SUBMISSION BEFORE THE EAC (INDUSTRY II) - PowerPoint Presentation

Slide1

SUBMISSION BEFORE THE EAC (INDUSTRY II) FOR PROPOSED EXPANSION OF DISTILLERY UNDER EBP PROGRAMME EXPANSION OF DISTLLERY FOR ETHANOL PRODUCTION FROM 200 KLD TO 845 KLD USINGC -Heavy Molasses/ B – Heavy Molasses / Cane Juice Syrup/ GrainsByM/s. THE UGAR SUGAR WORKS LIMITEDUgar Khurd Village, Athani Taluk, Belagavi District– 591316

Environmental Consultant: Samrakshan, BangaloreNABET No : NABET/EIA/1922/IA0051

Date:23.07.2021

Slide2

The information provided in EC proposal at PARIVESH Portal, in EMP report and the information reproduced in the presentation has no deviation and are same along with exact details of the project i.e. name of the project, its location, capacity, project proponent, etc.Declaration

2

Slide3

NABET Accreditation Certificate 3IA

EIA Co-ordinatorS. Nanda Kumar

Slide4

Project Proponent and Environmental Consultant

4Sl NoParticulars

Details

1

Project Proponent

Shri. Chandan Sanjeev Shirgaokar

Managing Director

2

Environmental Consultant

M/s

Samrakshan

, Bangalore

NABET Registration No. NABET/EIA/1992/IA0051

Validity :24

th

July 2021

3

CEO of Samrakshan &

Name of EIA Coordinator

Mr. S. Nanda Kumar

Slide5

The proposal is for seeking Environmental Clearance under Notification S.O.2339(E) dated 16.06.2021 under EBP Programme. To be appraised as B2 category

Proposed expansion of distillery to produce Ethanol 200 KLPD to 845 KLPD Affidavit executed and submitted swearing that the Ethanol Produced will be for EBP programme

The Proposal

5

Slide6

Appraisal requested under B2 category under MoEF Notification S.O.2339(E) dated 16.06.2021 Notification RequirementsConformance

Should have prior Environmental Clearance for the existing operationThe Unit has prior EC issued by the Ministry

Application in Form 1 as per EIA Notification 2006 and to submit EMP

Application in Form 1 along with Environmental Management Plan is submitted

Certificate from the CGWB regarding adequate availability of water

Not applicable (Water source

is River Krishna)

Adherence to conditions related to distilleries

The EC conditions are complied satisfactorily.

Certified by RO, MOEF .

Notarized Affidavit produced by proponent that ethanol produced from proposed project shall be used completely for EBP

programme

.

Affidavit has been executed swearing that the ethanol produced from the proposed project will be completely utilized for EBP

programme

.

6

Slide7

LOCATION OF THE PLANT

7

Existing Sugar complex total land area:

485 Acres

Additional land acquired: 68

Total land area will be 553 Acres.

 

Location:

M/s. The Ugar Sugars Works Ltd.,

Ugar

Khurd

village

, Survey Nos. 269/1B/2, 267/1, 267/2, 371/2, 373, 269/1D, 269/2B, 269/3, 269/4, 374/P, 371/3, 371/P, 260/2, 261/1G, 261/2, 261/2+1A/2B, 270/1B/5, 270/A/2A

Athani

Taluk, Belgaum District, Karnataka State

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Project location and Connectivity

8

Slide9

Topographical map

Source: Survey of IndiaTopo map No. E43U14, E43U10

9

Krishna river

Slide10

Total Land use pattern

10

Sl. No.

Particulars

Existing Area (acres)

Proposed Area (acres)

Total after expansion in Acres

1

Factory sheds and Buildings

60

15

75

2

Open space for fuel storage

50

20

70

3

ETP

35

13

48

4

Roads

25

4

29

5

Parking and cane yard

35

3

38

6

Greenbelt, R&D land

270

8

278

7Reserve for future expansion10515Total48568*553

Layout Plan Of Sugar, Co-gen and Distillery unit

Slide11

Details of ECs & CTOSl. No.

Environment ClearanceNumber and date of issueEC granted for

1

Environment Clearance

from MoEF vide letter No. J-11011/80/99-IA II (M) dated

17.08.2000.

45 KLD distillery plant to produce RS/ENA

2

Environment Clearance

from MoEF vide letter dated

07.11.2003.

Modernization of 30 KLD distillery unit

3

Environment Clearance

from MoEF & CC vide F. No. J-11011/315/2012-IA. II(I) dated

15.07.2017

Sugarcane crushing capacity from 10000 TCD to 20000 TCD,

Co-generation power plant from 44 MW to 75 MW

Molasses based Distillery from 75 KLPD to 200 KLPD by installing additional 155 KLPD plant and dismantling existing 30 KLPD plant.

