EXECUTIVE SUMMARY

Proposed Modernization cum Expansion of Sugar, Distillery and Cogeneration unit

Dr. Babasaheb Ambedkar Sahakari Sakhar Karkhana Limited

Arvindnagar, Post Keshegaon Tal & Dist: Osmanabad

Prepared By

VASANTDADA SUGAR INSTITUTE

Manjari (Bk), Pune, Maharashtra 412 307
Telephone: (020) 26902100, 26902343/7/6 Fax (020) 26902244
Web Site: www.vsisugar.com

January 2013

CONTENT EXECUTIVE SUMMARY

Sr. No 1.0 1.1 2.0 2.1 3.0 3.1 Introduction Project Information: Geographical Project Details Particulars Page 1 1 2

Sugar unit expansion CREP Guidelines and its compliance mechanism Polishing Unit for Condensate, spent lees and other minor distillery effluents

4 14 15

4.0 5.0 6.0

Greenbelt development Safety, occupational health management Social environment Aspects LIST OF TABLE

16 16 17

Table 1 2 3 4 5 6 7 8 9 10 11 12 13

Title
Water Balance: Sugar and Cogeneration Unit (Season) Water Balance: Cogeneration Unit (off -Season) Fuel Balance for crushing s eason

Page 6 6 7 8 8 9 9 10 12 12 15 17 19

Boiler details Power balance (Season) Power balance (off-Season) Cogeneration Expansion Scheme Summary of proposed distillery expansion project Summary of Environmental Setting in 10km radius area Pollution sources and types Polishing unit for condensate and other minor distillery effluents Budgetary allocations for environment management
Summary of Impact Assessment and miti gation measures

Executi ve Summa ry: Expansion of Suga r, Dis tillery and Cogenera tion Project Dr. Babasaheb Ambedka r SSK Limi ted, Osmanadba d

LIST OF FI GURE Figure 1 2 3 4 5 Title Flow diagram for sugar manufacturing process Process and Water Balance for 60KLPD Uni t Schematic of waste management at sugar and cogeneration project Schematic of water management Schematic of waste management Page 5 11 13 14 15

Executi ve Summa ry: Expansion of Suga r, Dis tillery and Cogenera tion Project Dr. Babasaheb Ambedka r SSK Limi ted, Osmanadba d

EXECUTIVE SUMMARY
1.0 Introduction

Dr. Babasaheb Ambedkar Sahakari Sakhar Karkhana Ltd (DBASSKL) is a cooperative sugar factory. It is located at Arvindnagar, post Keshegaon, Taluka and District Osmanabad, Maharashtra. Geographically Osmanabad district is situated in Marathwada province of Maharashtra. DBASSKL is one of the leading cooperative sugar factories from the Marathwada region. The sugar factory is registered under Maharashtra Co-Operative Society act 1959; - registration number OSM/ORG(A)/S-75/1997, dated 27-3-1997. The factory has done a remarkable progress under the leadership of Hon. Shri. Arvind Janardan Gore. There are 9968 member farmers (share holders) from 150 villages in the surrounding. Factory holds 310 acres of land, of which 125 acres are reserved for agricultural R&D programs. Though the sugar factory is located in draught prone area of Maharashtra it has shown significant achievements in various fields such as a) lower cost of production, b) minimum expenses on salary and non productive items, c) maximizing capacity utilization & sugar recovery, etc. However, due to time to time modernization and adopting new technologies, the factory could able to achieve operational efficiency of average 125% from a unit of 2,500Tons crushed per day (TCD) installed capacity. Factory has won an award for technical efficiency from state government. Now the management has planned to expand the sugar units installed capacity to 5,000TCD. Thereby, the factory could able to fulfill the need and demands of cane grower farmers for crushing of surplus cane. This will also support to produce and sell the sugar in national and international market. Due to increase in the crushing capacity the factory expects enhancement in the production of bagasse, molasses etc. Thus, to utilize this resources it has proposed to install a DEC type10MW STG, and enhance its cogeneration capacity to 26MW. Similarly, it has planned to expand its distillery by adding new 30KLPD unit so as to have a production capacity of 60KLPD. 1.1 Project information: Geographical Details Expansion of a) sugar unit by modernization of 2500TCD unit to 5000 TCD (installed capacity) b) Distillery unit from 30KLPD to 60KLPD

