EIA REPORT: Chapter I Siddhi Sugar and Allied Industries Limited, Latur

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3 EIA REPORT: Chapter I Molasses based 30KLPD Distillery Unit 2

4 EIA REPORT: Chapter I Molasses based 30KLPD Distillery Unit 3

5 EIA REPORT: Chapter I POINT WISE COMPLIANCE OF TERMS OF REFERENCE (TOR) Sr. No. Terms of reference Compliance 1 Executive summary of the project Prepared and Bound Separately and submitted along with EIA Report 2 Justification of the project Chapter I page Detailed break-up of the land area along with latest photograph of the area 4 Present land use based on satellite imagery and details of land availability for the project along with supporting document 5 Details of site and information related to environmental setting within 10 km radius of the project site 6 Information regarding eco-sensitive areas such as national park/wildlife sanctuary/ biosphere reserves within 10 km radius of project area 7 Total cost of the project along with total capital cost and recurring cost/annum for environmental pollution control measures 8 A copy of lease deed or allotment letter, if land is already acquired Chapter II page Chapter-III Point Chapter-III page.; table 3.2 page Chapter-III table and point Chapter II - Page NA 9 List of existing distillery units in the study area along with their capacity and sourcing of raw material Chapter III page Table Layout maps indicating existing unit as well as proposed unit Chapter II Molasses based 30KLPD Distillery Unit 4

6 EIA REPORT: Chapter I indicating storage area, plant area, greenbelt area, utilities etc Page No 2.3 figure Details of proposed products along with manufacturing capacity Chapter II - Page Number of working days of the sugar unit, distillery unit and CPP 13 Details of raw materials, its source with availability of all raw materials including - If molasses based distillery, then give source and quantity available for molasses Chapter -II Page No, 2.2 Chapter II -Page 2.8; Table Manufacturing process details of sugar, distillery and CPP along with process flow chart 15 Sources and quantity of fuel (rice husk/bagasse/ coal etc.) for the boiler. Measures to take care of SO2 emission. A copy of Memorandum of Understanding (MoU) signed with the coal suppliers should be Submitted. 16 Storage facility for raw materials, prepared alcohol, fuels and fly ash Chapter -II Page No, Chapter II Page no- 2.8, Table 2.3 Chapter IV; page 4.4 Chapter II Page no-2.8, table 2.2 and 2.3 page Action plan for ambient air quality parameters as per NAAQES Standards for PM10, PM2.5, SO2 and NOX as per GSR 826(E) dated 16th November, One season site-specific micro-meteorological data using temperature, relative humidity, hourly wind speed and direction and rainfall and AAQ data (except monsoon) for PM10, PM2.5, SO2, NOX, CO and HC (methane &non methane) shall be collected. The monitoring stations should take into account the pre-dominant wind direction, population zone and Chapter VI Page No- 6.24; table 6.6 Chapter III Page No Molasses based 30KLPD Distillery Unit 5

7 EIA REPORT: Chapter I sensitive receptors including reserved forests. Data for water and noise monitoring should also be included 19 Mathematical modeling for calculating the dispersion of air pollutants and ground level concentration along with emissions from the boiler s stack Chapter IV Page No An action plan to control and monitor secondary fugitive emissions from all the sources 21 An action plan prepared by SPCB to control and monitor secondary fugitive emissions from all the sources Chapter-VI Page No, 4.2, 4.8 Chapter VI- page 4.2, Details of boiler and its capacity. Details of the use of steam from the boiler 23 Ground water quality around proposed spent wash storage lagoon and the project area 24 Details of water requirement, water balance chart for existing unit as well as proposed expansion (as applicable). Measures for conservation water by recycling and reuse to minimize the fresh water requirement 25 Source of water supply and permission of withdrawal of water from Competent Authority Chapter II Page No-2.10 Chapter III Page no Chapter II Page No Chapter II Page No Photocopy of water drawl permission of sugar factory is attached as an annexure no- VI Molasses based 30KLPD Distillery Unit 6

8 EIA REPORT: Chapter I 26 Proposed effluent treatment system for grain/molasses based distillery (spent wash and spent lees) along with utility wastewater including CPP/Co-gen Unit (wherever applicable) as well as domestic sewage and scheme for achieving zero discharge. Details of treatment of effluent generation from sugar unit 27 Spent wash generation should not exceed 8 KL/KL of alcohol production. Details of the spent wash treatment for molasses based distillery based distillery 28 Capacity for spent wash holding tank and action plan to control ground water pollution Chapter II Page no Chapter II Page no-2.12 figure 2.3 Chapter II- Page no-2.22 Chapter IV -Page no Layout for storage of bagasse/biomass/coal Chapter II Page no Capacity for spent wash holding tank and action plan to control ground water pollution Chapter II- Page no-2.22 Chapter IV -Page no Dryer shall be installed to dry DWGS NA 32 Layout for storage of rice husk/biomass/coal Chapter II - Page no Details of solid waste management including management of boiler ash 34 Risk assessment for storage and handling of alcohol and mitigation measure due to fire and explosion and handling areas Chapter IV - Page no-, 4.14, Chapter VII Page no Action plan for development of green belt over 33 % of the total project area within plant premises with at least 10 meter Chapter VI Molasses based 30KLPD Distillery Unit 7

9 EIA REPORT: Chapter I wide green belt on all sides along the periphery of the project area, in downward direction, and along road sides etc Page no List of flora and fauna in the study area Chapter III page 3.29 table 37 Noise levels monitoring at five locations within the study area Chapter III page Detailed Environment management Plan (EMP) with specific reference to details of air pollution control system, water & wastewater management, monitoring frequency, responsibility and time bound implementation plan for mitigation measure should be provided 39 EMP should also include the concept of waste-minimization, recycle/reuse/ recover techniques, Energy conservation, and natural resource conservation. 40 Action plan for rainwater harvesting measures at plant site should be included to harvest rainwater from the roof tops and storm water drains to recharge the ground water Chapter VI Chapter VI Page 6.20 Chapter VI Page Details of occupational health surveillance programme Chapter VI Page no Details of socio-economic welfare activities Chapter IX Page no Transportation of raw materials and finished products for the project (proposed/expansion) in respect of existing traffic, type of vehicles, frequency of vehicles for transportation of materials, additional traffic due to proposed project, parking arrangement etc Chapter IV Page no- 4.2, 4.18 Molasses based 30KLPD Distillery Unit 8

10 EIA REPORT: Chapter I 44 Action plan for post-project environmental monitoring Chapter VI - Page Corporate Environmental Responsibility Chapter VI a) Does the company have a well laid down Environment Policy approved by its Board of Directors? If so, it may be detailed in the EIA report b) Does the Environmental Policy prescribe for standard operating process/procedures to bring into focus any infringement / deviation / violation of the environmental or forest norms / conditions? If so, it may be detailed in the EIA report. c) What is the hierarchical system or Administrative order of the company to deal with the environmental d) Does the company have a system of reporting of non compliance / violations of environmental norms to the Board of Directors of the company and / or shareholders or stakeholders at large? This reporting mechanism should be detailed in the EIA report 47 At least 5 % of the total cost of the project should be earmarked towards the Enterprise Social Commitment based on Public Hearing issues and item-wise details along with time bound action plan should be prepared and incorporated. 49 Total capital cost and recurring cost/annum for environmental pollution control measures NA NA chapter III page 3.29 chapter III page 3.29 Conditions shall be complied Chapter II -Page 2.13, Expansion/modernization proposals NA New Project Molasses based 30KLPD Distillery Unit 9

11 EIA REPORT: Chapter I i) Copy of all the Environmental Clearance(s) including Amendments thereto obtained for the project from MOEF/SEIAA shall be attached as an Annexure. A certified copy of the latest Monitoring Report of the Regional Office of the Ministry of Environment and Forests as per circular dated 30th May, 2012 on the status of compliance of conditions stipulated in all the existing environmental clearances including Amendments should be provided. In addition, status of compliance of Consent to Operate for the ongoing I existing operation of the project from SPCB shall be attached with the EIA-EMP report ii. In case the existing project has not obtained environmental clearance, reasons for not taking EC under the provisions of the EIA Notification 1994 and/or EIA Notification 2006 shall be provided. Copies of Consent to Establish/No Objection Certificate and Consent to Operate (in case of units operating prior to EIA Notification 2006, CTE and CTO of FY ) obtained from the SPCB shall be submitted. Further, compliance report to the conditions of consents from the SPCB shall be submitted 51 Any litigation pending against the project and / or any direction / order passed by any Court of Law against the project, if so, details thereof NA New Project NA New Project No any Molasses based 30KLPD Distillery Unit 10

12 EIA REPORT: Chapter I TABLE OF CONTENT CHAPTER PARTICULARS PAGE NO I INTRODUCTION 1.1 Project introduction Preliminary information of project and site Importance of the project Demand for alcohol: Indian Scenario Industrial alcohol Potable alcohol Objectives of the study Rational e of the study Structure of the report 1-7 II PROJECT DESCRIPTION 2.1 Introduction Selection of site Project Highlights Requirement/Availability of Raw material Land Molasses Water Steam and Power Fuel: Bagasse and biogas The Process Continuous fermentation process Multi-pressure Distillation Technology Ethanol (Absolute Alcohol) Dehydration with molecular sieve process 2-16 Molasses based 30KLPD Distillery Unit 11

13 EIA REPORT: Chapter I CHAPTER PARTICULARS PAGE NO 2.6 Environmental Aspects Effluent Treatment: Spentwash Primary Treatment for spentwash: Anaerobic digestion Secondary Treatment for spentwash: Multiple Effect Evaporation System Tertiary Treatment for spentwash: Process operation details Salient features of composting process Compost testing parameters Material balance Operation and maintenance guidelines for bio-composting Holding of spentwash Process condensate treatment plant: condensate polishing unit (CPU) CPU: Primary treatment CPU: Secondary Treatment CPU: Tertiary treatment Solid waste generation and management Greenbelt Development 2-32 III BASELINE ENVIRONMENTAL STATUS 3.1 Introduction Methodology of baseline study Description of the site and study area Geographical features surrounding the site Land use pattern Land use / Land cover classes details Climatic conditions 3-10 Molasses based 30KLPD Distillery Unit 12

14 EIA REPORT: Chapter I CHAPTER PARTICULARS PAGE NO Rainfall Temperature Humidity Cloudiness Winds Wind speed and wind direction Soil Hydrology Irrigation facilities cropping pattern Hydrogeology Air environment Observations Noise environment Method of monitoring Parameters measures Geography and Geology Geography Geology Ecology and Biodiversity Ecosystems Flora and fauna Socio-Economic environment Introduction Methodology Sources of Information 3-31 Molasses based 30KLPD Distillery Unit 13

15 EIA REPORT: Chapter I CHAPTER PARTICULARS PAGE NO Demography and development indicators Infrastructure Education facilities Health services Drinking water Transportation Tele-communication Electricity Religious places Economic profile Agriculture Industry Occupational structure Banking and financial services Other aspects 3-42 IV POLLUTION SOURCES AND CHARACTERISTICS 4.1 Introduction Air pollution Transportation Preventive, control and mitigation measures Manufacturing process Emissions due to burning of fuel dispersion modeling for air pollutants Prediction Fugitive and Other sources of air pollution 4-8 Molasses based 30KLPD Distillery Unit 14

16 EIA REPORT: Chapter I CHAPTER PARTICULARS PAGE NO Impact assessment Noise Pollution environment Preventive, control and mitigation measures Impact assessment Water pollution Wastewater form boiler blow down Condensate of MEE Spentwash Condensate water Floor washing Spent less Sanitary wastewater Thermal pollution Preventive, control and mitigation measures Reuse of water Recycle of water Conservation of water Impact Assessment Soil environment Preventive, control and mitigation measures Solid waste management Preventive, control and mitigation measures Impact Assessment Ecology and Biodiversity Preventive, control and mitigation measures 4-16 Molasses based 30KLPD Distillery Unit 15

17 EIA REPORT: Chapter I CHAPTER PARTICULARS PAGE NO Impact assessment Socio-economic environment Land use, geology and Hydrogeology/drainage Impact assessment Environment management plan Other Impact: Traffic 4-18 V ANALYSIS OF ALTERNATIVE TECHNOLOGY 5.1 Introduction Treatment and utilization options Reboiler Biomethanation Reverse osmosis Multiple effect evaporator Mist evaporator Treatment alternatives for condensate polishing unit (CPU) Process description for membrane technology Soil biotechnology process Selection of alternative 5-9 VI ENVIRONMENTAL MANAGEMENT PLAN 6.1 Overview EMP for construction phase EMP for operation phase Air environment management Noise environment Water environment CREP guidelines for molasses based distillery 6-9 Molasses based 30KLPD Distillery Unit 16

18 EIA REPORT: Chapter I CHAPTER PARTICULARS PAGE NO Spent lees and process condensate from ME Treatment unit Important aspect Operation and maintenance of other pollution control system Land environment Green belt development Rain water harvesting Safety, occupational health management EMP for social environment Environment monitoring program Environment management cell Monitoring plan: Air, Water, Noise Environment Flow measurement 6-29 VII RISK ASSESSMENT AND RISK MANAGEMENT 7.1 Introduction The risk equation Hazard identification Mechanical hazard Electrical hazard Thermal hazard Hazard generated by noise Hazard generated by vibration Hazard generated by material /substances Preliminary Hazard Analysis (PHA) Probable risk factor 7-4 Molasses based 30KLPD Distillery Unit 17

19 EIA REPORT: Chapter I CHAPTER PARTICULARS PAGE NO Fire Mitigation Measures For Fire Hazards Boiler Operations Fire Fighting Strategy Mechanical injury to body parts Qualitative Risk Assessment Risk assessment: health General assessment Acute Health effect Chronic Health effects Recommended risk-reduction measures Other methods to reduce exposure Risk assessment: Environment General assessment Acute ecological effect Chronic ecological effect Persistent in the environment Bio-accumulation in aquatic organisms Recommended risk reduction measures Risk assessment: Business General assessment 7-23 VIII DISASTER MANAGEMENT PLAN 8.1 Introduction Scope Physical Damage Casualties 8-6 Molasses based 30KLPD Distillery Unit 18

20 EIA REPORT: Chapter I CHAPTER PARTICULARS PAGE NO Public health Water supply Transport network Electricity and Communication Food Supplies Disaster Management Plan (Dmp) Cycles Pre Disaster situation Response Requirement for response phase Situation identification/ assessment Emergency management plan (on site) Emergency organization structure Designated persons functions Shut downs in emergency Personnel evacuation Personnel accounting Controlling disaster Repairs and safety Implements Medical treatment Arrangements Training and rehearsals Law and order All clear signal Special handling requirement Equipment and facilities in emergency Fire fighting Equipments Emergency medical supplies 8-20 Molasses based 30KLPD Distillery Unit 19

21 EIA REPORT: Chapter I CHAPTER PARTICULARS PAGE NO Training and drills Off-site emergency management plan Information to local authorities 8-21 IX PROJECT BENEFIT ANALYSIS 9.1 Project benefits: For the project proponent Project benefits: For the local society Benefits to country: Alcohol as a fuel Environmental benefit analysis 9-4 X DISCLOSURE OF CONSULTANTS 10.1 Consultant The Project Team OF EIA Study 10-2 LIST OF TABLES Number DESCRIPTION PAGE CHAPTER I 1.1 Performance Of SSAIL for last three seasons Total alcohol production of the world (Year ) 1-4 CHAPTER II 2.1 Required raw material and resources Land utilization details Water requirement (m 3 /day) Bagasse generation and net consumption estimates for the proposed project Product and storage details Project budget Capital investment on environment management 2-17 Molasses based 30KLPD Distillery Unit 20

22 EIA REPORT: Chapter I Number DESCRIPTION PAGE 2.8 Overview of environment management processes Spentwash characteristics at inlet of bio-digester Estimated Performance for biogas plant Bio-compost: Desired characteristics The composting requirements Mass Balance: Compost Details of existing greenbelt around Industrial Complex 2-35 CHAPTER III 3.1 Important Features Around the Project Site Summary of Environmental features of study area Land use/ land cover statistics of study area Details of sampling locations Rainfall for last five years Monitoring location details Soil analysis for samples from study zone Analysis report - Ground and surface water sources of study zone Irrigation System and facilities Cropping pattern for Ahmedpur Taluka Baseline Ambient Air Quality Noise monitoring Results (db A) Traffic density on sugar factory approach road (average for) Industries (Latur district) at a glance List of sugar and distilleries units in the district 3-32 CHAPTER IV 4.1 Analysis of Bagasse Model input data 4-6 Molasses based 30KLPD Distillery Unit 21

23 EIA REPORT: Chapter I Number DESCRIPTION PAGE 4.3 Resultant concentrations due to incremental GLC`s Noise levels General characteristics of Raw Spentwash Summary of impact assessment and environment management plan proposed for the respective aspect 4-20 CHAPTER V 5.1 Merits and Demerits of each alternative 5-6 CHAPTER VI 6.1 Summary of Environmental Management Plan Guidelines, formulated by Central Pollution Control Board (CPCB) new Delhi, for Bio-Composting Plants Characteristics of Untreated & Treated Composite effluent Species suggested for greenbelt development Flowering and foliage shrubs recommended for greenbelt Storage tank details Safety Committee of existing sugar unit Human Resource for Environment Management Cell Analysis of environmental parameters and its reporting schedule Suggestive schedule for maintenance of wastewater treatment unit Format for Water Consumption Reporting Schedule Capital and recurring investment on environmental management 6-30 CHAPTER VII 7.1 Storage details NFPA (National Fire Protection Association) Rating Probability of occurrence of hazard Hazard warning information for ethyl alcohol Summary of risk assessment and damage control 7-24 Molasses based 30KLPD Distillery Unit 22

24 EIA REPORT: Chapter I Number DESCRIPTION PAGE CHAPTER VIII 8.1 Various types of Hazards The items recommended for emergency cupboard Contact list for disaster situation 8-22 CHAPTER IX 9.1 Staff requirement for the proposed distillery unit 9-2 Molasses based 30KLPD Distillery Unit 23

25 EIA REPORT: Chapter I LIST OF FIGURES, IMAGES AND MAPS NUMBER DESCRIPTION PAGE NO. CHAPTER I Figure 1.1 Site Location Map 1-3 CHAPTER II Figure 2.1 Layout of sugar and distillery unit 2-2 Figure 2.2 Photograph of proposed distillery site 2-6 Figure 2.3 Photograph of proposed compost site 2-7 Figure 2.4 Water and mass balance 2-9 Figure 2.5 Schematic of manufacturing process of alcohol 2-12 Figure 2.6 Schematic of utilization of bagasse and steam resources 2-12 Figure 2.7 Schematic of spentwash holding tank 2-31 Figure 2.8 Schematic of compost yard 2-31 Figure 2.9 Schematic for complete compost process 2-32 Figure 2.10 Schematic of spraying network 2-32 Figure 2.11 Block diagram of CPU 2-33 Figure 2.12 Photographs of existing greenbelt 2-36 Figure 2.13 Schematic of Greenbelt Development 2-37 Figure 2.14 Decision making and its implementation hierarchy (from top to bottom) and reporting hierarchy (from bottom to top) for environmental conditions/compliances 2-37 Figure 2.15 Schematic of existing wet scrubber and wet ash handling 2-38 CHAPTER III Figure 3.1 Satellite image of project site 3-3 Figure 3.2 LULC map for study zone 3-7 Figure 3.3 Contour map of study zone 3-8 Figure 3.4 Habitation map of study zone 3-9 Molasses based 30KLPD Distillery Unit 24

26 EIA REPORT: Chapter I NUMBER DESCRIPTION PAGE NO. Figure 3.5 Satellite Imagery Showing site and surrounding 3-10 Figure 3.6 Environment Monitoring station network 3-11 Figure 3.7 Wind Rose Diagram 3-15 Figure 3.8 Soil types observed for Latur district 3-17 Figure 3.9 Drainage pattern observed for study zone 3-17 Figure 3.10 Demographic data - Ahmedpur 3-32 Figure 3.11 Socio-economic indicators - Ahmedpur 3-33 Figure 3.12 Economic indicators -Ahmedpur 3-34 Figure 3.13 Road network map - study zone 3-36 Figure 3.14 Seismic Zone Map of Maharashtra 3-43 CHAPTER IV Figure 4.1 Short term 24 hourly GLCs of particulate matter 4-7 Figure 4.2 Short term 24 hourly GLCs of So CHAPTER V Figure 5.1 Treatment options for raw spentwash 5-2 Figure 5.2 Layout of SBT media 5-8 CHAPTER VI Figure 6.1 Schematic of water conservation 6-9 Figure 6.2 Solid waste management scheme 6-17 CHAPTER VII Figure 7.1 Fire Extinguisher selection guide 7-9 CHAPTER VIII Figure 8.1 Probable cause of hazard 8-2 Figure 8.2 Schematic of disaster management process 8-4 Figure 8.3 Emergency organization structure 8-14 CHAPTER X Figure 10.1 Activities of Department of Environmental Sciences 10-1 Molasses based 30KLPD Distillery Unit 25

27 EIA REPORT: Chapter I LIST OF ABBREVIATIONS Abbreviation AA ACF AP AAQ AQ BOD COD CPCB CREP DG DO EC EIA EMP ENA EPA FAE GLC SHE HWMH ID IMD IMFL IS KLPD or KLD MINAS MOC MoEF MS Full Form Absolute alcohol/ anhydrous alcohol Activated charcoal filter Air pollution Ambient Air quality Air Quality Biological Oxygen Demand Chemical Oxygen Demand Central Pollution Control Board Corporate Responsibility For Environmental Protection Diesel Generator Dissolved Oxygen Environmental Clearance Environmental Impact Assessment Environment Management Plan Extra Neutral Alcohol Environmental (Protection) Act Functional area expert Ground Level Concentration Safety, Health and Environment Hazardous Waste (Management & Handling) Rules Induced Draft Indian Meteorological Department Indian Made Foreign Liquor Indian Standard Kilo Liter Per Day Minimal National Standards Material of construction Ministry Of Environment And Forests Mild steel Molasses based 30KLPD Distillery Unit 26

28 EIA REPORT: Chapter I Abbreviation MSDS MTD NAAQS OSHA PEL PM PPM PPE RM RO RS SPCB SPL SPM SS TCD TDS TLV TPH VSI Full Form Material Safety Datasheet Metric Ton Per Day National Ambient Air Quality Standard Occupational Safety And Health Administration Permissible Exposure Limit Particulate Matter Parts per million Personal Protective Equipments Raw material Reverse Osmosis Rectified Spirit State Pollution Control Board Sound Pressure Level Suspended Particulate Matter Suspended Solids Ton Crush per Day Total Dissolve Solid Threshold Limit Value Tons Per Hour Vasantdada Sugar Institute Molasses based 30KLPD Distillery Unit 27

29 EIA REPORT: Chapter I Molasses based 30KLPD Distillery Unit 28

30 CHAPTER I INTRODUCTION 1.1 PROJECT INTRODUCTION Siddhi Sugar and Allied Industries Limited (SSAIL), is a public limited sugar mill, located at Mahesh Nagar, village Ujana, taluka Ahmedpur, district Latur in Maharashtra. It is planning to set up a molasses based 30KLPD (kilo litres per day) distillery unit. In , the project proponent purchased, building, plant and machinery of Balaghat Shetkari Sahakari Sakhar Karkhana Limited from Maharashtra State Cooperative Bank Limited, Mumbai under Securization Act The initial installed crushing capacity of the sugar factory was 2500 tons crushed per day (TCD); however, due to modernization the factory could actually achieve a crushing rate of 3300 to 3500TCD during the season of The statistics of last three crushing seasons reveals that the factory is making remarkable progress under the leadership and vision of Shri. Balasaheb Jadhav; Chairman & Managing Director, Shri Babasaheb Patil. Since, the infrastructure such as land, boiler, stack, etc and resources such as molasses, fuel bagasse, steam, filter cake (press mud), power and partly human resource required for a distillery are available with sugar unit. Therefore, the management has decided to establish this allied unit. The proposed distillery will enable the industry to draw maximum benefits from the infrastructure and resources of sugar unit. The proposed distillery unit will be based on latest technology of continuous fermentation and multi-pressure distillation with molecular sieve dehydration system. The distillery unit will produce rectified spirit (RS), extra neutral alcohol (ENA) and fuel ethanol (anhydrous alcohol) as per the market demand. Table 1.1: Performance of SSAIL for last three seasons S. No. Particular Season Cane Crushed (MT) 2,25,117 3,70,387 4,92,670 2 Sugar production (Qtls.) 2,64,530 4,29,600 5,37,350 3 Recovery % Cane Molasses production (MT) 8,750 15,278 21,708 5 Press-mud production (MT) 7,699 14,075 18,820

31 EIA REPORT: Chapter I 1.2 PRELIMINARY INFORMATION OF PROJECT AND SITE Project Size/Capacity Location Geographical Location New molasses based distillery 30 Kilo Litre Per Day (KLPD) capacity Within existing sugar factory premises at Maheshnagar, village Ujana, Taluka Ahmedpur, District Latur, Maharashtra E and N. Altitude 509 m above MSL Road Nearest City/Town Latur Nanded state highway No km Ahmedpur (Taluka head quarter) 15km Latur (city & major market place of Maharashtra) 75 km Nanded (city & major market place of Maharashtra)- 70 km Railway Station (main) Air Port Nanded 70km, Latur ~75 km and Chakur ~35 Km Latur ~ 75 Km from the site Nanded ~ 70 Km from the site Project categorization as per EIA Notification Category A [ item 5g] Molasses based 30KLPD Distillery Unit 2

32 EIA REPORT: Chapter I Figure 1.1: Site Location Map Molasses based 30KLPD Distillery Unit 3

33 EIA REPORT: Chapter I 1.3 IMPORTANCE OF THE PROJECT In the present scenario, sugar industry is forced to explore the alternatives to attain financial viability while producing sugar. Distillery is one such alternative, because of availability of molasses as a raw material, bagasse as a fuel, own power generation ability and availability of the steam energy from own sugar factory. Therefore, the management of the factory has planned to establish a 30KLPD molasses based distillery within existing sugar factory premises. Ethyl alcohol is basically used for three purposes i.e. 1) Industrial alcohol for production of downstream chemicals, 2) Potable alcohol for manufacture of alcoholic beverages (Country Liquor and Indian Made Foreign Liquor) and 3) Fuel ethanol or anhydrous alcohol, which can be blended with petrol or diesel. The ethanol of commerce contains about five per cent water; hence, termed as "hydrous (watercontaining) alcohol". If the last traces of water are removed, "anhydrous alcohol" (water-free or "absolute") is obtained. The world alcohol consumption pattern for different applications for the year is as follows. Alcohol Consumption for (%) 1. Potable and Industrial Fuel Table 1.2: Total Alcohol Production Of World During The Year 2009 to 2013 Sr. No. World Regions Years & Production in Million Liters 2013* Total (for worlds geographical regions) World s top five alcohol producing countries 1 U.S.A Brazil China India Canada * Projected production. Molasses based 30KLPD Distillery Unit 4

34 EIA REPORT: Chapter I Source: - F. O. Licht s World Ethanol and Bio-fuels Report, Vol. 11, No. 17, 07/05/2013. The world total ethanol production in the year was billion litres and major consumption of alcohol was for fuel purpose. Many countries, including Brazil, USA, Canada, Sweden and China have already started using anhydrous ethanol for blending with petrol. In our country, the Central Government has taken a policy decision to start using anhydrous alcohol (fuel ethanol) for blending with petrol. Thus, it is expected that the demand of alcohol for fuel purpose is going to increase in coming years. 1.4 DEMANDS FOR ALCOHOL: INDIAN SCENARIO The Cabinet Committee on Economic Affairs (CCEA) of the Central Government has approved a proposal for implementation of the ethanol blended petrol (EBP) programme in the country. As a result, in January 2013 Petroleum Ministry floated a tender for supply of ethanol. As per the tender ethanol requirement was million liters for 5 % blending for 20 States and 4 Union territories and million liters for Maharashtra for 10 % blending Industrial Alcohol Ethyl alcohol is an important feedstock for the manufacture of chemicals. These chemicals are primarily the basic carbon based products like acetic acid, ethyl acetates, butanol, butadiene, acetic anhydride, vinyl acetate, PVC etc. During the last 5-6 years, number of alcohol-based industries have come up and the existing have marginally expanded. The raw material needs of the alcohol based chemical industry have to be met to facilitate maximum capacity utilization of these units in order to meet the domestic demands for the end products. These units are starving for want of raw materials. The shortage is wide spread & it has hit most of chemical, drug & other industries. The drug industry is also bedeviled by scarcity of industrial alcohol. Producers of insulin, antibiotics, tonics & several other essential bulk drugs & finished formulations are unable to obtain their quota of industrial alcohol, which is a vital raw material for them Potable Alcohol Manufacture of alcoholic beverages from alcohol is also an attractive diversification. According to the policy of the Government, it is necessary to obtain license for manufacture of potable liquor. It may not be possible to get license immediately but the same could be obtained as and when possible. There is large demand for alcoholic beverages. Molasses based 30KLPD Distillery Unit 5

35 EIA REPORT: Chapter I The use of alcohol for the purpose of potable liquor is as high as its use for industrial purpose. Alcohol is used for manufacture of country liquor. Basically, it involves dilution of rectified spirit with water to different grades of desired strength. Different varieties are produced by addition of flavors and are called spiced liquor. Liquors are manufactured in a synthetic way to imitate foreign liquors such as whisky, brandy, rum, gin and vodka. They are called Indian Made Foreign Liquor (I.M.F.L.). The excise duty on IMFL is much higher than that of country liquor. Supply of country liquor at low rates is very much useful to keep away the illicit liquor manufacturers and traders. Indian Made Foreign Liquor requires alcohol of very high purity. For this purpose separate distillation, plant to redistill and purify Rectified Spirit is necessary. This alcohol is called as extra neutral alcohol. Based on information from various sources, we anticipate demand for alcohol in the Maharashtra state as given below Industrial million liters Potable million liters Fuel 330 million liters (For 10 % blending) Total million liters During last few years, substantial quantity of alcohol (R.S., ENA and fuel ethanol) from the country has been exported to mostly Africa and countries of South-East Asia. During 2013, about 230 million liters of alcohol was exported from India. The demand of alcohol for industrial, potable & fuel alcohol in Maharashtra as well as in whole country will increase significantly in coming years. The proposed 30 KLPD distillery plant will contribute in fulfilling the alcohol and fuel ethanol requirement of Maharashtra and neighboring deficit states. 1.5 OBJECTIVES OF THE STUDY The prime objective of any EIA exercise is to identify and assess the impact of project before its implementation. This is necessary to take preventive, control and mitigation measures to minimize the adverse impact, which could be formulated early and cost-effectively. In view of this, the specific objectives of the EIA study are, 1. Appraise the current environmental status of the study area (10 km. radius) - collection of baseline data for ambient air, noise, water, land, ecology, hydro-geology, meteorology, socio-economic environments, etc. Molasses based 30KLPD Distillery Unit 6

36 EIA REPORT: Chapter I 2. Study in-depth and understand the project and identify the probable source/s of pollution that may arise from each stage of the project/allied activities; identify/assess impact causing factors 3. Assess an impact of the proposed activity on the surrounding environment. 4. Prepare a comprehensive Environmental Management Plan (EMP) for the project and ensure the environmental quality of the surrounding region would be preserved. 5. Formulate a strategy for effective environment monitoring 1.6 RATIONALE OF THE STUDY The notification SO-1533, issued by the Ministry of Environment and Forests (MoEF), Government of India, in September 2006 specifies that, the new molasses based distillery project of 30KLPD is placed under category A. This project requires Environmental Clearance (EC) from Ministry of Environment and Forestry (MoEF). Therefore, the management of SSAIL has entrusted the work of preparation of EIA/EMP to Vasantdada Sugar Institute (VSI), Manjari (Bk.), Pune. VSI is a renowned institute, providing research, technical and consultancy services to the sugar and distillery industries, since STRUCTURE OF THE REPORT The report is comprised of 10 chapters, and the relevant supporting documents are in the form of annexure. Executive Summary in English & Marathi is prepared and bound separately. Chapter I: Introduction Chapter II: Project Description Chapter III: Baseline Environment Study Chapter IV: Environmental Impact Assessment Chapter V: Analysis of Alternative Technologies Chapter VI: Environment Management Plan Chapter VII: Risk Assessment and Risk Management Chapter VIII: Disaster Management Plan Chapter IX: Project Benefit Analysis Chapter X: Disclosure of Consultants Molasses based 30KLPD Distillery Unit 7

37 CHAPTER II PROJECT DESCRIPTION 2.1 INTRODUCTION M/s. Siddhi Sugar and Allied Industries limited (SSAIL) is planning to setup a molasses based distillery unit of 30KLPD capacity. It will be established within existing sugar factory premises. The distillery is planned with a view to utilize available molasses, bagasse, steam and pressmud efficiently. Therefore, it can be considered as vertical integration for existing sugar factory. 2.2 SITE SELECTION The reasons for selecting the proposed site are as follows. The project requires only 15.5 acres of land and the proponent has 255 acres ( hectares) of land available. The existing sugar factory, its ancillary units and greenbelt is spread over ~35 acres of land. Thus, the proponent has adequate open land available to set up the unit. The land is already possessed by the sugar factory. The site fulfills site selection guidelines/criteria prescribed by the Ministry of Environment, Forests and Climate Change. Proximity to raw material: Chief raw material for the project i.e. molasses, fuel and necessary infrastructure in the form of power, water and steam will be made available from the sugar factory; Advantage of the same is saving on transportation cost and precious fuel for the import of raw material and fuel. Other infrastructure and facilities such as road, rail connectivity, communication and transport facilities, education, health centers, banks, etc. are available and adequate to cater the needs due to the proposed development Availability of technically skilled human resource Ease of control over sugar as well as distillery unit by one management and sharing common facilities like workshop etc. Therefore, the factory has not searched any alternative site for the proposed project.

