chapter 1 introduction -...

Environmental Impact Assessment Report 2014

1 M/s Ugar Sugar Works Ltd.Ugar Khurd, Tal: Athani, Dist: Belgaum

CHAPTER 1

INTRODUCTION



1.0 INTRODUCTION

1.1 BACKGROUND OF THE PROPOSED PROJECT

This is a proposal for expansion of Sugar cane crushing capacity from 10000TCD to

20,000 TCD, Co-generation power plant from 44 MW to 75 MW & Molasses based

Distillery from 75 KLPD to 200 KLPD in the premises of M/s UGAR SUGAR WORKS

LTD.(USWL) Ugar Khurd, Tal: Athani, Dist: Belgaum, State: Karnataka.

Image 1.1: The Ugar Sugar Works Ltd. Ugar Khurd

USWL has distillery, IML section and Co-generation plant. The company has expanded

its capacity from time to time and the present capacity is 10000TCD and 44 MW co-

generation, out of which 28 – 30 MW is exportable. The factory started Distillery in the

year 1963 & the present capacity of the distillery is 75 KLPD (30 KLPD batch type & 45

KLPD continuous type). Consisting of 20 KLPD Ethanol Plant & 50 KLPD ENA Plant with

blending & bottling of 9 different IML varieties. The company has provided fully fledged

effluent treatment plant which includes bio-digesters, concentration & spray drying of

spent wash, treatment of sugar factory effluent etc. The company has also provided

biogas plant where filter cake is used for domestic fuel requirement. The gas is provided

to 170 residential quarters. Filter cake is a by-product of sugar factory.



1.2 BACKGROUND OF PROJECT PROPONENT OF THE PROPONENT

The Ugar Sugar Works Ltd. is one of the pioneers in sugar production in the state of

Karnataka; the Company was incorporated on 11th September 1939, under the able

guidance and kind patronage of his late highness. The Rajasahab of Sangli with a

crushing capacity of 500 tons per day. Vaidya and Company was the first Managing

Agents. In the year 1940, M/s. Shirgaokar Brothers were called to manage the affairs of

the Company and they were the Managing Agents till 31st December 1969. M/s.

Shirgaokar Brothers who had by then made the Kolhapur Sugar Mills outstanding and

notable success proved to be successful in bringing up the Ugar Sugar Works Ltd., also.

Under the overall supervision and control of M/s. Shirgaokar Brothers the crushing

capacity of the factory has been increased from time to time.

The company has introduced number of irrigation schemes for the development of

sugarcane in the area. The company has started its own distillery during the year 1962-

63 and liquor section in the year 1967-68. New distillery plant unit with production

capacity of 45000 liters of rectified spirit has been commissioned in March 1995.

Present Director board of the company is as follows:

Ø Shri. R.V.Shirgaokar’ (C & M)

Ø Shri. P.V. Shirgaokar (E V C)

Ø Shri. S.S. Shirgaokar (MD)

Ø Shri N. S. Shirgaokar (Jt. MD)

Ø Shri C. S. Shirgaokar (Jt. MD)

Ø Shri M. R. Desai (Director)

Ø Shri V. Balasubramanyam (Director)

Ø Shri S. N. Inamdar (Director)

Ø Shri M. G. Joshi (Director)

Ø Shri D. B. Shah (Director)

1.3 PURPOSE OF THE ENVIRONMENTAL IMPACT ASSESSMENT

Industrial activities such as invariably involve utilization of natural resources and

generation of waste substances and they may have adverse consequence to the

environment. However, mankind as it is developed today cannot live without taking up

these activities for his food, security or other needs. Hence, there is a need to

harmonious developmental activities with the environmental concern. EIA is one of the



tools available with the planners to achieve the above goal. It is desirable to ensure that

the project activity is sustainable. Hence, the environmental consequence must be

characterized early in the project cycle and accounted for in the project design.

The objective of EIA is to foresee the potential environmental problems that would arise

out of the proposed development and address them in the project planning and design

stage. The present EIA report incorporates the environmental consequence of the

proposed ethanol project along with the measures adopted in the distillery for control of

pollution and enhancement of environmental quality.

Before establishment of any project, under Environmental Protection Act (EPA) 1986, it

is mandatory for the project proponents to obtain clearance on environmental angle from

State pollution control board. The industries seeking consent for establishment have to

make application to state pollution control board in the prescribed forms along with

Environmental Management Plan (EMP) and other details related to pollution control and

environmental protection.

Further, the proposed project is listed under EIA Notification dated 14-09-2006 of

Ministry of Environment and Forests (MoEF). As per the above notification, prior

environmental clearance from MoEF is mandatory before establishment of this industry.

Hence, the industry is to follow due course of procedure to secure EC including

application to MoEF for EC, Terms of References for conduct of EIA studies, Public

hearing/consultation and deliberation of the project at Expert Appraisal Committee of

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

with pre feasibility report to the MoEF New Delhi seeking Terms of Reference (TOR) for

conduct of EIA studies. MoEF, New Delhi has deliberated the project ‘Terms of

Reference (TOR)’ during the 5th reconstituted Expert Appraisal Committee (Industry)

held during 31st January, 2013– 1st February, 2013. The ToR granted by MoEF as per

MoEF letter no. J-11011/315/2012-1AII (I) dtd. 22 March 2013. Accordingly the EIA

studies were conducted and the present report is prepared for submission to authorities.

With EIA report and other documents the industry has to approach KSPCB to conduct

Public Hearing/ Consultation.



1.4 BRIEF DESCRIPTION OF NATURE, SIZE AND LOCATION OF PROJECT

Table 1.1: Description of Project

Sr.

No.

Project

Requirement Details

1 Proposed Project

expansion of Sugar cane crushing capacity from 10000

TCD to 20,000 TCD, Co-generation power plant from 44

MW to 75 MW & Molasses based Distillery from 75

KLPD to 200 KLPD in the existing premises of M/s

UGAR SUGAR WORKS LTD.(USWL) Ugar Khurd, Tal:

Athani, Dist: Belgaum, State: Karnataka.

2 Location

Survey nos.1, 1A, 45 A, 267, 267 A, 268,373, 376,376A.

Village - Ugar Khurd, Tal - Athani, Dist-Belgaum,

Karnataka.

Latitude: 16°39'0.90"N

Longitude: 74°49'14.71"E

3 Plot Area Total Plot area - 251.31 acres

4 Total Factory Area Present factory area – 55 acres

5 Total Water

requirement 14310 m3/day

6

RAW MATERIAL EXISTING PROPOSED

Cane 10000TCD 20,000 TCD

Lime 24 MT/day 40 MT/day( Rajasthan)

Sulphur 6 MT/day 10 MT/day.(Indian/Imported)

7

PRODUCTS EXISTING PROPOSED

Sugar 10,000 TCD 20, 000 TCD

BY PRODUCTS EXISTING PROPOSED

Bagasses

3000 MT/Day 6000 MT/Day



Filter cake 400 MT/Day 800 MT/Day

Molasses 400 MT/Day 800 MT/Day

8 Nearest City Miraj City is 25 Kms

9 Nearest Railway

Station Ugar khurd Railway Station: 2 Kms.

10 Nearest

Headquarters The Belgaum district headquarter is 100 kms.

11 Nearest Highway

1. The National highway No.4 is 70Kms

2. State highway Sankeshwar to Bijapur is 10 km away

from the sugar factory.

12 Wildlife Sanctuary,

Eco Sensitive Zone Does Not Exist

1.5 NEED FOR THE PROJECT

All the nearby plants are going for the expansion and the forecast is total crushing days

will be reduced. Previously it was only one sugar factory in Athani taluka, now there are

6-7 sugar factories in the radius of 20 to 30 KM.

Athani farmers sugar factory is going for expansion to 5000 TCD, Krishna SSK is going

for expansion to 5000 TCD, Renuka Sugar Kokatnur is going for expansion to 15000

TCD, Renuka Sugar Raibag SSK is going for expansion to 5000 TCD, Mohanrao Shinde

Arag is 2500 TCD and Shirguppi sugar has commissioning with capacity of 5000 TCD.

The new plant Shivshakti sugar is coming up with capacity 2500 TCD.

To achieve maximum crushing in minimum crop days with maximum sugar recovery it is

essential to go for expansion. Present overheads at Ugar are already high, which leads

to face difficulties in arriving at competitive cane price. Hence Ugar Sugar management

is proposing to expand the sugar plant capacity to 20000 TCD.

Ugar Sugar has already taken steps to overcome the bottlenecks faced to crush 416.66

TCH (10000 TCD in 24 hrs) and during last season USWL has crushed almost 416.66

TCH. One of the bottlenecks is still exists i.e.at cane unloading station of 42 x 84 mill.

Due to space constraint and lower capacity cane un-loaders they are unable to maintain



uniform cane feeding. Bagasse moisture will be on higher side, which leads to

fluctuations in boiler steam working parameters and in turn affects the crushing. Along

with cane unloading station the other parameters, i.e. reduction in crop days in future,

higher overheads per ton of cane and competitive cane price, sugar plant expansion

seems to be essential. Hence USWL proposing to expand the crushing capacity.

Along with the expansion of the sugar plant capacity to 20000 TCD it is also proposed to

expand cogen power plant capacity to 75 MW with distillery of 200 KLPD capacity.

1.6 Terms of Reference (TOR) Compliances:

Draft Terms of Reference (TOR) have been discussed and finalized during the 5th

Reconstituted Expert Appraisal Committee (Industry) held during 31st January, 2013–

1st February, 2013 for preparation of EIA/EMP report. Following are the ‘TORs’:

Table 1.2: ToR Compliance

Sr. no Terms of References

1 Executive summary of the project.

2 Compliance of environmental conditions prescribed by the SPCB for the existing sugar & Distillery unit

3 Detailed breakup of the land area along with latest photograph of the area.

4 Present land use based on satellite imagery.

5 Details of site and information related to environmental setting within 10 km radius of the project.

6 Location of national park/Wild life sanctuary/Reserve forest within 10 km radius of the project.

7 Permission from the forest department regarding the impact of the proposed plant on the surrounding reserve forest.

8 List of existing distillery units in the study area along with their capacity.

9 Number of working days of the distillery unit and CPP

10 The cost of the project along with total capital cost and recuring cost/annum for environmental pollution control measures.

11 Manufacturing process details of sugar plant and CPP along with process flow chart.

12 Details of raw materials and source of raw material molasses,bagasse etc.



13 Sources and quantity of fuel (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,in case coal is uesd.

14 Action plan prepared by the SPCB to control ambient air quality as per Standards for PM10 PM2.5 SO2&NOX as per GSR 826(E) dated 16 th

November,2009.

15 One season site-specific micro-meterological data using temperature,relative hourly wind speed and direction and rainfall and AAQ data(except monsoon)for PM10 ,SO2&NOX and HC(methane&non methane) should be collected.the sensitive receptors including reserved forests.Data for water and noise monitoring should also be included.

16 Mathamatical modeling for calculating the dispersion of air pollutents and ground level concentration along with emission from the boiler.

17 An action plan to control and monitor secondary fugitive emission from all the sources.

18 Details of boiler & its capacity.Details of the use of steam from the boiler.

19 Ground water quality around existing spent wash storage lagoon and the project area.

20 Details of water requirement,water balance chart for sugar & co-generation plant Measures for conservation water by recycling and reuse to minimize the fresh water requirement.

21 Prior’permission’ from competent Authority for the drawl of the total fresh water source of water supply.

22 Hydro-geological study of the area for availability of ground water.

23 Proposed effluent treatment system for sugar unit as well as CPP and scheme for achiving ‘zero’ discharge

24 Logoon capacity for sugar unit and spent wash as well measures to be taken to control ground water contamination.

25 Details of solid waste management including management of boiler ash.submit ash management plan.MoU with cement for the use of fly ash.

26 Green belt development as per the CPCB guidelines .

27 List of flora & fauna in the study area.

28 Noise levels monitoring at five locations within the study area.

29 Detailed Environment management plan(EMP)with specific reference to details of pollution control system,water & waste water management,monitoring



responsibility and time bound implementation plan for mitigation measure provided.

30 EMP should also include the concept of waste-minimization, recycle/reuse techniques,Energy conservation,and natural resource conservation.

31 Details of bagasse storage.Details of press mud requirement.

32 Action plan for rainwater harvesting measures at plant site should be included to harvest rainwater from the roof tops & storm water drains to recharge the ground water

33 Details of occupational health programme

34 Details of socio-economic welfare activities to be provided.

35 Traffic Study of the area for the proposed projects in respect of existing traffic,type of vehicles for transportation of materials,additional traffic due to proposed project,parking arrangement etc

36 Action plan for post-project environmental monitoring

37 Corporate Environmental Responsibility

38 Any litigation pending against the project and/or any direction/order passed by any court of law against the project ,if so,details thereof.

39 Public hearing issues raised & commitments made by the project proponent on the same should be included seperately in EIA/EMP Report in the form of tabular chart with financial budget for complying with the commitments made.

1.7 Scope of EIA Study:

The study envisages characterization of the existing status of physical environment such

as air, water, soil, land use, meteorology, socio-economic and heritage etc. as well as

biological environment such as flora and fauna of the study area of 10 km radius and

quantifying impacts on the environmental parameters. Based on the study, the EIA

evaluates the proposed control measures by the project and prepares an environment

management plan, outlining additional proposed activities and delineates the

requirements of environmental monitoring program. EIA study shall cover the following

aspects:

Ø Evaluation of present environmental factors through analysis of generated

and collected baseline data for one complete dry season (3 months).

Ø Assess the probable impact on the environmental factors due to

implementation of the project with respect to existing scenario.



Ø Analyze the predicted impact with respect to the regulatory environmental

standards.

Ø Assess the probable risk at the proposed plant.

Ø Develop an Environmental Management Plan and on site Disaster

Management Plan for the proposed project to mitigate the negative

significant impacts that would arise from the proposed project.

Ø Report shall help to obtain No Objection Certificate for consent to operate

from the State Pollution Control Board.

The baseline data has been collected for the following environmental components,

during September – November 2013:

· Air Quality

· Meteorology

· Noise Environment

· Water Use & Quality

· Soil Quality

· Land Use, Crop Pattern, Agricultural Practices

· Demographic & socio-economic aspects

· Terrestrial & Aquatic ecology

Baseline data on parameters of the above-mentioned aspects over a season provides

means for identifying possible impact-positive as well as adverse. An environmental

impact assessment and environment management plan comprising an overall

assessment of the impact due to project activity over baseline condition of the existing

environment and a mitigating action plan to counter the adverse impact as defined. An

environmental monitoring program is also prepared to provide scientific support to future

actions of environmental protection.

Methodology

A study area of 10 km radius with the proposed plant site of USL at the center was

considered for the present study. This study will help to determine the present

environmental status and likely impacts of the proposed unit’s operations, if any in the

region. The most predominant wind direction during study period was considered for

various facts of establishing and the monitoring stations were finalized.

Table: 1.3 Scope of Work for EIA report

Environmental No of Observations



Attributes Locations

Meteorology 1

Hourly observations for Temperature, Relative

Humidity, Wind direction, wind speed & Rain fall

during 3 month study period

AAQ 8

For PM10, PM2.5, SO2, NO2,Total Hydro carbon for

24 hours duration, 2 times in each week during 12-

week study period

Water 6

3 Surface water Locations

3 Ground water locations (including the place near to

the plant site), Parameters that are analyzed are as

per Analysis of Drinking Water Quality had been

carried out

Noise 8 Day and night noise levels once in every location

Ecology

Flora- Fauna &

Ecosystem

Total study period is 90 days. However predicted flora

– fauna also included for non-seasonal plant species

(ephemerals) based on existing secondary data and

field conditions

Land use

10 km Radius study area

Land use data based on satellite imagery of 10 km

radius study area.

Socio-economic data

Demography & Occupational

Details

Secondary data from the existing literature (Census

2001 & 2011)

Organisation of Report

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

maintained. The EIA report has been divided into following chapters:

Chapter-1 Introduction

This chapter provides background information of the project, brief description and

objectives of the project, description of the area, scope and organisation of the EIA

study.



Chapter-2 Project Description

This chapter deals with the process and specifications of the project. This also deals with

the sources of pollution for the proposed project and proposed control measures.

Chapter-3 Description of the Environment

This chapter presents the methodology and findings of field studies undertaken w.r.t to

meteorology, ambient air, water, soils, noise, and ecology to define the existing

environmental status in the area. Details on land use, socio-economic and hydro-

geology which are presented from published secondary data.

Chapter-4 Anticipated Environmental Impacts

This chapter highlights the inferences drawn from the environmental impact assessment.

It describes the overall impact of the proposed integrated project and underscores the

areas where applicable environmental standards are expected to be violated. The

impact is assessed after considering both pre-project and post-project scenario.

Chapter- 5 Environmental Monitoring Program

The Environmental monitoring requirements for determining the efficiency of the

environmental protection and mitigation measures are delineated in this Chapter along

with required institutional arrangements for ensuring their implementation.

Chapter- 6 Additional Studies

This chapter describes studies carried out as per the specified TOR of the EIA. This

includes a Risk Assessment for the proposed unit along with Social-Economic study,

review of the Safety and Disaster Management Plan proposed for the proposed power

plant.

Chapter- 7 Project Benefits

This Chapter highlights the expected benefits of the proposed plant to the socio-

economic scenario in the study area and to the country as a whole.

Chapter -8 Environmental Management Plan

This Chapter consolidates the proposed and recommended environmental protection

and mitigation measures and the required institutional structure that ensures its proper

implementation during the construction as well as operational phase of the project.



The assessment will cover the baseline data generation, predictions and evaluation of

impact on various environmental components and preparation of adequate

Environmental Management Plan.

* * * * *



CHAPTER 2

PROJECT DISCRIPTION

2.1 INTRODUCTION

M/s Ugar Sugar Works Ltd.Ugar Khurd, Tal: Athani, Dist: Belgaum, State:

Karnataka have Proposed Expansion of Sugar cane crushing capacity

f rom 10000TCD to 20,000 TCD, Co-generation power plant f rom 44 MW to

75 MW & Molasses based Dist i l lery from 75 KLPD to 200 KLPD.



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

f inished goods can be convent ional ly handled. Total land available with

sugar factory is about 255 Acres. Bagasse is available from the sugar

plant wi l l be uti l ized as inputs in the proposed project. Land required for

the project is avai lable in the exist ing industry. Procurement of addit ional

land for the project is not needed. Water requirement wi l l be managed

within the avai lable l imits.

2.2 LOCATION OF THE PROJECT

M/s. Ugar Sugar Works Limited, Ugar khurd, Tal- Athani, Dist-Belgaum,

Karnataka. Survey nos.1, 1A, 45 A, 267, 267 A, 268,373, 376,

376A.Vil lage - Ugar Khurd, Tal - Athani, Dist-Belgaum, Karnataka

Table- 2.1 Salient features of site location

1. Project site M/s Ugar Sugar Works Ltd.Ugar Khurd, Tal:

Athani,Dist: Belgaum, State: Karnataka

2. Latitude & longitude Latitude : 160 38’ 58. 42” N

Longitude: 740 49’14. 34” E

3. Nearest town/city

Miraj City is 25 Kms away from factory site. The

Belgaum district headquarter is 100 kms away from the

site.

4. Nearest Highway

The National highway No.4 is 70 Kms from the

proposed site and state highway sankeshwar to Bijapur

is 10km away from the sugar factory

5. Nearest Railway Junction Ugar khurd Railway Station: 2 Kms. From the sugar

factory.

6. Nearest Airport Belgaum airport is 100 Kms from the factory site.



7. Topography

· The factory site has leveled area.

· The elevation of about 554 meter above the sea

level.

· Climate : Semi - arid

8. Surroundings · The site is 1 km from Krishna river.

Image 2.1: Google Earth image

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

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

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

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

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

resources such as raw materials, fuel, power, water, manpower, connectivity for



transportation of man and material, market for the product and more important is

environmental compatibility and sustainability.

2.3 COMPONENTS OF PROJECT

USWL proposes to enhance Proposed Expansion of Sugar cane crushing capacity from

10000 TCD to 20,000 TCD, Co-generation power plant from 44 MW to 75 MW &

Molasses based Distillery from 75 KLPD to 200 KLPD. At Ugar Khurd, Tal: Athani,Dist:

Belgaum, State: Karnataka. The raw material of sugar cane is available in the vicinity of

the project site and the bagasse will be used as fuel for cogeneration power plant. The

project involves:

a. SUGAR UNIT

Numbers of new sugar factories have increased in the nearby area of The Ugar Sugar

Works ltd., and also existing sugar plant expansions are taking place in the nearby area.

Hence the total cane crushing capacity is increasing in the same cane growing area,

which in turn reduces the duration of crushing days. To maintain the ultimate sugar

production target it is essential to increase the crushing capacity of USWL. At the same

time expansion of cogeneration and distillery is also essential to balance the by-

products. In this line of action management of ugar sugar have decided to go for Sugar

Plant expansion in phased manner. It is proposed to expand sugar plant capacity to

20000 TCD and cogeneration 75 MW.



The main activity of the company is to manufacture white crystal sugar, Electrical

power, ENA, ethanol & IML

The daily Sugar cane crushing capacity of the plant after expansion will be 20000 TCD,

which means the production as follows.

Table- 2.2 Capacity of Sugar unit

Product Production per Annum in MT

Maximum

Sugar cane crushing MT 27,00,000 to 30,00,000

Sugar in QT 31,05,000 to 34,50,000

Proposed Power Generation

During season 75 MW

Proposed power export 52 MW

The raw material for manufacturing the above is Sugarcane i.e. 25 to 30 lakh MT which

is sufficient for 120 to 150 days @ 20000 TCD. The productivity of the sugar cane &

yield depend on water supply & hence, the cane can be grown in & around the

Ugar. Which is on the bank of river Krishna, has full & sufficient irrigation facility. It is

expected that yield will be 40 to 50 MT per Acre with recovery of sugar as 11% to 12%.

b. CO-GEN POWER PLANT

The co-gen plant is configured keeping in view that the sugar factory operations & also

to meet peak steam & power requirement. The installed capacity of co-gen plant is 44

MW with 4 numbers of boilers having 310 TPH capacities @ 62 bar 490 deg C temp.



Image 2.2 for the entire Boilers Wet Scrubbers Are Provided and the Stack Heights Are Maintained As Per KSPCB Norms

Image 2.3: 22.8 MW x 2 Nos SHIN NIPPON Turbine (Back)



Image 2.4: 18 MW SIEMENS Turbine Extraction Cum Condensing)

Image 2.5: Cogeneration Plant Control Room



C. DISTILLERY

The factory started Distillery in the year 1963 & the present capacity of the distillery is 75

KLPD (30 KLPD batch type & 45 KLPD continuous types). Consisting of 20 KLPD

Ethanol Plant & 50 KLPD ENA Plant with blending & bottling of 9 different IML varieties.

The company has provided fully fledged effluent treatment plant which includes bio-

digesters, concentration & spray drying of spent wash, aerobic treatment of sugar factory

effluent etc.

There are two distilleries available with the USWL. One is of very old with the capacity of

30 KLPD and another one is of 45 KLPD. Total existing capacity is 75 KLPD. USWL is

having IML section also wherein bottling with their own brand are being manufactured.

There is a separate effluent treatment plant i.e. evaporation and drying effluent to the

recover potash powder is available with USWL.

Image2.6: Distil lery Plant No.2



2.4 PRODUCTS:

Table 2.3: List of product and by products

Product Particulars Maximum Quantity

A)Products

Existing Proposed

Activity

Sugar 10,000 TCD 20, 000 TCD

B) By products

Bagasses 3000 MT/Day 6000 MT/Day

Filter cake 400 MT/Day 800 MT/Day

Molasses 400 MT/Day 800 MT/Day

C) Co-generation Power 44 MW 75 MW

D) Distillery Spirit, IML, Absolute

alcohol, ENA 75 KLPD 200 KLPD

2.5 RAW MATERIAL:

Table2.4: List of raw material

RAW MATERIAL EXISTING PROPOSED

Cane 12,000 TCD 20,000 TCD

Lime 24 MT/day 40 MT/day( Rajasthan)

Sulphur 6 MT/day 10 MT/day.(Indian/Imported)

In Belgaum district where the plant is located, sugar cane is available from the month of

October to April even many times the season has to extend up to the end of May.

Typically, sugar cane availability is for a period of 7 to 8 months in a year. The registered

area under sugar cane cultivation allocated to Ugar Sugar Company is 60000 acres. The



important factor with regard to the operation of USWL is that the cane arrival is fairly

uniform and the plant reaches the maximum crushing rate within a month of season

commencement. The total cane availability during a season is approximately 40 Lakh

tonnes and most of it reaches the plant during the crushing season. But now, due to new

sugar plants installed in the nearby area, crushing season days have reduced from 8

months to 5 to 6 months.

2.6 Manufacturing Process:

The manufactur ing process of integrated sugar industry is given in below

given chart:

2.6.1 Sugar unit

The process of manufacturing involves the following steps:

I. Extraction of cane juice from cane

II. Purification of cane juice

III. Evaporation of cane juice to facilitates crystallisation

IV. Crystallisation of Sugar

V. Separation of sugar and liquid by Centrifugal force

VI. Re-Boiling of Liquid

VII. Drying

· Brief Description of The Above Process Steps Are Given Below:

24 M/s Ugar Sugar Works Ltd.Ugar Kh

Figure 2.1 Manufacturing process flow of integrated sugar industry

· The sugar industry is a chemical based industry, where different of process

involved in it .Sugar manufacturing process in brief is as under.

· The sugar cane received at the factory is weighed and then it i

with the help of cane unloader or tippler on the feeder table which is fed into the

cane carrier. The feed cane is passed through

cutter, cane levelers, fibrizer for fine participation. The prepared cane is f

through mill tandem for extraction of juice. The bagasse is removed from the last

mill in the mill tandem 95% juice is extracted with approximate 20% imbibitions

water % on cane and bagasse is send to boilers as fuel for steam production and

balance bagasse is sent for baling and storage.

Environmental Impact Assessment Report

M/s Ugar Sugar Works Ltd.Ugar Khurd, Tal: Athani, Dist: Belgaum

ring process flow of integrated sugar industry

The sugar industry is a chemical based industry, where different of process

involved in it .Sugar manufacturing process in brief is as under.

The sugar cane received at the factory is weighed and then it is unloaded either


cane carrier. The feed cane is passed through preparatory devices like cane

cutter, cane levelers, fibrizer for fine participation. The prepared cane is f




gasse is sent for baling and storage.

2014

urd, Tal: Athani, Dist: Belgaum

ring process flow of integrated sugar industry

The sugar industry is a chemical based industry, where different of process

s unloaded either


preparatory devices like cane

cutter, cane levelers, fibrizer for fine participation. The prepared cane is feed






· Extracted juice form mill tandem is called mixed juice or raw juice. The raw juice

is weighed by mass flow meter and then it is send to raw juice heater. Here the

juice is heated up to 70°C to 75°C temperature. After raw juice heating the

heated juice is sent to sulphitation tank to remove non sugar and coloring matter

by using SO gas and milk of lime (Ca (OH) ). This juice is called as sculptured

juice. This sculptured juice is heated up to 100°C to 105°C temperature and this

juice is clarifier for settling, in this process the muddy juice is sent to raw juice

tank for reprocess.

· The clear juice from clarifier is sent to evaporator bodies for further boiling. Here

the juice is concentrated up to 55-60 Brix. This concentrated juice is called

unsulphured. This unsulphured syrup is sent to sulphitation tank for bleaching by

SO gas. This sulphur is sent to pan section for crystallization process.

· On pan section three masscult boiling system is followed. A-masscult and B-

masscult. In the pan sulphur syrup is boiled and mixture of crystals and mother

liquor called as masscult prepared. This masscult is stored in crystallizer. Then it

is sent to centrifugal section through pug mill at centrifugal section, sugar crystals

and molasses are separated, final molasses is sent to storage tank and other

molasses is re-used in process. Sugar crystals are in wet condition, dried on

hoppers with hot and cold air blowers. Dried sugar crystals are separated grade

wise through sugar grader and graded sugar.

I. Extraction of Cane Juice from Cane

The cane which is brought from fields by carts/trucks/tractors, weighed and unloaded in

the cane carrier for extraction of juice from sugarcane. The unloaded cane will pass

through preparatory devices (Chopper, leveller and fibrizer). The preparatory devices will

cut the cane stalks into pieces.

The prepared cane enters mills consist of multiple units of three roller combination

through which the prepared cane. To aid in the extraction of juice spraying thin juice

from previous mills and water before last mill, directed on the blanket of Bagasse as it

emerges from each mill help to leach out the sugar.



Use of Bagasse

The residue that leaves the last mill is called bagasse contains un-extracted sugar,

woody fibre and water. The bagasse will be used as fuel to produce steam and power as

co-generation. The generated steam will be used to run turbines for power generation.