Particulars Nature of the project

Executi ve Summa ry: Expansion of Suga r, Dis tillery and Cogenera tion Project Dr. Babasaheb Ambedka r SSK Limi ted, Osmanadba d

c) Cogeneration unit from 16MW to 26MW Size of the project After expansion a) sugar unit installed crushing capacity of 5,000 TCD b) distillery unit of 60KPD and c) cogeneration of 26MW Location of the project Within existing sugar factory premises at Dr. Babasaheb Ambedkar Sahakari Sakhar Karkhana Ltd is located at Arvindnagar post Keshegaon , District- Osmanabad Geographical Location Nearest City/Town 7611'2.29"E and 185'5.41"N. Altitude 672m above MSL Osmanabad 18km NW (district HQ) Tulajapur 15km SW (religious place) Road The site is located 3.5 km off Tuljapur -Ausa State Highway No. 3 Railway Station Air Port 2.0 Project Details M/s. Dr. Babasaheb Ambedkar Sahakari Sakhar Karkhana Ltd. (DBASSKL) (Cooperative sugar factory) Project Expansion of distillery, cogeneration and sugar units Modernization of existing 2500TCD Sugar unit so as to achieve 5,000 TCD (installed capacity) Cogeneration from 16 to 26MW Molasses based distillery from 30 to 60KLPD Project location Land Within existing sugar factory premised Proposed site meets the guidelines for industrial site selection, prescribed by Ministry of Environment and Forest as well as local guidelines of Maharashtra Pollution Control Board No need of acquisition of land Distillery unit Sugar and cogeneration Distillery and evaporation unit 1.5acres Compost yard 2.5 acres Approx 4 acres for expansion of sugar unit and 10MW STG unit Osmanabad is the nearest Railway Station 18km away Solapur domestic airport, 50 km Pune ~300km

Name of the Proponent

Executi ve Summa ry: Expansion of Suga r, Dis tillery and Cogenera tion Project Dr. Babasaheb Ambedka r SSK Limi ted, Osmanadba d

Greenbelt Total land requirement

2.65 acres for entire project 10.65 acres Products and byproducts

Alcohol (Considering 7.5% v/v alcohol in fermented wash)

i.

RS Conforming to ISI Grade I, 323 (1959) Production 57KLPD + 3KLPD Impure Spirit

ii.

Extra Neutral Alcohol, ISI Grade I, 6613 (1972) Production 56.4KLPD + 3.60KLPD Technical spirit

iii.

Ethanol ISI-Grade-I, 321(1964) /IS: 15464 (2004), Production of 30KLPD Impure Spirit Conforming to ISI Grade II, 323 (1964) Fusel oil

Electricity Sugar (subject to vari according to cane variety and crushing seasons conditions considering max. crushing rate @6,250TCD) Main Raw Material

i. ii. i. ii. iii. iv.

24.5MW during cane crushing season 10MW during off-season White Sugar (max recovery of 12%) ~750 MT/Day Bagasse (generation @28% on cane): ~1750 MT/Day Molasses : 250 MT/Day Press mud: 250 MT / Day

i) ii) iii)

Sugar Cane (minimum): 6,250 MT/Day Lime : 9.4 MT/Day (0.15% Cane ) Sulfur: 3.1MT/Day (0.05% Cane )

Water Requirement (Considering recycle/recirculation) Source of water Fuel

Sugar and cogeneration 655m3/day (for season); Cogeneration: 595 m3/day (for off-season) Distillery: 475m3/day Vadala Dam (Permission available ) Bagasse for season: 1,211MT/day Off-season: 515MT/day Cane Trash: 5,000MT/annum Imported coal (optional during off-season): 70MT/day

