sop sugar industries empri 2005 01

Standard Operating Procedures For

Sugar Industry

A Draft Report January 2005

Environmental Management B:

Policy Research Institute

TABLE OF CONTENTS

ITEM CHAPTER PAGE NUMBER

1 INTRODUCTION ---- 1

1.1 Background ---- 1 1.2 Gist Of Environmental Acts, Rules And

Notifications ---- 1

2 LEGAL AND REGULATORY FRAMEWORK ---- 2 2.1 Fundamental Rights And Duties Of A

Citizen ---- 2

2.2 State Policy ---- 2 2.3 Legislative Authority ---- 2 2.4 Relevant Legislations ---- 3 2.4.1 Factories Act, 1948 ---- 3 2.4.2 Environment Protection Act 1986. ---- 4 2.4.3 The Water (Prevention And Control Of

Pollution) Act, 1974 And Rules ---- 4

2.4.4 The Water (Prevention And Control Of Pollution) Cess Act, 1977 And Rules

---- 4

2.4.5 The Air (Prevention And Control Of Pollution) Act, 1981 And Rules

---- 4

2.4.6 The Environment Impact Assessment Notification 1994 & 1997

---- 5

2.4.7 The Noise Pollution (Regulation And Control) Rules, 2000

---- 5

2.4.8 The Hazardous Waste (Management & Handling Rules), 2000

---- 5

2.4.9 The Manufacture, Storage and Import of Hazardous Chemicals Rules, 1989

---- 5

2.5 Relevant Policies ---- 5 2.5.1 The National Environmental Policy ---- 6 2.5.2 The National Industrial Policy ---- 7 2.6 Relevant Institutions ---- 8 2.6.1 Ministry Of Environment And Forest,

Government Of India ---- 8

2.6.2 Department Of Ecology And Environment, Government Of Karnataka

---- 8

2.6.3 Karnataka State Pollution Control Board ---- 8 3 RESPONSIBILITIES OF THE SUGAR

INDUSTRIES ---- 11

3.1 Approvals ---- 11 3.2 Responsibilities ---- 11 4 WATER AND AIR (PREVENTION & CONTROL

OF POLLUTION) ACTS ---- 12

4.1 Consent Procedure ---- 12 5 WATER (PREVENTION & CONTROL OF

POLLUTION) CESS ACT ---- 13

6 ENVIRONMENTAL STATEMENT PROCEDURES ---- 14 6.1 Contents Of Environmental Statement ---- 14 7 ENVIRONMENTAL AUDITING ---- 15 7.1 Features Of A Good Environmental Audit ---- 15

ITEM CHAPTER PAGE NUMBER

7.2 Audit Procedure ---- 16 8 CHARTER ON CORPORATE RESPONSIBILITY

FOR ENVIRONMENTAL PROTECTION (CREP) ---- 17

9 ENVIORONMENTAL PERFORMANCE VERIFICATION EXERCISE

---- 18

10 TYPES, SOURCES AND NATURE OF POLLUTION FROM SUGAR INDUSTRY

---- 19

10.1 Process involved in Sugar Industry ---- 19 10.2 Pollution Effect ---- 21 10.2.1 Wastes Water ---- 21 10.2.2 Solid Waste ---- 21 10.2.3 Air Pollutants ---- 21 10.2.4 Molasses ---- 21 10.3 Good Operating Practices ---- 22 10.4 Steps To Be Taken At Different Stations Of

A Sugar Mill In Order To Reduce The Pollution

---- 22

10.4.1 Cane Yard & Cane unloading section ---- 23 10.4.2 Cane carrier section ---- 23 10.4.3 Milling Station ---- 23 10.4.4 Boilers - Boiler operation, Boiler Ash ---- 24 10.4.5 Clarification & Evaporation Station ---- 24 10.4.6 Entrainment from Pans and Evaporator ---- 25 10.4.7 Sulphitation ---- 26 10.4.8 Liming Station ---- 26 10.4.9 Crystallization Station ---- 26 10.4.10 Segregation of Effluents ---- 27 10.4.11 General Points ---- 27 10.5 Good Housekeeping Practices – Do’s &

Don’ts ---- 27

Appendix I ---- 34 Appendix II ---- 36 Appendix III ---- 38 Appendix IV ---- 48 Annexure Maintaining Log Books ---- 54 Verification Guidelines ---- 57

Standard Operating Procedures for Sugar Industries

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1 INTRODUCTION 1.1 BACKGROUND

Sugar industries are classified under seventeen category highly polluting industries as per the Government of India notification. In the last fifty years numerous sugar units have been established in the country and also in the state and as of today 56 units are working in different parts of the state. However the environmental problems of the sugar industries are quite unique and pose a challenge despite the fact that a well developed production technology is available. The problem is quite acute with units having old technology of crushing and sugar production. The process of sugar manufacture has many stages with most of the stages generating pollutants in different forms like waste water, solid wastes and air pollutants. The causes of these forms of pollution include leakages, spill-over, overloading, indifferent handling and crushing operations, improper molasses handling, etc.

Under these circumstances an attempt has been made to evolve a suitable standard operation procedure (SOP) to help the manufacturers to understand the current legal requirements and adopt the procedures to minimize the pollution as per the consent conditions. Presently, as per Rule 14 of the Environment Protection Rules, 1986, it is mandatory for persons carrying out an industry or operation or process which require consent under Water Act, 1974 or Air Act, 1981 or authorization under the Hazardous Waste Rules, 1989, to submit every year an Environmental Statement to the concerned State Pollution Control Board. However, the existing mechanism does not provide for rigorous analysis of Environmental Statement by the industries. Hence, it was felt that an effective institutional arrangement for implementing the Environmental Audit is necessary.

This document is a reference guide which provides for guidelines to sugar industries to standard procedures for environmental clearances, procedures for taking appropriate consents for establishing and operation of industries, the compliance standards set for the mining sector ensuring the consent conditions for discharges of effluent are met, best practices for cleaner production, etc.

This document also puts forth the linkages between the Environmental Impact Assessment document which is prepared at the initialisation of the project and the Environmental Statement to be provided by the project proponent. Also the document defines the responsibilities of the project proponent (internal auditor) and external and regulators, the precautionary measures to the taken, the method to be followed and records to be maintained by the project proponent. 1.2 GIST OF ENVIRONMENTAL ACTS, RULES AND NOTIFICATIONS

In the Sugar Sector the following Acts, Rules and Notifications are applicable: Environmental Legislations:

1. The Water (Prevention and Control of Pollution) Act, 1974 and Rules 2. The Water (Prevention and Control of Pollution) Cess Act, 1977 and Rules 3. The Air (Prevention and Control of Pollution) Act, 1981 and Rules 4. Relevant provisions under Environmental Protection Act and Rules, 1986

♦ The Noise Pollution (Regulation and Control) Rules, 2000 ♦ The Municipal Solid Waste (Management & Handling) Rules, 2000 ♦ The Hazardous Waste (Management & Handling) Amendment Rules, 2003

5. Factories Act, 1948


2 LEGAL AND REGULATORY FRAMEWORK To put the whole regulatory framework of India in perspective, a gist of constitutional

provisions that relate to the environment is given below. 2.1 FUNDAMENTAL RIGHTS AND DUTIES OF A CITIZEN

1. Under the Indian Constitution, Part III [Fundamental Rights] Article 21 states the fundamental right of protection of life and personal liberty of an individual, “No person shall be deprived of his life or personal liberty except according to procedure established by law”. It should be noted that though this Article does not explicitly mention the term ‘environment’, it is a fundamental norm recognized by the court that every person enjoys the right to a wholesome environment, which is a facet of right to life under the above-mentioned Article.

2. Part IV – A [Fundamental Duties] Article 51 – A (g) states that “It shall be the duty of every citizen of India to protect and improve the natural environment including forests, lakes, rivers and wildlife and to have compassion for living creatures”. This Article was inserted by the Constitutional (42nd Amendment) Act, 1976

2.2 STATE POLICY The State’s responsibility has been laid down in the Part IV – ‘Directive Principle of

State Policy’ of the Constitution. The Article 48 –A concerns the Environmental responsibility of the State and was inserted by the Constitutional (42nd Amendment) Act, 1976. The Article states that “The State shall endeavour to protect and improve the environment and to safe guard the forests and wild life of the country”. 2.3 LEGISLATIVE AUTHORITY

The Part XI of Constitution states the relationship between the Union and the States for sharing the legislative and administrative powers. Under this Part, the Article 245 of the Constitution gives the extent of the laws made by the Parliament and the State Legislatures. The Parliament has the power to legislate for the whole country while the State legislatures are empowered to make laws for their respective states. The Article 246 of the Part XI of Constitution divides the areas of legislation (subject wise) between the Union [List 1 or Union List in 7th Schedule, 97 subjects], State Legislatures [List II or State List in 7th Schedule, 66 subjects] and both Parliament and State Legislatures [List III or Concurrent List in 7th Schedule, 52 subjects]. The subjects related to environment in the 7th Schedule under the three lists are summarized below:

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LIST NO.

NAME SUBJECT NO. IN

LIST

SUBJECT

I Union 52 Industries List 53 Regulation and development of

oil fields and mineral oil resources

54 Regulation of mines and mineral development

55 Regulation and development of Inter-State rivers and river valleys

56 Fishing and fisheries beyond territorial waters

II State 6 Public health and sanitation


LIST NO.

NAME SUBJECT NO. IN

IST

SUBJECT

L List 14 Agriculture, protection against

pest and prevention of plant diseases

18 Land, colonization, etc. 21 Fisheries 23 Regulation of mines and mineral

development subject to the provision of List –I

24 Industries subject to the provision of List – I

III Concurrent 17 A Forests List 17 B Protection of wild animals and

birds 20 Economic and social planning 20 A Population control and family

planning

The Parliament has powers to legislate on subjects not covered by the three Lists [Article 248].

♦

♦

♦

♦

The Parliament is also empowered to legislate in the ‘national interest’ on matters enumerated in the State List [Article 249]. In event of a conflict between the Central law and State law on a concurrent subject the former prevails [Article 254 (1)]. In case of a State law passed subsequent to the Central law, the State law shall prevail in that State only if it has received Presidential Assent under Article 254 (2) of Part XI of Constitution.

From an environmental standpoint, the allocation of legislative authority is an important one as some environmental problems such as sanitation and waste disposal are best tackled at local level, while others like water pollution and wildlife protection are better regulated by uniform national laws. 2.4 RELEVANT LEGISLATIONS As stated earlier, the working environment within the factory is regulated by the Factories Act, 1948 while the environment (air & water emissions, noise, waste) are governed by environmental legislations. 2.4.1 Factories Act, 1948.

The Factories Act, 1948 sets the duties of the occupier to maintain the safety and health of all workers at work.

The occupier of every factory involving a hazardous process shall disclose all information regarding dangers, including health hazards and the measures to overcome such hazards arising from the exposure to or handling of the material or substances in the manufacture, transportation, storage and other processes to the workers employed in the factory, the Chief Inspector, the local authority within whose jurisdiction the factory is situate and the general public in the vicinity. The occupier of the factory shall draw up an on-site

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emergency plan and detailed disaster control measure for his factory and make it known to all stakeholders.

For factory involving a hazardous process or for the expansion of any such factory, the State Government may appoint a Site Appraisal Committee. The committee would examine application from the proponent and given recommendations. Where the State Government has granted approval to an application for the establishment or expansion of a factory involving hazardous process, it shall not be necessary for an applicant to obtain a further approval from the Central Board or the State Board established under the Water (Prevention and Control of Pollution) Act, 1974 and the Air (Prevention and Control of Pollution) Act, 1981. 2.4.2 Environment Protection Act 1986.

The Environment Protection Act 1986 section 3 provides for fixing standards for emission or discharge of environmental pollutants. The standards of emissions or discharge of environmental pollutants from the industries, operations or processes shall be as specified in (schedules 1 to IV). Since the KSPCB is not insisting on any of the provisions while issuing the consent only the EIA needs to be done to get the licenses. 2.4.3 The Water (Prevention and Control of Pollution) Act, 1974 and Rules

As per this Act the occupier or the operator of a mining activity has to fulfil the following obligations and duties to protect the environment and to prevent any environmental damage or pollution. Act makes it mandatory the occupier to discharge any trade effluent to the land or water body by treating it to the level of the standards prescribed by the Regulatory authority. (the standards are given in the annexure). Any violation of this section attracts legal action under the section 41 to of the Water Act.

2.4.4 The Water (Prevention and Control of Pollution) Cess Act, 1977 and Rules The purpose of Water (Prevention & Control of Pollution) Cess Act is levy and

collect cess on water consumed by 16 categories of industries specified in the act and also by local bodies with a view to augment the resources of the Central and State Pollution Control Boards. Water cess is levied based on the water consumed for domestic and specified industry. 2.4.5 The Air (Prevention and Control of Pollution) Act, 1981 and Rules

The objective of this Act is to provide for the prevention, control and abatement of air pollution, for the establishment, with a view to carrying out the afore said purposes, of boards, for conferring on and assigning to such boards powers and functions relating thereto and for matters connected therewith. Decisions were taken at the United Nations Conference on the Human Environment held in Stockholm in June 1972, in which India participated, to take appropriate steps for the preservation of the natural resources of the earth which among other things, includes the preservation of the quality of air and control of air pollution.

The Central and State Pollution Control Boards are entrusted to perform the functions under the Act. As per the Act, Air Pollution is defined means the presence in the atmosphere of any air pollutant. Air pollutant means any solid, liquid or gaseous substance (including noise) present in the atmosphere in such concentration as may be or tend to be injurious to human beings or other living creatures or plants or property or environment.

The primary responsibility of controlling air pollution is on the Board. The very first measure to be adopted in this respect is the declaration of any area or areas within the State as air pollution control area. In respect the Sate government has declared entire State as air pollution control area. The air pollution from industrial plants is controlled through consent mechanism by stipulating standards in respect of air pollutants. In case of non compliance, the act has made provisions for issuing directions to any person, officer or authority, and such

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person, officer or authority shall bound to comply with such directions. Power to issue direction includes the power to direct:

Closure, prohibition or regulation of any industry, operation or process or ♦ ♦ ♦

1. 2. 3. 4.