38 EIA REPORT: Chapter II Figure 2.1: Project Layout showing existing sugar unit and proposed distillery Molasses based 30KLPD Distillery Unit 2-2

39 EIA REPORT: Chapter II 2.3 PROJECT HIGHLIGHTS 1 Name of the M/s. Siddhi Sugar and Allied Industries Limited, (SSAIL) Proponent 2 Type of company Public Limited Company 3 Project Molasses based distillery; capacity - 30KLPD 4 Location of the project Maheshnagar, Post- Ujana, Tal Ahmedpur, Dist Latur. Maharashtra, Land Requirement 15.5 acres Provision for total requirement 6 Product Product Production Rectified Spirit Impure Spirit 28.5 KLPD 1.5 KLPD OR ENA Impure Spirit 28.2 KLPD 1.8 KLPD OR Anhydrous Alcohol Impure Spirit KLPD 1.5 KLPD By products Fusel oil 0.06KLPD = 60 liters per day Biogas ~11,000 to 11,500m 3 /day Bio-compost ~10,200 per annum 7. Operation Days per 300 Days annum 8. Main Raw Material Quantity/day Source Molasses MT= ~75m 3 Own sugar unit Nutrients N, P 15 Kg Market at Latur, Nanded, etc Turkey Red Oil (TRO) 27 Kg Market at Latur, Nanded, etc 9. Water Requirement Source Manar (Manyad) river 300 m 3 /day day-to-day operation of plant (after recycle of 330 m 3 /day of treated water) Molasses based 30KLPD Distillery Unit 2-3

40 EIA REPORT: Chapter II Application is in process at Upper Manar Irrigation Department/Division, Nanded 10. Steam required 6.0 to 6.5TPH maximum 144TPD Source: Own sugar mill boiler 11. Fuel Bagasse - Max MT/day (required only during off-season) Source: Own sugar factory Biogas: 11,000 to 11,500 cum/day Source: distillery biomethanation unit 12. Power 787kwh captive power source 13. Effluent Treatment System Spentwash: Bio-methanation followed by multi-effect evaporation (MEE) followed by bio-composting Spent lees, condensate and other effluent Primary treatment followed by aeration followed by tertiary treatment 14. Man power Total Project Cost Rs lakhs 16 Capital Expenses for Rs Lakhs Env. Management 2.4 REQUIREMENT/AVAILABILITY OF RAW MATERIAL Table 2.1: Required raw material and resources Sr. No. Particulars Consumption/ Production (per days) A. Raw Materials, Consumption Remarks 1. Molasses, MT 111MT Basis 47% of F.S. Source: Own sugar factory 22,000MT/Annum additional ~9,000-11,000MT from nearby sugar mills (List of nearby sugar mills is enclosed in chapter III table 3.16) B. Chemicals, Consumption Molasses based 30KLPD Distillery Unit 2-4

41 EIA REPORT: Chapter II Sr. No. Particulars Consumption/ Production (per days) Remarks 1. Nutrients (N,P) 15 kg Stored in Fermentation House 2. Turkey Red Oil (TRO)) 27kg C. Utilities, Consumption Source: Market at Latur/ Nanded/Aurangabad Source: Nearby Market Local market at Latur, Nanded, Aurangabad 1. Fuel: Bagasse Max. 65.5MT Source: Own Sugar Factory 2. Water 300m 3 Source: Mannar small scale reservoir 3. Steam, MT Max. 144 MT/day Source: Attached sugar factory (during season) (~6 MT/h) 4. Power Max. 787KW/h Source: captive Land The proposed distillery will require 15.5 acres of land including land for greenbelt. The sugar factory has adequate land to accommodate the proposed unit. The details of the same are mentioned in the following table. Sr. No Table 2.2: Land utilization and requirement details Particulars of land utilization Area (in Acres) A) Area utilized for sugar unit 1 Sugar unit ETP& spray pond Cane & bagasse yard Existing Green belt Internal roads Store/sugar, sulfur, lime go downs Office and miscellaneous units 1.0 Molasses based 30KLPD Distillery Unit 2-5

42 EIA REPORT: Chapter II Total area for sugar unit 34.5 B) Area allocation for proposed Distillery 1 For distillery, Bio-methanation, storage lagoon Bio-compost (including yard* + storage) Green Belt 4.0 Total area for distillery unit 15.5 Total land available with the sugar factory 255 Land utilized for sugar and distillery units (A + B) 50.0 Land available with the factory for future developments Figure 2.2: Photograph of proposed distillery site Molasses based 30KLPD Distillery Unit 2-6

43 EIA REPORT: Chapter II Figure 2.3: Photograph of proposed compost site Molasses Molasses is the chief raw material for the proposed project. Its requirement will be ~111MT per day; maximum up to 33,300 MT/annum. SSAIL is expected to have its own molasses to the extent of 22,000 MT in the year onwards. The balance quantity i.e. 11,300MT of molasses will be purchased from nearby sugar factories (List provided in chapter III table 3.14). At present, the factory is storing the molasses in three mild steel tanks each of 4,500 MT capacity. Molasses stored for two months is ideal for fermentation. The molasses can be pumped through pipeline, from storage tanks to the distillery Water Total requirement of water for 30 KLPD distillery and multiple effect evaporation system will be around 650m3 day without recycling of water. However, as a company policy, water conservation will be done at all possible extent. Therefore, after considering recycle of evaporation condensate, fresh water requirement will be around 300m 3 per day. The factory has a water storage tank of 6,000m 3 and distillery will draw the water from sugar factory storage/reservoir. The factory is receiving water from Upper Manar dam (minor irrigation project) at Molasses based 30KLPD Distillery Unit 2-7

44 EIA REPORT: Chapter II Limboti located ~8km from the factory. Suitable water treatment plant for supply of filtered water for process, soft water for cooling tower make-up and DM water for dilution of spirit has been considered in the plant and machinery. The factory already has water drawl permission for sugar unit and it has applied for permission for distillery unit. Table 2.3: Water Requirement (in Cum/day) Particulars Intake Consumption And Losses Generated Effluent Recycle and Reuse Daily Net requirement Industrial Process Cooling tower Boiler feed Domestic Total Molasses based 30KLPD Distillery Unit 2-8

45 EIA REPORT: Chapter II Molasses 111MT Dilution Water 255m 3 Steam 72MTPD from sugar Fermentation Distillation CO 2 28m 3 /day Sludge 8 MT RS/ENA/AA + IS = 30KL Spent wash 360m 3 Lees 30 m 3 + process condensate 300m 3 Cooling water 250m 3 /h Steam 60MT from sugar Biomethanation Spent wash 360m 3 ME Evaporation Spent wash 60m 3 CPU Steam condensate recycled Press mud Biocomposting Molasses 111MT Treated water available for recycle = 330cum Molasses dilution: 225m 3 Figure 2.4: Water and mass balance Steam and Power Steam will be required for distillation and MEE units. For distillation, its requirement depends up on the product to produce i.e. RS or ENA or AA. It will be 2.2kg/L for RS, 3.2kg/L for ENA and 2.8kg/L for AA, which would be maximum up to MT/h for the proposed unit. In addition, 2.0kg/L will be required for stand alone evaporation (MEE) which would be MT/h for concentration of biomethanated spentwash up to 30 % total solids. It is estimated that proposed distillery would be requiring daily maximum 144MT of steam. At present the sugar factory has two boilers, with total Molasses based 30KLPD Distillery Unit 2-9

46 EIA REPORT: Chapter II steam generation capacity of 64 TPH (32x2=64 tons per hour) at 32 kg/cm 2 (g) pressure. These two boilers supply steam to the steam turbine generator (STG) of 2.5 MW capacity. This captive power is being used for sugar factory operations Sugar factory management has decided to expand existing sugar factory crushing capacity from 2500 TCD to 4000 TCD along with new boiler of 20 TPH steam generation capacity at pressure of 45 Kg/cm 2 (g) and 1.50 MW turbo-alternator. This power will be used for distillery and its ancillary units such as biogas plant, standalone multiple effect evaporation plant, bio-composting, CPU and yard lightning during season and off-season. The exhaust steam of turbine at 3.5 kg/cm 2 (g) pressure will be used for distillery and MEE plant. Necessary arrangement for reducing the steam pressure & desuperheating will be made. Power requirement estimate is as follows. Unit KWh Fermentation and distillation 215 Utilities and cooling tower 150 MSDH unit 80 MEE 110 water treatment plant 60 Biogas and bio-composting 145 Plant and yard lighting 27 TOTAL Fuel: Bagasse and biogas Due to modernization of existing set up the sugar factory has now achieved an operating capacity of 3500TCD. Bagasse generation is 27% on cane crushing, considering the stoppage and reserve, etc. Thus, the factory produces bagasse at 945TPD or 39.37TPH. The existing sugar unit consumes bagasse of ~30TPH for existing requirement of captive power and sugar unit. The proposed distillery will be requiring ~6 TPH steam which will be produced from 2.7TPH of bagasse. Even after meeting the distillery requirement, the factory will have surplus bagasse of 6.67TPH available for distillery operations during off-season of sugar mill. In addition, the biogas produced in biomethanation unit will be used as fuel. Considering 1000m3 of biogas is equivalent to 2MT of bagasse, the bagasse requirement would be 43TPD. Therefore, additional 23TPD of bagasse saving will help the industry to operate distillery as well as captive Molasses based 30KLPD Distillery Unit 2-10

47 EIA REPORT: Chapter II power unit smoothly during off-season of the sugar unit. Sugar factory is having provision of bagasse yard of five acres, where baled bagasse is stored. It is transferred to the boiler on closed conveyer belts. A query was raised by Regional Officer, Maharashtra Pollution Control Board (MPCB), that 2.7 Ton of bagasse cannot produce 20 tons of steam. Clarification The statement has been misunderstood. The sugar factory has proposed to install a new boiler of 20 TPH considering its future requirements and this boiler will produce about 6 TPH steam from 2.7 TPH bagasse for the distillery. Table 2.4 Bagasse generation and net consumption estimates for the proposed project Description Per day Per season (160 days) Cane crushing 180TCH 3,500 TCD 560,000 Average bagasse 27.00% on cane 945 TPD 151,200 Net bagassse available = TPH Bagasse consumption for steam generation of sugar and existing captive unit = 30TPH Bagasse utilization by existing sugar and captive 720 MT 115,200 power unit (for Season) = 30 TPH Bagasse requirement for TPH 65.5 MT 19,650 MT (for 300 days of operation) Biogas generation 11,500m3 per day 1000m3 of biogass = 2MT of bagasse Bagasse saving (for 300 days) 23 MT 6,900 MT Molasses based 30KLPD Distillery Unit 2-11

48 EIA REPORT: Chapter II Yeast Fermentation Molasses Distillation RS/ENA/AA and fusel oil Spent wash and spent lees Figure 2.5: Schematic of manufacturing process of alcohol Power Captive consumption Bagass e Boiler Steam Turbo Generato r De-aerator Exhaust HP Heater Distillery (throughout the year) Figure 2.6: Schematic of utilization of bagasse and steam resources in sugar industry complex 2.5 THE PROCESS Molasses based 30KLPD Distillery Unit 2-12

49 EIA REPORT: Chapter II During the last decade, interesting developments have taken place in the field of technology of fermentation of alcohol, which promise high yield of alcohol, economy in space, economy in steam consumption and sizable reduction of quantity of effluent. There are variations in different processes of continuous fermentation. Some use only single fermenter whereas some use two fermenters or battery of fermenters. The continuous fermentation process involves addition of fresh nutrient medium either continuously or intermittently and withdrawal of portion of medium for recovery of fermentation products. In continuous process, fermenter is in constant usage with little shut down and after initial inoculation of yeast culture, further inoculation is not necessary. The continuous fermentation proposed is the latest and proven technology as compared to the old batch fermentation technology. It has many advantages like continuity of operation, higher efficiency and ease of operation. Continuous fermentation also results into consistent performance over a long period as compared with batch fermentation. Most modern ethanol production plants adopt this technology. Though the initial investment for continuous mode fermentation appears to be higher, the advantages of the technology are significant. Volume of effluent discharged is less than that of total effluent discharged in conventional distillation process Continuous Fermentation Process Molasses is the chief raw material used for production of alcohol. Molasses contains about 50% total sugars, of which 30 to 33 % are cane sugar and the rest are reducing sugar. During the fermentation, yeast strains to the species Saccharomyces cerevisiae, converts sugar present in the molasses in to alcohol. Chemically this transformation for sucrose to alcohol can be approximated by the equation:- I) C 12 H 22 O 11 + H 2 O Invertase 2C 6 H 12 O 6 Cane Sugar Glucose + Fructose II) C 6 H 12 O 6 2C 2 H 5 OH + 2CO Zymase 2 x x 44 Glucose/Fructose Ethyl alcohol + Carbon di-oxide Theoretically, 180g of sugars on reaction gives 92g of alcohol. Therefore, one MT of sugar gives kg of alcohol. The specific gravity of alcohol is , therefore, kg. of alcohol is Molasses based 30KLPD Distillery Unit 2-13

50 EIA REPORT: Chapter II equivalent to 511.1/ = liters of alcohol. During fermentation of other by-products like glycerin, succinic acids etc. also are formed from sugars. Therefore, actually 94.5 % total fermentable sugars are available for alcohol conversion. Thus, one MT of sugar will give only 644 x = liters of alcohol, under ideal condition theoretically. Normally only 80 to 82 % efficiencies are realized in batch type plant. One MT of molasses containing 45 % fermentable sugars gave an alcoholic yield of 230 liters per MT. Proper and careful handling of yeast, parameter such as ph, temperature control and substrate concentration are in optimum state results into effective conversion of sugars to alcohol. For yeast propagation & multiplication separate equipment is required. Yeast propagation set up is usually comprised of three stages namely 100 liters, 500 liters and 5000 liters. The equipments for the same are designed to facilitate boiling of molasses (to sterilize it), cooling it to the temperature of 33 0 C as well as transfer or drawl of culture. Boiling, cooling, introducing yeast culture etc. are done in aseptic manner. In pre-fermenter stage, yeast propagation is done in open tanks for about 8 hours in order to build up necessary concentration of yeast. Finally, the culture from pre-fermenter is transferred to fermenter, which is pre- cleaned and kept ready. Dilute molasses solution is allowed to flow in the fermenter so as to fill it to its working capacity. Nowadays readymade compressed yeast is used directly in the pre-fermenters. The fermentation of molasses in fermenters take about 24 to 30 hours for completely exhausting the sugars in molasses. The average efficiency of conversion of sugars from molasses to alcohol is 80 to 85 % of theoretical value in batch type distilleries. All the sugars are not converted to alcohol during the process or fermentation because chemicals like glycerin, succinic acid, etc. are also produced by yeast during their metabolic process. Therefore, it is not possible to have 100% efficiency of conversion of sugars to alcohol. The average yield of alcohol from molasses is about 230 liters from 1MT of molasses in batch type distilleries. Recently attractive developments have taken place in the field of fermentation and distilleries whereby one can get high yield of 265 to 280 liters per MT of molasses Multi-Pressure Distillation Technology After fermentation the next stage in the manufacture of alcohol is to separate alcohol from fermented wash and to concentrate it to 95 % (v/v) alcohol called as Rectified spirit (RS). For this purpose, method of distillation is employed. The distillation columns consist of number of bubble cap /Rh grid plates where wash is boiled and alcoholic vapours are separated and concentrated on Molasses based 30KLPD Distillery Unit 2-14

51 EIA REPORT: Chapter II each plate stage by stage. Multi-pressure distillation system for production of Rectified spirit consists of following distillation column. 1. Degasifying cum analyzer column 2. Rectification Column 3. Fusel Oil Concentration column 4. Extractive Distillation column For ENA mode 1. Degasifying cum analyzer column 2. Pre-rectifier column 3. Extractive Distillation column 4. Rectification Column 5. Refining /Simmering column 6. Fusel Oil Concentration column 7. Head Concentration column Advantages of Multi-Pressure Distillation 1) Maximum heat integration is possible. 2) Few columns operate under vacuum, few under pressure and few under atmospheric pressure. 3) Resolution of impurities is better. 4) Analyzer column operates under vacuum. Thereby scaling is minimized in distillation. 5) Formation of by-products such as acetal is minimized - improvement in quality of alcohol. 6) Pre-rectification column ensure removal of sulfur compounds /mercaptants, reduces load of lower boiling volatile compounds 7) Low steam consumption with reboiler (2.2 Kg/lit. of Rectified Spirit & 3.2 Kg/lit. of ENA) 8) Spentwash generation is less Ethanol (Absolute Alcohol) Fuel ethanol is an important product. As per IS specification, it is nearly 100% pure i.e. water free alcohol. Alcohol as manufactured by Indian distilleries is rectified spirit, which is 94.68% alcohol and rest is water. It is not possible to remove remaining water from rectified spirit by straight distillation since; ethyl alcohol forms a constant boiling mixture with water at this concentration. It is known as Molasses based 30KLPD Distillery Unit 2-15

52 EIA REPORT: Chapter II azeotrope. Therefore, special process for removal of water is required for manufacture of fuel (anhydrous) alcohol. The various processes used for dehydration of alcohol are as follows I) Azeotropic Distillation II) Molecular Sieve Dehydration (MSDH) III) Pervaporation / Vapour permeation system. From these, the SSAIL has planned to select molecular sieve dehydration (MSDH) technology Dehydration with Molecular Sieve process The rectified spirit from the rectifier is superheated with steam in feed super heater. Superheated rectified spirit from feed super heater is passed to one of the pair of molecular sieve beds for several minutes. On a timed basis, the flow of superheated rectified spirit vapour is switched to the alternate bed of the pair. A portion of the anhydrous ethanol vapour leaving the fresh adsorption bed is used to regenerate the loaded bed. A moderate vacuum is applied by vacuum pump operating after condensation of the regenerated ethanol water mixture. This condensate is transferred from recycle drum to the Rectified Column in the hydrous distillation plant via Recycle pump. The anhydrous alcohol draw is condensed in product condenser and passed to product storage. The life of molecular sieve may be around five to seven years. However, the operating cost is considerably less than azeotropic distillation. Table 2.5: Product and storage details Sr. Particulars Production per Receiver capacity Storage capacity No. (KL/Day) (Cum) Cum 1. Rectified Spirit x 3 = x2=1200 Impure Sprit OR x 3=30 2. EN.A x 3= x2 = 1200 Technical alcohol OR x2 = Anhydrous alcohol x 3 = x2 = 1200 Impure Spirit x 3 = 30 Table 2.6: Project budget Molasses based 30KLPD Distillery Unit 2-16

53 EIA REPORT: Chapter II Sr. No. Particulars Amount (Rs. in Lakhs) 1. Land Development Civil work and building Plant and machinery including taxes and duties Miscellaneous fixed assets Preliminary, pre-operative and other expenses Margin Money TOTAL Sr. No. Particulars Table 2.7: Capital investment on environment management Amount (Rs. in Lakhs) 1. Spent wash cooling and holding tank Compost yard with PCC top finish Leachate management system Laboratory shed and its glassware, equipments, etc Treatment units for condensate and other effluent Bio-methanation Unit stand alone MEE Bio-composting machinery, pipeline, DG and other Fire fighting equipments and other Tree plantation and bore well for composting Wet Scrubber TOTAL Recurring Expenses/annum 1. Salaries and wages Operation and maintenance of all pollution control devices, motors, pumps, pipelines, etc Molasses based 30KLPD Distillery Unit 2-17

54 EIA REPORT: Chapter II Sr. No. Particulars Fuel (composting activity) and Electricity (in case of diesel generator operation) Amount (Rs. in Lakhs) Fire protection, greenbelt, other waste management 2.00 Transportation 3.00 TOTAL ENVIRONMENTAL ASPECTS Table 2.8: Overview of environment management processes Sr. No Waste product and source Treatment and disposal 1. Effluent/Wastewater Spentwash Spent lees, condensate from MEE and Other effluent Sewage: Domestic wastewater Biomethanation followed by multi effect evaporation followed by bio-composting Hot water recycled after cooling Treated in CPU comprised of effluent primary treatment followed by aeration as secondary treatment and tertiary treatment As local acceptable practice, by septic tank and soak pit system 2. Gaseous emission Flue gasses from boilers Due to burning of bagasse and biogas Particulate emissions will be controlled by Wet scrubber and then vented through a common chimney of height 60m Bagasse is carbon neutral fuel, contains sulfur in trace amount Molasses based 30KLPD Distillery Unit 2-18

55 EIA REPORT: Chapter II Sr. No Waste product and source Bio-composting (CH 4; ) Diesel generators Fermentation unit: (CO 2 ) Treatment and disposal No loose bagasse, it will be in belled (block) form, plus bagasse transfer will be through closed conveyers hence fugitive dust will get controlled Since, the distillery is proposed within sugar factory premises, hence handling and transportation of various material will be minimal. It will help to control fugitive dust. Greenbelt of 33% of the plot area i.e. 4.0 acres Fully auto spraying and aerobic composting It will be operational only when captive as well as grid power supply failure, hence emissions anticipated to be less frequent and minor Fermenteres are covered, CO 2 scrubbed in water 3 Solid waste Boiler ash Fermented sludge: Yeast sludge, Polishing unit sludge Bagasse ash contains soil nutrients such as potash and phosphates. It will be mixed with bio-compost and sold to farmers for use in agriculture lands. The sludge from fermenter will be degradable, containing organic nutrient and micro elements. It will be mixed with bio-compost. Molasses based 30KLPD Distillery Unit 2-19

56 EIA REPORT: Chapter II Effluent Treatment: Spentwash The mother liquor left behind after distilling-off alcohol is called as spentwash. The spentwash of distillery poses a very serious problem by way of threat to the environment. The management of SSAIL has proposed to install 30 KLPD distillery based on Continuous fermentation with provision to operate the process on Fed-batch mode (if VFA content in molasses is high) and Multipressure distillation with MSDH technology to produce Rectified spirit or Extra Neutral Alcohol or fuel ethanol. Sugar factory management has also decided to install biogas plant suitable for 30 KLPD distillery plant effluent feed (360 M 3 /day) as a primary effluent treatment system followed by standalone multiple effect biomethanated spentwash evaporation plant (MEE) for concentration of biomethanated spentwash up to 30 % total solids (60 m 3 /day) content as a secondary effluent treatment system. Concentrated spentwash and pressmud will be used for making biocompost as a tertiary treatment to achieve Zero Spentwash Discharge as per CPCB norms. The spentwash evaporation condensate quantity of 300 m 3 /day will be treated in condensate polishing unit (CPU) and treated water will be reused for distillery cooling tower or for fermentation process (molasses dilution as make-up water). During Public hearing, Regional Officer of Maharashtra Pollution Control Board, had raised a query that, the now a days, average spentwash generation has been brought down to 8 lit per liter of alcohol and hence, spentwash generation needs to be 240 m 3 per day. The point raised is correct but not technically suitable when biomethanation is primary treatment because, if spentwash generation is reduced (from L per litre of alcohol to 8L) its percent solid or brix value increases and thus it become difficult to treat through biomethanation. It also affects the biogas generation. Therefore, even raw spentwash of 6% solid (or 6 o brix) is also diluted a little to keep solids less than 5% before biomethanation treatment. However, in the proposed distillery, the spentwash volume will be reduced after biomethanation 360m 3 to 60 m 3 per day Primary treatment for spentwash: Anaerobic Digestion The raw spentwash coming from the multipressure distillation system at the rate of 12 liter per liter of alcohol produced (i.e. approx 360 m 3 /day at about 10 to 12 % total solids) will be taken to the biogas plant for primary treatment. During the biomethanation process, the COD will be reduced by about 65 % and biogas will be produced at the rate of about 0.5 nm 3 / Kg of COD consumed. Total volume of biomethanated spentwash generated will be 360 m 3 /day containing approximately, 5 to Molasses based 30KLPD Distillery Unit 2-20

57 EIA REPORT: Chapter II 6% solids. In recent years, due to escalation of energy costs and environmental concerns have increased the interest in direct anaerobic treatment of distillery spentwash. The anaerobic method of waste treatment offers under the present circumstances a number of significant advantages with little serious or insuperable drawbacks over other treatment methods. The anaerobic degradation is performed by two groups of bacteria. 1. Acid producing bacteria: Acid forming bacteria (butyric & propionic acid) Acetogenic bacteria (acetic acid & hydrogen) 2. Methane producing bacteria: Acetoacetic methane bacteria (acetophilic) Methane bacteria (hydrogenophilic) Reaction Steps The anaerobic metabolism of a complex substrate, including suspended organic matter, can be regarded as a three-step process: 1. Hydrolysis of suspended organic and soluble organic of high molecular weight 2. Degradation of organic molecules to various volatile fatty acids, ultimately acetic acid 3. Production of methane, primarily from acetic acid, also from hydrogen and carbon dioxide Amongst these three steps, the second one is rather quick, while the two others are slow. This accounts for many instability problems encountered in anaerobic processes. Hydrolysis of organic matter is a rather slow process carried out by extra cellular enzymes. Factors like ph and cell residence time play an important role with respect to reaction rate. Lipids are hydrolyzed very slowly, therefore the hydrolysis step might be overall (including methane production) rate limiting for wastes containing considerable amount of lipids. The types of lipid apparently play a role, as the degradation of non-polar lipids in anaerobic processes seems to be considerably slower than the degradation of polar substances. Acid production results in formation of acetic acid or in case of instability, the higher fatty acids such as propionic, butyric, iso-butyric, valeric and iso-valeric acid. The acid production rate is high as compared to the methane production rate, which means that a sudden increase in easily degradable (soluble) organic will result in increased acid production with subsequent accumulation of the acids. This might inhibit the next step of the process the methane step. Methane production is a slow process, in general the rate-limiting step of anaerobic degradation. Methane is produced from Molasses based 30KLPD Distillery Unit 2-21

58 EIA REPORT: Chapter II acetic acid or from hydrogen and carbon dioxide. About one third of the methane has its origin in molecular hydrogen. The bacteria producing methane from hydrogen and carbon dioxide are fast growing ones as compared with the acetic acid utilizing bacteria. Environmental factors of primary importance to anaerobic processes are- Temperature Nutrients Toxic substances The loading rates permissible in an anaerobic waste treatment process are primarily dictated by the sludge retention in the anaerobic reactor. The solution for the biomass retention problem resulted in the development of different anaerobic processes. In the proposed project, there will be one CSTR type biodigester of 9000m3 capacity. Important ancillary units of biodigester system includes central and lateral agitators, gas holder, de-gasser, flare unit, flow meters, pumps, biogas blowers, biogas burning system, etc. Safety devices such as flame arresters with net, sediment/ moisture traps, high level/low level of pressure alarms for biogas control shall be provided as per the norms by Safety/ factory Inspectorate. Table 2.9: Spentwash characteristics at inlet of bio-digester ph BOD (mg/l) 60,000-65,000 COD (mg/l) 1,00,000-1,20,000 Table 2.10: Estimated Performance for biogas plant Sr. No. Parameters Performance parameter 1. Performance trial 30 days after stabilization of biogas plant 2. BOD reduction 85 % 3. COD reduction % 4. Biogas generation 0.5 m 3 /kg of COD reduced Molasses based 30KLPD Distillery Unit 2-22