The outlet of the turbine i.e., low pressure steam will be used for mill juice processing.

The condensed water will be sent back to boiler for steam generation during crushing

season.

II. Purification of Cane Juice – Clarification

The extracted juice from mills is strained to remove bagasse particles before sending for

process. This juice is sent through a mass flow meter and the quantity automatically

recorded. The dark green juice from mills is acidic and turbid. The universal process

employed to remove both soluble and insoluble impurities is called Sulphitation process.

The juice will be heated up to 70oC to 75oC to avoid inversion. In sugar plant as a

measure of steam economy primary heating will be done by tubular heat exchanger

using heat energy available from the condensates of evaporators and pans.

III. Evaporation

The clarified juice obtained in the clarifiers constitutes 75% water. The first stage of

concentration is carried out in equipment called the evaporator, which operates

continuously. The evaporator consists of five bodies, connected in series so that the

juice undergoes progressive concentration from the first effect to the last effect to

evaporate 75% of water which is present in the juice; for that we require steam, hence

exhaust steam from turbines at a pressure of 1.5 kg/cm2 at 125oCwill be fed to the effect

of evaporator. Subsequently due to the evaporation of the water in the first effect will

yield the same amount of vapour, which will be fed to the succeeding bodies. Due to the

difference in the pressure and the vacuum in the bodies the evaporation of juice will

takes place in all the evaporators. Initially clarified juice will have a brix of 14-160C,

reaching 55-60oC Brix from the outlet of the V body. This syrup is passed through a

tower consists of absorption of the SO2 (Sulphurdioxide) by the syrup, lowering its

original pH from 6.4 -6.8 to 4.6 -5.2. The water vapour generated from 1st evaporator will



be used in subsequent bodies and the generated condensate will be utilised for cane

juice extraction at mills, muddy juice filtration at vacuum filters, milk of lime preparation,

pan washing and centrifuge. The excess condensate will be cooled and used for plant

utilities and on land irrigation.

IV. Crystallization

Crystallization takes place in single effect vacuum pan. The syrup obtained from the

evaporator will be boiled until saturated with sugar. At this point “seed grain” is added to

serve as nuclei for the sugar crystals and more syrup is added as the water evaporates.

Continuing the above process the pans are filled up till the desire size crystals are built

up and dropped in mixers called crystallizers. The sugar and syrup forms a dense mass

known as Massecuite.

V. Separation of sugar and liquid by centrifugal force

From the crystallizers, the massecuite will be cured in the centrifugal machines. In

centrifugals the sugar and molasses will be separated. In centrifugals there are two

types of machines

I. Continuous centrifugal Machines

II. Batch Type centrifugal machine

The continuous centrifugal machines will be used for low grade massecuites like B and

C Massecuites. The separated molasses will be taken back to the process for extracting

the dissolved sugar which is present in molasses. The separated sugar having low purity

is made as a magma minglers and it will be melted in the sugar melter and will be taken

back to the A massecuite boiling. High grade massecuite i.e., A- Massecuite will be

cured in the batchtype centrifugals. The sugar discharged from the batch centrifugal has

a high moisture level with temperature of around 60 to 65 degree centigrade.

VII. Drying

The separated sugar from ‘A’ centrifugals cooling and drying of the sugar is carried out in

a multi tray hopper, in the hopper the cold and hot air will be pass in co-current direction

to bring down the moisture and temperature of the marketable sugar. From the drier, the


sugar passes through grader where the separation of sugar of various grades depending

on the size and colour like: L-30, M

sugar will be collected in bins. The

weighing scale, stitched and will be sent to the sugar godown. Sugar is stored in 50 kg

PP bags and 50kgs “A” twill gunny bags in sugar godown.

2.6.2 COGENERATION POWER PLANT BRIEF DESCRIPTION OF PROCESS

USWL proposes to implement the Cogeneration of 75 MW power plant by installation of

50 TPH to 55 TPH and temp up-gradation from 380 to 500 deg C. The scheme of Co

generation is designed to operate plant at the rated capacity of 20000 TCD.

Fig 2.2: Manufacturing process of Cogen power plant

Selection of Pressure and Temperature for the proposed Cogeneration Power

Cycle




30, M-30, S-30 and SS-31 will takes place. The graded

sugar will be collected in bins. The sugar from the bins will be weighed in automatic


PP bags and 50kgs “A” twill gunny bags in sugar godown.

COGENERATION POWER PLANT BRIEF DESCRIPTION OF PROCESS


gradation from 380 to 500 deg C. The scheme of Co

generation is designed to operate plant at the rated capacity of 20000 TCD.

cturing process of Cogen power plant


2014



31 will takes place. The graded

sugar from the bins will be weighed in automatic


COGENERATION POWER PLANT BRIEF DESCRIPTION OF PROCESS


gradation from 380 to 500 deg C. The scheme of Co-




While going for Sugar Unit of 20000 TCD, the factory has proposed 50 TPH to 55 TPH

and temp up-gradation from 380 to 500 deg C. The adaptation of pressure and

temperature are very suitable for obtaining the maximum power generation for proved

technology available for bagasse based cogeneration. Therefore, while implementation

of the cogeneration project; the parameters adopted shall be based on minimum 45 ata

pressure and 450C temperature of the boilers. Further, various parameters viz. optimum

cycle efficiency, metallurgy of pressure parts, standard range of turbine, operability,

maintainability and working performance of similar bagasse based cogeneration plants

recently commissioned have been taken into account

Operation of the Cogeneration Plant during Crushing Season


50 TPH to 55 TPH and temp up-gradation from 380 to 500 deg C. The scheme of Co-

generation is designed to operate plant at the rated capacity of 20000 TCD.The steam

balance, Bagasse balance and Power balance during the season operation of the

Cogeneration Plant are described as below

I. Steam Balance

Fig. 2.3: Steam balance non crushing season flow sheet

Bagasse 40.82 TPH

110 ata

540 Degree C

Steam at 2.5 ata Steam at 0.1 ata for

condenser

Steam at 8 ata

for Dist & SSP

& HP heater

12.04 TPH 61.11 TPH 26.35 TPH

100 TPH



Fig 2.4: PROPOSED STEAM BALANCE

130

Bagasse Production 254.55 TPH

Bagasse Saving 46.72 TPH

140 TPH 110 ata

22.8 MW SNM 1 Turbine

New DEC 22 MW TG

Sugar process @ 8 ata-13.64 Tph

HP heater @ 8 ata-15.55 Tph

Distillery @ 8 ata 25 TPH

12 MW Turbine

Sugar process @ 2.5 ata 363.64 TPH

1 x 55 TPH, 32 ata

& 480 Deg C

130 TPH

50 TPH 130.48 TPH

207.83 TPH

46.72 TPH

22.72 TPH 53.25 TPH

115 TPH

80 TPH

70 TPH @ 2.5 ata

Condenser 15 TPH

48 TPH

22.8 MW SNM 2Turbine

PRDS

80 TPH

15 TPH 15 TPH

115 TPH

310 TPH, 62 ata

131.81 TPH

290 TPH

DS

1.19Tp

DS

6.1Tph



II. Bagasse Balance

Fig 2.5: PROPOSED BAGASSE BALANCE

Crushing per day 20000 TPD

Average Cane Crushed 909 TPH

909 TPH Bagasse Production

(At 29%) 263.6 TPH

263.6 TPH

Bagasse for Oliver filter & Spillage

(Losses at 1%) 9.09 TPH

254.5 TPH

Bagasse required for Old Boiler to generate steam – 22.72 TPH

Bagasse required for other boilers to generate Steam – 131.81 TPH

Bagasse required for new boiler – 53.25 TPH

46.72 TPH Bagasse Saving per Hour 46.72 TPH



III. Power Balance

Fig 2.6: PROPOSED POWER BALANCE

Power export

v Total power generation: 52 MW

2.6.3 DISTILLARY

I. FERMENTATION SECTION:

In Fermentation process, fermentable sugars in juice/syrup/molasses are converted into

ethanol. This reaction is carried out by the yeast. This is basically metabolic activity of

yeast which converts sugar into ethanol. During the reaction Carbon-di-oxide is also

POWER GENERATION

From SNM TG Set – 44 MW

From New TG Set – 11.75 MW

From New DEC TG Set – 19.25 MW

POWER CONSUMPTION

Captive for Sugar Plant –17.55 MW

Captive for Cogen Plant –5.45 MW

EXPORTABLE POWER to

Grid – 52. MW

52. MW

75 MW


generated which is vented into atmosphere after scrub

loss.

Fig 2.7: Flow sheet of Distillery Process



generated which is vented into atmosphere after scrubbing with water to prevent alcohol

Fig 2.7: Flow sheet of Distillery Process

2014


bing with water to prevent alcohol



Being a exothermic reaction, heat is generated during the production of alcohol. To

maintain the Fomenter temperature constant, this heat is removed by means of external

cooling system arrangement. This system consists of Plate Heat Exchanger (PHE)

through which fermented wash is continuously recirculated by Recirculation Pumps and

heat is removed by cooling water passing through the PHE.

Air Spargers are provided in the fermenters to provide air (Oxygen) supply to the

growing yeast cells. Provision of air supply to fermenters is always better to keep yeast

cells active all the time. The air supply is regulated through flowmeters provided to each

fermenters. It also ensures suspension of the mass. Agiataors are also provided to keep

entire mass in suspension and proper mixing to have uniform temperature throughtout

the fermenter.

Fermentation System is designed to operate on both the modes

1) Continuous Fermentation

2) Batch fermentation

Depending upon the feed quality mode of operation can be selected. Yeast culturing &

prefermentation system provides active cell mass to fermenters for each batch of

fermenter or when required for continuous fermentation.

Wash Clarification System provided is exhaustive, comprising of Wash Settling Tank,

Sludge Settling Tank & Decanter removes sludge effectively from fermented wash. Clear

Fermented wash is stored in Beer well and continuously fed to distillation.

II. DISTILLATION SECTION:

WASH TO RECTIFIED SPIRIT

Multi pressure vacuum Distillation:



The system comprises of 4 columns operating under different pressures and is designed

to produce Rectified Spirit either in liquid or vapor form.

Following columns are considered.

1. Analyzer Column – under vacuum

2. Degasifying Column – under vacuum

2. Aldehyde Column- under vacuum

3. Rectification cum Exhaust Column- under pressure

Fermented Wash from Beer Well is first passed through Beer Heater, then to

Degasifying Column top through wash Preheater where is it is heated by spent wash

from Analyser Column bottom.

Degasser Column :

In Degasser column, non condensables like CO2 and low boiling impurities are

separated and fed to Aldehyde column in the form of vapors.

Analyser Column :

From fermented wash coming down from Degasser column alcohol is stripped off and

vapors from the Analyser top are condensed in the condensers. This condensate is fed

to Rectifier Column. Spent wash is taken out from the column bottom.

Heat is supplied to the column by rectifiers vapors through reboiler.

Aldehyde Column:

In aldehyde column, the noncondensables & low boiling impurities are concentrated and

taken out as Impure Cut from the top.

Remaining alcohol water mixture from the bottom is fed to Rectifier Column.

Rectifier cum Exhaust Column:

Liquid streams from two columns i.e. Analyzer condensate & Aldehyde bottoms are fed

to the Rectifier Column. In Rectifier column alcohol is concentrated at the top. Heavy &

Light Fusel oils are taken out from the tapping provided to this column. Spent Lees is

taken out from the bottom of the column.



Rectified Spirit is taken out from the tray which is few trays below the top tray.

Here additional provision is kept for taking out direct vapors to MSDH section for

production of ethanol.

Other Equipments:

Other equipments like Condensers, Coolers, Pumps, PHE, Vapor-Liquid Separator etc

are provided as per process requirement.

III. MOLECULAR SIEVE DEHYDRATION SYSTEM

This is basically adsorption operation where water from Rectified Spirit is removed by

molecular sieves (size – 3A).

This section can be operated in two modes

1) As Stand-alone – Ethanol production from RS in liquid form

2) Integrated – Ethanol production from RS vapors from Rectifier Column in

distillation section.

In first mode RS is fed to Evaporation column where it is vaporized.

Either these vapors or vapors from Rectifier Column are first superheated in

Superheater and fed to Molecular Sieve beds filled with molecular sieve and support

balls.

Molecular Sieve Beds (2 Nos) System

This beds operates on Pressure Swing Adsorption operation. Out of two, one bed

operates as Active (Adsorption) bed where water from RS is adsorbed by the molecular

sieve and dry ethanol is produced. At the same time another bed is in regeneration

(Disorption) mode where adsorbed water is removed from the bed. These beds operates

in cycles which are entirely controlled by the control system provided. The liquid



removed from beds contains alcohol in low concentration which is recycled back to

column.

The heat of ethanol vapor produced is used to preheat the regeneration liquid (low

strength alcohol) and the RS feed. Then the ethanol is cooled and sent to storage.

IV. BIO-METHANATION

The effluent from distillery unit is received into a receiving tank (Two day holding

capacity), where it is allowed to settle for 48 hrs. Suspended solids settled in this tank

can be removed from time to time, and clear effluent is pumped to bio digester.

The effluent after getting mixed with recycled biomass from Lamella Clarifier to maintain

a feed temperature of 36-380C is fed in to the digester. The feed rate is controlled by a

manual control valve and a flow meter provided in the feed line and the sludge recycling

line.

In the digester the effluent mixed with the recycled biomass from the Lamella Clarifier

gets further mixed with contents of the digester with the help of Central and Lateral

agitators, which provide homogeneous mixing in the digester. The digester has about

14-15 days retention capacity. Anaerobic digestion takes place in the Digester, as a

result of which BOD/COD is reduced and biogas is evolved.

The digested effluent/biomass mixture overflow into a degassing pond where entrapped

gases are released. Degassed effluent flows to Lamella Clarifier for separation of active

biomass from outgoing treated effluent.

The clarified effluent leaves the Lamella Clarifier for disposal or to secondary effluent

treatment plant, while the separated biomass is pumped back continuously into the

Digester. The excess biomass is removed form the bottom of digester regularly to

sludge during beds for disposal, or to be used as farm manure.

The biogas produced in the Digester accumulates in digester roof, from where it flows to

the gasholder. The gasholder acts as intermediate gas storage as well as a Pressure

Control Vessel (PCV).

The biogas is pumped to the boiler house by a biogas blower. Surplus gas, if any, is

burnt in a gas flare unit whenever gas is not being utilised in the boiler.



‘Flame Arresters’ are provided in gas lines to protect the digester from backfire from the

flare and/or the boiler burner. ‘Over/Under’ pressure release device is provided on

biogas digester for its safety from over pressure/v

2.7 UTILITIES

Utilities will be provided for smooth and efficient functioning of the enhanced project of

20000 TCD Sugar Unit and 75 MW Cogeneration Plant.

In addition to raw material and product details, utilities like Land, water, power etc. also

the essential aspects, which are discussed in below given sections:

A) Water

The Continuous fermentation based 200 KLPD Ethanol Plant with multi-product

integrated project requires water maximum to 14130m3/day. Company would be drawing

water from Krishna River. Sufficient water storage facility will be created for uninterrupted

water supply. USWL has obtained the requisite permission from State Govt. for lifting of

water.

To achieve better efficiency and to maintain the plant and machinery in good condition, it

is necessary to have proper water treatment system. Raw water will be treated in water

treatment unit before using it for the process. Cooling tower make-up water will be used

after treatment in a water-softening unit. By having proper water supply system as clear

water pump etc. the Ethanol Plant can have good water supply arrangements.

B) Land Requirement

The project is identified in a non-agricultural revenue land of 50 acre. The Land Use

break up is given in the following:



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

total area of 50 acre.

Table 2.5: Land Use Break up of Project Area

S. No. Description In Square meters

1. Built Up Area 1150

2. Vacant / open land 625

3. Area for Green Belt 200000

Total Area 201775

The detailed layout plant is given as f igure 2.8.



Fig 2.8: Plant Layout



C) FUEL:

Fuel requirement is mainly for generat ion of steam in the boiler.

Bagasse generated from the Sugar Plant and it wi l l be used as fuel for

operation of the boi ler. The fuel character ist ics are given as under:-

Table 2.6: Characteristics of Bagasse

S.No. Particulars Value

1 Calorif ic Value 4400 Kcal/kg (dry)

2250 Kcal/kg (wet)

2 Moisture content 45 – 55%

3 Ash Content 2 – 10 %

4 In sugar mill the crushed cane forms

bagasse 27 -32%

Table2.7: Characteristics of Diesel Fuel (IS: 1448)

S.No. Particulars Value

1. Acidity Nil

2. Ash%, by mass 0.01

3. Carbon residue %, by mass 0.30

4. Pour point, Max 030C for winter, 150C

for summer

5. Flash point 350C

6. Kinematic Viscosity, cSt at 40C 2.5-5.0

7. Sediment %, by mass (max) 0.05

8. Sulphur content by mass (max.) 0.05%



9. Water content, % by volume, Max. 0.05

D) DETAILS OF MACHINERY

Table2.8: Sugar Plant Machinery

Mill Section

S.No. Description of Equipment

1 Cane loader

2 Cane unloader

3 Feeder table

4 First cane carr ier

5 Cane chopper

6 Cane level ler

7 Swing Hammer Fibrizer

8 Rake type carr ier

9 Belt conveyor with tramp iron separator

10 Cane equalizer

11 Intermediate Rake carr ier

12 Mil l ing Plant

13 Mil l house Crane

14 Belt Conveyor

15 Rake type bagasse elevator

16 Lubrication System

17 Juice Tray



18 Donnelly Chute

19 Pumps

20 Lubricants for Mil l House Package

21 Rotary screen juice

Table2.9: Boiling House Machinery:

S.No. Particulars

1. Raw juice

2 Juice heaters

3 Juice sulphitor

4 Sulphur burner

5 Air blowers

6 Milk of l ime preparation

7 Juice clar if ier

8 Vacuum f il ter

9 Evaporator Quintuple

10 Syrup sulphitor

11 Syrup & molasses storage tanks

12 Batch type & Cont inuous vacuum pans

13 Crystal l izers

14 Condensers and injection pump station

15 Sugar melter



16 Sugar drying

17 Mild steel fabricated vapour pipe

18 Insulation

E) MAN POWER REQUIREMENT / EMPLOYMENT

The total number of employees (including off ice staff and contract

labour) wi l l be 1800 nos. (Permanent, seasonal & temporary).

F) PROJECT COST

The total project cost is estimated Rs.38367.48 lakhs; out of this Rs.

199 Crs are proposed for expansion.

G) BUILDING MATERIALS

The majority of construct ion work is in fabricat ion f rom Mild steel

structural. The or ientat ion is so kept as to balance near ly the cutt ing and

f i l l ing. The small requirements are avai lable systemat ical ly. The

construct ion –erect ion t ime wil l be smal l and wil l be done in day t ime.

Labour camp is not necessary.

2.8 CASCADING POLLUTION

There wil l not be any signif icant pol lut ion during the construction

phase. Adequate provisions wil l be made available during operat ional

phase.

2.8.1 AIR

Air quality around the project site will not be impacted dur ing

construction phase.

Further to minimize any impact fol lowing measures shall be taken:



Ø The raw material handling wil l be located as per the predominant

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

from the site wil l be primari ly contained within the construction

si te only.

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

generate minimum air born dust.

Ø Al l the loose material either stacked or transport wil l be provided

with sui table covering such as tarpaulin, etc.

Ø Water sprinkl ing wil l be done at the locations where dust

generation is anticipated.

Ø To minimize the occupat ional health hazard, proper personal

protective gears i .e. mask wil l be provided to the workers who

are engaged in dust generation activity.

Emission Control Equipments (ECE)

The air pollut ion caused by this industry is mainly from dust as

suspended part iculate matter (SPM) from Cogenerat ion power plant –

boi lers and fuel of diesel generat ing set (DG set).

USWL knows from which unit operat ion or process, air pol lutants are

expected. For the purpose of arresting and captur ing the pollutants,

measures are proposed and designed. The detai led note on Design

basis of boi lers along with f low sheet is enclosed as Annexure 13 &

14.

Sources of Air Pollutants

1. Boiler

The industry have proposes to cont inue the efforts of air pol lut ion

control and remain inside the limits.

Table no. 2.10 Existing Emission details

Source of Air pollution

Type of fuel Quantity of fuel

Height APC equipment



MYS 1736 50TPH

Bagasse 25 T/hr. 45.5 mtr Wet Scrubber

MR 8597 MR 8598 60TPH

Bagasse 60 T/hr 60 mtr. Wet Scrubber

KTK 2272 70TPH

Bagasse + coal

35 T/hr 50 mtr. ESP

KTK 2404 80TPH

Bagasse 40 T/hr 52 mtr. ESP

12 TPH Boiler Biogas &

Furnace oil 800 kg/hr 52 mtr. -

DG sets

1000KVA * 2 nos. HSD 230 Ltr/hr 12 mtr. -

2000KVA HSD 375 Ltr/hr 12 mtr. -

5 KVA * 2 nos. HSD 60 Ltr/hr & 80 Ltr/hr

12 mtr. -

The material of construct ion is RCC and shape is round. Adequate

facil i ty for collect ion of samples in the forms of ladder, platform, and

port-hole etc. is provided.

The industry also proposed the 2 nos.* 35TPH of slop f ired travel grate

incinerat ion boiler with ESP faci l ity.

2. Burning of fuel in standby DG set

Fugitive

# Source Pollutant In-plant

Measures

Control Equipment

1 Standby DG

set

SO2 Feed low

sulphur diesel

-

2 Process HCl Close container Fume hood vents

shal l be provided

with scrubber system



A number of mit igation measures wil l be taken to control fugit ive

emissions, the presence of which wi ll be noticeable by plain vision if

not controlled. The measures are thus taken seriously and

continuously such as:

Ø Rubber wheel carts / trucks to bring in raw materials wil l not be

f i l led high, side’s cladded, slow speed travel, avoiding vibrat ions

en-route.

Ø Engineering the plant layout wil l be in such a way so as to

vi rtual ly el iminate need of using heavy equipment for material

handl ing.

Ø Tree plantation on surrounding available area.

Ø The industry proposes to continue the efforts of air pol lution

control and remain inside the l imits.

2.8.2 WATER and WASTE WATER

There wil l not be any signif icant pol lution during the construct ion &

Operat ion phase as the development wi l l take place in exist ing building

structure. Adequate provisions wil l be made available to col lect the

runoff f rom the site, so that runoff wil l not be allowed to stand or enter

into the roadside or nearby drain.

Raw Water

The water used for the USWL plant wil l be supplied by Irr igat ion

department. The water wil l be treated ful ly to standard character ist ics.

The samples wi l l be tested & conf irmed. The details of required water

are given in table no. 2.7.

Table no. 2.11 Water Consumption (m3/day)

Sr. no. Existing capacity

Proposed capacity

1 Sugar Factory 2592 6600

2 Co-generation 2433 2388



3 Domestic 1920 2332

4 Distillery 1155 3000

Total 8100 14310

Disposal

Total ef f luent generated during the operation wil l be about 4960

M3/day from sugar & cogen unit. An eff luent treatment plant has been

provided which is cont inuously in operat ion and the results obtained

wil l be within the permissible l imits as prescribed by KSPCB.

Table no. 2.12 Waste water generation (m3/day)

Sr. no. Existing capacity

Proposed capacity

1 Sugar Factory 1000 2000

2 Co-generation 174 -

3 Domestic 500 500

4 Spent leese 250 960

5 Condensate - 1500

5 Distillery 900 3000

Presently, the sugar and cogenerat ion waste water are disposed

through 1750 m3/day capacity of full f ledge Eff luent treatment plant

and for dist i l lery waste water i.e. 900 m3/day are disposed through

closed biomethanation system (RCC digesters 4 nos.) as a primary

treatment. Bio gas is being used for Hot Air generator or Package

/55TPH Boi lers. After biomethanat ion eff luent fol lowed by Evaporator &

Dryer Plant to generate powder i e Zero Pollut ion.



For proposed expansion, the total quant ity of waste water wi l l be

generat ing from sugar and cogen unit is 4950m3/day and same will be

disposed through combined ETP & send for irr igation. In dist i l lery, out

of 2400 M3/day the 900 M3/day eff luent wil l send for closed

biomethanat ion system (RCC digesters 4 nos.) & one MS digester.

Total 5 No.digesters,as a primary treatment. The generated Bio gas is

being used for Hot Air generator & Package /55 TPH Boilers.

The Eff luent 1500 M3/day, wil l be treated in Evaporat ion &

concentration & the slop wil l be burnt along with bagasse in Cheema

Boilers 2 Nos. Condensate wil l be treated in combined ETP & send for

irr igat ion.

Brief ly:

Ø For exist ing sugar factory & domestic eff luent have been treated

in combined ETP, equalizat ion tank fol lowed by aeration system

where diffused aeration system is provided, followed by pr imary

clarif iers and secondary clarif iers, fol lowed by di lut ion with low

pollutant and cooling tower, over f low & f inal treated eff luent

with less than 100mg/l BOD is being sent for irr igat ion.

Ø For proposed sugar factory & domestic eff luent being treated in

combined ETP, Anaerobic lagoon followed by equalization tank

fol lowed by aerat ion system where diffused aerat ion system is

provided, fol lowed by primary clar if iers and secondary clar if iers,

fol lowed by di lut ion with low pollutant and cooling tower, over

f low & f inal treated eff luent with less than 100mg/l BOD is being

sent for irr igat ion.

Ø For exist ing dist i l lery, the waste water quantity is being sent to

biomethantion unit (bio-digesters) fol lowed by evaporat ion &

drying i .e. Zero pollut ion. Spent less is treated into combined

ETP.

Ø For proposed disti l lery, addit ional evaporation systems followed

by Chima boilers wi l l be instal led to achieve the zero pollut ion.



There wil l be no discharge of ef f luent outside. The detai led note on

ETP along with f low sheet is enclosed as Annexure 17 & 18.

Mitigation measures

As addit ional mit igat ion measures, USWL proposes to take-up

fol lowing measures:

Ø To spread awareness to the workers about the importance of

water quantity measurements and resource conservation.

Ø The treated domest ic waste water wil l be applied judiciously on

land for gardening so that there wil l not be any f looding of

excess water either to migrate to ground water table or get away

as runoff to join surface water drains.

Ø The industrial waste water is subjected to thermal treatment

result ing in hazardous sol id waste being sent to CHWTSDF &

evaporating the moisture.

2.8.3 SOLID WASTE

Minimum amount of sol id waste wil l be generated as there wi l l be

construction work. Following mit igat ion practice is the pol icy for future:

Ø Minimization at all levels need be attempted for discarded

products, empty containers, packing surpluses, incoming raw

material unloading spil lages and fugit ives.

Ø The sol id in process generate only as Ash from cogeneration

plant, ETP sludge and domestic waste.

Ø Other wi l l be empty drums which can be used for ref i l l or may be

disposed to original vendors

The solid waste generation from Sugar and dist i l lery units are

tabulated in table 2.13.

Table 2.13 Solid Waste Generation from Sugar Plant with disposal



Source Quantity Treatment & Disposal

CANE CRUSHING SEASON

Mill House Bagasse – 6000

T/day

Use in Boiler of Cogen plant

Process House Press Mud – 800

T/day

Disposed to Dist i l lery units by

product ion of potash powder

fert i l iser.

Boiler House –

Cogen Plant

Ash – 200 T/day The ash being r ich in nutr ient

composit ion, the same will be

disposed as fert i l izer for soi l

condit ioning.

Eff luent

treatment Plant

Sludge – 80-100

T/day

Disposed as Manure.

Evaporator &

Dryer plant

powder

10-12 MT/day Sold to farmers & fert i l izer

companies as a manure

2.8.4 NOISE

Mitigation measures:

During the construction stage, expected noise levels shall be in the

range of 75-80 dB. Al l the construction act ivit ies shal l be carried out

during the dayt ime. To prevent any occupational hazard, ear muff / ear

plug wil l be given to the workers working around or operat ing plant and

machinery emitt ing high noise levels. Use of such plant or machinery

wil l not be al lowed during night hour. Careful planning of machinery

operation and scheduling of operat ions shall be done to minimize such

impact.



No signif icant amount of noise wil l be generated during the operat ion

phase.

2.9 Mitigation Measures (Brief)

Every human act ivity creates some side-effects. This can make

signif icant adverse impact if lef t unattended. It is proposed to reduce

the impact by prevention, abatement and control and mit igation

mechanism. These are described in detai ls later in Chapter Four. Brief

resume can be indicated as fol lows.

Table no. 2.14 Mitigation measures

# Facets of

Environment

Mitigation & Impact Thereafter

1. Air The emissions from Boiler only. DG Set as stand by. Stack

attached to wet scrubber boiler and ESP boiler with 45.5 mtr,

60 mtr and meter & 50 mtr & 52 mtr heights respectively

provided as per the pollution control board guideline. The

CO2 from fermentation will be converted to liquid CO2. The

effluent treatment will be fully aerobic.