The stoppage or regulation of supply of electricity, water or any other service In addition to this, Provisions exist to make application to courts for restring persons from causing air pollution and punish the offender with imprisonment and fine.

2.4.6 The Environment Impact Assessment Notification 1994 & 1997 As per the notification it is mandatory on part of 30 categories of industries (list given

below) to obtain environmental clearance from Ministry of Environment and Forest, GOI before establishment or expansion or modernization. It should be noted that sugar industries do not have to obtain clearance. 2.4.7 The Noise Pollution (Regulation and Control) Rules, 2000

The State Government shall categorize the area into industrial, commercial, residential or silence area/zones for the purpose of implementation of noise, standards for different area. The ambient air quality standards in respect of noise for different areas/zones shall be such as specified in the Schedule annexed to these rules.

The noise levels in any area/zone shall not exceed the ambient air quality standards in respect of noise as specified in the Schedule.

The authority shall be responsible for the enforcement of noise pollution control measures and the due compliance of the ambient air quality standards in respect of noise. 2.4.8 The Hazardous Waste (Management & Handling Rules), 2000 These rules apply to handling of hazardous wastes specified in the Schedules 1, 2, & 3 of the rules. These rules do not apply to waste water and exhaust gases as covered under the provisions of the Water and Air Act and Rules made there under, wastes arising out of the operation from ships beyond five kilometers as covered under the provisions of the Merchant Shipping Act and radioactive wastes covered under the provisions of the Atomic Energy Act. 2.4.9 The Manufacture, Storage and Import of Hazardous Chemicals Rules, 1989 These rules apply to any industrial activity in which a hazardous chemical (criteria given in Schedule 1 of the Rules) is involved and where the isolated storage of a hazardous chemical is equal to or more than the threshold quantity specified (chemical and threshold listed in Schedule 2 of the Rules). The rules also specify the responsibility of the occupier to provide evidence to show that he has identified the major accident hazards and also taken adequate to prevent major accidents and provide adequate information, training, and equipment including antidotes necessary for safety. In case of a major accident occurring on the site or pipelines the occupier should notify the concerned authorities (Schedule 5 of the Rules, also see annexures) 2.5 RELEVANT POLICIES

The following list of the policies related to environment and sugar industries: The National Environmental Policy The Industrial Policy, 1991 The Policy Statement for Abatement of Pollution, 1992 The Export-Import Policy, 1997 It is evident that the Policies being pursued presently have been evolved with

experience and with the considerations of various national and international developments

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and the country's requirements for development. The Policies outline the guiding principles for the various developmental and industrial activities. 2.5.1 The National Environmental Policy

Although since long there was a concern for the environmental management in the country as evident from the various Policies and Legislation the lead was given in the Sixth Plan when a Chapter on 'Environment and Development' was included in the Plan document. The Chapter laying emphasis on the problems of environmental degradation provided guidelines to the administrators for formulating and implementing the development programs incorporating environmental concerns and laying down the institutional arrangements for environmental management, administration and protection. The Eighth Plan on the basis of the overview of the environmental and forest scenario identified the eight major tasks to meet the challenge of environmental degradation.

To complement the Constitutional sanctions, outlines earlier, MoEF in 1992 brought out a Policy Statement for Abatement of Pollution and the National Conservation Strategy and Policy Statement on Environment and Development which provides instruments in the form of legislation and regulation, fiscal incentives, voluntary agreements, educational programs and information campaigns for preventing, controlling and reducing environmental pollution. The overall objective of the Policy was to integrate environmental considerations into decision making at all levels and to achieve this, the following specific steps were identified.

1. Prevent pollution at source. 2. Encourage, develop and apply the best available practical solutions. 3. Ensure that polluter pays for the pollution control arrangements. 4. Focus protection on heavily polluted areas and river stretches. 5. Involve public in decision making. 6. Increase the safety of industrial operations. The MoEF issued the Environmental Action Program in 1993 with the objective of

integrating the environmental concerns into the process of development. The various issues addressed were reducing pollution at source, assistance for adaptation of the best available and practicable technologies, mass based standards, fiscal measures, environmental audit, environmental statistics, and public participation.

The National Conservation Strategy and Policy Statement on Environment and Development, 1992 formulated with a view to reinforcing traditional ethos and to building up a conservation society living in harmony with nature and making efficient use of the resources guided by the best available scientific and technical knowledge aimed at the following.

1. Ensuring sustainable and equitable use of the resources for meeting the basic needs of the present and future generations without causing damage to the environment.

2. Preventing and controlling the future deterioration of the life support systems. 3. Taking steps for restoration of ecologically degraded areas and for environmental

improvement in the rural and urban settlements. 4. Ensuring that the developmental projects are correctly cited with least adverse

environmental consequences. 5. Conserving and protecting the coastal areas and marine eco-systems.

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6. Protecting the scenic landscapes, areas of geomorphological significance, unique and representative bio-mass and eco-systems and wild life habitats, heritage sites/structures and areas of cultural heritage/importance.

For achieving the above the following actions were envisaged in the Policy. 1. Environmental impact assessment of all the developmental projects right from the

planning stage and integrating it with their cost-benefit considerations. 2. Compulsory prior environmental clearance of all projects above a certain size and for

those proposed to be constructed in ecologically sensitive and fragile areas. 3. Incorporation of environmental safeguards and protection measures in policies,

planning, site selection, choice of technology and implementation of the developmental projects, i.e., industries, mining and mineral processing, forestry and human settlements.

4. Encouraging research and developmental activities, adaptation of environmentally compatible technologies, and to promote application of the modern tools of science and technology for conservation, bridging of large gaps in supply and demand as well as controlling and monitoring of the natural resources.

5. Encouraging public participation in environmental improvement programs and integrating the environmental concerns in planning and implementation of the developmental programs.

6. Creating environmental consciousness through education and mass awareness programs.

7. Aiming at the modernization of the process of demand unleashed by the development process itself by taking measures to recycle waste materials and natural resources, conserving energy and the use of the natural resources in the industrial products by measures like wood substitution and generally trying to reach moderation in life style consistent with the sustainable development and the human dignity.

8. Developing appropriate organizational structure and a pool of professional manpower to serve as the cadre for environmental management services.

9. Efficiently implementing the various environmental laws and regulations for environmental protection through creation or strengthening of requisite enforcement machinery.

It is evident that the Policy directives mean effective protection and management of environment in all the developmental and industrial activities while keeping the goal of sustainable development in view. Since mining of minerals and fossil fuels is an important industrial activity essential for the development of the society and invariably mining is considered to be an environmentally unfriendly activity the directives of the Policy are to be taken into consideration not only in planning the mining and associated activities but also during and after the completion of the mining activities. 2.5.2 The National Industrial Policy

The New Industrial Policy, 1991 was formulated to provide an impetus to the pace of industrialization in the country. This resulted in abolition of all industrial licensing for all the industries except some specified industrial sectors. The Policy addresses the environmental concerns along with objectives of sustainable development and states:

“The major objectives of the new industrial policy package will be to build on the gains already made, correct the distortions or weaknesses that my have crept in, maintain sustained growth in productivity and gainful employment and attain international competitiveness. The pursuit of these objectives will be tempered by the need to preserve the environment and ensure the efficient use of available resources.”

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The New Industrial Policy lays stress on the following for the sustained development and growth of the industry in the country.

1. Substantial reduction in the scope of industrial licensing. 2. Simplification of procedures, rules and regulations. 3. Reforms in the Monopoly and Restrictive Trade Practices Act. 4. Reduction of the areas reserved exclusively for the public sector. 5. Disinvestment of selected public sector enterprises. 6. Enhancing limits of foreign equity participation in domestic industrial undertakings. 7. Liberalization of trade and exchange rate policies. 8. Rationalization and reduction of customs and excise duties. 9. Extension of the scope of modified value added tax (MODVAT).

2.6 RELEVANT INSTITUTIONS Three departments are directly involved in the protection of environment due to sugar industries in the state, including the Ministry of Environment and Forest, Govt. of India; The Department of Forests, Ecology and Environment, Govt. of Karnataka; and Karnataka State Pollution Control Board 2.6.1 Ministry of Environment and Forest, Government of India

Ministry of Environment and Forest (MoEF) is the nodal agency at national level, in the administrative structure for environmental protection and forest conservation. MoEF is assisted by the Central Pollution Control Board (CPCB), a statutory authority at the central level in executing responsibilities of prevention and control of pollution. Implementation of relevant Acts and Rules and policy issues at the State level is overseen by the State Pollution Control Boards (SPCB) and the State Department of Environment and Forest (DOEF). The governing Acts and Rules are: Environment Protection Act-1986, Forest Conservation Act-1980 and rules there under. 2.6.2 Department of Ecology and Environment, Government of Karnataka

Department of Ecology and Environment (DEE) is the state nodal regulating agency responsible for environmental management of the state and can exercise promotional and regulatory functions in mining sector under the Air, Water and Environment Protection and Forest Conservation Acts. The department also houses the State Environmental Clearance Committee (SECC) which gives clearances to projects. The applications seeking environmental clearances as per the EIA notifications are routed through DEE. 2.6.3 Karnataka State Pollution Control Board

KSPCB has regulatory and enforcement responsibilities with respect to air, water pollution control and hazardous waste management in mines under the Water (Prevention & Control of Pollution) Act, 1974, the Air (Prevention & Control of Pollution) Act, 1981 and rules there under, the Environment Impact Assessment Notification, 1994 & 1997 and Hazardous Waste (Management & Handling) Rules, 1989 & amendments rules 2000. KSPCB is responsible for conducting public hearing under Environmental Impact Assessment (EIA) notification for any developmental or new projects, including the mining sector.

At present the Karnataka State Pollution Control Board is issuing consent to the mining industries with only the stipulations for treating domestic wastewaters, as there is no generation of any trade effluent from any mining activity. However, in case where purification and beneficiation of the ore is to be taken up at the mining area, prior consent from the KSPCB should be taken and in such cases consent conditions for the disposal of trade effluents will be specified by the Board. Under The Air (Prevention and Pollution Control) Act, at present no compliance provision are indicated in the consent letter. However

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the following Acts that are still valid and applicable are discussed here as they are relevant to the sector. The Standards of Service of Karnataka State Pollution Control Board are given in Annexure I. 2.6.3.1 Condition prescribed by the KSPCB in the Consents to Establish and Operate

1. The maximum quantity of water consumed in a sugar factory shall not exceed 2 cubic meter per tonne of cane crushed.

2. The factory shall ensure treatment of all the wastewater generated in the factory before it is discharged.

3. The treated water shall be used in the irrigation and shall not be discharged into the stream or water bodies.

4. The application of the treated effluent shall be controlled so as to avoid either flooding of land or ground water contamination. Before allowing the usage of treated water for irrigation the State Pollution Control Board shall ensure that the factor shall submit a report on geophysical characteristics and assimilation capacity of land. Adequate number of bore wells shall be provided by the factory in and around the irrigated area to monitor ground water quality.

5. Chimneys of required height and other air pollution controlling equipments should be provided by the factory.

6. Biogases shall be collected and stored properly by the factory to avoid the fugitive emissions.

7. The factory shall ensure that the noise levels are within the stipulated limits and shall conduct periodic monitoring of noise levels at a designated location at specified intervals.

8. Press mud generated can be sold without treatment. However in case it is not sold it shall be collected composted within the factory under the supervision of the factory’s scientists.

9. Lime sludge shall be collected and disposed off by the factory scientifically. 10. Ash from the boilers shall be collected and disposed off by the factory scientifically. 11. The factory shall install water meters to measure the water consumed for different

purposes as per the Water (Prevention and Control Pollution) Cess Act, 1977; as amended and pay water cess.

12. The factory shall submit an Environmental Statement Report for the financial year ending the 31st March in the prescribed format to the state to the state pollution control board on or before the 30th day of September every year beginning 1993.

13. All tanks used for the storage and treatment of effluent shall be made impervious by providing adequate cement concrete/stone masonry/ stone slab lining with leak proof joints in the bottom and sides. Observation bores with pipes shall be provided around such tanks and monitored for leakage.

14. The factory shall store the molasses generated in adequately sized steel tanks provided with the roof cover.

15. The factory shall upgrade the pollution control systems as and when new technologies become available.

16. The factory shall ensure continuous and effective operation and maintenance of pollution control systems by employing qualified engineers.

17. The factory shall ensure continuous and uninterrupted power supply to see that the pollution control systems functions uninterruptedly. Separate energy meter shall be provided for the pollution control system.

18. A fully equipped laboratory shall be established by the factory with appropriate equipments to monitor the performance of pollution control systems and to test the effluents, emissions and soil for pollution related parameters.

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19. Every new factory shall submit the Environment Impact assessment report and Environmental management plan to the state pollution.

20. If the occupier has not taken consents under the Water (prevention and pollution control) Act 1974 and the Air (prevention and control of pollution) Act 1981, and the clearance under the Environment (protection) Act 1986, he shall not be allowed to run the factory. Action shall be taken by writing to the concerned Departments to stop supplies such as electricity, water etc.

21. For convenience the standards stipulated by the Karnataka sate pollution control Board both under the water (prevention and control of pollution) Act 1974 and the Air (prevention and control of pollution) Act 1981 for the effluents and emissions discharged respectively are given below. The standards for effluents and emissions discharged from sugar industry.

1 Effluent. Concentration not to exceed Milligram/lit

• Bio-chemical oxygen Demand. 100 for disposal on land. • Suspended solids 100 for disposal on land. 2 Emissions. • Bagasse-fired Boilers. 250 • Horse shoe/pulsating Grate. 500 (12% CO2). • Spreader stroker. 800 (12% CO2).

