SlideShare a Scribd company logo
1 of 93
SUBMISSION BEFORE THE EAC (INDUSTRY II)
FOR PROPOSED EXPANSION OF DISTILLERY
UNDER EBP PROGRAM
EXPANSION OF DISTLLERY FOR ETHANOL PRODUCTION FROM 60 KLPD TO 200 KLPD
using
B – heavy molasses / cane juice syrup
By
M/s. Mellbro Sugars Pvt. Ltd.
Shirur Village, Bagalkot Taluk and District,
Karnataka State - 587120
Environmental Consultant: Samrakshan, Bangalore
NABET No : NABET/EIA/1922/IA0051
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
NABET accreditation certificate
3
Project proponent and environmental consultant
4
Sl.
No.
Particulars Details
1 Project proponent
Kariyannavar S.V.
Executive Director
2 Environmental Consultant
M/s. Samrakshan, Bangalore
NABET Registration No. NABET/EIA/1992/IA0051
Validity :24th July 2021
3
CEO of Samrakshan &
EIA Coordinator
Mr. S. Nanda Kumar
 The proposal is for seeking Environmental Clearance under Notification
S.O.2339(E) dated 16.06.2021 under EBP Program. To be appraised as B2
category
 Proposed expansion of distillery to produce Ethanol from 60 KLPD to
200 KLPD
The Proposal
5
LOCATION OF THE PLANT
6
Existing industrial complex total land area: 100.99 Acres (40.87 hectares)
Location: Sy. No.s 1054/1, 1054/2, 1054/3, 1055/1, 1055/2, 1061/1A,
1061/1B, 1061/2+3A, 1061/2+3B, 1061/2+3/K/1, 1061/2+3/K/2, 1062/3,
1062/2/A, 1062/2/B, 1063/1, 1063/2, 1064/1, 1064/2, 1064/3, 1065/1,
1065/3, 1065/4, 1065/2A, 1072/1, 1070/3, 1080/1, 1079/1A+1B/1, 1123/1,
1123/2, Shirur Village, Bagalkot Taluk and District, Karnataka State – 587120
Distillery plant: 4.51 Acres (1.82 Hectares)
Project location and connectivity
7
M/s. Mellbro Sugar Pvt. Ltd.
Land use pattern – industry complex
Sl.
No
Particulars Area in
SQM
Area in
Acres
Area in
hectares
% of
the
land
1 Factory building & ancillary 70,890.58 17.52 7.09 17.3
2 Administrative & other
buildings area
20,053.9 4.96 2.01 4.9
3 Distillery 18,242.9 4.51 1.82 4.5
4 Cane yard 1,06,900.76 26.42 10.69 26.2
5 ETP 8,400 2.08 0.84 2.1
6 Open space for scrap yard
and dump
3,430.1 0.85 0.34 0.8
7 Reservoir area 500 0.12 0.05 0.1
8 Bagasse yard area 12,176 3.01 1.22 3.0
9 Roads 33,369.3 8.25 3.34 8.2
10 Tree plantation & greenbelt
area
1,34,736.46 33.29 13.47 33.0
Total plot area 408700 100.99 40.87 100.0
Reserve forests
Reserve forest (eucalyptus plantation)
located near Benakatti village
1.3 km - North
Reserve forest located near Sirur 3.5 km -
South
Reserve forest (eucalyptus plantation)
located near Mannikatti village
5.2 km –
North West
Nearest habitat
Banakatti 2 km - North
Water bodies
Kadival Halla 3.9 km – North East
Palati Halla 4.1 km - South East
Malaprabha River 6.7 km – East
Tumbu Halla 9.4 km – East
Almatti dam 23 km – North West
Ghatprabha River 12.7 km – North West
8
Topographical map
Source: Survey of India; Topo map No. E43V16 & EV3V12
Google map
9
Points
w.r.t.
google map
Latitude Longitude
A 16° 7'40.56"N 75°48'56.53"E
B 16° 7'46.84"N 75°48'55.78"E
C 16° 7'54.47"N 75°48'55.38"E
D 16° 7'55.17"N 75°48'57.38"E
E 16° 7'54.99"N 75°49'9.80"E
F 16° 7'52.34"N 75°49'9.86"E
G 16° 7'51.37"N 75°49'15.85"E
H 16° 7'57.68"N 75°49'15.89"E
I 16° 7'55.99"N 75°49'25.55"E
J 16° 7'47.14"N 75°49'26.98"E
K 16° 7'39.18"N 75°49'26.81"E
L 16° 7'39.20"N 75°49'23.49"E
M 16° 7'32.29"N 75°49'23.08"E
N 16° 7'28.00"N 75°49'21.93"E
O 16° 7'27.74"N 75°49'12.99"E
P 16° 7'32.61"N 75°49'16.41"E
Q 16° 7'36.64"N 75°49'16.31"E
R 16° 7'37.21"N 75°49'8.70"E
S 16° 7'40.42"N 75°49'8.88"E
T 16° 7'40.61"N 75°49'12.29"E
U 16° 7'44.40"N 75°49'12.16"E
V 16° 7'44.28"N 75°49'8.60"E
Appraisal requested under B2 category under MoEF Notification S.O.2339(E)
dated 16.06.2021
Notification requirements Conformance
Should have prior Environmental
Clearance for the existing operation.
 The Unit has prior EC issued by the Ministry.
To submit application in Form 1 as per
EIA Notification 2006 and EMP.
 Application in Form 1, Form 2 along with Environmental
Management Plan is submitted.
Certificate from the CGWB regarding
adequate availability of water.
 Not applicable (Water source is River Malaprabha).
Notarized Affidavit by proponent that
ethanol produced from proposed
project shall be used completely for
EBP program.
 Affidavit has been made that the ethanol produced from
the proposed project will be completely utilized for EBP
program.
10
Appraisal requested under B2 category under MoEF Notification S.O.2339(E)
dated 16.06.2021
Notification
requirements
Conformance
Adherence to
conditions related
to distilleries
 M/s. Mellbro Sugars Pvt. Ltd. is an integrated industry with sugarcane crushing capacity of 5000
TCD, co-generation power plant of 30 MW along with distillery. Construction and erection of
machinery is in progress and the industry is yet to be commissioned.
 Distillery of 60 KLPD for which prior Environment Clearance has been obtained has not yet been
installed. However, it is now proposed to increase the capacity of the distillery unit from 60
KLPD to 200 KLPD and correspondingly the captive power generation from 2 to 7.5 MW.
 Compliance report to the existing Environmental Clearance has been submitted to MoEF&CC, RO
Bengaluru. The industry is new and yet to be commissioned for production. However, status of
compliance report to the Consent To Establish (CTE) is obtained from Karnataka State Pollution
Control Board (KSPCB). to the Consent To Establish (CTE) is obtained from Karnataka State
Pollution Control Board (KSPCB) vide letter no. KSPCB/RO(BGK)/2021-22/454 dated
9th August 2021.
11
Current approvals – EC & CTE
12
Sl.
no.
Approval Products and
capacity
Number and date
of the consent
Remarks
1 Environmental
Clearance (EC)
Sugar plant 5000
TCD of sugar
cane, Co-
generation plant
30 MW and
Distillery 60
KLPD, capacity.
F. No. J-
11011/380/2017-
IA-II (I) dated 3rd
September 2019
Prior EC
2 Consent to
Establish (CTE)
Consent Order
No. CTE-318437
dated 18th June
2020
Construction and erection of
machineries are in progress.
Industry is planned to
commission in the ensuing
sugarcane crushing season.
Loan approval from DFPD for expansion
The Department of Food and Public Distribution, Directorate of Sugar
& Vegetable Oils, Government of India has approved loan of
Rs. 68.12 Crores initially for 60 KLPD distillery and further amount of
Rs. 113.96 Crores for expansion to 200 KLPD along with incineration
boiler under the Scheme for extending financial assistance to sugar
mills for enhancement and augmentation of ethanol production
capacity, vide letter F.No.4/1/2018-(BP & E) dated 2nd August 2019
and 5th January 2021 respectively.
13
Details of activity / production capacity
Particular Existing (EC obtained –
construction in
progress) capacity
Proposed
expansion
capacity
After expansion - total
capacity
Sugar plant 5000 TCD - 5000 TCD
Co-generation 30 MW - 30 MW
Distillery capacity (raw
material B heavy
molasses and
sugarcane syrup)
60 KLPD (not erected) 140 KLPD 200 KLPD
Ethanol production:
200 KLPD with sugar syrup
feedstock OR
140 KLPD with B heavy
molasses feedstock
Captive power 2 MW 1.5 MW 7.5 MW 14
Project details
Sl.
No.
Particulars Details
1 Project activity schedule
as per EIA notification
2006 & amendment
Schedule 5 (g) – Distilleries
2 Cost of the project Unit Investment on EC obtained
proposal Rs. Cores
Revised investment cost
in Rs. crores
Sugar & cogen 251.85 -
Distillery 79.41 (for 60 KLPD) 242.77 (for 200 KLPD)
Total 331.26 242.77
3 Water source &
requirement
 Source: Malaprabha River – 6.7 km from industry towards East.
 Quantity: Water drawl permission issued by Government of Karnataka to
lift 2100 KLPD or 15.72 MCFt /year for the sugar and distillery complex.
 Maximum fresh water requirement for distillery after expansion is 964
KLD.
4 Employees Sugar: 193; Cogen: 62; Distillery: 85
TOTAL: 340
15
Sl. No. Particulars Details
5 CER fund allocation Rs. 3 Crores
6 Environmental cell A full fledged Environmental Cell will be established during
operation phase.
7 Nearest highway SH 20 – Bachi, Raichur highway – 3.6 km – South
8 Nearest railway station Kadlimatti – 11.9 km – North
9 Nearest airport Belagavi Airport – 132 Km towards South West
10 Nearest village
Banakatti – 2 km - North
Project details Contd..
16
Sl. No. Particulars Details
12 Reserve forests
• Reserve forest (eucalyptus plantation) located
near Benakatti village - 1.3 km - North
• Reserve forest located near Sirur – 3.5 km - South
• Reserve forest (eucalyptus plantation) located
near Mannikatti village – 5.2 km – North West
13
Ecologically sensitive zone
within 10 km radius
None
14 Nearest town Bagalkot – 16.2 km – North West
15 District headquarters Bagalkot – 16.2 km – North West
Project Details Contd..
17
Layout plan of industry complex
21A
21A - RAINWATER HARVESTING TANK
Industry photographs
19
Land use / land cover classes in 10 km area
around the project site
20
Sl. No. Land use Land cover classes Area (ha) Area (%)
1 Forest 4,061.18 12.97
2 Agriculture 13,162.84 42.05
3 Agriculture Harvest 9,105.93 29.09
4 Open / Agriculture Fallow 4,483.49 14.32
5 Built up 357.71 1.14
6 Water 128.95 0.41
12.97
42.05
29.09
14.32
1.14
0.41
Area %
Forest
Agriculture
Agriculture Harvest
Open / Agriculture Fallow
Built up
Water
Typical process
flow of ethanol
manufacturing
and effluent
management
21
Bio-digestor
(optional)
Raw material requirement - distillery
22
Sl. No. Raw material and
chemicals
EC obtained 60 KLPD Total after proposed expansion
1 Sugar juice syrup - 726 KLPD (for 200 KLPD ethanol)
2 B-heavy molasses - 549 KLPD (for 140 KLPD ethanol)
3 Molasses 255 TPD -
4 Sulphuric acid 70 kg/day 600 kg/day
5 Caustic lye 70 kg/day 600 kg/day
6 Nutrient 4.25 kg/h 16 kg/h
7 Antifoam agent 3 kg/h 16 kg/h
8 Biocides - 2 kg/h
9 Cultured Yeast - For feedstock
sugar syrup: 7.3 TPD
B heavy molasses: 5.5 TPD
Water environment-water requirement,
water balance, wastewater generation,
wastewater treatment facilities
23
Water requirement
24
• Source: Malaprabha River – 6.7 km from industry towards East.
• Quantity: Water drawl permission issued by Government of Karnataka to lift 2100
KLPD or 15.72 MCFt /year for the sugar and distillery complex.
• In the EC the water requirement approved for sugar, cogen and distillery is 448
KLD during season and 868 KLD during off-season.
• Maximum fresh water requirement for 200 KLPD distillery after expansion is 964
KLD.
Distillery water use and wastewater generation
25
Scenarios with feedstock requirement
Sl.
No.
Feedstock Required quantity
after distillery
expansion, TPD
Ethanol production
capacity with
feedstock, KLPD
No. of working days
for which feedstock is
adequate
1 Sugar cane
syrup
726 200 150
2 B-heavy
molasses
549 140 52
3 Purchased
molasses
As per availability - -
26
Fresh water use :
2.8 KL/KL of alcohol
Concentrated spent
wash generation :
1.2 KL/KL of alcohol
27
200 KLPD ethanol with sugar syrup as feedstock
Fresh water requirement :
3.7 KL/KL of alcohol
Concentrated spent wash
generation : 1.8 KL/KL of
alcohol
28
140 KLPD ethanol with B-heavy molasses as feedstock
Comparison different scenarios
29
Sl.
No.
Feedstock / Raw
material
Ethanol
produced,
KLPD
Fresh water
requirement
KL/KL of ethanol
Raw spent wash
generation KL/KL
of ethanol
Concentrated
spent wash
generation KL/KL
of ethanol
1 Juice/syrup 200 2.8 6 1.2
2
B-heavy
molasses
140 3.7 6 1.8
Fresh water and recycle water for process and utilities
30
Sl.
No.
Particulars
Fresh water requirement in KLD
Proposed with sugarcane syrup
(ethanol 200 KLPD)
Proposed with B-heavy molasses
(ethanol 140 KLPD)
I Fresh water
1 Process (syrup / molasses dilution) 559 513
2 Incineration boiler 184 184
3 Lab 3 3
4 CO2 scrubber 90 68
5 DM plant 19 19
Total 855 787
II Reuse/Recycle water
1 Spent wash recycle for syrup / molasses dilution 240 168
2
Reuse from distillery CPU for process
(molasses/syrup dilution)
407 135.5
3 Cooling tower make up from distillery CPU & RO 900 810
Total 1547 1113.5
Total (1 + 2) 2402 1900.5
Wastewater generation - distillery
31
Sl.
No.
Process route Wastewater generation in KLD
200 KLPD 140 KLPD
Cane juice B-heavy molasses
A Spent wash
1 Total spent wash generation 1200 840
Direct recirculation 240 168
Concentrated in MEE and then incinerated in incineration boiler 960 672
Treatment & disposal
Concentrated spent wash incinerated in incineration boiler 240 248
B Other process effluents
1 Spent lees 337 250
2 Condensate from MEE 840 554
Total 1177 804
C Other lean effluents
1 Cooling tower bleed 105 101
2 Incineration boiler blow-down 33 33
3 CO2 scrubber wastewater 90 68
4 Lab wastewater 3 3
5 DM rejects 19 19
Spent wash treatment and disposal
• Raw spent wash holding lagoon of capacity 5000 m3 is proposed.
• Spent wash of 12-15 % solids is concentrated in Multiple Effect Evaporators
to about 60% solids. Stored in SS tank of 500 m3.
• Concentrated spent wash incinerated in 45 TPH incineration boiler along
with coal as auxiliary fuel.
32
Wastewater Treatment
In all the scenarios the entire treated effluent from distillery is reused in the
process and cooling tower water makeup. The plant will work on the principle of
Zero Liquid Discharge 33
Sl. No. Process route Treatment and disposal
A Spent wash Out of the total raw spent wash generated, part of it is directly recirculated to
fermenter for dilution of syrup/B heavy molasses and the rest is concentrated in
MEE. Concentrated spent wash / slop is incinerated in incineration boiler.
B Other process effluents Spent lees, condensate from MEE, cooling tower bleed-off, incineration boiler
blow-down, CO2 scrubber wastewater, lab wastewater, DM rejects are treated in
CPU of 2000 KLD capacity.
The treated water from CPU is partially recycled for syrup/molasses dilution and
rest is used for cooling tower makeup. A part of this water will also be used for
greenery and spraying water on roads to curb dust in the premises.
1 Spent lees
2 Condensate from MEE
C Other lean effluents
1 Cooling tower bleed
2 Incineration boiler blow-
down
3 CO2 scrubber wastewater
4 Lab wastewater
5 DM rejects
Schematic representation treatment flow chart in CPU
34
Flow Chart of Condensate Polishing Unit (CPU)
Spent Lees,
Cooling Tower
Blowdown
Equalization cum
Neutralization
Biodigester
Degasser
Lemella Clarifier
Aeration Tank-1
Clarifier-1 Aeration tank-2 Clarifier-2
Storage Tank
Multi Grade Filter
Activated Carbon
Filter
Reverse Osmosis
(RO)
Reuse in Process
Power and steam requirement
35
Power requirement
36
Sl. No. Particulars Power requirement in MW
EC obtained
1 EC obtained, 60 KLPD 2
After expansion
1 Cane syrup to ethanol, 200 KLPD 2.5
2 B-heavy molasses to ethanol,140 KLPD 1.9
3 ENA (in-built provision), 60 KLPD 1
MAX POWER REQUIRED AT A POINT OF TIME 2.5
POWER GENERATED FROM CAPTIVE POWER PLANT 7.5, HENCE ADEQUATE
Steam requirement
37
Sl.
No.
Description Steam
requirement, TPH
EC obtained
1 EC obtained, 60 KLPD 16.75
After expansion
1 Cane juice syrup operation
Wash – absolute alcohol including evaporation
32
2 B heavy molasses operation
Wash - absolute alcohol including evaporation
29
Wash - ENA including evaporation 18
MAX STEAM DEMAND AT A POINT OF TIME 32
STEAM GENERATION CAPACITY OF INCINERATION BOILER 45, HENCE
Air environment- sources of air pollution &
control measures, air pollution dispersion
modelling studies, odour sources & control
measures
38
Sources of air pollution & control measures – EC obtained
39
39
Sl.
No.
Stack
attached to
Fuel consumption Stipulated standards
particulate matter
mg/Nm3, and others
as indicated
APC equipment and
stack height in m
Retained/