2. Fugitive Internal roads paved, leveled, no undulations, no sharp

curves, slow speed. Press-mud, compost yard and compost

not involved. Tree plantation on surrounding available area.

3. Water and

Waste Water

The waste water generated will be treated through methane

bio-digester and evaporators. Spent wash will be converted

to Fuel and moderate will be treated aerobically with disposal

on seed/ demonstration plot or recycled.

4. Solid Waste Collection 100% every day. Segregated and treated/

disposed per SPCB norms.



5. Odour Limited source of odour. Controlled by keeping closed

regime during initial treatment. Use of heat exchanger for

cooling. Small capacity ETP for moderate and sober BOD

effluent will be aerobic and away with a barrier. No cess

pools in disposal area. Bio-digester is fully covered.

6. Noise Smooth roads, sturdy foundation and No Vibrations. Acoustic

enclosures to all DG Set as per manufacturers’ design. Use

as standby only. Trees are planted around. Side cladding.

Large No. of tree barriers. Factory placed away from

boundary.

2.10 CHAPTER CONCLUSION

After introducing the subject of study in Chapter One, in this Chapter

Two addit ional points are covered. Type of the project is underl ined.

The locat ion is described after ment ioning what cr iter ia of select ion

were kept before eyes. The Process is ful ly described and it may be

seen that best environmental opt ion is selected. Al l alternatives having

considered, i t is seen that “No Project” opt ion or abandoning the

project is not proper.

* * * * *



CHAPTER 3

DESCRIPTION OF THE ENVIRONMENT



3.1 Introduction:

Information is first assembled for the Region-District and then narrowed down to

10 km radius with the Project as Centre. In both the areas, both the components

of Environment (i.e. Natural and Man-made) are covered. The baseline

environmental quality has been assessed as per the TOR and all the studies

have been conducted from month of September 2013 to November 2013. The

standard methodology is adopted and discussed in this chapter.

Table No.3.1: Summary of Sampling

All the samples were collected by Standard Practices and analyzed as per Indian

Standard Specifications or by APHA (USA).

3.2.1 Materials:

The work involves three activities viz. (1) collection of dry data and statistics by

literature survey, interviewing resource institutes and general public, (2) wet

studies by sampling and laboratory analysis of ambient air, surface water, ground

water, noise, soil, etc. and (3) logically analyzing the findings of dry and wet

studies for interpretation, extrapolation and inference.

No. Media Stations Parameters Frequency

1 Surface Water 2 26 1

2 Ground Water 3 21 1

3 Ambient Air 6 12 Twice a week

4 Ambient Noise 5 2 1

5 Soil Study 4 12 1



A number of officers/offices were contacted in the course of this study. Samples

were collected in the month of September 2013 to November 2013; as follows,

vide Table No.3.1

3.2.2 Approach For a streamline work, a standard six-step model of working is adopted for this

Project study. The six generic steps associated with environment impacts are:

(1) Identification of pollutant emissions and impact concerns related to the

construction and operation of the development project,

(2) Description of the environmental setting in terms of existing environmental

quality, emission inventory, and natural data in the project study area,

(3) Procurement of relevant laws, regulations or criteria related to environmental

quality and/or pollution emission effluent standards,

(4) Conduction of impact prediction activities, including the use of simple dilution

calculations, qualitative predictions based on case study and professional

judgments.

(5) Use of pertinent information from step 3, along with professional judgment

and public input to assess the significance of anticipated beneficial/ detrimental

impacts, and

(6) Identification, development and incorporation of appropriate mitigation

measures for the adverse impacts.

3.3 The Region

The base line data has been collected within the 10 km radius surrounding the

project site of M/s. Ugar Sugar Works Ltd. Ugar Khurd. The Google image of the

study area showing 5 Km & 10 km radius area is given below as Image - 3.1.



Belgaum district is a district in the state of Karnataka, India. The city

of Belgaum is the district headquarters in North Karnataka. According to the 2011

Census of India, it has a population of 4,778,439 of which 24.03% live in urban

areas.

Image- 3.1 Google Image showing project site and 10km circle considering

project site at centre

3.3.1 Geographical Location and area The district of Belgaum is located east of the Western Ghats and is situated in

the northwestern part of Karnataka state. It is bordered by the state of Goa on its

southwest and Maharashtra state towards its west and north. The districts of

Bijapur and Bagalkot of Karnataka state lie towards its northeast and east

respectively whereas; the districts of Dharwar and Uttar Kanara lie towards its



south and southwest, respectively (Figure-1). The district lies between 15°00’

and 17°00’ north latitudes and between 74°00 and 75°30’ east longitudes. It

covers an area of 13,444 Sq. Km.

3.3.2 Physical Setting The state is situated in the Deccan Plateau and is bordered by the Arabian Sea

to the west, Goa to the northwest, Maharashtra to the north, Andhra Pradesh to

the east, Tamil Nadu to the east and southeast, and Kerala to the southwest. It is

situated at the angle where the Western Ghats and Eastern Ghats of South India

converge into the Nilgiri Hills. The state has three principal physical zones:

The coastal strip, between the Western Ghats and the Arabian Sea, which is

lowland, with moderate to high rainfall levels. This strip is around 320 km in

length and 48-64 km wide.

The Western Ghats, a mountain range inland from the Arabian Sea, rising to

about 900 m average height, and with moderate to high rainfall levels.

The Deccan Plateau, comprising the main inland region of the state, which is

drier and verging on the semi-arid. The humidity in these plains or maidans never

exceeds 50%.

3.3.3 Water Phase of Environment: 3.3.3.1 Rivers

The entire district falls in the Krishna river basin except small catchments of

Khanapur, Belgaum and Bailhongal taluks that fall in the catchments of Mahadayi

and Kalinadi rivers that flow towards the west. The river Krishna, along with its

tributaries Ghataprabha and Malaprabha are perennial and effluent in nature and

flow in easterly direction. The drainage density varies from 0.80 to 3.4km/sq.km

3.3.3.2 Irrigation in Belgaum District

The district has registered 1,73,684 irrigation pump sets out of which 173,452 are

electrified. Lift irrigation pumps are mostly located in the vicinity of the rivers, thus

providing surface water irrigation. Canals also contribute substantially to



irrigation. Out of the total irrigated area, about 50% is being irrigated by ground

water sources alone. The area irrigated by surface and ground water resources

is 3,72,497 hectares which is about 44% of the net sown area. Irrigation by the

ground water resources alone covers an area of 1,86,126 hectares, which is

about 22% of the ‘Net sown’ area.

3.4 Meteorology

Micro-meteorological data within the study area during the air quality survey period

is an indispensable part of air pollution studies as the micro-meteorological

parameters regulate the transport and diffusion of pollutants released into the

atmosphere. The meteorological data recorded during the monitoring period is

useful for the interpretation of the baseline condition and it can be compared with

the historical data in order to identify changes, which may have taken place in the

area.

3.3.1 Secondary Meteorological Data

The secondary data w.r.t. wind speed, wind direction, Special weather

phenomena, Temperature, Relative humidity and Rainfall collected from

climatological table of IMD, Pune for Miraj (Sangli) station, which is nearby

factory site than the Belgaum station and the same is presented in the below

given tables.

Table: 3.2 Mean Wind Speed

Month Mean Wind Speed

Km/Hour

January 7.4

February 7.7

March 8.9

April 10.6



May 14.2

June 16.3

July 18.0

August 15.4

September 12.2

October 8.4

November 8.5

December 8.4

Annual 11.3

Winds are light to moderate except in the south-west monsoon season when

they are stronger. In the south-west monsoon season, winds are from directions

between south-west and north-west, the westerlies being more frequent. In the

post-monsoon season they are predominantly from the north-east or east.

Easterlies and south-easterlies are common in the cold season. By February

westerlies and north-westerlies appear and these predominate in the summer.

Table: 3.2 Special Weather Phenomena (Miraj Station)

Mean No.

of days

with

Jan. Feb. Mar. Apr. May June July Aug. Sep. Oct. Nov. Dec. Annual

Thunder 0.0 0.0 1.7 4.4 6.1 3.1 0.1 0.9 2.0 4.0 0.9 0.4 23.6

Hail 0.0 0.0 0.1 0.1 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.2

Dust-

Storm 0.1 0.0 0.1 0.2 0.4 0.2 0.0 0.0 0.0 0.0 0.0 0.0 1.0

Squall 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0

Fog 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0



Thunderstorms occur in the hot season and in the post- monsoon season. In the

beginning and end of the south-west monsoon season rainfall is often associated

with thunder. The climate of this district is on the whole agreeable and is

characterised by general dryness in the major part of the year. The cold season

is from December to about the middle of February. The hot season which follows,

lasts till the end of May. June to September is the south-west monsoon season

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

retreating monsoon season.

The only meteorological observatory in the district is at Miraj. The records of this

observatory may be taken as representative of the climatic conditions over the

district in general. The cold weather starts by about the end of November and

lasts till about the middle of February, December being the coldest month. In this

month the mean daily maximum temperature is 29.50C, while the mean daily

minimum is 14.30C. The minimum temperature may sometimes go below 70C.

The period from about the middle of February to the end of May is one of

continuous increase of temperature. In May, the hottest month, the mean daily

maximum temperature is 37.50C and the mean daily minimum 22.70C. The heat

is intense and the maximum temperature may sometimes go up to 42.00C.

Afternoon thundershowers bring welcome relief from the heat on some days.

Table: 3.3 Mean Daily Maximum and Minimum Temperature and Relative

Humidity (Miraj Station)

Month

Mean daily maximum

temperature (0C)

Mean Daily minimum

temperature (0C)

Highest maximum

ever recorded

(0C)

Lowest maximum

ever recorded

(0C)

Relative Humidity

(%)

0830 1730

January 30.5 14.1 33.9 5.0 62 35

February 32.8 15.2 37.2 6.7 56 31



March 36.1 18.5 40.6 11.1 54 27

April 37.9 21.5 42.2 15.0 64 30

May 37.5 22.7 42.2 18.9 73 40

June 31.5 22.3 42.2 19.4 82 66

July 27.9 21.7 35.0 17.2 86 79

August 28.2 21.2 34.4 17.8 87 76

September 29.2 20.2 35.6 15.6 86 68

October 31.0 20.1 36.1 12.2 74 51

November 30.1 17.3 34.4 8.3 65 45

December 29.5 14.3 34.4 7.2 61 37

Annual 31.9 19.1 -- -- 62 35

The highest maximum temperature recorded at Miraj was 42.20C and the lowest

minimum temperature recorded at this station was 5.00C. In the south-west

monsoon months the air is highly humid. In the post-monsoon, summer and cold

seasons the air is dry particularly in the afternoons. Skies are generally clear or

lightly clouded during the months November to March. Cloudiness begins to

increase progressively from April and afternoons are more clouded than the

mornings. During the monsoon months the skies are heavily clouded to overcast.

Records of rainfall in the district are available for nine stations for periods ranging

from 15 to 83 years. The average annual rainfall in the district is 692.4 mm

(27.26"). The rainfall in the western portion of the district, near the Western Ghats

is considerably higher than in the rest of the district. The rainfall generally

decreases from the Western Ghats towards the eastern portions of the district;

Madhavpur (Vadgaon) near the western border of the district getting 1,225.8 mm

(48.26") and Jath in the eastern part getting only 528.2 mm (20.80"). Some

rainfall in the form of thunder-showers occurs in May but the main rainy season is

from June to September. The rainfall in the south-west monsoon months is about

68% of the annual total. July is the month with the heaviest rainfall.



About 19% of the annual rainfall is received in the post-monsoon season. The

rainfall at individual stations shows considerable variations from year to year. It

will be seen from table 3.4 that at some stations the rainfall has been as much as

double the normal in some years while in some other years rainfall has been

about half the normal. In the fifty year period 1901—1950 the annual rainfall in

the district was the highest in 1932 when it amounted to 140% of the normal.

Both 1918 and 1923 were years with the lowest rainfall which was only 57% of

the normal. In the same fifty year period, the annual rainfall was less than 80% of

the normal in 14 years. There were three occasions when consecutive two years

had rainfall less than 8/% of the normal. Consecutive four years of such low

rainfall occurred during the period 1923—1926. It will be seen from table 3.4 that

in 33 years out of fifty the rainfall in the district was between 500 and 800 mm

(19.69" and 31.50").

3.3.2 Primary Meteorological Data

Site-specific primary meteorological data was collected in the project site for the

month of September 2013 to November 2013. Meteorological station was installed

at Sugar Factory site 10 meters from the ground level to monitor parameters of

wind speed, wind direction, temperature, relative humidity and rainfall. The data

is recorded as the maximum, minimum, instantaneous value. Monitoring was

done as per IS: 8829: Micro-meteorological Techniques in Air Pollution.

The details of parameters monitored, equipment used and the frequency of

monitoring are given in Table.

Table 3.5 Meteorological Parameters monitored at Site

SR.

NO.

PARAMETERS INSTRUMENTS FREQUENCY

1. Wind Speed Counter Cup

Anemometer

Hourly/Continuous

2. Wind Direction Wind Vane Hourly/Continuous



3. Temperature Thermo-sensor Hourly/Continuous

4. Relative

Humidity

Thermo-hygro sensor Hourly/Continuous

5. Rainfall Rain gauge (automatic) Hourly/ Continuous

Temperature

It was observed that the temperature ranged from 16.2 °C to 36.8 °C. The

maximum temperature of 36.8 °C recorded in the month of November and

minimum temperature of 16.2 °C was observed to be in the month of November.

The monthly variations in the temperature are presented in Table 3.1.

Relative Humidity

During the monitoring period of three months, the relative humidity ranges from 35

% to 98 %. The maximum humidity (98%) was recorded in the month of October

whereas minimum humidity i.e. 35 % was observed in the month of October. The

monthly variations in the relative humidity are given in Table 3.1.

Table 3.6: Meteorological Data monitored at the Project Site

Month

Temperature (OC) Relative Humidity (%)

Max Min Avg. Max Min Avg.

September 34.00 19.60 26.8 97 41 69

October 32.2 18.6 25.4 98 35 66.5

November 36.8 16.2 26.5 87 43 65

Wind Speed and Direction

Winds are light to moderate throughout the study period. The month-wise and

season-wise pattern is discussed below. The monthly and seasonal wind roses are

presented in Figure 3.2 to 3.5.

Figure 3.1 : Windrose for the Month of September 2013



Figure 3.2 : Windrose for the Month of October 2013



Figure 3.3 : Windrose for the Month of November 2013

Figure 3.4: Windrose for the study Period September - November 2013



Wind pattern during September 13

A review of the wind pattern shows that predominant winds are mostly from west

and followed by North West as shown in Figure 3.1. Wind speed observed during

the whole month of September was 1.21m/s whereas calm winds are found to be

19.61%

Wind pattern during October 13

Wind pattern for the month of October shows that predominant winds are from

North and North East direction (Figure 3.2). Wind speed and calm winds observed

to be 1.26m/s and 15.65% respectively.

Wind pattern during November 13

Wind pattern for the month of November, shows that the predominant winds are

mostly from East North East direction (Figure 3.3). Wind speed and calm winds

observed to be 1.11m/s and 16.04% respectively.

Wind pattern during the Study Period (September to November 13)

Predominant wind found to be from the direction of ENE as shown in Figure 3.4.

Wind speed observed to be 1.19 m/s where as calm condition are found to be

17.08 %

3.5 AIR ENVIRONMENT

The baseline studies for air environment cover reconnaissance, identification of

specific air pollutants expected to have significant impacts and assessment of

their prevalent levels in atmosphere at representative locations (within the site

and the buffer zone).

3.5.1 Ambient Air Quality

The ambient air quality status with respect to the specific (identified) pollutants

across the study zone of 5 km radial distance from the project site during study



period will form the base line information over which the predicted impacts due to

the proposed project can be superimposed to find out the net (final) impacts

(post-project scenario) on air environment. If the final impacts due to the project

activities are known at the planning stage of the project, a viable Environmental

Management Plan (EMP) can be prepared based on impact assessment for the

air environment. The ambient air quality monitoring was carried out in

accordance with guidelines and National Ambient Air Quality Standards

(NAAQS) of MoEF & CPCB.

3.5.2 Procedure for Sampling and Analysis

Sampling location is shown in Map below and the monitoring data from 8 stations

at various directions is presented in table 3.7. Reconnaissance survey was

undertaken to establish the baseline status of air environment in the study region.

Keeping in view the nature and size of the proposed site and various guidelines

available, an area of 10 km radius from the proposed site, was covered for the

purpose of Environmental Impact Assessment. During study period, the study

region has predominating wind direction from ENE to WSW.

To establish the existing baseline air quality status of the air basin, around the

IFL plant, Seven ambient Air Quality Monitoring (AAQM) stations were selected

in different directions of project site as per guidelines of network siting criteria.

The identified locations of AAQM are shown in Figure 3.5.

Based on the nature of industries existing and various other activities within the

study area, the conventional air pollutants such as Suspended Particulate Matter

(SPM), Respirable Particulate Matter (RPM) and gaseous pollutants such as

Sulphur dioxide (SO2), and Oxides of nitrogen (NOx), were identified as

significant pollutants for ambient air quality monitoring.



Air quality was monitored with eight samplers, for 24 hours, twice a week, for a

total of 13 weeks as per the guidelines specified by the MoEF. The volumetric

flow rate of each sampler was maintained at 1.1-1.2 L/min. Air samples are

analyzed by using standard procedures prescribed by Central Pollution Control

Board (CPCB), Indian Standards: IS 5182. Details of techniques used for

analysis of air samples are given in

Table 3.6: Techniques Used for Analysis of Air Quality

Sr.

No. Parameter

Code of

Practice Sampler

Equipment/

Instruments for

Analysis

Methodology

Adopted

1

Suspended

Particulate

Matter (SPM)

IS: 5182

(Part IV) HVS

Balance, Oven

and Desiccators

Gravimetric

Method

2

Respirable

Particulate

Matter (RPM)

IS: 5182

(Part IV)

Respirable

Dust Sampler

with Cyclone

Separator

Balance Gravimetric

Method

3 SO2 IS: 5182

(Part V) HVS Colorimeter Colorimetric

4 NOx IS: 5182

(Part V) HVS Colorimeter Colorimeter

5

Carbon

Monoxide

(CO)

IS: 5182

(Part X)

Bladder and

Aspirator

Gas

Chromatograph

with Methaniser

Flame

Ionization

Detector

Figure 3.5 Air monitoring site map of 10 km radius area around Project Site



Table- 3.7 Ambient Air Quality Monitoring Locations

Sr.

No.

Code No.

Station Name Direction w.r.t. site

Distance w.r.t. site

km Description

1. AAQ1 Project Site -- -- Industrial

2. AAQ2 Ugar Khurd East 1.4 Residential / Rural area

3. AAQ3 Ugar Budruk West 2.0 Residential / Rural area

4. AAQ4 Ugar Khurd (Kudachi)

South East 3.8 Residential / Rural area

5. AAQ5 Ugar Khurd North East 3.2 Residential / Rural area

6. AAQ6 Kusnal South West 4.1 Residential / Rural area

The ambient air quality monitoring has been done twice in week for every location.

The baseline data of air environment is generated for the following parameters:



· Total Suspended Particulate Matter (TSPM);

· PM10 : Respirable Particulate Matter (RPM);

· Sulphur dioxide (SO2); and

· Oxides of Nitrogen (NOx)

· Carbon monoxide (CO);

· Lead (pb); and

· Hydrocarbons (HC)

3.4.2 Sampling Duration

Ø Twenty-four hourly samples, twice a week at all air-monitoring stations.

3.4.3 Instruments Used

Respirable Dust Samplers (APM-451) of “Envirotech” make are used for

sampling SPM, PM10 and gaseous pollutants like SO2, NOx. The gases are

collected in a sampling tray attached to the Respirable Dust Sampler.

3.4.4 Methodology for Analysis

The air samples are analyzed as per IS: 5182 "Method for Measurement of Air

Pollution".

· SPM/ PM10: Gravimetric Method (IS: 5182, Part IV)

· SO2: Modified West and Gaeke Method (IS: 5182, Part II)

· NOx: Jacobs and Hochheiser Method (IS: 5182, Part VI)

· CO: NDIR spectroscopy method

· pb: Atomic Absorption Spectroscopy (AAS) method

3.4.5 Presentation of Results The ambient Air quality monitoring data analysed and tabulated in the Table -

3.3.3 which is compared with National Ambient Air Quality Standards as tabulated

in Table - 3.3.2.

Table- 3.8 Ambient Air Quality Monitoring Results Village

(Location) Parameters

SO2

(mg/m3) NOx

(mg/m3) SPM

(mg/m3) PM10

(mg/m3) CO

(ppm)



AAQ1 Minimum 4.0 9.1 126.4 29.6 0.40

Maximum 9.0 16.6 184.2 54.6 1.20

Average 6.6 11.5 153.7 43.5 0.80

Std. Deviation

1.24 2.12 15.10 7.30 0.20

98th percentile

8.96 16.18 181.4 54.4 1.20

AAQ2 Minimum 4.0 8.1 106.1 28.1 0.51

Maximum 7.2 12.9 170.1 57.1 1.26

Average 4.9 9.8 141.4 42.0 0.80

Std. Deviation

0.81 1.09 17.1 7.4 0.20

98th percentile

7.1 12.5 166.2 56.4 1.16

AAQ3 Minimum 4.0 9.0 121.3 36.4 0.52

Maximum 7.1 12.9 185.3 65.4 1.11

Average 5.1 10.1 157.4 50.5 0.73

Std. Deviation

0.8 1.1 17.05 7.51 0.17

98th percentile

6.9 12.5 181.4 64.7 1.06

AAQ4 Minimum 6.7 13.6 106.8 34.4 0.87

Maximum 13.0 21.7 163.6 72.3 1.93

Average 9.5 17.8 145.4 48.8 1.22

Std. Deviation

1.5 2.2 15.9 8.4 0.33



98th percentile

8.8 17.7 163.4 66.9 0.92

AAQ5 Minimum 4.0 9.0 140.9 45.1 0.47

Maximum 7.2 14.6 168.8 55.2 1.20

Average 5.3 10.3 151.0 50.5 0.77

Std. Deviation

1.0 1.5 6.0 2.5 0.21

98th percentile

7.1 14.1 164.7 55.1 1.15

AAQ6 Minimum 4.0 9.0 107.9 29.6 0.52

Maximum 8.4 16.2 164.7 61.2 1.11

Average 5.6 11.6 146.5 45.4 0.73

Std. Deviation

1.1 1.9 15.9 9.2 0.17

98th percentile

7.9 15.6 164.5 60.6 1.06

Ambient air quality analysis results for the six monitoring locations which were

selected to represent baseline conditions of the region are given below.

AAQ1

The location comes under Industrial zone. The concentration of SPM ranged

from 126.4-184.2 µg/m3 while that of PM10 was in the range of 29.6-54.6 µg/m3,

SO2 and NOx were in the range of 4-9 µg/m3 and 9.1-16.6 µg/m3 respectively.

The CO values were observed in the range of 0.40-1.20 ppm.

AAQ2

The location comes under Non-Industrial zone. The concentrations of SPM and

PM10 at this location were in the range of 106.1-170.1 µg/m3 and 28.1-57.1

µg/m3 respectively. While the values of SO2 and NOX were observed in the range



of 4-7.2 µg/m3 and 8.1-12.9 µg/m3 respectively. The CO values were observed in

the range of 0.51-1.26 ppm.

AAQ3

The location comes in the residential /semi urban zone. Here the SPM and PM10

concentrations were in the range of 121.3-185.3 µg/m3 and 36.4-65.4 µg/m3

respectively. The concentrations of SO2 and NOX were observed in the range of

4-7.1 µg/m3 and 9-12.9µg/m3 respectively. The CO values were observed in the

range of 0.52-1.11 ppm.

AAQ4

This location comes within the residential zone. The concentrations of SPM and

PM10 at this location were in the range of 106.8-163.6 µg/m3 and 34.4-72.3

µg/m3 respectively. While the values of SO2 and NOX were observed in the range

of 6.7-13 µg/m3 and 13.6-21.7 µg/m3 respectively. The CO values were observed

in the range of 0.87-1.93 ppm.

AAQ5

The location comes under Non-Industrial Zone. The concentration of SPM

ranged from 140.9-168.8 µg/m3 while that of PM10 was in the range of 45.1-55.2

µg/m3. SO2 and NOx concentrations were in the range of 4-7.2 µg/m3 and 9-14.6

µg/m3 respectively. The CO values were observed in the range of 0.47-1.20 ppm.

AAQ6

The location comes under Non-Industrial Zone. The concentration of SPM

ranged from 107.9-164.7 µg/m3 while that of PM10 was in the range of 29.6-61.2

µg/m3. SO2 and NOx concentrations were in the range of 4-8.4 µg/m3 and 9-16.2

µg/m3 respectively. The CO values were observed in the range of 0.52-1.11 ppm.

The summary of the monitoring results including minimum, maximum and

average levels along with the 98th percentile values are presented in Table 3.8.

The results obtained were compared for 24 hrs average standards for residential

areas prescribed by the National Ambient Air Quality Standards (NAAQS). The

National Ambient Air Quality Standards are presented in Table 3.9.



Table 3.9: National Ambient Air Quality Standards (NAAQS)

Sr.

No

.

Pollutant Time Weighted

Average

Concentration in Ambient Air

(µg/m3 except indicated)

Industri

al Area

Residential,

Rural and

Other Areas

Sensitive

Area

1 Sulphur

Dioxide (SO2)

Annual Average

* 80 60 15

24 Hours** 120 80 30

2 Oxides of

Nitrogen (NOx)

Annual Average

* 80 60 15

24 Hours** 120 80 30

3

Suspended

Particular

Matter (SPM)

Annual Average

* 360 140 70

24 Hours** 500 200 100

4

Respirable

Particular

Matter (RPM)

Annual Average

* 120 60 50

24 Hours** 150 100 75

5 Carbon

Monoxide (CO)

8 Hourly

Average*

5.0

mg/m3 2.0 mg/m3 1.0 mg/m3

1 Hour

Average**

10.0

mg/m3 4.0 mg/m3 2.0 mg/m3

* Annual arithmetic mean of minimum 104 measurements in a year

taken twice a week 24 hourly at uniform interval

** 24 hourly/8 hourly values should be met 98% of the time in a year.

However, 2% of the time it may exceed but not on two consecutive

days

On the above observations of the results and their compliance to the 24 hourly

averages of NAAQ standards are well within the limits.

3.6 NOISE ENVIRONMENT



Noise is defined as unwanted sound, interferes with speech, communication,

sleep, causes annoyance and results in deterioration of the quality of human

environment. Perception of noise varies with a number of factors including

natural sensitivity and hearing ability, past experience, cultural factors and the

time of day at which the sound is experienced. Continuous sound is perceived

quite differently from intermittent sound at the same level. High or continuous

noise levels may cause permanent loss of hearing ranging from reduced

perception at certain frequencies to total deafness. Even at comparatively lower

levels, noise may have psychological effects including disturbance of sleep,

annoyance and irritation.

Monitoring of noise levels in the proposed site during summer season was

carried out to assess the present baseline levels. Impact of noise generated due

to propose Foundry activity was studied and also to know the impact of vehicular

traffic on human settlements. Studies pertaining to noise environment were

conducted in the following order:

Ø Reconnaissance survey

Ø Measurement of equivalent noise levels

Ø Impact of noise exposure on the communities

Noise Levels

The noise levels measured at the existing plant facility, proposed plant site and

villages located within 10 Km. radius are in Table 3.18

Table 3.9 Noise Monitoring Locations

Sr.

No.

Code No.

Station Name Direction w.r.t. site

Distance w.r.t. site

km Description

1. N1 Project Site -- -- Industrial

2. N2 Ugar Khurd East 1.4 Residential / Rural area

3. N3 Ugar Budruk West 2.0 Residential / Rural area

4. N4 Ugar Khurd South East 3.8 Residential / Rural area



(Kudachi)

5. N5 Ugar Khurd North East 3.2 Residential / Rural area

Fig 3.6: Noise monitoring site map of 10 km radius area around Project Site

Table 3.10 Noise Monitoring Scenario

Name of

Station

Noise Levels (dBA) Ambient Noise Standard (dBA)

Day Night Day Night Category

of area

Project Site 60.8 55.3 75 70 Industrial

Ugar Khurd 45.6 41.7 55 45 Residential

Ugar Budruk 48.4 42.2 55 45 Residential

Ugar Khurd (Kudachi)

50.3 43.9 55 45 Residential

Ugar Khurd 52.5 40.5 55 45 Residential



From the monitoring survey of noise levels it was observed that the day time

noise levels were observed in the range of 45.6-60.8 dB (A). The night time noise

levels observed at the 5 locations were found to be in the range of 41.7 – 55.3 dB

(A). Noise Levels are found to be within the day and night time standards

prescribed for residential, commercial, industrial zone.