4

Amendment to

Environment Clearance

from MoEF & CC dated

08.12.2020

.

Amendment to EC dated 15.07.2021

To provide MEE and spent wash drier instead of incinerator

to make spent wash powder/potash

5

CTO

No.

PCB/155/HPI/2017-18/OB-945 dated 10.1.2018

Valid up to 30.06.2021 extended for three months in view of COVID

pandemic

11

Slide12

Details of Production Capacity/Activity

12 Plant capacity

ENA from C- Heavy

Ethanol from

C- Heavy

Ethanol from B - Heavy

Ethanol from Sugar syrup

Ethanol from Grain (during sugar cane crushing off season)

45 KLD existing

45 KLD

45 KLD

45 KLD

45 KLD

-

155 KLD under

installation

155 KLD

155 KLD

155 KLD

155 KLD

-

645 KLD proposed

  -

-

-

645 KLD

400 KLD

The RS/ Ethanol production under different feed stock

200 KLD

200 KLD

845 KLD

400 KLD

Slide13

Project DetailsSl NoParticulars

Details 1Project Activity Schedule as per EIA notification 2006 & amendmentSchedule 5 (g) – Distilleries

2

Cost of the project

Existing - Rs. 35675.30 Lakhs

Proposed - Rs. 25626 Lakhs (includes expansion of Sugar unit from 10000 TCD to 20000 TCD, Co-generation unit 44 MW to 75 MW and Distillery expansion from 200 KLPD to 845 KLPD).

3

Water source & requirement

Krishna River – distance from factory 0.5 km towards South direction

Quantity: Water drawl permission issued by Government of Karnataka to draw

175

mcft

water for the sugar, co-gen and distillery complex.

Total freshwater requirement after expansion is 2247 KLD

for distillery unit

4

Employees

Distillery : Existing -68 Nos. After expansion – 87 Nos.

13

Slide14

Sl NoParticularsDetails 5

CER fund allocationRs. 60 Lakhs for the proposed expansion

6

Environmental cell

Environmental cell is established

7

Nearest highway

Miraj- Jamakhandi Highway is located 1 Km towards East direction

8

Nearest Railway station

Ugar Khurd Railway Station is located at 1.3 Km towards North direction

9

Nearest Airport

Belagavi Airport is located at 90 Km towards South West direction

10

Nearest Settlements

Ugar Khurd village is located adjacent to factory

Kudchi town located at 4 Km towards South East direction

11

Water bodies

River Krishna flows at distance of 0.5 Km towards South direction from the factory

Project Details

Contd

..

14

Slide15

Sl NoParticularsDetails12

Reserve forestsReserve forest located at 6 Km near Kotawadi village near North east direction

13

Ecologically sensitive zone within 10 km radius

There is no ecologically sensitive area

14

Nearest town

Kudchi town located at 4 Km towards South East direction

Athani Town located at 25 Km towards North East direction

15

District Head Quarters

Belagavi district is located at 93 Km towards South East direction

Project Details Contd..

15

Slide16

Water Requirement Details

Source of water –

Krishna River located at about 0.5 km

.

Water withdrawal

permission is obtained from Government of Karnataka to draw 175

mcft

water for the entire sugar, co-gen and distillery complex.

Total freshwater requirement for distillery unit is 2247 KLD after expansion during grain as raw material.

16

Slide17

Raw CO2 sent to bottling plant Process Flow Chart for distillery plant

17

Slide18

Raw Material Requirement for Ethanol production

18 

Distillery Capacity

Total

Scenario

45 KLPD

155 KLPD

645 KLPD

400 KLPD

C-Heavy molasses

187 KLD

644 KLD

-

-

831 KLD

B-Heavy molasses

176 KLD

608 KLD

-

-

1039 KLD

Sugar syrup/juice

163 KLD

563 KLD

2342 KLD

-

3028 KLD

Grains

-

-

-

1067 KLD

1067 KLD

Sl. No.

Chemicals

Quantity Kg /day

1

Suplphuric Acid 211.252Urea422.53Dia Ammonium Phosphate422.5

4Anti-Foam422.5

Other Raw Material Requirements

Slide19

Distillery water use and wastewater generationScenarios:

19

Slide20

20Specific water & W/w Generation

Water use : 8.84 kl/kl of Ethanol/ENAConc.spent wash : 0.77 kl/kl of ENA/Ethanol 

Water Balance for 200 KLPD plant using C-Heavy molasses

Slide21

21

Water Balance for 200 KLPD plant using B-Heavy molasses

Specific water use & w/w details

Water use : 6.4 kl/kl of alcohol

Conc. Spent wash : 0.6 kl/kl of alcohol

Slide22

Water Balance for 845 KLPD plant using Sugar syrupSpecific water & W/W detailsWater use: 2.05 kL/kL of AlcoholConc. Spent Wash: 3 kL/kL of Alcohol

22Specific water & W/W detailsWater use: 2.05 kL/kL

of Alcohol

Conc. Spent Wash: 0.27

kL

/

kL

of Alcohol

Slide23

Water Balance for 400 KLPD plant using GrainsSpecific water & W/W detailsWater use: 5.62 kL/kL of AlcoholConc. Spent Wash: 1.42 kL/kL of Alcohol

23

Slide24

Water Requirement - Distillery

Freshwater requirement for different scenarios

24

Sl. No.