Dropped
EC OBTAINED
1 125 TPH (co-
gen sugar
plant)
Bagasse: 1500 TPD 150 Electro Static
Precipitator (ESP)
and stack of height –
85 m AGL.
Retained
2 22 TPH
incineration
boiler
Concentrated spent wash (CSW): 158 TPD and
coal: 11.6 TPD (CSW and coal ratio 85:15)
150 ESP and stack of
height – 40 m AGL
Dropped
3 1000 kVA DG
set
HSD: 235 LPH NOx: 710 ppmv
NMHC: 100 mg/Nm3
PM: 75 mg/Nm3
CO: 150 mg/Nm3
Acoustic enclosure
and stack of height
30 m AGL
Retained
Sources of air pollution & control measures – proposed new
40
40
Sl.
No.
Stack
attached to
Fuel consumption Stipulated standards
particulate matter
mg/Nm3, and others
as indicated.
APC equipment and
stack height in m
Retained/
Dropped
PROPOSED
4 45 TPH
incineration
boiler
Sugar syrup as feed stock: Concentrated spent
wash: 324 TPD and coal: 131 TPD
(CSW and coal ratio 54:46)
150 ESP and stack of
height 80 m AGL
New
proposed
B heavy molasses as feed stock: Concentrated
spent wash: 335 TPD and coal: 126 TPD
(CSW and coal ratio 56:44)
Purchased bagasse can also be used based on
availability
5 800 kVA DG
set
HSD: 200 LPH - Acoustic enclosure
and stack of height
9 m ARL
New
proposed
Ambient air quality status –
project site (28th July 2021)
• Ambient Air Quality monitoring is carried out during the construction period as per
Consent condition by NABL Accredited laboratory.
• The resultant concentration is within the prescribed National Ambient Air Quality
Standards.
41
Sl.
No.
Parameter Monitored
values in µg/m3
Ambient Air Quality
Standards - MoEF&CC
dated 16.11.2009
1 PM10 64.3 100
2 PM2.5 33.8 60
3 SO2 13.6 80
4 NOx 19.2 80
Air pollution dispersion modeling studies
INPUTS
Incremental increase of criteria air pollutants is predicted using AERMOD Lakes
Environmental Software, Version 19191.
42
Particular
Stack
height in m
Stack
Dia. in
m
Flue gas exit
gas temp in o C
Exit gas
velocity in m/s
PM10
g/s
SO2
g/s
NOx
g/s
Boiler 125 TPH 85 3.2 160 12 6.9 0.1 1.6
Boiler 45 TPH 80 1.7 180 12.5 1.6 0.9 0.6
Predicted incremental short-term concentrations
Description
Maximum
incremental
concentrations,
µg/m3
Baseline
concentration
(Oct to Dec 2017),
µg/m3
Resultant
concentrations,
µg/m3
Concentration
during
construction
phase, near
main gate,
µg/m3
(10-07-2021)
NAAQ
standards
µg/m3 dated
16-11-2009
Distance
&
direction
Particulate
Matter (PM)
2.38 71.9 74.28 64.3 100
0.5 km –
South East
Sulphur di-oxide
(SO2)
0.64 12.5 13.14 15.2 80
0.3 km -
East
Oxides of
Nitrogen (NOx)
0.7 22 22.7 17.6 80
0.5 km –
South East
43
Note:
• Baseline concentration is prior to EC.
• Resultant concentration after expansion will be within NAAQ standards.
Isopleth - PM10
44
Isopleth - SO2
45
Isopleth - NOx
46
Odour sources and control measures
47
Odour is generated from fermentation area, spent wash drains, storage tanks/lagoons, molasses handling area, compost
area, effluent treatment facility of sugar plant and yeast handling and storage area.
The odour control measures are as follows;
 Odour is controlled at source by cGMP practices.
 Fermenter lids to be closed, gaskets and seals to be periodically checked.
 Odour producing materials such as RS/ENA/Ethanol are stored in tanks with proper safety measures, as per
standard practices and regular monitoring of the fixtures such as gaskets, seals etc. to be carried out.
 Regular monitoring to be done for checking of any leakages in piping and fittings.
 Better housekeeping maintained to ensure good hygienic condition in the premises.
 Effluent drains of distillery and sugar plant to be kept clean for easy flow.
 Effluent treatment plant maintained on regular basis.
 Fragrance flowering trees or shrubs to be planted near odour generating areas like fermenter tanks, ETP etc.
 Odour from sources such as holding ponds/lagoons to be controlled by atomized spray of chlorine dioxide.
 Better cane management to avoid staling of sugar.
 Regular steaming of all fermentation equipment.
 Control of temperature during fermentation to avoid in-activation / killing of yeast.
Solid waste generation & management
48
Solid waste generation & management - distillery
49
Sl. No. Solid waste
Total proposed
after expansion
Utilization existing and after proposed
modification
1 Yeast sludge
50 KLPD for cane
juice
OR
36 KLPD for B-
heavy molasses
Given to farmers along with pressmud
to compost and reuse.
2
Ash from
incineration
boiler
155 TPD Given to brick manufacturers.
Hazardous waste generation & management
50
Hazardous waste generation & management
51
Waste
category
Hazardous
waste
Quantity Method of handling
5.1 Used oil 1.5 KL/annum
Stored in leak proof containers in secure
manner and handed over to KSPCB
authorized re-processors/incinerator or
used for lubrication within the industry.
33.2
Waste residues
containing oil
0.1
MT/annum
Stored in leak proof containers in secure
manner and handed over to KSPCB
authorized re-processors/incinerator or
burnt in in-house boilers.
Environmental Management Plan (EMP)
52
Environmental Management Cell
53
Sl.
No.
Designation Member
1 Chairman Managing Director
2 Executive
Officer
General Manager
3 Convener Environmental
Officer
4 Other
department
heads
Manager (Sugars)
Manager (Power)
Manager (Distillery)
Manager (H. R.)
Chief Accounts
Officer
Chief Chemist
Security Officer
Cane Dev. Officer
Environmental
Engineer
Civil Engineer
Members
Environmental Management Plan – construction phase
54
Sl.
No.
Activity Impact Duration Mitigation measure Significance
1 Air environment
 Civil work like
levelling, excavation,
material unloading,
construction, erecting
etc.
 Vehicles used for
transporting
construction material
could result in
emissions to
environment.
 Gas cutting and
welding jobs – the
release of gaseous
pollutants.
 Construction debris
unloading and loading.
 On ambient
air quality –
generation of
airborne
particles.
 Effect on
respiratory
system of the
workmen.
 Deposit on
the
vegetation/
green belt.
Short
term
 To use well-maintained construction
machinery & vehicles.
 Construction materials to be stored in a
barricaded area and covered to avoid dust
getting air borne.
 To sprinkle water to suppress the dust
generated during levelling, excavation, and
other operations.
 The welding and cutting jobs to be carried out
with adequate ventilation/exhaust
arrangement.
 Collection of debris at designated places and
to cover in order to avoid fugitive emissions.
The debris to be disposed at low laying areas
or used in road making in consultation with
local body.
 Water sprinkling on internal roads to avoid
fugitive dust due to vehicle movement.
 To deploy transport vehicles having emission
under control test report.
Low and
reversible
Environmental Management Plan – construction phase
55
Sl.
No.
Activity Impact Duration Mitigation measure Significance
2 Noise environment
 Vehicular movement
carrying construction
materials.
 Some intermittent noise
is expected during
fabrication at site and
erection of equipment.
 Erection of machineries.
 Increased noise
level at work
zone.
 Hearing
impairment
 Irritation
Short
term
 To cover the work zone with barricades.
 To provide suitable PPE to personnel.
 To carry out the civil works only during day time
and to monitor and regulate the vehicular
movement.
Low and
reversible
3 Water environment
 Run off carrying silt
from accumulated
debris, construction
material etc.
 Domestic sewage from
workers.
Increase in
turbidity and
suspended solids
of surface water
quality.
Short
term
 Potable STP to be provided for treatment of
sewage from construction workers.
 Construction debris to be stored in a designated
place and covered to avoid washing off with
rain water.
 The debris to be disposed at low laying areas or
used in road making to avoid water logging at
construction site and also at disposal sites.
Low and
reversible
Environmental Management Plan – construction phase
56
Sl.
No.
Activity Impact Duration Mitigation measure Significance
4 Land environment
 Disposal of
excavated soil and
debris may result
in water logging
and loss of fertile
topsoil.
 Spillage of oil and
grease.
 Siltation of drains
 Deposition on vegetation
and property
Long term  To adopt soil conservation by proper
management viz., the excavated earth
collected and used for foundation,
levelling, plinth and disposed to low laying
areas, road works.
 To separate the top soil and use it for
gardening.
 To collect the spillage if any and dispose
scientifically.
Low and
irreversible
5 Ground water &
surface water
 Accumulation of debris
and runoff during rains.
 Domestic sewage from
construction workers
contaminating surface
drains.
Short
term
 Proper drainage system will be provided.
 Providing and strengthening greenbelt in
and around plant.
 Storage of construction material and debris
in a secured manner, to avoid runoff with
rain water.
Low and
reversible
6 Socio economics Employment opportunities Short
term
 Employment opportunities for skilled and
unskilled manpower.
Low and
beneficial
7 Ecology and bio
diversity
Flora, fauna, terrestrial and
aviation species.
No impact  As project site is vacant land, there will be
no impact on ecology and bio diversity.
-
EMP - operation phase - air environment
57
Source of
impact
Predicted impacts Mitigation measures Remarks
 CO2 emission
from
fermentation.
 Emissions
from boilers
 Emissions
form DG sets
 Vehicular
movement
 ETP area
 Solid and
hazardous
waste storage
area
 Greenhouse gas emission
contributing to global
warming.
 Odour nuisance.
 Anticipated incremental
increase in the baseline
concentration due to the
industry are PM10 2.38
µg/m3, SO2 0.64 µg/m3 &
NOx 0.7 µg/m3.
 To provide CO2 bottling plant.
 To provide ESP and chimney height of 85 m AGL for sugar
and co-gen boiler
 To provide ESP and 80 m AGL chimney for incineration
boiler.
 To provide for water sprinkling on internal roads to avoid
fugitive dust due to vehicle movement.
 To deploy transport vehicles having ‘emission under
control’ test report.
 To maintain the air pollution control equipments
provided to boilers.
 Finished product ethanol to be transferred using
automatic pumping system to the storage tanks provided
with tank farms.
 To maintain good housekeeping in the process area and
also inside industry premises.
 To maintain the DG sets and stacks of 8 m for 800 kVA and
30 m height for 1000 kVA.
Low
adverse
impact
(localized
in nature).
EMP - operation phase - air environment Cont…
58
Source of
impact
Predicted impacts Mitigation measures Remarks
Same as in
previous slide
 Emissions will impact the air
quality. Increase in particulate
matter concentration in AAQ,
results in respiratory problems in
humans, deposits on vegetation
and agricultural crops affecting
photosynthesis, plant growth,
yield etc.
 Effect on human health like
nausea, asthma, eye irritation.
 To practice regular maintenance of vehicles,
regular cleaning and watering of internal roads
and to regulate the movement of vehicles.
 To clean the spent wash, drain periodically.
 To reduce the storage time of spent wash to avoid
odour.
 Fragrance flowering trees or shrubs to be planted
near odour generating areas like ETP etc.
Low
adverse
impact
(localized
in
nature).
EMP - operation phase - noise
59
Source of impact Predicted impacts Mitigation measures Remarks
 Noise from
operation of
machineries,
motor pumps,
compressors
 Operation of
boilers, TGs, DG
sets.
 Vehicular
movement.
 Process section.
 Transportation
of raw materials
and finished
products.
 Operation of
utilities.
The nearest place of
habitation is Banakatti at a
distance of about 2 km
towards North from the
industry.
Hence impact on the village
is not anticipated.
 Ambient noise levels to be monitored at industry
boundary at regular intervals.
 To make mandatory for the workers and officers to
use PPE (ear plugs)/ear muffs in high noise area/s.
 To house motor pumps, compressors in enclosures.
 To maintain machineries and conveying system by
following routine and periodic maintenance to
reduce noise generation.
 DG sets and TG are within acoustic enclosures.
 Boilers – silencers to be provided to steam safety
valves and steam straps are to be provided to
steam main pipelines.
 To regulate the speed limit inside plant and
transportation to be done only during peak hours.
 To develop and maintain greenbelt at the project
site boundary.
Low adverse
impact
(localized in
nature)
EMP - operation phase - water environment
60
Source of impact Predicted impacts Mitigation measures Remarks
Discharge of
process effluents
from distillery viz.,
spent wash and
spent lees, utility
effluent boiler
blow down, cooling
tower bleed,
condensate from
MEE etc.
 Sugar and co-gen effluent
770 KLD.
 Max 1200 KLD of spent
wash and 337 KLD of spent
lees are generated from
distillery.
 Sewage generation is 32
KLD.
Water pollution affecting
surface and ground water
quality.
 To treat the sugar plant effluent in ETP and to use
300 KLD for green-belt/irrigation. Balance 470 KLD
to be treated with CPU, stored and reused during
off-season as per CTE.
 Spent wash from distillery to be concentrated in
MEE and used as fuel in incineration boiler.
 To explore the possibility of providing bio-
methanization plant between MEE and incineration
boiler to harvest bioenergy.
 Condensate from MEE along with spent lees,
cooling tower bleed-off, incineration boiler blow-
down, CO2 scrubber wastewater, lab wastewater,
DM rejects are treated in CPU of 2000 KLD capacity.
 To adopt ZLD concept for treatment and use for
distillery effluent.
 To store the raw materials and finished products in
dedicated storage area/tank farm.
Low adverse
impact
(localized in
nature)
EMP - operation phase - land environment
61
Source of impact Predicted
impacts
Mitigation measures Remarks
 Accidental spillage of
finished products.
 Spillage/ disposal of
hazardous waste
 Disposal of press mud
from sugar plant
 Disposal of yeast
sludge.
 Disposal of sludge
from the ETP.
 Disposal of disposal of
ash from the bagasse
fired boiler and
incineration boiler.
Land
contaminat
ion.
Leaching
into
ground.
Eye sore.
 Soil quality to be tested and studied each season.
 To follow the concept of ZLD for distillery effluent management;
treated wastewater reused in cooling tower makeup and for
dilution of molasses/sugar syrup.
 To segregate domestic solid wastes at source. The wet waste be
composted and the inert dry waste be disposed to authorized
recyclers.
 To cordon the accidental spillage of sugar syrup/molasses/spent
wash if any, take to respective holding tanks or spent wash holding
tank.
 To store the used oil in the secured manner and dispose to
authorized vendors.
 To collect and store yeast sludge, ash in a designated area.
Incineration ash given to brick manufacturers; Yeast sludge given
to farmers along with pressmud to compost and reuse. Sludge
from activated sludge process used as compost within the site.
No
significant
impact
EMP - operation phase – solid waste
62
Source of impact Predicted impacts Mitigation measures Remarks
 Disposal of yeast
sludge.
 Disposal of ash
from
incineration
boiler.
 Disposal of ash
from cogen
boiler.
 Anticipated solid waste
generation
 Ash from co-gen boiler –
10 TPD
 Ash from incineration
boiler – 155 TPD
 Yeast sludge – 50 KLPD
 Land contamination.
 Leaching into ground.
 Eye sore to the public.
 To collect the solid waste in a secured manner.
 Disposal and management as detailed above.
Low adverse
impact
(localized in
nature)
EMP - operation phase – socio-economics & biodiversity