59 EIA REPORT: Chapter II 5. Methane (CH 4 ) content in biogas % Secondary treatment for spentwash: stand alone multiple effect evaporation (MEE) system The management of SSAIL has proposed to install a standalone multiple effect evaporation system for the proposed unit. MEE will consist of minimum five effects. It will be based either on principles of falling film or forced circulation or combination of both. Inlet volume of biomethanated spentwash will be of 360 m 3 /day (having 5% solids), whereas outlet spentwash volume will be 60 m 3 /day (having 30 % solids). The spentwash evaporation plant will require around MT/hr of steam at 3.5 kg/cm 2 pressure. Biomethanated spentwash of 360 m 3 /day containing about 5-6 % total solids will be evaporated in a standalone multiple effect evaporator to 30% total solids (approx. 60m 3 /day). The evaporation condensate (app. 300 m 3 /day) after treatment in CPU, will be reused for distillery cooling tower make up or for fermentation process (molasses dilution as make-up water) Tertiary treatment for spentwash: Bio-composting Concentrated biomethanated spentwash (60m 3 /day) and pressmud will be used for making biocompost as a tertiary treatment to achieve Zero Spentwash Discharge as per CPCB norms. Biocomposting is a biological process in which organic matter is degraded under controlled conditions. It involves microbial mineralization. The mixing of spentwash and press-mud in 1:1 proportion (50-70 % moisture) will be carried out in trenches with the help of homogenizing/ aerotiller (Self propelling) machine for spraying, mixing, turning, loading and unloading of compost material. Addition of decomposing culture/cow dung will provide microbes required for bio-composting. It is observed that in the first five days, fungal activity is predominant and in subsequent days bacterial activity continues until stabilization of organic matter into humus is accomplished Process operational details A bio-composting cycle can be divided into two stages i.e. 50 days of windrow composting (Aerobic process) and 5-10 days for curing in heaps (anaerobic process). The degradation should get completed in 60 days. Bio-compost process can be divided into the following stages. Molasses based 30KLPD Distillery Unit 2-23

60 EIA REPORT: Chapter II Active Stage: After formation of windrows and spraying of inoculums active stage starts. During this stage rise in temperature takes place. This phase lasts for first days. Maturation Stage: Includes the greater part of maturation and extends to and beyond the period of temperature decline, which consists of the next 14 days when the temperature is maintained and the next 10 days when the temperature starts to decline. Ripening or Curing Stage: Allow the compost to age for 4 weeks, until the moisture stabilizes at 30% to 35%. a. Formation of windrows: Press-mud will be formed in windrow size of 3.5 x 1.5m. The windrows will be straight and have correct size. Windrow Size 3.5 m Width x 1.5 m Height Distance between two windrows 1m (by using self propelling machine). b. Inoculum application: Inoculum acts as an odor reducing agent as well as an activator to hasten the process of raising the temperature. Normally for every MT of pressmud 0.5 to 1.0 kg of inoculum is applied. It is diluted 100 times with effluent and sprayed on the windrows spreading over 3 days for effective results (in the 3 rd, 5 th and 10 th day) immediately after the application of inoculum, windrow should be aerated with mixing machine to spread the inoculum uniformly to all parts of windrow. c. Aeration: Normally aerotiller/ mixing machine is used for mixing up the windrow, loosen the same and create a situation congenial for natural aeration. When the moisture content reduces below 40% an addition of effluent should restore it to 65%. If the pressmud is wet (more than 70% moisture) there is lower supply of oxygen. Moisture content should be brought down to about 40 % by giving proper aeration. Microorganisms make use of nitrogen and carbon for their metabolic activities. The energy required for this process is derived by aerobic decomposition. Aeration should be given to raise the biocompost temperature and establish an aerobic condition. The temperature should be C in the windrow. Continue aeration till the completion of biocomposting cycle. spraying and Molasses based 30KLPD Distillery Unit 2-24

61 EIA REPORT: Chapter II d. Effluent Spraying: Spraying is done either before aeration or during the mixing/ aeration process. The quantity of effluent to be applied should be strictly controlled so that the windrows always have proper moisture content, which is optimum for aerobic composting. e. Merge Windrows: Proper degradation of organic matter of windrow reduces its height; hence, after about 15 days of initial composting the windrow height is likely to be reduced to about 0.5 meter. Therefore, it may be required to merge 2 windrows into one and continue further processing. f. Compost Curing: After completion of spraying of spentwash, aerate the windrow for 2 to 3 days. After reducing the moisture to about 30 % to 35 % heap the compost in the corner to a height of about 2 meter to have anaerobic process for about 15 days and also to make the space free for fresh windrow formation. A distinctive black loamy, free flowing and ready to pack compost, which has a pleasant earthy smell and moisture content of 30-35%, should be produced The Salient features of this process are as follows Zero Pollution No odour or fly nuisance. The finished product is entirely free from any repulsive odour. Destruction of BOD of the effluent High product value quick payback Dry product - easy to bag, handle and transport Negligible power/energy requirement Zero effluent discharge to inland or any of the watercourses Biocompost is rich in micronutrients (with organic and inorganic) Biocompost can be sold to farmers to generate income Compost Monitoring Parameters a. ph: Biocompost microorganisms operate best under ph is in the range of 5.0 to 8.5. During the initial stages of decomposition- organic acids are formed. The acidic conditions are favorable for growth of fungi and breakdown of lignin and cellulose. As composting Molasses based 30KLPD Distillery Unit 2-25

62 EIA REPORT: Chapter II proceeds, the organic acids gets neutralized, mature compost generally has a ph in the range of 6 to 8. b. Temperature: As organisms decompose waste, they generate heat. Decomposition is most rapid when the temperature is between C. Bio-compost pile temperature depends on how the heat produced by microorganisms is offset by the heat lost through evaporating the effluent. After an initial high temperature period, compost pile temperatures will gradually drop. Turning the compost rejuvenates the oxygen supply and exposes new surface to decomposition, causing temperature to rise. When the temperature drops down below 40 0 C, the composting process is nearly complete. c. Moisture: Active microorganisms need a moist environment. Microorganisms can use organic molecules only if they are dissolved in water. Ideally, composting materials should have between 50 and 70 percent water. When conditions are too wet, water will fill the pore space needed for air movement and anaerobic conditions can result. If conditions are too dry, the decomposition rate will slow down. Carbon to nitrogen (C: N) ratio: Microorganisms require a balance of carbon and nitrogen for healthy cell growth. Initially the press mud C: N ratio is 30:1 after composting it is breakdown to 14: 1. Table 2.11: Bio-compost: Desired characteristics Organic carbon % Nitrogen % Phosphorous % Potassium % Organic matter % ph 6-8 Performance 1. Average Press mud to spentwash ratio: 1:1 2. Biocompost cycle duration: 60 days/ five cycles Molasses based 30KLPD Distillery Unit 2-26

63 EIA REPORT: Chapter II 3. Culture required for biocomposting: 1 Kg/MT (culture in solid form) or 250 ml /MT (Culture in liquid form) of press mud Material balance for biocomposting Total concentrated spentwash generation per annum=300 days X 60 m 3 /day =18,000m 3 Press mud required to achieve SW : Press Mud Cake (PMC) mixing ratio at 1:1 = 18,000MT PMC production in : 18,820 MT/annum Table 2.12: The composting requirements Sugar Factory Crushing capacity after proposed expansion (maximum in TCD) 3500MT Annual Crushing (considering avg. season of 160 days) 560,000 Annual Pressmud produced 22,400MT Moisture content of Pressmud % Distillery Capacity (liter /day) 30 KLPD Days of operation 300 Annual spent wash production before evaporation (360m3/day) 1,8,000m 3 Annual spent wash production after evaporation (60m3/day) 18,000 m 3 Ratio Spentwash: Pressmud, (45 days cycle) 1:1 Pressmud required per annum of distillery operation Land required for PCC compost yard 18,000 MT 4.2 acres Table 2.13: Mass Balance: Compost Sr. No. Description Solid Content (%) Quantity Total Solids (MT) 1. Annual Raw Material Molasses based 30KLPD Distillery Unit 2-27

64 EIA REPORT: Chapter II a) Press mud* 30 18,000 MT 5400 b) Spent wash 30 18,000cum 5400 Total 10, Annual Compost 65 10,200MT Biocompost Yard Based on the CPCB norms and quantity of concentrated bio-methanated spentwash generation, PCC/RCC impervious compost yard of 4.2 acres will be constructed. Infrastructure required for bio-composting a. Spentwash holding tank (maximum 5 and 30 days capacity)- HDPE sheet & PCC/RCC work b. Impervious bio-compost yard (RCC- 1:2:4) for 4.2 acres c. Barbed wire fencing for the bio-compost yard d. Sump Well e. Leach ate water gutter, Pipeline etc. f. Homogenous auto spraying & mixing machine g. JCB excavator cum loader machine h. Dumpers / tippers i. Electrification at bio-compost site j. Magnetic flow meters k. Spentwash spraying network l. Pumps and motors m. Bore well and HDPE piping n. Green belt, etc. A) Land preparation for bio-compost yard: Basics 1. Preparation for the foundation of the bio-compost yard is very careful task. Strong emphasis needs to be laid on the preparation of the ground & providing proper compaction. 2. In the process of development of compost yard, we need to ensure that:- The land should be leveled and compacted properly. Molasses based 30KLPD Distillery Unit 2-28

65 EIA REPORT: Chapter II A soft soil cushion should be provided to lay the 250 micron thick HDPE sheet. Further, another layer of soft soil/soft sand needs to be provided over the 250 micron thick HDPE sheet before proceeding with the top finish. Provision of underground spentwash spraying network for auto spraying. Provision of leachate management system as per MPCB new guidelines. Top Finish: RCC (1:2:4); The gaps /joints may then be filled with Bituminous material to prevent any seepage in the sub soil. The thickness of the concrete layer should not be less than 100 mm. Use of building paper over the sand/soft soil cushion is recommended to prevent the water in the concrete from being absorbed by the sand cushion. It is suggested that a surface vibrator be used during the concreting process. Curing for at least 15 days by making water puddles on top of the concrete is must. Important Spentwash reacts with cement and may in due course render the concrete useless, to prevent this action the entire concrete laid on the biocompost yard should be painted with coal - tar for added life Operations & maintenance guidelines for bio-composting a. Rainy season It is not possible to run the Aerobic Biocomposting process at least for three months during rainy season. The reasons for stoppage of process during rains are: It is not possible to run the biocomposting machine during rainy season. Freshly sprayed spentwash that is yet to be decomposed may give some colored leachate after rain and will contaminate the soil. Due to rain, the biocomposting material in windrows may have moisture content of more than 70%, which can result in anaerobiosis. Heavy rains can wash off the press mud. b. Precautions to be taken before on set of rainy season The biocomposting area will be vacated before start of rain, Molasses based 30KLPD Distillery Unit 2-29

66 EIA REPORT: Chapter II As far as possible all, the compost on the site will be sold out before start of rain. The compost, which remains unsold, will be bagged and kept in stores / godown. After harvesting the last batch of compost a 2 cm surface layer of press mud over the brick on edge layer will be scrapped and this scrapped material shall be kept covered for blending with compost. The windrow of fresh press-mud will be formed after cleaning the scrapped area after rainy season. c. Un-seasonal rains Precaution to be taken if there is an un-seasonal rain during bio-composting cycle In order to avoid the leaching of spent wash, the windrows on the area will be covered with polyethylene sheets/pullover cover Stop spraying spent-wash, temporarily when it is raining. Spraying will be resumed when the sky is clear once again. The provision of the trenches towards slopping side will be made to collect the run off from windrow area. This run off will be collected in leachate collection pit. If necessary it will be pumped back to 30 days storage lagoon. The run off of outside compost yard should be suitably diverted so that it does not enter the compost yard Holding of spentwash Spentwash will be transported through closed conduct, HDPE/RCC pipes. It will be stored in impervious tank/lagoons. An impervious storage tank of maximum 30 days (10,800 cum in capacity) and five day holding (1,800cum) capacities will be constructed to store spentwash. Spentwash storage tanks will be constructed as per guidelines of regulatory authority. It will be duly lined with 200 mm thick black cotton soil (40%) + murum (60%), 250 micron HDPE sheet, pitched by stone/bricks with SRC mortar and SRC plaster 50 mm thick to prevent leachate. The sectional view of spentwash holding tank is given in the following figure. Molasses based 30KLPD Distillery Unit 2-30

67 EIA REPORT: Chapter II Figure 2.7: Schematic of spentwash holding tank Figure 2.8: Schematic of compost yard Molasses based 30KLPD Distillery Unit 2-31

68 EIA REPORT: Chapter II Figure 2.9: Schematic Figure for complete compost process Figure 2.10: Schematic of spraying network Molasses based 30KLPD Distillery Unit 2-32

69 EIA REPORT: Chapter II Process condensate treatment plant (Condensate polishing unit - CPU) Condensate from MEE, spent lees and miscellaneous wastewater such as cleaning in place will be sent to this unit where it will be treated in three stages namely primary, secondary and tertiary. Schematic diagram of this treatment is given in the following figure. Aeration unit Sludge drying beds Figure 2.11: Block diagram of CPU CPU: Primary Treatment i. Equalization Tank: Hot process condensate and other wastewater stream from the evaporation section are collected in a equalization tank where the stream are mixed well. ii. iii. Effluent Cooler: Hot effluent from the collection tank is pumped via plate heat exchanger which will be taken care in the evaporation section, where it is cooled to 35 0 C. ph Correction: The cooled effluent then enters in to a static mixer, where it is neutralized by using caustic solution. Depending on caustic solution is dosed using a dosing system consisting of dosing tank and dosing pumps. Dosing is controlled using ph sensor attached on downstream of the static mixer. Molasses based 30KLPD Distillery Unit 2-33

70 EIA REPORT: Chapter II CPU: Secondary Treatment i. Biological (Aerobic) Treatment: This is the main section where degradation of organic pollutants with the help of aerobic micro-organism takes place. In aeration tank activated biomass is developed in such a way that certain MLSS is maintained for continuous condensate flow which comes to aeration basin. Condensate is degraded in given retention time and activated sludge is further passed to clarifier and recycled as per requirement. The remaining sludge is passed to sludge drying bed. Air supply is provided by means of aeration equipment which has high oxygen transfer efficiency. ii. iii. iv. Secondary Clarifier: In secondary clarifier, condensate passed from aeration tank along with biomass (MLSS) gets settled here. The settled biomass recycled back to aeration tank as per requirement and excess biomass transfer to sludge drying bed. Disinfection: Supernatant from Tube settler, flow by gravity to the chlorine contact tank. To disinfect the harmful bacteria in the treated water as well as to remove the refractory organics from treated water, in this tank hypo chlorite solution is dosed with the help of dosing system Sludge disposal system:settled sludge from tube settler will be removed by pumping to the sludge drying bed CPU: Tertiary treatment Secondary treated water will be further passed through sand media filter followed by activated carbon filter. Filtered water will be collected in the Treated water Storage tank from where it will be reused for desired process/cooling application. Backwashed water from filters will return back to equalization tank Solid waste generation and management The project is likely to generate deferent solid wastes, listed as follows. Waste Quantity/day Characteristics Treatment/ disposal Yeast sludge 0.3 to 0.5MT Organic in nature Compost Ash 1.3MT Organic + Inorganic Compost Molasses based 30KLPD Distillery Unit 2-34

71 EIA REPORT: Chapter II CPU sludge 0.1 to 0.3 MT Organic Compost Spent oil from DG 0.1 to 0.2cu m/annum 2.7 GREEN-BELT DEVELOPMENT Hazardous burnt in boiler The sugar factory has developed a greenbelt along the roads, fencing and around process unit. It has also developed greenbelt around guest house and housing colony near the factory. Details of existing greenbelt are mentioned in table In the proposed activity, greenbelt developed around manufacturing unit will consist of small and medium size trees. These trees will be developed in 2-3 raw curtains, depending upon space availability. Ornamental shrubs, herbs including lawn will be developed at selective locations. Greenbelt will also be developed around the waste disposal areas, such as ETP, compost yard, spentwash storage lagoon, etc. This will be mainly for beautification. Since, the soil around industry is combination of clay and loam. Estimated the water requirement, for four acres of greenbelt is 75-80m 3 per day. Treated effluent from sugar mill/distillery will be used for watering plants. Table2.14: Details of existing greenbelt around Industrial Complex Name of species Individual Location Coconut 1,500 Neem (Melia azadiracta) 300 Around fencing Palm 250 Along the road Peltoforum pterocarpum 100 Gulmohor 50 Polyalthia longifolia (Ashok) 100 Terminalia cattapa (Desi Badam) 50 Along the internal road, Around fencing, near housing colony Garden areas, Along internal road side, around fencing, near housing colony Garden areas, internal road side, around fencing, near housing colony Around fencing, near guest house and housing colony Around fencing, Along internal road side, near housing colony Suru 50 Around fencing, near housing colony Avala 30 Around fencing as well as other open areas Molasses based 30KLPD Distillery Unit 2-35

72 EIA REPORT: Chapter II Chinch 30 Around fencing as well as other open areas Nilgiri 50 Total 2510 Figure 2.12: Photographs of existing greenbelt Molasses based 30KLPD Distillery Unit 2-36

73 EIA REPORT: Chapter II The greenbelt for the distillery unit is described in details in chapter VI (Environment Management Plan). Schematic of greenbelt development for proposed unit is represented in Fig Fig.2.13: Schematic of Greenbelt Development Board of Direectors (Management) General Manager Chief Chemist sugar Cheif enineer Sugar/cogen unit Distillery Manager Environment Officer/Chemist Environment Officer/Chemist Figure 2.14: Decision making and its implementation hierarchy (from top to bottom) and reporting hierarchy (from bottom to top) for environmental conditions/compliances Molasses based 30KLPD Distillery Unit 2-37

74 EIA REPORT: Chapter II Figure 2.15: Schematic of existing wet scrubber and wet ash handling Molasses based 30KLPD Distillery Unit 3-38

75 EIA REPORT: Chapter III CHAPTER III BASELINE ENVIRONMENT STUDY 3.1 INTRODUCTION The baseline environmental and socio-economic study of the project was done for following objectives. Understand the prevailing environmental as well as socio-economic characteristics of the study zone Further, assess the environmental impact of the proposed project/developments based on the existing environmental quality. Identify linked factors (environmental or geographical) that could preclude future developments, if any. 3.2 METHODOLOGY OF BASELINE STUDY The baseline data collection was based on the set of broad guidelines suggested by Ministry of Environment, Forests and Climate Change (MoEFCC). Considering the proposed site as a centre, 10 km radius area was considered as a study area for collecting baseline data. The primary data collection for air, water, noise, soil, etc. was carried out in the summer season of 2014 i.e. February to May The baseline study begins with site visits and exploration survey in the study area. During these visit the locations were fixed for the monitoring and collection of primary data. Various government agencies were approached for getting information and relevant data as a secondary data. 3.3 DESCRIPTION OF SITE AND STUDY AREA Geographical features surrounding the Site The proposed site is located within the existing sugar factory premises at Mahesh Nagar, post village Ujana, Taluka Ahmedpur, District Latur; State: Maharashtra. Latur district is situated in the Marathwada province of the Maharashtra state. The state highway SH-03 that connects Latur to Nanded is approx 2.5 km from the site. Latur and Nanded are nearest main cities, railway stations as well as air ports are at approx 75 and 70km respectively. The geographical coordinates of the site are N and E. The site is 511 meter Molasses based 30KLPD Distillery Unit 3-1

76 EIA REPORT: Chapter III above mean sea level. The proposed project site is on a plateau. The land in the project premises is more or less flat terrain. Presently sugar mill has occupied approx 35acres of 255acres of land available with project proponent. The plot/site is having slope towards south, Southeast. The proposed distillery and ancillary units are located towards north of the plot, adjacent to the sugar mill. Except wild seasonal grasses, there is no vegetation on the proposed area of construction. A channel of irrigation canal, having <1m width is passing through north boundary of the site. Wadarwadi is the nearest habitation located at 1.0km towards north of the site. Village Ujana (residential area) is located at west 2.2km from sugar mill, village Ralga is located towards NE at 2km from the factory. River Manyar (Manyad) is located at approx 3km towards south of the site. Molasses based 30KLPD Distillery Unit 3-2

77 EIA REPORT: Chapter III Figure 3.5: Satellite image of Project site Housing colony of the sugar factory is the nearest residential area to the site. Apart from it, village Wadar wadi is approx 1.5 km towards north of the site. Small artificial ponds/tanks are located at 1km towards southeast as well as southwest of the site. Other geographical features of the site are listed in table 3.1. Molasses based 30KLPD Distillery Unit 3-3

78 EIA REPORT: Chapter III Table 3.1: Important Features Around the Project Site # Direction Important Geographical Features Distance (km) 1. West village Ujana Northeast Village Ralga South River Manyad 3.0 Village Sangvi 4. North Village Wadar wadi 1.4 Table 3.2: Summary of Environmental features of study area # Facet In brief 1 General characteristics Semi arid and drought prone Agro-climatic zone seven of Maharashtra 2 Rainfall Average 800 mm/annum; Mainly in July-Aug 3 Temperature In summer 24 0 C to 40 0 C. for few days C. In winter 14 0 C to 22 0 C for few days below 10 0 C. 4 Humidity High in Monsoon >85% ; decreases up to 30 % 5 Wind Predominantly from southwest 6 Land use Fallow land 47%, scrub 23%, agricultural 19.4% 7 Air Quality complies NAAQ standards of Nov Noise Complies the standard 9 Ground water As per Central Ground Water Board report Good and suitable for drinking and irrigation purpose, however localized nitrate and total hardness contamination is observed. 10 Soil light and light medium soil of inferior type Nearest sanctuary Yedshi sanctuary in Osmanabad district at approx 130km from the site Molasses based 30KLPD Distillery Unit 3-4

79 EIA REPORT: Chapter III Land Use Pattern Land use, land cover is a fundamental parameter describing the Earth s surface. This parameter is a considerable variable that impacts on and links many parts of the human and physical environments. Satellite remote sensing, in conjunction with geographic information systems, has been widely applied and been recognized as a powerful and effective tool in analyzing land cover/use categories. This study made use of remotely sensed data and GIS technologies; to evaluate qualitatively and quantitatively outcome of land cover/use distribution. Obtained results were compared, visualized and analyzed, in Geographic Information System. The study area of proposed distillery unit of SSAIL is covered in survey of India Topo-sheet no. 56B/13, 56B/14, 56F/1and 56F/2, and lies within latitudes of 18 48'11.88"N 18 48'48.07"N to and longitudes of 76 57'15.79"E to 76 57'54.90"E. I. Software and Hardware Satellite Data: LANDSAT_8, OLI_TIRS cloud free data has been used for Landuse / land cover analysis Satellite Sensor: LANDSAT_8, OLI_TIRS Path and Row: Path 145, Row 47 Spatial Resolution: 30 m. Date of Pass: 02 Feb 2014 II. Ancillary Data PC based GIS and image-processing software was used for the purpose of image classification and for delineating drainage and other features in the study area. Number of peripheral devices such as scanner, plotter, printer etc. has also been interfaced with the system. Satellite data is then displayed in standard false colour composite format by assigning blue, green and red colour guns of monitor to the green, red and near infra red bands of multispectral data respectively. Histogram stretching, an image enhancement technique is applied to a 16-bit multispectral data. In order to correct systematic distortions such as earth curvature image rectification and registration was performed on satellite data. The random distortions were corrected using well distributed ground control points (GCP) occurring in Molasses based 30KLPD Distillery Unit 3-5

80 EIA REPORT: Chapter III raw data and captured with the help of GPS survey of the study area. To achieve planimetric accuracy, the multispectral data was rectified with respect to SOI maps of 1:50,000 scale. The GCP s in the scene such as rail-road intersections, corners of water reservoirs, bunds, etc. were identified on the image as well as on the reference map. Third order polynomial model was constructed and finally registration of image was carried out with nearest neighborhood resampling technique taking SOI map as a reference. Then, the subset of image was taken according to the boundary of the study area. The digital classification technique has been used for the extraction of the landuse/landcover (LULC) information from the imagery. Eight different landuse/landcover classes have been identified in the area under study. Table 3.3 shows the information about the extent of LULC classes in the study area Landuse/ Landcover Classes Details Satellite data of Rabi season was classified using supervised classification technique. Maximum likelihood algorithm classifier was used for the analysis. The scenes were individually classified and then were integrated to get a composite classified output where information from Rabi season is available. A truth table was generated taking 0.95 as the conversion threshold. After aggregation, the final classified output was converted in raster format. The image was then converted in raster format, which is understood by GIS software. Site visit and ground truth study supported the digital data. Area under each class has been described in following table. Table 3.3: Landuse/ Landcover Statistics of the study Area S. No. Classes Area (Ha) Area (%) 1 Waterbody Current Fallow Long Fallow Open Scrub Agriculture Vegetation Built-up Land Barren Land Molasses based 30KLPD Distillery Unit 3-6

81 EIA REPORT: Chapter III Figure 3.6: LULC map for study zone Relief indicates the variation in the nature of the land surface i.e. "the lie of the land". It thus shows the broad features and relative heights of highlands and lowlands such as flood plains, spurs, hills, plateaues etc. Contouring is the standard method of representing relief on topographic maps. Contour lines are lines joining points of equal elevation on the surface of the ground. They can also be thought of as the lines of intersection between a series of horizontal planes and the ground surface. For the given contour map (figure 3.3) the vertical distance between adjacent contour lines or the contour interval is fixed i.e.20m. By examining the horizontal distance between successive contours it is possible to visually estimate the variation in slope of parts of the terrain. As the vertical distance between contours is the same, the closer the contour lines are together the steeper the slope. The maximum height of the terrain in given study area of 10sq.km is 540m. There are some undulations in the western direction of the site, other parts are relatively flat Molasses based 30KLPD Distillery Unit 3-7

82 EIA REPORT: Chapter III It is observed from the habitation map (figure 3.4) that, there are only nine villages in 5km radius zone where impact is usually more conspicuous. There are about 49villages in the study area of 314 sq. km, These habitation areas were more concentrated towards north, north-west and southwest boundaries of the study zone. Figure 3.7: Contour map of study zone Figure 3.8: Habitation map of study zone Molasses based 30KLPD Distillery Unit 3-8

83 EIA REPORT: Chapter III Figure 3.9: Satellite Imagery Showing site and surrounding (image date Jan 29, 2014) Molasses based 30KLPD Distillery Unit 3-1

84 EIA REPORT: Chapter III Figure 3.10: Environment Monitoring station network Table 3.4: Monitoring location details Location Location Aspect monitored code 1 Factory site AAQ, noise, soil, water 2 Ralga AAQ, Noise, soil, water 3 Dongargaon AAQ, Noise, soil, water 4 Ujana AAQ, Noise, soil, water 5 Gangahipparga AAQ, Noise, soil, water 6 Tandulwadi Soil, water 7 Shednri AAQ, Noise, soil, water 8 Bembdewadi Soil, water 9 Sangvi AAQ, Noise 10 Limboti Soil, water Molasses based 30KLPD Distillery Unit 3-2

85 EIA REPORT: Chapter III Climatic Conditions The climate observed in the district is semi-arid type; average rainfall in the district is 800 mm. This is usually during the monsoon months from July - October. Climatic conditions i.e. hot and humid climate during rainy season and dry and cool climate during winter season are quite favorable for the vegetative growth and accumulation in sugar in sugar cane, respectively. The rainfall is unpredictable in tune with the Indian monsoon. In Latur, moderate temperatures are mainly observed throughout the year. Summers here begin from mid February to July. Summer months are dry and hot. The temperature ranges from 24 C to 39.6 C, though at the peak they may reach >41 C. From November to January, is the winter season. Temperatures at the peak drop to single digits but usually they hover around 13 C to 22 C sometimes lowers up to 8-9 C. December up to mid February weather is more pleasant Rainfall Table 3.5: Rainfall for last five years YEAR Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Annual rainfall Avg Molasses based 30KLPD Distillery Unit 3-3

86 EIA REPORT: Chapter III Rainfall pattern for Latur district Rainfall Normal RF(mm) Normal rainy days (number) SW monsoon (June to Sep) NE monsoon (Oct to Dec) Winter (Jan-Feb) 06 - Summer (Mar-May) 43.6 Annual Source: Indian Meteorological Department, Temperature Gradual increase in temperature is observed since February. May and June are generally the hottest months. During May and June nights are comparatively warmer than in April. On individual days during the summer the temperature occasionally rises above 40 0 C. The average maximum temp is 39 0 C in summer. With the onset of the Southwest monsoon, there is an appreciable drop in the day temperature, but nights are quite warm as in the latter part of the hot season. From September, there is a slight increase in the day temperature and in October, day temperature is observed to be significantly high like month of May. Minimum temperature during winter is 12 0 C Month Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Year Average Max C Average low C Humidity The relative humidity depends not only an amount of water vapour in the atmosphere, but also on temperature. The humidity is generally high, being over 85% in the monsoon season and decreases in the post-monsoon period. The driest part of the year is the period from January to March, when the relative humidity in the afternoon is about 30% Molasses based 30KLPD Distillery Unit 3-4

87 EIA REPORT: Chapter III Cloudiness The cloudiness is recorded in Oktas i.e. in one-eights of the sky covered. The sky is mostly heavily clouded or overcast during the southwest monsoon period. But cloudiness decreases in the post-monsoon period i.e. October and November. The sky is generally clear during the period from November to April. Cloudiness increases from May onwards Winds The winds are generally gentle with some increase in force during the late summer and monsoon seasons. In October, winds blow commonly between north and northwest directions but on some days they are from southwest or west. During November to February the winds are mostly north- easterly or easterly. Westerly winds appear from the month March onwards; the Southwesterly from late May last till September Wind Speed And Wind Direction The windrose diagram for the proposed site shows following features. The predominant wind direction observed during the study period was south-west followed by north-west. A wind rose diagram (fig. 3.7) shows the details of the wind pattern for the site. Molasses based 30KLPD Distillery Unit 3-5

88 EIA REPORT: Chapter III Figure 3.11: Wind Rose Diagram Soil There are nine agro-climatic zones in Maharashtra and Latur district is in zone seven which is assured rainfall zone. In this zone, soil colour ranges from black to red and soil types observed are vertisols, entisols & inceptisols. The district can be divided into the following two zones based on soil characteristics i.e., the first zone which occurs in eastern part of the district comprises of Ahmedpur, Udgir and parts of Latur and Ausa talukas. It consists of light and light medium soil of inferior type. They are not retentive of moisture and are therefore Molasses based 30KLPD Distillery Unit 3-6

89 EIA REPORT: Chapter III suitable for the cultivation of Kharif crops only. The soil in some parts of Nilanga taluka is of lateritic type and the second zone which occurs in western part of the district comprising parts of Latur and Ausa talukas. They are heavy deep black cotton soils. Owing to the peculiarity of the soil, both Kharif and Rabi crops are cultivated in this zone. The majority of the soils in the study zone was light and light medium. Major Soils types (Latur district) Area ( 000 ha ) Percent (%) of total geographical area Deep soils Medium deep soils Shallow soils (Source: NBSS and LUP, Nagpur) Table 3.6: Soil analysis for samples from study zone Parameter Ganga Hiperga Ralga Ujjana Factory Site Shendri Bembdewadi Tandulwadi ph EC(mmho) Organic Carbon(%) Available N (kg/ ha) Available P (kg/ha) Available K (kg/ha) Molasses based 30KLPD Distillery Unit 3-7