Feedstock

Fresh water requirement per KL/KL of Ethanol

Ethanol 200 KLPD

Ethanol -200 KLPD

Ethanol -845 KLPD

Ethanol -400 KLPD

1

C-molasses

8.84

-

-

-

2

B-molasses

-

6.40

-

-

3

Sugar syrup/ juice

-

-

2.05

-

4

Grain

-

-

-

5.62

Slide25

Spent Wash Generation Details

25Sl. No.Raw Material

Spent wash generation & disposal per KL/KL of Ethanol

C-molasses (Ethanol –

200 KLPD)

B-molasses (Ethanol –

200 KLPD)

Syrup

(Ethanol –

845 KLPD)

Grain (Ethanol –

400 KLPD)

1

Raw spent wash generation KL/KL

8

6

6

6

2

Raw spent wash after recycle KL/KL

8

6

3

4.8

3

After treatment spent wash disposal

0.77

0.60

0.27

1.42

Slide26

Fresh Water for Process and Utilities

26Sl. No. Feedstock

Quantity Required

(in KLD)

Existing

After expansion

1

Using C-Heavy Molasses

440

1769

2

Using B-Heavy Molasses

-

1406

3

Using sugar syrup

-

1736

4

Using Grains

-

2247

Sl. No.

Feedstock

Treated water recycled (in KLD)

Total Recycled Water (in KLD)

Cooling Tower

Scrubber

1

Using C-Heavy Molasses

1976

120

2096

2

Using B-Heavy Molasses

1317

120

14373Using sugar syrup348312036034Using Grains2222

1202342

Recycle water for process, cooling tower

Slide27

Wastewater generation -Distillery

27Quantity of Wastewater from process and Utilities

Sl. No.

Particulars

Unit

C-molasses (Ethanol -200 KLPD)

B-molasses (Ethanol -200 KLPD)

Syrup (Ethanol -845 KLPD)

Grain (Ethanol -400 KLPD)

From Process

 

1

Raw Spent wash

KLD

1690

1590

5070

2400

(a) Recycled to Process

KLD

-

-

2810

480

(b) To MEE

KLD

1690

1590

2260

1500

(c) To Wet cake

KLD

-

-

-

420

2

Concentrated spent wash from MEE to drier KLD154181240-3Thin slop from MEE and decanter to wet cake KLD

--

-

570

4

Spent lees

KLD

560

473

1568

496

For Utilities

 

4

DM reject

KLD

25

25

25

25

5

Boiler blow-down

KLD

18

18

18

18

6

Wet Scrubber

KLD

120

120

120

120

7

Cooling tower bleed

KLD

100

90

200

120

Total Wastewater Generation

KLD

2667

2497

7241

3749

Slide28

28In Scenario 1 & 2: 200 KLPD Ethanol using C-Heavy and B- Heavy Molasses respectively:Raw spent wash will be partially recycled back to fermentation process and remaining will be treated in Biodigester and followed by MEE.Concentrated spent wash will be sent to drier. Potash Powder is given to Fertilizer industry.

Spent lees and MEE condensates will be taken into Stripper & UV Treatment. Boiler blowdown, Wet scrubber effluent and DM regenerate will be sent to Sugar ETP.Cooling tower overflow will be recycled back to Cooling tower for water makeup.Treated effluent from Stripper & UV Treatment system will be reused in cooling tower makeup and in wet scrubber.

In Scenario 3: 845 KLPD Ethanol using Syrup/Juice:

Raw spent wash will be partially recycled back to fermentation process and remaining will be treated in MEE and Concentrated spent wash will be sent to drier.

Potash Powder is given to Fertilizer industry.

Spent lees and MEE condensates will be taken into Biodigester followed by Stripper & UV Treatment.

Cooling tower overflow will be recycled back to Cooling tower for water makeup.

Treated effluent from Stripper & UV Treatment system will be reused in cooling tower makeup and in wet scrubber.

Wastewater Treatment

Slide29

29In Scenario 4: 400 KLPD Ethanol using Grains:Raw spent wash will be treated in Decanter. Partial thin slop as wet cake taken to DDGS drier and remaining spent wash is taken to MEE.Concentrated spent wash (thick slop) from MEE will be sent as wet cake to DDGS drier. DDGS is given for Cattle feed.