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3 RESPONSIBILITIES OF THE SUGAR INDUSTRY AUTHORITIES

3.1 APPROVALS Approval for setting up Sugar Industries include:

1. Should obtain prior “Consent for Establishment” approval from the State Pollution Control Board under the Water (Prevention and Control of Pollution) Act, 1974 and the Air (Prevention and Control of Pollution) Act, 1981.

2. Should obtain prior approval from the competent authorities for industries.

3.2 RESPONSIBILITIES Should comply with the consent conditions laid down by State Pollution Control

Board Should maintain relevant log books for daily water consumption, raw material used

and products manufactured, energy use and consumption, hazardous and solid waste generated, waste water generated, air emissions, etc. Should submit yearly “Environmental Statement” to the concerned State Pollution

Control Board Should submit yearly “Water Cess Returns” to the concerned State Pollution Control

Board Should provide for waste water treatment facility, air pollution control devices and

noise pollution abatement measures.

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4 WATER AND AIR (PREVENTION & CONTROL OF POLLUTION) ACTS The Water (Prevention & Control of Pollution) Act is an act to provide for prevention

of control of water pollution and maintaining or restoring of wholesomeness of water while, the Air (Prevention & Control of Pollution) Act provides for the prevention, control and abatement of air pollution. Under these two acts any new industry prior to commissioning should obtain consent of the concerned State Pollution Control Board to establish and to operate. 4.1 CONSENT PROCEDURE All new establishments like industries, water and wastewater treatment systems, sewage treatment systems are required to obtain “Consent for Establishment” and subsequently obtain “Consent for Operation” under the Air and Water Acts. All the consent applications received will be subject to technical evaluation and conditions imposed to protect the environment. Application Form I and Form XIII, under the Air and Water Act, respectively, to be filled by the applicant along with the consent fee and relevant documents. Pass Book system has been introduced for renewal of consents. Depending upon the industries varying in pollution potential (red, orange, and green) and capital investment (small scale, medium scale, and large scale) the consent fees varies.

The industries under large scale and medium scale RED category are required to obtain consent every year.

♦

♦

♦

Medium scale ORANGE and GREEN category industries are required to obtain consent every year with an option for once in two years by paying two years fee. Small scale RED ORANGE and GREEN category have to obtain consent every year with an option of once in three years by paying three year fee. Tiny industries have to renew consent once in ten years by paying one year consent

fee. See Annexure II for Consent fee, frequency of consent application and the periodicity of monitoring based on the classification of industries

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5 WATER (PREVENTION & CONTROL OF POLLUTION) CESS ACT

The purpose of Water (Prevention & Control of Pollution) Cess Act is levy and collect cess on water consumed by 16 categories of industries specified in the schedule I of the act and also by local bodies with a view to augment the resources of the Central and State Pollution Control Boards. Water cess is levied based on the water consumed for domestic and specified industry. Cess is calculated on rate specified in Schedule II of the Act for different water users. As per section 4 of the act the concerned industries are required to install standard water meters at such places as may be required by the concerned authority for measuring and recording the quantity of water consumed by the industry. The industry consuming water shall furnish the cess returns in the prescribed form on or before 5th of every month to the Member Secretary of the State Pollution Control Board. The returns filed are assessed by the authority after due verification and amount payable is intimated to the user, which should be paid by demand draft by the user. If the industry complies with the regulation by providing effluent treatment plant which meets the standards prescribed in terms of quantity and quality, it is entitled to a rebate of 25%.

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6 ENVIRONMENTAL STATEMENT PROCEDURES Environmental Management in industries hitherto based on and off pipe waste

treatment, is now based on the emerging philosophy of waste prevention and reduction. In order to prevent or reduce waste generation, one needs to examine the production processes, to identify the origins of wastes, the operational problems associated with the process and the areas requiring improvement. As per the notification issued by the Ministry of Environment & Forest, Government of India on 13th March, 1992 (amended vide notification no. GSR 386 (E) dtd. 22.04.1993) under the Environment (Protection) Act, 1986, all those carrying on an industry, operation or process requiring consent to operate under section 25 of the Water (Prevention & Control of Pollution) Act, 1974 and / or under section 21 of the Air (Prevention & Control of Pollution) Act, 1981 and/ or authorization issued under the Hazardous Waste (Management & Handling) Rules, 1989 and the Environment (Protection) Act, 1986 are required to submit the environmental statement for every financial year ending 31st March in the prescribed form [Form V] to the concerned State Pollution Control Boards on or before 30th day of September every year beginning 1993. Non-compliance with this mandatory requirement amounts to violation of the Environment (Protection) Act, 1986. 6.1 CONTENTS OF ENVIRONMENTAL STATEMENT

A statement prepared by the industry shall include the following; i. A description of the company’s activities at site considered

ii. An assessment of all the significant environmental issues relevant to there activities iii. A summary of the figures on energy consumption, water consumption, raw materials

consumption, pollutant emissions, waste generation and other significant environmental aspects.

iv. The industry’s environmental policy objectives and targets v. Details of the programme to be followed and the environmental management system.

Environmental Statement helps industry to take a comprehensive role at their industrial operations and facilities, understanding of material flows and focus on areas where waste reduction and consequently saving input costs, if possible. Environmental Statement is to be prepared by every industry by filling up one “Environmental Statement Form V (enclosed vide Annexure ) supplied by Pollution Control Board. For the preparation of Environmental Statement, log book need to be maintained by the mining authorities in their premises which would make the statement summarising easier. The log book list is provide below

1. Water log book 2. Raw Material log book 3. Energy log book 4. Pollutant log book 5. Hazardous log book

The day to day summary from the log book can be summarised on monthly basis. A sample log book is provided in Annexure

14


7 ENVIRONMENTAL AUDITING Environmental Audit has become a step to comply with the requirement to furnish the

Environmental Statement, though the importance of Environmental audit lies in achieving increased productivity and reduced waste generation. ‘Auditing’ in general is a methodical examination involving analysis, tests and confirmation of local procedures and practices whose goal is verify whether they comply with legal requirements, internal polices and accepted practices. Auditing differs from assessment in that it requires collection and documentation of competent and sufficient evidence rather than an opinion based primarily on professional judgement.

“Environmental Audit” is a technique being introduced for integrating the interest of the industry and the environment so that there could be mutually supportive. This technique is basically a part of industry’s internal procedures to meet their responsibilities towards better environment. Environment Auditing is a management tool comprising a systematic documented periodic and objective evaluation of how well the management systems are performing with the aim of:

• Waste preventive and reduction • Assessing compliance with regulatory requirements • Facilitating control of environmental practices by a company’s management, and • Placing environmental information in the public domain.

Environmental Audit in India is different from that in developed countries and the definition of International Chamber of Commerce (ICC) is accepted. ICC defines Environmental Audit is “It is a management tool comprising a systematic, documented, periodic and objective evaluation of how well environmental organization, management and equipment are performing with the aim of helping to safe guard the environment by:

♦ ♦

♦

♦ ♦

♦ ♦ ♦ ♦ ♦ ♦

Facilitating management control of environmental practices. Assessing compliance with company policies, which would include meeting, regulatory requirement. ‘Environmental Statement’ which is a part of the Environmental Audit. “Environment Policy” means a statement of a company’s overall aims and principles

of action with respect to the environment. 7.1 FEATURES OF A GOOD ENVIRONMENTAL AUDIT

A good Environmental Audit defines sources, quantities & types of waste generation Collates information on unit operations, raw materials, products, water usage and wastes and increases knowledge of the process. Highlights process deficiencies and poor management Helps to set targets for waste reduction Permits the development of effective waste management strategies. Rises awareness in the workforce regarding the benefits of waste reduction Helps to improve process efficiency Enables legislative compliance & avoids litigation.

7.2 AUDIT PROCEDURE

15


A step-by-step methodology for Environmental Audit as recommended by the United Nations Environment Programme and the United Nations Industrial Development Organisation (UNIDO) is illustrated in figure 1.

AUDIT PREPARATION Step 1 Prepare and organise audit team and resources. Step 2 Divide Process into unit operation Step 3 Construct process flow diagram linking unit operation

PROCESS OUTPUTS Step 7 quantify products / by-products Step 8 Account for waste water Step 9 Account for gaseous emissions Step 10 Account for offsite wastes

PROCESS INPUTS Step 4 Determine inputs Step 5 Record water usage Step 6 Measure current levels of waste reuse/recycling

DESERVE A MATERIAL BALANCE Step 11 Assemble input and output Information Step 12 Derive a preliminary material balance Step 13 and 14 evaluate and refine material balance

IDENTIFY WASTE REDUCTION OPTIONS Step 15 Identify obvious waste reduction measures Step 16 target and characterize problem wastes Step 17 Investigate the possibility of waste segregation Step 18 Identify the long term waste reduction measures

e options

Phase 3: Synthesis

Phase 2: Material Balance

Phase 1: Pre-Assessment

WASTE REDUCTION ACTION PLAN Step 20 Design and implement a waste reduction action plan to achieve improved process efficiency

EVALUATE WASTE REDUCTION OPTIONS Step 19 Undertake environmental and economic evaluation of waste reduction options, list viabl

Quick Reference Audit Guide

16


8 CHARTER ON CORPORATE RESPONSIBILITY FOR ENVIRONMENTAL

PROTECTION (CREP) As it is necessary to comply with the regulatory norms for prevention and control of

pollution, it is also imperative to go beyond compliance through adoption of clean technologies and improvement in management practices. Commitment and voluntary initiatives of industry for responsible care of the environment will help in building a partnership for pollution control. For this very purpose a Charter on Corporate Responsibility for Environmental Protection (CREP) was prepared by a series of industry-specific interaction meetings organised by the Ministry of Environment and Forests. During interaction meetings, the representatives of some industrial sectors sought extension of time to meet the regulatory norms because of techno-economic constraints. In case of units falling in such industrial sectors, time bound action has been proposed in the Charter. This measure has been agreed on the understanding that a bank guarantee would be furnished by the concerned units indicating the commitment to the action plan. However, this is without any prejudice to the stipulations made in the existing standards and action already taken/initiated for non-compliance and area-specific requirements warranting stringent actions. The industrial units which are not complying with the national standards notified under the Environment (Protection) Act, 1986, will submit action plan to meet the standards and bank guarantee to respective State Pollution Control Board within 3 months (by June, 2003). The Maharashtra Pollution Control Board on 03.01.2003 held the consultation for sugar industries at Mumbai. Following are the stipulations for Sugar Industries 1. Waste Water Management

Operation of ETP shall be started atleast one month before starting of cane crushing to achieve desired MLSS so as to meet the prescribed standards from day one of the operation of mill.

♦

♦ ♦ ♦

Reduce wastewater generation to 100 litres per tonne of cane crushed by April 2004. To achieve zero discharge in inland surface water bodies by December 2004. To provide 15 days storage capacity for treated effluent to take care of no demand for irrigation by April 2004.

2. Emission Control To install ESP/bag filter/high efficiency scrubber to comply with standards for particulate matter emission to <150 mg/Nm3 by April 2004.

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9 ENVIRONMENTAL PERFORMANCE VERIFICATION EXERCISE

Though the sugar industries do not have to obtain clearance under the EIA Notification, the sugar industries are required to submit yearly ‘Water Cess Returns’ and ‘Environmental Statement’ to the concerned State Pollution Control Boards. As of now, there is no provision to analyse the ‘Environmental Statement’ which is submitted yearly. However, this is an important step which would not only give the yearly compliance but also the status of the environment over a period of time. In this chapter we are suggesting the following activities which would provide a rigorous analysis of environmental statement submitted by the sugar industries and develop an effective institutional arrangement for implementing Environmental Audit in the state.

1. Verification of Environmental Audit by the Sugar Industry 2. Verification of Environmental Audit by the Regulatory Authorities 3. Verification of Environmental Audit by the Third Party

For the verification process the following steps are suggested: Step 1: Verification of maintenance of Log Books Step 2: Verification of maintenance of Yearly Resource Auditing Books Step 3: Verification of compliance of Environmental Plan and Consent Aspects Step 4: Verification of Environmental Aspects Step 5: Verification of Environmental Statement in line with the data provided

18


10 TYPES, SOURCES, AND NATURE OF POLLUTION FROM SUGAR INDUSTRY 10.1 PROCESSES INVOLVED IN SUGAR INDUSTRY

The sugar industry is of a seasonal nature and operates for 120 to 240 days in a year, beginning from early November and ending on May or June. Large volumes of effluents and wastes are produced during manufacture of sugar and effluents contain a high pollution load. Because of the sugar mills being located mostly in rural areas where there are no suitable options like large flowing water courses for effective disposal of the effluents by dilution and because of the rainfall during the major part of the crushing season being practically nil, extreme pollution of small rivers, foul smell in the vicinity of sugar mills, and unpleasant look inside the mill are commonly experienced. Variation in volume of the effluent, its pollution load is due to various causes like poor housekeeping, condition of plant and machines, mode of their operation and maintenance, and water use.

As the process of sugar manufacture has many stages and in most of the stages pollution/wastes are generated in different forms like wastewater, solid wastes and air pollutants. The causes of these forms of pollution are leakage, spillover, overloading, indifferent handling and crushing operations, improper molasses storage and handling and so on. The different sources/stations where generation of pollution is of concern are: cane yard & cane unloading section, cane carrier section, milling station, bagasse handling, boilers, washings, clarification and evaporation section, filter washings, sugar house and so on. The sources & types of pollution from sugar industry are shown in adjoining figure. Sugar industry generates three types of effluents.

Effluents requiring pre-treatment like oil and grease separation, pH correction etc., before going to ETP.

♦

♦

♦

Effluents which do not require any pre-treatment, but highly polluted and need treatment in ETP. Effluents with little or no pollution, which do not require treatment.

From all such sources/operations, the pollution load can be reduced considerably by adopting various pollution prevention measures. These measures could include good housekeeping practices, change in the materials/process/ design, improving current operation and maintenance procedures, waste minimization, clean technology options and so on. Since our focus in this course will be on good housekeeping practices, which include aspects like proper maintenance practices, inventory management, good operating practices, storage, segregation of wastes, cleaning operations etc., we will be discussing more about all these. But before we go in details let us see the sources, volume of effluents/waste and parameters of concern (refer Table 10.1). Table 10.1: Wastes and Effluents From Different Sources.