90 EIA REPORT: Chapter III Figure 3.12: Soil types observed for Latur district Figure 3.13: Drainage pattern observed for study zone Molasses based 30KLPD Distillery Unit 3-8

91 EIA REPORT: Chapter III Hydrology Geomorphologically, Balaghat plateau running eastwards is the main geomorphological unit. In general the area of the district shows uneven topography with residual hills belonging to Balaghat ranges. The altitude of the area ranges between 500 to 715 m above mean sea level (m amsl). Physiographycally, the district can be divided into two parts i.e., Higher Elevated Plateaus, which occurs in the western and southern parts of the district in Latur, Ausa, and Nilanga talukas and Lower Elevated River Valleys, which comprises valley plains of Manyar and Lendi rivers in Ahmedpur and Udgir talukas and valley plains of Manjra and Tawarja rivers and plains of Terna River and its tributaries. The district forms a part of Godavari basin. Manjra River, a tributary of Godavari River flowing south-easterly is the major river in the district. Tawarja and Terna rivers are the main easterly flowing tributaries while Gharni and Rena rivers are southerly flowing tributaries of Manjra River. The rivers shows dendritic and rectangular drainage pattern Manjara: This is the main river of the district. Its origin is near the Gaukhadi Village of Beed district. The river flows from the northern boundaries of the Osmanabad district and cutting across the Latur district goes to Karnataka State Terna: This is the main tributary of Manjara which flows on the southern boundary of the Ausa Taluka Manyad: This river takes its origin at Dharmapuri in Beed district and flows through the Ahmadpur taluka into Nanded district, it s a tributary of river Godavari Lendi: The river has its origin in Udgir taluka and flowing through the Ahmadpur taluka joins the Tiru river in Nanded district Gharni: The river has its origin near Wadval and flows through Chakur taluka. Tawarja: Tawarja originates near Murud in Latur taluka and joins the Manjara river at Shivani on the Latur-Ausa boundary Drainage map of a study area shows highest order of drainage as 6 th order. The study area is under the confluence of Manar river which is one of the major river in Latur ditrict. Many streams are contributing to the Manar river from surrounding part of the study area. The pattern of drainage for the study area is mixture of rectangular and draindritic. Molasses based 30KLPD Distillery Unit 3-9

92 EIA REPORT: Chapter III Table 3.7: Analysis report - Ground and surface water sources of study zone Parameter Lake Water (Donga rgaon) Hand pump (Dong argao n) Well Water (Shendri) Bore well Water (Shendr i) Well Water (Bembd ewadi) Well Water (Ralga) Well Water (Tandu lwadi ) Well Water (Nimbo ti Dam) Well Water (Ganga Hiparga ) Handpu mp water (Ujjani) Surface water ( Ujjani lake) Borew ell water ( Ganga Hiparg a) Well water (Ujjani) Canal (Near Factory ) ph at 25 O C EC (mmho) Temperatur e ( O C) DO TDS Chloride Sulfates Phosphate BDL BDL BDL BDL BDL Molasses based 30KLPD Distillery Unit 3-10

93 EIA REPORT: Chapter III Parameter Lake Water (Donga rgaon) Hand pump (Dong argao n) Well Water (Shendri) Bore well Water (Shendr i) Well Water (Bembd ewadi) Well Water (Ralga) Well Water (Tandu lwadi ) Well Water (Nimbo ti Dam) Well Water (Ganga Hiparga ) Handpu mp water (Ujjani) Surface water ( Ujjani lake) Borew ell water ( Ganga Hiparg a) Well water (Ujjani) Canal (Near Factory ) Residual Chlorine Phe. Alkalinity Methyl O. Alkalinity BDL BDL 5.31 BDL 1.77 BDL BDL BDL BDL BDL BDL BDL BDL 10 BDL BDL BDL 6.0 BDL BDL BDL BDL BDL 16 BDL Calcium Magnesium Sodium Turbidity BDL Potassium Molasses based 30KLPD Distillery Unit 3-11

94 EIA REPORT: Chapter III Parameter Lake Water (Donga rgaon) Hand pump (Dong argao n) Well Water (Shendri) Bore well Water (Shendr i) Well Water (Bembd ewadi) Well Water (Ralga) Well Water (Tandu lwadi ) Well Water (Nimbo ti Dam) Well Water (Ganga Hiparga ) Handpu mp water (Ujjani) Surface water ( Ujjani lake) Borew ell water ( Ganga Hiparg a) Well water (Ujjani) Canal (Near Factory ) Total Hardness COD BOD Cadmium BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL Copper BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL Manganese BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL Total Chromium BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL Detection Limit: 1) Cadmium, Copper, Manganese and Total chromium = 0.2mg/L; 2) phosphate = 1mg/L,; 3) Phenolphthalein alkalinity = 2mg/L; 4) residual chlorine = 0.1mg/L Molasses based 30KLPD Distillery Unit 3-12

95 EIA REPORT: Chapter III Irrigation Facilities Though, this area is classified as assured rainfall zone in agro-climatic zone map, this area is drought prone and rain fall varies between 500 to 800mm. Therefore, the government agencies and farmers in the operational area have carried out, various water harvesting projects. Barrages and Kolhapur type weirs (KTW) are constructed on the rivers to restrict the water to provide the water for irrigation in summer days. The command area of the sugar mill is mainly irrigated by the minor reservoir present on river Mannar. Canal networking through these projects supplies the water for irrigation. Table 3.8: Irrigation system and facilities Irrigation system Number Area (ha ) Canal barrages/ storage tanks wells facilities Oil engines Electrical motors Cropping Pattern In the operational area of the factory, different crops are being taken in a various seasons, the details of which are as follows (Table 3.9). Molasses based 30KLPD Distillery Unit 3-13

96 EIA REPORT: Chapter III Table3.9: Cropping pattern for Ahmedpur Taluka Sr. No Type of crop Area ( ha) 1 Cereals Paddy, 991 Jowar 11,158 wheat and other cereals 2,050 2 Cotton 1,026 3 Oil Seeds Groundnut, 381 soybean and other oil seeds 25,640 4 Sugar cane 3,095 5 Other crops 23,108 Total 67, Hydrogeology Almost entire district is underlain by the Basaltic lava flows of upper Cretaceous to lower Eocene age. The shallow Alluvial formation of Recent age also occur as narrow stretch along the banks of major rivers flowing in the area but it does not form potential aquifer. Deccan Traps occurs as Basaltic lava flows, which are normally horizontally disposed over a wide stretch and give rise to tableland type of topography, on weathering also known as plateau. Ground water in Deccan Trap Basalt occurs under phreatic conditions at shallow depths upto 15 to 20 m. At deeper levels, the ground water occurs under semi-confined to confined conditions. The weathered and fractured trap occurring in topographic lows, form the main aquifer in the district. The vesicular portion of different lava flow varies in thickness from 15 to 25 m and forms the potential zones. The yield of dug wells tapping upper phreatic aquifer ranges between 25 to 250 m3/day, whereas that of bore wells varies from 0.50 to m3/day, depending upon the local hydro-geological conditions Air Environment Ambient air quality of the study area has been assessed through a network of seven ambient air quality stations keeping in view the wind pattern in the study area. The monitoring locations are shown in figure 3.6. Air, water, soil and noise sampling locations are given in Table 3.4. Molasses based 30KLPD Distillery Unit 3-14

97 EIA REPORT: Chapter III Method IS- 1029(Part 23) for Particulate matter; IS- 5182(Part vi) 1975 for NOx and IS- 5182(Part ii) for SOx analysis Table 3.10: Baseline Ambient Air Quality 1) Proposed site Param eter Observed values (weekly - in g/m 3 ) Avera ge PM PM NO x SO ) Village Ujana Param eter Observed values (weekly - in g/m 3 ) Avera ge PM PM NO x SO Molasses based 30KLPD Distillery Unit 3-15

98 EIA REPORT: Chapter III 3) Village Sanghvi Param eter Observed values (weekly - in g/m 3 ) Avera ge PM PM NO x SO ) Village Ralga Param eter Observed values (weekly - in g/m 3 ) Avera ge PM PM NO x SO Molasses based 30KLPD Distillery Unit 3-16

99 EIA REPORT: Chapter III 5) Village Tandulwadi Param eter Observed values (weekly - in g/m 3 ) Avera ge PM PM NO x SO ) Village Shendri Param eter Observed values (weekly - in g/m 3 ) Avera ge PM PM NO x SO Molasses based 30KLPD Distillery Unit 3-17

100 EIA REPORT: Chapter III 7) Village Dongergaon Param eter Observed values (weekly - in g/m 3 ) Avera ge PM PM NO x SO NAAQS for Rural residential as well as industrial areas PM 10 (24h): 100 µg/m 3 PM 2.5 (24h): 60 µg/m 3 SOx (24h): 80 µg/m 3 NOx (24h): 80 µg/m Observations The values for PM 10 and PM 2.5 for all monitored locations were well within National Ambient Air Quality (NAAQ) Standard limits. The particulate matter concentration towards predominant downwind direction (NE) was quite low compared to concentration observed at village Ujana, Sanghvi and shendre. This could be due to proper dispersion of pollutants, and control measures adopted by the factory. The values reported at Ujana, Sanghvi and Shendre appear higher in comparison to other locations. This could be due to local agricultural activities, brick making unit near Sangvi, transportation of cane, sand and bricks, proximity of these three locations to the cane transport route. Concentration of SOx and NOx were significantly low compared to NAAQS. (Clarification for the query raised during public hearing by Hon. DM for PM 10 value reported for Sanghvi) Molasses based 30KLPD Distillery Unit 3-18

101 EIA REPORT: Chapter III Noise Environment Noise, in general, is sound which is composed of many frequency components of various loudness which is distributed over the audible frequency range. The most common and universally accepted scale is the weighted scale which is measured as db. This is more suitable for audible range of 20-20,000 Hz and has been designed to weigh various components of noise according to the response of a human ear. The environmental impact assessment of a noise from the industrial activity, vehicular traffic can be undertaken by taking into consideration various factors like potential damage to hearing, physiological responses, annoyance and general community responses which have several effects varying from rise Noise Induced Hearing Loss (NIHL) etc. Noise survey had been conducted in the study area to assess the background noise levels in different zones viz. Industrial, commercial and residential zones. Noise levels were measured using a sound level meter. A total of seven noise sampling locations were identified (table 3.4) Method of Monitoring Sound pressure level (SPL) measurements were undertaken at all locations, with an interval of 10 seconds over a periodicity of 15 minutes for 24 hours. The day noise levels had been monitored during 6 am to 10 pm and night levels during 10pm to 6am at all mentioned locations Parameters Measured For noise levels measured over a given period of time interval it is possible to describe important features of noise using statistical quantities. Noise levels at certain locations were exceeding the limits during the day time interval. The results of the noise monitoring at the places monitored are given in Table Molasses based 30KLPD Distillery Unit 3-19

102 EIA REPORT: Chapter III Table 3.11: Noise Monitoring Results Location code Location 1 Factory main gate (Industrial area) 1 Factory Laboratory (Industrial area) 1 Factory ETP (Industrial area) 1 Proposed site (Industrial area) Avg. level day time (6am to 10pm) Avg. level night time (10pm to 6am) Standard Day time Night time Ralga (rural residential area) Dongergaon rural residential area) 4 Ujana (rural residential area) 5 Gangahipperga (rural residential area) 7 Shendri (rural residential area) 9 Sanghvi (Near to State highway - busy road) Molasses based 30KLPD Distillery Unit 3-20

103 EIA REPORT: Chapter III 3.4 GEOGRAPHY AND GEOLOGY Geography The Latur District is in the south-eastern part of the Maharashtra state. The district is situated on the Maharashtra Karnataka boundary. On the eastern side of the Latur is Bidar district of Karnataka, whereas Nanded is on the northeast, Parbhani on the northern side, Beed on the Northwest and Osmanabad on the western and southern side. The entire district of Latur is situated on the Balaghat plateau, 540 to 638 meters from the mean sea level Geology The Marathwada region is characterized by the Deccan traps (Upper cretaceous to lower Eocene). The granitic rocks have given rise to red as well as black cotton soils. Major part of the region has deep black soil derived from the trap rock. Certain variations occur due to exposure and protection. A mixture of laterite and black soil, for example, is encountered in the eastern parts together with sandy soil along river banks. Most of the hill tops are bare or covered by coarse gravel while the low lying area accumulates clay and loam. 3.5 ECOLOGY AND BIODIVERSITY Ecosystem The study zone was representing semi-arid type of villages, near residential areas and village roads. Forest was not reported in 10km radious area. Lentic and Lotic fresh water ecosystems are in the form of farm ponds/tanks and river Manar respectively. There is no any reserve forest or wildlife sanctuary or national park or biosphere reserve observed in 10km as well as 25km radius Flora and fauna The wild vegetation observed is matching to the semi-arid habitat with grasses and scrub vegetation dominance. Tree species show stunted growth and many of them are thorny. Predominant tree species of the area are Babhul (Acacia indica), Khair (Acacia catechu), Hiwar (Acacia) Salai, Bor (Zizyphus jujuba), Dhawda (Anogesis latifolia), Babuldhaman, Apta (Bauhinia recemosa), Sitaphal. Also trees like Arjun, Teak, Bel, Dikamals are found. Grasses include shedya, mavvel, Kusali etc; Shrubs include Lantana etc. Molasses based 30KLPD Distillery Unit 3-21

104 EIA REPORT: Chapter III Here, domestic animals were very common and dominant. Amongst other groups of animals species of fishes, frogs and toads, snakes, lizards, geckos and birds which are commonly observed near human settlements were recorded. In the study zone, no rare or endangered species of plants or animals have been recorded. The site is not located in the migration route of any animal or birds, etc. 3.6 SOCIO- ECONOMIC ENVIRONMENT Introduction Socio- economic status of the population is an indicator for the development of the region. Any developmental project of any magnitude will have a bearing on the living conditions and on the economic base of population in particular and the region as a whole. Similarly, the proposed unit will have its share of socio-economic influence in the study area Methodology Data collection on Demography of the area, social and economic indicators, infrastructure available, etc. through site visit, official web site of the district, district gazetteer, census of India and other government offices Sources of Information As per the scope of this study, the information on socio-economic aspects has been gathered and compiled from several secondary sources. These include Taluka Office, Collectorate office, Agriculture Department, Irrigation Department, Central Ground Water Board, Department of Mines and Geology etc. The demographic data has mainly been compiled from the website of Census of India The socio-economic details are briefly described in following sections Demography and development indicators The population of Ahmedpur Taluka is 228,438 of which 52% of the population is male and females are 48%. There are 124 villages and 24 wadis in the Taluka. There are 27,546 small farmers and 37,075 landless labours in the Taluka. Almost 70 of population is below poverty Molasses based 30KLPD Distillery Unit 3-22

105 EIA REPORT: Chapter III line (BPL). Hence, alternative employment opportunities are very essential for the locals. Social development indicators Below poverty line % Infant mortality rate (IMR): 10 Maternal mortality rate 0.6 Birth rate 19.4 Death rate 3.4 Molasses based 30KLPD Distillery Unit 3-23

106 EIA REPORT: Chapter III Figure 3.14: Demographic data - Ahmedpur Molasses based 30KLPD Distillery Unit 3-24

107 EIA REPORT: Chapter III Figure 3.15: Socio-economic indicators - Ahmedpur Molasses based 30KLPD Distillery Unit 3-25

108 EIA REPORT: Chapter III Figure 3.16: Economic indicators -Ahmedpur Molasses based 30KLPD Distillery Unit 3-26

109 EIA REPORT: Chapter III Infrastructure Availability of infrastructure and facilities denote the level of overall development in the study area. The availability of facilities with regard to education, health, transport and communication, water supply and availability of electricity are dealt with in the following Education Facilities Presently there are more than 2093 schools, 33 degree colleges, 12 ITIs, three polytechnics, two engineering college, two medical college, agriculture & biotechnology college in the district. Shree Ramanand Tirtha (SRT) university has its sub center in Latur extending courses in technology, management and social Science. Latur is well known for its Latur Pattern in educational field at national level. It is a cumulative outcome of leadership, educational institutions, people, teachers, parents & students. Latur is upcoming as Educational Hub because of its educational movement Health Services There are 12 government hospitals, 46 PHCs, 19 dispensaries and 234 primary health support groups. Government-run primary health centres, sub-centres or dispensaries provide basic healthcare to nearly 30% of the villages and 50% of the rural population. The Civil Surgeon and Civil (District) Hospital offering tertiary healthcare in a three-tier healthcare system are located at the district headquarters Drinking Water The villages in the study area are drawing water from river, according to the sources of drinking water used by the villages are Water Tank, Well, River, Hand Pump, Tap Lake etc Transport State highway SH-77 is 2 km from the Industry. running through the district are Among the important state highways Yedashi -Latur-Nanded ( NH-151) of 215km four lane road and connect Latur to National Highway. Nagpur--Bori--Adhampur, state highway; Daund--Barshi--Osmanabad--Bantal--Ausa state highway; Molasses based 30KLPD Distillery Unit 3-27

110 EIA REPORT: Chapter III Miraj--Pandharpur--Barshi--Latur state highway and Manjarsumba--Kij--Lokhandi--Savargaon state highway. Renapur-Latur- Ausa corridor of 40km four lane road will stimulate Ausa Renapur as satellite town to Latur city Bus routes to the district headquarters connect 80 % of the villages. Latur is now well connected by Rail track to all major cities. The district has 148 km of broad gauge railways. The connectivity routes are - Latur-Kurduwadi-Pune-Mumbai (West ) Latur-Udgir-Hyderabad (South) Latur-Purna-Akola-Nagpur-Kolkatta.(East) Latur-Manmad- Bhusawal-Delhi (North ) The 889 villages are connected by road among which 781 are by all season roads. The 845 Km state highway is running across the district. Figure 17: Road network map - study zone Molasses based 30KLPD Distillery Unit 3-28

111 EIA REPORT: Chapter III Table 3.12: Traffic density on sugar factory approach road (average for peak hour) # Vehicle type No. 1 Trucks, tankers, etc Tractors- trailor (mainly for cane transport) 12 3 bullock carts (mainly for cane transport) 15 4 pick-ups wheelers wheelers (Including bicycles) 55 Total Tele-communication More than 1600 km optical fibers line, 146 telephone exchange and landline connections provide telephone connectivity to each corner of district. Existing 129 Broad Band stations and proposed 17 BB station will provide dedicated line for data transfer (uplink 256 kbs & downlink 2Mbs). BSNL, Airtel, Reliance,Idea & Vodaphone operates cellular services in district. 3G cellular service with 25 station operated by BSNL 3 Wi- Max station is in operation Electricity All villages have power supply from Maharashtra State Electricity Distribution Corporation Limited (MSEDCL). Disaster vulnerability Flood: Earthquake: Cyclone: Drought: No Indicated in zone IV: very high probability; massive earthquake in 1993 Yes Drought-prone Molasses based 30KLPD Distillery Unit 3-29

112 EIA REPORT: Chapter III Medical facilities Hospitals Health facilities Blood banks: There are 12 government hospitals, 46 PHCs, 19 dispensaries and 234 primary health support groups. Government-run primary health centres, sub-centres or dispensaries provide basic healthcare to nearly 30% of the villages and 50% of the rural population. The Civil Surgeon and Civil (District) Hospital offering tertiary healthcare in a three-tier healthcare system are located at the district headquarters. Two Language The primary language is Marathi. Urdu, Telegu, Kannada, and Hindi Language/s: Food are also spoken. Gujarati Rajasthani are spoken by very small population People prefer eating rotis, rice, dal (pulses) and sabji (vegetables). Transportation and communication In the district, there is one head post office, 30 sub-post offices and Post and telegraph services: 258 branch post offices providing its services. Apart from regular postal services they are also engaged in providing services such as Saving Banks, Saving Certificates. Postal Life Insurance and Rural Postal Life Insurance. Telephone Revenue Collection, Instant Money Order. Electronic Money Order. International Money Transfer Service. E-Payment. E-Post. Delivery Of Postal Articles There are seven branch offices of post in Ahmedpur Taluka (PIN ) Molasses based 30KLPD Distillery Unit 3-30

113 EIA REPORT: Chapter III Telephone connection ( ) 57, Religious places 1. Wadwal Nagnath- This small hillock near Chakur about 40km from the site. It is home to many species of plants, most of them believed to be of medicinal use in Ayurveda. Every year, yatra is held here when thousands of pilgrims from the district and nearby throng to Wadwal. 2. Sai Nandanwan- Another tourist spot near Chakur. Recently developed. Spread into nearly 400 acres (1.6 km 2 ), it has mango plantations, water park and amusement park. A temple of Satya Sai Baba is situated in the middle of the park. 3. Devarjan- Another small hill in Udgir Taluka (approx 55km from site) with small temple on the top. 4. Kharosa - It has located in Ausa Taluka (approx 100km from the site) caves carved out into latterite rocks. Believed to belong to 8th century AD. 5. Lohara village in Udgir Taluka known for the Mahadev Bet (hill) & Gabeisaheb Bet. there will be also one of the famous trust that is Beninath Maharaj matth (It is an Anicient Trust from Nijam Sahi) Economic Profile This section deals with the economic aspects of study area, which includes agriculture, industry and occupational structure of inhabitants as per 2001 Census. Different aspects are dealt in the separately following sections Agriculture Agriculture is most predominant activity of the area spreading over major geographical area and with about 50 % of main workers engaged in the activity. The city is a major Sugarcane and edible oils, Soyabean, Grapes, Mango production center. A fine blend of mango with locally grown mangoes was developed as Keshar Amba Molasses based 30KLPD Distillery Unit 3-31

114 EIA REPORT: Chapter III Industry The Latur, Additional Latur and Khandapur MIDC Industrial Areas are prominent industrial zones on the outskirts of the city, with various major multinational groups having set up manufacturing or processing plants in and around the city. There is one Special Economic Zone (SEZ) have been approved by central government for this city and these are, in Agro Processing SEZ Occupational Structure The primary occupation in this region is farming. Cattle farming and service in the industry are the secondary occupations Banking And Financial Services Ahmedpur which is a taluka place, having public sector and private banks In addition to this many cooperative banks are available here. Table 3.13: Industries (Latur district) at a glance Categor Cumulative figures up to March 2012 y No. of enterprises Employment generation Investment (Rs. In Lakhs) Mfg. Service Total Mfg. Service Total Mfg. Service Total Micro 1, ,560 14, ,320 13, ,406 Small , ,589 31, ,121 Medium Large ,727-5,727 41, ,295 Molasses based 30KLPD Distillery Unit 3-32

115 EIA REPORT: Chapter III Table 3.14: List of sugar and distilleries units, in approx 200km radius of the SSAIL Name of unit District: Latur Crushing capacity (TCD) Distillery capacity (KLPD) - 1. Shetkari Killari Sahakari Sakhar Karkhana Ltd Jawan J.Kisan Sahakari Sakhar Karkhana Ltd Manjara Sahakari Sakhar Karkhana Ltd S.P. Nilangekar Sahakari Sakhar Karkhana Ltd Siddhi Sugar and Allied Industries Ltd 2500 Proposed 6. Pannageshwar Sahakari Sakhar Karkhana Ltd Vikas Sahakari Sakhar Karkhana Ltd Sant Shiromani Sahakari Sakhar Karkhana Ltd Priyadarshini Sahakari Sakhar Karkhana Ltd Rena Sahakari Sakhar Karkhana Ltd Saibaba Sahakari Sakhar Karkhana Ltd Jagruti Sugar District: Osmanabad Terna Sahakari Sakhar Karkhana Ltd Tulja Bhavani Dharashiv Sahakari Sakhar Karkhana Ltd Natural Sugar Vithal Murum Sahakari Sakhar Karkhana Ltd Dr. Ambedkar Sahakari Sakhar Karkhana Ltd Shivshakti Washi Sahakari Sakhar Karkhana Ltd Shambhu Mahadev Sahakari Sakhar Karkhana Ltd Narsinha Washi Sahakari Sakhar Karkhana Ltd Bhimashankar Washi Sahakari Sakhar Karkhana Ltd Bhairavnath Sahakari Sakhar Karkhana Ltd Banganga Sahakari Sakhar Karkhana Ltd B. Birajdar Sahakari Sakhar Karkhana Ltd Molasses based 30KLPD Distillery Unit 3-33

116 EIA REPORT: Chapter III Name of unit Crushing capacity (TCD) 26. Jaylaxmi Sugar Sahakari Sakhar Karkhana Ltd Lokmangal Mauli Sahakari Sakhar Karkhana Ltd District: Nanded Godavari Manar Sahakari Sakhar Karkhana Ltd Kalambar Sahakari Sakhar Karkhana Ltd Shankar Sahakari Sakhar Karkhana Ltd Bhaurao Chavan Sahakari Sakhar Karkhana Ltd H.J.Patil Sahakari Sakhar Karkhana Ltd Jai Ambika Sahakari Sakhar Karkhana Ltd Jai Shivshankar Sahakari Sakhar Karkhana Ltd District: Parbhani Renuka Sahakari Sakhar Karkhana Ltd Tridhara Sugar Sahakari Sakhar Karkhana Ltd Gangakhed Sahakari Sakhar Karkhana Ltd Yogeshwari Sahakari Sakhar Karkhana Ltd MH Shetkari Sahakari Sakhar Karkhana Ltd Distillery capacity (KLPD) District: Hingoli Marathwada Sahakari Sakhar Karkhana Ltd Purna Sahakari Sakhar Karkhana Ltd Barashiv Hanuman Sahakari Sakhar Karkhana Ltd OTHER ASPECTS From Seismic Zone map (figure 3.15), it appears that, the proposed site is in Earthquake zone IV. In this zone, the probable earthquake intensity of 5-7 Richter scale could be observed. No defense installations or recreational sites, historically or archeologically important/ notified sites, ecologically sensitive sites, national parks, sanctuaries, biosphere reserves present in 10km radius study area. Molasses based 30KLPD Distillery Unit 3-34

117 EIA REPORT: Chapter III Figure 3.18: Seismic Zone Map of Maharashtra Molasses based 30KLPD Distillery Unit 3-35

118 EIA REPORT: Chapter III CHAPTER IV ENVIRONMENTAL IMPACT ASSESSMENT 4.1 INTRODUCTION This chapter discusses anticipated environmental impacts based on the quantities and/or characteristics of various pollutants/ causing factors likely to be generated from different activities of the proposed project. 4.2 AIR POLLUTION Transportation Transportation activities causes air pollution through vehicular exhaust emissions, dust from roads, and loading unloading of material, etc. In present case, transportation of raw material will be minimal since major raw material such as bagasse and molasses will be made available from the sugar factory. Transportation of finished product i.e. RS/ENA or AA usually takes place in bulk. Considering the gross collective capacity of storage tanks (eight in numbers) 4000m 3 it will require about 270 tankers (considering each tanker of 15m3 capacity). Apart from finished product, the molasses required (13,300MT or 8800m3) will be transported through 590 tankers. This will be also transported in bulk. Hence, this is anticipated to cause increase in particulate matter and NOx, particularly during the period/days of transportation. Vehicles of employees and visitors could be a regular source of emissions. The project is going to provide employment to approx 70 persons, in addition there could be some contractual or seasonal employees. The project is located in rural area, where people prefer two wheelers (bicycles, motor cycles, scooters, etc) to commute. Hence, about 90-95% of such vehicular emissions are anticipated from two wheelers (~50-60 in numbers) and remaining 5-10% due to passenger cars and other types of vehicles (~5-7 in number). Therefore, transportation activity of the proposed project is anticipated to cause minor increase in vehicular emissions Preventive, control and mitigation measures Provision of asphalted roads inside the premises and for approach road up to state highway Provision of adequate parking for goods as well as staff vehicles Molasses based 30KLPD Distillery Unit 4-1

119 EIA REPORT: Chapter III Engage authorized transport agency for goods transport on the term to use well maintained vehicles for the activity While bulk transportation, check the time to fill a tanker and call those many which could get filled in 2-4 hours, example if one tanker requires about 8-10 minutes than call 12 tankers at a time and call next 12 after one and half to two hours; this will help to reduce the risks of traffic congestion and minor accidents, waiting period for vehicles and over all air pollution. Provide separate entrance and exit lanes/gates for goods as well as employees vehicles Strict prohibition on washing and maintenance of vehicles on site or in parking area All roads with street light and proper signage at strategic locations Main gate/s with 24x7 security arrangements Manufacturing process The manufacturing process is likely to generate two forms of air pollutants i) is due to burning of fuel to generate steam and ii) from fermentation process Emissions due to burning of fuel In the proposed project, bagasse will be used as a fuel, which is a byproduct of sugar unit. Bagasse is an excellent source of renewable energy. Conventionally, coal or natural gas is used as a fuel in many other industries. Both, coal as well as natural gas is a fossil fuels and non-renewable energy source. Burning of fossil fuels is considered as a one of the prime Green House Gas (GHG) emission source. Hence, use of renewable energy sources is encouraged all over the world. Use of biomass energy is encouraged especially in power generation sector, due to its carbon neutral characteristics. The flue gasses generated due to it will emit ash, which is the main source of air pollution. The analysis of bagasse is given as bellow. Molasses based 30KLPD Distillery Unit 4-2

120 EIA REPORT: Chapter III Table 4.1: Analysis of bagasse Parameter Value (in %) Carbon Hydrogen 2-6 Oxygen Nitrogen Moisture 50% Ash content % Sulphur <0. 01 Calorific value 2,250 kcal/kg Bagasse analysis report shows that the elements such as nitrogen and sulfur are present in trace quantities, i.e. less than 0%. Thus, the generation of sulfur-dioxide (SO 2 ) and oxides of nitrogen due to combustion of bagasse are anticipated to be very low. The quantity of ash generated can be calculated as follows Bagasse required to generate 145MT steam per day (generally observed bagasse to steam ratio 1:2.2) = 65.5 MT/day Ash content = 2.00 % Total Ash generated = 1.31MT/day = MT/h ( Kg/h) In case of fuel bagasse, fly ash generation is usually 40% of total ash generated. The proponent has planned to install wet scrubber, to control fly ash, which will be entrapped and collected as slurry. Bottom ash Fly ash generation Fly ash controlled by wet scrubber Fly Ash emission = Kg/h = Kg/h = Kg/h (considering Max. efficiency 98%) = Kg/h = g/sec Apart from this, trifling fugitive dust emission due to opening and leaks in duct and manholes and also from ash handling operation at unloading and transfer point are the minor pollution sources Molasses based 30KLPD Distillery Unit 4-3