Spent lees and MEE condensates will be treated in Stripper & UV Treatment. Cooling tower overflow will be recycled back to Cooling tower for water makeup.Treated effluent from Stripper & UV Treatment system will be reused in cooling tower makeup and in wet scrubber. Wastewater Treatment

Slide30

Power Requirement

30RequirementQuantity in MW

Existing

0.75

Under Implementation

2

Proposed

5

After Expansion

7.75

Slide31

Details of Steam Requirement (Distillery plant)

31Sl. No.

Product capacity

Steam requirement in TPD

Process Section

Multi Effect Evaporator (MEE)

Drier Section

Total

1

200 KLD using B-Heavy / C- Heavy Molasses

625

443

191

1259

2

845 KLD using Syrup

1589

443

240

2272

3

400 KLD using Grains

944

443

575

1962

No additional boiler is proposed in the expansion project. Total steam required for 845 KLD plant will be 2,272 TPD. However, from the 55 TPH boiler in distillery unit steam generated will be 1,320 TPD and remaining steam of 952 TPD will be met from sugar plant will be utilized 200

KLD

Slide32

Sources of Air Pollution & Control Measures

32Sl. No.

Source of air pollution

Fuel

Consumption

 

Chimney height (m)

APC equipment provided

Remarks

1

Boiler – 50 TPH boiler will be upgraded to

55 TPH

Bagasse

25-30 TPH

 

45.5 m

Wet Scrubber

Existing stack height of 45.5 m AGL and Wet Scrubber will be sufficient even after expansion of distillery unit

3

DG Set –

2000 kVA

HSD

250 LPH

30 m

Acoustic enclosure

Existing

Slide33

Ambient Air Quality Status

Ambient Air Quality monitoring is carried out regularly in industry premises as per Consent condition by NABL Accredited laboratory.The resultant concentration is within the prescribed National Ambient Air Quality Standards.

33

Sl. No.

Project Location

Monitoring values in mg/NM

3

(PM

10

)

Monitoring values in mg/NM

3

(PM

2.5

)

Monitoring values in mg/NM

3

(SO

2

)

Monitoring values in mg/NM

3

(NOx)

1

Near guest house

73.60

32.86

4.61

10.38

2

Near ETP plant

86.81

49.74

4.25

9.92

3

Near hospital

71.3320.584.179.73Ambient Air Quality Standards-MoEF & Cc dated 16.11.2009100608080

Slide34

Air Pollution Dispersion Modeling Studies

Inputs considered for air quality monitoring studiesIncremental increase of criteria air pollutants is predicted using Lakes Environmental Software, Version 18081 and designed for multiple sources for predicting the GLC.

34

Particular

Stack height in m

Stack Dia. in m

Stack exit gas temp in

o

C

Gas velocity in m/s

SPM

g/s

SO

2

g/s

NO

2

g/s

Boiler 80 TPH

50

3

131

7.28

4.76

0.474

1.06

Boiler 80 TPH

52

3

140

8.11

4.644

0.492

0.946

Boiler 55 TPH

45

3.4

1297.714.6870.571.06Boiler 75 + 75 TPH 6051508.411.71.4413.37

Slide35

Predicted Incremental Short-term Concentrations

35

Ambient Air Quality monitoring is carried out regularly in existing industry premises by NABL Accredited laboratory.

The resultant concentration will be within the prescribed National Ambient Air Quality Standards even after the expansion of the boilers.

Description

Maximum concentrations, µg/m

3

Distance & Direction

Particulate Matter (SPM)

3.92

Site boundary towards South West direction

Sulphur di-oxide (SO

2

)

1.17

Oxides of Nitrogen (NO

x

)

1.03

Slide36

Isopleth - SPM

Air Pollution Dispersion Modeling - SPM

36

Slide37

Air Pollution Dispersion Modeling - SO2

Isopleth

37

Slide38

Air Pollution Dispersion Modeling - NOx

Isopleth

38

Slide39

Odour Sources and Control Measures

39

Odour is controlled at source by GMP practices in the process

Fermenter lids to be closed, gaskets and seals are periodically checked

The odour producing materials such as RS/ENA/Ethanol is stored in tanks with proper safety measures and as per standard practices and regular monitoring of the fixtures such as gaskets, seals etc.

Regular monitoring is done for checking of any leakages in piping and fittings

Better housekeeping is maintained to ensure good hygiene condition in the premise

Effluent treatment Plant is maintained on regular basis

Fragrance flowering trees or shrubs are planted near odour generating areas like near ETP etc.,

Odour from sources such as holding ponds/lagoons and sewage pre or post treatment effluent to be controlled by atomized spray of chlorine dioxide.