Sl. No

Source Activities causing pollution

Resulting form of waste

Vol m3/ tonne of

cane

Parameters of concern

1 Cane yard unloading and carrier section

Unloading of cane, cow dung etc

Cane trash, cut pieces, cow dung etc

- Suspended solid, odour, foul smell

2 Mill House (milling section)

Continuous gland cooling and intermittent floor washings spill over from leakage of grease and oil from bearings.

Containing oil, grease and sugar juice from spills and leaks, overflows

0.03 to 0.05

Suspended solids, oil and grease foul smell

3 Bagasse handling

Movement of bagasse through conveyors

Bagasse dust particulate on

- Dust particles, suspended solids

19


burning air pollutants fibres (un burnt)

4 Boiler house and boiler section

Boiler blow down, boiler station fuel (bagasse)

Waste with inorganic salt generation Boiler ash

0.03 0.01

TDS, Ash can be used for agricultural lands. Particulate matter from chimney

5 Clarification section rotary filter

Periodical washings, overflows spillage etc

Waste contains inorganic & organic matter

0.04 SS, TDS, BOD, COD

6 Evaporator & Pan Boiling

Pump leakage, entrainments, through vapours from pan boiling and evaporator (mill overloading) & poor operating condition)

Sugar loss into condensate pollutes water

- BOD effluent loading

7 Washing (juice heaters, pan evaporators cleaning)

Washings from scale removal & cleaning

Waste discharged into drains (high inorganic & low organic content)

- TDS, BOD effluent loading

8 Evaporators, centrifugal house, pumps, pipes, floor washings, molasses spillover etc

Occasional spills and leaks due to poor house keeping and maintenance. Overflows

Waste discharged into drains

- Very high SS, BOD, oil and grease

9 Sulphur & lime houses

Washings of sulphur and lime houses

Inorganic waste water, carbonates/ sulphates

- TDS

10 Molasses storage tanks (pan house)

Poor storage handling, leakage & overflows from tank

Pollution load of effluents is increased (too much)

- Very high BOD & COD

11 Sugar house Transportation through conveyors (Movement), packing process etc

Sugar dust - Dust, sugar loss

Note: Spray pond and cooling water overflows and condensates are not included since these can be recycled/reused and any surplus flowing out will be mixed with the treated effluent.

The effluents of intermittent and regular nature from different sources are shown in Tables below: Table 10.2: Sources of Waste Water Generation

Regular Sources Mill House Effluent Spray Pond

Overflow Floor Washings Boiler Blow

Down Parameters of concern SS, O & G TDS, BOD,

COD SS, BOD, O & G TDS

Intermittent Sources Pump

Leakage Overflows Excess

Condensate

Soda and Acid Wash Waste

Sulphur & Lime House

Molasses Spillage (Prohibited)

Parameters of concern

BOD BOD BOD TDS, BOD TDS Very high BOD & COD

20


10.2 POLLUTION EFFECT 10.2.1 Wastes Water

Pollution load at the end of the manufacturing processes is increased if pollution and waste generation is not prevented at source during the input and process stages. Apart from odour, shabby look inside the factory and economic loss of sugar and energy, and wastage of water, generation of liquid wastes, the final effluent from a sugar mill, many times carry heavy pollution load. The organic pollutants present in the effluent remain in solution, being mainly sugar and other carbohydrates. When the effluent stagnates in an area for few hours, biological action starts and obnoxious condition soon develops in the region. The septic condition results in production of hydrogen sulphide gas, imparting black colour to the effluent. If the effluent is discharged in a small stream its oxygen is rapidly exhausted, resulting in the death of fish and other aquatic life. 10.2.2 Solid Waste

Bagasse: Generally bagasse does not pose a problem of disposal of waste as it is almost fully (90-96 %) used as fuel in boilers for steam generation and remaining is sold to paper mills or hand processing paper mills and cardboard manufacturing units or, as fuel for cogeneration factories. Sometimes fibres from the bagasse find their way into waste stream via surface drains particularly during rainy season. However, entry of such fibres into waste steam can be avoided by proper housekeeping and should not cause any specific problem.

Press mud: Press mud originates from the settled sludge in the juice clarification process. It contains all non-sucrose impurities in the juice along with CaCO3, precipitates and sulphates. As the press mud of double sulphination process contains valuable nutrients like nitrogen, phosphorus, potassium etc., it is used mainly as organic manure and does not pose any problem of disposal. The press mud from the units using double carbonation process is used for land filling, and is not used as manure. The possibility of spillage cannot be ruled out, where press mud is collected. But good housekeeping, maintenance, and proper timely disposal of press mud can very well prevent this spillage/wastage. 10.2.3 Air Pollutants

The bagasse on burning produces particulate, viz. unburned, carbon particles and gaseous pollutants like oxides of nitrogen, water vapour and other organic compounds of the particulate waste, the heavier particles slowly settle down in the surrounding area. Such dust fall leads to the problems of cleaning, reduction in property value, effect on vegetation etc. The main gaseous pollutant is CO and CO2 reported to be in the range of 12 % to l4%.

Inside sugar factory, at sugarhouse, the sugar dust gradually settles on machines, floors, conveyors etc., giving an unpleasant look and also it leads to poor working conditions inside the factory. However, to a large extent the release of sugar dust can be controlled by use of proper dust collectors, wet scrubbers and good housekeeping practices. 10.2.4 Molasses

Molasses have an extremely high BOD; hence proper care should be taken so that there are no chances in the mill for the molasses to spill over into the wastewaters. It is observed that in some sugar mills, molasses are stored in unlined (kutcha) pits, which is environmentally unsound practice. During rainy season and also owing to the ground water table conditions molasses get diluted and become unsuitable for fermentation. Sometimes, sugar mill discharge unsuitable molasses into the natural river bodies thereby causing pollution and damage to aquatic life. At no stage should molasses be allowed to accumulate in the sugar factory area in an open pit/nallah.

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10.3 GOOD OPERATING PRACTICES A general approach of pollution prevention through good operating practices is given

in the following Table 10.3 Table 10.3: Pollution Prevention Through Good Operating Practices

Sl.No Good operating practices Nature of activity for pollution prevention 1. Waste segregation/

separation ♦

♦

Prevent mixing of wastes of low, medium and high concentration Isolate liquid waste from solid wastes

2 Preventive maintenance ♦

♦

♦ ♦

Maintain equipment/ machines history cards on equipment location, characteristics and maintenance. Maintain a master Preventive Maintenance (PM) schedule Keep vendor/ supplier maintenance manual handy Have regular inspection for leakage, losses, overflows etc.

3 Training and awareness building programme

Provide training to employees/staff for: ♦

♦ ♦

♦

Operation of the equipment to minimize material waste and energy use. Proper materials handling to reduce waste and spill Awareness of the importance of pollution prevention by explaining the economic and environmental ramifications of waste generation and disposal. Detecting and minimizing material loss to air, land or water.

4 Effective supervision ♦

♦

Closer supervision may improve production efficiency and reduce inadvertent waste generation Centralize waste management. Appoint a safety/ waste management officer. Educate staff on the benefits of pollution prevention. Establish pollution prevention goals and perform pollution prevention assessments.

5 Employee participation ♦ Use “Quality Circles” (free forums/ groups between employees and operators, supervisors) to identify ways and methods to reduce wastes.

6 Production scheduling ♦ Optimise production rates (crushing rate) to reduce wastage, overflows and other losses and to maintain high efficiency at all stations.

7 Cost allocation and accounting

♦

♦

Charge direct and indirect costs of all air, land and water discharges to specific processes or products. Allocate waste treatment and disposal costs to the operations that generate the waste.

10.4 STEPS TO BE TAKEN AT DIFFERENT STATIONS OF A SUGAR MILL IN ORDER TO REDUCE THE POLLUTION.

10.4.1 Cane Yard & Cane unloading section: The above areas accumulate lot of cane trash materials and cow dung. The cow dung

accumulation is more in the factories, which are getting higher percentage of cane through bullock carts. The materials should not be allowed to accumulate and rot. The same must be removed from the yard then and there or at least in regular intervals. The removal can be done departmentally or through contractor. The above waste material, if composted together

22


would become very good organic manure, which can be sold profitably. 10.4.2 Cane carrier section:

There would be almost continuous & regular accumulation of cut cane pieces, powdery materials below the cane carrier. This material contains juice and hence must be regularly removed and put on the carrier before the mill at a convenient place. Care also must be taken to see that there is no water seepage in this area. Any water entering in this area is to be pumped out as the same gets mixed up with prepared cane particles, and carries some sugar also and hence creating liquid effluent with high BOD. Hence,

• Fall of the cut particles from the carrier down must be minimized. • The fallen particle materials should be removed at regular intervals. • Water should not be allowed to flow into the area below the can carrier. • During rainy season even if water enters, if the area is kept cleaned of the cut cane

materials, the effluent generated will be of lesser pollution concentration. • The water if enters, must be pumped out then and there itself. • The spillage of cut/ prepared can pieces from the carrier edges and from the rake

elevator must be avoided. 10.4.3 Milling Station

The following are contributing to generation of effluents in the milling station. • Leakage of lubricating oil and grease materials. • Leakage of bearing cooling water • Spillage of bagasse and bagaillo materials. • Spillage of can juice from rollers, DSM screens and also whiles pumping the diluted

juices for recirculation. • Leakage of juices from gutters, whirling tanks, pipelines etc. • Overflow of juice from whiling tanks. • Washing of the mills with hot water for mill sanitation purpose.

Use of lubricants should be judicious. Excess and improper application of lubricants will result in waste of lubricants and the same will find/its way into effluent. Bearing cooling water must be properly guided back into troughs or funnels without allowing the same to flow out creating effluents. The leaked water along with spilled over juice and bagasse particles and also the leaked lubricants will cause highly polluted effluent. If water leakage is avoided, the mill can be subjected to dry cleaning to remove the bagasse particles from spillage of juice and leak of oils etc., if any. The spillage of bagasse and also juice should be avoided by properly guiding the delivery pipelines of juices (imbibition, DSM screens etc.). Similarly the spurting and spilling of juices from rollers must be avoided by suitable guide plate wherever necessary.

Close monitoring is essential on any leakage of juice from gutters, pipe lines and pump glands etc. Any leak must be arrested then and there. All the juice in the mill house and also the imbibition water pump must be regularly monitored for its proper working without leakage. Regular renewal of gland packing, bushes etc., to avoid leakage of juice through glands are necessary. A preventive maintenance system with proper schedule shall be introduced. Similarly monitoring is necessary for avoiding leakage in gutters and from pipelines. Overflow from whirling tanks should be avoided. This can be done to a great extent by maintaining whirling action by recirculation of juice and avoiding big pieces of bagasse coming into tank. Often there would by heavy foaming in the whirling tanks requiring frequent washing thereby generating effluents. The bagasse dust entering the factory. If due to too fine preparation of cane, there is dust found flying out even inside the factory (which is observed in some sugar mills) dust collectors are to be installed in strategic

23


locations say when bagasse is transferred from one carrier to the other. (When it leaves bagasse elevator and falls on to the return carrier etc.). The screens, which are used to collect on the bagasse conveyor, must be cleaned properly at regular intervals. The bagailo blower must be checked for its efficient working. Any accumulation of bagasse dust at the bottom of blower should be cleaned regularly. The above steps will avoid/reduce the pollution inside the factory. 10.4.4 Boilers - Boiler operation, Boiler Ash

No washing need to be done anywhere in the boiler station, and hence no liquid effluent is generated in the station. But there is hot water with certain amount of dissolved solids discharged from the boilers either continuously or at regular intervals through ‘blow downs’. However it is desirable and preferable to allow steady and continuous blow down so that the same can be let out for mixing with the treated effluent. Excess air allowed should be just adequate to have proper combustion. Too much of excess air; pressurising the furnace and overloading the boiler should be avoided in order to minimize the fly ash escape.

The boiler station generates ‘solid waste’ in the form of “boiler ash”. However, the bagasse which is used as a fuel contains very little ash (2.5 to 3 %). Boiler ash from the sugar factories is generally used for land filling and sometimes applied to agricultural lands in measured quantities. Boiler ash should not be allowed to accumulate and it must be removed as and when produced and should be transported to the designated locations.

Generally the modern boilers are provided with multi-cyclone mechanical dust collectors. There should be regular checking to see that there is no accumulation/choking in their drain pipes. Some factories are using wet scrubbers for collecting the dust from the flue gas called ‘fly ash arrestors’. Here, again regular monitoring is necessary to see that the water spray is steady and adequate quantity. The collected ash must be removed and transported to the designated place. 10.4.5 Clarification & Evaporation Station:

This station normally generates effluents in the following form. • Over flows • Leakage from pumps, tanks, pipelines etc • Floor washings • Cleaning day washing

There is more number of pumps in this station than in Mill house and hence this station is more vulnerable for creation of pollution from pump leakage, through glands. Here again regular maintenance and monitoring can arrest the pollution due to pump leakage. Selection of proper material for gland packing is also necessary. Poor quality gland packing will result in frequent gland leakage. Metallic packing is found useful in case of perpetually leaking pumps like clear juice, vapour cell juice pumps etc. Besides regular preventive maintenance system has to be adopted for repairing and replacing the pump parts or the pump itself when becomes necessary.

Any leakage observed from any tank or pipelines (even water leakage) should be arrested then and there. Similarly, care must be taken to avoid overflows. Level indicators, limit switches, overflow alarms and automatic level controllers are available, by installation of which (wherever necessary), it should be possible to avoid overflows. However, it is desirable to have some small pits near each cluster of pumps vulnerable to leakage in order to collect leakage if any taking place ‘in between’ periods escaping observation. The liquids so collected must be pumped back to the process source according to convenience. Steam ejectors can be used for pumping back the solutions. On no occasion the leaked materials should be washed into the drains. This will increase the pollution load. Any accidental

24


overflows, leakage etc. if take place the same may be contained with in a reasonable area using bagasse and the area must be ‘dry cleaned’. This bagasse so used must be transferred on to the mills or on to bagasse conveyor depending upon the juice content in such bagasse.