63
Source of impact Predicted impacts Mitigation measures Remarks
Socio-economics
 Employment of
local people.
 Socio economic impact  To employ locally available manpower to the
maximum possible extent based on qualification.
 To engage the local people for raw material supply,
transportation and security system.
 To aim at capacity building by skill development to
encourage the local people to take up job in the
factory.
 To aim at development of local infrastructure
facility.
 To take up development of social facilities like
construction of temple, educational facilities etc.
Strongly
beneficial
(positive)
impact
Biodiversity
 Operation of
distillery, sugar
and
cogeneration
Impact on flora, and fauna
due to the noise and
emission from the boilers
 To keep all the pollution control facilities in
operating condition and to meet the regulatory
compliance and beyond to ensure that the
biodiversity is not affected.
 No trees shall be cut.
No significant
impact
EMP - operation phase - traffic management
• The entry and exit of vehicles to be organized effectively so that the movement of vehicles do
not disturb or create traffic jam for other public transport vehicles.
• Erection of traffic signs at strategic locations.
• Covering of vehicles carrying bagasse, ash & press mud with tarpaulin to avoid spillage.
64
Sl.
no.
Vehicle type Total, no.s
1 Heavy tankers for ENA & ethanol 20
2 Heavy vehicles (JCB, hydra, tractors) for sugarcane
transport, press mud & ash transport
JCB & hydra- 05, sugarcane
transport tractors –750
3 Four-wheeler for factory employees (car, jeeps) 4
4 Two wheelers for factory employees, visitors/cane growers
(bikes, scooters)
4
5 Buses 2
Environmental monitoring program
65
Sl.
No.
Particulars Monitoring frequency Duration of
monitoring
Important parameters
for monitoring
Air environment
1 Ambient air quality within
project premises – one each at
downwind, up wind &
crosswind directions.
Twice a month during
crushing season and bi-
monthly during the
rest of the year.
48 hours (2
consecutive
days)
PM10, PM2.5, NOx, SO2,
CO
2 Stack monitoring
a. Boiler stack- 125 TPH
b. Incineration boiler 45 TPH
c. DG set stack attached to
1 x 1000 KVA
 Monthly for boilers
& online
monitoring
 Bi-annually for
1000 KVADG
Grab &online
monitoring
SPM, SO2, NOx
Environmental monitoring program
66
Sl.
No.
Particulars Monitoring
frequency
Duration of
monitoring
Important parameters for
monitoring
Noise environment
3 At the boundary of
the factory.
During crushing
season
Day and night Noise level in dB (A) Leq.
Water environment
4 Raw spent effluent Once a week Grab pH, TSS, TDS, total solids, COD,
BOD, potash, chloride and
phosphate
5 Concentrated spent
wash
Once a week Grab pH, COD, BOD, total solids
6 All intermediate
stages of ETP/CPU
Once a week Grab pH, TSS and COD
Min once a day Grab pH and COD
Environmental monitoring program
67
Sl.
No.
Particulars Monitoring
frequency
Duration of
monitoring
Important parameters for
monitoring
Water environment
7 Treated effluent
sugar plant ETP outlet
Once a week Grab and
online
monitoring
pH, TSS, TDS, COD, BOD, potash,
chloride and phosphate
Online monitoring of pH, BOD,
COD and TSS
Min once a day Grab pH, MLSS
8 Ground water /
piezometer monitoring
within industry site
Twice a year.
Before and after
monsoon
Grab pH, BOD, COD and total solids
Soil environment
9 Within project premises at
two locations near
hazardous waste storage
and effluent storage.
Once in a year Composite
sample
EC, organic carbon, pH, available
NPK
Test procedure and the cost of monitoring
68
Sl.
no.
Particulars Methods of monitoring Cost of monitoring in Rs. Amount in Rs.
per year
Air environment
1 Ambient air quality at
project premises
PM2.5: IS 5182:part-23: 2006
PM10: IS 5182:part-23: 2006
SO2: IS 5182:part-2: 2001
NOx: IS 5182:part-6: 2006
25,950 per station. To
monitor three stations.
9,34,200
2 Stack monitoring –
process section
a. Boilers
b. DG set
PM: IS 11255:part-1: 1985
SO2: IS 11255:part-2: 1985
NOx: IS 11255:part-7: 2005
Rs. 6,650 per stack. Two
stacks of boiler
(monthly) and one stack
of DG (biannually)
1,72,900
Test procedure and the cost of monitoring
69
Sl.
no.
Particulars Methods of
monitoring
Cost of monitoring in Rs. Amount in Rs.
per year
Noise environment
1 Noise level at the
boundary of the factory.
Sound level meter Rs. 3,500 per station.
Three stations; four times
per annum.
42,000
Water environment
1 Ground water /
piezometer
Standard analytical Rs. 2,400 per station. Two
piezometers sampled twice
a year
9,600
2 Raw and treated effluent. Procedure for water
by APHA and AWWA.
Monitoring in in-house lab
-
Test procedure and the cost of monitoring
70
Sl. no. Particulars Methods of monitoring Cost of monitoring in Rs. Amount in Rs.
per year
Soil environment
1 Soil within project
premises
Standard analytical
procedure.
Rs. 3,350 per sample at two
locations near hazardous waste
storage and effluent storage.
6,700
Total budget for monitoring 11,65,400
Or say
11,66,000
Rupees Eleven Lakhs Sixty Six Thousand Only
Budget allocation – environment management - capital
71
Sl. No. Application
Budget towards EMP,
Rupees
in Crores
1 Capital investment (sugar, co-gen and distillery)
1.1
Air pollution control facilities sugar and co-gen (ESP, stack and ash
handling)
20
1.2
Waste water treatment facilities -Establishment of
10.22
ETP & MEE,
Incineration boiler, ESP, Stack, ash handling 12
CPU 4.5
1.3 Noise pollution control 1
1.3 Green belt 0.5
1.4 Laboratory and monitoring facilities 10
1.5 Online monitoring system 1
1.6 Occupational Health & safety 0.5
1.7 Rain water harvesting 1.75
Total 61.47
Rupees Sixty One Crores Forty Seven Lakhs Only
Budget allocation – environment management - recurring
72
Sl. No. Application
Budget towards EMP,
Rupees
in Crores
2 Recurring cost of operation and maintenance in Crores
2.1 Air pollution control 0.5
2.2 Water pollution control 1
2.3 Monitoring cost 0.12
2.4 Maintenance and calibration of online monitors 0.02
2.5 Green-belt maintenance 0.1
2.6 Occupational health & safety 0.05
Total 1.79
Rupees One Crore Seventy Nine Lakhs Only
Budget allocation after proposed expansion for CER with target date
Corporate Environmental Responsibility - CER
73
Sl.
No.
Activity
Fund allocated,
Rupees Crores
Period of execution
in years from the
commencement of
project
1 Avenue plantation in community areas in surrounding
villages (Banakatti, Shirur, Kamatagi etc.)
3.0
5 years
2 Support for health care related to COVID ailments.
3 Gifting of tabs/books to underprivileged school
children
4 Providing drinking water facility to the surrounding
villages (Banakatti, Shirur, Kamatagi etc.)
Total 3.0 -
Rupees Three Crores Only
Occupational Health - budget
74
Occupational health hazards associated with the industrial activity
Sl.
No.
Activity Aspect Impact
1 Bagasse handling
/conveying
Air borne
dust
On respiratory system like
Chronic Obstructive
Pulmonary Disease (COPD)
2 Boilers/ DG sets
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
75
Preventive and corrective actions to reduce/eliminate occupational
health hazards
Sl.
No.
Occupational health
hazards
Preventive action Corrective action
1 Respiratory system Reduce dust getting airborne Periodic Medical
Examination – Spirometry
/ PFT / Pulse oxymetry
2 Noise Induced Hearing
Loss (NIHL) /
Cardiovascular
Disease/ Hypertension
1.Reduce noise at source by
changing design / proper
maintenance/ providing
acoustic enclosures
2.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
76
Sl.
No.
Activity Aspect Impact Preventive action Corrective
action
1 Bagasse handling
/conveying
Air borne dust On respiratory system
like chronic
obstructive
pulmonary disease
(COPD)
Reduce dust getting
airborne
Periodic
Medical
Examination –
Spirometry /
PFT / Pulse
oxymetry
2 Boilers/ DG
sets operation/
compressors
Noise Noise Induced
Hearing Loss (NIHL) /
cardiovascular
disease/
hypertension
1. Reduce noise at source
by changing design /
proper maintenance/
providing acoustic
enclosures
2. Provide PPE
Audiometry
3 Molasses
handling
Odour Headache/nausea Control odour at source by
providing high rise vents
Job rotation
4 Boiler operation Exposure to
heat
Heat exhaustion Proper location/design of
operator cabin
Job rotation
Occupational health hazards & ppreventive and corrective actions
to reduce/eliminate them
77
Health check-up parameters
Sl. No. Test Details
1 Physical Fitness Certificate
2 Pulse
3 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)
78
Budget for occupational health
Sl. No. Particulars Budget Rs. per annum
1 Periodic medical examination 7,00,000
3 Personal Protective Equipment like gloves, safety shoes,
aprons, goggles, Self-contained breathing apparatus (SCBA)
3,00,000
4 Training on occupational health & safety 1,00,000
Total Rs. 10.00 Lakhs
/Annum
79
Risk safety measures
a. Fire hydrant systems will be provided all around the industry.
b. Workplace specific PPEs will be provided for workers at the industry to ensure their safety.
c. All storage tanks to be constructed in line with PESO guidelines.
d. Dyke walls will be provided as per PESO requirement.
e. Occupational health and safety monitoring at regular intervals.
f. Regular health check-ups of workers and maintenance of records.
g. Regular safety training and fire fighting mock drills.
h. Only trained persons deployed for industrial operations.
80
Identified
hazard
Precautions taken Mitigation measures
Fire
• There shall not be any electrical overhead lines in ethanol
storage tank area.
• All ethanol storage area pipelines will have jumper for avoiding
static electricity.
• All tank thickness test will be done by competent person.
• All tanks and motors will have proper earthing system and
double earthing.
• Flameproof type lighting system will be provided for controlling
of spark.
• Portable fire extinguishers will be
provided at identified locations in
distillery section.
• Sand buckets will be provided.
• Entire plant will be covered with
fire hydrant line and foam monitor
system.
• Warning and informatory signage’s
will be displayed.
• Mobile usage prohibited in distillery plant.
• No smoking allowed in factory premises.
• Flameproof motors will be provided in distillery section.
• Welding and gas cutting prohibited in distillery section premises.
• Work permit followed for all high risk work.
• Firefighting training will be
provided to all employees.
• Mock drill will be conducted once
in 2 months.
Risk mitigation measures – ethanol plant
General safety measures/precautions to be followed
 All the work places will be provided with MSDS of chemicals & materials being
handled. The concerned employees will be trained and all the employees will be
made aware of the hazards in handling chemicals.
 Inspection and preventive & breakdown maintenance of all the equipment
including pollution control equipment will be undertaken.
 Compulsory use of necessary PPEs.
 Installation of fire extinguishers at required places.
 Regular work place monitoring.
 Provision of part time qualified medical officer as per factories act guidelines.
 Regular medical check-up of employees by qualified medical practioner.
 Monitoring of occupational hazard parameters like noise, ventilation, chemical
exposure at frequent intervals.
 Display of various instruction boards, cautionary notices etc., at different
locations.
82
Green belt development
 Out of 40.87 hectares of the integrated sugar plant and distillery complex, 33 % i.e, 13.47 hectares
(33.29 acres) is earmarked for the green belt development
 Number of trees to be planted for 13.47 hectares is 20,205 at the rate of 1500 trees per hectare as
per guidelines.
 3000 tree saplings of Hebbevu (Melia dubia) have already been planted.
 Number of trees to be planted is 17,205.
83
Rain water harvesting
 Rainwater harvesting potential of the site = 816 m3
 A rain water harvesting tank / pond of total holding capacity 1500 m3 is proposed
for collection and reuse of rain water.
 Groundwater recharge pits of 4 x 10 x 3 m filled with graded media comprising of
boulder at bottom and with coarse aggregates to facilitate percolation to recharge
ground water table will be provided at different locations within the premises.
84
Rating of impact matrix
Identification and Rating of Environmental Impacts
Sl.
No.
Activity Cause/Aspect
Impact
Scale
1 to 5
Severity
1 to 5
Probability
1 to 5
Duration
1 to 5
Significance
rating =
S x S x P x D
Construction phase
1
Erection of
machineries
Dust getting airborne 1 1 5 2 10
Noise nuisance 2 1 3 2 12
Spillage of oil 1 1 2 2 4
Gaseous emissions 1 1 1 1 1
Domestic waste generation 1 1 3 2 6
85
86
Operation phase
1 Operation of boilers
Air emissions 3 2 5 2 60
Wastewater generation 1 1 5 1 5
2
Operation of DG set
and TG sets
Air emissions 3 1 2 2 12
Noise nuisance 1 1 5 1 5
3
Manufacturing
activity and ZLD
operation
Fugitive emissions 2 1 3 2 12
Noise due to machinery 1 1 5 1 5
Domestic sewage 2 1 5 1 10
Wastewater from utility 2 1 5 1 10
Wastewater from process 3 2 5 2 60
Domestic solid waste 1 1 5 1 5
Hazardous waste 1 1 2 1 2
Those impacts with SSPD score of 24 and above are considered as most significant.
Rating of impact matrix
Criteria for rating scale, severity, probability and duration
Scale S Rating Severity S Rating
At the work area 1 Minor Injury requiring first aid 1
Within premises 2 Injury requiring hospitalization 2
Outside premises in 1 km radius 3 Temporary disability 3
Outside Premises beyond 1 km & less
than 5 km radius
4 Permanent disability 4
Beyond 5 km radius 5 Loss of life/s 5
Probability of Occurrence P Rating Duration D Rating
Once a Year 1 Less than 1 hour 1
Once a month 2 Less than 4 hours 2
Once a week 3 One day 3
Daily but intermittently 4 More than a day 4
Continuous 5 Few months 5
87
Severity mapping
• The Severity mapping has been carried out using the ALOHA Areal Locations of
Hazardous Atmospheres) software 5.4.7.
• 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).
88
Threat zone mapping
89
Storage capacities
90
Sl. No. Description of the storage tank No. of tanks Capacity, KL
Raw materials
1 Molasses 4 10,000 MT each
2 Syrup buffer tank 1 250 m3
Products
1 RS bulk storage tank 2 1500 each
2 ENA storage tanks 2 1500 each
3 IS storage tank 1 200
4 Ethanol storage tanks 5 2270 each
Day receiver
1 Hydrous alcohol and impure spirit (rectified
spirit)
3 132 each
2 Fuel ethanol 9 126 each
3 Extra Neutral Alcohol (ENA) 3 132 each
4 IS 2 15 each
5 Ethanol issue tanks 3 295 each
By-products / Intermediates / Waste
1 Spent wash feed tank 1 60 m3
Aloha simulation analysis
Summary of MCA analysis - Ethanol
91
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
recommende
d
LOC value --- (N/A =
ERPG-3)
Flammable
area of vapour
cloud
17 19800 ppm = 60% LEL =
flame pockets
2 Leaking tank chemical
is burning and forms a
pool fire
Thermal
radiation from
pool fire
13 10.0 kW/(sq m) =
potentially lethal within
60 sec
CONCLUSION AND PRAYER
• The proposed project is distillery expansion to manufacture ethanol under Ethanol
Blended with Petrol (EBP) 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.
• Self declared notarized affidavit has been made that the ethanol produced from the
proposed project will be supplied as bio-ethanol for the purpose of blending with
petrol under EBP programme.
M/s. Mellbro Sugars Pvt. Ltd. humbly requests the committee to kindly
recommend the proposal for grant of Environmental Clearance
92
Thank You
93

