annual rainfall = 595mm Considering Runoff co-efficient as 0.85 Total water recharged by harvesting = (Area X Annual Rainfall X Runoff coefficient for roof top) = m 2 x m x 0.85 Total water recharged by harvesting = m 3 Figure :8.2 Rooftop Rain Water Recharge Bhagavathi Ana Labs Ltd., Hyderabad. 83

98 Figure :8.3 Design of Trench cum Injection Wells The recharging pit i.e., the bottom basin of the recharging pit will be of size 15mx15mx4.5m deep. The bottom basin will consist of many nos. of 100 mm dia PVC perforated pipes installed upto the sand strata depth from the basin bed level. The perforated pipes will be wrapped with coir, so that the water is filtered while passing to the ground. Hand rails will be provided to the recharging pit at the top bench with hard footpath for safety purpose. 8.5 Housekeeping Salient features of housekeeping will be adopted are as follows:- Mechanized cleaning of roads and floor area inside the plant premises by using road sweeper and mobile vacuum cleaner on regular basis; Training on regular basis to all workers and staff about the importance of cleanliness; Careful garbage transportation to dumping site and disinfection of transport vehicles body; Decorative plantation and gardening to improve aesthetics of the plant; and Construction of suitably designed drains all along the roads and boundary of the plant premises. Bhagavathi Ana Labs Ltd., Hyderabad. 84

99 8.6 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. Table 8.1 Health Evaluation schedule: Frequency of Periodical Examination of Occupational Health Occupation Type of evaluation Frequency Cane Crushing Area Sugar Process Area& Cogeneration Area Pre-placement Chest X-ray, spirometry and vision testing Chest X-ray, spirometry and vision testing Noise prone areas Audiometry Annually Main Control Room Far & Near Vision; Colour Vision; and Hearing tests Ash Handling Area& Bagasse Handling Area Chest X-ray, spirometry, Vision; and Hearing tests Every 5 years to age <30; Every 4 years to age 31-40; and every 2 years to age 41-50; Every 5 years to age <30; Every 4 years to age 31-40; and every 2 years to age 41-50; Every 5 years to age <30; Every 4 years to age 31-40; And every 2 years to age 41-50; Every 5 years to age <30; Every 4 years to age 31-40; And very 2 years to age 41-50; The precautionary measures, which will be followed to reduce the risk due to dust on the workers, engaged in and around the material handling areas: Adequate arrangements are made for preventing the generation of dust by providing the chutes at transfer points to reduce the falling height of material, preventing spillage of material by maintaining the handling equipment, isolating the high dust generating areas by enclosing them in appropriate housing and appropriately de-dusting through high efficiency bag filters; Massive plantation will be undertaken in the plant. The tree cover acts as a sink for both gaseous as well as particulate matter. Due care will be taken to maintain continuous water supply in the water spraying system and all efforts would be made to suppress the dust by water spraying at appropriate points; All material handling systems are automatic. The workers engaged in material handling system will be provided with personal protective equipment like dust masks, respirators, helmets, face shields etc; Bhagavathi Ana Labs Ltd., Hyderabad. 85

100 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 Green belt development in around 33 % of the total plant area i.e acres will be developed. Green belt of around 50 m width will be provided throughout the periphery of the existing project site Green Belt and Plantation Plan Green belt development in an industry is one of the most effective environmental pollution control measures. Trees play vital role in keeping the ground level concentrations in control within the plant premises and also in preventing the horizontal dispersion of the pollutants to the surrounding areas. They are very effective in trapping the pollution causing agents viz. dust and gaseous pollutants. They are also considered to be excellent indicators of excessive ground level concentrations. The green belt is being proposed for the following objectives. Out of the total acres of land, green belt will be developed 33% in acres. Apart from the bulk plantation around the boundaries, Roadside avenue plantations will also be taken up. Based on the agro-climatic conditions of the region, location of the Sugar Plant with Cogeneration Unit, physico-bio-chemical properties of the soil strata, nature of the pollutants and their rate of dispersion, it is suggested to develop greenbelt around the plant. Such green areas would improve the floral status and serve the dual purpose of arrest of any fugitive dust from unpaved or open areas and also help to abate the noise effects through dampening effects. Table-8.2 Suggested Plant Species for Road Side Plantation S. No. Scientific Name Vernacular name 1 Bauhimapururea Kachnar 2 Leucaenaleucocephala Subabool 3 Delonixregia Gulmohar 4 Cassia fistula Amaltas 5 Pongamiapinnata Karanj 6 Samaniasaman Rain tree Table Bhagavathi Ana Labs Ltd., Hyderabad. 86