3.7 WATER ENVIRONMENT

Water environment consists of water resources such as river, ponds, streams,

etc. The water quality forms the essential component of EIA that helps to identify

and evaluate critical impacts / issues with a view to suggest appropriate

mitigation measures for implementation. Water quality of ground water has been

studied in order to assess various uses of water such as during construction, in

process, drinking, horticulture, etc. with respect to the proposed project.

Approach Reconnaissance Survey for ground and surface water bodies in the study region

shows that both ground and surface water are important sources of drinking

water found in the study region.

3.7.1 Surface Water Environment

The district falls in the Krishna river basin except small catchments of Khanapur,

Belgaum and Bailhongal taluks that fall in the catchments of Mahadayi and

Kalinadi rivers that flow towards the west. The river Krishna, along with its

tributaries Ghataprabha and Malaprabha are perennial and flow in easterly

direction.

Sampling and Analysis

Water samples were collected in the month of September 2013 to November

2013 from bore/open wells located within 10 Km. radius from the proposed site.

The water samples collected were analyzed for pH, COD, BOD, Suspended

Solids, Oil and Grease, Chlorides, Sulphates and Total Hardness. The results

are presented in Table 3.12. Methodologies adopted for analyzing the samples



for the parameters mentioned above were according to the APHA prescribed

methods. 3.11 Surface water Sampling Locations:

Sr.

No. Sampling Location Name

Direction from

project site

Distance from

project site

SW1 Krisna river at Kudachi SE 1 Km

SW2 Krisna river at Kudachi SE 1 Km

Fig. 3.8: Surface water sampling site map

Surface Water Quality Scenario

Surface water samples analyzed during the study period indicate that the water is

free from the industrial pollution. Water from these wells is used for drinking,

gardening, industrial and agricultural purposes. Concentrations of suspended

solids and dissolved solids were low. BOD, COD levels which indicate organic

pollution are also low. All the other parameters are within the prescribed limits.

Table: 3.12 Surface Water Analysis results



Sr. No

Parameter Unit Limits as

per IS:2296-C

SW1 SW2

1 pH - - 7.7 8.0

2 Electrical Conductivity mmhos/cm NS 317.6 969.2

3 Chlorides (Cl-) Mg/l 600 68.3 101.9

4 Total Hardness mg/l NS 99.2 139.2

5 Total Alkalinity mg/l NS 117.4 412.2

6 Total Dissolved Solids mg/l 1500 250.3 630.6

7 Sulphate (SO4-) mg/l 400 45.5 93.7

8 Iron (Fe+) mg/l 50 0.1 0.2

9 Fluoride (F-) mg/l 1.5 0.7 0.7

10 Calcium (Ca+) mg/l NS 31.9 43.7

11 Magnesium (Mg+) mg/l NS 10.5 11.6

12 Nitrates (NO3-) mg/l 50 7.0 5.6

13 Total suspended solids

mg/l NS 76.4 83.7

14 B O D mg/l 3 1.1 1.3

15 Dissolved Oxygen mg/l 4 (min) 4.9 4.4

16 Copper (Cu) mg/l 1.5 BDL BDL

17 Manganese (Mn) mg/l NS BDL BDL

18 Mercury (Hg) mg/l NS BDL BDL

19 Selenium (Se) mg/l 0.05 BDL BDL

20 Cyanide (CN) mg/l NS BDL BDL

21 Chromium (Cr+6) mg/l NS BDL BDL



22 Lead (Pb) mg/l NS BDL BDL

23 Zinc (Zn) mg/l NS BDL BDL

24 Aluminum (Al) mg/l NS BDL BDL

25 Cadmium (Cd) mg/l NS BDL BDL

26 Arsenic (As) mg/l 0.2 BDL BDL

For the monitoring of surface water quality, three surface water samples have

been analyzed once during the study period. The results of analysis are given in

Table - 3.12. Which are compared with the standards for Class-C water of IS:

2296 (Water quality fit for drinking after conventional treatment).

A perusal of the table reveals that the results of all parameters are well within the

specified limits. The pH values are in the range of 7.7 to 8.0 throughout the study

period, which shows that the surface water of the study area is slightly alkaline in

nature, which may be due to carbonates and bicarbonates. The concentration of

the total dissolved solids and total alkalinity are in the range of 250 to 630 mg/lt

and 117 to 412 mg/lt. The DO values at all locations are found to be appreciable

which indicates self-purification capacity of the surface water body. The heavy

metal concentrations at all the three locations during the study period were found

below detectable limits.

3.7.2 Ground Water Quality

Ground water is the accumulation of water below the surface of earth, caused by

the portion of rainfall that percolates through the soil pores and rock crevices,

flown by natural gravity till it reaches an impervious stratum. The study area

receives limited rains, but has considerable groundwater presence. The quality of

groundwater is examined by drawing samples from open dug wells as well as

from deep wells from the study area. Analysis was done by Standard methods.



The results are summarized below in tabular form, and compared with limits of

IS:10500

3.13 Ground water sampling Locations

Sr.

No.

Sampling Location

Name

Direction from

Project site

Distance from project

site

1 Ugar khurd (GW1) NE 3.5Km

2 Ugar budruk (GW2) W 3.5 Km

3 Kudachi (GW3) SE 3.5 Km

Fig 3.9 Groundwater sampling site map

Ground Water Quality Scenario:

Ground water samples analyzed during the study period indicate that the water is

free from the industrial pollution. Water from these wells is used for drinking,

gardening, industrial and agricultural purposes. All the other parameters are

within the prescribed limits. The results of the analysis of ground water are

tabulated in Table 3.14



Table 3.14: Ground Water analysis results

Sr. No.

Parameter Unit

Limits as per IS:10500

(Desirable/ permissible)

Ground Water

GW1 GW2 GW3

1 pH 6.5 –8.5 6.5 6.9 6.4

2 Conductivity mmhos/c

m NS 108.5 112.8 284

3 Chlorides (Cl-) ppm 250/ 1000 92.8 137.6 19.6

4 Total Hardness ppm 300/ 600 236.8 310.4 64.6

5 Alkalinity as CaCO3 ppm 200/600 448.0 284.8 69.6

6 Total Dissolved Solids ppm 500/ 2000 704.0 736.0 211

7 Sulphate (SO4-) ppm 250/ 400 176.0 116.0 64.2

8 Iron (as Fe) ppm 0.3/1.0 0.1 0.1 0.1

9 Fluoride (F-) ppm 1.0/ 1.5 1.5 1.3 0.4

10 Calcium (Ca+) ppm 75/ 200 67.2 89.6 23.34

11 Magnesium (Mg+) ppm NS 16.8 20.8 8.96

12 Nitrates (NO3-) ppm 45/100 2.9 3.0 4.8

13 Copper (Cu) ppm 0.05/1.5 BDL BDL BDL

14 Manganese (Mn) ppm NS BDL BDL BDL

15 Mercury (Hg) ppm 0.001/NR BDL BDL BDL

16 Selenium (Se) ppm 0.01/NR BDL BDL BDL

17 Cyanide (CN) ppm 0.05/NR BDL BDL BDL

18 Chromium (Cr+6) ppm 0.05/NR BDL BDL BDL

19 Lead (Pb) ppm 0.05/NR BDL BDL BDL



20 Zinc (Zn) ppm 5.0/15.0 BDL BDL BDL

21 Cadmium (Cd) ppm 0.01/NR BDL BDL BDL

22 Arsenic (As) ppm 0.05/NR BDL BDL BDL

23 Total Coliform, Nos./100

ml Absent 8 5 6

24 Faecal Coliforms. Nos/100m

l Absent 0 0 0

The ground water analysis results are compared with the drinking water quality

standards of IS: 10500-1991. The observed values of ground water analysis

during the study period are given in Table - 3.13. The pH value ranges within 6.4

to 6.9 which are found to be slightly towards the lower limit.

The electrical conductivity ranges 284 to 1314 mmhos/cm at all sampling

locations during the study period. Total dissolved solids (TDS) ranges between

211 to 872 ppm. The fluoride concentrations are between 0.4 to 1.5 ppm. These

values are due to the existing geological structure of the area and cannot be

attributed to industrial causes.

The total hardness during study period observed in the ranges 64.4 to 345.6

ppm. It was observed that the total hardness is found to be within the desirable

limits. The concentrations of heavy metals are below detectable limits throughout

the study period.

3.8 Flora and Fauna Objectives of study Flora and Fauna around the 10 km area was recorded. The study was undertaken with a view to understand the status of ecosystem along the following line



Ø To assess nature and distribution of the vegetation in the area Ø Preparation of checklist of flora and fauna. Ø Generation of primary data to understand baseline status of floral and faunal

elements, sensitive habitats and rare species Methods adopted for the study To achieve the objectives, general ecological survey covering an area around the proposed project site was carried out in the month of November. Ø General field visit on site and closed vicinity area Ø Reconnaissance Survey Ø Information from local peoples and forest department

Observations and Results

Flora: The floral study was conducted in the study area during the month of

September 2013 to November 2013. The floral diversity in the area is described

in Table. During this survey total 36 plant species comprising of 15 Tree species,

5 climber species, 3 shrub species and 13 herb species were recorded. These

plants are the common habitant in the project area.

Table3.15: List of flora available in study area

Sr.

No

Name of

Species

Vernacular

name Family

Phenology

Habitat

Distribution

1. Mangifera

indica Amba Anacardiaceae

January -

May

Evergreen

and semi-

evergreen

forests and

also widely

cultivated

Indo-Malesia

2. Terminalia

arjuna Arjun Combrataceae

November

- June

Dry

Deciduous

forests

India and Sri

Lanka

3. Bridelia

retusa Asana Euphorbiaceae

August –

December

Semi-

evergreen Indo-Malaya



and

deciduous

forests,

also in the

plains

4. Morinda

tinctoria Ashi Rubiaceae

March -

June

Moist and

dry

deciduous

forests,

also in the

plains

Indo-Malesia

5. Thespesia

populnea Bhendi Malvaceae

March -

June

Grown as

fence-

posts and

avenue

tree, also

in

mangrove

forests

Pantropical

6. Ziziphus

mauritiana Bor Rhamnaceae

February –

April

Dry

deciduous

forests,

also

planted in

the plains

Paleotropics

7. Tamarindus

indica Chinch Fabaceae

February –

April Cultivated

Native of

Tropical

Africa;

introduced

and widely

grown in

India and

other parts



of tropics

8. Terminalia

catapa

Deshi

badam Combrataceae

March –

January

Grown as

ornamental

tree

Malaysia to

North

Australia

and

Polynesia,

commonly

planted in

the tropics

9. Grewia

tiliaefolia Dhaman Tiliaceae

February -

June

Moist

deciduous

forests

Tropical

Africa, India

to Indo-

China

10. Acacia

auriculiformis Kadambo Fabaceae

Throughout

the year

Grown as

avenue

tree, also

raised in

plantations

Native of

Tropical

Australia

11. Azadiracta

indica Kadulimb Meliaceae

February –

September

Dry

deciduous

forests,

also widely

planted

Indo-Malesia

12. Cocus

nucifera Naral Arecaceae

Throughout

the year Cultivated

Cultivated

throughout

the tropics

13. Ficus

religiosa Pimpal Moraceae

November

- February

Widely

planted in

tem

ple

premises

East

Himalayas;

planted and

naturalised

in India and

neighbouring

14. Samanea Rat-shirish Fabaceae March – Grown as Native of



saman May avenue

tree

Central and

South

America;

widely

planted in

the tropics

as avenue

tree

15. Tectona

grandis Sag Verbanaceae

May –

January

Moist

deciduous

forests,

also raised

in

plantations

South and

South East

Asia

CLIMBERS

Sr.

No.

Name of

Species

Vernacular

Name Family

Phenology

Habitat

Distribution

1. Mikania

micrantha

Bittervine Asteraceae

February –

April

Forest

plantations

and also in

the plains

in moist

localities

Pan-tropical

2. Ipomia

muricata Bhovari convolvulaceae October

Cultivated

as

vegetable

Native of

tropical

Africa and

Asia

3. Momordica

dioica Kantoli Cucurbitaceae

July -

December

Deciduous

and semi-

evergreen

forests,

also in the

Indo-

Malesia and

China



plains

4. Mucana

prurita Khaj-kuili Fabaceae

October –

February

In

secondary

forests at

low

altitudes,

also in the

plains

India,

Myanmar

and Sri

Lanka

5. Vigna

radiata

Jungle

moong Fabaceae

August -

December

Mostly

under

cultivation,

also

naturalised

in the

plains

Paleotropics

SHRUBS

Sr.

No.

Name of

Species

Vernacular

Name Family

Phenology

Habitat

Distribution

1. Lantana

camera Lantana Verbenaceae April - June

Introduced

as

ornamental

plant; now

naturalised

as weed

Native of

Tropical

America,

widely

naturalised

in the tropics

and

subtropics

2. Calotropis

gigantea Rui Aslepiadaceae

Throughtout

the year Wastelands Tropical Asia

3. Hibiscus

subdariffa ambadi Malvaceae

December -

February

Cultivated

as

vegetable,

Native of

Tropical

Africa;



but now

naturalised

widely

cultivated in

all tropics

regions

HERBS

Sr

No

Name of

Species

Vernacular

Name Family

Phenolo

gy

Habitat

Distributio

n

1. Achyranthe

s aspera Aghada

Amaranthace

ae

October -

March

Dry

deciduous

forests

and forest

plantations

, also in

the plains

Pantropical

2. Solanum

surattense Bhuiringani Solanaceae

August -

Novembe

r

Degraded

forest

areas,

also along

roadsides

and

wasteland

s

India,

Himalaya,

South East

Asia,

Malesia,

Australia,

Polynesia

3. Physalis

minima

Choti

phulwa Solanaceae

July –

Decembe

r

Degraded

forests

and waste

places

Tropical

Asia, Africa

and

Australia

4 Ephorbia

hirta Dudhi

Euphorbiacea

e

Througho

ut the

year

Degraded

forest

areas and

forest

plantations

Native of

Tropical

America;

now

Pantropical



, also in

the plains

5. Alternanthra

sessilis Kacheri

Amaranthace

ae

Througho

ut the

year

Along

sides of

water

courses

and

marshy

areas

Pantropical

6. Triumfetta

rhomloidea Jhinjhira Tiliaceae

August -

January

Degraded

deciduous

forests,

also in the

plains

Pantropical

7. Aeschyomm

ene indica Bhatsola Fabaceae

August -

Decembe

r

Moist

deciduous

forests

and

waterlogg

ed areas

in the

plains

Pantropics,

probably

native in

South East

United

States

8. Tridax

procumbens kambarmodi Asteraceae

Througho

ut the

year

Deciduous

forests,

also waste

lands in

the plains

Native of

Tropical

America;

now

widespread

throughout

tropics and

subtropics

9. Aerva

lanata

Kapurmadh

uri

Amaranthace

ae

Sepetmb

er – April

Deciduous

forests

and waste

Widespread

in the

tropics and



lands in

the plains

subtropics

10

Commelina

benghalensi

s

kena Commelinace

ae

July -

Novembe

r

Wasteland

s, also in

deciduous

forests

Africa,

India,

China,

Japan and

Malesia

11 Celosia

argentea kurdu

Amaranthace

ae

Novembe

r -

Decembe

r

Weed in

cultivated

areas and

wasteland

s

Cosmopolit

an

12 Mimosa

pudica Lajalu Fabaceae

July -

January

Weed in

the plains

Native of

South

America;

now

Pantropical

13 Urena

lobata vanbhendi Malvaceae

August -

Decembe

r

Degraded

forests,

also in the

plains

Pantropical

Conclusion: - There is no flora species existing at site which are in the red list

species category.

Fauna: The faunal study was conducted in the study area during the month of

September 2013 to October 2013 The faunal diversity in the area is described in

Table. Inquiry was made with the villagers in the concerned cluster regarding

availability of wildlife fauna in the study area. The faunal diversity is very meager,

only common species of mammals, birds and reptiles are available in the study

area. No any wildlife Sanctuary or National Park is present in this study area.

Table 3.16: List of fauna available in study area



1. Mammals:

Common Name Scientific Name Habitat IUCN Status

Indian palm squirrel Funambulus palmarum Plantation Least

Concern

2. Avian Fauna

Common Name Scientific name Habitat IUCN Status

House crow Corvus splendens Plantation, habitation Least

Concern

Common myna Acridotheres tristis Plantation Least

Concern

Black drongo Dicrurus

macrocercus

Plantation Least

Concern

Black-headed oriole Oriolus xanthornus Tropical moist-

deciduous biotope:light

forest, plantations,

village groves, gardens

Least

Concern

Lesser coucal Centropus

bengalensis

Scrub jungle and tall

grassland

Least

Concern

Common myna Acridotheres tristis Plantation Least

Concern

Common buzzard Buteo buteo Sailing flight over tree

top

Least

Concern

Red whiskered bulbul Pycnonotus jocosus Plantation, shrubs Least

Concern

Red-vented bulbul Pycnonotus cafer Cultivation, Scrubs Least

Concern

Black kite Milvis migrans Urban localities Least

Concern

Large pied wagtail Motacilla

maderaspatensis

Streams, grasses,

irrigation reservoirs

Least

Concern



3. Butterfly/insects

Species Observed Scientific name Habitat

Dot dash sergent Athyma kanwa Scrub, plantation, habitation

Blue tiger Tirumala limniace Hills, plains, not in desserts and at

high altitude, gardens

Common Indian

crow

Eupoloea core Among milkweed butterflies, this

is most abundantly found,

Mountains till 8000 feet,

occasionally it swarms in the low,

wet, jungles

Common evening

brown

Melanitis leda Very common throughout India,

except in the arid northwest

Common grass

yellow

Eurema hecabe Scrub, plantation, habitation

4. Reptilian fauna

Species Observed Scientific name Habitat Status

Common garden

lizard

Calotes versicolor Occupies all

biotopes from dry

desert to thick

forest, Indian

subcontinent

It is commonest agamid

lizard of India

5. Amphibian fauna

Common name Scientific name Habitat Status

Asian Common Toad Bufo melanostictus Home in almost all

biotopes found in

India, commonest

among Indian

species

commonest

among Indian

species and also

the amphibian

most likely to be

seen

Conclusion: - There is no fauna species existing at site which are in the red

list species category.



Reference:

1. “The Book of Indian Birds” Thirteenth Edition 2012 by Salim Ali,

Bombay Natural History Society

2. “The Book of Indian Reptiles and Amphibians” 2002 by J. C. Daniel,

Bombay Natural History Society.

3. Discussions with local people

3.9 SOIL ENVIRONMENT

Soil Quality

The soil in and around the proposed site is formed due to weathering of rocks

and can be classified as reddish gray / brown silty type. Rocks underneath are of

volcanic origin. The rocks are dark colored of basaltic composition and mainly

comprise of plagioclase, pyroxenes iron ores, primary glass and some secondary

minerals.

Table 3.17 Soil Quality Sampling Location:

Sr.

No.

Sampling Location

Name

Direction from

project site

Distance from

project site 1. Ugar khurd NE 2.7 km

2. Ugar Budruk W 1.5 km

3. Ugar khurd SE 1.7 km

Fig 3.10 Soil sampling site map of 10 km radius area around Project Site



Table 3.18 Soil Monitoring Scenario

Sr.

No. Parameters

Project

Site

Ugar

Khurd

(1.7 km)

Ugar

Budruk

Ugar

Khurd

(1.7

km)

Unit

1. pH 7.92 8.03 8.1 7.7 -

2. Conductivity 0.85 0.69 0.92 1.01 Ms/sec

3. Chlorine(Cl) ND ND ND ND Mg/ltr

4 Nitrogen(N) 102 111 100 124 Kg/Ha

5 Phosphorous(P2O5) 22.2 19.4 20.2 18.0 Kg/Ha

6 Potassium(K2O) 241 320 329 237 Kg/Ha



7 Iron(Fe) 6.2 7.4 6.9 7.0 ppm

8 Calcium(Ca) 26.0 21.2 23.4 20.8 Kg/Ha

9 Manganese (Mn) 8.1 10.2 9.3 8.9 ppm

10 Zinc (Zn) 0.62 0.72 0.69 0.70 ppm

11 Copper (Cu) 0.88 0.86 0.94 1.03 ppm

12 Organic Carbon 0.82 0.74 1.03 0.97 %

3.10 Remote Sensing and GIS Study

Remote Sensing is a process of identification and demarcation of various earths’

objects from a distance without directly coming into contact with them. Remote

sensing is largely concerned with the measurement of electromagnetic radiation

from the sun, which is reflected, scattered, and emitted by the objects on the

surface of the earth. Different objects on the surface of the earth reflect different

amounts of the electromagnetic spectrum. The potential of remote sensing in

natural resources mapping basically depends on spatial, radiometric and

temporal resolution of the sensor. Thus the satellite remote sensing with its

capability of repetitive coverage, multi-spectral imaging, synoptic view and low

cost can play an important role in the delineation of various landuse landcover

classes.

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. Remote sensing technique has ability to

represent of land cover categories by means of classification process. With the

availability of multispectral remotely sensed data in digital form and the

developments in digital processing, remote sensing supplies a new prospective

for land-cover/land-use analysis. Geographical Information Systems have

already been used for assessing environmental problems, since they provides a



flexible environment and a powerful tool for the manipulation and analysis of

spatial information for land cover feature identification and the maps of all

variables were combined to extract information to better understand analyzing.

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 part of dist. Pune land cover/use distribution. Obtained results were

compared, visualized and analyzed, in Geographic Information System.

The project site is having latitudes 16°39'0.90"N and longitudes 74°49'14.71"E.

The 10 km radius area around project site is having latitudes 16°33'35.452"N to

16°44'26.361"N and longitudes 74°43'37.116"E to 74°54'52.303"E.

Software and Hardware

Satellite Data: RESOURCESAT-2 cloud free data has been used for Landuse /

landcover analysis.

Satellite Sensor – RESOURCESAT-2 LISS- III

Path and Row – Path 97 Row 61 Resolutions - 23.5 m.

Date of Pass: 29 Apr 2013

Ancillary Data:

PC based GIS and image-processing software’s are 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.

Objectives:

· Delineation of Landuse/ Landcover categories at 10 km radius area

around Project site.

· Generation of digital cartographic database using secondary data sources.



Fig.3.11. Toposheet map of 10 km radius area around Project Site.

Methodology:

The multispectral data obtained from sensors, due to its synoptic view and revisit

capability, can effectively be used for continuous monitoring of land surface. The

spatial, spectral and radiometric resolutions are the three primary factors in the

estimation of various landuse/landcover classes.

The satellite data is then taken into a hard disk and then converted in the

standard false colour composite by assigning blue, green and red to green, red

and near infra red band respectively. Image enhancement has been done by the

technique called histogram stretching between the ranges of 0-255, as the data

content is 8-bit. Applying formulae derived by modeling the sources of distortions

in order to correct the systematic distortions such as earth curvature carried out

rectification and registration of satellite data. The random distortions were

corrected using well distributed ground control points occurring in raw data. To

achieve planimetric accuracy, the remote sensing scene was rectified with



respect to SOI maps on 1: 50,000 scales. The GCP’s in the scene such as

railroad intersections, corners of water reservoirs, bunds, etc. were identified on

the image as well as on the reference map. Third order model was constructed

and finally registration of image was carried out with nearest neighborhood

resampling taking map as reference and one map registration was achieved.

Then the subset of image has been taken according to the boundary of the study

area. The digital classification technique has been used for the extraction of the

landuse/landcover information from the imagery. Eight different

landuse/landcover classes have been identified in the area under study. Table

shows the information about the extent of landuse/landcover classes in the study

area.



Fig.3.12. Satellite Image of 10 km radius area around Project Site.



Landuse/ Landcover Classes Details:

Satellite data for 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. Eight landuse /

landcover classes identified in total 10 km radius area around Project Site. The

area under each class has been calculated and given below.

Table 1: Landuse/ Landcover Statistics of the Ten Km radius Area.

Sr. No.

LAND USE AREA (Ha)

AREA (%)

1 Built-Up Land

Settlements 599.52 1.9 2 Water Bodies

Tank/River/Dry Reservoir etc.

455.4 1.44

3 Forest

Vegetation 537.66 1.7 4 Crop Land

Irrigated crop land 8198.68 26.05 Fallow land 8501.12 27.07

5 Waste Lands

Land with scrub 6691.23 21.23 Land without scrub 6488.37 20.61

Total 31471.98 100.00



Fig.3.13. Landuse/landcover map of 10 km radius area around Project Site.



Digital Cartographic Database preparation in GIS

GIS is an integrated information system having capability to capture, store, edit,

manipulate, analyze and retrieve all types of spatial and non-spatial information

about a particular area. The advent of electronics and computing techniques coupled

with the development of GIS has increased the potential of creating and maintaining

databases using geographical space as the key field. The database can be used for

speedier monitoring, assessment, planning, and management of various aspects of

natural resources.

Comprehensive GIS based database was generated for the study area that

comprises of the following data sets. Resource data such as landuse from remote

sensing data, soil map, geology, water bodies, surface and ground water sampling

locations, drainage, contour.

The methodology used for database preparation involves the following steps

Data Input:

The function of data input is to convert the existing data from one into another that

can be used in GIS. Georeferenced data are commonly provided as maps, satellite

images, and associated attributes.



· Drainage Map: Drainage layer, which was generated after scanning the

thematic manuscripts, was edited for line the errors. Two different layers were

made separately for line drainage. Drainage order was given to all the drain

lines in the layer‘s. Strahler method of ordering was used for giving order to

drainage. Whenever two drains of any order joined the order of next drain was

increase by one. The study area has an order of fourth. River name also

attached as attribute to drainage layer. All the water bodies and river with

sufficient width were put in polygon layer.

The area shows not much of undulating topography thus it shows the

Dendritic drainage patterns.

Fig. 3.14: Drainage map of 10 km radius area around Project Site.

· Contour – Thematic manuscript for contour layer was generated from Survey

of India toposheet at 1:50,000 scale. After scanning coverage was generated.



Coverage was edited to remove all errors of dangle. Attribute value was given

to each contour in the coverage.

Fig.3.15: Contour map of 10 km radius area around Project Site.

3.11 Socio-Economic Environment: Social and economical consideration is basic in the man-made environment. Any

human activity is undertaken for a sole objective of economic benefit to the human

society. In other words if the socio-economic impact is not positively beneficial, one

will not enter into that activity at all. It is, therefore, worthwhile to make a socio-

economic impact assessment (SIA) in advance before deciding on commencement

of the activity. SIA is done honestly, keeping the following framework.

• SIA is a systematic effort to identify, analyze, and evaluate social impacts due to a

proposed project or policy change on the individuals and social groups within a

community or on an entire community in advance of the decision making process in

order that the information derived from the SIA can actually influence decisions.



• SIA increase knowledge on the part of the project proponent and the impacted

community.

• SIA raises consciousness and the level of understanding of the community and

puts the residents in a better position to understand the broader implication of the

proposed action.

• SIA includes within it a process to mitigate the social impacts likely to occur, if that

action is desired by the impacted community. For further discussions this study area

which is fully of rural component will be considered.

· Village Map: Village layer was prepared from SOI toposheet at 1:50,000

scale, 10 km radius area around the project site. After scanning the

manuscript layer was prepared. The point layer was prepared. Errors were

removed after editing the layer.

Fig. 3.16: Village map of 10 km radius area around Project Site.



· Accessibility Map: Major Road and Railway network layer was prepared

from SOI toposheet at 1:50,000 scale 10 km radius area around the project

site. After scanning the manuscript layer was prepared. Errors were removed

after editing the layer. Attributes were given to different types of road and

railway.

Fig. 3.17: Accessibility map of 10 km radius area around Project Site.

3.12 HYDROGEOLOGY

Water table generally follows the topography of the area and is at greater depths in

the water divides and topographic highs, but becomes shallower in the valleys and

topographic lows and therefore, groundwater moves down and follows the gradient

from the higher to lower elevations, that is, from recharge area to discharge area.

Therefore, locally direction of flow from higher elevations is towards the rivers.

Overall, the general flow direction of ground water in the district is generally towards

the east.



The district is underlain by gneisses, schist, limestone, sandstone, basalts, alluvium

etc. of Archaean to Recent age. Deccan basalts cover an area of 7,650 Sq.Kms. in

the northern part of the district and have a maximum thickness of around 256 m,

which gradually thins out in the southern direction.

Hard rocks occupy a major part of the district; majority of which are basaltic lava

flows. Most of these rocks have poor capacity of storing and transmitting water,

except through favourable zones and at favourable locations. Aquifer systems

encountered are therefore limited in nature. Ground water occurs both in weathered

and fractured zones. Ground water occurs in all weathered formations of the district

under phreatic conditions and in fractured and jointed formations under semi-

confined conditions.