121 EIA REPORT: Chapter III Sulphur Dioxide (SO 2 ): Another source of air pollution could be the SO 2 formed due to burning of biogas in the sugar factory boiler. The H 2 S present in the biogas will release the sulphur; that will react with the oxygen present in the air to form SO 2 the reaction will be as follows. 2H 2 S + 2O 2 SO 2 + 2H 2 O + S (Equation 1) 2(2+32) + 2(16) (32+32) (2+16) Estimated Biogas production (Considering COD 1,10,000 mg/liters) = 11,880 m 3 /day 1.) General composition of biogas produced by using distillery molasses are Methane (CH 4 ) 64% Carbon dioxide CO 2 34% Hydrogen sulfide (H 2 S)Max 02% Amount of H 2 S from 25,200 m 3 Biogas = m 3 /day (Considering the density of H 2 S =1.539kg/m 3 ) = kg As per equation I 68 gm of H 2 S combustion required 64gm of oxygen i.e. 94% of total volume x 0.94 = kg oxygen required Since the amount of Oxygen required = amount of SO 2 generated Total SO 2 produced = kg/day Thus, SO 2 Emission will be 3.98g/seconds In case of NOx, there are mainly two opportunities for NOx formation. They are: 1. Thermal NOx - The concentration of thermal NOx is controlled by the nitrogen and oxygen molar concentrations and the temperature of combustion. Combustion at temperatures well below 1,300(C (2,370(F) forms much smaller concentrations of thermal NOx 2. Fuel NOx - Fuels that contain nitrogen (e.g., coal) create fuel NOx that results from oxidation of the already-ionized nitrogen contained in the fuel. Theoretically, Nitric oxide (NO) is generated to the limit of available oxygen (about 200,000 ppm) in air at temperatures above 1,300(C (2,370(F). At temperatures below 760(C Molasses based 30KLPD Distillery Unit 4-4

122 EIA REPORT: Chapter III (1,400(F), NO is either generated in much lower concentrations or not at all. In case of bagasse fired boilers, the temperature usually observed is around C, mainly due to high moisture content of bagasse (~50% moisture). This temperature is much lower for formation of NO, which is usually formed above C. However, as a worst case scenario it is assumed that the NO formation may take place at 50% rate. Secondly, the bagasse analysis data shows that, the N percentage is less than 0% which is in the range of 0.10 to 0.20%. Therefore, an average of 0.15% of N content is considered while calculating NO emissions in the present case. Thus, the second probability of fuel NOx becomes insignificant Dispersion modeling for air pollutants The Impact of proposed project on ambient air quality of the study zone was studied with the help of simulation studies. This enabled to understand probable incremental concentration in particulate matter (PM10) and SOx. The main sources of these pollutants are burning of bagasse in the furnace to generate steam. Presently the sugar mill is operating two boilers of 30TPH and it has plan to install a new boiler of 20TPH for the proposed project. The distillery unit is going to use low pressure exhaust steam from the captive power unit of the sugar mill. No additional fuel will be burnt for steam generation during sugar cane crushing season. Flue gases are released through 60m tall stack. Wet scrubber is installed to control particulate emissions which is >98% efficient to trap particulate matter. This will be modified to suite the enhanced capacity of the boilers. During the offseason, the fuel requirement for distillery unit will be only 6 6.5TPH, which will be very small compared to existing sugar unit (32TPH). Thus, it could be inferred that, the present ambient air quality of 10km radious area may not get affected due to the proposed distillery unit. On this background, the baseline air quality data presented in chapter III table 3.10, observed at all locations were within NAAQS. However, to calculate incremental load for PM and SOx it is assumed that, there would be additional bagasse to be burnt. Prediction of impact on air environment has been carried out employing mathematical model based on a steady state Gaussian plume dispersion model designed for multiple point sources for short term. In the present case, Industrial Source Complex-Short Term [ISCST3] developed by United States Environmental Protection Agency [USEPA] has been used for simulations from point sources. Molasses based 30KLPD Distillery Unit 4-5

123 EIA REPORT: Chapter III Table 4.2: Model Input Data Parameters Unit Stack Attached to Boiler 32x2 +20 TPH Stack height m 60 Stack diameter at exit / top m 3.0 Stack exit gas velocity m/s 7.3 Stack gas temperature at exit Deg. C 140 Bagasse requirement TPH Emission rate of SPM g/s g/s Emission rate of SO 2 g/s 3.98 g/s Ash content 2% and dust removal efficiency of wet scrubber 98% Main fuel: Bagasse; Auxiliary fuel: biogas, (approx 11,000m3/day) The quantity of ash generated can be calculated as follows The simulation is made to evaluate PM and SO 2 incremental short-term concentrations due to operation of boiler for proposed activity. Modeling has been done considering boiler/s as source and is centre of grid for prediction. Hourly meteorological data recorded at site for summer season on wind speed, direction and temperature is used as input. For the sitespecific mixing heights CPCB document PROBES/88/ is followed Prediction The predicted results with baseline concentrations are tabulated below in Table 4.3 while incremental dispersion trend is shown as isopleths in Figure 4.1 & 4.2. Table 4.3: Resultant Concentrations Due To Incremental GLC's Scenario Incremental Concentration Baseline Concentration Resultant Concentration CPCB Limit for Residential & Rural Areas PM 10 ( g/m 3 ) SO 2 ( g/m 3 ) Molasses based 30KLPD Distillery Unit 4-6

124 EIA REPORT: Chapter III * The baseline concentration (98th percentile) recorded at village Ralga at 2.5km Northeast of the site The resultant concentrations of SPM and SO 2 after operation of Boilers are within the prescribed National Ambient Air Quality Standards (NAAQS) for Residential & Rural Areas Figure 4.19: Short term (24h) GLC for particulate matter Figure 4.20: Short term (24h) GLC for SO2 Molasses based 30KLPD Distillery Unit 4-7

125 EIA REPORT: Chapter IV Fugitive and Other sources of air pollution Carbon dioxide generated from fermentation process, will be of biological origin, i.e. liberated from an agro-based waste material. Hence, it is assumed to be neutral for GHG and therefore a minor source. Along with carbon dioxide, methane will be produced from biomethanation process of spentwash treatment. This methane (biogas) will be used as a fuel for furnace of sugar (during season) and distillery (during off-season) unit. Odour is anticipated mainly due to storage of spentwash and partly from composting activity Fugitive Emissions: This will be mainly from Bagasse and dust particles. Since, fly ash will be collected through wet scrubber and transported in covered vehicles/conveyers to the compost site, thus, ash is assumed to be negligible source. Preventive, control and mitigation measures Use of Bagasse as a fuel, transported to boiler through closed conveyer Remaining Bagasse will be belled and stored in yard; no loose Bagasse will be stored or handled Sprinkling of water on non-asphalted roads Wet scrubber to control fly ash (PM) and partly SO 2 Round RCC stack with 60m height Green belt of 4.0 acres around the project area Methane produced from biodigesters will be used as a fuel; flare unit is an alternate arrangement when it will not be used as fuel CO2 scrubbers for fermentation unit Composting will be done aerobically using machines Ash slurry as well as bottom ash will be used to mix in compost since Bagasse ash is rich in potash Impact assessment Air quality: Minor negative impact is anticipated mainly due to stack gas emissions and transportation activities of the proposed project; Ecology and biodiversity: Minor negative impact is anticipated on avi-fauna due to stack gas temperature (approx o C), and on flora/plants in close vicinity of the project due to dust (particulate matter) Molasses based 30KLPD Distillery Unit 4-8

126 EIA REPORT: Chapter IV 4.3 NOISE POLLUTION The identified chief sources of noise in the proposed project are - Boiler, Motors and pumps Distillation Transportation Diesel generator (rarely used only in case of total power failure) Table 4.4: Noise levels Source Noise Level at source (average in db(a) Boiler 83.0 Motors and pumps 75.2 distillation 72.5 Transportation 81.3 DG Preventive, control and mitigation measures Use motors, pumps and other machines which comply national/international standards. Noise generating activities will be under roof Preventive as well as regular maintenance Provision of personal protective equipments as per requirement Rotation of duties at high noise generating areas Leveled and wide internal roads Adequate parking space Impact assessment Ambient air: Noise related hazards/ailments are anticipated on persons working close to noise/vibration source. Minor negative impact is anticipated Ecology and biodiversity: Minor negative impact of noise from transportation activity is anticipated on particularly human population and fauna, along the approach road (approx 3km length) that connects site with Nanded-Latur state high way. Molasses based 30KLPD Distillery Unit 4-9

127 EIA REPORT: Chapter IV 4.4 WATER POLLUTION Following wastewater sources have been identified for the proposed project Blow down from boiler/cooling tower Spent wash Spent lees Wastewater from washing/cleaning Condensate water Sewage Waste water from boiler blow down The water used in boiler contains suspended solids, dissolved solids like Ca-salts, Mg-salts, Na-salts, Fe-salts etc. These salts get concentrated after generation steam from the original water volume. These solids have to be expelled from time to time to save the boiler being covered up by scales. This water has following characteristics. BOD - 60 to 70 mg/l SS to 1500 mg/l TDS - 1,500 to 3,500 mg/l Temperature - 90 to 100 o C The estimated volume form boiler blow down is 3m 3 /day. It could be recycled after cooling Condensate of MEE The excess condensate does not normally contain any pollutant and is used as boiler feed water and the washing operations. Sometimes, it gets contaminated with juice due to entrainment of carryover of solids with the vapours being condensed in which case it goes into the waste water drain. The treatment requirement in this case is almost negligible and can fresh water or it can be let out directly as irrigation water after cooling it to ambient temperature. The estimated excess condensate is 300m 3 /day totally recycle or reuse after cooling Spentwash In the production of alcohol from molasses using a continuous fermentation technology about 10 liters of spentwash is produced per lit of alcohol produced. It is having high temp, highly acidic in nature, and dark brown in colour. It also contains high percentage of Molasses based 30KLPD Distillery Unit 4-10

128 EIA REPORT: Chapter IV dissolved organic & inorganic matter; hence its BOD and COD are also significantly high. The general qualitative characteristics of spentwash are highlighted below. Table 4.5: General Characteristics of Raw Spentwash # Parameter Continuous Fermentation Process 1. Volume, Liters. per Liters of Alcohol Colour Dark brown ph COD 1,00,000-1,10,000 mg/l 5. BOD 55,000-65,000 mg/l 6. Solids - Total Solids Total Volatile Inorganic dissolved 1,30,000-1,60,000 60,000-75,000 35,000-45,000 Unit mg/l mg/l mg/l 7. Chlorides 6,000-7,500 mg/l 8. Sulphates 4,500-8,500 mg/l 9. Total nitrogen 1,000-1,400 mg/l 10 Potassium 10,000-14,000 mg/l 11 Phosphorus mg/l 12 Sodium 1,400-1,500 mg/l 13 Calcium 4,500-6,000 mg/l Spent wash could cause severe pollution of surface and ground water. It could act as a fertilizer if applied in controlled manner under skilled supervision. But, often applied in excess that contaminates soil and run off from such field contaminates nearby water bodies. Therefore, storage and disposal of spentwash considered to be important processes from environment management perception Condensate Water The cooling water contain very little pollution load. Usually, it recycled back for cooling / condensation. Molasses based 30KLPD Distillery Unit 4-11

129 EIA REPORT: Chapter IV Floor Washing Other wastewater originates from washing of the floor, fermentation, vats and other equipment. The quantity of floor washing will be about 4m 3 /day and will be reused for gardening activity, within factory premises Spentlees Spentlees is also an important source of pollution. The acidic nature of the spent lees is main cause of the pollution. It will have a ph in the range of 3 4. Quantity of spentlees expected from the proposed distillery will be approx. 30m 3 /day. treatment unit and reused in the distillery. The spentlees will be sent to Sanitary wastewater In the proposed project, sewage generation will be about 5-6m 3 /day. It will be disposed by septic tank and soak pit system Thermal Pollution The hot effluents are boiler blow down and cooling tower blow down. The hot water will of about C temperature and the quantity will be of 40-45m 3 /day. This hot water will be cooled down to normal temperature in cooling pond and then recycled. Hence, there will be no thermal pollution of any surface water body around the project site Preventive, control and mitigation measures Spentwash of 360 m 3 /day will first treated in biodigesters to produce biogas from this organic rich wastewater. Followed by biodigestion spentwash will be sent to multi effect evaporation unit to reduce its volume from 360m 3 to 60m 3. Then, it will be sent to biocomposting process where it will be mixed into pressmud (a solid waste from sugar mill) to produce compost; thus achieving zero liquid discharge for this highly polluted entity Spentwash storage lagoons and the compost yard will be constructed as per CREP guidelines (discussed in chapter VI ) Reuse of water (after proper treatment) Wastewater due to cleaning and washing, Spentlees and condensate water will be treated in CPU. This unit will comprised of primary treatment followed by aeration followed by Molasses based 30KLPD Distillery Unit 4-12

130 EIA REPORT: Chapter IV filtration treatment in CPU unit (discussed in chapter II); treated water of 350m3 per day will be used for dilution of molasses, cooling tower make up, irrigation, or cleaning activities, etc Recycle of water Blow down water from boiler and cooling tower will be cooled in ponds and recycled then after Conservation of water Rain water harvesting to improve the ground water aquifer and partly fulfill the requirement during startup Impact assessment Water availability: No negative impact envisaged since, Irrigation Dept will provide the water allocated for industrial activities only; reuse, recycle of water will save significant of freshwater intake Water/aquatic environment: No negative impact envisaged on water environment as well as aquatic ecosystems of the surrounding area since zero liquid discharge scheme is adequate and efficient Air environment: minor negative impact is envisaged due to odour of spentwash and due to generation of methane and CO 2 from composting process Soil Environment: Due to impervious lagoons as well as compost yard, probability of soil pollution could get reduced to zero percent. Hence, no negative impact is anticipated; The compost prepared from spentwash, pressmud and solid waste filler material will help to recycle the soil nutrients, thus positive impact is anticipated Ecology and biodiversity: No negative impact, food chain/web envisaged to get strengthened due to composting process as composting supports large number of microorganisms and insects. Thereby, it usually supports avian fauna. Molasses based 30KLPD Distillery Unit 4-13

131 EIA REPORT: Chapter IV 4.5 SOIL ENVIRONMENT Soil is likely to get affected due to following. a. Percolation of spentwash and disposal of untreated solid (ash, sludge, etc) and/or hazardous waste (spent oil, etc) in soil b. During construction of various units, removal of top soil layer which is usually more fertile c. Excavation activity particularly for spentwash storage lagoons and compost yard d. Construction of various permanent structures/roads at project site e. Degradation of soil due to construction material (cement, concrete) Preventive, control and mitigation measures Top soil layer of 15-20cm to be kept separate and use for greenbelt development Disposal of excavated material safely for construction of spentwash storage lagoons, compost yard, leveling of roads, etc Solid Waste Management Wastes from a sugar industry include bagasse, molasses, press mud, boiler ash and sludge from effluent treatment plant. Waste Material Type Upshot Ash 1.31MT/day Used as a filler material for bio-compost, final disposal system for the spentwash i.e. distillery effluent Yeast Sludge and sludge from effluent treatment unit 0.4 to 0.8 MT/day mixed with bio-compost Preventive, control and mitigation measures a. Boiler Ash Molasses based 30KLPD Distillery Unit 4-14

132 EIA REPORT: Chapter IV Bagasse ash is usually non-hazardous, non-toxic in nature, it is rich in potash. Hence, there are three alternatives for the disposal of it. i. Mix it with bio-compost prepared at distillery unit (practiced for spentwash disposal treatment) as a filler material. ii. iii. Directly sold to farmer as it is as a potash enriching material Sell it to bricks manufacturing unit in the nearby areas. The factory is planning to use it in the composting process. b. Sludge from ETP This sludge is usually bio-degradable, organic and nearly neutral in nature. It doesn t contain any toxic or hazardous elements. Therefore, this could be safely disposed by adding it to bio-compost. c. Hazardous Waste The only hazardous waste likely to be generated in the project will be the scrap oil from DG set. However, the DG set will be used only in case of total power failure i.e. captive as well as Electricity board power supply failure. Thus, the quantity of used or scrap oil is assumed to be very minor. This waste oil can be disposed off safely by giving it to authorized hazardous waste oil dealer. Alternatively, it can be used as a fuel for the boiler along with Bagasse during startup phase Impact Assessment Soil environment: no negative impact of solid waste; The bio-compost produced from mixing of spentwash and pressmud. It is envisaged to have positive impact on soil since organic carbon and soil nutrients are likely get recycled by the process Ecology and Biodiversity: No negative impact envisaged due to solid waste; enhancement in micro-flora due to compost Water environment: No negative impact envisaged due to solid waste Molasses based 30KLPD Distillery Unit 4-15

133 EIA REPORT: Chapter IV 4.6 ECOLOGY AND BIODIVERSITY Generally, an impact of industrial activity on ecology and biodiversity is observed due to following major reasons. Tree cutting/ removal of vegetation Habitat destruction Threat to rare, endangered flora and fauna Disturbance to wild life Pollution In case of proposed project, no tree cutting or habitat destruction is involved. National parks, sanctuaries, or biosphere reserves are not observed in 10km as well as 25km radius of the site. Rare, endangered species of plants or animals are not recorded from the region Preventive, control and mitigation measure Greenbelt development Zero Liquid discharge will be achieved Safe disposal of solid waste Adequate measures to prevent, control and mitigate air, noise pollution Impact Assessment No impact on fauna (other than avian) envisaged as the species diversity is very low (ref annexure IX), species abundance is also low due to scanty rainfall and agricultural developments in the surroundings. No rare or endangered species has been reported from the study area. Site is not located in the migration route of any wild animal or birds. However, Minor negative impact is envisaged on avian fauna due to thermal pollution from flue gases; Minor negative impact envisaged on the flora, located in the close vicinity of the site, due to particulate matter. no negative impacts from other activities are anticipated; Positive impact envisaged due to Increase in the greenbelt, that will help to maintain and enhance the biodiversity Molasses based 30KLPD Distillery Unit 4-16

134 EIA REPORT: Chapter IV 4.7 SOCIO-ECONOMIC ENVIRONMENT Impact causing factor Population flux Pressure on infrastructure such as road, electricity, water Situation for proposed project Project will provide 69 new employment opportunities Captive power water from Irrigation Department Minor increase in vehicle number Adequate school, college, medical facilities are available Public transport, telecommunication, banks and other infrastructure already exist and adequate to support minor increase in population Control, preventive and mitigation measure Local candidates will be preferred Few candidates from distant places if recruited, housing colony could accommodate such minor increase Emphasis on water conservation by recycling and reuse Rain water harvesting Public transport facilities likely to get improved due to project Improvement envisaged for primary school, health services and commodity market Impact No negative impact No negative impact Similarly improvement in daily utility services are also anticipated Maintenance of internal road and approach road Employment Direct employment to 69 people Raw material molasses is derived from sugar cane, which is cultivated in agricultural fields, hence indirect employment to farmers, laborers, cane transporters, etc. Local candidates will be preferred Indirect employment to plenty of locals Positive impact While analyzing the impact on of proposed project on socio-economy, following factors were considered. Ahmedpur Taluka is comparatively less developed and there are approx 37,000 labourers who are dependent mainly on agricultural activities In Latur district, overall 69% of the population is BPL (below poverty line) The performance of existing sugar mill for last three season is excellent and has boosted several socio-economic activities in the region. Molasses based 30KLPD Distillery Unit 4-17

135 EIA REPORT: Chapter IV The management, themselves have initiated several welfare activities for employees, their family members, local farmers as well as neighboring society The project is a vertical integration to utilize the available resources such as molasses, steam, bagasse, electricity, land and man power up to some extent Production of alcohol will generate large amount of revenue by way of taxes and duties for local as well as state government Therefore, a positive impact is anticipated on the regional economy due to the proposed project. The project could also help in maintaining and developing the infrastructure required by the society. 4.8 LAND USE, GEOLOGY AND HYDRO-GEOLOGY /DRAINAGE Impact assessment Since, the proposed site is already under possession of existing sugar mill, no change in land use pattern envisaged. Additionally, LULC map suggests that the site is coming under barren class. Therefore, the impact on LU is positive i.e. barren is getting converted into future built up class which is beneficial for local population. If we consider drainage map of the study area then it could be a minor impact on drainage, as some first order streams are passing close to the project boundary. No impact is envisaged on geology and hydrogeology of the site due to the project Environment management plan Not to damage the first order drainage streams passing close to the project boundary. Precautions need to be taken to preserve or maintain these streams in their natural form or need to be considered while landscape development. Earthquake resistant construction as per national building code for seismic zone IV Well defined disaster management plan and proper implementation of it Training to the personnel for disaster situation, mock drills at periodic interval 4.9 OTHER IMPACT: TRAFFIC In the project, the transportation activity will take place mainly during the construction phase. Considering the availability of road network, the nominal increase in vehicles during construction phase may not cause any traffic congestion. During operation phase, the Molasses based 30KLPD Distillery Unit 4-18

136 EIA REPORT: Chapter IV transportation of RS/ENA and AA will take place in bulk. It is anticipated that, such bulk transport will take place for several days; hence, probability of traffic congestion is least. Road The site is located approx3 km off Latur-Nanded State Highway Good network of road exist in the district Peak hour traffic flow on approach Road is about 117 vehicles Summary of traffic flow in percentage, present and future stage Two Four Lorry/Truck/ Tractor Wheelers Wheeler tanker Added (in Percentage) Traffic management measures Present road condition is good. Will be maintained. Road markings will be done. Topography is level and rains are not problematic. Culverts will be maintained. Village roads connecting are of good surface. Will be maintained. Our approach road will be constructed wide with illumination at 30 m spacing. All factory vehicles to have back red light/reflectors All gates manned by trained security 24x7 Trees along the road Molasses based 30KLPD Distillery Unit 4-19

137 EIA REPORT: Chapter IV Table 4.6: Summary of Impact Assessment and environment management plan proposed for the respective aspect Environm Potential cause Potential Impact Preventive control and mitigation Probable Resultant EMP ental factors/sour measures Impact Issue ce Air Particulate Burning of fuel, Impact on human Wet scrubber to control PM from Levels of PM Regular health check Quality matter (PM) handling health by PM 2.5 flue gases; resultant ground level 2.5,PM10, SOx and up of workers (twice a SOx and and/or Respiratory, lung concentration at nearest downwind NOx anticipated to year/season), air NOx transportation diseases will be be within NAAQS quality monitoring of material Impact on ecology stack height 60 m, Minor negative within the project mainly due to PM, Use of renewable source s of energy impact on health of premises and upwind SOx, NOx and such as bagaase and biogas workers and and downwind emission of heat Enhancement of existing greenbelt by disturbance to avi directions at village from flue gases 1) 4000 trees fauna due to flue Due to PM - internal roads to make asphalting gases, its reduction in adequate parking for all types of temperature photosynthesis vehicles leads to decrease in the yield Molasses based 30KLPD Distillery Unit 4-20

138 EIA REPORT: Chapter IV Environm Potential cause Potential Impact Preventive control and mitigation Probable Resultant EMP ental factors/sour measures Impact Issue ce Odour, Spentwash and odour nuisance Biogas as a primary treatment for Methane and CO2 Proper maintenance methane molasses, Green house gas spentwash; it will utilized as a fuel, likely to get of biodigester and and CO2 composting emission provision of flare unit when biogas generated in traces skilled supervision on activity not used as fuel (methane will not from composting composting process; get released in an atmosphere) and storage of storage and disposal Follow the guidelines of regulatory organic waste of spentwash as per authorities for storage, handling and CREP guidelines only transportation of such material Avoid anaerobic condition development for composting Green belt development CO 2 generated will be from non-fossil source, hence considered as neutral while considering GHG potential Noise Operation Noise Impact on human High noise potential activities are not No negative impact Provision of personal of generated health, involved during operation phase, outside the protective Molasses based 30KLPD Distillery Unit 4-21

139 EIA REPORT: Chapter IV Environm Potential cause Potential Impact Preventive control and mitigation Probable Resultant EMP ental factors/sour measures Impact Issue ce machinery, during the disturbance to Noise increase at specific locations premises; equipments for equipments, operation fauna only, most of the machinery will be minor negative workers at high noise transportati of the under roof impact inside the areas; monitor noise on machinery Enhancement of existing greenbelt by premises on mainly levels at ambient as 4500 trees workers as well as well as work place internal roads to make asphalting partially on faunal areas; adequate parking for all types of elements During construction vehicles phase restrict noise generating activities for day time only Water Spentwash, Contamination surface and ground Spentwash disposal thorough No negative impact Install piezometer/s Quality spent lees, of surface &/or water pollution, biomethanation followed by MEE on ground or and bore well condensate ground water thermal pollution of followed by bio-composting surface water, towards downstream and other Soil water bodies, Spentlees and condensate water minor of compost site wastewater Contamination recycled after treatment contamination of check the water treated water reused mainly for soil while handling quality of bore well; Molasses based 30KLPD Distillery Unit 4-22

140 EIA REPORT: Chapter IV Environm Potential cause Potential Impact Preventive control and mitigation Probable Resultant EMP ental factors/sour measures Impact Issue ce cooling, gardening/irrigation near compost or vigilance for spent wash storage, handling, storage areas accidental spillage of compost yard as per CREP norms spentwash and for damage to impervious storage lagoon or compost yard Water water Water Depletion of Water conservation thro recycling No negative impact Strictly implement Resource availability Consumption available water and reusing treated/condensate since water is proposed by the project resource water allocated for conservation practices Rain water harvesting industrial activity and encourage the only staff to save and conserve water at all possible extents Soil and change in project change in land use, Proposed site is open, barren under No change in land check the land land use activities soil pollution due to the possession of the sugar factory use pattern characteristics of solid solid waste, solid waste or Solid waste generated in the project No negative impact waste and compost at Molasses based 30KLPD Distillery Unit 4-23

141 EIA REPORT: Chapter IV Environm Potential cause Potential Impact Preventive control and mitigation Probable Resultant EMP ental factors/sour measures Impact Issue ce effluent/wa effluent is biodegradable hence utilized in on soil quality, least twice a stewater composting process minor negative season/year Disposal of effluent as per the impact due to Monitor the soil regulatory authorities guidelines excavation of soil quality where treated Excavated soil to be stacked and for project activities water is used for reused for gardening, greenbelt Solid waste disposal irrigation twice a activity, material other than soil to be activity season/year used for leveling and similar activities (Composting) support micro flora, insects, warms and indirectly supports the avi fauna feeds on it positive impact on ecology Micro nutrients will get recycled due to Molasses based 30KLPD Distillery Unit 4-24

142 EIA REPORT: Chapter IV Environm Potential cause Potential Impact Preventive control and mitigation Probable Resultant EMP ental factors/sour measures Impact Issue ce compost positive impact on soil quality and ecology Ecology project Cutting of trees Destruction of project within the existing sugar No negative impact Prefer local species for activities or destruction terrestrial and factory premises, and the land is on ecology and greenbelt of habitat aquatic flora or barren and open, flat land no tree biodiversity development, provide Impact due to fauna felling is required Greenbelt helpful to funds and manpower contamination wildlife sanctuary, national park not improve biodiversity to maintain it of water within 25km radius Monitor air, water soil bodies. Effluent/Wastewater recycled/reused at site and after proper treatment surrounding area at Green belt development pre-defined interval Zero Liquid Discharge scheme implemented Molasses based 30KLPD Distillery Unit 4-25

143 EIA REPORT: Chapter IV Environm Potential cause Potential Impact Preventive control and mitigation Probable Resultant EMP ental factors/sour measures Impact Issue ce Hazard Storage of fire damage to living as Implementation of safety norms as Negative impact Training and mock and Risk raw well as non-living per the regulatory authorities only in accidental drills for safety Assessm material and things guidelines case Policy under PLI act ent finished Appointment of safety officer 1991 product Lightening arresting system Risk assessment to be water hydrant, fire extinguishing done through system and training to staff for its professional risk operation also training for first aid assessors and safety Socio- population Temporary and pressure on social Maximum local labour for Population flux Initiate and Economic flux permanent infrastructure construction and local candidates for could be negligible, implement social Impacts workforce employment hence no negative developmental associated with Housing facility is available with sugar impact anticipated activities as a part of the project mill to accommodate marginal Beneficial impact CSR increase due to direct and indirect Molasses based 30KLPD Distillery Unit 4-26

144 EIA REPORT: Chapter IV Environm Potential cause Potential Impact Preventive control and mitigation Probable Resultant EMP ental factors/sour measures Impact Issue ce employment, government and local institutions benefitted through taxes, improvement in infrastructure such as transportation, education, medical facilities, etc. due to the project Molasses based 30KLPD Distillery Unit 4-27

145 EIA REPORT: Chapter V CHAPTER V ANALYSIS OF ALTERNATIVE TECHNOLOGY 5.1 INTRODUCTION The technologies for the treatment and safe disposal of spentwash- most polluting element from distilleries are discussed in this chapter. Traditionally, the spent wash was used for irrigation of crops and for composting with press mud from sugar mills as filler material. At several places in the country, it used to be spread on land in an uncontrolled fashion resulting in destruction of agricultural land and pollution of ground water. When it was not possible to use it on land, it was often discharged in surface waters affecting the riparian rights of other users of the water body. The new recommendations of CPCB/MoEF imposed a restriction on such utilization, of spentwash on agricultural land. Therefore, it has become necessary to look for technologies to reduce the volume and concentrate the spentwash, so that it can be handled effectively without damaging the environment. Molasses based 30KLPD Distillery Unit 5-1

146 EIA REPORT: Chapter V 5.2 TREATMENT AND UTILIZATION OPTIONS Spentwash Biomethanation (for distilleries attached to sugar mills) Concentration and Incineration (stand alone distilleries) Reverse osmosis Concentration Multiple effect evaporation Mist evaporatio Bio-composting Concentration Figure 5.1: Treatment Options for Raw Spent Wash Reboiler Reboilers are used in distilleries for concentrating raw spentwash and simultaneously recovering heat and water. Depending upon the input spentwash quality and the reboiler design, the spentwash volume can be reduced to 75 to 85% of its original volume. When the spentwash is to be used for composting and the rate of production of spentwash is more than 10 m 3 per KL of alcohol production, in volume through heating and evaporation of water in a reboiler results in a corresponding increase in the concentration of BOD, COD, nitrogen and TDS. Further, the efficiency of conversion of organic matter (BOD) to biogas in the biomethanation step may also decrease when a more concentrated spentwash is treated. At present there is no prescribed recommendation regarding the quality of spentwash to be used for preparation of compost. In order to achieve 'Zero Liquid Discharge', many distilleries are concentrating their spentwash using reverse osmosis (RO) process also. The Molasses based 30KLPD Distillery Unit 5-2