It is normal practice to clean the heating surfaces in evaporator vessels and juice heaters periodically. On such days the process will be stopped and all the equipment and vessels are flushed well using huge quantities of water. It will form substantial quantity of effluent with fairly high pollution load. Most sugar mills use chemical solution containing caustic soda & common salt for cleaning the heating surfaces and the same is let out after cleaning. It is preferable to have a separate storage tank for collecting the cleaning day washings and allows the same to mix with normal effluent slowly and steadily in order to avoid sudden surge into the effluent treatment plant. It is a normal practice in many sugar factories to clean the juice heaters at regular intervals without waiting for cleaning days. The cleaning of juice heaters generates effluents with pollution. This can be mixed with the regular inflow to the E.T.P.

All gland-cooling waters from the pumps must be collected separately for reuse for inhibition purpose. This station produces a by-product called ‘Filter Cake’ or ‘Filter Mud’, which is a residual material after filtering out the juice from the muddy juice in the vacuum filters. This mud from the ‘Vacuum filter’ should be conveyed through the conveyors (preferably through rubber belt conveyors) into a storage bin at a comfortable height from where the filter mud can be unloaded on to trucks/tractors/bullock carts. The system should avoid spillage of the ‘mud’ totally.

The ‘filter mud’ is good manure if used after little composting (allowing it for a month or two). Generally the sugar-cane farmers would be willing to collect/purchase the same as produced in the sugar mill and heap it in their fields for use as and when they require. If the growers do not lift the same, the factory can have a dumping yard suitably for this purpose. Some sugar mills are having technology to convert the same into bio-fertilizers. In any case the spillage of this material should be avoided as otherwise the same may get mixed with wash water/rain water etc. and may create effluents of high pollution.

In the same station, some small quantities of lime grits are also generated as waste after slaking the burnt lime. The quantity depends upon the type and quality of burnt lime used. This material being very small can be used for land filling and also for road repairing/construction works. This has no pollution value. 10.4.6 Entrainment from Pans and Evaporator

Entrainment of sugar solutions while boiling in evaporators or pans would cause contamination of sugar in the injection water making the entire spray pond polluted. The following steps are necessary to be taken to avoid entrainment.

The ‘catch all’ in evaporator and pans should be checked frequently for any choking of the pipes/holes meant for draining back the collected liquid.

♦

♦ ♦ ♦

High level of juice in evaporator should be avoided. Vaccum fluctuations should be avoided. There should be ‘Tell Tale’ bottles fitted on the vapour pipes of all the pans and the last body of the evaporator. Regular test must be made for finding our any sugar getting entrained with the vapours. If any observed, steps must be taken to locate the reason and rectification of the same immediately.

While soda boiling on cleaning days in evaporators and pans, care should be taken to see that the vapours are led outside the building through separate vent pipes, which are extended to go beyond the roof level.

25


10.4.7 Sulphitation The sulphur dioxide gas generation, which is bubbled through (i). Juice Sulphitation

Vessel and (ii). Syrup Sulphitation Vessel, should be continuous and as uniform as possible. The flow and also the pressure of the compressed air should be steady. Both the vessels should have chimneys extending to over the roof of the building, so that any traces of gas carried along with the air and vapour is released to the atmosphere above the building. However the sulphitation vessels should be designed properly with scrubbing arrangement to absorb the sulphur dioxide gas fully and only the air and vapour, free of gas goes out of chimney. 10.4.8 Liming Station

A tall chimney should be provided in the lime-slaking drum at the point where the lime is added to the rotary drum. The lime dust created while transferring the lime should- be evacuated through the chimney, which again should be extended to above the roof level. 10.4.9 Crystallization Station

Generally the lubricating oil would leak/overflow from the wirm wheel tray or wirm wheel and gear arrangement of the crystalisers. Regular maintenance will avoid such leakage and spillage. However any such spilled/leaked lubricant material should not be allowed to trickle down on the ground floor. Such materials should be ‘dry cleaned’ using bagasse and should be transferred to bagasse carrier leading to boiler. 10.4.10 Segregation of Effluents

There are different kinds of effluents generated in a sugar mill ranging from highly polluted to pure water, which can be listed as below;

1 High Pollution i) Effluent flowing out of mill station ii) Floor washings of clarification station iii) Floor washings of boiling, crystallization and centrifugal

house. 2 Low Pollution i) Laboratory washings etc

ii) Normal cleaning and floor washings etc 3 No Pollution i) Spray pond overflow water

ii) Bearing cooling water iii) Hot condensate

Out of the above, item (1) & (2) are normally mixed and are fed to the effluent treatment plant. However some of the effluents may need pretreatment like oil and grease removal etc., before going to ETP. Such effluents can be segregated (e.g. mill house effluents), and subjected to pretreatment, after which, can be mixed with those effluents going to ETP (without pretreatment). Out of the item no. 3, above the spray pond water overflow must be mixed with the treated effluent before going out. The bearing cooling water, though re-circulated to a large extent, a portion of the same is sent out regularly for maintaining the temperature. This water can be added to the spray pond water, which works out as make up water. The hot condensate even after recirculation and reuse is often found in excess. If there is a cooling arrangement, this water can be cooled and reused in place of fresh water, or else this has to be let out which is wastage of water. This outlet can be connected to the outflow of the E.T.P. 10.4.11 General Points

• Plenty of trees must be planted all around the factory. • There should be no hose pipe allowed inside the factory for floor washing. Once the

hose connection is given the floor washing and through that the pollution load will increase. All floor cleaning must be ‘dry cleaning’. Any water required must be carried through buckets.

26


10.5 GOOD HOUSEKEEPING PRACTICES – DO’S & DON’TS Table l0.4 specifically provides pollution prevention measures attributed to good

housekeeping practices with respect to different sections/ stages of operation in sugar industry.

27 •


Table 10.4: Good Housekeeping Practices - Do's & Don’ts

Waste origin/ Sections

Waste type Pollution prevention measures mainly from the point of ‘Good Housekeeping’ Dont’s

Before milling i.e. cane receiving cane yard, can unloading cane carrier section

Inadvertent spills, can pieces (small) and wastage, cow dung

• Use just in time ordering system • Maintain a clean, even surface in yard area • Inspect material (cane) for quality, quantity etc., before unloading • Concrete road for vehicles/ carts to stand and automatic unloading of can will

reduce spillage • Set up written procedure for loading/ unloading • Remove cane trash and cow dung then and there • Failing cut cane pieces/powder must be removed from below the cane carrier.

• Don’t overload • Do not mix up many operations

at the same time. • Do not allow to accumulate can

trash material and cow dung • Do not allow water seepage in

this area under any circumstances

Mill Section Effluent continuous

gland cooling and intermittent floorwashings, leakage of oil, grease and spill over, leakage of juice, leakage of bearing cooling water, spillage of bagasse and can juice from rollers, whirling tanks,pipelines, overflow of juice from whirling tanks.

• Construct concrete drains closed with steel jellies having lids at intermittent

places for inspection and maintenance

• As a precautionary measure keep trays of proper design and shape to collect oil

and grease spillages/ wastes.

• Prevent concrete ‘sweating’ by raising the drum of storage tank pads

• Drains leading to the effluent collection pit in the mill house should have proper slope and drain time of liquid should be adequate.

• Inspect regularly glands, valves and pumps for leakage and attend repairs immediately.

• Use lubricants judiciously and properly • Schedule production rate to achieve maximum efficiency.

• Install overflow alarms for tanks/vessels • For bagasse, use closed transfer system (hoods) • Provide system with guards/guides for bearing cooling water • Dry clean at places wherever possible • Separate oil, grease and bagasse from effluents using proper grits • Use disinfectants judiciously

• do not hold waste water for long at one place.

• Do not allow to get mixed oil, grease, juice and water waste.

• Do not keep drains open. Let it be closed with proper slope and lining.

• Do not use excess oil and grease • Avoid improper application of

lubricants. • O/G pit should not be much

away from the mill • Do not use too much of water

for mill washings • Do not use overdoses of

disinfectants.

Juice Dilution and Chemical areas of work

Tank bottoms: off spec and excess material; spill residues leaking vessels, pumps, valves, tanks, pipes, damaged containers, dirtaccumulation, floor

hi

• Use seal less pumps or pumps with metallic seals. • Instruct operators not to bypass alarms, signs or significantly alter set points

without authorization. • Document all spillage • Set up control points to dispense chemicals and wastes • Store containers/vessels/tanks in such a way as to allow for visual inspection for

corrosion and leaks.

• Do not use excess water, which may prove to be wastage.

• Tanks and containers should not be left without monitoring for overflows, spills, leaks etc.,

28


washings etc., • Provide adequate light and ventilation in the storage area. • Maintain distance between different types of chemicals to prevent cross

contamination. • Follow manufacturer’s suggestions in storage and handling of chemicals. • Use mechanical wipers on mixing tanks. • Use closed storage and transfer system. • Use clean-in place systems. • Improve cleaning efficiency. • If possible, use large containers with height to diameter ratio equal to one (1)

Clarification (Sedimentation) Section and Vacuum filters

Leakage from pump gland, overflows. Leakage from pipe, tanks etc

• Install secondary containment areas. • Segregation of effluents will reduce pollution loading. • PH controller, temperature gauges and overflow indicator and water meter at

appropriate places will help in control of overdoses, identification of leakage spots i.e. increase use of instrumentation.

• Use closed storage and transfer system. • Use cleaning systems those avoid or minimize solvents and clean only when

needed. If possible use high pressure water cleaning or dry cleaning or dry • Adhere to regular preventive maintenance and monitoring • Have some pucca tank/ pit to collect effluents with oil and grease. • Install overflow alarms for all tanks/vessels • Maintain physical integrity of all tanks and vessels • Clean drains at regular intervals

• Do not allow waster to stagnate at any open place in case of spillage overflow etc.

• Do not keep tanks and vessels in direct contact with floor, it becomes difficult to clean

• Do not go for poor quality of gland packing material.

• Do not push/allow dirt/leaked material into drains.

• Do not allow sudden surge of effluent into ETP

• Avoid stacking containers against processing equipment

Boiler house Waste with inorganic salt concentrationboiler blow down contaminant, boiler dust from flue gases, boiler ash

• Boiler blow down can be recycled for use in lower pressure boiler as make up

water. If needed, some segregation may be required. • Regular inspection and preventive maintenance of boiler and its accessories for

leakages, corrosion, scaling mush be done. • Cleaning of boiler should be done properly and on the basis of deposit

thickness, so as to reduce frequent waste generation. • Improve equipment seals to prevent air and cooling water leaks into the boiler. • Use wet scrubbers, fly ash arrestors properly and effectively. • Use modern multicyclone type dust collectors. Use of ESP can also be

considered. • Regularly inspect for choking etc. • Allow adequate quantity of air for proper combustion. • Remove boiler ash to designated locations in closed conveyors/ transportation

systems.

• Do not allow scaling, corrosion on surrounding/surface areas of boiler.

• Boiler ash should not be allowed to accumulate.

• Do not allow too much of air for combustion, to prevent fly ash to escape.

29


Sulphitation (Bleaching)

Possible SO2 leakage, overflow of juice from tanks, spillage etc.

• Use properly designed tanks and vessels (juice receiving and reaction tanks) for their intended purposes.

• Install overflow alarms for all tanks/vessels. • Document all spillage. • Place tanks/ vessels in such a way as to allow for visual inspections. • Use adequate scrubbing arrangements in sulphitation tank to absorb sulphur

dioxide (SO2) to gas. • Chimney from sulphitation vessels should extend above roof to an adequate

height. • Adequate lighting and ventilation around the sulphitation area is must. • Use steel pipes of good quality and proper seals for collar positions. • Improve cleaning efficiency. • Install SO2 detectors at possible leakage points/ sources • Adequate open area/ventilation must be provided to avoid any accident due to

SO2 leakage (if any)

• Do not overcrowd the place of sulphitation area

• Do not neglect monitoring work. • Do not neglect the maintenance

of sulphitation vessels/ tanks and accessories.

• Do not allow flow and pressure of compressed air to fluctuate too much.

Crystallization and Pan Boiling

• Leakage frompumps

• Arrange layout such that visual inspection for leakage and spills must be possible

• Leakage /spills from gutters

• Inlet and outlet vents losses

• Oil and grease from equipment cleaning andmaintenance

• Check cooling elements regularly for the leak proof working.

• Maintain pumps, tanks, wheel and gear arrangements as per preventive maintenance plan/schedule.

• Segregate effluents as per loading. • Water leaving crystallizers and sulphur burners can be sent to condenser water

cooling system (injection water). • Inlet and outlet vents must be checked for leakage/losses.

• Maintain physical integrity of crystallizers, centrifuges and pans. • Isolate equipment or process lines, pipes etc, those leak or not in service. Use

seal less pumps or metallic seals. • Use clean in place systems. • Adopt ‘dry cleaning’ using bagasse. • Use mechanical wipers on mixing tanks. • Use improved seals for pipes, valves, pumps etc.

• Do not pump cold ‘C’ massecuties.

• Do not dilute massecuties. • Do not undermine habit/attitude

of inspection and preventive maintenance.

• Do not allow spilling/ leaking lubricants material to trickle down on floor..

Spray pond overflow • Overflow water form spray ponds, oil & grease from equipment cleaning/ poor maintenance

• This can be reused for irrigation through segregation of streams in lined drains/channels.

• Regular inspection and preventive maintenance is essential. • Water channels/drains must be leak proof. Inspect for leakage, stagnation and

take immediate measures (cleaning, disinfectant etc) • Check for the minimum depth of water in spray pond.