Regular steaming of all fermentation equipment

Control of temperature during fermentation to avoid in-activation / killing of yeast

Slide40

Solid Waste Generation & Management - Distillery

40SI.No.

Details of the Solid waste

Quantity in MT/Day

Utilization existing and after proposed expansion

Existing

Proposed

After expansion

Distillery plant

1

Sludge (Yeast)

40

40

80

Supplied to farmers as manure

2

Fly Ash

3.5

0.5

4

Supplied to brick manufacturers and to farmers as manure.

3

Bottom Ash

2.5

0.1

2.6

Waste category

Hazardous

Waste

Quantity – Existing

Method of handling

5.1

Used Oil

9.54 kL

Used oil is reused for lubrication purpose for factory machineries during the season

5.2

Oil-soaked cotton waste

1.5 MTOil-soaked cotton waste is burnt in boilers.Hazardous waste generation & Management

Slide41

Environmental Management Cell

41

Slide42

Environmental Management Plan – Construction Phase

Impact on Environment

Source of impact

Mitigation measures

Effect on ambient Air Quality (PM, SO2, NOx, CO)

Dismantling of old 30 KLPD plant

To inventories the dismantled structure

To retrieve the parts from the dismantled structure if it can be reused in the expansion

To quantify the disposable metal parts/scrap

To dispose/scrap materials from dismantled 30 KLPD plant in secured manner.

Effect on ambient Air Quality (PM, SO2,

NOx

, CO)

Civil work like leveling, excavation, construction, erecting.

Use of properly well maintained construction machinery & vehicles &

Water sprinkling to suppress the dust generated during excavation, leveling and other operations

Use of earth moving equipment for civil work & other vehicles for transporting construction material

Earth moving equipment and transport vehicles with emission test report indicating normal values will be deployed

Internal roads will be sprinkled with water to avoid fugitive dust due to vehicle movement

Gas cutting and welding jobs – the release of gaseous pollutants. 

Low, as the welding and cutting jobs will be carried out with adequate ventilation/exhaust arrangement.

Accumulation of construction debris

Construction materials to be stored in a barricaded area and covered to avoid dust getting air borne

Implementation of suitable disposal methods of construction material and debris at designated places to avoid fugitive emissions

42

Slide43

Impact on Environment

Source of impact

Mitigation measures

Effect on Land /soil

Spillage of oil and grease

Spillage will be collected immediately & disposed scientifically.

Disposal of excavated soil and debris may result in water logging and loss of fertile topsoil

Adoption of soil conservation by proper management viz., the excavated earth will be collected and used for refilling in foundation, leveling, plinth, landscaping and excess disposed to land filling in low laying areas and road construction

Runoff during rainy season. wind carrying fugitive dust.

Separating top soil and use it for gardening

Effect on Noise quality

Noise generation from earth excavating equipment

Site will be cordoned and it will be ensured that the PPE are used by workers

Movement of vehicles

Regular vehicle maintenance will be done and honking in the premises will be prohibited

Ground water & Surface Water pollution

Accumulation of debris and runoff during rains.

Water will be required for domestic purpose for the workers deployed for erection activities and is anticipated to generate wastewater

Proper drainage system will be provided

Strengthening of green belt in and around plant

Storage of construction material and debris in a secured manner, to avoid runoff with rain water.

Environmental Management Plan – Construction Phase

43

Slide44

EMP - Operation Phase - Air environment

Source of impact

Predicted impacts

Mitigation measures

Raw material handling - transportation, storage

Cumulative Emission of air pollutants from the AERMOD prediction modeling studies from the change in the configuration of the boilers located in both sugar and distillery units are as under;

SPM: 3.92 µg/Nm

3

SO

2

: 1.17 µg/Nm

3

Nox

: 1.03 µg/Nm

3

Finished products Ethanol to be transferred using automatic pumping system to the storage tanks provided with tank forms.

To reduce the storage time of spent wash to avoid

odour

Fragrance flowering trees or shrubs will be planted near

odour

generating areas like near ETP etc.

44

Slide45

EMP - Operation Phase - Air environmentSource of impact Predicted impactsMitigation measures

CO2 emission from fermentationTotal CO2 emission in 645 KLD plant is 495 T/D.Greenhouse gas emission contributing to global warming.

The CO

2

which is liberated in fermentation is scrubbed in water with the help of CO2 scrubber and sent to CO2 plant for production of liquefied CO2 used for commercial purpose

Emissions from Boilers

Emissions will impact the air quality. Increase in Particulate matter concentration in AAQ, resulting in respiratory problems on the humans, deposits on the vegetation and on agricultural crop will affect the plant growth, yield

etc

particulate deposits will be affecting the photosynthesis

To continue to operate and maintain the wet scrubber as Air pollution control equipment provided for emission for 55 TPH (after expansion) to meet the emission limits for the pollutants stipulated by MoEF & CC / SPCB and stack height of 45.5 m.