101 Plant Species Suggested for Green Belt Development suggested by CPCB S.No. Botanical name of the plant Size of the grown up Type and suitable site, where the plants are to be plotted tree 1 Acacia auriculaeformis Medium Semi-evergreen fragrant white flowers suitable in green belts and on road sides 2 Adina corodifolia Large Deciduous, a light demander, suitable on open areas and near flares 3 Aeglemarmelos Medium Deciduous, good for green belts near temples. 4 Anogeissuslatifolia Medium Deciduous, Suitable for green belts 5 Artabotryshexapetaius Small Evergreen shrub with fragrant flowers good for gardens and inside boundary wall and long canals 6 Averrhoacarambola Small Semi evergreen, good in narrow green belts along the ash pond 7 Azadirachtaindica Large Evergreen, suitable in green belts along the boundary and outside office & sensitive buildings like hospitals. 8 Bauhinia variegate Medium Deciduous, good in green belts in garden and as a second row avenue tree 9 Borassusflabellifer Large A tall deciduous palm can be used as wind break when of different age. 10 Boswelliaserrata Medium Deciduous suitable on green belt on willow soils 11 Bureraserrata Medium Evergreen, suitable on willow soils as a green belt or avenue tree 12 Buteamonosperma Medium Deciduous for green belt and as a second row avenue tree 13 Caesalpiniapulcherrima Small A large shrub, suitable for gardens outside offices and along channels 14 Callistemon lanceolatus Medium Deciduous for some time, ornamental plant in garden 15 Carevaaroborea Large Deciduous, good in green belts Bhagavathi Ana Labs Ltd., Hyderabad. 87

102 S.No. Botanical name of the plant Size of the grown up Type and suitable site, where the plants are to be plotted tree 16 CarrisaCarandas Small Semi evergreen large bushy shrub good as a hedge to protect against noise. 17 Carhotaurents Large A lofty palm, good as a wind break 18 Cassia fistula Medium Deciduous, good ornamental tree in green belts. 19 C.siamea Large Evergreen, good as an avenue tree. 20 Casuarinaequisetifolia Medium Evergreen suitable for covering low lying area and in green belts and along ponds. 21 Cedrelatoona Large Deciduous, good in open spaces, in green belts and along ponds. 22 Ficusbengalensi Large Deciduous, widely spaced avenue tree (15 m apart) 23 Ficusreligiosa Large Deciduous, widely spaced avenue tree also as a single tree in isolated sites. 24 Maducaindica Medium Deciduous, good in green belts. 25 Peltophoruminerme Medium Semi evergreen, suitable on road sides, in gardens and outside office buildings. 26 Saracaindica Medium Evergreen tree good on road sides within campus 27 Tamarindusindica Large Evergreen tree good along boundary and road sides. 28 Terminaliacatappa Large Deciduous tree 29 Terminaliaarjuna Large Evergreen tree for road sides and in green belts 30 Zanthoxyium Medium Deciduous in green belts 8.8 Measures to Improve Socio-Economic Conditions For the benefit of the community in the vicinity of the project, JSL 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. Bhagavathi Ana Labs Ltd., Hyderabad. 88

103 Providing drinking water Construction of schools Construction of community centres Construction of roads and drainage Construction of health centres Table 8.4 Corporate Social Responsibility (CSR) Budget S. No. Description Amount in 1 Construction of schools, health centre, community centres, and training program for local employable youth 2 Maintenance of water supply, village roads, drainage, development of parks, school buildings 3 Health check-up camps, medical camps, logistic support, Ambulance facility, Fire Safety, drug de-addiction movement 4 Providing scholarships to poor children, distributing books, adult literacy Rs. Lakhs 5 Home for disabledand orphanage Total Landscaping The various servicei 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 Fire Fighting & Protection System Safety Policy and Regulations Bhagavathi Ana Labs Ltd., Hyderabad. 89

104 Keeping in view of the safety requirement during construction, operation and maintenance phase, M/s Limited has formulated safety policy with the following regulations:- To allocate sufficient resources to maintain safe and healthy conditions at work place. To take, steps to ensure that all known safety factors are taken into account in the design, construction, operation and maintenance of plants, machinery and equipment. To ensure that adequate safety instructions are given to all employees. To provide wherever necessary, protective equipment, safety appliances and clothing and to ensure their proper use. To inform employees about materials, equipment or processes review for making necessary changes from the point of view of safety in the light of experience and up to date knowledge. To provide appropriate instruction, training and supervision in health and safety, first aid and to ensure that adequate publicity is given to these matters. To ensure proper implementation of fire prevention and an appropriate fire fighting service together with training facilities for personnel involved in this service. To ensure that professional advice is made available wherever potentially hazardous situations exists or might arise. To organize collection, analysis and presentation of data on accident, sickness and incident involving personal injury to health with a view to taking corrective, remedial and preventive action. To prepare safety rules for each type of occupation/process involved in a project. To ensure regular safety inspection by a competent person at suitable intervals of all buildings, equipment, work places and operations Fire Protection System 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. Fire hydrants at suitable locations for TG building, boiler area, & storage area. Medium velocity water spray system for the cable gallery Bhagavathi Ana Labs Ltd., Hyderabad. 90