• Do not allow spilled water to stagnate at spots/ corners

30


activities • Check pipes/valves/pumps/nozzles for leakage/losses and spillage. • Use sealless pumps with metallic seals. • Maintain pumps/ valves as per manufacturer’s suggestions

Evaporation Section and Pan Boiling

• Sugar loss in the condensates through entrainment, thus pollutes cooling water.

• Leaking pumps, valves & vessels and pipes.

• Poor operating & maintenance conditions.

• Caustic soda scrap scales

• Oil and grease from equipment cleaning/ operation and maintenance

• Continuous automatic recording and indication of brix of syrup will be useful for supervisory staff.

• Use sealless pumps. • Use good quality seals and valves • Provide adequate lighting and ventilation near storage area • Provide segregation drains and collection pits for water wastes from evaporators

and pans. • Inspect regularly pumps, gauges, valves, vessels, pipes for choking leakage,

spillage and splashes etc. • Preventive maintenance schedule must be adhered to. • Check the ‘catch all’ in evaporator and pans frequently.

• Do not overload mill – avoid erratic crushing

• Do not neglect good operating conditions.

• Do not overlook the preventive maintenance schedule of equipment/ machines/ pumps etc,

• Do not allow mixing of high pollution effluent, oil or grease into this water.

• Do not allow entrainment of sugar solutions

• Do not keep very high level of juice in evaporators.

• Do not allow vacuum fluctuations in vacuum pans.

Evaporator, Pans&Juice heater cleaning

• The wastewater from cleaning of scales increases pollution load of effluent streams

• Reduce frequency of cleaning of evaporator using desealants. • Cleaning of scales by electric driven flexible shafts using compressed air. • Improve cleaning efficiency • Segregate and collect the wastewater in lined drains. • Explore alternative cleaning methods without using chemicals. • Holding tank used for avoiding shock loadings in ETP should be leak proof with overflow alarms. • Establish spill prevention, control & countermeasures (SPCC/plans). • Maintain physical integrity of all tanks vessels. • Document all spillage • Preferably use seal less pumps for all purposes or use quality seals. • Keep aisles clear of obstructions • Scales can be partially softened/ or partially dissolved before high pressure cleaning

• Avoid scaling of tubes by keeping proper watch on control parameters at set/identified points. • Do not use cutter tools to remove scales unless scales are very hard. It may damage tubes. • Brushes can be used with care. • Do not leave scales unremoved on cleaning day.

Molasses storage tanks (final molasses)

• Poor handling, leakage, improper

• Provide collecting pits/ chambers around the tank for collecting cold water used for spray and also any foam overflowing etc.

• Do not allow overflow/ spillage of molasses

31


storage, overflows from tank.

• Handling of molasses should be careful without spillage/ losses. • Store molasses on storage tanks fitted with all accessories/fittings as prescribed including overflow alarm, inlet valve, washout valve, outlet for pump, temperature gauges, manhole vent. • Arrangement for spraying cold water spray coil, level indicator etc. • Properly label all tanks,. containers. • Conduct periodic analysis of molasses • Provide lids and vents on tanks (fixed roof type) • Thoroughly clean the tanks with water whenever they are empted • Use splash guards • Inspect/ check for losses, spills around tanks & immediately attend it. • Immediately clean floors using dry cleaning or other appropriate cleaning system. • Regular lifting of molasses should be monitored. • Prefer intact and closed transportation/ conveyance system

• Do not keep the storage areas unattended as far as routine cleaning is concerned. • Do not store molasses in open areas or kutcha pits. • Do not neglect regular inspection and maintenance of storage tanks. • Do not forget to label tanks appropriately. • Do not allow trickling of molasses from storage tanks, pipes, valves etc.

Solid Waste Bagasse • Bagasse fibres find their way into waste streams.

• Storage of bagasses in open area may create pollution problems

• Keeping segregated waste through streams/drains/channels closed having (inspection points open) proper slope and lining will prevent fall of bagasse fibres into streams (i.e. closed transfer system). • Use industrial vacuum cleaners/dry cleaners/clean in place system and these should be routine features of the mill. • Automatic transportation feeding of bagasse must be there as per required quantity • Storage of bagasse (if any) should be in proper storage yards. • 5% of total bagasse can be used for other by products like paper and pulp, paperboard etc, • Keep wet while storage and use closed transportation systems and conveyors • Clean the screens used on conveyors properly at regular intervals. • Clean bottom of blower properly and regularly

• Do not allow bagasse fibres to remain on floor for long by not cleaning it. • Do not allow water seepage in this area at any cost. • Do not allow can trash materials and bagasse particles to fall on juice/water • Do not allow accumulation of dust at bottom of blower.

Press mud or ‘filter cake’ (obtained at juice clarification station from rotary vacuum filters)

• Contains inorganic salts and organic materials.

• Due to spillage (while transportation and collection) from conveyors, unloading etc)

• Automatic and closed transfer systems/ conveyors will reduce this problem. • Provide splashguards. • Automatic unloading through hopper bottom directly on to the trucks can help

in keeping the floors and premises clean. • Clean equipment after use. • Maintain a clean, even surface (concreted) in transportation/ movement areas.

• Avoid spillage of mud during its movement on conveyor and during unloading operations.

• Do not allow to accumulate the fallen (if any) filter cake prices/ splashes (remove them, then & there)

32


AIR POLLUTION Sugar dust from sugar house and particulates from bagasse burning (boiler house)

• Sugar dust is explosive and pollutes insideatmosphere.

• Use closed loading & unloading system for sugar packing.

• They fly ash particles are likely to escape out.

• Use closed conveyor and transportation system

• Vacuum cleaning/dry cleaning will keep the area neat and clean. • Proper handling of equipment, better operations and maintenance practices will

reduce release of sugar dust. • Adequate light and ventilation near sugar packing area will not suffocate the

environment inside the plant. • Efficient and effective air pollution control devices like dust collectors, fly ash

collectors, cyclones/wet scrubber type fly ash arrestors and bag filters of required efficiency and effectiveness shall preferably be used appropriately.

• Do not allow untrained operators to handle pollution control devices. Only trained operators and supervisors must be allowed to operate/supervise pollution control devices.

• Do not go in for manual packing of sugar

• Sugar loss is more in manual packing.

33

Standard Operating Procedure for Sugar Industries

Appendix I: Continued . . . Appendix I: Standards of Service of Karnataka State Pollution Control Board

The Karnataka State Pollution Control Board deals with Government, individuals, community groups, NGOs, local bodies, industries and businesses. The Board has set its standards for various services

SR. NO NAME OF ACT OR RULES IMPLEMENTING

AGENCIES OBJECTIVE OF ACTS OR

RULES KSPCB’S SERVICE KSPCB’S STANDARDS

1 GeneralResponding to

request for Information

A written response within 7 working days of receiving letter

or e-mail including the information sought will be sent.

In cases which need more time to respond correspondence will be

dispatched immediately followed by the information within 2

calendar months

Responding to complaints

An immediate response where possible. A written response

within 15 working days of receipt of complaint

2 Air (Prevention and Control of Pollution) Act, 1981 KSPCB, CPCB

Provides for the control and abatement of air pollution.

Board issues consent to industry which emit air pollutants with emission

limits

Responding to an application

submitted by the stakeholder

Decisions will be made within 21 days of receiving a filled-in application and supporting

information. (Form No I ). In case of refusal of consent the

reasons will be intimated

3 Water (Prevention and

Control of Pollution) Act, 1974 and Rules

KSPCB, CPCB

Establishes an institutional structure for preventing and

abating water pollution. Board issues consent to

industry and local bodies which discharge effluent

with effluent limits

Responding to an application

submitted by the stakeholoder

Decisions will be made within 21 days of receiving a filled-in application and supporting

information. (Form No XIII ). In case of refusal of consent the

reasons will be intimated

4 Water (Prevention and

Control of Pollution) Cess Act, 1977 and Rules

KSPCB, CPCB

Provides for the levy and collection of cess on water consuming industries and

local bodies. Collection of

Scrutinising the returns submitted

and to issue assessment order

Decision

34


Appendix I: Continued . . . SR. NAME OF ACT OR RULES IMPLEMENTING OBJECTIVE OF ACTS OR KSPCB’S KSPCB’S STANDARDS NO AGENCIES RULES SERVICE

cess enhances the funds of the Board for effective

implementation of environmental legislation

to enable stakeholders to file cess returns

5 The Noise Pollution

(Regulation and Control Rules), 2000

KSPCB, CPCB

6 Environmental Protection Act, 1986 KSPCB, CPCB

35


Appendix I: Continued . . . Appendix II: Consent Fee to be paid by the Industries based on the capital investment, frequency of consent application and the periodicity of monitoring

based on the classification of industries

Sr. No.

Classificationi Category Capital Investment by Industries in Rupeesii

Consent Fee in Rupeesiii

Consent Applicationiv Periodicity ofMonitoring

1 Redv Large > 1000 Crores 2,00,000 Every Year Once in a month >500 < 1000 Crores 1,50,000 >250 < 500 Crores 1,00,000 >50 < 250 Crores 75,000 >25 < 50 Crores 50,000 >10 < 25 Crores 30,000 >5 < 10 Crores 20,000 Medium >1 < 5 Crores 15,000 Every Year Once in two months Small >50 lakhs < 1 Crore 6,000 Every Year (option of Once in 3-4 months >25 lakhs < 50 lakhs < 3,000 once in 3 years by >10 lakhs < 25 lakhs 2,000 paying 3 years fee) >5 lakhs < 10 lakhs 1,500 >1 lakh < 5 lakhs 500 < 1 lakh 200 2 Orangevi Large > 1000 Crores 1,75,000 Every Year Once in two months >500 < 1000 Crores 1,25,000 >250 < 500 Crores 90,000 >50 < 250 Crores 60,000 >25 < 50 Crores 40,000 >10 < 25 Crores 25,000 >5 < 10 Crores 17,500 Medium >1 < 5 Crores 12,500 Every Year (option of once in 2

years by paying 2 years fee) Once in 3 months

Small >50 lakhs < 1 Crore 5,000 Every Year (option of Once in 4-6 >25 lakhs < 50 lakhs < 2,500 once in 3 years by months >10 lakhs < 25 lakhs 1,750 paying 3 years fee)

36


Appendix I: Continued . . . Sr. No.

Classificationi Category Capital Investment by Industries in Rupeesii

Consent Fee in Rupeesiii

Consent Applicationiv Periodicity of Monitoring

>5 lakhs < 10 lakhs 1,250 >1 lakh < 5 lakhs 250 < 1 lakh 150 3 Greenvii Large > 1000 Crores 1,50,000 Every Year Once in 3 months >500 < 1000 Crores 1,00,000 >250 < 500 Crores 75,000 >50 < 250 Crores 50,000 >25 < 50 Crores 30,000 >10 < 25 Crores 20,000 >5 < 10 Crores 15,000 Medium >1 < 5 Crores 10,000 Every Year (option of once in 2

years by paying 2 years fee) Once in 6 months

Small >50 lakhs < 1 Crore 4,000 Every Year (option of Once in 12 months >25 lakhs < 50 lakhs < 2,000 once in 3 years by >10 lakhs < 25 lakhs 1,500 paying 3 years fee) >5 lakhs < 10 lakhs 1,000 >1 lakh < 5 lakhs 200 < 1 lakh 100

i Categories of industries is as per GOI, MoEF, Official Memorandum No J20011 / 15/ IA/ dated 27th Sept 1988 read with amendment issued time to time ii Capital investment on land, building, staff quarters, plant and machinery including all movable and immovable assets as detailed in the project report for new industry or

audited report for existing industry or twenty times the annual lease value in case where land and/or buildings are taken on lease iii Notification No FEE 115 ENV 95 (P) dated 19th February 1998, published in Karnataka Gazette dated 2nd April 1998. Fees shall be paid by Bank Draft in favour of

KSPCB, Bangalore encashable at Bangalore. Fees are the same for ‘Consent for Establishment’ and Consent for Operation iv Form I and Form XIII under the Air Act (1981) and Water Act (1974), respectively. Tiny industries have to renew consent once in ten year by paying one year consent fee. v Consent for establishment and operation to be obtained from Head Office for large and medium category. However Consent for operation can be obtained either from

Divisional or Regional Office for investments < Rs. 1.00 Crores. vi Consent for establishment and operation to be obtained from Head Office. However Consent for operation can be obtained either from Divisional (investment Rs. 1.00 to

20.00 Crores) or Regional Office (investment < Rs. 1.00 Crores) vii Consent for establishment and operation to be obtained from Head Office (investment > 20.00 Crores), Divisional (investment Rs. 1.00 to 20.00 Crores) or Regional Office

(investment < Rs. 1.00 Crores)

37


Appendix III.

STANDARDS FOR DISCHARGE OF EFFLUENTS FOR SUGAR INDUSTRY (Extracts From Environment Protection Rules, 1986)

(Rule 3 (2)) Rule 3 of the Environment Protection Rules, 1986 provides for the Standard for emission or discharge of environmental pollutants. The standards are specified in Schedules I to IV for various emissions or discharges of environmental pollutants from the industries, operations or processes. Those pertaining to the sugar industry have been complied below

Schedule I: Sl No 4

Effluent Concentration not to exceed Milligram/lit Bio-Chemical Oxygen Demand. 100 for disposal on land, 30 for disposal in surface

waters Suspended solids 100 for disposal on land, 30 for disposal in surface

waters

Schedule I: Sl No 59

Emissions Agriculture residue fired boilers (including bagasse) Emissions Concentration in Milligram/lit Step grate Particulate matter 250 Horse shoe/Pulsating Grate Particulate matter 500 (12% CO2) Spreader stroker Particulate matter 800 (12% CO2) (Note: In case of horse shoe and spreader boilers, if more than one boiler is attached to a single stack, the standard shall be fixed based on added capacity of all the boilers connected with the stack)


Emission Standards for new generator sets (upto 19 kilowatt) run on petrol and kerosene with implementation schedule. The emission standards for portable generator sets run on petrol and kerosene shall be as follow: B. From June 1, 2001

Class Displacement (CC) CO (g/kw-hr) HC + NOx (g/kw-hr) 1 <65 519 54 2 >65<99 519 30 3 >99<225 519 16.1 4 >225 519 13.4

C. Test method shall be as specified in SAE J 1088. Measurement mode shall be D1 Cycle specified under ISO 8178 (Weighting Factor of 0.3 for 100% load, 0.5 for 75% load and 0.2 for 50% load). D. Following organisations shall test and certify the generator sets -

Automotive Research Association of India, Pune. ♦ ♦ ♦ ♦

Indian Institute of Petroleum, Dehradun. Indian Oil Corporation, R&D Centre, Faridabad. Vehicle Research Development Establishment, Ahmednagar.