More Related Content

Similar to 24082021lkmnz2tiu2k89025662pptMellbro45TPH1 - Repaired.pptx

Dakshina kannada Lok adalath
Dakshina kannada Lok adalath  Dakshina kannada Lok adalath
Dakshina kannada Lok adalath
prakash_dcpa
 
Success story of tidal swamp farming system in barito kuala
Success story of tidal swamp farming system in barito kualaSuccess story of tidal swamp farming system in barito kuala
Success story of tidal swamp farming system in barito kuala
pdatarawa
 

Similar to 24082021lkmnz2tiu2k89025662pptMellbro45TPH1 - Repaired.pptx (20)

Suthep Liumsirijarern: Biofuels Perspectives and Policies
Suthep Liumsirijarern: Biofuels Perspectives and PoliciesSuthep Liumsirijarern: Biofuels Perspectives and Policies
Suthep Liumsirijarern: Biofuels Perspectives and Policies
 
Indonesia achievement on conservation and sustainable peatland management
Indonesia achievement on conservation and sustainable peatland managementIndonesia achievement on conservation and sustainable peatland management
Indonesia achievement on conservation and sustainable peatland management
 
Ntpc report
Ntpc reportNtpc report
Ntpc report
 
training report NTPC Muzaffarpur Bihar
training report  NTPC Muzaffarpur Bihar training report  NTPC Muzaffarpur Bihar
training report NTPC Muzaffarpur Bihar
 
A summer training report on NTPC
A summer training report on NTPCA summer training report on NTPC
A summer training report on NTPC
 
A summer traning report on ntpc
A summer traning report on ntpcA summer traning report on ntpc
A summer traning report on ntpc
 
EIA - SEWAGE WATER TREATMENT PLANT FFC MIRPUR MATHELO
EIA - SEWAGE WATER TREATMENT PLANT FFC MIRPUR MATHELOEIA - SEWAGE WATER TREATMENT PLANT FFC MIRPUR MATHELO
EIA - SEWAGE WATER TREATMENT PLANT FFC MIRPUR MATHELO
 
Rice husk based cogeneration power plant for finance, subsidy & project rel...
Rice husk based cogeneration power plant   for finance, subsidy & project rel...Rice husk based cogeneration power plant   for finance, subsidy & project rel...
Rice husk based cogeneration power plant for finance, subsidy & project rel...
 
Rice husk power plant information for finance, subsidy & project related su...
Rice husk power plant information   for finance, subsidy & project related su...Rice husk power plant information   for finance, subsidy & project related su...
Rice husk power plant information for finance, subsidy & project related su...
 
Ghazi Barotha Hydropower project Internship Report
Ghazi Barotha Hydropower project Internship ReportGhazi Barotha Hydropower project Internship Report
Ghazi Barotha Hydropower project Internship Report
 
Bagalkote District profile
Bagalkote District profileBagalkote District profile
Bagalkote District profile
 
Solar power plants in rajasthan
Solar power plants in rajasthanSolar power plants in rajasthan
Solar power plants in rajasthan
 
Dakshina kannada Lok adalath
Dakshina kannada Lok adalath  Dakshina kannada Lok adalath
Dakshina kannada Lok adalath
 
Indonesia regulation on peatland ecosystem: criteria, indicators, and monitor...
Indonesia regulation on peatland ecosystem: criteria, indicators, and monitor...Indonesia regulation on peatland ecosystem: criteria, indicators, and monitor...
Indonesia regulation on peatland ecosystem: criteria, indicators, and monitor...
 
Rice Mill ToR (1).pptx
Rice Mill ToR (1).pptxRice Mill ToR (1).pptx
Rice Mill ToR (1).pptx
 
Indian power sector 2017
Indian power sector 2017Indian power sector 2017
Indian power sector 2017
 
BEST REAL ESTATE COMPANY IN PATNA
BEST REAL ESTATE COMPANY IN PATNABEST REAL ESTATE COMPANY IN PATNA
BEST REAL ESTATE COMPANY IN PATNA
 
DDDF.docx
DDDF.docxDDDF.docx
DDDF.docx
 
Success story of tidal swamp farming system in barito kuala
Success story of tidal swamp farming system in barito kualaSuccess story of tidal swamp farming system in barito kuala
Success story of tidal swamp farming system in barito kuala
 
Bccl VT Report pb 132Kv substation by rahul kumar saw & prabhat agarwal bit...
Bccl VT Report pb 132Kv  substation by rahul kumar saw & prabhat agarwal  bit...Bccl VT Report pb 132Kv  substation by rahul kumar saw & prabhat agarwal  bit...
Bccl VT Report pb 132Kv substation by rahul kumar saw & prabhat agarwal bit...
 