Emissions form DG set

To maintain the DG sets stacks of 30 m AGL height

45

Slide46

Source of impact Predicted impactsMitigation measuresVehicular movementETP area Solid and hazardous waste storage areaOdour

nuisanceThe impact of air pollution will have effect on the health of the people like nausea, asthma, eye irritation. The particulate deposit on plant will affect the photosynthesisTo provide water sprinkling to internal roads to avoid fugitive dust due to vehicle movementTo deploy transport vehicles having emission under control test reportTo maintain good housekeeping in the process area and inside industry premisesTo clean the spent wash, drain periodically

To reduce the storage time of spent wash to avoid

odour

Fragrance flowering trees or shrubs will be planted near

odour

generating areas.

EMP - Operation Phase - Air environment

46

Slide47

EMP - Operation Phase - Water environment

47

Sources

Impact

Mitigation Measures

Discharge of process effluents from distillery viz., spent wash and spent Lees, utility effluents DM plant rejects, boiler blowdown, cooling tower bleed, condensate from MEE etc.

5070 KLD of Spent Wash (worst case Sugar syrup as raw material) out of which 2810 KLD of spent wash is recycled in fermentation process and 2260 KLD spent wash will be sent to evaporator. Spent lees and evaporator condensers and other utility effluents from distillery unit will be treated in existing UV and stripper.

Water Pollution effect the quality of surface and ground water quality.

To treat Spent wash from molasses/sugar-based/grain-based distillery in existing MEE of 360 m

3

/day and 700 m

3

/day capacity and proposed 1500 m

3

/day capacity. Concentrated spent wash will be sent to drier to obtain potash rich powder.

To treat Spent lees and MEE Condensates and other lean effluents provided with existing

Bio Digester, Aeriation tank

and UV and stripper. Treated effluents reused for cooling tower makeup.

To treat domestic sewage in Sugar ETP

To adopt ZLD concept.

Raw materials and finished products to be stored in dedicated storage area/tank farm.

To provide impervious surface for storage of used oil drum in an enclosed room and will be handed over to the recycler.

To store the used oil drum in an enclosed room and disposed to authorized agency.

Slide48

EMP - Operation Phase - Noise environment

48

Sources

Predicted Impacts

Mitigation measures

Noise from operation of Machineries, motor pumps, compressors

The ambient noise levels are within the stipulated standards.

To make mandatory for the workers and officers to use PPE (ear plugs)/ear muffs in high noise area.

To house the motor pumps, compressors in enclosures.

To maintain the machineries and conveying system by following routine and periodic maintenance to reduce noise generation

Operation of Boilers, TGs, DG set

The average results of noise levels at main gate 69.4 dB(A)

leq

, near the turbine is 70.8 dB(A)

leq

and mill house 72.9 dB(A)

leq

, near ETP Plant 71.0 dB(A)

leq

.

DG sets and TG are within acoustic enclosures.

Boilers – Silencers are provided to steam safety valves and steam straps are provided to steam main pipelines

Vehicular movement

Transportation of raw materials & finished products

There is no impact on the nearest community as the nearest habitation is adjacent to the plant in the West direction

To regulate the speed limit inside plant and transportation to be done only during peak hours.

To maintain the greenbelt at the project site boundary

Slide49

EMP -Operation Phase - Land Environment & BiodiversitySource of impact

Predicted impacts Mitigation measuresDischarge of treated effluent

Land Contamination

Leaching in to ground.

The soil quality to be tested and studied each season

Distillery effluent - ZLD

Accidental Spillage of finished products

Spillage/ disposal of hazardous waste

To store the used oil in the secured manner and dispose to authorized vendors.

To cordon the accidental spillage of molasses/spent wash if any, take to respective holding tanks spent wash holding tank

.

Disposal of

yeast sludge

,

ETP sludge

Press mud & yeast sludge being supplied as manure.

Boiler ash is supplied to farmers as soil conditioner.

49

Slide50

EMP -Operation Phase –Socio Economic EnvironmentSourcesImpactMitigation MeasuresEmployment of local people

Strongly beneficial (positive) impactTo employ locally available manpower to the maximum possible extent based on qualificationCultural impactTo engage the local people for raw material supply, transportation and security systemTo take up development of social facilities like, temple, educational facilities to the local etc

Operation of distillery unit

Impact on flora, and fauna due to the Noise and emission from the boilers

To keep all the pollution control facility in operating condition and to meet the regulatory compliance and beyond to ensure that the biodiversity is not affected. No trees shall be cut.