147 EIA REPORT: Chapter V effect of such salt laden spentwash, which also would be containing a higher concentration of organic matter, on the process of composting and the quality of compost, is not known Biomethanation Biomethanation is now a well-established process. Many types of reactor systems are commonly used, namely, up or down-flow fixed film reactor, up-flow partly fluidized bed reactor, commonly known as up-flow anaerobic sludge blanket (UASB) reactor and continuously stirred tank reactor. Each system may have different variations of reactor configuration, effluent and sludge recirculation and mixing. One variation employs twostage decomposition in two slurry reactors in series. The bio-methanation reactors when properly designed and operated are capable of treating spentwash having BOD in the range of 40,000-50,000 mg/l with an efficiency of 90% thus producing an effluent having a BOD in the range of 4,000-5,000 mg/l. There is also some reduction in the TDS content of the spent wash. Sulphate is reduced to hydrogen sulphide, which escapes with the biogas, and there is a corresponding increase in the carbonate alkalinity. This in turn results in precipitation of some calcium. The TDS of the spent wash may decrease to 15,000-25,000 mg/l. ph of spentwash, after bio-methanation increase up to 7 or 8. Some reactor designs may require the raw spent wash to be diluted before it can be treated. This is particularly when the distillery uses continuous fermentation process for production of alcohol in which case the COD of raw spent wash may be in the range of 100,000 to 120,000 mg/l. Central Pollution Control Board has recommended that the dilution water should not be more than 30% of the original volume of the spent wash. Depending upon the fuel, which the biogas replaces, (i.e. bagasse, coal or furnace oil) the cost of the biomethanation reactor is recovered in 2 to 4 years Reverse Osmosis (RO) In the past reverse osmosis (RO) has been used commonly as the final step in tertiary treatment of wastewaters to remove dissolved inorganic solids and some recalcitrant compounds. It is used to recover good quality of water from grossly polluted wastes. This has been made possible due to development of new membranes and the membrane module configuration, which allows easy accessibility for cleaning and replacement of membranes. Molasses based 30KLPD Distillery Unit 5-3

148 EIA REPORT: Chapter V In any RO system, the preliminary treatment of wastewater is extremely important. Adjustment of ph and temperature of the waste, which is compatible with the material of the membrane, increases the membrane life and prior removal of total suspended solids (TSS) decreases the rate of membrane fouling. Further, the flux of the dissolved substances in permeate is lower if it is removed before hand to the possible extent by conventional methods. It also allows operation of the system at comparatively lower pressure, hence results in savings in operational and maintenance costs. With a poor quality of the feed water, the quality of the permeate may be maintained only at the expense of recovery. Pre-treatment usually comprises ph correction, pressure sand filtration followed by cartridge filtration. The effluent is then pressurized and passed through RO modules. The vendor of the RO system usually supplies the pre-treatment units also. Effluent permeate from the RO plants contains carbon dioxide and sulphides. Its quality can be improved and stabilized by stripping with compressed air in a packed column to increase the scope of its utilization. In case there is a premium on the recovery water, the reject from the RO plant is further treated through a secondary RO system or nano-filtration, which uses a more 'open textured' membrane. This step produces permeate having 22,000-25,000 mg/l TDS, 3,500-4,500 mg/l COD and 1,000-1,200 mg/l BOD. The permeate recovery is 11-14% of the first stage feed. The operation of the RO plant requires skilled personnel. The spares for regular maintenance may also not be available in the open market. The Membrane required to be imported. The fouling could be a problem. Running of the plant therefore should be entrusted to the supplier to ensure efficient and continuous operation Multiple Effect Evaporators Though evaporation is an established unit operation in chemical engineering practice, its use for concentration of spentwash is recent. With improvements in design and materials and the willingness of the alcohol industry to spend more on pollution control equipment, some distilleries are in the process of installing evaporation and drying plants. Biomethanated effluent can be input to the multiple effect evaporators. However, both biomethanated and raw SW can be fed to the evaporators. Steam used in the evaporation process and the evaporated water from the SW feed form the condensate or the recovered Molasses based 30KLPD Distillery Unit 5-4

149 EIA REPORT: Chapter V water. The condensate has a slightly acidic ph and BOD and COD of about 10 and 100 mg/l, respectively. The biomethanated feed containing about 4-5% of solids is concentrated to 30-33% solids content. The concentrated SW can be either used for the preparation of compost or further dried in a spray dryer to yield a solid powder containing about 4-5% moisture. The calorific value of the powder is 2500 kcal/kg and it can be burnt for production of steam. The ash obtained from the combustion of the powder is saleable for its potash content. The dry powder also has a market value of about Rs.750 / T, as a soil additive rich in organic matter and potash. The concentrated spentwash after evaporation can also be used directly as an auxiliary fuel along with other fuel for generation of steam. From a 300 m 3 /d plant treating biomethanated spentwash about 620 kg/hr effluent powder is generated, which when burnt yields 127 kg/h ash. The ash contains about 21% potash. In case raw spentwash containing 10% solids is concentrated the yield of effluent powder and ash is 1875 kg/hr and 394 kg/h, respectively Mist Evaporator As the name implies the mist evaporator creates a mist of small droplets by pumping spentwash through small diameter nozzles placed around the periphery of a duct through which air is blown. The unit is placed at the edge of a lagoon and the spentwash is pumped. The resulting mist forms a trajectory reaching as high as 18 m and going up to 55 m in the horizontal direction. The large surface area of the mist results in evaporation of water and a concentrated SW falls back in the lagoon. The rate of evaporation depends on temperature, humidity and wind speed. Experience with the mist evaporator in the country is limited. It is in use only at one location for a distillery of 30 KL/d capacities. The manufacturers of the evaporator claim that for the yearly average ambient conditions 2 units, each of 30 KW would be required to evaporate 300 m 3 /d of spentwash. The setting up of the unit is easy and requires minimal supervision and maintenance compared to other concentration methods. However, it will operate with varying efficiency during the year. In the rainy season or in humid weather, there will be little or no evaporation and the spentwash will have to be stored. Since, the wind direction is likely to Molasses based 30KLPD Distillery Unit 5-5

150 EIA REPORT: Chapter V change a number of times for short periods over a day, there is likelihood of the mist spray falling outside the lagoon. A more definite comment can be made after the unit is operated for more time and systematic data regarding the solids balance are available. The concentrated or thickened spentwash will have to be properly disposed. At present, composting seems to be a possible alternative. Table 5.2: Merits and Demerits of Each Alternative # Technology Merits Demerits 1. Concentration Reduction in volume. Energy generation after combustion. Start-up and restart-up is a problem. Scaling problem. 2. Biomethanation Energy generation. Increase in volume. 3. Biocomposting Zero pollution can be achieved. Production of good quality manure. 4. R.O. System Recovery of water Reduction in volume. Higher initial cost. It is a primary treatment only. Large area required Problem of smell Operation in rainy season not possible. Availability of filler material is a problem. Higher initial and operational cost. Fouling problem. Membranes are not indigenously available. Molasses based 30KLPD Distillery Unit 5-6

151 EIA REPORT: Chapter V 5.3 Treatment alternatives for Condensate Polishing Unit(CPU) Condensate polishing unit, treats condensate from process/mee as well as spentlees and other minor effluents. Following alternatives are available for CPU i. Conventional aerobic treatment (Extended aeration) ii. Conventional aerobic treatment followed by membrane technology iii. Conventional anaerobic treatment followed by membrane technology iv. RO MBR Technology v. Soil biotechnology Process description for membrane technology The proposed system is based on cross-flow membrane filtration technique and is designed for removal of organic acids from the spent wash distilled stream like evaporation condensate of a distillery unit. The condensate treated by such system can be reused back in to the alcohol manufacturing process as cooling water make-up thereby reducing the requirement of fresh water as well as solving the waste disposal to a great extent. The system is based on following principle operations. i) Cooling & Neutralization ii) iii) Membrane filtration of the neutralized stream to remove volatile acids. Recycle of treated streams back to process. System typically recovers 85 % of the condensate as clean reusable water and has about 15 % reject. Note: a) The quantity of caustic solution required is depends on the characteristics of feed to the membrane ETP. b) Phosphoric acid is required for cleaning of the membranes; the frequency of cleaning depends on the quality of input to the membranes and will establish during operation of the plant. Molasses based 30KLPD Distillery Unit 5-7

152 EIA REPORT: Chapter V Soil biotechnology process Considering the initial capital investment and recurring cost for operation of the scheme, Soil bio-tsechnology appears to be most economical for treatment of process condensate of distillation, evaporation, RO permeate etc. The system is designed for treatment of evaporation process condensate or RO permeate and spent lees of a distillery unit. The process condensate and spent lees treated by such system can be reused back in to the distillery cooling tower as cooling water make-up thereby reducing the requirement of fresh water as well as solving the waste water disposal to a great extent. The technology is based on a bio-conversion process where fundamental reactions of nature, namely respiration, photosynthesis & mineral weathering take place in a media housing micro & macro organisms which bring about the desired purification. SBT is an oxygen supplying biological engine and so the process can treat all types of water domestic, municipal & industrial. SBT is suitable for treating water with salinity <2500 mg/l. When salinity levels exceed, reaction rates in the SBT system are lower and hence the system design is adjusted suitably to achieve the purification desired. If salinity is very high, an additional facility using RO technology can also be included. The facilities of a treatment process for water & waste water consists of a raw water tank, bioreactor containment, treated water tank and associated piping, pumps & electrical. The layout of media on the bioreactor is shown in Fig 5.2. Figure 5.2: Layout of SBT Media Molasses based 30KLPD Distillery Unit 5-8

153 EIA REPORT: Chapter V 5.4 SELECTION OF ALTERNATIVE Considering all available technological options, the industry has planned to implement biomethanation followed by multi effect evaporation followed by bio composting for the safe treatment and disposal of spent wash. It is based on the volume of spentwash to be disposed, availability of land, press mud for biocomposting and the cost involved for the technology. In case of CPU and spent lees the proponent has planned for conventional primary treatment followed by aerobic treatment supported by tertiary treatment. Treated water will be recycled/ reused in the industry. The proposed option will be able to achieve the aim of zero liquid discharge. Molasses based 30KLPD Distillery Unit 5-9

154 EIA REPORT: Chapter VI CHAPTER VI ENVIRONMENT MANAGEMENT PLAN 6.1 OVERVIEW The Environmental Management Plan (EMP) aims to identify and address the requirements for successfully mitigating the probable adverse environmental impacts of the project at various stages of project formulation and execution. It also identifies the preventive, control measures and post project monitoring requirements to manage environmental attributes. EMP framework is a site specific document for the project, to ensure that the project can be implemented in an environmentally sustainable manner, where all concerned persons of the industry as well as contractors understand the potential environmental impact arising from the proposed project and take appropriate actions to properly manage such impact. The objectives of EMP Overall conservation of environment and thereby promote sustainable development Minimization of waste generation at source and thereby the pollution Judicious use of natural resources and water Safety, welfare and good health of work force and populace Ensure effective operation of all control measures Vigilance against probable disasters and accidents Monitoring of cumulative and future impacts The EMP is based on following facts/considerations The proposed project is an ancillary unit of existing sugar mill The present management has taken this sugar mill for operations since, , prior to that the unit was closed due to financial as well as many other reasons The site is well connected by asphalted road from nearest state highway (Latur-Nanded) The project proponents are law abiding and having remarkable contribution in local social development The site is located at >1km from any of the nearest village The sugar mill is implementing various welfare schemes for employees as well as beneficial schemes for farmers Molasses based 30KLPD Distillery Unit 6-1

155 EIA REPORT: Chapter VI Therefore, it is assumed that the factory management will implement the preventive, control and mitigation measures suggested in this report and chapter to maintain the environmental conditions at site as well as in the surroundings 6.2 EMP FOR CONSTRUCTION PHASE The construction activity involves installation of various units of distillery such as storage tanks for raw material as well as finished products, boilers, air pollution control device, distillation towers, treatment units such as bio-digesters and development of compost yard, etc. Thus, the major activities involved for construction phase would be: Preparation / processing of construction material Loading / unloading of construction material Excavation work as per requirement for installation of various structures Transportation of the material and workers to & from the proposed project location Installations of various units Disposal of the liquid and solid waste generated by the temporary work force employed for construction Considering the various types of pollution associate with the construction activities, recommended mitigation measures are as follows. Fugitive dust emission from non-asphalted roads can be controlled by sprinkling water on dust generating surfaces as well as material such as soil, sand, etc. while loading/unloading The upper soil layer of 10-20cm is productive part of the landscape; hence, this layer should be carefully removed and preserved separately for future use. If these soil piles are dry it needs to be covered with tarpaulin or similar material. This soil is to be reused for the development of greenbelt. The excess of excavated soil is to be used for greenbelt by adding adequate amount of manure, organic fertilizers to it. The material like stones, etc to be used within the project site, mainly for minor leveling activities/internal roads, plinth etc The runoff from the construction site to be controlled by ditches and shall not allowed to percolate in the surrounding land or enter into any water body The contractor should employ maximum local labour. Thereby, the local people will get an employment opportunity. It will also help in reducing the problems associated Molasses based 30KLPD Distillery Unit 6-2

156 EIA REPORT: Chapter VI with accommodation/housing of the labour, thus it will help in reducing linked issues such as as demand for water, sanitation and hygiene at the labour colony, etc. However, he should provide the basic sanitation facility at the work site by using septic tanks and soak pits. The activities generating noise should be restricted to daytime only Run-off of loose soil should be prevented by means of compacting the soil Transport contractors should be instructed to maintain their vehicles properly so as to minimize the exhaust emissions, reduce the noise and prevent the oil leakages from vehicles Table 6.1: Summary of Environment Management Plan Environmental Aspect Impact causing factor Environment Management Plan Air environment Particulate Matter (PM) Water environment Formation of SO 2, NOx H 2 S from Biogas Carbon dioxide due to fermentation, composting process Odour Effluent generation from processes, cleaning, blow down water, & condensate Storage of spentwash, its treatment and Wet scrubber to control ash emission through stack Stack height 60m covered fomenters Installation of CO 2 scrubber Bagasse contains traces of S & N, hence generation of SO X and NO X anticipated to be limited Proper ash and bagasse handling system Use of biogas as fuel Provision of flare unit Aerobic Composting by using aero-tiller machines Storage of spentwash as per CREP guidelines Bagasse is a renewable sources of energy & carbon neutral fuel Development of greenbelt Zero liquid discharge will be adopted by implementing Bio-methanation as primary treatment for spent wash Evaporation (MEE) as a secondary treatment to reduce the spentwash Molasses based 30KLPD Distillery Unit 6-3

157 EIA REPORT: Chapter VI Environmental Aspect Soil environment Impact causing factor disposal Ash Sludge from Fermentation unit, CPU and Bio-digesters Excavated fertile soil Environment Management Plan volume followed by evaporation, Concentrated spentwash will be mixed with press mud cake (PMC) to produce bio-composting Spentlees, condensate of MEE and other effluents will be treated in condensate polishing unit (CPU) and treated water will be reused for distillery activities Thereby, all the effluent will be properly treated and utilized/disposed within the premises Storage of spentwash in 30 days and five day impervious lagoons which will be as per CREP guidelines Construction of impervious compost yard with leachate collection drainage and other facilities - strictly as per CREP guidelines Fresh water requirement will be reduced by recycling of water (treated water), using rain water during start up period Bore well, in downstream area of biocompost to monitor ground water quality Use of biogas as fuel Provision of flare unit Bagasse ash is rich in potash, hence utilized in the process of bio-composting (mixed with compost) Sludge is degradable, organic in nature hence, utilized in the process of biocomposting stacked separately and reused for greenbelt development Stones and excess soil will be used for foundation or internal roads or leveling purpose within premises Molasses based 30KLPD Distillery Unit 6-4

158 EIA REPORT: Chapter VI Environmental Aspect Impact causing factor Environment Management Plan Noise Ecology and Biodiversity Socio-economy Increase in noise level due to operation of machines, vehicular movement, etc. s Air, water, soil and noise pollution Tree cutting failing disturbance to wildlife due to project Rehabilitation and restoration (RR), pressure on available man-made infrastructure/resource due to population flux Regular maintenance of machines and factory vehicles Separate provisions of parking for goods and other vehicles is adequate internal Roads are asphalted, Leveled, illuminated and well maintained proximity of Latur -Nanded state highway Safety sign boards at strategic locations within premises Provision of Adequate personal protective equipments for workers Job rotation for high noise level work places if required Regular health check up of workers Adequate preventive, control and mitigation measures for air, water and soil pollutants No tree cutting failing involved since project is on flat, barren land No wildlife sanctuary, national park or biosphere reserve in 10km radious, site is not in migratory route of any wildlife, no rare and endangered species of plants/animals reported from the region Development of greenbelt will help to enhance the biodiversity and may provide habitat to many species No Rehabilitation and restoration issued involved since site is already under the possession of project proponent Local candidates will be preferred for employment skilled work force is available at Ahmedpur, Udgir, Latur, Ausa, Nanded, Parbhani and other nearby towns and cities Molasses based 30KLPD Distillery Unit 6-5

159 EIA REPORT: Chapter VI Environmental Aspect Impact causing factor Environment Management Plan Safety and occupational health Risk and disaster management Accidents, improper work practices Fire, accidents, earthquake, etc. Safety officer and safety committee will be formulated Provision of adequate safety gears Other safety measures as per the norms Insurance policy for workers Regular health check-up The entire premises will be no smoking zone Lightening arresting system will be in place ethanol vapor condensing system at storage area Proper storage of molasse, ethanol, Bagasse fire fighting system as per OISD guidelines Earthquake resistant construction 6.3 EMP: OPERATION PHASE Air Environment Management Air Emissions: As discussed in previous chapter, the sources of air pollution are emissions due to combustion of fuel i.e. bagasse and biogas in the boiler furnace, fugitive dust due to handling of bagasse, processes such as fermentation, bio-compost, etc. Emissions from diesel generator and vehicles are anticipated as a minor sources. Considering this following management plan is proposed. Installation of wet scrubber as air pollution control equipment (PCE), to arrest fly ash emissions Criteria for the design of wet scrubber will be mainly based on the characteristics of fuel, its quantity, generation of pollutant, estimated volume of flue gas, etc. Flue gases will be released through existing stack of 60 meter height Preventive maintenance and regular checking of wet scrubber Adequate arrangements for preventing generation of fugitive dust by providing the chutes at transfer points to reduce the failing height of material Molasses based 30KLPD Distillery Unit 6-6

160 EIA REPORT: Chapter VI Isolating the high dust generating areas by enclosing them in appropriate housing and appropriately de-dusting through high efficiency bag fitters to prevent fugitive dust preventing spillage of material by properly maintaining the handling equipment Fermentor covered; CO 2 scrubber will be installed Installation of ash and bagasse handling system Proper maintenance of internal roads Biogas produced from the biomethanation process will be utilized as a fuel. In a rare case if it is unutilized, it will be burnt through flare unit; but in any circumstances it will not be freely released in the atmosphere Disposal of potash rich ash (fly as well as bottom ash) by mixing it with compost Composting process will be carried out in aerobic conditions, by using modern machines for rotation operations/supply of air/oxygen Development of lawn on open areas with plantation of ornamental shrubs/trees in between so as to reduce the dust generation from open areas and improve aesthetics Greenbelt of minimum three tiers along the project boundary Monitoring of stack emissions periodically Ambient air quality (AAQ)to be monitored in factory premises at least at three locations apart from one another AAQ also to be monitored at nearest villages (settlement area) i.e. Ujana, Ralga and Wadarwadi which are in upwind and downwind directions Compliance of other regulatory norms such as health, safety, etc Noise Environment In case of the proposed distillery, the main processes are fermentation and distillation. In these processes, there are no major noise sources involved. Hence, simple measures such, as maintenance of machines, equipments & vehicles, needs to be implemented. Additional measures includes The noise management practices could be in following sequences Prevent generation of noise at source by good design and maintenance Minimise or contain noise at source by observing good operational techniques and management practice Molasses based 30KLPD Distillery Unit 6-7

161 EIA REPORT: Chapter VI Use physical barriers or enclosures to prevent transmission to other media e.g. for boiler, STG, DG room Increase the distance between the source and receiver Sympathetic timing and control of unavoidably noisy operations; Job rotation for workers placed at high noise areas. Greenbelt development with suitable species for noise attenuation Water Environment For molasses based distilleries, spentwash is a highly polluting element, which is potentially the major threat to environment. Thus, it is imperative to manage it properly. Considering the pollution potential of spentwash, the Ministry of Environment and Forests (MoEF), has recommended a guideline through Corporate Responsibility for Environment Protection (CREP), charter in According to these guidelines, it is mandatory for the distillery to achieve Zero Liquid Discharge (ZLD). The project proponent has developed following scheme to achieve ZLD and has made necessary financial provisions towards the planned activities. For spent wash, bio-methanation as primary treatment to convert organic matter into biogas an energy source In the secondary treatment stage, biomethanated spentwash will be sent to Multi-effect Evaporation (MEE) unit to reduce its volume from 360 to 60cum Following evaporation, concentrated spentwash will be mixed with press mud cake (PMC - generated in the sugar mill) to produce bio-composting Spentlees, condensate of MEE and other effluents will be treated in condensate polishing unit (CPU); treated water will be reused for distillery activities Steam condensate will be recycled back as a boiler feed water. Thus, the industry is determined to put all its efforts for the recycle/reuse of water. Molasses based 30KLPD Distillery Unit 6-8

162 EIA REPORT: Chapter VI Minimizing wastewater generation Reducing freshwater intake Water conservation Recycling and reusing treated water Rainwater harvesting Figure 6.21: Schematic of water conservation CREP guidelines for molasses based distilleries The industry has opted for Bio-methanation as primary treatment followed by bio composting for the safe disposal of spent wash. The guidelines recommended through CREP, which will be implemented by the project proponent, are as follows. Spentwash storage lagoon not >30 days capacity The lagoons must be impervious, constructed leak-proof, lined with HDPE sheets and protected by brick lining The compost yard lined with HDPE sheets and protected with brick/ concrete/ Bituminous Macadam Provisions for leachate collection gutter and sump well Molasses based 30KLPD Distillery Unit 6-9

163 EIA REPORT: Chapter VI A) Land Preparation for Compost Yard Basic 1. While designing and preparing compost yard, its foundation need to be constructed with utmost care. Therefore, preparation of the ground & proper compaction plays very important role in the development of compost yard. 2. Therefore, it is to ensure that- The land is leveled and compacted properly Soft soil cushion is essential to lay a 250 micron thick HDPE sheet Further, another layer of soft soil/soft sand needs to be provided over the 250 micron thick HDPE sheet before proceeding with the top finish Provision of underground spentwash spraying network for auto spraying Provision of leachate management system as per guidelines There are few options for top finish of compost yard, they are - Brick on-edge gaps filled with dry sand/soft local soil Providing Plain Cement Concrete (PCC) 1:3:6 in bays & scaling the joints with bitumen. Bituminous asphalting Providing and laying interlocking concrete paving blocks The project proponent has opted an impervious compost yard lined with HDPE sheet and top finish of PCC (1:3:6) B) Operations & maintenance guidelines for composting i) Rainy season It is not possible to run the aerobic composting process in rainy season. The reasons are: Freshly sprayed spentwash that is yet to be decomposed may give some colored leachate after rain and will contaminate the soil Due to rain, the composting material in windrows may have moisture content of 70%, which can result in anaerobiosis It is not possible to run the composting machine during rainy season Heavy rains can wash off the press mud Precautions to be taken before onset of rainy season The composting area must be vacated before start of rains Molasses based 30KLPD Distillery Unit 6-10

164 EIA REPORT: Chapter VI As far as possible, all the compost on the site should be sold out before start of rain. The compost, which remains unsold, should be properly bagged and kept in godown/covered area After harvesting the last batch of compost a 2 cm layer of pressmud should be scrapped over the surface layer of compost yard and this scrapped material shall be kept covered for blending with compost. After cleaning the scrapped area, fresh windrow of pressmud shall be formed only after rainy season. ii) Unseasonal rains Precaution to be taken, if there is unseasonal rain during composting cycle In order to avoid the leaching of spentwash, which is yet to decompose all the windrow on the yard should be covered with polyethylene sheets/pullover covers Stop spraying spentwash, temporarily when it is raining. Spraying can be resumed when the sky becomes clear. The provision of the trenches towards slopping side should be made to collect the runoff from windrow area. This runoff should be collected in leachate collection pit. It should be pumped back to 30 days storage lagoon. The run off of outside compost yard should be suitably diverted so that it does not enter the compost yard. In order to achieve Zero Liquid Discharge the industry will be adopting biomethnation followed by Biocomposting process. Impervious lagoons will be constructed for storage of spent wash and impervious compost yard (1:3:6 PCC) with HDPE lining as per CREP norms. Table 6.2: Guidelines, Formulated By Central Pollution Control Board (CPCB) New Delhi, For Bio-Composting Plants # Description Requirement as per C.P.C.B. Norms Actual Design and Provisions 1. Working days of Distillery (Rainy season shall be avoided and the entire compost area shall be kept dry before starting of the rainy period) 270 days 270 days Molasses based 30KLPD Distillery Unit 6-11

165 EIA REPORT: Chapter VI # Description Requirement as per C.P.C.B. Norms Actual Design and Provisions 2. Spentwash storage tank capacity (duly lined with 250 micron HDPE sheet and pitched by stone/bricks with cement mortar to prevent leachate). 30 days of generation 30 days 3. Pressmud: Spentwash ratio 1: :1 4. No. of days required to complete one composting operation cycle 45days/60 days 45/60 days 5. Land required for compost plant Construction of compost yard as under I) Compaction of soil II) 5 cm sand cushion (top) III) 250 micron HDPE sheet 850 MT/acre/cycle 850 MT/acre/cycle IV) 5cm sand cushion (bottom) V) PCC top In case the coefficient of permeability is less than 10-8 cm/sec (as in black cotton soil), 30 cm depth of impervious soil, compacted with 30 cm depth of murum at the top may also be used. (with arrangement of leachate collection and surface runoff and its pumping to holding lagoon and laying of pipe net work for automatic spraying of spentwash) 6. Maximum allowable cycle/annum 1) Five cycles in case of 45 days composting period 2) Four Cycles in case of 60 days composting period Five Cycles 7. Pressmud storage on compost site during monsoon season after taking due care for protection by using HDPE Equivalent to one cycle NIL Molasses based 30KLPD Distillery Unit 6-12

166 EIA REPORT: Chapter VI # Description Requirement as per C.P.C.B. Norms Actual Design and Provisions sheets etc. 8. Land required for storage of ready compost. It should be raised 12 inch above ground level and quantity equivalent to 33% of the total compost should be stored 9. Compost quality specification Moisture: < 35% Organic Carbon:20-25% C:N ratio : <17:1 Nitrogen: 1.5-2% Phosphorous:1.5-2% Potassium: 2-3.5% Total Volatile Solids: 50-60% on dry wt. basis Compliance as per required norms would be done Compliance as per required norms would be done Spent lees and condensate treatment unit (CPU) The proposed system is designed for treatment of spent lees and other minor effluent of proposed distillery. The treated water will be recycled to the distillery cooling tower as make-up water thereby reducing the requirement of fresh water as well as solving the wastewater disposal to some extent. The system is based on following principle operations. iv) Cooling & Neutralization v) Recycle of treated streams back to Cooling tower make up A) Description of unit operation and process i) Equalization tank Spent lees (30m 3 /day) from the distillation will be collected in a equalization tank, where the stream will get mixed with other minor effluents (cleaning, CT blowdown, etc) Molasses based 30KLPD Distillery Unit 6-13

167 EIA REPORT: Chapter VI ii) Effluent cooler Hot effluent from the equalization tank will be pumped using priming pump via plate heat exchanger, where it will be cooled to ambient temperature before entering to neutralization tank. iii) ph correction The cooled effluent will be then sent to a static mixer, where it will neutralized using caustic solution. Caustic solution will be dosed using a dosing system consisting of dosing tank and dosing pumps. Dosing will be controlled by, using ph sensor installed on downstream of the static mixer. Neutralized effluent then sent to aeration tank provided to reduce BOD & COD. vi) Aeration tank The neutralized effluent will be treated in aeration tank to reduce BOD & COD and to increase the dissolved oxygen. v) Clarifier vi) vii) Treated effluent from aeration tank sent to the clarifier for removal of suspended particle. The separated sludge will be utilized in composting process. Holding tank The clear treated water coming from clarifier will be stored in holding tank. Filter media Clear effluent from holding tank will be filtered through Sand filters or Activated Carbon Filter (ACF) to minimize odour and suspended solids. viii) Water softener If required, the treated water from filtration unit will be passed through water softener, to reduce the TDS. Thus, the clear treated water will be recycled to distillery cooling tower as makeup water. Molasses based 30KLPD Distillery Unit 6-14

168 EIA REPORT: Chapter VI Table 6.3: Characteristics of Untreated & Treated Composite effluent Sr. Parameters Composite Effluent No. Untreated Treated 1. Quantity 330 m 3 /day 330 m 3 /day 2. Temperature 65 0 C ambient 3. Chemical Oxygen Demand (COD) mg/lit < 250 mg/l 4. Biochemical Oxygen Demand (BOD) mg/lit. < 30 mg/l 5. Total Dissolved Solids (TDS) mg/lit. 5 mg/l 6. ph Important aspect a. Spentwash: Its transportation to the treatment site by laying suitable and protected pipeline of HDPE or similar material b. Electricity: Provision of diesel/electricity required for carrying the mixing turning aeration machine is must at the composting site. Three phase, 440 V electricity cable is to be provided and laid down by factory to the inlet of isolation switch of MCC c. Compost: Arrangement for transports of compost from composting site (compost pit/ windrows) will be performed by the sugar factory d. Press-mud, boiler ash and sludge as a filler material in required quantity and proportion will be made available by the sugar factory and it will be transported by them up to the composting site e. Other Infrastructure: Tree plantation (As a greenbelt development) will be done by the sugar factory f. Water required for plantation / drinking etc. will be made available by the sugar factory Precautionary Measures Cooling ponds shall be constructed of masonary/brick work with impervious one using PVC lining duly finished and sulphate resistant cement shall be used. Since the spent wash is highly acidic in nature, the corrosive resistant epoxy coatings shall be made. Molasses based 30KLPD Distillery Unit 6-15

169 EIA REPORT: Chapter VI Storage tanks of 30 days and five days capacity shall be constructed by providing and laying leak-proof tar-felt coating and waterproofing primer for joints Surface windrows should be constructed as described earlier Bore well towards the downstream of the compost site to check the ground water quality regularly Provision to cover the windrows with HDPE sheets, in case of rains Provision of lined garland drains around the surface compost pits to collect run-off Operation and maintenance of other pollution control system All the pollution control system such as, effluent treatment system, air pollution control (APC) equipment and any other system provided by the industry should be operated and maintained strictly as per the operational manual/guidelines. The record related to this should be maintained and need to be available for the inspection by the regulatory authorities The preventive maintenance of all the plant and machinery including civil/mechanical structure shall be carried out as per the planned schedule Housekeeping in and around plant/pollution control system should be maintained properly LAND ENVIRONMENT As discussed in previous chapters, the major threat to land environment is due to percolation of spentwash or release of untreated effluent into the soil or disposal of the same by land application etc. Change in land topography due to installation of various distillery units is another permanent impact. Therefore, the environment management measures are as follows. Implementation of Zero Liquid Discharge (ZLD) Spentwash storage lagoons and compost yard shall be as per CREP guidelines; hence, these measures will help to reduce the land pollution due to spent wash and effluent Generally, solid & hazardous waste are also major sources of land/soil pollution. The EMP for this is as follows. Molasses based 30KLPD Distillery Unit 6-16