Recently uploaded

XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX
XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX
XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX
ssuser89054b
 
Digital Communication Essentials: DPCM, DM, and ADM .pptx
Digital Communication Essentials: DPCM, DM, and ADM .pptxDigital Communication Essentials: DPCM, DM, and ADM .pptx
Digital Communication Essentials: DPCM, DM, and ADM .pptx
pritamlangde
 
Standard vs Custom Battery Packs - Decoding the Power Play
Standard vs Custom Battery Packs - Decoding the Power PlayStandard vs Custom Battery Packs - Decoding the Power Play
Standard vs Custom Battery Packs - Decoding the Power Play
Epec Engineered Technologies
 
1_Introduction + EAM Vocabulary + how to navigate in EAM.pdf
1_Introduction + EAM Vocabulary + how to navigate in EAM.pdf1_Introduction + EAM Vocabulary + how to navigate in EAM.pdf
1_Introduction + EAM Vocabulary + how to navigate in EAM.pdf
AldoGarca30
 

Recently uploaded (20)

S1S2 B.Arch MGU - HOA1&2 Module 3 -Temple Architecture of Kerala.pptx
S1S2 B.Arch MGU - HOA1&2 Module 3 -Temple Architecture of Kerala.pptxS1S2 B.Arch MGU - HOA1&2 Module 3 -Temple Architecture of Kerala.pptx
S1S2 B.Arch MGU - HOA1&2 Module 3 -Temple Architecture of Kerala.pptx
 
NO1 Top No1 Amil Baba In Azad Kashmir, Kashmir Black Magic Specialist Expert ...
NO1 Top No1 Amil Baba In Azad Kashmir, Kashmir Black Magic Specialist Expert ...NO1 Top No1 Amil Baba In Azad Kashmir, Kashmir Black Magic Specialist Expert ...
NO1 Top No1 Amil Baba In Azad Kashmir, Kashmir Black Magic Specialist Expert ...
 
XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX
XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX
XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX
 
Digital Communication Essentials: DPCM, DM, and ADM .pptx
Digital Communication Essentials: DPCM, DM, and ADM .pptxDigital Communication Essentials: DPCM, DM, and ADM .pptx
Digital Communication Essentials: DPCM, DM, and ADM .pptx
 
Unit 4_Part 1 CSE2001 Exception Handling and Function Template and Class Temp...
Unit 4_Part 1 CSE2001 Exception Handling and Function Template and Class Temp...Unit 4_Part 1 CSE2001 Exception Handling and Function Template and Class Temp...
Unit 4_Part 1 CSE2001 Exception Handling and Function Template and Class Temp...
 
💚Trustworthy Call Girls Pune Call Girls Service Just Call 🍑👄6378878445 🍑👄 Top...
💚Trustworthy Call Girls Pune Call Girls Service Just Call 🍑👄6378878445 🍑👄 Top...💚Trustworthy Call Girls Pune Call Girls Service Just Call 🍑👄6378878445 🍑👄 Top...
💚Trustworthy Call Girls Pune Call Girls Service Just Call 🍑👄6378878445 🍑👄 Top...
 
Electromagnetic relays used for power system .pptx
Electromagnetic relays used for power system .pptxElectromagnetic relays used for power system .pptx
Electromagnetic relays used for power system .pptx
 
Ground Improvement Technique: Earth Reinforcement
Ground Improvement Technique: Earth ReinforcementGround Improvement Technique: Earth Reinforcement
Ground Improvement Technique: Earth Reinforcement
 
Standard vs Custom Battery Packs - Decoding the Power Play
Standard vs Custom Battery Packs - Decoding the Power PlayStandard vs Custom Battery Packs - Decoding the Power Play
Standard vs Custom Battery Packs - Decoding the Power Play
 
Ghuma $ Russian Call Girls Ahmedabad ₹7.5k Pick Up & Drop With Cash Payment 8...
Ghuma $ Russian Call Girls Ahmedabad ₹7.5k Pick Up & Drop With Cash Payment 8...Ghuma $ Russian Call Girls Ahmedabad ₹7.5k Pick Up & Drop With Cash Payment 8...
Ghuma $ Russian Call Girls Ahmedabad ₹7.5k Pick Up & Drop With Cash Payment 8...
 
Design For Accessibility: Getting it right from the start
Design For Accessibility: Getting it right from the startDesign For Accessibility: Getting it right from the start
Design For Accessibility: Getting it right from the start
 
School management system project Report.pdf
School management system project Report.pdfSchool management system project Report.pdf
School management system project Report.pdf
 
UNIT 4 PTRP final Convergence in probability.pptx
UNIT 4 PTRP final Convergence in probability.pptxUNIT 4 PTRP final Convergence in probability.pptx
UNIT 4 PTRP final Convergence in probability.pptx
 
1_Introduction + EAM Vocabulary + how to navigate in EAM.pdf
1_Introduction + EAM Vocabulary + how to navigate in EAM.pdf1_Introduction + EAM Vocabulary + how to navigate in EAM.pdf
1_Introduction + EAM Vocabulary + how to navigate in EAM.pdf
 
Online electricity billing project report..pdf
Online electricity billing project report..pdfOnline electricity billing project report..pdf
Online electricity billing project report..pdf
 
457503602-5-Gas-Well-Testing-and-Analysis-pptx.pptx
457503602-5-Gas-Well-Testing-and-Analysis-pptx.pptx457503602-5-Gas-Well-Testing-and-Analysis-pptx.pptx
457503602-5-Gas-Well-Testing-and-Analysis-pptx.pptx
 
AIRCANVAS[1].pdf mini project for btech students
AIRCANVAS[1].pdf mini project for btech studentsAIRCANVAS[1].pdf mini project for btech students
AIRCANVAS[1].pdf mini project for btech students
 
Jaipur ❤CALL GIRL 0000000000❤CALL GIRLS IN Jaipur ESCORT SERVICE❤CALL GIRL IN...
Jaipur ❤CALL GIRL 0000000000❤CALL GIRLS IN Jaipur ESCORT SERVICE❤CALL GIRL IN...Jaipur ❤CALL GIRL 0000000000❤CALL GIRLS IN Jaipur ESCORT SERVICE❤CALL GIRL IN...
Jaipur ❤CALL GIRL 0000000000❤CALL GIRLS IN Jaipur ESCORT SERVICE❤CALL GIRL IN...
 
Theory of Time 2024 (Universal Theory for Everything)
Theory of Time 2024 (Universal Theory for Everything)Theory of Time 2024 (Universal Theory for Everything)
Theory of Time 2024 (Universal Theory for Everything)
 
PE 459 LECTURE 2- natural gas basic concepts and properties
PE 459 LECTURE 2- natural gas basic concepts and propertiesPE 459 LECTURE 2- natural gas basic concepts and properties
PE 459 LECTURE 2- natural gas basic concepts and properties
 