50

Slide51

Environmental Monitoring Program

51Sl No.Particulars

 

Monitoring frequency

Duration of monitoring

Important parameters for monitoring

Air environment

1

Ambient Air quality of Project premises at downwind and up wind direction at 120º angle

Once in a month 48 hours (2 consecutive days)

48 hours (2 consecutive days) in a month during

PM

10,

PM

2.5

, NO

x

, SO

2

, CO, NH

3

2

Stack monitoring

Distillery Boiler stack- 55 TPH

Once in a month &

Online monitoring

Grab & Online monitoring

Particulate, SO

2,

NO

x

Noise environment

1

At the boundary of the factory.

Once in six months

Day and Night

Noise level in dB (A) Leq.

2Boiler houseOnce in six monthsDay and Night Water environment 1Raw spent effluentOnce a weekGrabpH, TSS, TDS, COD, BOD, potash, chloride & Phosphate2All intermediate stages of ETPOnce a weekGrabpH, TSS and COD Min once a dayGrab

pH and COD3

Ground Water within industry site and Piezometer monitoring

Twice a year

Grab

pH, TSS, TDS, Nitrate and Phosphate, Ca and Mg.

5

Surface water sources at inlet point in river and reservoir.

Twice a year, before and after monsoon.

Grab

pH, DO, EC, TSS, TDS, N, P, K, Chlorides, bacteriology

Soil environment

1

Within project premises, one at location around HW storage site

Once in a year

Composite sample

EC, Organic carbon, pH, available NPK

Slide52

Piezometers provided around the ETP area

Slide53

Environmental Management Budget Allocation

53Sl.No.

Description

Financial provision in Rs.

Capital cost in Rs.

Recurring

cost in Rs. /Annum

1

Solid and Hazardous waste storage facilities.

50 Lakhs

10 Lakhs

2

Installation of MEE and drier

1500 Lakhs

600 Lakhs

3

Air Pollution Control Systems

Existing 50 TPH boiler will be upgraded to 55TPH

-

25 Lakhs

4

Personal protection safety gadgets and health care

-

25 Lakhs

5

Tree plantation & landscaping measures

50 Lakhs

2 Lakhs

6

Online monitoring system

-

10 Lakhs

7

Environmental Monitoring Plan (air, noise, water and solid waste)

-

15 Lakhs

8

Corporate Environment Responsibility -60 Lakhs Total 1600 Lakhs747 Lakhs

Slide54

Corporate Environmental Responsibility - CER

CER activities completed during the year 2017-2021

54

Slide55

Budget allocation during proposed expansion for CERs with target date

Corporate Environmental Responsibility - CER

55

Sl. No.

Activity

Fund allocated

Rs. In Lakhs

Period of execution in years from the commencement of project

1

Avenue plantation in community areas for Ugar khurd, Parmeshwarwadi and Ugar BudrukVillages

60

4 years

 

2

Gifting of new books to underprivileged Government schools’ children located at Ugar

khurd

,

Parmeshwarwadi

,

Kusanal

and Ugar

Budruk

Villages

3

Health checkup camps Conducting for the School children/Community people (farmers)

Total

60

-

Slide56

Occupational Health Hazards Associated with the Industrial ActivitySl. No.ActivityAspect

Impact1Bagasse Handling /conveying

Air borne dust

On Respiratory system like

Chronic obstructive pulmonary disease

(

COPD

)

2

Boiler/ DG Set operation/Compressors

Noise

Noise Induced Hearing

loss (NIHL) / Cardiovascular Disease/ Hypertension

3

Molasses handling

Odour

Headache/Nausea

4

Boiler Operation

Exposure to Heat

Heat

Exhaustion

56

Slide57

Preventive and Corrective Actions to reduce/eliminate Occupational Health HazardsSl. No.Occupational Health HazardsPreventive Action

Corrective action1Respiratory system

Reduce dust getting airborne

Periodic Medical Examination – Spirometry / PFT / Pulse

oxymetry

2

Noise Induced Hearing loss (NIHL) / Cardiovascular Disease/ Hypertension

Reduce Noise at source by changing design/ proper maintenance/ providing acoustic enclosures

Provide PPE

Audiometry

3

Headache/Nausea due Odour

Control Odour at source by providing high rise vents

Job rotation

4

Heat Exhaustion

Proper location/design of operator cabin

Job rotation

57

Slide58

Health check-up parametersSl. No Test Details

1Physical Fitness Certificate2Pulse3

Blood Pressure

4

Complete Blood Examination

Haemoglobin

% (Hb%), WBC, RBC, Etc.

5

Vision

6

Central Nervous System (CNS)

7

Respiratory System-Lung Function (RS)

8

Cardio Vascular System (CVS)

9

Electro Cardio Gram (ECG)

10

Chest X-ray

11

Total Leucocyte Count (TC)

12

Differential Leucocyte Count (DLC)

13

Absolute Eosinophil Count (AEC)

14

Complete Urine Examination [Physical / Chemical /Albumin, Sugar & Bile Salt etc.