Deccan basalts act as a multilayer aquifers having low to medium permeability. In

Deccan basalts that comprise different flows, fractures and interstitial pore spaces of

vesicular zones, are good repositories of ground water. Groundwater occurs under

phreatic conditions in weathered zone of these basalts and under semi-confined to

confined conditions in inter-trapeans and also in joints and fractures at deeper levels.

In limestone, solution cavities are considered to be more potential than weathered

and fractured ones. In gneisses and schist, weathered zone varies from 7 to 12 m

and water-bearing zones extend down to 80m.

The aquifers occurring within the shallow depth range of 0 to 20 m bgl are mainly

weathered and fractured formations. Groundwater occurs in these formations under

phreatic conditions and the average thickness of these aquifers ranges from 5 to

15m. In general, 60% area of the district is having the weathered thickness in the

range of 5 to 10 m. About 25% of the district area has weathered thickness in the

range of 10 to 15m and 15% in the range of 15 to 20m.

In the major parts of the district, the decadal mean of depth to water level generally

ranged between 5 to 20 m bgl (Figure-3). During pre-monsoon period i.e. May 2006,

8%, 28%, 37%, and 27% of the wells had depth to water level ranges between 0-2,

2-5, 5-10 and 10-20m bgl respectively (Figure-4). There was a rise of water level in



30%, 20% and 30% of the wells during post monsoon period i.e. November 2006 in

the range of 0-2, 2-4 and more than 4m respectively.

On the other hand 12%, 5% and 3% of the wells showed a fall in water levels in the

ranges of 0-2, 2-4 and more than 4m respectively. Therefore, more than half of the

district had depth to water level between 2-5m bgl during post-monsoon period i.e.

November 2006 and the overall depth to water level in the district was between 0 to

10m bgl, except in a small strip towards southern part of Ramdurg taluk where it is

more than 10m bgl.

The long-term pre-monsoon water level trend (1996-2005) shows a rise in 53% of

the wells, while there is a fall in 47% of the wells. On the other hand during post-

monsoon period, 68% of the wells show falling trend, while there is a rising trend in

32% of the wells. Over all the annualised trend shows a fall in 61% of the wells and

rise in 39% of the wells.

Based on the pumping test data of the dugwells, it is inferred that there is a

progressive increase in the permeability exceeding >100m/ day in the water table

phreatic zones of basaltic aquifers towards the east, even though the area falls in the

northern dry and transitional zone having low to moderate rainfall. Similar is the case

with other lithologic units. On the other hand in Khanapur taluk, though it falls in high

rainfall hill zone agro-climatically, the permeability of the principle water table

aquifers of schists and gneisses range from < 25 to 50m/ day.

Analyses of Pumping test data of exploratory borewells show that wells have yielded

discharges in the range of 0.02 to 7.58 lps and the draw down ranged between 0.068

to 32.44 m. The transmissivity (T) computed was between 1 and 2,220 m2/day.



Fig 3.18: Hydrogeology of Belgaum district, Karnataka

Source: Central Ground Water Board South Western Region Bangalore August 2007

3.13 SEISMICITY Based on the tectonic features and records of earthquake, a Seismic Zoning map

has been developed for the country by Bureau of Indian Standard (BIS). Seismic

Zoning Map of India is placed as Figure 3.13



Figure 3.19 : Seismic Zone Map

The area under study falls in Zone-II, according to the Indian Standard Seismic

Zoning Map. Suitable seismic coefficients in horizontal and vertical directions

respectively, have to be adopted while designing the structures.

* * * * *



CHAPTER 4

ANTICIPATED ENVIRONMENTAL

IMPACTS & MITIGATION

MEASURES



4.0 Identification of Impacts

Identification, prediction and assessment of potential impacts of the proposed expansion

project on the surrounding environment during construction and thereafter during

operation stage have been discussed in this section. In line with any industrial

development, the Sugar, cogen & distillery expansion project have environmental

impacts during construction and operational phases. By and large the impacts are local

and there are no major sub regional or regional negative impacts.

The proposed expansion of integrated project installation will involve activities such as

erection of plant and machinery, creation of infrastructure to transport raw material and

finished products as the main activities during construction phase. These activities

during construction phase will have impacts on air & water quality, noise levels, socio-

economic conditions. However the impact on environment will be limited to construction

phase. Following paragraphs give a brief description of the environmental impacts of

proposed of sugar, cogeneration & Distillery projects during construction and operational

phases.

· During construction phase: These may be regarded as temporary or short term

and ceases with implementation of the project.

· During operation phase: These impacts are continuous warranting built in

permanent measures for mitigation and monitoring.

Construction and operation phase of the project comprises of various activities, each of

which will have an impact on some or other environmental parameters. Impacts on

environmental parameters during construction and operational phase have been studied

to estimate the impacts on environment as below.

4.1 Impacts during Construction Phase and Mitigation Measures

Construction activity includes foundation works, fabrication of storage tanks and erection

of plant-machineries. The construction phase is expected to be about three months. The

major activities during construction phase include

1. Site preparation and development

2. Civil construction work

3. Vehicular movement

4. Loading and unloading civil items and plant machineries

5. On site storage of civil items & plant machineries.



6. Erection of plant and civil structures

7. Power supply

8. Maintenance of construction machinery

9. Disposal of solid wastes

Probable environmental impacts during construction phase are typically due to activities

related to clearing of vegetation, leveling of site, civil constructions erection of structures

and installation of equipment.

The activities will have impact on land environment, water environment, air environment,

noise level and socio-economics of the region and these are discussed below.

4.1.1 Air Environment

Impact on Air Quality

During construction phase, suspended particulate matter will be the main pollutant,

which will be generated from site development activities and movement of vehicles. The

impact will be mostly confined within the project boundary and is expected to be

negligible outside the plant boundary. The transportation and construction activity is for a

limited period and therefore the air emissions due to vehicles or construction equipment

will be for a limited period only. The impact of such activities would be temporary and

restricted to construction phase.

The main sources for impact of air quality during construction period is due to movement

of vehicles and construction equipment at site, dust emitted during leveling, grading,

earthmoving, foundation works, transportation of construction material etc. Hence,

during the construction phase, particulate matter (PM10 & PM2.5) would be the main

pollutants. The emissions from vehicles and construction equipment could also be of

some concern on a local level. The internal roads will be paved or tarred. Proper upkeep

and maintenance of vehicles, sprinkling of water on roads and construction site are

some of the measures that would greatly mitigate the impacts on air environment during

the construction phase.

All the vehicles permitted at the project site will be possessing Pollution under Control

certificate. All the contractors will be instructed to carry out regular maintenance of

vehicles in order to keep pollution under check.



Air Pollution Mitigation Measures

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

of water. The impacts will be localized in nature and the areas outside the project

boundary are not likely to have any major impact with respect to ambient air quality.

The construction of proposed units would result in the increase of SPM concentrations

due to fugitive dust. Frequent water sprinkling in the vicinity of the construction sites

would be undertaken and will be continued after the completion of plant construction as

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

will be properly maintained to comply with exhaust emission requirements.

4.1.2 Noise Environment

Impact on Noise Levels

Noise will be generated during the construction phase due to vehicular traffic, movement

and operation of construction equipment like dozers, scrapers, concrete mixer, cranes,

generators, compressors, vibrators etc. The operation of these equipments will generate

noise ranging between 70-85 dB (A). Major construction work will be carried during the

day time. Personnel protective devices such as ear muffs will be provided to the

operators of this machinery to prevent harm due to noise.

Since noise levels reduce @ square of distance, effect of construction activity noise shall

not be significant on surrounding areas.

Noise Levels Mitigation Measures

The noise control measures during the construction phase include provision of caps on

the construction equipment and regular maintenance of the equipment. Equipment will

be maintained appropriately to keep the noise level within 75 dB(A). Wherever possible,

equipment will be provided with silencers and mufflers. High noise producing

construction activities will be restricted to daytime only. Further, workers deployed in

high noise areas will be provided with necessary protective devices such as ear plug,

ear-muffs etc. Overall, the impact due to increase in noise on the environment would be

insignificant, localized and confined to the day hours.



4.1.3 Water Environment

Impact on Water Resources and Quality

Due to civil construction activities, during rainy season the surface run off may contain

more of eroded soil and other loose matter. Construction activities may be avoided

during rainy days to mitigate the small impacts on soil quality caused due to construction

activity. Segregation of construction area and proper drainages facilities will prevent the

contamination of water due to construction activity. Proper garland drains will be

provided so as contaminants like oil and grease, diesel fuel, paints etc do not mix with

soil. Water after washing will be collected in drain in an impervious pond, filtered and

used for irrigation.

Proper drinking and sanitation facilities will be constructed first for workers. The sewage

will be collected in a septic tank with overflow as well as sludge will be used for irrigation.

Water Pollution Mitigation Measures

Toilets with septic tanks will be constructed at site for workers and it will be ensured that

domestic wastewater generated in worker colonies does not flow to water bodies. The

overall impact on water environment during construction phase due to expansion

activities is likely to be short term and insignificant. By adopting necessary mitigation

measures the overall impact on water environment during construction phase of the

project will be temporary and insignificant.

4.1.4 Land Environment

Impact on Land use

Additional construction will be carried out on barren lands which are already available

with USWL. It is a plain land almost in level. No major earth moving / leveling will be

involved. There is no vegetation or trees or water bodies present on factory land. Most of

the land will be open with storage sheds, roads, effluent treatment systems installed.

Construction will be only in small portion.

33% of open land and belt around the factory premises will be developed as green belt.

Plant sampling suiting local conditions will be planted



Impact on Topography

Topographically, the area forms slightly elevated land and general elevation is from

North to South. Most of the area forms plain land covered with mixed soil. Adequate

storm water drains will be provided to collect and carry the surface runoff during

monsoon to the natural drainage system of the project area.

4.1.5 Socio-economic Environment

The socio-economic impacts during the construction phase of the proposed

Enhancement Sugar plant with Cogeneration Plant & distillery unit could result due to

migrant workers, worker camps, induced development etc. Increase in floating

population. The local population will have employment opportunities in related service

activities like petty commercial establishments, small contracts/sub-contracts and supply

of construction materials for buildings and ancillary infrastructures etc. consequently, this

will contribute to economic up liftment of the area. Normally, the construction activity will

benefit the local population in a number of ways, which include the increase in

requirement of construction skilled, semi-skilled and un-skilled workers, tertiary sector

employment and provision of goods and services for daily needs including transport.

Ø Local people will be given preference for employment depending on their

suitability;

Ø All the applicable guidelines under the relevant Acts and Rules related to labour

welfare and safety will be implemented during the construction phase;

Ø The contractor has been advised to provide fire wood/kerosene/LPG to the

workers to prevent cutting of nearby trees for firewood; and

Ø The construction site will be secured with fencing and is having guarded entry

points.

4.1.6 Storage of Hazardous Material

The hazardous materials used during construction may include diesel and lubricating

oils.. These materials will be stored and handled carefully under applicable safety

guidelines. Some of the precautions of storage include the following:-



Ø Dyked enclosures will be provided so as to contain complete contents of the

largest tank;

Ø Diesel and other fuels will be stored in separate dyke enclosures;

Ø Tanks having large storage capacity for will be separated by fire insulating walls

from other storage tanks; and

Ø The distance between the storage tanks will be maintained half their height.

4.1.7 Facilities to be provided by Labour Contractor

The contractor will be made to provide the following facilities to construction work force:

First Aid

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

necessary appliances including sterilized cotton wool etc. Ambulance will be kept at the

site and made available at workplace to take injured person to the nearest hospital.

Potable Water

Sufficient supply of water fit for drinking will be provided at suitable places.

Sanitary Facility

Sanitary facilities will be provided at accessible place within the work zone and kept in a

good condition. The contractor will conform to requirement of local medical and health

authorities at all times.

Canteen

The canteen will be provided for the benefit of workers.

Security

USWL will provide necessary security to work force in co-ordination with State

authorities.



4.2 Impacts during Operation Phase

During the Operation Phase the establishment of the project, results in emissions,

generation of wastewater and solid waste.

4.2.1 Air Pollution

The proposed project will use own generated bagasse, available bagasse from nearby sugar

mills for the proposed Boiler of the Integrated Sugar plant. The unit will use bagasse for

which steam turbine has been envisaged. In extreme emergency, Diesel Generator will be

used for running the important equipment and street light. This will be limited to a few hours

only. As such, the pollutants expected to be released in the emission will mainly be the

Particulate Matter (PM).

The concerning emission will be only from Point Source i.e. from Stack of Boiler, which

will be released through a stack of 75 m. height.

Mitigation Measures

The measures to minimize air pollution have been envisaged as under:

v Providing adequate stack height as per norms of MoEF & KSPCB for wider

dispersion of pollutants, resulting in lower ground level concentration.

v Stacks of Boiler will be equipped with ESP.



Electro Static Precipitator (ESP) Details

Ø A suitable ESP so that the fly ash contents of flue gases leaving the chimney

confirm to the rules and regulations of the pollution act as applicable to the

factory and as outlet concentration below 100 mg/Nm3.

Ø A certificate to this effect should be obtained from pollution control board under

whose jurisdiction this mills falls.

Ø The ESP shall be installed on the suction side of the I.D. fan and shall to be

complete with rotary airlock valve with drive provided with local and remote push

button control, and a side manual gate. The minimum elevation of discharge

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

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

facilitate regular inspection and cleaning of the ESP.

Ø Even with one field of ESP out of service the ESP must remain in operation. The

ESP with only one field in service at 100% boiler MCR with bagasse as fuel.

Ø All electrical including MCC, rectifiers, panels, electrical & control cables, earthing

will be in place. ESP control shall be from control room

Ø The design & supply will suitable flue gas cleaning system to ensure that the flue

gases entering the chimney do not contain SPM in excess of 100 mg/Nm3.

The exhausts of DG set will be provided with adequate height as per norms prescribed

by Central Pollution Control Board.

Impact Assessment

The impact on air quality has been assessed considering the following:



a) The air quality impacts have been predicted for the release of emissions

from Stack of Boiler.

b) Plume Rise and Effective Stack Height

Brigg’s modified equation as suggested by Central Pollution Control Board

has been used for calculation of effective Stack Height.

c) Dispersion Coefficient: Brigg’s dispersion coefficients have been used to

determine sy and sz for rural conditions.

d) Particulate Matter (SPM) has been considered taking maximum limit of 150

mg/Nm3 for Stack as prescribed by Central Pollution Control Board for stack

in general.

Air Quality Modeling

The air dispersion model used is Industrial Source Complex Short Term (ISCST 3),

Version 02035 developed by the US Environmental Protection Agency (US EPA) and

recommended by Ministry of Environment & Forests (MoEF).

The main air pollutant from the operations would be Particulate Matter and for the same

short term 24-hourly GLC’s has been computed. The GLC’s are estimated using the site-

specific meteorological data. The details of stack and emissions for the proposed project

are presented in Table 4.2.

AIR POLLUTION MODELLING

Prediction of impacts 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, AERMOD View version 8.0.0

dispersion model based on steady state Gaussian plume dispersion, designed for

multiple point sources for short term and developed by Lake Environment has been used

for simulations from open pit source.

Presentation of results

The maximum GLCs for Particulate Matter after implementation of the stone quarry are

likely to be within the prescribed standards for industrial areas. The impact on ambient

air quality due to the proposed plant has been assessed by estimating the maximum



Ground Level Concentrations (GLC's). Site specific meteorology data recorded for the

period September 2013 to November 2013. In the Short-term simulations, the

concentrations were estimated around 441 receptor points chosen to obtain an optimum

description of variations in concentrations over the site in an area of 10 km radius

around plant centre.

The highest predicted results for each pollutant are tabulated. The incremental

concentrations are estimated at ambient air quality monitoring locations and are

superimposed over the baseline concentrations to know the likely resultant

concentrations and are depicted below in Table.

TABLE 4.1 RESULTANT CONCENTRATIONS

Pollutant Maxi AAQ Conc. Recorded during study period (µg/m3)

Max incremental Conc. Due to project (µg/m3)

Resultant Conc (µg/m3)

PM10 72.3 0.00062 72.30062

SO2 9.1 0.20966 9.30966

NOx 16.6 0.20912 16.80912

Maximum incremental concentration was obtained at project site, when added with

baseline values resultant concentration was obtained which is below NAAQ standards.

The isopleaths obtained were presented in figure 4.1 to 4.3.



Input Parameters

For modeling purposes Particulate Matter (PM) have been considered. The emission of

SO2 & NOx has not been considered because of its insignificant concentration in

Emission.

The PM has been taken maximum 150 mg/Nm3 (as prescribed by CPCB for Stack

Emission). The details are presented in Table 4.2 as under.

Table – 4.2 Stack & Emission Details

Source of Air pollution

MYS 1736 50TPH

MR 8597 MR 8598 60TPH

KTK 2272 70TPH

KTK 2404 80TPH

Type of fuel Bagasse Bagasse

Bagasse + coal

Bagasse

Quantity of fuel 25 T/hr. 60 T/hr 35 T/hr 40 T/hr

Height 45.5 mtr 60 mtr. 50 mtr. 52 mtr.

APC equipment Wet Scrubber

Wet Scrubber ESP ESP

Gas quality m3/hr 36.3 42.4 20.7 19.3

Temp 0C 11 140 100 110

Exit gas velocity m/sec

10.3 13.6 5.9 6.2

SPM (mg/Nm3) 11.4 7.9 17.3 10.2

SO2 (µg/Nm3) 41.1 42.2 39.2 40.1

NOx (µg/Nm3) 42 40.7 46.0 44

Results & Discussions

The predictions have been made for the summer season i.e. September 13 – November

13. The hourly data on wind speed, direction, atmospheric stability, temperature have

been used.



For the short-term simulations, the concentration was estimated around 396 receptors to

obtain an optimum description of variations in concentrations over the site in 10 km.

covering 36 directions for the monitoring period. For each time scale i.e. for 24 Hrs. the

model computes the 50 highest concentrations observed during the period over all

measurement points.

The resultant concentration after the commissioning of the proposed boiler on the GLC

of SPM as predicted and super imposing the predicted values on the maximum baseline

concentrations recorded during the study period respective to the direction and distance

of the monitoring location . The predicted GLCs for SPM after commissioning of the

proposed project are not found to be significant to add up on the existing ambient air

quality. However, the proposed air pollution control system for boiler, Electro Static

Precipitator (ESP) will be installed for further improving the existing ambient air quality

and help in bringing down the ambient air quality.

The estimated cumulative GLCs for SPM after commissioning of the proposed project

are found to be well within the ambient air quality standards prescribed by CPCB.

Hence it can be concluded that the impact on Air Quality by the proposed project will be

negligible. The environment around the proposed site has enough buffers to assimilate

these insignificant values. The favorable wind and the proposed height of stack will

disperse these pollutants in different directions fast to longer distance with negligible

concentrations.

4.2.2 Impact on Water Quality

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

the development will take place in existing building structure. Adequate provisions will be

made available to collect the runoff from the site, so that runoff will not be allowed to

stand or enter into the roadside or nearby drain.

The water used for the USWL plant will be supplied by Irrigation department. The water

will be treated fully to standard characteristics. The samples will be tested & confirmed.



Total effluent generated during the operation will be about 4960 M3/day from sugar &

cogen unit. An effluent treatment plant has been provided which is continuously in

operation and the results obtained will be within the permissible limits as prescribed by

KSPCB.

This will be achieving ‘Zero Discharge’ plant to meet the guidelines of MoEF. The

effluent from the sugar mill will essentially be subjected to the effluent treatment plant

and then will be utilized for irrigation and other horticultural uses. The domestic effluent

will be treated into STP followed by Gardening. The details of water budget and process

of ETP are enclosed as Annexure.

4.2.3 Solid Waste

Minimum amount of solid waste will be generated as there will be construction work.

Following mitigation practice is the policy for future:

Ø Minimization at al l levels need be attempted for discarded products,

empty containers, packing surpluses, incoming raw material

unloading spi l lages and fugit ives.

Ø The solid in process generate only as Ash from cogenerat ion plant,

ETP sludge and domestic waste.

Ø Other wi l l be empty drums which can be used for ref i l l or may be

disposed to original vendors

The solid waste generation from Sugar and dist i l lery units are tabulated in

table 2.9.

Table 2.9 Solid Waste Generation from Sugar Plant with disposal

Source Quantity Treatment & Disposal

CANE CRUSHING SEASON

Mil l House Bagasse – 6000

T/day

Use in Boi ler of Cogen plant

Process House Press Mud – 800

T/day

Disposed to Dist i l lery units by

product ion of potash powder.



Boiler House –

Cogen Plant

Ash – 200 T/day The ash being r ich in nutr ient

composit ion, the same will be

disposed as fert i l izer for soil

condit ioning.

Eff luent

treatment Plant

Sludge – 80-100

T/day

Disposed as Manure.

Evaporator &

Dryer plant

powder

10-12 MT/day Sold to farmers & fert i l izer

companies as a manure

Hazardous wastes such as waste oil from machinery would be generated from the

proposed project. Such waste oils shall be collected, stored safely at a designated

area. The waste oils would further be sold to oil recyclers, duly approved by Central

Pollution Control Board (CPCB).

4.2.4 Impact on Ecology

The enhanced project will not have any significant impact on ecology as there are no

reserve forests in the study area and in addition to that the project will implement an

effective environmental management plan to control the emissions from the project.

Green belt development

Out of the total project area 33% will be used for green belt development. Local species

will be preferred for green belt development.

4.2.5 Demography and Socio-economics

The impacts due to enhanced project on demography and socio economic condition are

as follows:-

Ø Increase in employment opportunities and Reduction in migrants to outside for

employment.

Ø Increase in literacy rate.

Ø Growth in service sectors



Ø Increase in consumer prices of indigenous produce and services, land prices,

house rent rates and Labour prices.

Ø Improvement in socio cultural environment of the study area.

Ø Improvement in transport, communication, health and educational services.

Ø Increase in employment due to increased business, trade commerce and service

sector.

Ø The overall impact on the socio economic environment will be beneficial.

4.2.6 Impact on Health

Adequate air pollution and noise control measures will be provided. The environmental

management and emergency preparedness plans will be prepared to ensure that the

probability of undesired events and consequences would be reduced, and adequate

mitigation measures will be provided in case of an emergency. The overall impact on

Human health is negligible during operation of plant.

4.3 MITIGATION MEASURES AGAINST ENVIRONMENTAL IMPACTS

The main objective of mitigation measures is to conserve the resources, minimize the

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

It also incorporates greenery development and landscape of open area and also the

post project monitoring of environmental quality. The measures under mitigation plan are

classified as,

· Measures built in the process

· Measures during construction phase

· Measures during operation phase.

4.3.1 MEASURES BUILT IN THE PROCESS

Built in measures for resource conservation and pollution control in the industry are

discussed along with project. The main objective is to follow environments friendly

process, with efficient utilisation of resources, minimum waste generation and built in

waste treatment and operation safety. The measures adopted are,

Co-Gen Power Unit



Ø Boilers will be fired with multi fuels having low sulphur content.

Ø Boilers are provided with ESP and chimney of 50 m height to control the impact

of gaseous emissions.

Ø Bagasse is Conveyed through covered mechanical conveyors in the plant.

Distillery Unit

Ø Continuous fermentation to improve alcohol yield and recovery and thereby

Ø molasses consumption reduced.

Ø Separation, recovery and recycle of yeast present in fermenter wash for reuse

Ø in fermenter. This reduces the use of fresh culture and nutrients in the fermenter

and also improves ethanol yield.

Ø Use of live steam is avoided by employing re-boiler in distillation columns. This

reduces the generation of wastewater.

Ø Multi pressure distillation system is used to reduce the consumption of steam and

quantity of effluent.

Ø Use of pumps with mechanical seals to avoid liquid leakages.

Ø Scrubbing of fermenter vent gases containing CO2 to recover traces of alcohol

present in it.

Ø Water utilization reduced by

a. Evaporation of spent wash with recovery of condensate water for use in cooling

tower,

b. Re-boiler reduces water utilization,

c. Recycle of lees water for dilution of molasses and

d. Decanter centrifuge and recycle of thin yeast slurry saves water and improves

alcohol recovery.

Ø Bio recovery from spent wash for use as fuel.

Ø Concentrated spent wash is used as fuel in boiler.

* * * * *



CHAPTER– 5

ENVIRONMENTAL MONITORING

PROGRAM



Environmental Monitoring Program

5.0 Introduction:-

The Objective of this Study is to minimize or off-set the adverse impacts that might be

created due to this project. Various mitigation measures are designed and described. In

operation phase we shall have to check continuously as to (1) whether our measures are

being operated as per design and (2) whether the resultant impacts are coming inside

the tolerance limits. This can happen only if we have a specialized cell, higher

management support for the cell, adequate funding, support of library- laboratory, open

dialogue corridor with all the stakeholders and authorities, and if the success indicators

are in agreement with our findings. Documentation is necessary along with periodic

Reporting to factory management and statutory authorities such as MoEF, KSPCB,

Factory inspectorate etc.

It is proposed to frame an Environmental Monitoring programme both in Construction

and Operational stages to monitor the effectiveness of the mitigation measures by

judging the impact on environment. A separate budget is proposed for the same as also

a dedicated Cell. A transparent approach will be kept with documentation and Reporting

with statistical treatment to the data. Checklist of Statutory Obligations will be maintained

and compliance with it will be monitored.

A chemical or process industry in general produces solid, liquid and gaseous wastes,

which are discharged to the environment. These discharges pollute receiving media

such as air, water and land which in turn harm living beings and property. The waste

product may contain one or more chemical constituents. It is the responsibility of the

industries to prevent or minimize the discharges of waste products by adopting suitable

control measures in the factory to avoid harm to the environment. The effectiveness of

such measures is ascertained by systematic monitoring of discharges at factory level

and at receiving level. Systematic monitoring of various environmental parameters is to

be carried out on regular basis to ascertain the following.

1. Pollution status within the plant and in its vicinity.

2. Generate data for predictive or corrective purpose in respect of pollution.

3. Effectiveness of pollution control measures and control facilities.



4. To assess environmental impacts.

5. To follow the trend of parameters which have been identified as critical;

Pollution Monitoring and Surveillance Systems

For Proposed Enhanced Sugar, Cogeneration power plant and Distillery unit, the Indian

Emission Regulations stipulate the limits for particulate matter emissions and

appropriate stack heights will be maintained for keeping the emission levels in the

ambient within the air quality standards. The characteristics of the effluent from the plant

would be maintained so as to meet the requirements of the State Pollution Control Board

and the National Standards for Sugar Plant stipulated by the Central Board for

Prevention and Control of Water Pollution.

5.1 Environmental cell

An Environmental Cell will be established in the industry to implement and monitor

environmental policy and program. Environmental management Environmental cell

consisting of Managing director and departmental heads will be created to effectively

manage the environmental activities in the industry.

5.2 Environmental Department

Environmental department will be formed with environmental scientist, laboratory

chemists and operators to implement and operate pollution control and environmental

protection measures.

5.3 Environmental Monitoring Plan

Self monitoring system consisting of well equipped laboratory and manpower will be

established in the industry with facilities to analyze wastewater, soil, stack emissions,

ambient air etc. to ascertain the compliances of environmental norms and standards.

The routine monitoring program as indicated below is already practiced in the existing

industry. The same facility and system is adequate even after expansion of the proposed

power plant. However additional monitoring facility will be provided for stack emissions

of the boiler.

Regular monitoring of important and crucial environmental parameters is of immense

importance to assess the status of environment during plant operation. The knowledge

of baseline status and monitored data is an indicator to ascertain for any deterioration in

environmental conditions due to operation of the plant. Based on these data, suitable



mitigation steps could be taken in time to safeguard the environment. Monitoring is as

important as that of pollution control since the efficiency of control measures can only be

determined by monitoring. A comprehensive monitoring system in the industry is

parented below.

5.4 Environmental Records

Environmental department will maintain log sheets and records for operation and

maintenance of pollution control and related facilities. Self monitoring system will be

established in the industry with manpower and facilities to ascertain the compliances of

environmental norms and standards. A laboratory is established to analyze wastewater,

soil, stack emission, ambient air etc. The parameters are monitored as per

MoEF/KSPCB guidelines. The quality and quantity of wastes discharged from the

industry and the significant parameters of environment will be regularly monitored during

operation of the industry.

Air Quality monitoring programme

The purpose of air quality monitoring is acquisition of data for comparison against

prescribed standards, thereby ensuring that the quality of air is maintained within the

permissible levels. It is proposed to monitor the following from the stack emissions:-

v Particulate Matter (SPM, PM10& PM2.5)

v Sulphur dioxide

v Oxides of Nitrogen

It is proposed to monitor particulate emission qualitatively and quantitatively in the stack

and with the aid of a continuous particulate stack monitoring system. The stack

monitoring data would be utilized to keep a continuous check on the performance of

ESPs and Scrubbers. Further it is proposed to monitor and record the weather

parameters such as temperature (maximum & minimum), Relative humidity, wind

direction, wind speed, rainfall etc. on daily basis, for this purpose, it is proposed to install

Weather Monitoring Station with necessary gadgets.