170 EIA REPORT: Chapter VI Sludge from Fermenters, ETP units, bio-digesters Bottom and fly ash from furnace Press-mud from sugar unit Bio- Composting Figure 6.22: Solid waste management scheme Greenbelt development could help in improving aesthetics of the site Bio-compost could help in improving soil fertility Recycling of potash could be achieved through mixing of bagasse ash in bio-compost 6.4 GREENBELT DEVELOPMENT Development of greenbelt in and around an industrial complex is an effective way to attenuate air pollution. The degree of pollution attenuation is depends upon height, width, foliage, surface area of leaf and density of species, etc. The major objectives of the proposed green belt development will be Mitigate impact due to fugitive emissions Create an aesthetic environment Enhance the bio-diversity of the vicinity Help to restore the ground water table Prevent soil erosion and surface run-off While planning and designing greenbelt, its various functions will be considered. They are- Spatio-visual separation of larger parts of the premises Entrance and roadside greenery helps in separating the main industrial structures Provision of greenery along all interior pedestrian network Molasses based 30KLPD Distillery Unit 6-17

171 EIA REPORT: Chapter VI Provision of (smaller) resting areas for the workforce during breaks (park benches, etc,) Provision of reserve sites eventually becoming necessary at a later development stage. Selection of plant species will be based on their following characteristics Trees interspacing Fast growing Thick canopy cover Perennial and ever green Large leaf area Preferably Indigenous Resistant to pollutants and should maintain ecological balance for soil and geohydrological conditions of the region. tree density Size/type Location per 100m 2 3 x 3m 25 Shrubs, small and medium trees 5 x 5m 09 medium to large size trees Boundary of sugar and cogeneration, Garden/landscape areas Boundary of plot area 20-25m Large size trees Road side large size trees Since, the greenery development will be done as per the requirement i.e. type of activity performed at a particular area/block/plot, thus the tree spacing will vary from plot to plot. Therefore, >4,500 plants (including shrubs and trees) are proposed for the greenbelt development. There are two nurseries located near the site a) Sanghvi-Sunegaon Nursery located at village Sunegaon, Ahmedpur and b) Jagdamba Nursery at village Pokharni in Parbhani district. In these nurseries following species are readily available for greenbelt development. Molasses based 30KLPD Distillery Unit 6-18

172 EIA REPORT: Chapter VI Table 6.4: Species suggested for greenbelt development S No. Name Place Climatic condition (Rainfall) 1. Dalbargia sissoo (Shisoo) 2. Acacia leucophloea (Babhul) 3. Delonix regia (Gulmohar) 4. Azadiracta indica (Neem) Jagdamba Nursery Feature/remark mm Tolerant to air pollution, common in the region -do mm Tolerant to air pollution, very common in the region -do- as well as Sunegaon Jagdamba nursery mm Fly ash tolerant mm Fly ash tolerant,tolerant of alkaline and Saline soil, common in the area 5. Bassia latifolia -do- 6. Albizia lebbak (Shiris) -do mm Tolerant of CO mm Tolerant of acidic soil 7. Tamarindus indica (Chinch) 8. Peltoforum pterocarpum -do- as well as Sunegaon -do- as well as Sunegaon 9. Emblica officinalis -do mm Derris indica (Karanj) -do- as well as Sunegaon mm Tolerant to air pollution, common in the region 11. Casurina equisetifolia Sunegaon mm Tolerant of sandy soil (Suru) nursery 12. Tectona grandis (Saag) -do- Dust tolerant 13. Polyalthia longifolia (Asopalav Ashok) -do- - Dust tolerant and ornamental 14. Terminalia arjuna -do mm Tolerant of alkaline/saline soil 15. Samania saman -do- Dust tolerant 16. Anona squamosa -do mm Fly ash tolerant 17. Aegal marmalose -do mm Tolerant to air pollution, common in the region Molasses based 30KLPD Distillery Unit 6-19

173 EIA REPORT: Chapter VI Table 6.5: Flowering and foliage shrubs recommended for greenbelt # Flowering plant (Shrubs) # Foliage plant (Shrubs/Under tree) 1 Hibiscus 1 Duranta species 2 Shankasur (Ceasalpinia spp.) 2 Dracena 3 Ixora 3 Euphorbia pulcherima 4 Tagar 4 Muscanda 5 Cassia biflora 5 Maranta bicolor 6 Powder puff 6 Agave 7 Nerium 7 Palm spp. 8 Alamanda 8 Croton 9 Chitrak (Plumbago) 10 Hemalia petans 11 Vinca rosea 12 Ratrani 13 Gardenia 14 Canna 16 Chrysanthemum 6.5 RAIN WATER HARVESTING Rain water is one of the purest sources of water for improving the water table and water quality in the sub-soil. Rain water which is otherwise wasted has to be recharged in to the soil. This can be adopted either by using traditional way or by modern technologies. The various types of rain harvesting schemes are, diverting rain water collection through proper channels to the nearest pond or open wells and run off from built in areas mainly roofs are diverted to storm water drains, which is again taken to the nearest lake / pond. The other method of rain water harvesting (RWH) is ground water recharging. In this option the recharging structures should be prepared in scientific way. Recharging pits of size approx. 2x2 m and 3m depth need to be constructed and filled with pebbles/rubbles of sizes more than 2. At the center of this structure 6 or 8 pipe is driven to the depth of approx.10m, with perforation of 1or2. Such structures can be built at pre-defined places Molasses based 30KLPD Distillery Unit 6-20

174 EIA REPORT: Chapter VI (minimum 4 or 5 places, depending up on the site situation) so that maximum quantity of rain water within the premises can be collected. The water diverted through channels, from roof tops and other means can be collected in this recharge structure, which will definitely improve the water table as well as quality of the water and feed water to the plant during operational season. The management has a plan to implement RWH scheme similar to sugar unit which is in place. Rain water from roof tops and paved areas will be collected and transferred to storage tanks. Cooling pond as well as treated water sump of ETP/CPU of sugar and distillery unit will be used for the said purpose. The sugar unit of SSAIL has implemented the RWH schemes the details of which are as follows. The sugar mill is having roof top area of approx 11,300sqm available for RWH. It has laid down separate pipeline that channelizes the water to storage tanks. The first heavy shower is flushed to clean up the system. This water is filtered at two stages before collected in the tanks. The rain water is stored in DM water tank, spray pond as well as ground water reservoir of 30Lakh liters capacity (since, sugar mills are closed in rainy season). Rain water harvesting calculations for the existing scheme are as follows. Description Of Catchment Area Area Avg Rain-Fall Run Water Avail-Able Per Year Off Per Annum SQM M % CUM Roof top area (sugar unit only) 11, ,328 Table 6.6: Storage tank details Tank Dimensions (in m) Area Total Volume Provided L B H Cum Cum DM water Spray pond Ground storage reservoir Radius 14m This water is used during start up operations of sugar factory during crushing season. Molasses based 30KLPD Distillery Unit 6-21

175 EIA REPORT: Chapter VI 6.6 SAFETY, OCCUPATIONAL HEALTH MANAGEMENT For the existing sugar unit, the management had identified that during operation phase, dust is 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. Hence, it has implemented following measures. Adequate arrangements for preventing generation of dust by providing the chutes at transfer points to reduce the failing 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 fitters Apart from these measures, a team of housekeeping labours is engaged in maintaining the cleanliness, especially removing dust from the shop floor. In addition, the management has developed a safety committee (for sugar unit) of 15 members chaired by the General Manager (Table 6.7). The factory organizes health checkup camps for workers as well as their family members (Refer annexure VIII) SAFETY & HEALTH POLICY It is the policy of Board of Directors of Siddhi Sugar & Allied Industries Limited that all works & operations shall be carried out within the requirements of the health & safety at work place as per, Factory Act 1948 of 73L & all other relevant statutory provision and codes of practice. The policy reflects the commitment of the Board of Directors and those accountable, to Board for its implementation. The overall co-ordination of the policy shall remain the direct responsibility on Board of Directors. The company's Safety Manager will monitor the effectiveness of the Policy and advice and instruct on safe working practices. The policy will be kept under constant review and revised when required. In addition to every employee's duty under section 7 of health and safety at work, Act 1948, every employee must strive to maintain the highest Standards of safety and comply fully with the Act and the provisions laid down within this policy and our safety and Molasses based 30KLPD Distillery Unit 6-22

176 EIA REPORT: Chapter VI Environmental procedure/manual. Management will liaise with the Health & Safety and Environmental Manager when required. Management will liaise with the Health & Safety Executive and other appropriate authorities and organizations concerning Health & Safety. The Board of Directors acknowledges that Safety Training is an essential Ingredient in establishing a safe system of work and will ensure that training of employee in Health& Safety requirements will be provided as appropriate. The Directors and Senior Managers of SSAIL are constantly striving to ensure, so for as is reasonably practicable, the Health & Safety of it s employees and others who may be affected by its operations. They recognize that the success of this policy depends on the combined efforts of individuals & to this aim will support any individual encountering Difficulties to implement the policy. General Manager Table 6.7: Safety Committee of existing sugar unit S. No Designation Role in safety committee 1 General Manager President 2 Factory Manager Vice President 3 Safety Engineer Secretary 4 Chief Chemist Member 5 Civil Engineer Member 6 Perches Officer Member 7 Store Keeper Member 8 Mill Fitter B Grade Member 9 Boiler Supervisor Member 10 Mill Fitter A Grade Member 11 Juice Supervisor Member 12 Boiling Ha. Fitter Member 13 Juice Supervisor Member 14 Electrical Supervisor Member 15 Security Officer Member Molasses based 30KLPD Distillery Unit 6-23

177 EIA REPORT: Chapter VI In case of proposed distillery project, aspects of Safety and Occupational Health are given with the due consideration, over and above applicable legislations such as Factories Act Extra attention is paid to provide measures for ensuring safety and health of workers as well as integrity of the unit. Following applicable national or international standards shall be followed Use of flameproof and standard electrics Suitable operating procedures shall be adhered to ensure Safety, Health and Environment throughout the premises Provision of safety gears such as safety shoes, gloves, goggles, helmets, masks, ear plugs, etc. to workers Workers working in high noise/ high risk areas must be rotated to other areas Smoking and other igniting activities should be strictly prohibited in the distillery, biogas as well as bio-compost area In exceptional case, when biogas couldn t be consumed as a fuel in the boiler then as a safety measure a flare unit shall be installed The plant and buildings meet the corresponding provisions of statutes regarding inter-distances, exits, ventilation, illumination, etc. Fire fighting arrangements shall be provided as per the required statutes as well as corresponding standards Plan of evaluation of health of workers By pre designed format during pre placement and periodical examinations. Proper schedule will be devised and followed with help of occupational health experts and doctors. Health effects of metals used and health hazard plans based on monthly correlation of these metal related diseases and people affected. Schedule of medical check-up during operational phase Comprehensive pre-employment medical checkup for all employees General check up of all employees once a year Medical examination of employees after retirement is recommended for a period of 5 years Molasses based 30KLPD Distillery Unit 6-24

178 EIA REPORT: Chapter VI Local hospitals and Govt. health monitoring system will be engaged Dispensary and ESI facility will be provided to all workers as applicable All safety gears will be provided to workers and care will be taken by EMC that these are used properly by them. All safety norms will be followed 6.7 ENVIRONMENT RESPONSIBILITY OF THE INDUSTRY (MANAGEMENT PLAN FOR SOCIAL ENVIRONMENT) The management of SSAIL is implementing following schemes/activities for the social welfare. Operates school for the children of cane harvesters The factory provides employees approx 400 workers as seasonal workers, trainees or on daily wages during cane crushing season; and even in off-season also it provides approx 225 employment opportunities in these categories Provides computer training to workers and their children Encourages the farmers to buy tractors Promotes lift and drip irrigation schemes Provides good quality seed and onsite guidance to farmers Implementing various labour welfare activities such as health checkup camps, rewards, celebration of various festivals, providing housing facility etc. In case of the proposed project the management of SSAIL will definitely continue with these activities. In addition, it will undertake many other activities to maintain as well as improve socio-economic conditions of the region. These activities includes Conservation of fresh water resources Providing health facilities to even family members of the employees, labours, contract labours, etc. Prefer local candidates for employment Provide employment to backward classes/communities as per the regulatory norms as well as encourage female candidates to apply Proper implementation of schemes for employee s health, insurance, welfare, etc. Pay special attention on schemes for women and child welfare Compliance of norms of regulatory authorities as applicable Molasses based 30KLPD Distillery Unit 6-25

179 EIA REPORT: Chapter VI Policy under PLI Act 1991 is mandatory Promote water conservation measures such as drip irrigation while implementing cane development Maintain the road infrastructure Help to strengthen the other infrastructures such as school, medical facilities, drinking water, sanitation, etc Pay respective taxes, levies, cess etc on time to local and state government Help to maintain and improve social harmony in the region 6.8 ENVIRONMENT MONITORING PROGRAMME In order to maintain the environmental quality within the standards, regular monitoring network to maintain, environmental quality will be implemented. The sugar factory is already having a monitoring program for various attributes and also has a full-fledged laboratory and technical manpower for the pollution matters. The same can be extended to the distillery and ETP since the distillery is proposed to be within the sugar factory complex. The existing laboratory needs to be upgraded so as to serve the proposed project requirement Environment Management Cell It is recommended to constitute, a separate Environment Management Cell (EMC) by including following personnel. It should be established to monitor and control the environmental quality in and around the industrial complex. Members of the EMC should be well qualified and experienced in their respective/concerned field. Table 6.8: Human Resource for Environment Management Cell General Manager/Production Manager Bio-compost/ETP I/c. Laboratory Chemist Environmental Chemist /biodigester supervisor One One One One Molasses based 30KLPD Distillery Unit 6-26

180 EIA REPORT: Chapter VI Safety Officer Supporting Staff One Two to five Monitoring Plan: Air, Water, Noise Environment Water samples from bore well/s located towards downstream of compost yard should be collected and analysed periodically Install peizometer near compost yard/spentwash storage lagoon Spentwash as well as compost samples should be analysed periodically Water Cess should be submitted to Pollution Control Board as per the schedule Environment Statement Reports also to be filed as per the schedule prescribed by Pollution Control Board Some of the routine tests of wastewater such as ph, solids, temperature, etc. could be carried out in the laboratory of sugar factory. However, for additional tests of water, wastewater, soil, air etc. services of reputed laboratories approved by Ministry of Environment and Forest (MoEF), New Delhi - under EPA 1986, could be hired. Table 6.9: Analysis of environmental parameters and its reporting schedule S. No. Particulars Parameter Frequency # 1 Stack Emissions Particulate matter, SO 2, NO x Monthly 2 Ambient Air Quality PM 10, PM 2.5, SO 2, NO x Monthly within premises and twice in a season at village Ujana, Ralga and Wadarwadi 3 inlet and outlet of polishing unit 4 Bore well /ground water sample nearer to compost ph, BOD, COD, SS, TDS, Oil & Grease etc. ph, COD, BOD, Total solids, Chlorides, Sulphate, Phosphates, and Calcium. Monthly Quarterly /monthly Molasses based 30KLPD Distillery Unit 6-27

181 EIA REPORT: Chapter VI yard 5 Noise monitoring Noise Levels measurement at high noise generating places as well as sensitive receptors in the vicinity Monthly 6 Analysis of ready bio-compost Moisture, Organic Carbon, and C:N ratio, Nitrogen, Phosphorous, Potassium, etc. Each batch of compost 7 Occupational health health and fitness checkup of employees get exposed to various hazards All other staff (except above) Quarterly Twice a year # if consent conditions are different from recommended frequency then follow the consent conditions Periodical Analysis of raw and bio-methanated spent wash Table 6.10: Suggestive schedule for maintenance of wastewater treatment unit # Part See (*) Frequency 1 Bearings See temperature Daily Change grease bi-monthly 2 Gland Change packing bi-monthly/as required 3 Indicators Pressure gauge, vacuum gauge tri-monthly calibration of 4 All type valves Change packing six-monthly 5 Impellor Check all blades, sleeves, bearing, impel nut check Yearly, change if required 6 Electric motor Open side doors, blow dust, check air gap Monthly Molasses based 30KLPD Distillery Unit 6-28

182 EIA REPORT: Chapter VI # Part See (*) Frequency 7 Motor winding Blow off dust, test insulation bi- Yearly 8 All hand carts, wheel Grease wheels Monthly barrows Change rubber tyres six-monthly if reqd 9 Gear box Oil level Check every week, replenish tri-monthly 10 Scraper shoe Tighten nut bolts, change tri-monthly broken-bent members, change leather-rubber shoes 11 Central turn table See oil level Weekly Check chain of sprocket, steel Yearly balls, gear 12 Aerator See oil and grease Weekly Painting-coating blades Yearly (*)As applicable to the unit Flow Measurement Water required for distillery process, boiler, cooling, cleaning and domestic purpose needs to be measured by installing flow meter at source. Quantity of spent wash generated is also need to be measured with the help of V-notch or flow meter. Molasses based 30KLPD Distillery Unit 6-29

183 EIA REPORT: Chapter VI Table 6.11: Format for Water Consumption Reporting Schedule # Particulars m 3 /hr m 3 /D m 3 /A 1. Dilution of Molasses 2. Distillation process, dilution for ENA 3. Cooling tower (CT) make-up for distillery 4. CT make-up for cooling spentwash for biogas plant 5. Boiler make-up 6. Floor washings sterilize 7. Sanitary Requirement 8. Domestic Use for Colony Total 9. Water consumption per KL of alcohol production 10. Power consumption for water lifting, KWH 11. Expenses for Electricity (Rs.) Water Cess (Rs.) Water Bills (Rs.) 12. Total Expenses (Rs.) 13. Expenses on water per liter of alcohol Table 6.12: Capital and recurring investment on environment management Sr. No. Particulars Amount (Rs. in Lakhs) 12. Spent wash cooling and holding tank Compost yard with PCC top finish Leachate management system Laboratory shed and its glassware, equipments, etc Treatment units for condensate and other effluent Bio-methanation Unit stand alone MEE Bio-composting machinery, pipeline, DG and other Molasses based 30KLPD Distillery Unit 6-30

184 EIA REPORT: Chapter VI 20. Fire fighting equipments and other Tree plantation and bore well for composting Wet Scrubber TOTAL Recurring Expenses/annum 6. Salaries and wages Operation and maintenance of all pollution control devices, motors, pumps, pipelines, etc. 8. Fuel (composting activity) and Electricity (in case of diesel generator operation) Fire protection, greenbelt, other waste management Transportation 3.00 TOTAL Molasses based 30KLPD Distillery Unit 6-31

185 EIA REPORT: Chapter VII CHAPTER VII RISK ASSESSMENT AND MANAGEMENT 7.1 INTRODUCTION Risk associated with any activity or project can be assessed and managed in terms of their effect on human health, environment and business operations, in general. When discussing a particular chemical substance, each of these categories should be examined to ensure a comprehensive understanding of a total risk and to provide the basis for an acceptable risk management plan. The uses of simple presence in a chemical commodity in the work place or the environment in general, present some level of risk. Assessing the nature or severity of this risk is dependent upon a number of factors, all of which focus on one common element: exposure. In assessing a risk a questions of exposures must consistently be asked. Are personnel being exposed? Is there an exposure to the environment? What is the risk to continue success in business operations if there is an exposure to personnel and/or the environment? Therefore, risk assessment, which is the basis for risk management, is partially contingent upon an understanding of term Exposure. However, an exposure to chemical doesn t always mean that the results will be detrimental. If such exposure occurs (i.e. those with no detrimental or adverse effect to human health, the environment or business operation) then additional question must be asked what is the nature of the risk associated with such exposure? Are these exposures hazardous or toxic? Hence, it is not always enough to have experienced an exposure to a chemical to accurately assess the risk posed by such. One must determine (assess) if the exposure was also hazardous before the level or nature of risk can be properly identified. In other words, the specific hazards of an exposure that present risk to a person and/ or the environment must be examined. It becomes clear that the risk assessor or risk manager must understand the principals of hazard, exposure, and risk. 7.2 THE RISK EQUATION Risk is the probability that the hazard will occur (i.e. that an adverse effect or/event will result from a given set of exposure condition). Since the risk is typically expressed as a mathematical probability, the range of risk can be stated as zero (having no possibility of Molasses based 30KLPD Distillery Unit 7-1

186 EIA REPORT: Chapter VII adverse effect or event). One (having a certainty that an adverse effect or event will result) having established this, it is important to note that risk is the mathematical product of hazard and exposure. This relationship can, be expressed in the following simple formula. Risk = Hazard x Exposure Simple multiplication rule tells us that, multiplying any number by zero forces a product of zero. Therefore, the above equation means that an extremely hazardous substance can be present with little risk of adverse effect if it is handled with safe and proper conditions (i.e. when the exposure component of the risk equation is driven towards zero). Similarly, risk can be reduced towards zero by driving the hazard component of the equation towards zero (e.g. changing the process design, substituting less hazardous commodity, using a lesser amount of a chemical, etc.), even if there is still a high probability of exposure. Of course, the ultimate risk management solution would be driving both the exposure and the hazard components of the equation to as low probability as possible. Such measures would virtually guarantee a low or no risk scenario; however, in the real world of everybody, operations, it is not always practical, feasible, or possible to reduce the elements of risk to zero level or probability. For this reason, risk assessment and risk management have become extremely vital element to successful business operations in recent years. More importantly, the proper assessment and management of risks, which may be pose by the use, transport, storage, or disposal of hazardous chemical can be laterally save lives, prevent illness and injury and preserve the precious environmental resources. 7.3 HAZARD IDENTIFICATION Mechanical Hazard It mainly involves properties of machine parts or work pieces, such as: a. Shape: It may cause injury to workman b. Relative location: Confined location during repairs & maintenance c. Mass and stability: May cause physical Injury d. Inadequacy of mechanical strength e. Accumulation of energy inside the equipment: steam/ air /water pressure cause injury to workman Molasses based 30KLPD Distillery Unit 7-2

187 EIA REPORT: Chapter VII f. During commissioning, Operation and Maintenance of plant Crushing hazard, shearing hazard, cutting or severing hazard, Friction or abrasion hazard and High pressure fluid injection or ejection hazard can not ruled out Electrical Hazard Probable incidences for electrical hazards, could be a. Contact of persons with live parts (direct contact), b. Contact of persons with parts which have become live under faulty conditions (indirect contact), c. Approach to live parts under high voltage, d. Electrostatic phenomena, e. Thermal radiation or other phenomena such as the projection of any particles and chemical; f. Effect of short circuits, overloads, etc identified during construction, production and maintenance Thermal Hazard Probable causes of thermal hazards could be - a. Burns, scalds and other injuries by a possible contact of persons with objects or materials with an extreme high or low temperature, by flames or explosions and also by radiation of heat sources b. Damage to health by hot or cold working environment c. Thermodynamic Hazard such as over/under pressure, over/under-temperature need to be avoided by providing system management Hazard generated by noise In the proposed project probable source of noise are boiler, motors and pumps, etc. Usually prolong exposure to high noise level, results into 1. hearing loss (deafness), other physiological disorder (e.g., loss of balance, loss of awareness) 2. Interference with speech communication, acoustic signals, etc. Molasses based 30KLPD Distillery Unit 7-3

188 EIA REPORT: Chapter VII Hazard generated by vibration In the proposed project the hazard due to vibrations could be due to - 1. Use of hand-held machines resulting in a variety of neurological and vascular disorders 2. Whole body vibration, particularly when combined with poor postures Hazards generated by materials/substances 1. Hazards from contact with or inhalation of harmful fluids such as: Anti rusting chemicals, Cleaning agents/acids/organic solvents gases, Superheated steam through leaks, bagasse dust, etc. 2. Fire hazard dry bagasse, alcohol and molasses storage area, furnace 3. Biological or microbiological (viral or bacterial) hazards:-workplace exposure to dusts from the processing of bagasse can cause the chronic lung condition pulmonary fibrosis Preliminary Hazard Analysis (PHA) Preliminary hazard analysis (PHA) is a semi-quantitative analysis that is performed to identify all potential hazards and accidental events that may lead to an accident, rank the identified accidental events according to their severity and identify required hazard controls and follow-up actions. This tool analysis is based on applying prior experience or knowledge of hazard to identify future hazards, hazardous situation. This can be used for product, process and facility design. This can be used in early development of a project where there is little information in detail is available. 7.4 PROBABLE RISK FACTORS Following scenarios feel under Maximum Credible Accident Scenario Fire in fuel yard (bagasse yard) Fire and explosion at storage yard (molasses and alcohol storage tanks) Fire due to short circuits Injury to body and body parts (mechanical) Molasses based 30KLPD Distillery Unit 7-4

189 EIA REPORT: Chapter VII Fire The storage areas are most vulnerable for fire. This includes, storage of alcohol and molasses. Table 7.1: Storage details Sr. No. Particulars Receiver capacity Storage capacity Cum (Cum) 1. Rectified Spirit 40 x 3 = x2=1200 Impure Sprit OR 10 x 3=30 2. ENA 40 x 3= x2 = 1200 Technical alcohol 200x2 = And Anhydrous alcohol 40 x 3 = x2 = 1200 Impure Spirit 10 x 3 = Molasses 4500MTx3 = 13,500MT This is the most common accident known to occur in any plant, while storing and handling fuel. Since such incident takes sufficient time to get widespread, enough response time gets available for plant personnel to get away to safer distance. An elaborate fire hydrant network and fire fighting system including trained crew and facilities will be provided to mitigate the risk of such incidents. In addition, as per requirement fire alarm system and smoke detectors will be installed. Table 7.2: NFPA (NATIONAL FIRE PROTECTION ASSOCIATION) Rating Chemical NFPA Ratings Health Hazard Fire Reactivity Ethanol Molasses based 30KLPD Distillery Unit 7-5

190 EIA REPORT: Chapter VII NFPA Classifications Health Definition Hazard 4 Materials which on very short exposure could cause death or major residual injury even though prompt medical treatment were given 3 Materials which on short exposure could cause serious temporary or residual injury even though prompt medical treatment were given 2 Materials which on intense or continued exposure could cause temporary incapacitation or possible residual injury unless prompt medical treatment is given 1 Materials which on exposure would cause irritation but only minor residual injury even if no treatment is given 0 Materials which on exposure under fire conditions would offer no hazard beyond that of ordinary combustible material Flammability Definition 4 Materials which will rapidly or completely vaporise at atmospheric pressure and normal ambient temperature, or which are readily dispersed in air and which will burn readily 3 Liquids and solids that can be ignited under almost all ambient temperature conditions. 2 Materials that must be moderately heated or exposed to relatively high ambient temperatures before ignition can occur 1 Materials that must be preheated before ignition can occur 0 Materials that will not burn Reactivity Definition 4 Materials which in themselves are readily capable of detonation or of explosive decomposition or reaction at normal temperatures and pressures 3 Materials which in themselves are capable of detonation or explosive reaction bur require a strong initiating source or which must be heated under confinement before initiation or which must be heated under confinement before initiation or which react explosively with water. Molasses based 30KLPD Distillery Unit 7-6

191 EIA REPORT: Chapter VII 2 Materials which in themselves are normally unstable and readily undergo violent chemical change but do not detonate. Also materials which may react violently with water or which may form potentially explosive mixtures with water 1 Materials which in themselves are normally stable, but which can become unstable at elevated temperatures and pressures or which may react with water with some release of energy but not violently 0 Materials which in themselves are normally stable, even under fire exposure conditions, and which are not reactive with water Mitigation Measures For Fire Hazards A. Storage Alcohol (RS, ENA or AA) and molasses will be stored in leak-proof MS tanks, gauges of MOC will be strictly as per IS or relevant standards; Storage area will be well ventilated with adequate spacing between units Lightening arresting system Provision of alcohol vapor condensation system Strictly declared No Smoking Zone and prohibition of use of any ignitable material (e.g. even cell phones, etc.) Electrical fittings of good quality that comply national or international standards B. Fire fighting system The factory management is vigilant on the issues of safety of workers and plant. Hence, it has developed a fire fighting system for existing sugar unit; details of which are as follows. Pipeline (m.s) of 1200meter, 100mm diameter operates with High speed Motor Pump (65HP: 2970rpm) 2260L/minute mounted on water Reservoir of 60lakhs Liters capacity for fire fighting around Factory, Bagasse yard and Godowns Fixed Hydrant Post- 28 in number (90mm dia. Beat valve operated with Female coupling.) 15meterFlexible Hose Pipe:-45 in number (63mm dia. With male female couplings.) 63mm Fire Nozzles:-10 in numbers Revolving Branch Manager Post:-05 in number (90mm dia. Butterfly valve operated.). Molasses based 30KLPD Distillery Unit 7-7

192 EIA REPORT: Chapter VII Portable Fire Extinguishers; o o Water type- 5 each of 50 litres and 3 each of 9 litres Dry Powder type- 4 each of 5 litres and 7 each of 9 litres With the same vigilance the management will look at the fire fighting requirement of the proposed distillery unit. It has planned following fire fighting System a. Guidelines of OISD-STD-117 will be implemented b. Lightening arresting system for the plant as well as storage c. Alcohol vapors condensing system for storage tanks d. The fixed water spray system will be provided on all tanks, fire water flow rate will be calculated at a rate of 25 lpm/m 2 as per OISD-STD-117 e. Fire water system will be designed for a minimum residual pressure of 7 kg/cm2(g) at hydraulically remotest point in the installation considering single largest risk scenario f. Water for the fire fighting will be stored in easily accessible surface or underground tanks of RCC/steel with minimum four hours aggregate rated capacity of pumps. There will be one or two standby diesel engine driven pumps of the same type, capacity & head as the main pumps will be provided; Jackey pump (one in number - AC motor driven) for maintaining pressure g. Hydrant system covering the entire plant including all important auxiliaries and buildings is proposed. The system will be complete with piping, valves instrumentation, hoses, nozzles and hydrants, valves etc. h. High velocity water spray system near storage tanks i. Portable extinguisher such as pressurized water type, carbon dioxide type and foam type will be located at strategic locations throughout the plant j. The diesel engines will be quick starting type with the help of push buttons located on or near the pumps or located at a remote location. k. Portable foam and/or water-cum-foam monitors will be provided for suppression of pool fire in tank farm area. l. Fire water pumps & storage will be located at 30 m (minimum) away from equipment or where hydrocarbons are handled or stored. m. Fire water pumps will be exclusively used for firefighting purpose only Molasses based 30KLPD Distillery Unit 7-8