24082021lkmnz2tiu2k89025662pptMellbro45TPH1 - Repaired.pptx

  • 1. SUBMISSION BEFORE THE EAC (INDUSTRY II) FOR PROPOSED EXPANSION OF DISTILLERY UNDER EBP PROGRAM EXPANSION OF DISTLLERY FOR ETHANOL PRODUCTION FROM 60 KLPD TO 200 KLPD using B – heavy molasses / cane juice syrup By M/s. Mellbro Sugars Pvt. Ltd. Shirur Village, Bagalkot Taluk and District, Karnataka State - 587120 Environmental Consultant: Samrakshan, Bangalore NABET No : NABET/EIA/1922/IA0051
  • 2. 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
  • 4. Project proponent and environmental consultant 4 Sl. No. Particulars Details 1 Project proponent Kariyannavar S.V. Executive Director 2 Environmental Consultant M/s. Samrakshan, Bangalore NABET Registration No. NABET/EIA/1992/IA0051 Validity :24th July 2021 3 CEO of Samrakshan & EIA Coordinator Mr. S. Nanda Kumar
  • 5.  The proposal is for seeking Environmental Clearance under Notification S.O.2339(E) dated 16.06.2021 under EBP Program. To be appraised as B2 category  Proposed expansion of distillery to produce Ethanol from 60 KLPD to 200 KLPD The Proposal 5
  • 6. LOCATION OF THE PLANT 6 Existing industrial complex total land area: 100.99 Acres (40.87 hectares) Location: Sy. No.s 1054/1, 1054/2, 1054/3, 1055/1, 1055/2, 1061/1A, 1061/1B, 1061/2+3A, 1061/2+3B, 1061/2+3/K/1, 1061/2+3/K/2, 1062/3, 1062/2/A, 1062/2/B, 1063/1, 1063/2, 1064/1, 1064/2, 1064/3, 1065/1, 1065/3, 1065/4, 1065/2A, 1072/1, 1070/3, 1080/1, 1079/1A+1B/1, 1123/1, 1123/2, Shirur Village, Bagalkot Taluk and District, Karnataka State – 587120 Distillery plant: 4.51 Acres (1.82 Hectares)
  • 7. Project location and connectivity 7 M/s. Mellbro Sugar Pvt. Ltd. Land use pattern – industry complex Sl. No Particulars Area in SQM Area in Acres Area in hectares % of the land 1 Factory building & ancillary 70,890.58 17.52 7.09 17.3 2 Administrative & other buildings area 20,053.9 4.96 2.01 4.9 3 Distillery 18,242.9 4.51 1.82 4.5 4 Cane yard 1,06,900.76 26.42 10.69 26.2 5 ETP 8,400 2.08 0.84 2.1 6 Open space for scrap yard and dump 3,430.1 0.85 0.34 0.8 7 Reservoir area 500 0.12 0.05 0.1 8 Bagasse yard area 12,176 3.01 1.22 3.0 9 Roads 33,369.3 8.25 3.34 8.2 10 Tree plantation & greenbelt area 1,34,736.46 33.29 13.47 33.0 Total plot area 408700 100.99 40.87 100.0
  • 8. Reserve forests Reserve forest (eucalyptus plantation) located near Benakatti village 1.3 km - North Reserve forest located near Sirur 3.5 km - South Reserve forest (eucalyptus plantation) located near Mannikatti village 5.2 km – North West Nearest habitat Banakatti 2 km - North Water bodies Kadival Halla 3.9 km – North East Palati Halla 4.1 km - South East Malaprabha River 6.7 km – East Tumbu Halla 9.4 km – East Almatti dam 23 km – North West Ghatprabha River 12.7 km – North West 8 Topographical map Source: Survey of India; Topo map No. E43V16 & EV3V12
  • 9. Google map 9 Points w.r.t. google map Latitude Longitude A 16° 7'40.56"N 75°48'56.53"E B 16° 7'46.84"N 75°48'55.78"E C 16° 7'54.47"N 75°48'55.38"E D 16° 7'55.17"N 75°48'57.38"E E 16° 7'54.99"N 75°49'9.80"E F 16° 7'52.34"N 75°49'9.86"E G 16° 7'51.37"N 75°49'15.85"E H 16° 7'57.68"N 75°49'15.89"E I 16° 7'55.99"N 75°49'25.55"E J 16° 7'47.14"N 75°49'26.98"E K 16° 7'39.18"N 75°49'26.81"E L 16° 7'39.20"N 75°49'23.49"E M 16° 7'32.29"N 75°49'23.08"E N 16° 7'28.00"N 75°49'21.93"E O 16° 7'27.74"N 75°49'12.99"E P 16° 7'32.61"N 75°49'16.41"E Q 16° 7'36.64"N 75°49'16.31"E R 16° 7'37.21"N 75°49'8.70"E S 16° 7'40.42"N 75°49'8.88"E T 16° 7'40.61"N 75°49'12.29"E U 16° 7'44.40"N 75°49'12.16"E V 16° 7'44.28"N 75°49'8.60"E
  • 10. Appraisal requested under B2 category under MoEF Notification S.O.2339(E) dated 16.06.2021 Notification requirements Conformance Should have prior Environmental Clearance for the existing operation.  The Unit has prior EC issued by the Ministry. To submit application in Form 1 as per EIA Notification 2006 and EMP.  Application in Form 1, Form 2 along with Environmental Management Plan is submitted. Certificate from the CGWB regarding adequate availability of water.  Not applicable (Water source is River Malaprabha). Notarized Affidavit by proponent that ethanol produced from proposed project shall be used completely for EBP program.  Affidavit has been made that the ethanol produced from the proposed project will be completely utilized for EBP program. 10
  • 11. Appraisal requested under B2 category under MoEF Notification S.O.2339(E) dated 16.06.2021 Notification requirements Conformance Adherence to conditions related to distilleries  M/s. Mellbro Sugars Pvt. Ltd. is an integrated industry with sugarcane crushing capacity of 5000 TCD, co-generation power plant of 30 MW along with distillery. Construction and erection of machinery is in progress and the industry is yet to be commissioned.  Distillery of 60 KLPD for which prior Environment Clearance has been obtained has not yet been installed. However, it is now proposed to increase the capacity of the distillery unit from 60 KLPD to 200 KLPD and correspondingly the captive power generation from 2 to 7.5 MW.  Compliance report to the existing Environmental Clearance has been submitted to MoEF&CC, RO Bengaluru. The industry is new and yet to be commissioned for production. However, status of compliance report to the Consent To Establish (CTE) is obtained from Karnataka State Pollution Control Board (KSPCB). to the Consent To Establish (CTE) is obtained from Karnataka State Pollution Control Board (KSPCB) vide letter no. KSPCB/RO(BGK)/2021-22/454 dated 9th August 2021. 11
  • 12. Current approvals – EC & CTE 12 Sl. no. Approval Products and capacity Number and date of the consent Remarks 1 Environmental Clearance (EC) Sugar plant 5000 TCD of sugar cane, Co- generation plant 30 MW and Distillery 60 KLPD, capacity. F. No. J- 11011/380/2017- IA-II (I) dated 3rd September 2019 Prior EC 2 Consent to Establish (CTE) Consent Order No. CTE-318437 dated 18th June 2020 Construction and erection of machineries are in progress. Industry is planned to commission in the ensuing sugarcane crushing season.
  • 13. Loan approval from DFPD for expansion The Department of Food and Public Distribution, Directorate of Sugar & Vegetable Oils, Government of India has approved loan of Rs. 68.12 Crores initially for 60 KLPD distillery and further amount of Rs. 113.96 Crores for expansion to 200 KLPD along with incineration boiler under the Scheme for extending financial assistance to sugar mills for enhancement and augmentation of ethanol production capacity, vide letter F.No.4/1/2018-(BP & E) dated 2nd August 2019 and 5th January 2021 respectively. 13
  • 14. Details of activity / production capacity Particular Existing (EC obtained – construction in progress) capacity Proposed expansion capacity After expansion - total capacity Sugar plant 5000 TCD - 5000 TCD Co-generation 30 MW - 30 MW Distillery capacity (raw material B heavy molasses and sugarcane syrup) 60 KLPD (not erected) 140 KLPD 200 KLPD Ethanol production: 200 KLPD with sugar syrup feedstock OR 140 KLPD with B heavy molasses feedstock Captive power 2 MW 1.5 MW 7.5 MW 14
  • 15. Project details Sl. No. Particulars Details 1 Project activity schedule as per EIA notification 2006 & amendment Schedule 5 (g) – Distilleries 2 Cost of the project Unit Investment on EC obtained proposal Rs. Cores Revised investment cost in Rs. crores Sugar & cogen 251.85 - Distillery 79.41 (for 60 KLPD) 242.77 (for 200 KLPD) Total 331.26 242.77 3 Water source & requirement  Source: Malaprabha River – 6.7 km from industry towards East.  Quantity: Water drawl permission issued by Government of Karnataka to lift 2100 KLPD or 15.72 MCFt /year for the sugar and distillery complex.  Maximum fresh water requirement for distillery after expansion is 964 KLD. 4 Employees Sugar: 193; Cogen: 62; Distillery: 85 TOTAL: 340 15
  • 16. Sl. No. Particulars Details 5 CER fund allocation Rs. 3 Crores 6 Environmental cell A full fledged Environmental Cell will be established during operation phase. 7 Nearest highway SH 20 – Bachi, Raichur highway – 3.6 km – South 8 Nearest railway station Kadlimatti – 11.9 km – North 9 Nearest airport Belagavi Airport – 132 Km towards South West 10 Nearest village Banakatti – 2 km - North Project details Contd.. 16
  • 17. Sl. No. Particulars Details 12 Reserve forests • Reserve forest (eucalyptus plantation) located near Benakatti village - 1.3 km - North • Reserve forest located near Sirur – 3.5 km - South • Reserve forest (eucalyptus plantation) located near Mannikatti village – 5.2 km – North West 13 Ecologically sensitive zone within 10 km radius None 14 Nearest town Bagalkot – 16.2 km – North West 15 District headquarters Bagalkot – 16.2 km – North West Project Details Contd.. 17
  • 18. Layout plan of industry complex 21A 21A - RAINWATER HARVESTING TANK
  • 20. Land use / land cover classes in 10 km area around the project site 20 Sl. No. Land use Land cover classes Area (ha) Area (%) 1 Forest 4,061.18 12.97 2 Agriculture 13,162.84 42.05 3 Agriculture Harvest 9,105.93 29.09 4 Open / Agriculture Fallow 4,483.49 14.32 5 Built up 357.71 1.14 6 Water 128.95 0.41 12.97 42.05 29.09 14.32 1.14 0.41 Area % Forest Agriculture Agriculture Harvest Open / Agriculture Fallow Built up Water
  • 21. Typical process flow of ethanol manufacturing and effluent management 21 Bio-digestor (optional)
  • 22. Raw material requirement - distillery 22 Sl. No. Raw material and chemicals EC obtained 60 KLPD Total after proposed expansion 1 Sugar juice syrup - 726 KLPD (for 200 KLPD ethanol) 2 B-heavy molasses - 549 KLPD (for 140 KLPD ethanol) 3 Molasses 255 TPD - 4 Sulphuric acid 70 kg/day 600 kg/day 5 Caustic lye 70 kg/day 600 kg/day 6 Nutrient 4.25 kg/h 16 kg/h 7 Antifoam agent 3 kg/h 16 kg/h 8 Biocides - 2 kg/h 9 Cultured Yeast - For feedstock sugar syrup: 7.3 TPD B heavy molasses: 5.5 TPD
  • 23. Water environment-water requirement, water balance, wastewater generation, wastewater treatment facilities 23
  • 24. Water requirement 24 • Source: Malaprabha River – 6.7 km from industry towards East. • Quantity: Water drawl permission issued by Government of Karnataka to lift 2100 KLPD or 15.72 MCFt /year for the sugar and distillery complex. • In the EC the water requirement approved for sugar, cogen and distillery is 448 KLD during season and 868 KLD during off-season. • Maximum fresh water requirement for 200 KLPD distillery after expansion is 964 KLD.
  • 25. Distillery water use and wastewater generation 25
  • 26. Scenarios with feedstock requirement Sl. No. Feedstock Required quantity after distillery expansion, TPD Ethanol production capacity with feedstock, KLPD No. of working days for which feedstock is adequate 1 Sugar cane syrup 726 200 150 2 B-heavy molasses 549 140 52 3 Purchased molasses As per availability - - 26
  • 27. Fresh water use : 2.8 KL/KL of alcohol Concentrated spent wash generation : 1.2 KL/KL of alcohol 27 200 KLPD ethanol with sugar syrup as feedstock
  • 28. Fresh water requirement : 3.7 KL/KL of alcohol Concentrated spent wash generation : 1.8 KL/KL of alcohol 28 140 KLPD ethanol with B-heavy molasses as feedstock
  • 29. Comparison different scenarios 29 Sl. No. Feedstock / Raw material Ethanol produced, KLPD Fresh water requirement KL/KL of ethanol Raw spent wash generation KL/KL of ethanol Concentrated spent wash generation KL/KL of ethanol 1 Juice/syrup 200 2.8 6 1.2 2 B-heavy molasses 140 3.7 6 1.8
  • 30. Fresh water and recycle water for process and utilities 30 Sl. No. Particulars Fresh water requirement in KLD Proposed with sugarcane syrup (ethanol 200 KLPD) Proposed with B-heavy molasses (ethanol 140 KLPD) I Fresh water 1 Process (syrup / molasses dilution) 559 513 2 Incineration boiler 184 184 3 Lab 3 3 4 CO2 scrubber 90 68 5 DM plant 19 19 Total 855 787 II Reuse/Recycle water 1 Spent wash recycle for syrup / molasses dilution 240 168 2 Reuse from distillery CPU for process (molasses/syrup dilution) 407 135.5 3 Cooling tower make up from distillery CPU & RO 900 810 Total 1547 1113.5 Total (1 + 2) 2402 1900.5
  • 31. Wastewater generation - distillery 31 Sl. No. Process route Wastewater generation in KLD 200 KLPD 140 KLPD Cane juice B-heavy molasses A Spent wash 1 Total spent wash generation 1200 840 Direct recirculation 240 168 Concentrated in MEE and then incinerated in incineration boiler 960 672 Treatment & disposal Concentrated spent wash incinerated in incineration boiler 240 248 B Other process effluents 1 Spent lees 337 250 2 Condensate from MEE 840 554 Total 1177 804 C Other lean effluents 1 Cooling tower bleed 105 101 2 Incineration boiler blow-down 33 33 3 CO2 scrubber wastewater 90 68 4 Lab wastewater 3 3 5 DM rejects 19 19
  • 32. Spent wash treatment and disposal • Raw spent wash holding lagoon of capacity 5000 m3 is proposed. • Spent wash of 12-15 % solids is concentrated in Multiple Effect Evaporators to about 60% solids. Stored in SS tank of 500 m3. • Concentrated spent wash incinerated in 45 TPH incineration boiler along with coal as auxiliary fuel. 32
  • 33. Wastewater Treatment In all the scenarios the entire treated effluent from distillery is reused in the process and cooling tower water makeup. The plant will work on the principle of Zero Liquid Discharge 33 Sl. No. Process route Treatment and disposal A Spent wash Out of the total raw spent wash generated, part of it is directly recirculated to fermenter for dilution of syrup/B heavy molasses and the rest is concentrated in MEE. Concentrated spent wash / slop is incinerated in incineration boiler. B Other process effluents Spent lees, condensate from MEE, cooling tower bleed-off, incineration boiler blow-down, CO2 scrubber wastewater, lab wastewater, DM rejects are treated in CPU of 2000 KLD capacity. The treated water from CPU is partially recycled for syrup/molasses dilution and rest is used for cooling tower makeup. A part of this water will also be used for greenery and spraying water on roads to curb dust in the premises. 1 Spent lees 2 Condensate from MEE C Other lean effluents 1 Cooling tower bleed 2 Incineration boiler blow- down 3 CO2 scrubber wastewater 4 Lab wastewater 5 DM rejects
  • 34. Schematic representation treatment flow chart in CPU 34 Flow Chart of Condensate Polishing Unit (CPU) Spent Lees, Cooling Tower Blowdown Equalization cum Neutralization Biodigester Degasser Lemella Clarifier Aeration Tank-1 Clarifier-1 Aeration tank-2 Clarifier-2 Storage Tank Multi Grade Filter Activated Carbon Filter Reverse Osmosis (RO) Reuse in Process
  • 35. Power and steam requirement 35
  • 36. Power requirement 36 Sl. No. Particulars Power requirement in MW EC obtained 1 EC obtained, 60 KLPD 2 After expansion 1 Cane syrup to ethanol, 200 KLPD 2.5 2 B-heavy molasses to ethanol,140 KLPD 1.9 3 ENA (in-built provision), 60 KLPD 1 MAX POWER REQUIRED AT A POINT OF TIME 2.5 POWER GENERATED FROM CAPTIVE POWER PLANT 7.5, HENCE ADEQUATE
  • 37. Steam requirement 37 Sl. No. Description Steam requirement, TPH EC obtained 1 EC obtained, 60 KLPD 16.75 After expansion 1 Cane juice syrup operation Wash – absolute alcohol including evaporation 32 2 B heavy molasses operation Wash - absolute alcohol including evaporation 29 Wash - ENA including evaporation 18 MAX STEAM DEMAND AT A POINT OF TIME 32 STEAM GENERATION CAPACITY OF INCINERATION BOILER 45, HENCE
  • 38. Air environment- sources of air pollution & control measures, air pollution dispersion modelling studies, odour sources & control measures 38