5.5 Post Project Environmental Monitoring

Environmental monitoring will be conducted on regular basis to assess the pollution level

in the plant as well in the surrounding area. Therefore, regular monitoring program of the



environmental parameters is essential to take into account the changes in the

environment. The objectives of monitoring are:-

Ø To verify the result of the impact assessment study in particular with regards to

new developments;

Ø To follow the trend of parameters which have been identified as critical;

Ø To check or assess the efficacy of the controlling measures;

Ø To ensure that new parameters, other than those identified in the impact

assessment study, do not become critical through the commissioning of new

installations or through the modification in the operation of existing facilities;

Ø To check assumptions made with regard to the development and to detect

deviations in order to initiate necessary measures; and

Ø To establish a database for future Impact Assessment Studies for expansion

projects.

The attributes, which merit regular monitoring, are specified below:-

v Air quality;

v Water and wastewater quality;

v Noise levels;

v Soil quality;

v Ecological preservation and afforestation; and

v Socio Economic aspects and community development

The post project monitoring will be carried out at the industry level is discussed below:

5.6 Monitoring and Reporting Procedure

Regular monitoring of important and crucial environmental parameters has an immense

importance to assess the status of environment during plant operation. With the

knowledge of baseline conditions, the monitoring programme can serve as an indicator

for any deterioration in environmental conditions due to operation of the plant and

suitable mitigation steps could be taken in time to safeguard the environment. Monitoring

is as important as that of control of pollution since the efficiency of control measures can

only be determined by monitoring. The following routine monitoring programme would

therefore be implemented. A comprehensive monitoring program will be implemented is

given in the Table 5.1.

Table 5.1 Post Project Monitoring Source

Source Location Parameters to Frequency Responsibility



be monitored

Meteorology At the project

site

Wind speed,

direction,

temperature,

relative

humidity

rainfall

Hourly M/s USWL

(MoEF

recognized Lab)

Ambient Air

Quality

Within plant

and

surrounding

10km radial

zone.

PM10, PM2.5

SO2, NOx

Monthly M/s USWL

(MoEF

recognized Lab)

Water Quality Within the plant

and

surrounding

10km radial

zone Surface

Water As well

as Ground

Water

As per IS:

10500

Monthly M/s USWL

(MoEF

recognized Lab)

Noise Levels Within the plant

and

surrounding

10km radial

zone.

Noise levels Monthly M/s USWL

(MoEF

recognized Lab)

Soil quality Within the plant

and 10 km

radial zone

Soil

parameters

Monthly M/s USWL

(MoEF

recognized Lab)

Boilers & DG

sets

Individual Units Particulate

matter, SO2,

NOx

Monthly M/s USWL

(MoEF

recognized Lab)

Wastewater Inlet and outlet

of ETP Steam–

Generator

pH, TDS, COD,

SS and others .

pH, SS, Oil,

Monthly M/s USWL

(MoEF

recognized Lab)



Blow down

Cooling Tower

Grease, Cu,

Iron

Phosphates

5.7 Environmental Laboratory Equipment

The plant will have an in-house environmental laboratory for the online monitoring of air,

noise, water and soil. For all non-routine analysis, the plant may utilize the services of

external accredited laboratory facilities. The laboratory equipment required for

monitoring and analysis are given below:

Table-5.2 List of Equipment for the Environmental Laboratory

Name of the Equipment Nos.

Automatic Weather Station, which can record wind speed, wind

direction temperature, relative humidity, rainfall, Solar radiation

Sunshine

1

a) Online Automatic gaseous stack monitoring kit for SO2, NOx,

O2, Flue gas volume, Temperature etc. b) On line dust monitor

1

Fine Particulate Matter samplers with PM10& PM2.5 provision 5

Portable Flue Gas Combustion Analyser 1

Atomic Absorption Spectrophotometer 1

Mercury analyzer 1

Portable Noise level meter (Dosimeter) 2

Portable Waste Water Analysis Kit 1

BOD Incubator 1

COD Digester 2

Electronic Balance 1

Calorimeter 1

Conductivity Meter 2

Different micron sieves (set) 1 set

Dissolved Oxygen Meter – Brief case size 2

Electronic colony counter 1

Flask Shaker 1



Hot Air Oven 2

Laboratory Water Distillation and 147emineralization (DM) unit 2

5.9 Environmental Management Group

A separate environmental management group will be established to implement the

management plan. The group will be headed by a Superintending Engineer. The group

will ensure the suitability, adequacy and effectiveness of the Environment Management

Program. The management review process will ensure that the necessary information is

collected to allow management to carry out its evaluation. This review will be

documented. Functions of Environmental Management Group (EMG) at Site will be:-

Ø Obtaining consent order from State Pollution Control Board.

Ø Environmental monitoring.

Ø Analysis of environmental data, reports, preparations and transmission of report

to statutory authorities, Corporate Centre etc.

Ø Co-ordinate with statutory bodies, functional groups of the station, head office

etc.

Ø Interactions for evolving and implementation of modification programs to improve

the availability / efficiency of pollution control devices / systems.

Ø Environmental Appraisal (Internal) and Environmental Audit.

5.10 Expenditure and Environmental Measures

The budget for Environmental Protection Measures in Lakhs is given as under:-

The investment of Rs.70.50 crs/annum is earmarked for environmental monitoring plan

& auditing & Rs.14.95 crs for laboratory facilities.

Table 5.3: Budget provision for Environmental Management plan

S.

No.

ITEM Capital

Cost in Crs.

Recurring Cost per

Annum in Crs.

1 Air Pollution Control 15.00 6.00

2 Water Pollution Control 50.00 6.00



3 Noise Pollution Control 0.50 0.10

4 Environment Monitoring and

Management

1.00 0.10

5 Solid waste management 2.00 1.00

6 Occupational Health 0.50 0.05

7 Green Belt 1.00 0.05

8 Safety management. 0.50 0.05

9 Laboratory and chemicals -- 0.10

10 Salaries and wages of workers. -- 1.50

Total 70.50 14.95

* * * * *



CHAPTER– 6

ADDITIONAL STUDIES

(RISK ASSESSMENT AND DISASTER

MANAGEMENT PLAN)



Risk Assessment

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).

1. Introduction

The word 'disaster' is synonymous with 'emergency' as defined by the Ministry of

Environment and Forests (MoEF). An emergency occurring in the proposed

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

serious injuries, loss of lives, extensive damage to environment or property or serious

disruption outside the plant. It will require the best use of internal resources and the use

of outside resources to handle it effectively. It may happen usually as the result of a

malfunction of the normal operating procedures. It is imperative to conduct risk analysis

for all the projects where hazardous materials, fuels are handled.

The following have been addressed as part of the risk analysis.

ü Introduction

ü Hazard Identification and Risk Analysis

ü Risk Reducing Measures

The Introduction deals with the objective and methodology of carrying out the risk

analysis. Hazard Identification and Risk Analysis discusses about the various types of

hazards associated with the operation of the Plant due to process, storage & handling,

human errors, electric failures and natural calamities. It also presents the calculated

frequencies of occurrence of different accident scenarios for the identified potential

hazard occurrence in the proposed plant and the details of consequence modelling/

analysis for the identified potential accidents/disaster scenarios in the plant. Risk

Reducing Measures based on the calculated frequencies and consequences.

An industry with its complex nature of activities involving various plant machineries, raw

materials, products, operations, intermediates and environmental discharge has a

number of associated hazards. A minor failure can lead to major failure resulting into a



disaster causing heavy losses to life, property and environmental. Risk assessment

studies are being conducted to ensure safety and reliability of any new plant, through a

systematic and scientific methods to identify possible failures and prevent their

occurrences before they actually cause disasters and production loss.

Accidents can occur in any industry despite of taking efforts to prevent them. The

suffering and damage as a result of the accident is determined by the potential for loss

surrounding the event, but by taking correct action at the time of the occurrence of the

incidence the full potential loss can largely avoided and effective action will be possible if

a pre-planned and practiced procedure for handling major emergencies utilizing the

combined resources of factory and the outside emergency services is in existence.

The best way of managing an emergency lies in its prevention it is recognized that in

spite of our best efforts to prevent emergencies by good engineering design and

construction, reliable safety system careful selection of personnel & training, audits and

inspections, use of state of art technology and sophisticated equipments etc. things can

still go wrong therefore it is essential to properly prepare, develop and update

emergency plans and rehearse them and be prepared for emergencies. The objective of

the emergency plan is to contain and control incidence to safe guard the employees and

any one nearby who might be affected and to minimize property loss & to protect the

environment.

2. Safety, Health & Environment Policy:

Safety Policy:

01. We believe that accidents are preventable and health hazards can be minimized by

Training and Retraining of the employees.

02. We will comply all the legislation & rules regarding Safety & Health.



03. We are committed to provide safe machinery, equipment, methods & tools and to

continual improvement in Health and Environment (HSE) performance.

04. Our Policy is to maintain Safety beyond compromise.

05. We believe that rules are sacred and must be observed.

06. While on duty, we will concentrate on our job.

07. Care & Caution is our guide in the life.

08. Safety, Security & Punctuality keep us always happy.

09. Our Motto – No Accidents due to human failure.

10. Our employees are more valuable than anything and we expect the employees to

follow the HSE norms.

Environment Policy:

We shall –

1. Conduct our operation in an environment friendly manner and to comply with the

relevant regulation and prevent pollution.

2. Strive for continuous improvement in our environmental performance by setting



challenging targets.

3. Conduct necessary programmes to enhance environmental awareness amongst

our employees and the general populace around plant and site.

4. Strive to conduct industrial and commercial operation in such a way that the

quality of the environment now and in the future is preserved.

5. Make wastes and effluents value added products in an environment friendly

manner.

6. Demonstrate our commitment through involvement of all employees for

achievement of environmental performance.

3. Identification of Hazards Sugar and Co generation Plant :

Sl.

No

.

Operatio

n /

Process /

Departme

nt

Hazards

Identification.

Precautionary measures taken.

Remark.

1 Cane

yard /

sugar

cane

milling

1) Movement of

trucks and tractors

in haphazard

manner may

cause accident.

1) For smooth movement of vehicles

route marking is done properly and

two-way traffic is arranged separately

for incoming and outgoing of cane and

controlled by adequate security staff.

Driving license & other legal

documents are checked strictly at

entry gate.

In case of

any

emergency

the units will

be tripped

immediately

by using

tripping

devices.



2) The sugar cane

is lifted through

crane & there are

chance of cane

bundle being

dropped.

2) Safety Helmets and training is

provided to the workers working near

cane lifting area.

3) Collapse of

EOT crane due to

damaged wire

rope and improper

clamping

3) Cranes,wire ropes and lifting

tackles are tasted once in a year by

competent Authority and routine

preventive maintenance will carried

out.

4) Miss-operation

of cranes due to

defect in eyes of

crane operators

may cause of

accident.

4)Eye testing of cane operators will be

done periodically.

5) Unguarded

machinery

5) All rotating dangerous machines in

mill section are provided with

adequate guards.

6) Slippery floor 6) Floor washing is done regularly.

7) Flying of

Bagasse particles

7) Suitable face mask are provided

and flying of Bagasse will be

minimized at possible extent.

8) Electrical short

circuiting

8) Suitable fire extinguisher are kept

and loose electrical connections are

avoided.



2 Clarificati

on

section

1) Leakage of So2

gas

1) All sulphur Burners and related

pipelines are tested properly during

off-season and necessary preventive

maintenance will be taken to avoid

any damage in season. Workers are

provided with necessary PPEs.

Safety

shower cum

Eye wash

fountain is

installed at

working

area.

2) Contact with

lime dust & milk of

Lime.

2) Workers are provided with

necessary PPEs.

Sufficient

ventilation is

provided.

3) Slippery floor 3) Leakage of juice and water will be

avoided.

4) Heat stress at

sulphur furnace

4) Necessary ventilation is provided

and workers are provided with

suitable PPEs.

3 Evaporati

on and

Pan

boiling

section.

1) Slippery floors

and walk ways.

As explained above.

Sufficient

free air flow

is

maintained

& air cooler

& pedestal

fans are

installed at

pan floor &

at

evaporator

section

2) Juice leakage

from valves.

3) Heat stress in

surrounding area.

4) Un-guarded

crystallizer units.

4 Centrifug

al section

1) Machine

operators are

exposing to

noise,vibration and

1) All operators are provided with

necessary PPEs



heat stress.

2) Leakage of

steam,hot water

due to which

slippery floor

causes.

2) As explained above.

3) Unguarded

machineries.

3) All rotating dangerous machines

are well guarded and properly

covered with inter locking

arrangement.

4) All

centrifugal

machines

are tested

once in a

year from

competent

authority.

4) Collapse of

centrifugal

machines due to

imbalance of

basket & shaft.

4) During off-season and season

preventive maintenance will be

prepared for testing of shafts &

baskets.

5) Electrical short

circuiting.

5) As explained above.



5 Sugar

drying

and

cooling /

packing

Godown.

1) Lot of dust,

noise and

vibration.

As explained above.

2) Fire hazards

due to loose wiring

/ defective

electrical

appliances.

As explained above.

3) Un-guarded

Hopper drives.

As explained above.

4) Back injury due

to improper

handling of bags.

Training to the workers regarding

safe handling of sugar bags.

5) Entanglement

of persons on the

moving conveyors.

Pull card system provided.

6) Slippage and

falling of bags in

sugar Godown.

The pyramid system of bag stacking

is followed

Proper ventilation will be provided. 7) Ventilation

6 Boiler

section.

1) Failure of

pressure parts &

explosion.

As sugar industry is a seasonal one

during off-season all the pressure

parts are tested for its thickness, and

if necessary replacement of tubes

and other pressure parts will be

carried out with the permission of

statutory bodies.

Boiler are

manufacture

d by reputed

manufacture

s registered

with

statutary

authorities

and repair

work if any

2) High Temp work

area.

Lagging of all high temperate lines

and steam lines to avoid heat

dissipation in working area.



3) Fire at Bagasse

yard.

Separate high pressure fire hydrant

line is provided.

will be

carried out

by IBR

approved

contractors.

7 Co-

generatio

n Plant (

Turbine &

Power

House)

1) Noise

Less noise equipment are selected

and regular preventive maintenance

to keep the noise level to minimum.

2) Fire

The sound proof control room panel

is provided and minimum numbers of

workers with minimum duration with

PPE's like ear plugs and Muffs.

Sand buckets and fire extinguisher

are provided and workers are

trained.

3) Shock

Operators are issued Shock

resistance rubber hand gloves &

safety shoes. Electrical grade rubber

Mat is also provided to all panel

board control room. Also chart is

displayed regarding First-aid if

person got electrical shock.



8 Switch

Yard

1) Fire

In Switch Yard only hazard is Fire &

Electrical Shock. Suitable and

Sufficient Fire extinguishers are kept

near Transformer. Person’s are also

trained in fire extinguisher operation.

Total switch yard area is barricaded

to avoid unauthorized entry inside the

premises. Caution boards are also

displayed. Electrical grade rubber

mat is provided wherever necessary.

2) Electrical Shock

9 Diesel

Storage

tank.

1) Fire

We have storage of 130 KL of HSD

inside the factory for power house

use during emergency.

1) Suitable and sufficient fire

extinguisher are kept and person's

are trained.

2) Sand buckets are also provided

near HSD tanks.

2) Leakage of

HSD.

3) Suitable Dyke wall with proper

drainage arrangement is provided.

4) Permission / License is obtained

from legal authorities & it is get

Renewed time to time.

5) Storage area is completely

barricaded to avoid unauthorized

entry of person.

6) Smoking is strictly prohibited &

sign boards are also displayed.

7) Tanks are properly Earthed to

avoid static electricity.

8) Tanks is constructed as per



applicable IS standards.

10 Molasses

Tanks

1) We have

storage of 34000

MT of molasses in

tanks. There is

source of ordinary

fire hazards;

Molasses when

stored for a long

time without being

turned over there

is likelihood of

spontaneous

combustion. No

flame or smoke

will be seen but

whole content

becomes solid

mode of ashes.

Hence it should

not be allow to be

stored for a long

time and it should

be always kept in

semisolid

condition.

External water cooling arrangement

is done so that during summer,

Molasses temperature will be kept

normal.

2) Spillage due to

failure of Tanks

overflow and

. Dyke walls are provided so that

spilled molasses will be collected in

that Dyke wall.

. Constructed as per applicable IS

Standard by the reputed fabricators.



leakages. . Hydro static test is carried out

periodically during off-season and

any leakages found will be rectified.

Safety Precautions During Storage and Handling of Hazardous Material

Bagasse & Coal :

Bagasse & coal are the main sources of fire in sugar factory especially dried Bagasse is

highly combustible in nature. It catches fire automatically by way of spontaneous

combustion without external sources if it is stored for a long time. The fine bagasse will

accumulate in all workplace like electrical cables,steam pipes. If they are not cleared

periodically they will catch the fire and lead to big loss to industry. The bagasse and coal

will come under Class ' A ' fire which needs to be extinguished by water spray method

only. We propose to store coal in separate coal yard and separate fire hydrant system

will be made after storage of coal in coal yard.

Existing Control Measures at Bagasse Yard.

Bagasse yard is open area where large amount of bagasse being stored. At present we

are having two bagasse yard one is outside the factory premises & another one is inside

factory premises at boiler section.

1) At outside factory premises we are having storage capacity of 40000 MT of baled

bagasse.

a) We are having two fire hydrant 10HP pumps with 50 mt head connected to water

well.

b) Water is sprayed through hydrant points total 36 points with fire hose & fire



hydrant valve.

c) In summer season one separate fire fighting team will be formed to keep

continuous watch and for spraying water near bagasse stack so that surrounding

area is kept cool.

d) Round the clock security is working to avoid unauthorized entry inside premises.

e) Smoking is strictly prohibited & sign boards are also displayed.

f) Water well is connected to both river water & bore well water.

g) Lighting arrestors are also provided to protect against Lighting.

h) Telephone arrangement is made during emergency. Telephone no 407

i) Security persons are with full fledged communication system.

2) In boiler area also where small amount of bagasse is being stored, we are having two

Separated fire hydrant line covering entire bagasse yard & belt conveyors. One line is

having 6 hydrant points connected to delivery of +ve section of four pumps having

capacity 45 lit / sec pressure 5 kg/cm2 & head of 50mtr. Another high pressure fire

hydrant pump line is having 14 hydrant points connected to pump of 7 kg pressure.

Discharge 2000LPM & head 70 mtrs with + ve section. Both pumps are connected to

water reservoir of capacity 5 Lakh Lit used for both fire fighting and process & water is

supplied to reservoir directly from river water through high pressure pumps. Also we are

having DG set to run the pumps during power failure. Same precautionary measure

taken as at out side bagasse yard area.



Health Hazard:

Bagasse is very hazardous especially dried & fine bagasse for health of the workers

working there. Due to prolonged inhalation of fine bagasse a disease may occur i.e

Bagassosis. Hence due attention must be given to health of the workers.

Measures:

1) Suitable face masks & goggles will be provided to workers working in that place,

strict use will be enforced.

2) Periodical medical checkup of workers will be done & health records will be

maintained.

Sulphur storage & preparation of SO2 gas:

Sulphur will be used in our industry for the manufacture of SO2 gas. The oxygen present

in the air reacts with sulphur & SO2 is formed. This gas is used for clarification of juice &

syrup.

Hazards of SO2 Gas:

So2 is one of the most widely encountered contaminants in the workplace.So2 is an

irritant gas. It may enter the body through the respiratory tract and cause respiratory

problems. In sugar industry So2 poisoning will be of chronic in nature. The substance

has local irritant action & produces a sensation of burning & pain in nose & throat.



Safety & Health Measures:

1) Sufficient ventilation is maintained in this work.

2) Workers are provided with gas mask to prevent inhalation of So2 gas.

3) Safety shoes, goggles, hand gloves & aprons are provided to the workers to

protect from the heat & fire.

4) Periodical medical checkup of the workers will be done and health records will be

maintained.

5) Smoking & eatables will be strictly avoided in that area.

6) Safe operating procedures will be displayed.

7) Eye wash fountain is installed at work area.

Hazards in Sulphur Storage:

Sulphur is highly combustible material. It comes under class ' A ' fire. we are having

200mt of sulphur storage in godown.

Measures taken:

1) Full fledged fire hydrant system will be provided.

2) Suitable fire extinguishers are kept in godowns.

3) Smoking is strictly prohibited.

4) Godown is kept with locking arrangement.

5) Suitable PPE's (Personal Protective Equipment) are provided those handling sulphur.

6) Adequate ventilation and natural lighting is provided.

7) Cautionary boards are displayed.



HCL Storage:

We are having storage capacity of 30 MT for boiler make up water treatment & HCL is

required is stored in FRP storage tanks. The only hazard in this area is release toxic

vapor.

The following remedial measures are taken.

1) Storage of HCL in FRP tanks, which will be located in the area free from all

ignition sources.

2) Sufficient water is provided during emergency.

3) All vents are taken to open area where there is no danger to workers.

4) People working in this area will be fully trained during emergency.

5) Handling of HCL is totally by mechanical system. So that there should be no

spillage all joints are leak proof.

6) Cautionary notices & instructions will be displayed.

7) Smoking & eatables are strictly avoided in this area.

8) Dyke wall is provided to storage tank.

9) Eye wash fountain is provided at working area.

H2So4 STORAGE:

We are storing H2so4 at D.M.Plant for water treatment purpose.H2so4 is stored in

carboys and kept in a separate room and carboys are kept on sand. Total storage

capacity 5MT.

Measures will be taken:

1) H2so4 is highly corrosive chemical and it is kept in separate room.

2) Sufficient ventilation is provided.

3) Cautionary boards are displayed.



4) All required PPE's are provided for handling H2so4.

5) Eye wash fountain is provided near D. M. plant area.

6) Safe operating procedures are displayed.

Sugar Godowns:

Since sugar is combustible material due importance is to be given for fire safety in sugar

storage godown. Sugar is packed in gunny bags and PP bags and stored in sugar

godown. We are having 19 sugar godowns of storing capacity 15 lakhs of sugar bags.

Falling of sugar bag bunches on workers is a major concern. Hence due importance is

given while stacking of sugar bags so that there is no slippage of bags from stack.

Precautionary Measures:

1) Suitable fire extinguishers are kept in sugar godown.

2) Smoking is strictly prohibited.

3) All electrical arrangement is flame proof.

4) Sufficient ventilation will be provided to godowns.

5) Sugar is stacked properly to avoid slippage of bags.

6) Sugar bags are stacked in pyramid shape. Only well experienced contractor is

engaged in sugar bag stacking work.

7) Training is given to concerned workers regarding safety precautions to be taken

while handling of sugar bags in sugar godowns.

Noise & hazards & control measures.

Noise is one of most common health hazards found in the work place. Exposure to

excessive noise can cause noise induced hearing loss. In Sugar Industry high level

noise areas are

1) Generator room.

2) Turbine house.

3) Boiler house.



4) Centrifugal Machines.

5) Noise due to steam leakages.

6) Compressor room.

Noise control measures are divided into the following categories:

1) Elimination

2) Substitution

3) Isolation

4) Engineering control at source and in transmission path.

5) Personal Protection Equipments.

All above methods will be tried to reduce the noise level in the factory and ensured that

there will be no bad effects noise in the work place.

In addition to this following steps will be taken-

1) Suitable Personal Protective Equipments are provided for workers expose to

noise like Ear plugs,Ear Muffs etc.

2) Acoustic measures will be provided wherever necessary.

3) Periodical medical checkup of workers is being done and necessary action will be

taken.

4) Noise aspects are taken care in the design process of the plant.

5) Noise level departments layout is designed in such way that noise will not effect

other departments.

6) Noise level is measured periodically and if exceeds prescribed normal then

necessary action will be taken.

7) Training and Education of workers.

Safety Precautions while Operating ESP (Electrostatic Precipitator)



We have installed two numbers ESP for 80T & 70T Krupp boilers for controlling

environment pollution. The only hazard present is Fire & Explosion.

Causes:

1) Unburnt % in fly ash

2) Prolong accumulation / storage of fly ash.

3) Air ingress

4) Excess Carbon Monoxide generation during upset conditions

Control Measures:

1) Control over combustion

2) Periodic checking of ash

3) In order to ensure the air tightness each of the by-pass chute opening should

have air tight blanks. The blank will be allowed to open only after I D fan stops.

4) Carbon Monoxide monitoring kit to be installed at upstream and well ahead of

ESP.

5) Fix a carbon monoxide monitor well upstream of ESP- with a tripping logic for all

T/R sets while carbon monoxide set point goes above the set point.

6) Main equipment (boiler) operation should be efficient so that proper combustion

happen and reducing the risk of carbon monoxide generation.

7) The ESP should be maintained properly for all tightness so that ambient air

ingress can be controlled within permissible limit. Regular checking door

gasket will reduces the chances of such air ingress by 85%.

Do's & Don’t of ESP operation of boiler:

Many of times ESP cannot be commissioned at boiler because of low temperature

interlock, which is associated to lower boiler load. in that situation you cannot start up T /

R sets because of low temperature interlock, but you need to run all ESP auxiliaries at



all the time including the ash handling system and the bypass chute remains closed at

all time please note that during start up the chances of accident are more due to process

instability & high carryover of unburnt. For more details of operation and safety

measures please refer operation and maintenance manual given by the manufacture

and kept at boiler section.

Identification of Hazards in Distillery Plant:

Sl

.

N

o

Operation

/ Process /

Departmen

t

Hazards

Identification.

Precautionary measures

taken.

Remark.

1 Fermentati

on section

1) Fire

2) Fermentation

1.All electrical appliances are

flame proof like motors,lighting

etc,.

2.Suitable fire extinguisher are

kept in section

3.Smoking and using of mobile

is strictly prohibited.

4) Unauthorized person's entry

is restricted.

5) No smoking boards are

displayed.

7) Full fledged fire hydrant

system is provided to cover the

entire area.

1. Adequate ventilation is

In case of any

emergency

the units will

be tripped

immediately

by using

tripping

devices.



odour

3) Slippery floor

4)Un- guarded

machinery

5) Noise

6)Leakage of

fermentation wash

provided.

2.Workers are provide suitable

PPE

3. Good housekeeping is

maintained.

1. All pumps, pipelines, are well

maintained. And are checked

periodically to avoid leakages.

2. Necessary gutters are

provided to avoid overflow.

3. Floor washing is done in every

shift.

All rotating dangerous

machineries in this section's are

provided with adequate guards.

Workers are provided with

suitable PPE's.

1. Suitable dye wall will be

provided. So that spilled

fermented wash will be collected

in dye wall.

2. All tanks are constructed as

per IS standard by the reputed

Safety shower

cum Eye wash

fountain is



7) Static electricity

fabricators.

3. Every year thickness testing

will be done & necessary action

will be taken. Proper earthing is

provided to all tanks, to avoid

static electricity Hazards.

installed at

working area.

Sl

.

N

o

Operation

/ Process /

Departmen

t

Hazards

Identification.

Precautionary measures

taken.

Remark.

2 Distillation

section

1) Fire

2) Noise

3)Leakage of

Distillation

As explained above.

3 Ware

House

1) Fire

2) Leakage of

Denatured spirit.

As explained above.




4) Loading

/unloading of spirit.

1. Proper earthing is done to

vehicles & tans before filling.

2.Proper checking of pipeline

tanks and pumps

3. Before transfer, take

approval from Electrician &

using flame proof pump, tube

light, No naked light, No

smoking zone.

4. Keeping fire extinguisher,

water line ready at ware

house.

4 R.S./ N.S.

ware

house

1) Fire

2) Leakage of

Rectified spirit.

3) Leakage of

Neutral spirit.


5) Slippery floor

As explained above.



5 Ethanol

ware

house

1) Fire

2) Leakage of

Ethanol


4) Slippery floor

As explained above.

Sl.

No

Operation /

Process /

Department

Hazards Identification.

Precautionary measures taken.

Remark.

6 Cask ware

house

1) Fire

2) Leakage of Malted

spirit.

As explained above.




4) Slippery floor

7 IML Section/

Bottling ware

house.

1)Fire hazards due to

loose wiring / defective

electrical appliances.

2)Back injury due to

improper handling of box.

3)Entanglement of

persons on the moving

conveyors.

4) Ventilation

5)Flying/strucking of

glass pieces due to

broken bottles.

6)Leakage of blending

vat

Routine preventive maintenance will

be carried out.

Suitable fire extinguisher are kept

and loose electrical connections are

avoided.

Training to the workers regarding

safe handling of box.

Pull card system& Emergency

switches are provided.

Proper ventilation will be provided.

Workers are provided with safety

goggle,hand gloves & gumboots for

handling bottles.

As Explained above



8 Packed

liquor ware

house

1) Fire

2)Leakage of alcohol

As Explained above

4. Risk Involved Through Risk Analysis.

1) Fire & explosion.

2) Electrical Shock.