These organisations shall submit the testing and certification details to the Central Pollution Control Board annually. The Central Pollution Control Board may send the experts in the field to oversee the testing.


38


Appendix III: Continued . . . Noise Limit for Generator Sets run with Petrol or Kerosene

1. Noise limit Noise limit for new generator sets run with petrol or kerosene shall be as given below:

Noise Limit from September 1, 2001 September 1, 2002

Sound Power Level Lwa

90 dBA 86 dBA

2. Applicability These rules shall apply to all new generator sets using petrol or kerosene as fuel, manufactured in or imported into India: Provided that these rules shall not apply to: (a) Any genset manufactured or imported for the purpose of exports outside India, or (b) The genset is intended for the purpose of sample only and not for sale in India.

3. Requirement of certification Every manufacturer or importer (hereinafter referred to as “supplier”) of genset (hereinafter referred to as “product”) to which these rules apply must have a valid certificate of type approval for all the product models being manufactured or imported after the specified dates.

4. Verification of conformity of production (COP) Every supplier shall subject its products to the verification for conformity of production, by certification body specified in clause 8, every year.

5. Sale of generator sets not complying with. these rules The sale of a product model, not having valid type approval certificate, or not complying with the noise limits, as determined by the verification for conformity of production, shall be prohibited, in India.

6. Requirement of conformance labeling 6. (1) The supplier of the ‘product’ must affix a conformance label on the product meeting

the following requirements: a. The label shall be durable and legible, b. The label shall be affixed on a part necessary for normal operation of the ‘product’

and not normally requiring replacement during the ‘product’ life. 6. (2) The conformance label must contain the following information:

a. Name and address of the supplier (if the address is described in the owners manual, it may not be included in the label)

b. Statement that “this product conforms to the Environment (Protection) Rules, 1986.

c. Type approval certificate number and time phase (i.e. September 2001 or September 2002).

7. Nodal agency 1. The Central Pollution Control Board shall be the nodal agency for implementation

of these rules. 2. In case of any dispute or difficulty in implementation of these rules the matter

shall be referred to the nodal agency. 3. The nodal agency shall constitute a Standing Committee to advise it on all matters;

including the disputed matters, related to the implementation of these rules. 8. Certification body

The following agencies are authorized for type approval and for verification of conformity of production.

39


Appendix III: Continued . . .

Automotive Research Association of India, Pune; National Physical Laboratory, New Delhi; Naval Science & Technology Laboratory, Visakhapatnam; Fluid Control Research Institute, Palghat; and National Aerospace Laboratory, Bangalore.

9. Compliance and testing procedure The compliance and testing procedure shall be prepared and published by Central Pollution Control Board, with the help of the certification agencies.


Noise Limit for Generator Sets run with Diesel 1. Noise limit for diesel generator sets (upto 1000 KVA) manufactured on or after the 1st

July, 2003. The maximum permissible sound pressure level for new diesel generator (DG) sets with rated capacity up to 1000 KVA, manufactured on or after the 1st July, 2003 shall be 75 dB(A) at 1 metre from the enclosure surface. The diesel generator sets should be provided with integral acoustic enclosure at the manufacturing stage itself. The implementation of noise limit for these diesel generator sets shall be regulated as given in paragraph 3 below.

2. Noise limit for DG sets not covered by paragraph 1. Noise limits for diesel generator sets not covered by paragraph 1, shall be as follows:

2.1 Noise from DG set shall be controlled by providing an acoustic enclosure or by treating the room acoustically, at the users end.

2.2 The acoustic enclosure or acoustic treatment of the room shall be designed for minimum 25 dB(A) insertion loss or for meeting the ambient noise standards, whichever is on the higher side (if the actual ambient noise is on the higher side, it may not be possible to check the performance of the acoustic enclosure/acoustic treatment. Under such circumstances the performance may be checked for noise, reduction up to actual ambient noise level, preferably, in the night time). The measurement for Insertion Loss may be done at different points at 0.5m from the acoustic enclosure/room, and then averaged.

2.3 The DG set shall be provided with proper exhaust muffler with insertion loss of minimum 25 dB(A).

2.4 These limits shall be regulated by the State Pollution Control Boards and the State Pollution Control Committees.

2.5 Guidelines for the manufacturers/users of Diesel Generator sets shall be as under: 01. The manufacturer shall offer to the user a standard acoustic enclosure of 25 dB

(A) insertion loss and also a suitable exhaust muffler with insertion loss of 25 dB (A).

02. The user shall make efforts to bring down the noise levels due to the DG set, outside his premises, within the ambient noise requirements by proper siting and control measures.

03. Installation of a DG set must be strictly in compliance with the recommendations of the DG set manufacturer.

04. A proper routine and preventive maintenance procedure for the DG set should be set and followed in consultation with the DG set manufacturer which would help prevent noise levels of the DG set from deteriorating with use.

3. Limits of Noise for DG sets (upto 1000 KVA) manufactured on or after the 1st July, 2003.

40



3.1. Applicability 01. These rules apply to DG sets upto 1000 KVA rated output, manufactured or

imported in India, on or after 1st July, 2003. 02. These rules shall not apply to

a. DG sets manufactured or imported for the purpose of exports outside India; and

b. DG sets intended for the purpose of sample and not for sale in India. 3.2. Requirement of Certification

Every manufacturer or importer (hereinafter referred to as "supplier") of DG set (hereinafter referred to as "product") to which these regulations apply must have valid certificates of Type Approval and also valid certificates of Conformity of Production for each year, for all the product models being manufactured or imported from 1st July, 2003 with the noise limit specified in paragraph 1.

3.3. Sale, import or use of DG sets not complying with the rules prohibited No person shall sell, import or use of a product model, which is not having a valid Type Approval certificate and Conformity of Production certificate.

3.4. Requirement of Conformance Labelling i. The supplier' of the 'product' must affix a conformance label on the product meeting

the following requirements: a. The label shall be durable and legible. b. The label shall be affixed on a part necessary for normal operation of the

'product' and not normally requiring replacement during the 'product' life. ii. The conformance label must contain the following information:

a. Name and address of the supplier (if the address is described in the owner's manual, it may not be included in the label)

b. Statement “This product conforms to the Environment (Protection) Rules, 1986".

c. Noise limit viz. 75 dB (A) at 1m d. Type approval certificate number. e. Date of manufacture of the product.

3.5. Nodal Agency i. The Central Pollution Board shall be the nodal agency for implementation of these

regulations. ii. In case of any dispute or difficulty in implementation of these regulations, the matter

shall be referred to the nodal agency. iii. The nodal agency shall constitute a Committee to advise it on all matters; including

the disputed matters, related to the implementation of these regulations. 3.6. Authorized agencies for certification

The following agencies are authorized to carry out such tests as they deem necessary for giving certificates for Type Approval and Conformity of Production testings of DG sets and to give such certificates:

i. Automotive Research Association of India, Pune ii. National Physical Laboratory, New Delhi

iii. Naval Science & Technology Laboratory, Visakhapatnam iv. Fluid Control Research Institute, Palghat v. National Aerospace Laboratory, Bangalore

3.7. Compliance and Testing Procedure The compliance and testing procedure shall be prepared and published by the Central Pollution Control Board, with the help of the certification agencies.

41


Appendix III: Continued . . . Schedule III: (See rule 3)

Ambient Air Quality Standards in Respect of Noise

Limits in dB (A) Leg. Area Code Category of Area Day Time Night Time

A Industrial area 75 70 B Commercial area 65 55 C Residential area 55 45 D Silence Zone 50 40

Note- 1 Day time is reckoned in between 6 a.m. and 9 p.m. Note- 2 Night time is reckoned in between 9 p.m. and 6 a.m. Note- 3 Silence zone is defined as areas upto 100 metres around such premises as

hospitals, educational institutions and courts. The Silence zones are to be declared by the Competent Authority. Use of vehicular horns, loudspeakers and bursting of crackers shall be banned in these zones.

Note- 4 Mixed categories of areas should be declared as one of the four above-mentioned categories by the Competent Authority and the corresponding standards shall apply.]

42



Schedule VI: (See rule 3(3A))

GENERAL STANDARDS FOR DISCHARGE OF EFFLUENTS Part A: Effluents

STANDARDS SL. NO PARAMETER INLAND

SURFACE WATER

PUBLIC SEWERS

LAND FOR IRRIGATION

MARINE COASTAL

AREAS

METHOD

I Colour and Odour See Note I ---

See Note I See Note I No.2120 Visual comparison Method Spectrophotometeric Method No. 2150 Threshold odour test

2 Suspended Solids mg/l, Max.

100 600 200 (a) For process wastewater 100 (b) For cooling water effluent, 10% above total suspended matter of influent

No. 2130 Nephlometric Method

3 Particular size of Suspended Solids

Shall pass 850 micron IS Sieve

(a) Floatablesolids max. 3 mm (b) Settleable solids, max 850 microns

4 pH value 5.5 to 9.0 5.5 to 9.0 5.5 to 9.0 5.5 to 9.0 No. 4500- H+

Electrometric Method 5

Temperature Shall notexceed 50C above the receiving water temperature

--- ---

Shall not exceed 50C above the receiving water temperature

No. 2550 Laboratory and field methods

6 Oil and Grease mg/l, Max 10 20 10 20 No.5520 Partition Gravimetric method Extraction method for sludge samples

7 Total Residual Chlorine mg/l, Max.

1.0 - - 1.0 No. 4500-Cl Iodometric method- Amperotric titration method

8 Ammonical Nitrogen (as 50 50 - 50 No4500- NH3 Primary distillation steps Titrimetric

43




SURFACE WATER

PUBLIC SEWERS

LAND FOR IRRIGATION

MARINE COASTAL

AREAS

METHOD

N), mg/l, Max. method Phenate method 9 Total Kjeldhal Nitrogen

(as NH3), mg/l, Max. 100 - - 100 No. 4500 N-org Macro kjeldhal Method

Semimicro Kjeldhal Method 10 Free Ammonia (as NH3),

mg/l), Max. 5.0 - - 5.0

12 Chemical Oxygen Demand, mg/l, Max. 250 - - 250 No. 5220 Titrimetric method, Colorimetric method

13 Arsenic (as As), mg/l, Max. 0.2 0.2 0.2 0.2 No. 3500- As Atomic absorption spectrometric method

14 Mercury (as Hg), mg/l, Max. 0.01 0.01 - 0.01 . No. 3500- Hg, Cold Vapour Atomic absorption Method,

Dithizone Method 15 Lead (as Pb), mg/l, Max. 0.1 1.0 - 2.0 No. 3550-Pb AAS Method, Dithizone Method

16 Cadmium (as Cd), mg/l, Max. 2.0 1.0 - 2.0 No. 3550-Pb AAS Method, Dithizone Method

17 Hexavalent Chromium (as Cr+6), mg/l, Max. 0.1 2.0 - 1.0

18 Total Chromium (as Cr), mg/l, Max. 2.0 2.0 - 2.0 No. 3550-Cr, AAS Method, Colorimetric method, Ion

Chromatographic method

19 Copper (as Cu), mg/l, Max. 3.0 3.0 - 3.0 No. 3550-Cu, AAS Method, Neo cuproine Method

20 Zinc (as Zn), mg/l, Max. 5.0 15 - 15 No. 3550-Zn, AAS Method, Inductively coupled plasma method, Dithizone Method, Zincon method

21 Selenium (as Se), mg/l, Max. 0.05 0.05 - 0.05 No. 3500- Se, Colorimetric method, Fluorometric method

22 Nickel (as Ni), mg/l, Max. 3.0 3.0 - 5.0 No. 3550-Zn, AAS Method, Inductively coupled plasma method

23 Cyanide (as CN), mg/l, Max. 0.2 2.0 0.2 0.2 No. 4500, Titrimetric method, Cyanide- Selective

Electrode Method, Colorimetric method

24 Fluoride (as F), mg/l, Max. 2.0 15 - 15 4500- F-, Ion- selective electrode method

Ion Chromatographic method

25 Dissolved Phosphates (as P), mg/l, Max. . 5.0 - - -

No. 4500- P Vandomolybdo phosphori acid Colorimetric method Stannous chloride method

44




SURFACE WATER

PUBLIC SEWERS

LAND FOR IRRIGATION

MARINE COASTAL

AREAS

METHOD

Ascorbic acid method

26 Sulphide (as S), mg/l, Max. 2.0 - - 5.0 No. 4500- S2 Methylene blue method

Iodometric method, Ion selective electrode method

27 Phenolic Compounds (as C6H5OH), mg/l, Max. 1.0 5.0 - 5.0

No. 6420 Liquid –Liquid extraction gas Chromatographic method Mass Spectrometric method

Radioactive materials: (a) Alpha emitter Micro curie/ml

10-7 10-7 10-8 10-7 28

(b) Beta emitter Micro curie/ml 10-6 10-6 10-7 10-6

No. 7110 Evaporation method for grass alpha, beta

29 Bio-assay test

90% survival of fish after 96 hours in 100% effluent




30 Manganese (as Mn) 2 mg/l 2 mg/l - 2 mg/l No. 3500- Mn AAS Method Inductively coupled plasma method Persulphate Method

31 Iron (as Fe) 3 mg/l 3 mg/l - 3 mg/l No. 3550-Fe AAS Method Inductively coupled plasma method Phenanthroline method

32 Vanadium (as V) 0.2 mg/l 0.2 mg/l - 0.2 mg/l No. 3550-V AAS Method Inductively coupled plasma method Gallic acid method

33 Nitrate Nitrogen 10 mg/l - - 20 mg/l 4500- NO2- Ion Chromatographic method Colorimetric Method

34 Dissolved Solids (Inorganic), mg/l, Max. 2100 2100 2100 -

35 Sulphate (as SO.), mg/l, Max. 1000 1000 1000 - 4500- NO2- Ion Chromatographic method Gravimetric

method with ignition of residues Turbidimetric method NOTE:

45



1. All efforts should be made to remove colour and unpleasant odour as far as practicable. 2. Parameters at Sl.No.34 & 35 are retained by the State Board, exercising Rule 3(2) of Environment (Protection) Rules, 1986. 3. Hydraulic loading of effluent for application on land for different soils are as under:

Sl.No. Soil Texture Loading Rate in

m3/Ha/Day 1 Sandy 225 to 280 2 Sandy Loam 170 to 225 3 Loam 110 to 170. 4 Clay loam 055 to 110 5 Clayey 035 to 055

Part B: Wastewater Generation Standards Sl. No. Industry Quantum

2 Sugar 0.4 [m3 / tonne] of cane crushed

46



[SCHEDULE VII] [See rule 3(3B)]

NATIONAL AMBIENT AIR QUALITY STANDARDS

Concentration in ambient air (in ug/m3 for all pollutants except carbon monoxide

which is in mg/m3)

Pollutant

Time Weighted average

Industrial Area

Residential Rural & Other areas

Sensitive Area

Method of measurement

Annual Average*

80 60 15 Sulphur (SO2)

24 Hours** 120 80 30

1. Improved West and Gaeke Dioxide method.

2. Ultraviolet fluorescence

Annual Average*

80 60 15 Oxides of Nitrogen as NO2

24 Hours** 120 80 30

Jacob & Hochheiser Modified (Na-Arsenite) method. Gas Phase Chemiluminescence.