 15

Random blood Sugar (RBS)

58

Slide59

Risk Safety Measures

Onsite Emergency Plan is prepared and approved for existing facilityNOC taken for existing storage facilityFire hydrant systems is in place all around the industry PPE are provided for workers at the industry to ensure their safetyDyke walls are provided for existing storage tanks farm Occupational Health and Safety monitoring is in placeRegular health check-ups of workers are carried out and record are maintainedRegular safety training and fire fighting mock drill for workers is being carried out

Only trained persons are allotted for industrial operations

59

Slide60

General safety measures/precautions followedEmployees will be trained in the safe handling practices of hazardous chemicals such as chemicals, acids, caustics, etc.Standard operating procedures will be established and followed when cleaning up spills, handling of toxic/hazardous chemicalsTo know the material nature, potential hazards (health, fire, reactivity and environmental) and how to work safely with the materials MSDS will be provided at the work placeMaterials which give off toxic, asphyxiate, or anesthetic vapours

or fumes will be stored in remote or isolated locations when not in useIn case of leakage the toxic / hazardous materials automatic water sprinkler systems are switched on to control the toxic vapours at work placeGoggles/face shields are provided for eye/face protectionIn case of spillage/leakage while handling of hazardous materials spill control kit will be provided at work place

60

Slide61

Green belt development

Out of 553 acres, 278 Acres is earmarked for the greenbelt development which accounts for 50.27 %. Massive tree plantation programme is being implemented Tree species already planted – 50525 Nos.Tree species to be planted – 53700 Nos.

61

Slide62

Rain Water Harvesting

62Industry is provided with rain water storage reservoirs and same is used for rain water harvesting collection. Considering Factory sheds and Buildings of the proposed project is about 303514 Sq m. For rain water harvesting consider 75% of this area = 2,27,635.5Sq m.

Quantity of Rain Water that can be harvested from the proposed project is calculated as below.

The average annual rainfall in Belagavi District is 495 mm/annum

Considering 83 rainy days in a year, the average daily rain fall is 495/83 = 5.96 mm/day

Rain water harvested per day = Average daily Rainfall X Area X Collection Efficiency = 5.96/1000x 227635.5 x 0.9

=

1221 m

3

/day

Slide63

SEVERITY MAPPINGThe Severity mapping has been carried out using the ALOHA Areal Locations of Hazardous Atmospheres) software 5.4.3 A technique used to generate an incident list is to consider potential leaks and major releases from storage facilities. The study displays its estimate as a threat zone, which is an area where a hazard (such as toxicity, flammability, thermal radiation, or damaging overpressure) has exceeded a user-specified Level of Concern (LOC). 63

Slide64

STORAGE CAPACITIES64Existing Proposed

Material stored Tank Nos.

Capacity in KL

RECTIFIED SPIRIT

1

50

2

32

3

32

4

435.40

Total

549.40

E. N. A

1

16.53

2

446.61

3

446.61

4

50

5

50

6

11

7

11

8

35

9

35

Total

1101.76

MIDDLE GRADE ALCOHOL (IMPURE SPIRIT)

1

352353343510

610

Total

96

ETHANOL

1

435.40

2

14

3

14

4

14

5

14

 

Total

491.40

Material stored

Capacity

Nos.

Total quantity

Impure spirit

100 kL

1

100 kL

Ethanol

550

6

3300 kL

3400

6

20400

kL

Slide65

ALOHA SIMULATION ANALYSISSUMMARY OF MCA ANALYSISEthanol

65

Sl. No.

Scenario

Threat Modelled

Damage Distance in m

Consequential Impacts

1

Leaking tank, chemical is not burning and forms an evaporating puddle

Toxic area of vapour cloud

no recommended

LOC value --- (N/A = ERPG-3)

Flammable Area of Vapour Cloud

<10 m

19800 ppm = 60% LEL = Flame Pockets

2

Leaking tank chemical is burning and forms a pool fire

Thermal radiation from pool fire

 

< 10 m

10.0 kW/(sq m) = potentially lethal within 60 sec

Slide66

CONCLUSION AND PRAYER The proposed project is Distillery expansion to manufacture Ethanol under Ethanol blended with petrol program. All the relevant pollution control measures; safety norms & precautionary measures will be incorporated in the system, to ensure that the project is environmentally viable.It is committed to develop its operation without any adverse impacts on the environment and also lays emphasis on the implementation of EMP in true spirit.

At present we are supplying ethanol to oil processing industries. After expansion of the plant we will continue to supply bio-ethanol for the purpose of blending with petrol under EBP programme. M/s. The Ugar Sugar Works Limited., humbly requests the committee to kindly recommend the proposal for grant of Environmental Clearance

66

Thank You