  • 39. Sources of air pollution & control measures – EC obtained 39 39 Sl. No. Stack attached to Fuel consumption Stipulated standards particulate matter mg/Nm3, and others as indicated APC equipment and stack height in m Retained/ Dropped EC OBTAINED 1 125 TPH (co- gen sugar plant) Bagasse: 1500 TPD 150 Electro Static Precipitator (ESP) and stack of height – 85 m AGL. Retained 2 22 TPH incineration boiler Concentrated spent wash (CSW): 158 TPD and coal: 11.6 TPD (CSW and coal ratio 85:15) 150 ESP and stack of height – 40 m AGL Dropped 3 1000 kVA DG set HSD: 235 LPH NOx: 710 ppmv NMHC: 100 mg/Nm3 PM: 75 mg/Nm3 CO: 150 mg/Nm3 Acoustic enclosure and stack of height 30 m AGL Retained
  • 40. Sources of air pollution & control measures – proposed new 40 40 Sl. No. Stack attached to Fuel consumption Stipulated standards particulate matter mg/Nm3, and others as indicated. APC equipment and stack height in m Retained/ Dropped PROPOSED 4 45 TPH incineration boiler Sugar syrup as feed stock: Concentrated spent wash: 324 TPD and coal: 131 TPD (CSW and coal ratio 54:46) 150 ESP and stack of height 80 m AGL New proposed B heavy molasses as feed stock: Concentrated spent wash: 335 TPD and coal: 126 TPD (CSW and coal ratio 56:44) Purchased bagasse can also be used based on availability 5 800 kVA DG set HSD: 200 LPH - Acoustic enclosure and stack of height 9 m ARL New proposed
  • 41. Ambient air quality status – project site (28th July 2021) • Ambient Air Quality monitoring is carried out during the construction period as per Consent condition by NABL Accredited laboratory. • The resultant concentration is within the prescribed National Ambient Air Quality Standards. 41 Sl. No. Parameter Monitored values in µg/m3 Ambient Air Quality Standards - MoEF&CC dated 16.11.2009 1 PM10 64.3 100 2 PM2.5 33.8 60 3 SO2 13.6 80 4 NOx 19.2 80
  • 42. Air pollution dispersion modeling studies INPUTS Incremental increase of criteria air pollutants is predicted using AERMOD Lakes Environmental Software, Version 19191. 42 Particular Stack height in m Stack Dia. in m Flue gas exit gas temp in o C Exit gas velocity in m/s PM10 g/s SO2 g/s NOx g/s Boiler 125 TPH 85 3.2 160 12 6.9 0.1 1.6 Boiler 45 TPH 80 1.7 180 12.5 1.6 0.9 0.6
  • 43. Predicted incremental short-term concentrations Description Maximum incremental concentrations, µg/m3 Baseline concentration (Oct to Dec 2017), µg/m3 Resultant concentrations, µg/m3 Concentration during construction phase, near main gate, µg/m3 (10-07-2021) NAAQ standards µg/m3 dated 16-11-2009 Distance & direction Particulate Matter (PM) 2.38 71.9 74.28 64.3 100 0.5 km – South East Sulphur di-oxide (SO2) 0.64 12.5 13.14 15.2 80 0.3 km - East Oxides of Nitrogen (NOx) 0.7 22 22.7 17.6 80 0.5 km – South East 43 Note: • Baseline concentration is prior to EC. • Resultant concentration after expansion will be within NAAQ standards.
  • 47. Odour sources and control measures 47 Odour is generated from fermentation area, spent wash drains, storage tanks/lagoons, molasses handling area, compost area, effluent treatment facility of sugar plant and yeast handling and storage area. The odour control measures are as follows;  Odour is controlled at source by cGMP practices.  Fermenter lids to be closed, gaskets and seals to be periodically checked.  Odour producing materials such as RS/ENA/Ethanol are stored in tanks with proper safety measures, as per standard practices and regular monitoring of the fixtures such as gaskets, seals etc. to be carried out.  Regular monitoring to be done for checking of any leakages in piping and fittings.  Better housekeeping maintained to ensure good hygienic condition in the premises.  Effluent drains of distillery and sugar plant to be kept clean for easy flow.  Effluent treatment plant maintained on regular basis.  Fragrance flowering trees or shrubs to be planted near odour generating areas like fermenter tanks, ETP etc.  Odour from sources such as holding ponds/lagoons to be controlled by atomized spray of chlorine dioxide.  Better cane management to avoid staling of sugar.  Regular steaming of all fermentation equipment.  Control of temperature during fermentation to avoid in-activation / killing of yeast.
  • 48. Solid waste generation & management 48
  • 49. Solid waste generation & management - distillery 49 Sl. No. Solid waste Total proposed after expansion Utilization existing and after proposed modification 1 Yeast sludge 50 KLPD for cane juice OR 36 KLPD for B- heavy molasses Given to farmers along with pressmud to compost and reuse. 2 Ash from incineration boiler 155 TPD Given to brick manufacturers.
  • 50. Hazardous waste generation & management 50
  • 51. Hazardous waste generation & management 51 Waste category Hazardous waste Quantity Method of handling 5.1 Used oil 1.5 KL/annum Stored in leak proof containers in secure manner and handed over to KSPCB authorized re-processors/incinerator or used for lubrication within the industry. 33.2 Waste residues containing oil 0.1 MT/annum Stored in leak proof containers in secure manner and handed over to KSPCB authorized re-processors/incinerator or burnt in in-house boilers.
  • 53. Environmental Management Cell 53 Sl. No. Designation Member 1 Chairman Managing Director 2 Executive Officer General Manager 3 Convener Environmental Officer 4 Other department heads Manager (Sugars) Manager (Power) Manager (Distillery) Manager (H. R.) Chief Accounts Officer Chief Chemist Security Officer Cane Dev. Officer Environmental Engineer Civil Engineer Members
  • 54. Environmental Management Plan – construction phase 54 Sl. No. Activity Impact Duration Mitigation measure Significance 1 Air environment  Civil work like levelling, excavation, material unloading, construction, erecting etc.  Vehicles used for transporting construction material could result in emissions to environment.  Gas cutting and welding jobs – the release of gaseous pollutants.  Construction debris unloading and loading.  On ambient air quality – generation of airborne particles.  Effect on respiratory system of the workmen.  Deposit on the vegetation/ green belt. Short term  To use well-maintained construction machinery & vehicles.  Construction materials to be stored in a barricaded area and covered to avoid dust getting air borne.  To sprinkle water to suppress the dust generated during levelling, excavation, and other operations.  The welding and cutting jobs to be carried out with adequate ventilation/exhaust arrangement.  Collection of debris at designated places and to cover in order to avoid fugitive emissions. The debris to be disposed at low laying areas or used in road making in consultation with local body.  Water sprinkling on internal roads to avoid fugitive dust due to vehicle movement.  To deploy transport vehicles having emission under control test report. Low and reversible
  • 55. Environmental Management Plan – construction phase 55 Sl. No. Activity Impact Duration Mitigation measure Significance 2 Noise environment  Vehicular movement carrying construction materials.  Some intermittent noise is expected during fabrication at site and erection of equipment.  Erection of machineries.  Increased noise level at work zone.  Hearing impairment  Irritation Short term  To cover the work zone with barricades.  To provide suitable PPE to personnel.  To carry out the civil works only during day time and to monitor and regulate the vehicular movement. Low and reversible 3 Water environment  Run off carrying silt from accumulated debris, construction material etc.  Domestic sewage from workers. Increase in turbidity and suspended solids of surface water quality. Short term  Potable STP to be provided for treatment of sewage from construction workers.  Construction debris to be stored in a designated place and covered to avoid washing off with rain water.  The debris to be disposed at low laying areas or used in road making to avoid water logging at construction site and also at disposal sites. Low and reversible
  • 56. Environmental Management Plan – construction phase 56 Sl. No. Activity Impact Duration Mitigation measure Significance 4 Land environment  Disposal of excavated soil and debris may result in water logging and loss of fertile topsoil.  Spillage of oil and grease.  Siltation of drains  Deposition on vegetation and property Long term  To adopt soil conservation by proper management viz., the excavated earth collected and used for foundation, levelling, plinth and disposed to low laying areas, road works.  To separate the top soil and use it for gardening.  To collect the spillage if any and dispose scientifically. Low and irreversible 5 Ground water & surface water  Accumulation of debris and runoff during rains.  Domestic sewage from construction workers contaminating surface drains. Short term  Proper drainage system will be provided.  Providing and strengthening greenbelt in and around plant.  Storage of construction material and debris in a secured manner, to avoid runoff with rain water. Low and reversible 6 Socio economics Employment opportunities Short term  Employment opportunities for skilled and unskilled manpower. Low and beneficial 7 Ecology and bio diversity Flora, fauna, terrestrial and aviation species. No impact  As project site is vacant land, there will be no impact on ecology and bio diversity. -
  • 57. EMP - operation phase - air environment 57 Source of impact Predicted impacts Mitigation measures Remarks  CO2 emission from fermentation.  Emissions from boilers  Emissions form DG sets  Vehicular movement  ETP area  Solid and hazardous waste storage area  Greenhouse gas emission contributing to global warming.  Odour nuisance.  Anticipated incremental increase in the baseline concentration due to the industry are PM10 2.38 µg/m3, SO2 0.64 µg/m3 & NOx 0.7 µg/m3.  To provide CO2 bottling plant.  To provide ESP and chimney height of 85 m AGL for sugar and co-gen boiler  To provide ESP and 80 m AGL chimney for incineration boiler.  To provide for water sprinkling on internal roads to avoid fugitive dust due to vehicle movement.  To deploy transport vehicles having ‘emission under control’ test report.  To maintain the air pollution control equipments provided to boilers.  Finished product ethanol to be transferred using automatic pumping system to the storage tanks provided with tank farms.  To maintain good housekeeping in the process area and also inside industry premises.  To maintain the DG sets and stacks of 8 m for 800 kVA and 30 m height for 1000 kVA. Low adverse impact (localized in nature).
  • 58. EMP - operation phase - air environment Cont… 58 Source of impact Predicted impacts Mitigation measures Remarks Same as in previous slide  Emissions will impact the air quality. Increase in particulate matter concentration in AAQ, results in respiratory problems in humans, deposits on vegetation and agricultural crops affecting photosynthesis, plant growth, yield etc.  Effect on human health like nausea, asthma, eye irritation.  To practice regular maintenance of vehicles, regular cleaning and watering of internal roads and to regulate the movement of vehicles.  To clean the spent wash, drain periodically.  To reduce the storage time of spent wash to avoid odour.  Fragrance flowering trees or shrubs to be planted near odour generating areas like ETP etc. Low adverse impact (localized in nature).
  • 59. EMP - operation phase - noise 59 Source of impact Predicted impacts Mitigation measures Remarks  Noise from operation of machineries, motor pumps, compressors  Operation of boilers, TGs, DG sets.  Vehicular movement.  Process section.  Transportation of raw materials and finished products.  Operation of utilities. The nearest place of habitation is Banakatti at a distance of about 2 km towards North from the industry. Hence impact on the village is not anticipated.  Ambient noise levels to be monitored at industry boundary at regular intervals.  To make mandatory for the workers and officers to use PPE (ear plugs)/ear muffs in high noise area/s.  To house motor pumps, compressors in enclosures.  To maintain machineries and conveying system by following routine and periodic maintenance to reduce noise generation.  DG sets and TG are within acoustic enclosures.  Boilers – silencers to be provided to steam safety valves and steam straps are to be provided to steam main pipelines.  To regulate the speed limit inside plant and transportation to be done only during peak hours.  To develop and maintain greenbelt at the project site boundary. Low adverse impact (localized in nature)
  • 60. EMP - operation phase - water environment 60 Source of impact Predicted impacts Mitigation measures Remarks Discharge of process effluents from distillery viz., spent wash and spent lees, utility effluent boiler blow down, cooling tower bleed, condensate from MEE etc.  Sugar and co-gen effluent 770 KLD.  Max 1200 KLD of spent wash and 337 KLD of spent lees are generated from distillery.  Sewage generation is 32 KLD. Water pollution affecting surface and ground water quality.  To treat the sugar plant effluent in ETP and to use 300 KLD for green-belt/irrigation. Balance 470 KLD to be treated with CPU, stored and reused during off-season as per CTE.  Spent wash from distillery to be concentrated in MEE and used as fuel in incineration boiler.  To explore the possibility of providing bio- methanization plant between MEE and incineration boiler to harvest bioenergy.  Condensate from MEE along with spent lees, cooling tower bleed-off, incineration boiler blow- down, CO2 scrubber wastewater, lab wastewater, DM rejects are treated in CPU of 2000 KLD capacity.  To adopt ZLD concept for treatment and use for distillery effluent.  To store the raw materials and finished products in dedicated storage area/tank farm. Low adverse impact (localized in nature)
  • 61. EMP - operation phase - land environment 61 Source of impact Predicted impacts Mitigation measures Remarks  Accidental spillage of finished products.  Spillage/ disposal of hazardous waste  Disposal of press mud from sugar plant  Disposal of yeast sludge.  Disposal of sludge from the ETP.  Disposal of disposal of ash from the bagasse fired boiler and incineration boiler. Land contaminat ion. Leaching into ground. Eye sore.  Soil quality to be tested and studied each season.  To follow the concept of ZLD for distillery effluent management; treated wastewater reused in cooling tower makeup and for dilution of molasses/sugar syrup.  To segregate domestic solid wastes at source. The wet waste be composted and the inert dry waste be disposed to authorized recyclers.  To cordon the accidental spillage of sugar syrup/molasses/spent wash if any, take to respective holding tanks or spent wash holding tank.  To store the used oil in the secured manner and dispose to authorized vendors.  To collect and store yeast sludge, ash in a designated area. Incineration ash given to brick manufacturers; Yeast sludge given to farmers along with pressmud to compost and reuse. Sludge from activated sludge process used as compost within the site. No significant impact
  • 62. EMP - operation phase – solid waste 62 Source of impact Predicted impacts Mitigation measures Remarks  Disposal of yeast sludge.  Disposal of ash from incineration boiler.  Disposal of ash from cogen boiler.  Anticipated solid waste generation  Ash from co-gen boiler – 10 TPD  Ash from incineration boiler – 155 TPD  Yeast sludge – 50 KLPD  Land contamination.  Leaching into ground.  Eye sore to the public.  To collect the solid waste in a secured manner.  Disposal and management as detailed above. Low adverse impact (localized in nature)