105 Necessary electric driven, Jockey pumps with piping valves & instrumentation for safe operation Corporate Environment Policy Corporate Responsibility for Environmental Management 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. The unit has also initiated improvement measures to get ISO14001 certification. 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. The unit has resolved to become a zero waste integrated agro business sugar complex and in itscommitment to ensure zero discharge. Measures will be implemented to recycle and reuse waste water to avoid effluent discharge into the environment. The unit complies with the various requirements and standards stipulated by Ministry of Environment & Forests, Central Pollution Control Board and Karnataka Pollution Control Board. The unit recently commissioned a new mist cooling system with automation for cooling the evaporator and pan condenser water. Involvement of workmen in Safety Management through the Safety Committee which is empowered to review accidents and initiate corrective and preventive action. Ensuring high standards of housekeeping in the factory premises, resulting in a Safe Shopfloor, All personnel are trained on First Aid and basics of Safety Management. Bhagavathi Ana Labs Ltd., Hyderabad. 91

106 Chapter 9 Summary and Conclusions M/s. Limited has proposed for Enhancement of Sugar Unit from 2500 TCD to 3500 TCD and 15 MW to 27 MW Cogeneration Unit at Village Nad KD, Taluk Indi, District Bijapur and Karnataka state. Salient Features of the project Capacity of the Plant:-Sugar Unit TCD and Cogeneration Plant of 27 MW capacity Project Area: acres. Cost of the Project:-The total project cost is Rs.180 Crores Cost for Environmental Management Plan:- The capital cost for EMP measures is Rs750 Lakhs and recurring cost is Rs65 lakhs. Cost for Corporate Social Responsibility:-The capital cost for CSR activities is Rs 9.00 crores. Water requirement:-the total Water requirement for the factory is nearly 2600m 3 /day during the crushing and during the slack season.water will be sourced from Bhima River. Gross Power Generation:-Crushing Season:20,780 KW Off-season:23,840 KW All liquid effluents will be suitably treated and consumed for internal use like landscaping and green belt. The effluent will be neutralized by the addition of either acid or alkali to achieve the required ph. All equipment vulnerable to explosion or fire will be designed to relevant IS codes & statutory regulations. Suitable fire protection system comprising hydrants and spray systems will be provided for fire protection. There will be an environment cell and qualified chief chemist in charge of analytical measurements and qualified engineers for pollution control. The total employees required during plant operation are 91persons. 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 Bhagavathi Ana Labs Ltd., Hyderabad. 92

107 onthe local environment. Implementation of the project will have beneficial impact in terms of providing direct and indirect employment opportunities. There will be a positive socioeconomic development in the region. Quality of life of the people will be improved. Recommendations made in the CREP for Sugar Plant will be implemented.jsl will also undertake various community welfare measures for the upliftment of the villages of the study area. Bhagavathi Ana Labs Ltd., Hyderabad. 93

108 Chapter 10 Disclosure of Consultants Engaged Name of the Consultants: M/s Bhagavathi Ana Labs Limited /5/A/42, Venkateswara Hills Colony Road No. 3, Banjara Hills Hyderabad Telephone , Fax Website: Bhagavathi Ana Labs Limited is a professional services company providing Environmental Consultancy, Environmental Engineering, Analytical and Quality testing, Water Resource studies, Technical Training and Enviro-legal services. Since inception in 1984, the company has completed number of projects spread all over India. The company has qualified and experienced staff of more than 100 people operating across seven offices in India. The Professionals and Technicians include Environmental Engineers, Environmental Scientists, Environmental Planners, Chemists, Mining Engineers, Geologists, Hydro-geologists, Economic and Social Science specialists etc. Bhagavathi Ana Labs Limited is an ISO Company and is accredited by: Ministry of Environment and Forests (MoEF), Govt. of India, New Delhi National Accreditation Board for Education & Training (NABET) Registered EIA Consultants Organization, Quality Council of India, Reg No: EIA National Accreditation Board for Testing and Calibration Laboratories (NABL) as per ISO/IEC 17025:2005 Bureau of Indian Standards (BIS), New Delhi Bhagavathi Ana Labs Ltd., Hyderabad. 93

109 Bhagavathi Ana Labs Ltd., Hyderabad. 94