Annual Average*

360 140 70 Suspended Particulate Matter

24 Hours** 500 200 100

(Average flow rate not less than 1.1 m3/minute)

Annual Average*

120 60 50 Respirable Particulate matter (size less than 10µm)

24 Hours** 150 100 75

Annual Average*

1.0 0.75 0.50 Lead (Pb)

24 Hours** 1.5 1.00 0.75

AAS Method after sampling using EPM 2000 or equivalent filter paper.

8 hours** 5.0 2.0 1.0 Carbon Monoxide (CO) 8 hours** 5.0 2.0 1.0

Non-dispersive infrared Spectroscopy.

* Annual Arithmetic mean of minimum 104 measurements in a year taken twice a

week 24 hourly at uniform interval.

** 24 hourly/S hourly values should be met 9S% of the time in a year. However, 2% of the time, it may exceed but not on two consecutive days.

Note. 1. National Ambient Air Quality Standard: The levels of an air quality necessary with

an adequate margin of safety, to protect the public health, vegetation and property. 2. Whenever and wherever two consecutive values exceed the limit specified above for

the respective category, it shall be considered adequate, reason to institute regular/continuous monitoring and further investigations.].

47



ENVIRONMENTAL STATEMENT (TO BE SUBMITTED AS PER ENVIRONMENT PROTECTION ACT, 1986)

FORM V Environmental Statement for the financial year ending the 31st March ………………..

PART A (i) Name and address of the owner/ occupier of the industry, operation or process. (ii) Industry category primary.- (STC Code) Secondary.- (SIC Code) (iii) Production Capacity.- Units.- (iv) Year of establishment (v) Date of the last environmental statement submitted

PART B WATER AND RAW MATERIAL CONSUMPTION:

(i) Water consumption m3/d Process Cooling Domestic

Name of products Process water consumption per unit of product output

During the previous financial year

During the current financial year

(1) (2) (1) (2) (3)

(ii) Raw material consumption

Name of raw

materials Name of products Consumption of raw material per unit of

output during the previous

financial year during the current

financial year

* Industry may use codes if disclosing details of raw material would violate contractual

obligations, otherwise all industries have to name the raw materials used.

PART C POLLUTION DISCHARGED TO ENVIRONMENT/ UNIT OF OUTPUT

(Parameter as specified in the consent issued) Pollutants Quantity of

pollutants discharged (mass/day)

Concentrations of pollutants in discharges (mass/ volume)

Percentage of variation from prescribed standards with reasons

(a) Water (b) Air

48



PART D HAZARDOUS WASTES

(as specified under the Hazardous Wastes/ Management and Handling Rules, 1989) Hazardous wastes Total quantity (kg.) during the previous


financial year (a) From process (b) From Pollution control facilities

PART E SOLID WASTES

Total quantity during the previous


financial year (a) From process (b) From pollution control facilities (c) (1) Quantity recycled or

reutilized within the units (2) Solid (3) Disposed

PART F Please specify the characterizations (in terms of composition and quantum) of

hazardous as well as solid wastes and indicate disposal practice adopted for both these categories of wastes.

PART G

Impact of the pollution abatement measures taken on conservation of natural resources and on the cost of production.

PART H

Additional measures/ investment proposal for environmental protection including abatement of pollution, prevention of pollution.

PART I

Any other particulars for improving the quality of the environment.

49



FORM XIII APPLICATION FOR CONSENT FOR ESTABLISHING OR TAKING ANY STEPS FOR

ESTABLISHMENT OF INDUSTRY OPERATION PROCESS OR ANY TREATMENT DISPOSAL SYSTEM FOR DISCHARGE, CONTINUATION OF DISCHARGE UNDER SECTION 25 OR

SECTION 26 OF THE WATER (PREVENTION AND CONTROL OF POLLUTION) ACT, 1974 (See Rule 32)

From Date………………………. …………………………… ……………………………

To

The Member Secretary, Central Pollution Control Board.

Sir,

I/We hereby apply for Consent/Renewal of Consent under section 25 or section 26 of the Water (Prevention and Control of Pollution) Act, 1974 (6 of 1974) for establishing or taking any steps for establishment of Industry/ operation/ process/ or any treatment/ disposal system to bring into use any new/ altered outlet for discharge of *sewage/ trade effluent*/ to continue to discharge *sewage/ trade effluent* from land/premises owned by..

The other relevant details are as below: 1. Full name of the applicant.. 2. Nationality of the applicant. 3. Status of the applicant:

a. Individual b. Proprietary concern c. Partnership firm

(Whether registered or unregistered) d. Joint family concern e. Private Limited Company f. Public Limited Company g. Government Company

1. State Government 2. Central Government 3. Union Territory

h. Foreign Company (If a foreign company, the details of registration, incorporation, etc.).

i. Any other Association or Body: 4. Name, Address and Telephone Nos. of the Applicant. (The full list of individuals, partners, persons, Chairman (full-time or part-time),

Managing Directors, Managing Partners, Directors (full time or part-time), other kinds of office-bearers are to be furnished with their period of tenure in the respective office with telephone Nos. and address).

5. Address of the Industry (Survey No., Khasra No., location as per the revenue records, Village Firka, Tehsil,

District, Police Station or SHQ, jurisdiction of the First Class Magistrate). 6. Details of commissioning, etc.:

a. Approximate date of the proposed commissioning of work.

50



b. Expected date of production: 7. Total number of employees expected to be employed. 8. Details of license, if any obtained under the provisions of Industrial

Development (Regulation) Act, 1951: 9. Name of the person authorized to sign this form (the original authorization

except in the case of individual/proprietary concern is to be enclosed). 10. (a) Attach the list of all raw materials and chemicals used per month.

(b) Licensed Annual Capacity of the Factory/Industry. 11. State daily quantity of water in kilolitres utilized and its source (domestic/

industrial/ process/ boiler / cooling/ others). 12. (a) State the daily maximum quantity of effluents and mode of disposal (sewer

or drains or river). Also attach analysis report of the effluents. Type of effluent quantity in kilolitres,

mode of disposal. i. Domestic

ii. Industrial (b) Quality of effluent currently being discharged or expected to be discharged. (c) What monitoring arrangement is currently there or proposed.

13. State whether you have any treatment plant for industrial, domestic or combined effluents.

Yes/No If yes, attach a description of the process of treatment in brief. Attach information

on the quality of treated effluent vis-à-vis the standards. 14. State details of sold wastes generated in the process or during waste treatment. Description Quantity Method of collection Method of disposal

I/We further declare that the information furnished above is correct to the best of my/our knowledge. I/We hereby submit that in case of change either of the point of discharge or the quantity of discharge or its quality, a fresh application for CONSENT shall be made and until such CONSENT is granted no change shall be made. I/We hereby agree to submit to the Central Board an application for renewal of consent one month in advance of the date of expiry of the consented period for outlet/ discharge if to be continued thereafter. I/We undertake to furnish any other information within one month of its being called by the Central Board. I/We enclose herewith cash receipt No./bank draft No………………………. dated …………………... for Rs…………...….. (Rupees…………………………………………………………………......) in favour of the Central Pollution Control Board, New Delhi, as fees payable under section 25 of the Act.

Yours faithfully, Signature of the applicant.

[Note: *Strike out which is not relevant.]

51



FORM I (See rule 4 of Water (Prevention and Control of Pollution) Cess Act, 1974

RETURN REGARDING WATER CONSUMED DURING THE MONTH OF..........

Name and Address of the

consumer

Purpose for which water consumed

Reading at the beginning of the

first day of calendar month under report

Reading at the end of the last day of calendar month

under report 1 2 3 4

Quantity of water consumed in

kilolitres

If the meter was out of order the

monthly average consumption of

water for the previous 3 months

of the working period

Quantity of water qualifying for rebate

according to the assessee

Remarks*

5 6 7 8 1. Industrial cooling spraying in mine

pits or boiler feed.

i. from Municipal water supply mains ii. from well/ tube-well

iii. from canal iv. from river v. from any other source

2. Domestic purpose.



3. Processing whereby water gets polluted and the pollutants are easily bio-degradable.



4. Processing whereby water gets polluted and the pollutants are not easily bio-degradable and are toxic.



Signature of the consumer............................. Name……………………………………….. Address……………………………………..

* For claiming rebate under column 7 the assessee shall indicate in this column the

analytical and other reports annexed to this return in support of this claim.

52



ANNEXURE TO FORM I Report of Analysis of treated effluent showing performance of the treatment plant for the month of.................................................................... Sample collected on………………………... Sample tested on……………………………. By the Laboratories…………………………

Date on which SI. No.

Polluting parameters as mentioned in the conditions imposed under consent granted under sections 25/26 of the Water (Prevention and Control of Pollution) Act, 1974

Maximum permissible limits or ranges allowed as per consent condition

Concentration of range of parameters as per report

There was break down or failure of the plant

On which under perfor-mance noticed

1 2 3 4 5 6 End. : Original Analysis report of Laboratory.

Signature…………………… Date………………………… Name……………………….. Address……………………...

53


ANNEXURE ……. MAINTAINING LOG BOOKS

Log Book 1: Log Book for Daily Water Balance Sheet (Volume m3)

WATER INTAKE Mode of Abstraction of Water 1/2/04 2/2/04 3/2/04 4/2/04 5/2/04 6/2/04 7/2/04 … …

Tanker Surface Water Ground Water Piped Water Rain Water (harvested) Total

WATER CONSUMPTION Mode of Use of Water

of Water 1/2/04 2/2/04 3/2/04 4/2/04 5/2/04 6/2/04 7/2/04 … …Process Cooling Domestic Water Sprinkling systems

Total

54


Log Book 2: Log Book for Daily Resources Balance Sheet (Weight Kg)

RAW MATERIAL INTAKE DATES Type of Raw material used 1/2/04 2/2/04 3/2/04 4/2/04 5/2/04 6/2/04 7/2/04 … …

To

tal

PRODUCTION DATES Type of Products manufactured 1/2/04 2/2/04 3/2/04 4/2/04 5/2/04 6/2/04 7/2/0

4 … …

Total

Note:For only mining projects the products includes the ore which is transported

55


Log Book 3: Log Book for Daily Energy Balance Sheet (Kilowatts)

ENERGY INTAKE DATES Source of Energy 1/2/04 2/2/04 3/2/04 4/2/04 5/2/04 6/2/04 7/2/04 … …

Grid Diesel Generator Set Solar Energy Any other Total

ENERGY CONSUMPTION DATES Energy Consumption

1/2/04 2/2/04 3/2/04 4/2/04 5/2/04 6/2/04 7/2/04 … …Process Cooling Air Pollution Control Devices

Water Pollution Control Devices

Water Sprinkling systems Total

56

CHECK LIST –I

(FOR INTERNAL AND EXTERNAL AUDITORS)

Format 1 (VG1): Verification Guidelines on Resource Auditing Aspects

A. Monthly Water Balance Sheet

WATER INTAKE [a]

WATER CONSUMPTION [b]

Mode of Abstraction of Water

Volume (m3)

Mode of Use of Water Volume (m3)

Tanker Process Surface Water Cooling Ground Water Domestic Piped Water Water Sprinkling systems Rain Water (harvested) Total Total Note: a = b + waste water generated + loss due to evaporation

B. Monthly Raw material consumption

RAW MATERIAL INTAKE [i]

PRODUCT PRODUCED [ii]

Type of Raw material used

Weight (Kg)

Type of Product produced

Weight (Kg)

Total Total Note:i = ii + waste products + fugitive losses through air and water

C. Monthly Energy Balance Sheet

ENERGY INTAKE [a]

ENERGY CONSUMPTION [b]

Source of Energy Kilowatts Mode of Use of Energy Kilowatt Grid Process Diesel Generator Set Cooling Solar Energy Air Pollution Control

Devices

Any other Water Pollution Control Devices

Water Sprinkling systems Total Total Note: a = b + loss due to heat

57

sop sugar industries empri 2005 01

Documents

control rules

nature of pollution

pollution effect

sugar industry

national environmental

environmental auditing

good environmental audit

noise pollution regulation