3) Bursting of boiler.

4) Electrical short circuiting.

5) Collapse of tall structures.

6) Failure of machinery.

7) Leakage of Hazardous / toxic materials like Co2 gas

5. Severity / severity mapping:

If any emergency occur, the severity of the incident will be within factory premises & not

outside the premises at any cost.

6. Identification of emergency in each hazard activity:

It is already defined in this on site emergency plan in heading “ Identification of hazards

in sugar & cogen plant.”

7. Mitigation measures required:

It is already defined in this on site emergency plan in heading “ Identification of hazards

in sugar & co-generation plant.”

8. Mitigation measures possessed by industry:



We are having following mitigation measures in our industry.

1) Full fledged fire fighter of capacity 4500 lit & additional Foam tank of 500lit

Capacity.

2) Fire hydrant system at bagasse yard, belt conveyors, Entire distillery & IML

section.

3) Suitable PPE's like safety shoes, helmet, goggles, mask.

4) We are having separate Ambulance facility round the clock.

5) Emergency siren.

6) Emergency organization.

7) Well trained fire fighters & first aider.

8) Full fledged occupational health centre.

9. Identification of Mutual aid partners:

We have not defined any mutual aid partners; we have sufficient resources at our own to

mitigate the emergency. if at all required we will call nearest Fire stations like Athani,

Chikkodi etc.

10. Identification of resource suppliers:

We have not identified the resources suppliers. We are having our own.

11. Alert Action plan (Action on site):

1. The effective handling of an emergency will depend on the decision and

action taken at the time, based on the situation and seriousness of the

incident. Each and every incident cannot be foreseen and hence it is not

practicable to include every action which may be required to be taken in a

given situation, however certain actions which are of general nature must be

considered in the emergency management plan. Hence suitable guidelines for

all major foreseeable incidences must be included in the emergency

management plan.



2. Incident controller shall initiate all such actions as essential on the shop floor.

3. Evacuate all the personal on the shop floor not required for controlling the

situation or hazard.

4. Shall immediately grasp the problem / hazard and shall give instructions to

the concerned teams to act in a manner required to control the situation.

5. In case of fire, shall ring up the fire force.

6. Simultaneously shall call the workman in the fire fighting procedures and

organize controlling / extinguishing the fire.

7. With the view to ensure that declarer / controller of emergency shall have

assistance from the teams former.

12. Control room :

The security office shall function as the control room since security office is ideally

situated nearer to the main gate and away from the plant there shall be no problem with

regard to vapor / smoke of any toxic substances affecting security office. However,

should there be a situation where/ when entire premises have to be declared as

emergency the control room shall operate from the FSS office which is outside the main

gate. Required communication facility like walky talkies, mobiles & telephone facility is

provided. Required resources like PPE's, fire extinguishers, firefighting equipments like

fire hose, valves are kept in security office. Important telephone numbers list is displayed

at control room.

13. Site Plan:

Site plan is enclosed.

14. MSDS:

Major chemical MSDS are enclosed.

15. List of Important Telephone Numbers:



Fire fighter 265 / 273

Ambulance 265 / 273

Telephone operator 09

Hospital / Medical Officer 277

Chief engineer 250

Manager Administration 205

Safety officer 434

Security 267

Distillery I / c 261

Shift engineer / chemist

Boiler Engineer

268

423

16. ON SITE EMERGENCY STRUCTURE:

Sl.

No.

Designation Personnel Responsible Scope of responsibilities

1. INCIDENT

CONTROLLER

(In charge of the

scene of the

incident)

CHIEF ENINGEER will be

the incident controller

during the general shift and

whenever present in the

works.

1) As soon as he has been

made aware of an

incidence, the incident

controller should decide

whether a major

emergency exists or is

likely. If so he should



SECURITY OFFICER

/SECURITY WATCHMAN.

will be the incident

controller during all 24 hrs &

holidays also.

immediately activate the

onsite emergency plan

2) He should assume duties

of the site main controller

pending the latter’s arrival,

in particular to:

1. Ensure the emergency

services have been

called.

2. Direct the shutting

down and evacuation

of the areas likely to be

affected.

3. Ensure the key

personal have been

summoned

3) His main function,

however, is to direct all

operations at scene of the

incident as follows.

Ø Rescue and fire

fighting operations

until the arrival of fire

brigade.

Ø Search for casualties

Ø Evacuation of non-

essential workers to

assembly areas.

Ø Set up a

communications point

with telephone or in

case of failure of

telephone

communication use



walky-talky messenger

contact with the

emergency control

center.

Ø Give advice and

information as

requested to the

emergency services.

Sl.

No.

Designation Personnel Responsible Scope of responsibilities

2. SITE MAIN

CONTROLLER

Managing Director: Will be

site main controller during

general shift.

SECURITY OFFICER/

WATCHMAN SECURITY:

Will be site main controller

during all 24 hrs & holidays

also.

Ø The Site main

controller should go to

the emergency control

center and take charge

from the incident

controller for over all

control

Ø If he decides that a

major emergency

exists or is likely, he

should ensure that the

emergency services

have been called and

the on site plan is

activated.

Ø He shall take over the

situation and shall start

in such a manner as to

control the situation

and curb it as soon as

possible.

Ø Control the traffic



movement within the

works.

Ø Issue authorized

statements to the news

media.

Ø Control rehabilitation of

affected areas after

emergency.

Ø Ensure that proper

consideration is given

to the preservation of

evidence.

Emergency organization:

Communication Team

Team A Team B Team C

Team D

SITE MAIN CONTROLLER – Managing Director

INCIDENT CONTROLLER – CHIEF ENGINEER



Communication Team:

1) Manager (Administration)

2) Security officer

3) Shift Telephone Operator

4) Head Timekeeper

Team A

1) Shift Engineer/Boiler Engineer

2) Shift Chemist

3) Electrical Engineer.

4) Fire fighting team

1) Shri R.T.Patil

2) Shri M.G.Mataguli

3) Shri L.S.Ganennavar

4) Shri D.V.Gharge

5) Shri C.S.Khurd

6) Shri B.H.Jagli

7) Shri M.R.Hukkeri

8) Shri R.T. Visapure

9) Shri A.L.Mallewade

Team B

1) Chief Chemist

2) Workshop I/c

3) Dy. Manager (P)

4) Timekeeper

5) Distillery & IML Incharge.

Team C

1) Factory Manager



2) Safety Officer

3) Medical Officer

4) Environment Engineer

5) Motor Department I/c

Team D

Personnel’s which are not included in emergency action team.

Role of communication team:

Manager (Administration)

Ø Proceed to control center and take orders from main site controller.

Ø Arrange mutual aid/fire brigades as requested by main site controller.

Ø Inform police if advised by main site controller.

Ø Inform neighbouring factories.

Ø Requisition vehicles and ambulance as required.

Security Officer/Watchman

After getting information activate the siren.

Control Traffic at the gate.

Arrange a guard at gate to inform incoming essential personal of the nature of

emergency.

Prevent unauthorized entry.

Depute guard to control traffic and block roads at the scene of emergency.

Inform about location of emergency to mutual aid / city fire brigade.

Assemble all the victims at assembly point.

Telephone operator.

On receipt of information in case of siren is not yet actuated, inform security personal to

blow siren.

Inform security so that guards are released to control traffic around the emergency-

visitors are kept out.

Await further instructions from site main controller and keep telephone free from

incoming calls.

Inform others as directed by site main controller.



ROLE OF ACTION TEAM A:

Inform site main controller / telephone operator of location and nature of emergency.

Switch off electrical supply.

Alert every occupant to leave the area to reach the assembly point safely.

Simultaneously trained employees to start fire fighting and rescue operation

Follow instruction of incident controller / site main controller.

Ensure that fire hydrant systems / pumps are in good condition.

Provide engineering assistance to incident controller/ site main controller.

Proceed to scene of emergency.

Consult area supervisor regarding special precautions if any.

Decide line of action in consultation with incident controller/ site main controller.

Keep stock e.g. water, personal protective equipments.

ROLE OF ACTION TEAM B:

Ensure that fire pumps are operating normally.

Shut off power.

Shut down the plant in consultation with incident controller/ site controller.

Evacuate to assembly points in a single line by the safest route without panic

Stand in lines assembly point for ease of head count.

Section in charge has to take head count and locate missing persons if any.

Follow instruction from incident controller/ site main controller.

Get back to your work place (if safe) and when all clear signal is received from site main

controller.

ROLE OF ACTION TEAM C:

Safety/Environment Officer.

Approach the site of incidence immediately

Be in contact with incidence controller/ site main controller.

Coordinate between incidence controller/ site main controller and other key personal.

Check evacuation and head count is done properly at assembly point near the affected

area.

Follow instructions from main site controller.



Notify evacuation squad if required.

Medical Officer

Keep ambulance ready to proceed to scene of emergency at short notice.

Priorities casualties for treatment.

Considered casualties for special treatment.

Arrange hospitalization, additional ambulances.

Call trained first aid members for assistance.

M.T.D. In charge

Arrange transport as required.

Arrange driver for ambulance.

Requisition vehicles, drivers as necessary for evacuation.

First aid team:

1) Shri D V Patil

2) Shri D.D.Datar

3) Shri P.A.Herawade

4) Shri M.B.Kumbhar

5) Shri R.Y.Shirgannavar

6) Shri S.B.Patil

8) Shri R.B.Vasawade

9) Shri R.M.Billur

10) Shri N.P.Savant

Proceed to affected area / medical center as requested and render all assistance.

ROLE OF ACTION TEAM D:

Leave the site immediately by the safest route to assembling point.

Assist in head count at assembly point.

Avoid panic.

Do not go to scene of emergency unless specifically instructed by site main controller

Do not re enter site unless directed personally or announced.

17. Types of emergencies considered:



A major Emergency or disaster occurring at works is the one that may affect several

departments within works and may cause serious injuries, loss of life, extensive damage

to property or serious disruption outside the works. Usually a major emergency is the

result of malfunctioning or bypassing of inbuilt safety devices and systems. Deviation

from the normal operating procedure. Emergency disasters could be due to natural

causes or manmade causes they include.

1) Fire and explosion

2) Bursting of Boiler

3) Leakage/Spillage of Effluent/molasses/chemicals ( Spent wash/ Effluent)/

chemicals/spirit/flammable materials/Alcohol ( Spent wash/ Effluent)

4) Malfunctioning of E.T.P

5) Plane crash over the works

6) War (affecting works e.g. Bombing over the works)

7) Over flow of E.T.P (Discharge Pumps failure)

8) Toxic releases like Methane & Co2 gas

18. Objectives:

The main objective of the emergency plan should be to make optimum use of all

available resources both internal and external to achieve the followings.

Ø Contain the extent of emergency and cascading effects of the original

emergency and bring the incident under control with priority to saving life and

preventing further injury.

Ø Controlling the original incident and prevent an onsite emergency from turning

in to an offsite emergency report.

Ø Mitigate the consequences of the emergency by arranging rescue and

treatment casualties.

Ø Safe guard over the people.

Ø Minimize the damage to environment property.

Ø Identify any fatalities and notify the relatives.

Ø Provide for the need of relatives.

Ø Secure the safe rehabilitation of affected areas.

Provide authentic and authoritative information to the news media through the



Companies authorized person.

19. Safe Assembly Points and Emergency Exits:

We have marketed and identified assembly points at following Work places where

nearby workers can gather safely during emergency.

1) Main gate.

2) In front of distillery section.

3) In front of civil department.

4) Sugar cooling tower (i.e. In front of Godown No.7)

5) Co generation Cooling tower.

6) Co generation ash bed area.

7) M.T.D. Front area.

Also we have marked and identified section wise emergency exits and gangways and

shown in annex II. We have trained all workers in respect of above points.

20. Notification of Emergency/Duties of employee during emergency:

1) If the employee notices the symptoms of fire, leakage of chemical or any other

unusual occurrences he has to inform the Security Department through

Telephone No 273 and Safety Department Telephone No 434, Electrical

Department Telephone No 256, Workshop Incharge Telephone No 259, If the

telephone is out of order send a special messenger to the Security Department.

Also he has to specify the exact location and cause for the first inform the shift

Incharge who is at all times on the shop floor shall identify the same, he shall

report to the chief engineer.

2) Use the suitable fire extinguisher available in the department if there is leakage of

chemicals do not allow anybody to touch or smoke nearby and flush with water

and in case of electrical short circuit use appropriate fire extinguisher don’t use

water in case of electric short circuit.

3) If the fire seems to be uncontrollable call fire brigade/fire fighting team & also

inform them exact location & causes of fire so that they will come with right type

of fire extinguishers.



4) Immediately arrange for removing the combustibles nearby.

5) Cool the surrounding area with the help of fire hydrant water.

6) Fire fighting operations or approach should be from the opposite direction of

smoke.

7) In case anybody trapped must wear breathing apparatus before enter into the

smoke for rescue.

8) Clear the public gathering.

Security Department:

a) Order the fire crew to reach the spot at shortest possible time.

b) Arrange to start the fire hydrant pump.

c) Barricade the area.

d) Instruct the main gate person to keep open the gate full for fire brigade entry.

e) Instruct one security guard to come along with the fire brigade from the gate to

avoid searching the spot.

f) Arrange to remove the nearby fire prone wastes.

Safety Department:

a) Visit the spot immediately has quick check over the spot for explosives

combustible Materials etc.

b) Arrange for switching off the electrical mains pertaining to that area.

c) If the area is covered with dense smoke, see that the people must wear

respirators.

d) If anybody falls down on the ground because of the suffocation arrange for the

medical treatment.

21. Declaration of Emergency:

Under this plan the Chief Engineer is identified and nominated as the

DECLARER/CONTROLLER OF EMERGENCY. No sooner he gets information from

shift in-charge ,he shall move to the place of hazard/calamity & he shall assess the

situation & decide to declare emergency either in particular section or in the entire plant.

If the Emergency is to be declared in one section the other plant will work normally.



He shall start functioning in such a manner as to control the situation & curb it as soon

as possible. Only the site main controller should declare the end of emergency and such

declaration should be made only after his fully satisfied the following things.

· All fires have been extinguished.

· There is no risk of re-ignition.

· Source of emission of hazardous gas has been effectively isolated.

· All gas clouds have been disposed and

· No toxic contamination exists.

· After considering all these aspects and satisfying him that the site is safe to

enter the emergency reader may order entry to restore the normalcy. he shall

then arrange for blowing the siren three times which indicates an all clear

signal.

22. Warning system:

· One electrical operated hooter siren & steam blown siren installed on the top

roof of the Factory. It can be heard throughout the factory premises and

nearby outside area also. The siren will be blown to indicate the emergency.

· Internal telephones & Walky –Talkies and Mobiles are available from all

places to inform emergency at a time at any time.

· On getting the warning all those should act as per the role mentioned in the

action team.

23. Emergency Shutdown of Various Sections:

The only hazards i.e. expected in the factory are fire: immediate action to be taken in

each of the sections for the purpose of emergency shutdown would be as under.

1) MILL SECTION

Stop D.C. Drives.



2) BOILER SECTION

Stop the Boiler.

3) CLARIFICATION SECTION

Switch of the pumps & steam Valves.

4) BOILING HOUSE & PAN SECTION:

Switch of the Machines, Valves & pumps.

5) Turbine House.

Stop the Turbines.

At Distillery / IML Section

1) CUT OF MAINS SUPPLY

2) DISTILLERY SECTION

Stop all distillations.

3) BOILER SECTION

Stop the Boilers.

4) BOTTLE FILLING SECTION:



Switch off the filling lines and stop filling.

5) PACKING SECTION:

Stop packing.

6) STOP ETHNOL PROCESS.

24. Evacuation of Personnel:

Siren will blown within short note many times in addition to the shouting for evacuation

and security staff] runs to each department to drive out the person safe place. When a

major accident occurs and if there is case of workmen has supervisory personnel

fainting or losing consciousness any other type of accident, it shall be the responsibility

of Team-B to evacuate them in the vehicle to our dispensary after providing necessary

First Aid in the office. The well laid out roads in around the plant in factory premises and

they should choose the safest road to come out from the plant.

25. Accounting of personal:

Accounting of personnel will be done at each assembly point by timekeeper & section

Incharge. Total strength will be tallied with actual attendance at timekeeper office. If

anybody is missing immediately inform to any one of emergency team for necessary

action. When persons engaged in the department or in emergency the section in

charges are responsible to bring out the employee to safe place and make arrangement

for their medical treatment, department head also visits the site of emergency to ensure

that nobody has been trapped. The persons who have trained in the First Aid and

Firefighting also quick check up for ensuring that nobody has been trapped. It shall be

the responsibility of Team B to immediately take stock of the personnel on duty and



cross check with the personnel who have come out of the plant / have got stuck-up. This

team shall co-ordinates with team D and ensure that all personnel are accounted for. It is

also essential for team ' B ' to counter check with the security if any visitors or transport

workers have entered the plant and if so they should also be accounted for.

26. Controlling of Emergency:

The declarer / controller of emergency shall take steps to train all the teams & shall draw

up an action plan forthwith. The maintenance in charge is marked as Work incident

controller and he shall act as the Incharge at the site of the hazard to control the entire

operations.

27. Arrangements for medical treatment:

We have full fledged own occupational health center with all facilities & required staff to

treat injured during emergency & also we will shift the injured persons to nearby

hospitals & if higher treatment is required we can arrange to shift the injured persons to

Miraj city hospital which we have close contact.

28. Information to the relatives of injured:

Chief engineer & Dy. Manager (Personal) will inform the relatives of injured through

phone & messengers.

29. Information to the government authorities:



Manager (A& P), CE & Dy. Manager (Personal) will communicate govt. authorities

regarding emergency occurred and status.

30. Law and Order:

We have close contact with the Kagwad Police station to meet our emergency

requirement.

The Dy. Director of Factories & Director of Factories, Member secretary and State

Pollution Control Board, shall also be informed.

31. All Clear Signals:

Once the emergency is controlled and normalcy regained completely and the

DECLARER / CONTROLLER OF EMERGENCY is of the opinion that there is no further

hazard involved there and the work can go on normally, he shall then arrange for

blowing the siren three times which indicates an all clear signal.

32. Emergency Transport Facility:

We have sufficient vehicles to transport injured persons. We are having separate motor

department of our own & they have the facility to control the situation also we have one

full fledged ambulance ready round the clock.

33. Drawing of fire hydrant and Extinguishers:

Details are enclosed in (Annexure II & III) & location of fire extinguishers is given below

Location wise Fire Extinguisher Details

Sr.

No.

Location Type Capacity Qty.

1 Sulphur House CO2 4.5 kg. 2 Nos.

2 -do- D.C.P. 10 kg. 1 No.

3 Boiling House CO2 4.5 kg. 2 Nos.



4 -do- D.C.P. 10 kg. 1 No.

5 Sugar House CO2 4.5 kg. 2 Nos.

6 -do- D.C.P. 10 kg. 1 No.

7 Shift In-charge Cabin. CO2 4.5 kg. 2 Nos.

8 -do- D.C.P. 10 kg. 2 Nos.

9 Mill Turbine CO2 4.5 kg. 2 Nos.

10 -do- D.C.P. 10 kg. 1 No.

11 -do- CO2 22.5 kg. 1 No.

12 Workshop CO2 4.5 kg. 1 No.

13 -do- D.C.P. 10 kg. 2 Nos.

14 Store Water type

CO2

9 Ltr. 3 Nos.

15 Civil CO2 4.5 kg. 1 No.

16 -do- D.C.P. 10 kg. 1 No.

17 Main Gate CO2 4.5 kg. 2 Nos.

18 -do- D.C.P. 10 kg. 1 No.

19 Weighbridge CO2 4.5 kg. 1 No.

20 -do- D.C.P. 10 kg. 1 No

21 Material Godown Water type

CO2

9 Ltr. 1 No.

22 Sulphur Godown Water type

CO2

9 Ltr. 3 Nos.

23 M.T.D. CO2 4.5 kg. 1 No.



24 -do- D.C.P. 10 kg. 1 No.

25 Sugar Godown Water type

CO2

9 Ltr. 2 Nos.

26 Belt Conveyor CO2 4.5 kg. 1 No.

27 -do- D.C.P. 10 kg. 1 No.

28 Diesel Tank Foam type 9 Ltr. 5 Nos.

29 Switch yard D.C.P. 22 kg. 2 Nos.

30 -do- CO2 22.5 kg. 1 No.

31 Cogen Cooling Tower CO2 9 Ltr. 1 No.

32 Back TFR D.C.P. 22 kg. 1 No.

33 Triveni Turbine down side. CO2 22.5 kg. 2 Nos.

34 Centrifugal CO2 22.5 kg. 1 No.

35 80 T. Boiler CO2 22.5 kg. 1 No.

36 TFR D.C.P. 22.5 kg. 2 Nos.

37 33x66 Mill TFR CO2 22.5 kg. 2 Ns.

38 42x84 Mill TFR CO2 22.5 kg. 1 No.

39 42x84 Mill CO2 22.5 kg. 1 No.

40 D.C. Drive D.C.P. 10 kg. 1 No.

41 Power House CO2 4.5 kgs. 2 Nos.

42 -do- D.C.P. 10 kg. 1 No.

43 Paras Boiler CO2 4.5 kg. 1 No.

44 -do- D.C.P. 10 kg. 1 No.

45 70 T. Boiler D.C.P. 10 kg. 1 No.



46 Boiler Compressor CO2 4.5 kg. 1 No.

47 Paras Boiler I.D. CO2 4.5 kg. 1 No.

48 70 T. Boiler I.D. CO2 4.5 kg. 1 No.

49 Cogen. TFR CO2 22.5 kg. 1 No.

50 Cogen. Turbine CO2 4.5 kg. 1 No.

51 -do- D.C.P. 22.5 kg. 5 Nos

At Distillery & IML Section:

Location wise Fire Extinguisher Details

Sr.

No.

Location Type Capacity Qty.

1 Distillery (old) D.C.P. 10 kg. 1 No.

2 Distillery (old) D.C.P. 5 kg. 1 No.

3 Distillery (old) Main Panel

Board. D.C.P. 4.5 kg. 1 No.

4 Distillery (old) Pump House D.C.P. 5 kg. 1 No.

5 Distillery (old) D.N.S.

Warehouse D.C.P. 5 kg. 1 No.

6 Praj Distillery Panel Board CO2 4.5 kg. 2 Nos.

7 Praj Distillery warehouse Water type 9 Ltr. 1 No.

8 Distillery Column No. 2 D.C.P. 10 kg. 1 No.

9 Distillery Col. No. 4 D.C.P. 5 kg. 1 No.



10 Fermentation House D.C.P. 5 kg. 2 Nos.

11 Packed liquor ware house D.C.P 5kg 2Nos

12 Packed liquor ware house Water Type 9lit 2Nos

13 IML bottling CO2 22.5kg 2Nos

14 IML bottling D.C.P 10 kg. 2Nos

34. Location of First Aid Boxes.

We have kept and maintained First Aid Boxes with prescribed medicines in all sections.

Location of First Aid Boxes is given below.

Sl No. Location

1 T. K. OFFICE

2 DISTILLERY (PRAJ)

3 DISTILLERY (IMFL)

4 SULPHUR HOUSE / CHEMICAL

5 PAN SECTION (CHEMICAL)

6 SUGAR HOUSE

7 BELT

8 M.T.D.

9 KRUPP BOILER

10 PARAS BOILER

11 POWER HOUSE

12 D. M. PLANT



13 SWITCH YARD

14 CIVIL

15 COGEN. TURBINE

16 42”x 84” Mill

17 33”x 66” Mill

18 WORKSHOP – Welder

19 WORKSHOP – Moulder shop

20 FIRE FIGHTER

21 AMBULANCE

22 ENVIRONMENT DEPT.

23 TRAINING CENTRE

35. Electrical drawings:

Details are enclosed in (Annexure IV)

36. Display of prominent telephone numbers of at least:

Deputy Commissioner (0831) 2407200

Superintendent of / Local Police (0831) 2405204

Local Police Kagawad (08339) 264633

Fire Services Athani

Chikkodi

Sadalga

(08289) 251740

(08338) 273333

(08338)251900

Hospitals – Ugar sugar hospital

Wanless Hospital Miraj

(08339) 272230

(0233) 222329

Occupier / Manager (08339) 272230



Directorate of Factories & Boilers (080) 26531201

Karnataka State Pollution Control

Board Bangalore, Belgaum

(080) 25581383

(0831)2459121

Blood Bank – Dr.Shirgaokar Blood

Bank Sangli.

(0233) 2372376

Vasantdada Blood Bank Miraj (0233) 2222319

37. Key personal of the industry:

Name of the Person Designation Telephone number

P.V.Shirgaokar Executive VC 9972022205

S.S.Shirgaokar Managing Director 9972022206

N.S.Shirgaokar Joint Managing Director 9972024447

C.S.Shirgaokar Joint Managing Director 9972024448

G.N.Bellary DGM (A&P) 9900559181

S.N.Gurav Dy. Manager (P) 7259186058

D.K.Pendse DGM(Sugar) / Factory

Manager

9900559190

R.B.Shegunshi Safety Officer 9972372425

S.S.Sardesai DGM El ( Sugar

&Cogen)

9900559160

C.G.Pimpalkar DGM ( Process) 9900559188

B.N.Akiwate DGM (Cogen) 9900559162

N.B.Kagwade Dy.CE (cogen) 9972372423

M.B.Joshi CE El (Sugar & Cogen) 9900559177



Dr.B.V.Zadbuke Medical Officer 9740979188

Dr.S.M.Pattanshetty Chief Env. Manager 9900559179

D.B.Patil Distillery I / c 9972372427

B.T.Viapure

S.V.Shula

IML Manager

IML Incharge

9900559168

9972372428

Namdev Kharade Security Officer 9740083842

38. Waste disposal:

Waste should be disposed off in scientific manner. Debris should be collected in tractor

and trailers and dumped for land filling purpose. For this state rules and regulations

regarding waste disposal will be considered.

*****



CHAPTER– 7

PROJECT BENEFITS



Project Benefits

7.0 Benefits

M/s Ugar Sugar Works Ltd.Ugar Khurd, Tal: Athani,Dist: Belgaum, State: Karnataka

have Proposed Expansion of Sugar cane crushing capacity from 10000 TCD to 20,000

TCD, Co-generation power plant from 44 MW to 75 MW & Molasses based Distillery

from 75 KLPD to 200 KLPD. This project development will give rise to social and

economic development measures in the study area.

7.1 Improvement in Physical Infrastructure

The Enhancement project is expected to yield a positive impact on the socio-economic

environment. It helps in sustainable development of this area including further

development of physical Infrastructural facilities. The following physical infrastructure

facilities will improve due to proposed project:-

Ø Road Transport facilities

Ø Educational facilities

Ø Water supply and sanitation

7.2 Improvement in Social Infrastructure

The Enhancement project will lead to direct and indirect employment opportunity.

Employment is expected during civil construction period, in trade, garbage lifting,

sanitation, plantation works and other ancillary services. Employment in these sectors

will be primarily temporary or contractual and involvement of unskilled labour will be

more. This will enhance their income and lead to overall economic growth of the area.

The following changes in socio-economic status are expected to take place with this

project.

The project will have a strong positive employment and income effect, both direct as well

as indirect because of better indirect employment opportunities due to this project. The

project is going to have positive impact on consumption behavior by way of raising

average consumption and income through multiplier effect. The project is going to bring

about changes in the pattern of demand from food to non-food items and sufficient

income is generated. Following development of social infrastructures will be carried out.



ü Education facilities

ü Banking facilities

ü Post offices and Communication facilities

ü Medical facilities

ü Recreation facilities

ü Business establishments

ü Community facilities

7.3 Places of Historical Importance

There is no historical or archaeological monument within 10 km of the area. Industrial

development and consequent economic development will lead to improvement in the

living standards of the people and enhanced social awareness. On the other hand, the

Enhancement project is likely to have several benefits like improvement in indirect

employment generation and economic growth of the area, by way of improved

infrastructure facilities and better socio-economic conditions.

7.4 Other Tangible Benefits

The Expansion project is likely to have other tangible benefits as given below:-

Ø Indirect employment opportunities to local people in contractual works like housing

construction, transportations, sanitation, for supply of goods and services to the

project and other community services;

Ø Additional housing demand for rental accommodation will be increased;

Ø Market and business establishment facilities will be also increased; Cultural,

recreation and aesthetic facilities will be improved;

Ø Improvement in communication, transport, education, community development and

medical facilities.

7.5 Project benefit:

Sugar is an essential food product. The by-products such as bagasse, molasses, and

press mud produced from sugar plant will be profitably utilized in the industry itself.

Bagasse is used as fuel in production of electrical power. Surplus power exported to

public distribution system will reduce the power scarcity in the region. The bagasse is

obtained from renewable source and is a substitute to fossil fuels such as coal or

petroleum.