  • 63. EMP - operation phase – socio-economics & biodiversity 63 Source of impact Predicted impacts Mitigation measures Remarks Socio-economics  Employment of local people.  Socio economic impact  To employ locally available manpower to the maximum possible extent based on qualification.  To engage the local people for raw material supply, transportation and security system.  To aim at capacity building by skill development to encourage the local people to take up job in the factory.  To aim at development of local infrastructure facility.  To take up development of social facilities like construction of temple, educational facilities etc. Strongly beneficial (positive) impact Biodiversity  Operation of distillery, sugar and cogeneration Impact on flora, and fauna due to the noise and emission from the boilers  To keep all the pollution control facilities in operating condition and to meet the regulatory compliance and beyond to ensure that the biodiversity is not affected.  No trees shall be cut. No significant impact
  • 64. EMP - operation phase - traffic management • The entry and exit of vehicles to be organized effectively so that the movement of vehicles do not disturb or create traffic jam for other public transport vehicles. • Erection of traffic signs at strategic locations. • Covering of vehicles carrying bagasse, ash & press mud with tarpaulin to avoid spillage. 64 Sl. no. Vehicle type Total, no.s 1 Heavy tankers for ENA & ethanol 20 2 Heavy vehicles (JCB, hydra, tractors) for sugarcane transport, press mud & ash transport JCB & hydra- 05, sugarcane transport tractors –750 3 Four-wheeler for factory employees (car, jeeps) 4 4 Two wheelers for factory employees, visitors/cane growers (bikes, scooters) 4 5 Buses 2
  • 65. Environmental monitoring program 65 Sl. No. Particulars Monitoring frequency Duration of monitoring Important parameters for monitoring Air environment 1 Ambient air quality within project premises – one each at downwind, up wind & crosswind directions. Twice a month during crushing season and bi- monthly during the rest of the year. 48 hours (2 consecutive days) PM10, PM2.5, NOx, SO2, CO 2 Stack monitoring a. Boiler stack- 125 TPH b. Incineration boiler 45 TPH c. DG set stack attached to 1 x 1000 KVA  Monthly for boilers & online monitoring  Bi-annually for 1000 KVADG Grab &online monitoring SPM, SO2, NOx
  • 66. Environmental monitoring program 66 Sl. No. Particulars Monitoring frequency Duration of monitoring Important parameters for monitoring Noise environment 3 At the boundary of the factory. During crushing season Day and night Noise level in dB (A) Leq. Water environment 4 Raw spent effluent Once a week Grab pH, TSS, TDS, total solids, COD, BOD, potash, chloride and phosphate 5 Concentrated spent wash Once a week Grab pH, COD, BOD, total solids 6 All intermediate stages of ETP/CPU Once a week Grab pH, TSS and COD Min once a day Grab pH and COD
  • 67. Environmental monitoring program 67 Sl. No. Particulars Monitoring frequency Duration of monitoring Important parameters for monitoring Water environment 7 Treated effluent sugar plant ETP outlet Once a week Grab and online monitoring pH, TSS, TDS, COD, BOD, potash, chloride and phosphate Online monitoring of pH, BOD, COD and TSS Min once a day Grab pH, MLSS 8 Ground water / piezometer monitoring within industry site Twice a year. Before and after monsoon Grab pH, BOD, COD and total solids Soil environment 9 Within project premises at two locations near hazardous waste storage and effluent storage. Once in a year Composite sample EC, organic carbon, pH, available NPK
  • 68. Test procedure and the cost of monitoring 68 Sl. no. Particulars Methods of monitoring Cost of monitoring in Rs. Amount in Rs. per year Air environment 1 Ambient air quality at project premises PM2.5: IS 5182:part-23: 2006 PM10: IS 5182:part-23: 2006 SO2: IS 5182:part-2: 2001 NOx: IS 5182:part-6: 2006 25,950 per station. To monitor three stations. 9,34,200 2 Stack monitoring – process section a. Boilers b. DG set PM: IS 11255:part-1: 1985 SO2: IS 11255:part-2: 1985 NOx: IS 11255:part-7: 2005 Rs. 6,650 per stack. Two stacks of boiler (monthly) and one stack of DG (biannually) 1,72,900
  • 69. Test procedure and the cost of monitoring 69 Sl. no. Particulars Methods of monitoring Cost of monitoring in Rs. Amount in Rs. per year Noise environment 1 Noise level at the boundary of the factory. Sound level meter Rs. 3,500 per station. Three stations; four times per annum. 42,000 Water environment 1 Ground water / piezometer Standard analytical Rs. 2,400 per station. Two piezometers sampled twice a year 9,600 2 Raw and treated effluent. Procedure for water by APHA and AWWA. Monitoring in in-house lab -
  • 70. Test procedure and the cost of monitoring 70 Sl. no. Particulars Methods of monitoring Cost of monitoring in Rs. Amount in Rs. per year Soil environment 1 Soil within project premises Standard analytical procedure. Rs. 3,350 per sample at two locations near hazardous waste storage and effluent storage. 6,700 Total budget for monitoring 11,65,400 Or say 11,66,000 Rupees Eleven Lakhs Sixty Six Thousand Only
  • 71. Budget allocation – environment management - capital 71 Sl. No. Application Budget towards EMP, Rupees in Crores 1 Capital investment (sugar, co-gen and distillery) 1.1 Air pollution control facilities sugar and co-gen (ESP, stack and ash handling) 20 1.2 Waste water treatment facilities -Establishment of 10.22 ETP & MEE, Incineration boiler, ESP, Stack, ash handling 12 CPU 4.5 1.3 Noise pollution control 1 1.3 Green belt 0.5 1.4 Laboratory and monitoring facilities 10 1.5 Online monitoring system 1 1.6 Occupational Health & safety 0.5 1.7 Rain water harvesting 1.75 Total 61.47 Rupees Sixty One Crores Forty Seven Lakhs Only
  • 72. Budget allocation – environment management - recurring 72 Sl. No. Application Budget towards EMP, Rupees in Crores 2 Recurring cost of operation and maintenance in Crores 2.1 Air pollution control 0.5 2.2 Water pollution control 1 2.3 Monitoring cost 0.12 2.4 Maintenance and calibration of online monitors 0.02 2.5 Green-belt maintenance 0.1 2.6 Occupational health & safety 0.05 Total 1.79 Rupees One Crore Seventy Nine Lakhs Only
  • 73. Budget allocation after proposed expansion for CER with target date Corporate Environmental Responsibility - CER 73 Sl. No. Activity Fund allocated, Rupees Crores Period of execution in years from the commencement of project 1 Avenue plantation in community areas in surrounding villages (Banakatti, Shirur, Kamatagi etc.) 3.0 5 years 2 Support for health care related to COVID ailments. 3 Gifting of tabs/books to underprivileged school children 4 Providing drinking water facility to the surrounding villages (Banakatti, Shirur, Kamatagi etc.) Total 3.0 - Rupees Three Crores Only
  • 75. Occupational health hazards associated with the industrial activity Sl. No. Activity Aspect Impact 1 Bagasse handling /conveying Air borne dust On respiratory system like Chronic Obstructive Pulmonary Disease (COPD) 2 Boilers/ DG sets 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 75
  • 76. Preventive and corrective actions to reduce/eliminate occupational health hazards Sl. No. Occupational health hazards Preventive action Corrective action 1 Respiratory system Reduce dust getting airborne Periodic Medical Examination – Spirometry / PFT / Pulse oxymetry 2 Noise Induced Hearing Loss (NIHL) / Cardiovascular Disease/ Hypertension 1.Reduce noise at source by changing design / proper maintenance/ providing acoustic enclosures 2.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 76
  • 77. Sl. No. Activity Aspect Impact Preventive action Corrective action 1 Bagasse handling /conveying Air borne dust On respiratory system like chronic obstructive pulmonary disease (COPD) Reduce dust getting airborne Periodic Medical Examination – Spirometry / PFT / Pulse oxymetry 2 Boilers/ DG sets operation/ compressors Noise Noise Induced Hearing Loss (NIHL) / cardiovascular disease/ hypertension 1. Reduce noise at source by changing design / proper maintenance/ providing acoustic enclosures 2. Provide PPE Audiometry 3 Molasses handling Odour Headache/nausea Control odour at source by providing high rise vents Job rotation 4 Boiler operation Exposure to heat Heat exhaustion Proper location/design of operator cabin Job rotation Occupational health hazards & ppreventive and corrective actions to reduce/eliminate them 77
  • 78. Health check-up parameters Sl. No. Test Details 1 Physical Fitness Certificate 2 Pulse 3 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) 78
  • 79. Budget for occupational health Sl. No. Particulars Budget Rs. per annum 1 Periodic medical examination 7,00,000 3 Personal Protective Equipment like gloves, safety shoes, aprons, goggles, Self-contained breathing apparatus (SCBA) 3,00,000 4 Training on occupational health & safety 1,00,000 Total Rs. 10.00 Lakhs /Annum 79
  • 80. Risk safety measures a. Fire hydrant systems will be provided all around the industry. b. Workplace specific PPEs will be provided for workers at the industry to ensure their safety. c. All storage tanks to be constructed in line with PESO guidelines. d. Dyke walls will be provided as per PESO requirement. e. Occupational health and safety monitoring at regular intervals. f. Regular health check-ups of workers and maintenance of records. g. Regular safety training and fire fighting mock drills. h. Only trained persons deployed for industrial operations. 80
  • 81. Identified hazard Precautions taken Mitigation measures Fire • There shall not be any electrical overhead lines in ethanol storage tank area. • All ethanol storage area pipelines will have jumper for avoiding static electricity. • All tank thickness test will be done by competent person. • All tanks and motors will have proper earthing system and double earthing. • Flameproof type lighting system will be provided for controlling of spark. • Portable fire extinguishers will be provided at identified locations in distillery section. • Sand buckets will be provided. • Entire plant will be covered with fire hydrant line and foam monitor system. • Warning and informatory signage’s will be displayed. • Mobile usage prohibited in distillery plant. • No smoking allowed in factory premises. • Flameproof motors will be provided in distillery section. • Welding and gas cutting prohibited in distillery section premises. • Work permit followed for all high risk work. • Firefighting training will be provided to all employees. • Mock drill will be conducted once in 2 months. Risk mitigation measures – ethanol plant
  • 82. General safety measures/precautions to be followed  All the work places will be provided with MSDS of chemicals & materials being handled. The concerned employees will be trained and all the employees will be made aware of the hazards in handling chemicals.  Inspection and preventive & breakdown maintenance of all the equipment including pollution control equipment will be undertaken.  Compulsory use of necessary PPEs.  Installation of fire extinguishers at required places.  Regular work place monitoring.  Provision of part time qualified medical officer as per factories act guidelines.  Regular medical check-up of employees by qualified medical practioner.  Monitoring of occupational hazard parameters like noise, ventilation, chemical exposure at frequent intervals.  Display of various instruction boards, cautionary notices etc., at different locations. 82
  • 83. Green belt development  Out of 40.87 hectares of the integrated sugar plant and distillery complex, 33 % i.e, 13.47 hectares (33.29 acres) is earmarked for the green belt development  Number of trees to be planted for 13.47 hectares is 20,205 at the rate of 1500 trees per hectare as per guidelines.  3000 tree saplings of Hebbevu (Melia dubia) have already been planted.  Number of trees to be planted is 17,205. 83
  • 84. Rain water harvesting  Rainwater harvesting potential of the site = 816 m3  A rain water harvesting tank / pond of total holding capacity 1500 m3 is proposed for collection and reuse of rain water.  Groundwater recharge pits of 4 x 10 x 3 m filled with graded media comprising of boulder at bottom and with coarse aggregates to facilitate percolation to recharge ground water table will be provided at different locations within the premises. 84
  • 85. Rating of impact matrix Identification and Rating of Environmental Impacts Sl. No. Activity Cause/Aspect Impact Scale 1 to 5 Severity 1 to 5 Probability 1 to 5 Duration 1 to 5 Significance rating = S x S x P x D Construction phase 1 Erection of machineries Dust getting airborne 1 1 5 2 10 Noise nuisance 2 1 3 2 12 Spillage of oil 1 1 2 2 4 Gaseous emissions 1 1 1 1 1 Domestic waste generation 1 1 3 2 6 85
  • 86. 86 Operation phase 1 Operation of boilers Air emissions 3 2 5 2 60 Wastewater generation 1 1 5 1 5 2 Operation of DG set and TG sets Air emissions 3 1 2 2 12 Noise nuisance 1 1 5 1 5 3 Manufacturing activity and ZLD operation Fugitive emissions 2 1 3 2 12 Noise due to machinery 1 1 5 1 5 Domestic sewage 2 1 5 1 10 Wastewater from utility 2 1 5 1 10 Wastewater from process 3 2 5 2 60 Domestic solid waste 1 1 5 1 5 Hazardous waste 1 1 2 1 2 Those impacts with SSPD score of 24 and above are considered as most significant. Rating of impact matrix
  • 87. Criteria for rating scale, severity, probability and duration Scale S Rating Severity S Rating At the work area 1 Minor Injury requiring first aid 1 Within premises 2 Injury requiring hospitalization 2 Outside premises in 1 km radius 3 Temporary disability 3 Outside Premises beyond 1 km & less than 5 km radius 4 Permanent disability 4 Beyond 5 km radius 5 Loss of life/s 5 Probability of Occurrence P Rating Duration D Rating Once a Year 1 Less than 1 hour 1 Once a month 2 Less than 4 hours 2 Once a week 3 One day 3 Daily but intermittently 4 More than a day 4 Continuous 5 Few months 5 87
  • 88. Severity mapping • The Severity mapping has been carried out using the ALOHA Areal Locations of Hazardous Atmospheres) software 5.4.7. • 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). 88
  • 90. Storage capacities 90 Sl. No. Description of the storage tank No. of tanks Capacity, KL Raw materials 1 Molasses 4 10,000 MT each 2 Syrup buffer tank 1 250 m3 Products 1 RS bulk storage tank 2 1500 each 2 ENA storage tanks 2 1500 each 3 IS storage tank 1 200 4 Ethanol storage tanks 5 2270 each Day receiver 1 Hydrous alcohol and impure spirit (rectified spirit) 3 132 each 2 Fuel ethanol 9 126 each 3 Extra Neutral Alcohol (ENA) 3 132 each 4 IS 2 15 each 5 Ethanol issue tanks 3 295 each By-products / Intermediates / Waste 1 Spent wash feed tank 1 60 m3
  • 91. Aloha simulation analysis Summary of MCA analysis - Ethanol 91 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 recommende d LOC value --- (N/A = ERPG-3) Flammable area of vapour cloud 17 19800 ppm = 60% LEL = flame pockets 2 Leaking tank chemical is burning and forms a pool fire Thermal radiation from pool fire 13 10.0 kW/(sq m) = potentially lethal within 60 sec
  • 92. CONCLUSION AND PRAYER • The proposed project is distillery expansion to manufacture ethanol under Ethanol Blended with Petrol (EBP) 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. • Self declared notarized affidavit has been made that the ethanol produced from the proposed project will be supplied as bio-ethanol for the purpose of blending with petrol under EBP programme. M/s. Mellbro Sugars Pvt. Ltd. humbly requests the committee to kindly recommend the proposal for grant of Environmental Clearance 92