193 EIA REPORT: Chapter VII n. Fire water mains, hydrant & monitor stand posts, risers of water spray system will be painted with Fire Red paint as per IS: 5. o. Hose boxes, water monitors and hydrant outlets will be painted with Luminous Yellow paint as per IS: 5 p. Electric audible fire siren will be to the farthest distance in the installation and also in the surrounding area up to 1 km from the periphery of the installation that will sound differently with respect to shift alarm with continuous power supply q. Communication system like Telephone, Public Address System, etc. to be provided in non-hazardous areas of the installation Figure 7.23: Fire Extinguisher selection guide Boiler Operations 1. Provision of adequate sets of Personnel protective equipment's 2. Pilot lights will be provided on electrical panel boards 3. Provision of hand operable fire fighting cylinders at strategic locations Fire Fighting Strategy 1. In case of small fire, it can be extinguished by using suitable extinguisher as shown in above chart 2. If it is a major fire, cordon the area and restrict entry of any unauthorized personnel Molasses based 30KLPD Distillery Unit 7-9

194 EIA REPORT: Chapter VII 3. Call the fire brigade station nearest to the site are located at Ahmedpur the Taluka head quarter, at Udgir (Contact number ) and Latur (contact number /401) 4. Keep a safe distance, if there is any possibility of explosion 5. In the event of any threat to the neighbouring residents, besides alerting those on the incident ensure that necessary precautions have been taken by them with the help of Civil Administration Authorities. 6. Mutual aid to be activated and district authorities shall be contacted for activating off site emergency preparedness. 7. Proper safety equipment should be used & back up of fire fighting/rescuing team to be provided. 8. Keep constant vigil on that particular spot and as well as on the neighbouring area. 9. Avoid directing heavy streams of water on the roof to avoid water stagnation. 10. Follow the instruction of Man-In-Charge during the entire fire fighting exercise. 11. Cooling water streams should be applied to the top of tank (excluding floating roof tank) so that the run-off down the sides of the tank will reduce the heat input to the tank. 12. Water must be applied on tank appurtenances, un-insulated supports and any porting of the tank shell above the liquid level where there is direct flame contact. 13. If the flames from vents are discharging onto the top of the shell of the tank, water must be directed on that area to keep it cool. 14. Cooling of tanks usually in needless unless there is direct flame contact or sufficient radiant heat to scorch the paint. 15. As a rule, ground fires around the tanks must be controlled or extinguished before attempting to extinguish the fire in the tank Mechanical injury to body parts In an industry, there are several places where workers are likely to be involved with accidents resulting in injury to body parts. The places are workshop, during mechanical repair work in different units, during construction work, road accidents due to vehicular movement, etc Molasses based 30KLPD Distillery Unit 7-10

195 EIA REPORT: Chapter VII Workers exposed to mechanical accident-prone areas will be given personal protective equipment. The non-respiratory PPE includes tight rubber goggles, safety helmets, welders hand shields and welding helmets, plastic face shields, ear plugs, ear muffs, rubber aprons, rubber gloves, shoes with non-skid soles, gum boots, safety shoe with toe protection. All safety and health codes prescribed by the BIS will be implemented. 7.5 QUALITATIVE RISK ASSESSMENT Probability of occurrence of hazard Table 7.3: Probability of occurrence of hazard Sr. Hazard Probability Severity Mitigation Measure No Mechanical Hazard 1. Physical injury to hand/legs Frequent Once Minor Use PPE/PPA during process per month or more often 2. Boiler Explosion Remote Catastrophic Layers of Protection area(lopa) 3. Fingers nipping in between Probable Once Major Fixed /Movable Molasses based 30KLPD Distillery Unit 7-11

196 EIA REPORT: Chapter VII moving part. E g Belt per year Guards at probable sites 4. Steam pipe leakages Frequent Once Major Proactive per month or Maintenance/PPE more often 5. Working on height Probable Once Critical Work permit Impact /falling down per year system Life belts/helmet 6. Water feeder pump failure Occasional Once Critical Alarming/communi per 10 years cation arrangements Electrical Hazard 7. Contact of persons with Occasional Once Major PPE/PPA/Permits parts which have become per 10 years live under faulty conditions (indirect contact) 8. Approach to live parts under Occasional Once Catastrophic Guards/ high voltage per 10 years authorization Enter Restriction 9. Electrostatic phenomena Remote Major Earthling, avoid Dust Explosion 10. Thermal radiation or other Probable Once Major PPE/Checking Short circuits, overloads, etc. per year /Inspection Thermal Hazard 11. Burns, scalds and other injuries by steam Occasional per 10 years Once Major Safe working distance/ppa/prote ctive dress code Molasses based 30KLPD Distillery Unit 7-12

197 EIA REPORT: Chapter VII 12. Damage to health by hot Frequent Once Critical Minimum exposure working environment per month or more often Ventilation /Humidity control Hazard generated by Noise 13. Belt movement. Pump/Motor Turbo generator Frequent Critical Confinement of source Use Ear Muff/Plugs Hazard generated by Vibration 14. Whole body vibration, during working on feeder Remote Major Engineering solutions platform *Severity - Minor, Major, Critical, Catastrophic Table 7.4: Hazard Warning Information for Ethyl Alcohol Product Name Synonyms Chemical Family SECTION I Ethyl Alcohol, Anhydrous Ethyl Alcohol, Dehydrated Alcohol Alcohol Molecular Weight Formula C 2 H 5 OH Health Fire Reacti ve Other Degree of Hazard Colour Coding Other Codes = Minimum 1 = Slight 2 = Moderate 3 = Serious 4 = severe Health = Blue Fire = Red Reactivity = Yellow Other = White Ox = Oxidiser Acid = Acid Alk = Alkaline COR = Corrosive W = No use water SECTION II INGREDIENTS Molasses based 30KLPD Distillery Unit 7-13

198 EIA REPORT: Chapter VII Composition Cas Rn. Nominal Wt/Wt% Pel/Tlv Hazard Ethyl Alcohol ppm Flammable/Nervous System Depressant PEL = Personal Exposure Limit TLV = Threshold Limit Value SECTION III HEALTH INFORMATION Inhalation Ingestion Eye Contact Skin Contact Exposure to over 1000 ppm may cause headache, drowsiness and lassitude, loss of appetite, and inability to concentrate. Irritation of the throat. Can cause depression of central nervous system, nausea, vomiting, and diarrhea. Liquid or vapor may cause irritation. May cause irritation and defatting of skin on prolonged contact. SECTION IV OCCUPATIONAL EXPOSURE LIMITS PEL (OSHA Permissible Exposure Limit): Mixture TLV (ACGIH Threshold Limit Value): Mixture See Section II See Section II SECTION V EMERGENCY FIRST AID PROCEDURE For Overexposure By Swallowing Inhalation Contact With Eyes Or Skin If victim is conscious and able to swallow, have victim drink water or milk to dilute. Never give anything by mouth if victim is unconscious or having convulsions. Call A Physician Or Chem- Trec (Poison Control) Immediately. Induce vomiting only if advised by physician (Poison Control) Immediately remove victim to fresh air. If victim has stopped breathing, give artificial respiration, preferably mouth-tomouth. Get Medical Attention Immediately Immediately flush affected area with plenty of cool water. Eyes should be flushed for at least 15 minutes. Remove and wash Molasses based 30KLPD Distillery Unit 7-14

199 EIA REPORT: Chapter VII contaminated clothing before reuse. Get Medical Attention Immediately SECTION VI PHYSICAL DATA Boiling Point 173 F (78 0 C) Melting Point -173 F ( C) Vapor Pressure 44.6 mm 68 F (20 0 C) Specific Gravity 60 /60 F Vapor Density (Air = 1) 1.59 Solubility In Water Appearance And Color Complete in water, chloroform, acetone, ether, benzene and methanol Clear and colorless, volatile liquid with a weak, vinous, alcohol odour and bitter taste. Odour threshold = 84 ppm SECTION VII FIRE AND EXPLOSIVE HAZARDS Flash Point Auto-Ignition Temperature Flammable Limits In Air, % By Volume NFPA (National Fire Protection Association) RATING 56 F ASTM D-56 (Tag Closed Cup) 685 F LOWER: 3.3 UPPER: 19 HEALTH (0) FIRE (3) REACTIVITY (0) Fire Fighting Procedures (Note: Individuals should perform only those fire-fighting procedures for which they have been trained.) Use dry chemical, alcohol foam, or carbon dioxide; water may be ineffective, but water should be used to keep fire-exposed containers cool. If a leak or spill has not ignited, use water spray to disperse the vapors and to protect men attempting to stop a leak. Water spray may be used to flush spills away from exposures and to dilute spills to nonflammable mixtures. Firefighters should wear self-contained breathing apparatuses in the positive pressure mode with a full-face piece when there is a possibility of exposure to smoke, fumes, or hazardous decomposition Molasses based 30KLPD Distillery Unit 7-15

200 EIA REPORT: Chapter VII products. SECTION VIII REACTIVITY STABILITY HAZARDOUS POLYMERIZATION CONDITIONS & MATERIALS TO AVOID Generally stable. Not likely. Contact with acetyl chloride and a wide range of oxidizing agents may react violently. SECTION IX EMPLOYEE PROTECTION Control Measures Respiratory Protection Protective Clothing Eye Protection Handle in the presence of adequate ventilation. Where exposure is likely to exceed acceptable criteria, use NIOSH/MSHA approved respiratory protection equipment. Respirators should be selected based on the form and concentration of contaminant in air and in accordance with OSHA (29 CFR ). Wear gloves and protective clothing, which are impervious to the product for the duration of the anticipated exposure if there is potential for prolonged or repeated skin contact. Wear safety glasses meeting the specifications of ANSI Standard Z87.1 where no contact with the eye is anticipated. Chemical safety goggles meeting the specifications of ANSI Standard Z87.1 should be worn whenever there is the possibility of splashing or other contact with the eyes. SECTION X ENVIRONMENTAL PROTECTION Environmental Precautions Spill Or Leak Procedures Avoid uncontrolled releases of this material. Where spills are possible, a comprehensive spill response plan should be developed and implemented. Wear appropriate respiratory protection and protective clothing as described in Section IX. Contain spilled material. Transfer to secure containers. Where necessary, collect using absorbent media. In the Molasses based 30KLPD Distillery Unit 7-16

201 EIA REPORT: Chapter VII event of an uncontrolled release of this material, the user should determine if the release is reportable under applicable laws and regulations. Waste Disposal All recovered material should be packaged, labeled, transported, and disposed off, or reclaimed in conformance with applicable laws and regulations and in conformance with good engineering practices. SECTION XI HANDLING AND STORAGE Precautions Keep locked up. Keep away from heat. Keep away from sources of ignition. Ground all equipment containing material. Do not ingest. Do not breathe gas/fumes/ vapor/spray. Wear suitable protective clothing. In case of insufficient ventilation, wear suitable respiratory equipment. If ingested, seek medical advice immediately and show the container or the label. Avoid contact with skin and eyes. Keep away from incompatibles such as oxidizing agents, acids, alkalis, and moisture. Storage Store in a segregated and approved area. Keep container in a cool, well-ventilated area. Keep container tightly closed and sealed until ready for use. Avoid all possible sources of ignition (spark or flame). Do not store above 23 C (73.4 F). 7.6 RISK ASSESSMENT: HEALTH General Assessment The toxicity of ethyl alcohol is much lower in comparison to methanol or propanol. Ethyl alcohol is primarily toxic to humans by ingestion. While inhalation of its vapors can produce some toxic effects, its ability to enhance the effects of other chemicals poses a greater health risk for inhalation. Skin contact can cause topical damage and absorption is, therefore, not likely. It should be noted that most manufacturers of ethyl alcohol for use in industrial applications would normally mix it with a denaturant (a substance added to make it un desirable to drink). These include gasoline, acetone, formaldehyde, or methyl alcohol. Therefore, industrial exposures resulting from ingestion are very unlikely. Molasses based 30KLPD Distillery Unit 7-17

202 EIA REPORT: Chapter VII Inhalation can cause irritation of the eyes, nose, throat, upper respiratory tract, and associated mucosa. There may be headache, nervousness, tremors, dizziness, tearing, fatigue, nausea, somnolence, and narcosis with stupor and loss of consciousness. There are no reports of cirrhosis occurring as a result of inhalation exposures. However, chronic exposure to ethyl alcohol vapors caused brain damage in mice. Vapor exposure can also increase the toxic effects of other chemicals being inhaled. Also, the toxicity of ethyl alcohol is enhanced with the presence of compounds such as barbiturates, carbon monoxide, and methyl mercury. Liquid contact with the eyes causes immediate burning and stinging with lachrymator and reflex closure of the lids. There may be injury to the corn epithelium and possible hyperemia (excessive blood) the conjunctiva. Skin contact results in drying cracking, which can lead to secondary infections dermatitis. Ingestion of ethyl alcohol is not likely to occur in the industrial environment. However, if it does, symptoms can include sleep disorders, hallucinations, distorted perceptions, ataxia, motor function changes, convulsions and tremors, coma, headaches, pulmonary changes, alteration of gastric secretions, menstrual cycle changes, glandular changes, nausea or vomiting, and decrease in body temperature Acute Health Effects The following acute (short-term) health effects occur immediately or shortly after exposure to alcohol. Skin Eye Lung Central Nervous System (CNS) Causes dryness and cracking leading to dermatitis and possible infection. Severe irritation with burning and possible damage to the cornea and conjunctiva. Irritation of the eyes, nose, throat, and respiratory tract. High concentrations can cause depression the CNS with symptoms of sleepiness and I of concentration. Molasses based 30KLPD Distillery Unit 7-18

203 EIA REPORT: Chapter VII Chronic Health Effects The following chronic (long-term) health effects occur at some time after exposure to ethyl alcohol can last for months or even years: Cancer Hazards Reproduction Ethyl alcohol is known to cause liver cancer in humans, primarily due to ingestion. Industrial exposures through ingestion are not likely but are certainly possible According to the references, ethyl alcohol can affect human reproduction by ingestion. It causes changes in the female fertility index. Effects on newborns include changes in the apgar score, neonatal measures or effects, and drug dependence. Other Effects Chronic Very high or prolonged expo- sure may result in mucous membrane irritation, head- ache, and depression of the CNS with symptoms of somnolence and lack of concentration. Prolonged skin contact can cause dermatitis Recommended Risk-Reduction Measures Even though ethyl alcohol is a known carcinogen, this effect is primarily the result of ingesting large amounts of alcoholic beverages. Industrial exposures by this route are not likely to occur. Engineering controls are the other most effective methods of reducing exposures. The best protection is to enclose operations' and/or provide local exhaust ventilation at the site of chemical release. While not always operationally feasible, isolating operations can also reduce exposure risk. Using respiratory protection is less effective than the controls mentioned above, but is still advisable whenever working with or around ethyl alcohol. For concentrations over the Permissible Exposure Limit (PEL i.e ppm), an air-purifying respirator with an organic vapor cartridge will suffice. For higher exposures, a supplied-air respirator with full face piece operated in positive pressure mode, or a self-contained breathing apparatus (SCBA) with full face piece and operated in pressure demand mode are the recommended respiratory protection methods of choice. If a full face piece is not available, then chemical goggles should be worn to protect the eyes. Whenever a chemical splash hazard exists, a Molasses based 30KLPD Distillery Unit 7-19

204 EIA REPORT: Chapter VII face shield and a protective apron should be worn. To pre- vent hand and skin exposures, impervious gloves should be used. Administrative controls should also be in place to minimize the potential for human exposures. These may include written procedures or policies, which specify the methods and techniques that will be practiced whenever personnel are to work with ethyl alcohol. All personnel should receive training on- the use, hazards, protective measures, emergency actions, and other precautions (Hazard Communication), prior to the first assignment in an area where ethyl alcohol is used or stored. If symptoms develop or overexposure is suspected, the following medical tests are recommended a. Liver function tests; b. Skin testing with dilutes ethyl alcohol to help diagnose allergy (performed by a qualified allergist). Any medical evaluation should include a careful history of past and present symptoms with an examination. Medical tests that look for existing damage are not a substitute for controlling exposures. Also, since consuming large quantities of alcoholic beverages can lead to liver dysfunction and even cancer, persons with alcohol addiction who arc exposed to ethyl alcohol on the job may develop symptoms much quicker and with greater intensity than those who do not drink under identical exposure conditions. Prudent risk management requires careful consideration of all possible factors that may be causing the appearance of exposure symptoms Other Methods to Reduce Exposure a. Hazard warning information should be posted in the work area. In addition, as part of an on-going education and training program, all information on the health and safety hazards of ethyl alcohol should be communicated to all potentially exposed workers. b. Always ensure that proper protective clothing is worn when using chemical substances. c. Wash hands / body parts thoroughly immediately after exposure to ethyl alcohol and at the end of the work shift or before eating, drinking, or smoking. Molasses based 30KLPD Distillery Unit 7-20

205 EIA REPORT: Chapter VII 7.7 RISK ASSESSMENT: ENVIRONMENT General Assessment The environment is at risk of exposure during transportation, storage, disposal, or destruction of ethyl alcohol. In almost every scenario, the threat of environmental exposure is contingent upon the proper handling of the chemical substance. Accidental spills, large or small, can result in fire, explosion, and possible contamination of the surrounding environmental mediums (water, soil, and air). Ethyl alcohol is considered a class IB flammable liquid (according to OSHA 29 CFR ). Its low flash point and relatively low boiling point present a serious fire and explosion hazard concern. Also, because it is incompatible with a number of common materials, especially strong oxidizers and many metal nitrates, contact can result in violent and explosive reactions. It can form explosive mixtures in air and can ignite on contact with heat, fire, or sparks. It will react and then explode in contact with acetic anhydride + sodium hydrogen sulfate. It also reacts violently with acetyl bromide (evolves hydrogen bromide). These characteristics require special consideration during any emergency situation involving a leak or spill of ethyl alcohol. Ethyl alcohol can enter the environment through unchecked industrial discharges into effluents and through spills Acute Ecological Effects Acute (short-term) toxic effects may include the death of animals, birds, or fish, and death or low growth rate in plants. Acute effects are seen 2 to 4 days after animals or plants are exposed to ethyl alcohol. This chemical has moderate acute toxicity to aquatic life. Insufficient data are available to evaluate or predict the short-term effects of ethyl alcohol to plants, birds, or terrestrial animals Chronic Ecological Effects Chronic toxic effects may include shortened life span, reproductive problems, lower fertility, and changes in appearance or behavior in exposed animals. These effects can be seen long after first exposure(s) to toxic chemicals. Ethyl alcohol has moderate chronic toxicity to aquatic life. Insufficient data are available to evaluate or predict the long-term effects of ethyl alcohol to plants, birds, or land animals. Molasses based 30KLPD Distillery Unit 7-21

206 EIA REPORT: Chapter VII Water Solubility: Ethyl alcohol is highly soluble in water. Concentrations of 1000 milligrams and more can be expected to mix with a liter of water Persistence in the Environment Ethyl alcohol is slightly persistent in water, with a half- life of between 2 to 20 days. The half- Life of a pollutant is the amount of time it takes for one-half of the chemical to be degraded. About 90% of ethyl alcohol will eventually end up in the air; the remainder will end up in water Bioaccumulation in Aquatic Organisms Some substances increase in concentration, or bioaccumulate, in living organisms as they breathe contaminated air, drink contaminated water, or eat contaminated food. These chemicals can become concentrated in the tissues and internal organs of animals as well as humans. The concentration of ethyl alcohol found in fish tissues is expected to be about the same as the average concentration of ethyl alcohol in water from which the fish was taken Recommended Risk-Reduction Measures Proper training of all transporters will reduce the likelihood of a mishap or accident resulting in a leak or spill to the environment. The correct labeling while transportation on all transporting vehicles should be enable emergency responders to react properly and quickly to any disaster thereby reducing the potential risk to the environment and to personnel. Storage of ethyl alcohol should be segregated from incompatible chemicals to minimize the risk of cross contamination or contact. Buildings designated for storage should be equipped with appropriate fire protection systems (alarms, sprinklers, emergency lighting, portable extinguishers). Equipment should be designed to meet explosion-proof standards. If a spill or leak to the environment has occurred, fire department, emergency response, and/or hazardous materials spill personnel should be notified immediately. Cleanup should be attempted only by those trained in proper spill containment procedures. Contaminated soils should be removed for incineration and replaced with clean soil. If ethyl alcohol should contact the water table, aquifer, or navigable waterway, time is: of the essence. It is highly soluble in water and, therefore, total containment and remediation may not be entirely possible. When such spills occur, the local and/or state emergency response authorities must be notified. A comprehensive emergency response of disaster preparedness/recovery Molasses based 30KLPD Distillery Unit 7-22

207 EIA REPORT: Chapter VII plan should be in place prior to any operations involving the use, transportation, storage, or disposal of ethyl alcohol. If ethyl alcohol is spilled or leaked, the following specific steps are recommended: a. Restrict persons not wearing protective clothing from area of spill or leak until cleanup is complete and area can be opened for normal work. b. Ventilate area and remove ignition sources. c. Absorb liquids in vermiculite, dry sand, earth, or a similar material and deposit in sealed containers. Use non-sparking tools. d. It may be necessary to dispose of ethyl alcohol as a hazardous waste. The state PCB should be contacted for specific recommendations. 7.8 RISK ASSESSMENT: BUSINESS General Assessment Accidents or mishaps involving ethyl alcohol can present a moderate threat to business operations. The loss or damage of equipment or facilities can significantly affect fiscal viability. Lawsuits that may result from personnel injury/death, public exposures, and/or environmental contamination will also require a serious expenditure of resources. Media attention surrounding an injury, death, or environmental damage can also result in a loss of profits and loss of current as well as future business Recommended Risk-Reduction Measures Company attorneys, safety and health professionals, and environmental specialists should be involved in the development of any procedures or policies intended to manage the use of chemicals in the workplace. A company official should be pre-designated as a public relations officer with specific training in dealing with the press. Corporate plans and policies should be developed, approved, and implemented long before any need for such arises Safety Provisions Proposed: Others 1. Frequent checking of pipelines and storage units will be done. 2. Prohibiting welding or similar maintenance activities near combustible material storage 3. Pumps of reliable quality will be installed. 4. Lightening protecting system as per Indian electricity rules Molasses based 30KLPD Distillery Unit 7-23

208 EIA REPORT: Chapter VII 5. keep safe distance between fuel storage area and main unit 6. Corrosion protection methods for pipelines 7. All locations where the above ground pipelines are close to traffic movement, protection like crash guards will be provided 8. Flame arresters' will be provided in gas lines to protect the digester from back fire from the flame and / or the boiler burner. 9. Over / under pressure release device will be provided on biogas digester for its safety from over pressure / vacuum. 10. Transfer of alcohol only mechanically Table 7.5: Summary of risk assessment and damage control High risk equals 16to 25 Medium risk equals 9 to 15 Low risk equals 1 to 8 High Risks activities should cease immediately until further control measures to mitigate the risk are introduced Medium Risks should only be tolerated for the short-term and then only whilst further control measures to mitigate the risk are being planned and introduced, within a defined time period. Note: Medium risks can be an organizations greatest risk, its achilles heel, this due to the fact that they can be tolerated in the shortterm. Low Risks are largely acceptable, subject to reviews periodically, or after significant change etc. Molasses based 30KLPD Distillery Unit 7-24

209 EIA REPORT: Chapter VII General Risk Assessment 1. Responsibility: Site Controller: Head- Production Incident Controller: Shift- In charge Emergency Coordinators: Departmental Heads Hazards and details Persons at risk Control measures Action recommended in case of emergency Risk Likelihood Severity Risk rating L S RR=LxS Furnace/boil er- Fire hazard caused by fuel/ ignitable substances Persons working near the furnace area- Burns may be possible if directly come in contact Emergency alarm to be put on to signal the emergency Emergency kit to be kept ready near the work place Fire fighting equipments power/ foam type extinguishers on vehicles and mounted on walls to be kept readily available Provision of water hose Strictly No smoking zone and prohibition of ignitable activities Plant workers to be trained to fight fire Switch off the system. Fire extinguishers are to be used immediately Water hose to be operated to set out the fire depending on the situation Outside fire brigade is to be called if the fire cannot be extinguished immediately Inform the in-charge/ manager and activate the onsite emergency plan Immediate first aid to victims and sent to hospital for treatment Molasses based 30KLPD Distillery Unit 7-25

210 EIA REPORT: Chapter VII 2. Responsibility: Site Controller: Head- Electrical Incident Controller: Shift- In charge Emergency Coordinators: Departmental Heads Hazards and details Persons at risk Control measures Action taken in case of emergency Risk Likelihood Severity Risk rating L S RR=LxS Electrical Transformer- Electrical shock and fire Person near the transformer Shock proof insulated PCC platform Cut off power supply. Treat the injured for electrical shock If fire is caused, immediately fight fire with available resources, summoning outside help if necessary Molasses based 30KLPD Distillery Unit 7-26

211 EIA REPORT: Chapter VII 3. Responsibility: Site Controller: Head- Laboratory Incident Controller: Shift- In charge Emergency Coordinators: Departmental Heads Hazards and details Persons at risk Control measures Action recommended in case of emergency Risk Likelihood Severity Risk rating L S RR=LxS Lab chemicals- in case of bottle breakage, causes burns and damage to respiratory systems due to inhalation. Persons working in the lab Proper care to be taken while handling the chemicals. First aid box to be made available on site with all required medicines and devices Fire fighting equipments like fire extinguishers, sand buckets should be always available Instruction boards to be displayed for knowledge of other workers to care of the situation in the event of occurrence Immediately treat the persons as guided in the MSDS Hospitalize the affected person if necessary Molasses based 30KLPD Distillery Unit 7-27

212 EIA REPORT: Chapter VII 4. Responsibility: Site Controller: Manager- Services Incident Controller: Shift- In charge Emergency Coordinators: Departmental Heads Hazards and details Persons at risk Control measures Action taken in case of emergency Risk Likelihood Severity Risk rating L S RR=LxS Cooling Tower- Burns from returning hot water Persons working with cooling tower All workers are not permitted near the tank and hot water line. Railing is to be provided all around the tank Always precautionary measures should be taken and adopted Victims are first aided by trained persons and then referred to doctor/ hospital If any worker get injured/hurt, then immediate first aid should be provided to him and he should be referred to the hospital/ doctor for further treatment Molasses based 30KLPD Distillery Unit 7-28

213 EIA REPORT: Chapter VII 5. Responsibility: Site Controller: Manager Incident Controller: Shift- In charge Emergency Coordinators: Departmental Heads Hazards and details Persons at risk Control measures Action taken in case of emergency Risk Likelihood Severity Risk rating L S RR=LxS Water tank- Drowning of personnel Persons near the water tank Water tank will be fenced/ covered Drowned person should immediately be given first aid The tank will not be permitted for domestic utility Molasses based 30KLPD Distillery Unit 7-29

214 EIA REPORT: Chapter VII 6. Responsibility: Site Controller: Head- Production Incident Controller: Shift- In charge Emergency Coordinators: Departmental Heads Hazards and details Persons at risk Control measures Action taken in case of emergency Risk Likelihood Severity Risk rating L S RR= LxS Control roomselectrical shocks Persons working in the control room Earth leakage circuit breaker installed. Main supply will be immediately shut off Molasses based 30KLPD Distillery Unit 7-30

215 EIA REPORT: Chapter VIII CHAPTER VIII DISASTER MANAGEMENT PLAN 8.1 INTRODUCTION According to the UN International Strategy for Disaster Reduction, (UNISDR) A Disaster is a sudden, calamitous event that causes serious disruption of the functioning of a community or a society involving widespread human material economic or environmental losses and impact which exceeds the ability of the affected community or society to cope using its own resources. Disaster Management is "it is action taken to prevent Hazard from converting into Disaster". A major disaster in a work is one which has potential to cause serious injury or loss of life. It may cause extensive damage to property and serious disruption both inside and outside the work. Normally, assistance of outside emergency services is required to handle disaster situation effectively. Whatever are the causative factor like plan failure, human error, earthquake, lightning, vehicle crash sabotage etc. they will normally manifest in three basic forms viz. fire, explosion and/or toxic release. Pre-disaster planning is crucial for ensuring an efficient response at the time of a disaster. A well-planned and well-rehearsed response system can deal with the exigencies of calamities and also put up a resilient coping mechanism. Optimal utilization of scarce resources for rescue, relief and rehabilitation during times of crisis is possible only with detailed planning and preparation. Keeping in view these factors, preparation of Disaster Management Plans (DMP) is imperative. 8.2 SCOPE Disaster : A serious disruption of the functioning of a society, causing widespread human, material or environmental losses which exceed the ability of the affected community to cope up by using its own resources. Hazard: Hazard is an event or occurrence that has potential for causing injury or loss of life or damage to property or the environment. Following factors are considered to identify hazard Molasses based 30KLPD Distillery Unit 8-1

216 EIA REPORT: Chapter VIII Physiology of the hazard or and its peculiar characteristics. Impact & probability of occurrence The elements by affecting, life / property or environment, likely to get affected High power committee on Disaster Management, Government of India has identified 32 types of hazards in India depending on area, probable damage, repentance of occurrence and impact on Life, Property and environment etc. Categorization of Hazards Figure 8.1: Probable causes of hazard Natural Drought Flood Cyclones Land Slides Man Made Air, Rail & Road Accidents Industrial Accidents Civil Commotions Terrorism Cloud Bursts Earthquakes Molasses based 30KLPD Distillery Unit 8-2

217 EIA REPORT: Chapter VIII Table 8.1: Various types of hazards Geological Hazards 1. Earthquake 2. Landslide 3. Tsunami 4. Dam burst 5. Volcanic eruption 6. Mine Fire Water & Climatic Hazards 1. Tropical Cyclone 2. Cloudburst 3. Tornado and Hurricane 4. Landslide 5. Floods 6. Heat & Cold wave 7. Drought 8. Snow Avalanche 9. Hailstorm 10. Sea erosion Environmental Hazards 1. Environmental pollution 2. Desertification 3. Deforestation 4. Pest Infection Biological 1. Human / Animal 2. Food poisoning Epidemics 3. Pest attacks 4. Weapons of Mass Destruction Accident related 1. Forest fires 2. Air, Road & Rail accidents 3. Urban Fires 4. Festival related Disasters 5. Mine Flooding 6. Electrical Disasters & Fires 7. Oil Spills 8. Boat Capsizing Molasses based 30KLPD Distillery Unit 8-3

218 EIA REPORT: Chapter VIII 9. Major Building collapses 10. Village fires 11. Serial Bomb Blasts The geographic region of the proposed project may face probable hazards such as earthquake, drought, thunder storms, accidents and environmental hazard such as pollution, etc. So considering these probabilities, the disaster management plan is being recommended. Figure 8.2: Schematic of Disaster Management Process Molasses based 30KLPD Distillery Unit 8-4