Molasses is a raw material for production of ethyl alcohol which gains importance for its

use as fuel and as a starting material for various organic chemicals. The molasses is

thus a renewable resource and dispense the use of petroleum for fuel and organic

chemicals.

Press mud produced from sugar plant is composted along with spent wash generated

from the distillery plant to produce enriched bio-manure. It will be supplied to farmers for

use in cultivation of sugarcane and other crops. The composted bio-manure is rich in

nutrients and use of the same will reduce the need for chemical fertilizer.

Sugarcane cultivated in the region is presently transported through 30-60 km and

supplied to existing factories. Sugarcane cultivation gives higher economical returns to

the farmers. It will improve the economic status of the farmers growing sugarcane.

Hence more land will be brought under sugarcane cultivation.

The industry is established in the backward region of the state. The presence of the

industry helps to develop road and transportation facilities in the region. Commencement

of this industry will create direct and indirect employment opportunities to more than

2000 persons in terms of factory employment, transportation, vehicle maintenance, petty

shops etc. It will also benefit more than 500 sugarcane growing farmers in the region.

The expansion of integrated sugar industry will thus meet the national interest of

economical power and food through sustainable development without adverse effects to

the environment. Further it helps in the up-liftment of rural mass.

* * * * *



CHAPTER– 8

ENVIRONMENTAL MANAGEMENT

PLAN



Environmental Management Plan

8.0 Introduction

The proposed project involves utilization of natural resources and generation of waste

and polluting substances. Depletion of natural resources will affect the competitive

users. The waste and polluting materials if discharged with out control and treatment is

likely to have adverse consequence to the environment parameters including water, air,

soil, flora and fauna. Further, it may exert stress to the existing infrastructural and other

facilities and also to the existing socio economic status of the region. It is the

responsibility of the project proponents to control the utilization of resources and

discharges of waste products by adopting suitable control measures in the factory to

avoid adverse consequence of industrial activities on the environment and inturn to

enhance the quality of the existing environment.

The Environment Management Plan describes both generic good practice measures and

site-specific measures so as to mitigate potential impacts associated with the proposed

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

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

economic measure are summarized below:- The EMP provides a delivery mechanism to

address potential adverse impacts and to introduce standards of good practice to be

adopted for all project works. For each stage of the program, the EMP lists all the

requirements to ensure effective mitigation of every potential environmental attribute and

socio-economic impacts. For each impact type during construction and operation the

following information is presented:-

v A comprehensive listing of the mitigation measures (actions) that are needed to

implement;

v The parameters that will be monitored to ensure effective implementation of the

action;

v The timing for implementation of the action to ensure that the objectives of

mitigation are fully met.

8.1 Environmental Management Plan during Construction Phase


The setting up of enhanced project from 10000 to 20000 TCD of Sugar Plant and 44MW

to 75 MW of Cogeneration power plant would result in increase of dust concentrations



due to fugitive dust. Frequent water sprinkling in the vicinity of the construction sites

would be undertaken and will be continued after the completion of plant construction, as

there is scope for heavy truck mobility. It will be ensured that both petrol and diesel

powered vehicles are properly maintained to comply with exhaust emission

requirements.

The sources of particulate emissions from the Sugar Unit and Co-generation plant shall

be controlled to less than 150 mg/N m3 by the use of high efficiency ESP/ wet scrubber.

Stacks with suitable heights will be provided for long term distance travel of pollutant and

wide dispersion as per norms


There will be marginal increase in noise levels during construction phase, which is

temporary and intermittent.

· Adequate measures taken to keep noise and vibrations under control

· The noise will be < 75 dB and these will be fleeting noise sources noise sources.

For the workers personal protective equipments will be provided viz. earmuffs,

earplugs.

· Processing will be under closed system, so no noise pollution will be controlled.

8.1.3 Water Environment

During construction, provision for infra-structural services including water supply,

sewage, drainage facilities and electrification will be mad Proper measures will be taken

to reduce the water consumption. The waste water shall be treated in an elaborate ETP

consisting of two stage activated sludge process which will be used for gardening/

irrigation purpose. For distillery there is a separate ETP i.e. evaporation and drying

effluent to form powder. In anaerobic digestion of spent wash, methane gas is produced

which can be used as a fuel in boiler. Hence, there will not be any adverse impact on the

environment.

8.1.4 Land Environment

Any hazardous material required for constructional activity will be stored as per safety

norms. Further construction site will be provided with suitable toilet and treatment

facilities etc for maintaining hygienic conditions.



8.1.5 Socio-economic Environment

Any construction activity will benefit the local population in a number of ways. The

company management will give preference to local eligible people through both direct

and indirect employment. It will provide ample opportunity to the locals to up-lift their

living standards by organizing events that propagate mutual benefits to all, such as

health camps, awareness campaigns, donations to poorer sections of society and down-

trodden.

8.1.6 Safety and Health

Adequate space will be provided for construction of temporary sheds for construction

workers mobilized by the contractors. M/s USWL will take care of supply of potable

water for the construction workers. The safety department will supervise the safe

working of the contractor and their employees. Work spots will be maintained clean,

provided with optimum lighting and enough ventilation to eliminate dust/fumes. A

comprehensive Occupational Health and Safety management plan is put in place to

address any sort of eventuality.

8.2 Environmental Management Plan during Operations Phase


The major pollutants emerged due to Sugar Plant and Cogeneration Plant operations

are suspended particulate matter (SPM), fine particulate matter (PM10& PM2.5),

Sulphur dioxide (SO2) and Oxides of Nitrogen (NOx).

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

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

efficiency ESP and Wet Scrubber.

Ø Particulate Matter emission level from the stack chimney will be less than 50

mg/Nm3 and the stack height is proposed to 75 m.

Ø SO2 concentration will be negligible as the bagasse will be used as fuel for boiler.

Ø The periodic evaluation for the efficiency performance of Wet Scrubber will be

carried out.

Ø For controlling fugitive dust, in hopper, reclaimer, conveyors, silos etc. bag filters

shall be installed.

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

spillages shall be continuously monitored and controlled.



Ø Water conservation measures shall be undertaken for effective implementation.

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

Ø Thermal insulation will be provided wherever necessary to minimize heat

radiation from the equipment, piping etc., to ensure protection of personnel.


ü All rotating items are well lubricated and provided with enclosures as far as

possible to reduce noise.

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

in the working areas.

ü Extensive vibration monitoring system will be provided to check and reduce

vibrations. Allfans, compressors etc., are provided with vibration isolators to

reduce vibration and noise.

ü Noise generating equipment including fans, blowers, pumps, motors etc., will be

running with speed less than 1500 rpm and reduce noise levels.

ü Provision for silencers wherever possible.

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

ü Requisite enclosures will also be provided on the working platform/areas to

provide local protection in high noise level areas.

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

ü Proper lubrication and house equipment will be kept in better condition

ü Necessary PPE will be provided such as ear plugs, ear muffs etc.

By these measures, it is anticipated that noise levels in the plant will be maintained

within the permissible limits at the boundary of the plant premises. Plantation on the

periphery of the plant would further attenuate noise levels.

8.2.3 Solid Waste Management

Dry fly ash and furnace bottom ash

Fly ash collected from the ESP hoppers and the air heaters hoppers and the ash

collected from the furnace bottom hoppers can be used as landfill. The high potash

content in the bagasse ash makes the ash as good manure. Filter cake will be sold to

farmers as manure. The liquid molasses will be sent to distillery for manufacture of

alcohol.



Sewage from various buildings in the plant

Sewage from various buildings in the plant area will be conveyed though separate drains

to the septic tank. The effluent from septic tank will be disposed in soil by providing

disposing trenches. There will be no ground pollution because of leaching due to this.

Sludge will be used as manure for green belt development.

8.2.4 Water and Wastewater Management

Continuous efforts would be made to reduce the water consumption and thereby to

reduce the wastewater generation. Flow meters would be installed for all major water

inlet and the flow rates would be continuously monitored. Periodic water audits would be

conducted to explore the possibilities for minimization of water consumption. Water will

be drawn from Krishna River to meet the plant consumptive water requirement.

Considering the quality of water, the Cycle of Concentration (COC) of the cooling tower

is considered as 1.5.

Waste water Management

The treated water quantity will be used for dust suppression. Water Pollution control

measures to be undertaken are given as under:-

v No trade effluent shall be discharged from the Plants

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

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

Township shall be treated in the Sewage Treatment Plant to meet the Statutory

Norms and the treated sewage shall be used for Green Belt;

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

v Periodical monitoring for specific parameters shall be done regularly.

v Rainwater harvesting structures shall also be developed as proposed from the

roof tops of Plants as well as Township areas to supplement the water supply

from the river.

Wastewater treatment

Waste water treatment for the plant will be based on discharges of the various effluents

to ponds for clarification and filtration. Oily water will be treated separately to remove

oil/grease before discharge into effluent ponds. The oily water collection in the plant is



basically due to floor cleaning, leaky oil filters, etc. Clarification is used to settle out large

suspended particles and condition smaller colloidal particles to make them settle. A

pond, reservoir tank or tank is used to allow larger particles to settle in a matter of hours.

The finer particles overflow and are made to settle more quickly by the addition of

chemical agents, coagulants and polymers that cause agglomeration to sizes large

enough to settle out of suspension. As required and with approvals from appropriate

regulating bodies, final waste stream pH is controlled by combining various plant

streams to provide a neutral pH product. Where needed, acid or alkali addition will be

used to achieve the final pH.

Final Disposal of the wastewater

The treated effluent from the effluent tank will be used for horticulture and green belt

development within the plant.

Monitoring of Wastewater Treatment

The treated effluent would be monitored regularly for the flow rate and quality to identify

any deviations in performance of Effluent treatment plant.

Thermal Pollution Management

A closed circuit cooling water system with cooling towers is present in the existing area.

This eliminates the letting out of high temperature water into the canals and prevents

thermal pollution. Blow down from the cooling tower will be trenched out and ultimately

conveyed to the effluent ponds. Hence, there is no separate pollution on account of blow

down from cooling water system.

8.4 Rain Water harvesting System

Rain Water harvesting System The rain (storm) water from the building roofs, non-

process area and grade level surfaces will be directed through the rain water harvesting

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



system. The storm water from the storm drainage system will be discharged outside the

plant boundary. All drains will be lined and will be arranged to provide the shortest

possible drainage path for efficient drainage.

8.5 Housekeeping

Salient features of housekeeping will be adopted are as follows:-

v Mechanized cleaning of roads and floor area inside the plant premises by using

road sweeper and mobile vacuum cleaner on regular basis;

v Training on regular basis to all workers and staff about the importance of

cleanliness;

v Careful garbage transportation to dumping site and disinfection of transport

vehicles body;

v Decorative plantation and gardening to improve aesthetics of the plant; and

v Construction of suitably designed drains all along the roads and boundary of the

plant premises.

8.6 Occupational Health & Safety

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

due to gas cutting, welding, noise and high temperature and micro ambient conditions

especially near the boiler and platforms, which may lead to adverse effects (Heat

cramps, heat exhaustion and heat stress reaction) leading to local and systemic

disorders.

The occupational health surveillance program is to address pre employment health

examination and periodic health examination. Every employee on his appointment for a

job with a possibility of exposure to airborne asbestos shall get the pre-employment

medical examination done within stipulated days of his employment, by the employer.

Scheme for health surveillance shall include exposure data at each pertinent work place,

periodical examination of workers, X-ray examination for radiological changes, lung

function test for digestive disorder and clinical examination for early detection of signs of



asbestosis. These tests are to be recorded for pre-employment, periodic surveillance

and at cessation of employment as per the concerned state government regulations.

Occupational health surveillance is to be carried out by occupational physician or chest

physician trained in occupational medicine. The occupational health surveillance

program is to be drawn for all the employees potentially exposed to asbestos dust and it

is to be provided free of cost.

The medical records is to be maintained and stored for period of 15 years following the

termination of employment or for 40 years after first day of employment, whichever is

later. The medical records is to be maintained covering the details of pre-employment

examination, the periodical medical examinations, medical examination done at other

times, if any and the medical examinations conducted at cessation of employment and

further follow-up examinations, where done. The records shall also be maintained of the

individual employee’s occupational exposure profile to asbestos, specific work practices,

and preventive measures prescribed, if any.

The occupational health surveillance program is to address the following aspects

· Pre-employment medical examination

· Periodic medical examination

· Medical employment at cessation of employment

· Maintenance of medical records and

· Health education

Scheme for occupational health monitoring is to be prepared in detail [BIS code of

practices IS: 11451-1986 (Reaffirmed 2005) (Recommendations for safety health

requirements relating to occupational exposure to asbestos)]

Table – 8.1 Health Evaluation schedule: Frequency of Periodical Examination of

Occupational Health

Occupation Type of evaluation Frequency

Pre-placement

Cane Crushing Area Chest X-ray, spirometry

and vision testing

Every 5 years to age <30;

Every 4 years to age 31-



40; and every 2 years to

age 41-50;

Sugar Process Area &

Cogeneration Area

Chest X-ray, spirometry

and vision testing



40; and every 2 years to

age 41-50;

Noise prone areas Audiometry Annually

Main Control Room Far & Near Vision; Colour

Vision; and Hearing tests



40; And every 2 years to

age 41-50;

Ash Handling Area&

Bagasse Handling Area

Chest X-ray, spirometry,

Vision; and Hearing tests



40; And every 2 years to

age 41-50;

Ø All workers engaged in material handling system will be regularly examined for

lung diseases such as PFT (Pulmonary Function Test) tests;

8.7 Design of Green Belt

Green belt development in around 33 % of the total plant area will be developed. Green

belt of around 50 m width will be provided throughout the periphery of the existing

project site.

8.7.1 Green Belt and Plantation Plan

Green belt development in an industry is one of the most effective environmental

pollution control measures. Trees play vital role in keeping the ground level

concentrations in control within the plant premises and also in preventing the horizontal

dispersion of the pollutants to the surrounding areas. They are very effective in trapping

the pollution causing agents viz. dust and gaseous pollutants. They are also considered

to be excellent indicators of excessive ground level concentrations. The green belt is

being proposed for the following objectives.



Out of the total 251 acres of land, green belt will be developed 33% in 95.20 acres. Apart

from the bulk plantation around the boundaries, Roadside avenue plantations will also

be taken up. Based on the agro-climatic conditions of the region, location of the Sugar

Plant with Cogeneration Unit, physico-bio-chemical properties of the soil strata, nature of

the pollutants and their rate of dispersion, it is suggested to develop greenbelt around

the plant. Such green areas would improve the floral status and serve the dual purpose

of arrest of any fugitive dust from unpaved or open areas and also help to abate the

noise effects through dampening effects.

Table-8.2 Suggested Plant Species for Road Side Plantation

S.

No.

Scientific Name Vernacular name

1 Bauhimapururea Kachnar

2 Leucaenaleucocephala Subabool

3 Delonixregia Gulmohar

4 Cassia fistula Amaltas

5 Pongamiapinnata Karanj

6 Samaniasaman Rain tree

Table-8.3 Plant Species Suggested for Green Belt Development suggested by

CPCB

S.No

.

Botanical name of the

plant

Size of the

grown up tree

Type and suitable site,

where the plants are to be

plotted

1 Acacia auriculaeformis Medium Semi-evergreen fragrant white

flowers suitable in green belts

and on road sides



2 Adina corodifolia Large Deciduous, a light demander,

suitable on open areas and

near flares

3 Aeglemarmelos Medium Deciduous, good for green

belts near temples.

4 Anogeissuslatifolia Medium Deciduous, Suitable for green

belts

5 Artabotryshexapetaius Small Evergreen shrub with fragrant

flowers good for gardens and

inside boundary wall and long

canals

6 Averrhoacarambola Small Semi evergreen, good in

narrow green belts along the

ash pond

7 Azadirachtaindica Large Evergreen, suitable in green

belts along the boundary and

outside office & sensitive

buildings like hospitals.

8 Bauhinia variegate Medium Deciduous, good in green belts

in garden and as a second row

avenue tree

9 Borassusflabellifer Large A tall deciduous palm can be

used as wind break when of

different age.

10 Boswelliaserrata Medium Deciduous suitable on green

belt on willow soils

11 Bureraserrata Medium Evergreen, suitable on willow

soils as a green belt or avenue

tree

12 Buteamonosperma Medium Deciduous for green belt and

as a second row avenue tree

13 Caesalpiniapulcherrima Small A large shrub, suitable for

gardens outside offices and

along channels



14 Callistemon lanceolatus Medium Deciduous for some time,

ornamental plant in garden

15 Carevaaroborea Large Deciduous, good in green belts

16 CarrisaCarandas Small Semi evergreen large bushy

shrub good as a hedge to

protect against noise.

17 Carhotaurents Large A lofty palm, good as a wind

break

18 Cassia fistula Medium Deciduous, good ornamental

tree in green belts.

19 C.siamea Large Evergreen, good as an avenue

tree.

20 Casuarinaequisetifolia Medium Evergreen suitable for covering

low lying area and in green

belts and along ponds.

21 Cedrelatoona Large Deciduous, good in open

spaces, in green belts and

along ponds.

22 Ficusbengalensi Large Deciduous, widely spaced

avenue tree (15 m apart)

23 Ficusreligiosa Large Deciduous, widely spaced

avenue tree also as a single

tree in isolated sites.

24 Maducaindica Medium Deciduous, good in green

belts.

25 Peltophoruminerme Medium Semi evergreen, suitable on

road sides, in gardens and

outside office buildings.

26 Saracaindica Medium Evergreen tree good on road

sides within campus

27 Tamarindusindica Large Evergreen tree good along

boundary and road sides.

28 Terminaliacatappa Large Deciduous tree

29 Terminaliaarjuna Large Evergreen tree for road sides



and in green belts

30 Zanthoxyium Medium Deciduous in green belts

8.8 Measures to Improve Socio-Economic Conditions

For the benefit of the community in the vicinity of the project, USWL will take several

measures to develop various amenities in an effort to improve standard of living, some of

which are; Capital budget of Rs.199.52 Crs will be allotted for the following works in

consultation with local administration.

ü Providing drinking water

ü Construction of schools

ü Construction of community centres

ü Construction of roads and drainage

ü Construction of health centres

Table – 8.4 Corporate Social Responsibility (CSR) Budget

S. No. Description Amount in

Rs. Lakhs

1 Donations 10.00

2 Krishi melas 1.00

3 Medical Aid 35.0

4 Sports /recreation 5.0

5 Road repairs 25.0

6 Aid to School 20.0

7 Aid to places of worships 5.0

Total 101.00



8.9 Landscaping

The various services I utility areas within the plant will be suitably graded to different

elevations. Natural features of the plant site will be retained as far as possible to

integrate with the buildings to form pleasant environment. Areas in front of various

buildings and the entrance of Sugar Plant with Cogeneration Unit will be landscaped with

ground cover, plants, trees based on factors like climate, adaptability, etc. The green belt

will consist of native perennial green and fast growing trees. Trees will also be planted

around the plant boundary to minimize the dust pollution. Adequate afforestation will be

carried out as per the guidelines of MoEF.

8.10 Fire Fighting & Protection System

Safety Policy and Regulations

Keeping in view of the safety requirement during construction, operation and

maintenance phase, M/s USWL has formulated safety policy with the following

regulations:-

v To allocate sufficient resources to maintain safe and healthy conditions at work

place.

v To take, steps to ensure that all known safety factors are taken into account in

the design, construction, operation and maintenance of plants, machinery and

equipment.

v To ensure that adequate safety instructions are given to all employees.

v To provide wherever necessary, protective equipment, safety appliances and

clothing and to ensure their proper use.

v To inform employees about materials, equipment or processes review for making

necessary changes from the point of view of safety in the light of experience and

up to date knowledge.

v To provide appropriate instruction, training and supervision in health and safety,

first aid and to ensure that adequate publicity is given to these matters.

v To ensure proper implementation of fire prevention and an appropriate fire

fighting service together with training facilities for personnel involved in this

service.

v To ensure that professional advice is made available wherever potentially

hazardous situations exists or might arise.



v To organize collection, analysis and presentation of data on accident, sickness

and incident involving personal injury to health with a view to taking corrective,

remedial and preventive action.

v To prepare safety rules for each type of occupation/process involved in a project.

v To ensure regular safety inspection by a competent person at suitable intervals of

all buildings, equipment, work places and operations

Fire Protection System

v The plant has proposed adequate number of wall/column mounted type portable

fire extinguishers in various strategic areas of the plant including the control

room, administration building, stores, pump house etc. These portable fire

extinguishers are basically of carbon dioxide and dry powder type.

v Fire hydrants at suitable locations for TG building, boiler area, & storage area.

v Medium velocity water spray system for the cable gallery

v Necessary electric driven, Jockey pumps with piping valves & instrumentation for

safe operation.

8.11 Corporate Environment Policy: Corporate Responsibility for Environmental

Management

Ø The plant has an Environmental Management Committee headed by the Director

& Chief Operating Officer and comprises of key personnel in the plant. The

Committee meets regularly to review the status of various aspects of pollution

control measures will be implemented in the plant.

Ø The unit has also initiated improvement measures to get ISO14001 certification.

Ø Suggestion scheme has been launched and various suggestions given by the

workers and employees have been implemented in order to improve safety and

protect environment.

Ø The unit has resolved to become a zero waste integrated agro business sugar

complex and in its commitment to ensure zero discharge. Measures will be

implemented to recycle and reuse waste water to avoid effluent discharge into

the environment.

Ø The unit complies with the various requirements and standards stipulated by

Ministry of Environment & Forests, Central Pollution Control Board and

Maharashtra Pollution Control Board.



Ø The unit recently commissioned a new mist cooling system with automation for

cooling the evaporator and pan condenser water.

Ø Involvement of workmen in Safety Management through the Safety Committee

which is empowered to review accidents and initiate corrective and preventive

action.

Ø Ensuring high standards of housekeeping in the factory premises, resulting in a

Safe Shop floor,

Ø All personnel are trained on First Aid and basics of Safety Management.

* * * * *



CHAPTER 9

SUMMARY AND CONCLUSIONS



SUMMARY AND CONCLUSIONS

M/s. Ugar Sugar Works Ltd. Ugar Khurd, Tal: Athani, Dist: Belgaum, State: Karnataka

have Proposed Expansion of Sugar cane crushing capacity from 10,000 TCD to 20,000

TCD, Co-generation power plant from 44 MW to 75 MW & Molasses based Distillery

from 75 KLPD to 200 KLPD. This project development will give rise to social and

economic development measures in the study area.

1. The proposed agro based sugar industry has national priority to overcome energy

and food crisis. Sugar industry also has export potentials to earn foreign

exchange. Commencement of this industry will create employment opportunities

and improve the economic status of the farmers of this rural under-developed

region.

2. Wastewater generated from co-gen sugar unit is treated and used for irrigating

agricultural land for growing sugarcane.

3. The by-products such as bagasse, molasses, press mud produced from the

sugar plant will be profitably utilized in the industry itself in the production of

electrical power, alcohol and bio-manure respectively.

4. The project activity is an example as sustainable development as the resources

used from the nature are sent back to the environment by recycling process. The

concept of reduce, reuse and recycle is practiced in the industry as per the eco-

policy of Govt. of India.

5. This industry does not produce any toxic products and does not have significant

adverse effect on the quality of land, water and air. The industry has taken all the

necessary preventive measures to mitigate even the small effects which may be

caused by industrial activities.

6. There are no protected forests, sanctuary, archeological important structures or

other sensitive locations in the vicinity of the factory except the rivers Krishna &

Don rivers. Therefore, the proposed industry will not have adverse effect on the

environment or the eco system.

7. This industry does not have significant adverse effect on environment. The

industry proposes to adopt an effective environment management system and

environment management plan to protect the environment. Due priority is given

for greenery development and rainwater harvesting in the factory premises.



Environmental management plan and suggested measures for pollution control are

adequate for protection of environment and to seek environmental clearance to the

project.

Conclusion

The potential environmental, social and economic impacts have been assessed. The

proposed Sugar Unit, Cogeneration plant and distillery unit will have certain levels of

marginal impacts on the local environment. Implementation of the project will have

beneficial impact in terms of providing direct and indirect employment opportunities.

There will be a positive socio-economic development in the region. Quality of life of the

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

implemented. USWL will also undertake various community welfare measures for the

upliftment of the villages of the study area.

.

* * * * *



CHAPTER 10

DISCLOSURE OF CONSULTANT



Chapter 10

DISCLOSURE OF CONSULTANT

This EIA report is prepared on behalf of the proponents, taking inputs from

proponent’s office staff, their R & D wing, Architects, Project Management

Professionals etc. by Environmental Consultants M/s. Ultra-Tech Environmental

Consultancy & Laboratory, Thane, Mumbai , who have been accredited by QCI-

NABET vide official memorandum of MoEF S.N. 93 of LIST ‘A’ of MoEF - O.M. No. J

11013/77/2004/IA II(I) dated September 30, 2011, S. No.157 of list of Consultants

with Provisional Accreditation * (Rev.23) of dated 07th August, 2014.

M/s Ultra-Tech Environmental Consultancy & Laboratory:

Ultra-Tech Environmental Consultancy & Laboratory [Lab Gazetted by MoEF – Govt.

of India] not only give environmental solutions for sustainable development, but

make sure that they are economically feasible. With innovative ideas and impact

mitigation measures offered, make them distinguished in environmental consulting

business. The completion of tasks in record time is the key feature of Ultra-Tech. A

team of more than hundred environmental brigadiers consists of engineers, experts,

ecologists, hydrologists, geologists, socio-economic experts, solid waste and hazard

waste experts apart from environmental media sampling and monitoring experts and

management experts , strive hard to serve clients with up to mark and best services.

Ultra-Tech offers environmental consultancy services to assist its clients to obtain

environmental clearance for their large buildings, construction, CRZ, SEZ, high rise

buildings, township projects and industries covering sugar and distilleries from

respective authorities. Ultra-Tech is in the process of getting QCI-NABET final

accreditation for its EIA organization.

Ultra-Tech also provide STP/ETP /WTP project consultancy on turn-key basis apart

from Operation and Maintenance of these projects on annual contract basis. Also,

having MoEF approved environmental laboratory, Ultra-Tech provide laboratory

services for monitoring and analysis of various environmental media like air, water,



waste water, stack, noise and meteorological data to its clients all over India and

abroad.

Functional area experts and assistance to FAE involved in the EIA study for “M/s

Indian Sugar Manufacturing Co. Ltd. Turk Pimpri, Barshi Tehsil, Solapur District,

Maharashtra,” is as follows:

* EIA COORDINATOR : NAME : MR. A.K.MHASKAR

* PERIOD OF INVOLVEMENT : September 2013 – November 2013

* CONTACT INFORMATION : ULTRA-TECH Environmental consultancy & Laboratory,

EIA TEAM MEMBERS

S/ No.

Name of Sector

Name of Project

NAME OF EIA

COORDINATOR

FUNCTIONAL AREA EXPERTS

INVOLVED

1 Distilleries 5 (g), Sugar 5 (j) & Co- Gen 1 (d)

Indian Sugar Mfg co. Ltd. (Industrial Project)

Mr. A.K. Mhaskar Associates: Mr. Kishor Sawant, Dr. Prashant Banne

FA Names AP Mr. Akshay Kulkarni WP Ms. Pardnya Parkhi EB Ms. Bharti Khairnar SE Mr. Shrikrishna Kulkarni

SHW Ms. Pradnya Parkhi LU Associate: Mr. Amogh Bodas

LABORATORY FOR ANALYSIS

S/ No. Name of

Laboratory Scope of Services ACCREDITATION

STATUS 1 Green Circle INC. Monitoring and Analysis of:

1. Ambient Air Quality Monitoring 2. Ground and Surface Water Quality Monitoring 3. Noise Level Monitoring and 4. Soil Quality Monitoring 5. Metrological data collection

Gazetted by MoEF- Govt. of India

* * * * *



List of Annexure

Annexure

No.

Title of Annexure

1 Site Layout Plan

2 Existing unit MPCB consent to Operate Under Air act

3 Existing unit MPCB consent to Operate under Water act

4 Licence for Manufacture of Sugar

5 Distil lery Licence

6 Brief note on Sugar Manufacture Process

7 Schematic flow diagram of Sugar Manufacturing Process

8 A short note on Extra Neutral Alcohol Process

9 Flow Diagram of Disti l lery Plant

10 Flow Diagram of Disti llation Plant

11 Flow sheet for ENA process

12 Flow chart of IML Plant

13 Design basis of Single- Drum, Slop fired (TG) Boiler

14 Cogeneration – Package Boiler f low sheet

15 General Arrangement of Diesel power house

16 Data on Air quality modell ing

17 Note on Eff luent Treatment Plant (ETP)

18 Site plan of ETP

19 Note on Agriculture management plan

20 Map showing that irrigated area by disti llery effluent

21 Environmental Monitoring reports

22 Lab recognition & NABET accreditation certif icates

23 Copy of ToR (Terms of Reference) received from MoEF

chapter 1 introduction -...

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