Power

Captive power source Season Off-season

Executi ve Summa ry: Expansion of Suga r, Dis tillery and Cogenera tion Project Dr. Babasaheb Ambedka r SSK Limi ted, Osmanadba d

Total power Generation (in MW) Total Captive Power Consumption (in MW) Surplus power for export to state grid (in MW) Manpower Project Cost EMP Cost Days of Operation per year (Maximum) Approx 95-100 Rs. 101.00crores Rs. 17.50crores

24.500 8.500 16.000

10.00 1.85 8.15

Sugar unit 210 days Distillery: 270 days Cogeneration: 300 days

2.1 Sugar unit expansion The expansion of sugar unit will be due to modernization of the existing sugar unit of 2,500TCD. It is focused on reducing the captive steam and power consumption and to improve the technical performance of the sugar unit. As a result of the modernization, the factory could able to expand its Installed cane crushing capacity to 5,000TCD. Usually it is observed in sugar industry that the unit could be operated at 125 to 130% efficiency of installed capacity. Considering this fact, the modernized 5,000TCD unit is also anticipated to be operated at 125% efficiency of its installed capacity. Therefore, after expansion the sugar factory is anticipated to be operated at maximum crushing rate of 6,250 TCD (~284 TCH on 22hours basis).

Executi ve Summa ry: Expansion of Suga r, Dis tillery and Cogenera tion Project Dr. Babasaheb Ambedka r SSK Limi ted, Osmanadba d

SUGAR MANUFACTURING PROCESS Cane Supply Boiler

Steam

Milling

Bagasse

Juice Lime & Sulfur House Rotary vacuum filter Press mud

Sulphitation

Clarification Evaporation

Pan boiling Crystallizer

Centrifugals

Sugar

Packing Figure 1: Flow diagram for sugar manufacturing process

Executi ve Summa ry: Expansion of Suga r, Dis tillery and Cogenera tion Project Dr. Babasaheb Ambedka r SSK Limi ted, Osmanadba d

Table 1: Water Balance: Sugar and Cogeneration Unit (Season)

WATER INPUTS (Unit m3/day) DM Water For Boiler feed Milling section (including washing) Water For Turbine/boiler parts cooling, Vacuum Pump & Others Water For spray pond Makeup Water to Ash handling system Other Domestic Usage Total Water Input at start up WATER OUTPUTS Steam Condensate Hot water from turbine and boiler parts Evaporation & Losses Domestic Consumption Losses at ash handling system Excess condensate Wastewater generated from various units Total Water Outputs RECYCLE STREAMS Steam Condensate Recycle For Boiler Water from boiler and turbine parts after cooling Condensate total Recycle after cooling Treated effluent Total Recycling of water per day Total Fresh Water Input 2660 220 1,335 650 4,805 655 2,660 220 550 20 25 1,335 650 5,460 2,720 1,925 220 550 25 20 5,460

Table 2: Water Balance: Cogeneration Unit (off-Season) WATER INPUTS (Unit m3/day) DM Water For Boiler feed Water For Turbine/boiler parts cooling, Vacuum Pump & 1130 100

Executi ve Summa ry: Expansion of Suga r, Dis tillery and Cogenera tion Project Dr. Babasaheb Ambedka r SSK Limi ted, Osmanadba d

Others Water For spray pond Makeup Water to Ash handling system Other Domestic Usage Total Water Input at start up WATER OUTPUTS Steam Condensate Hot water from turbine and boiler parts Evaporation & Losses Domestic Consumption Losses at ash handling system Wastewater generated from various units Total Water Outputs RECYCLE STREAMS Steam Condensate Recycle For Boiler Water from boiler and turbine parts after cooling Treated Water Recycle Total Recycling of water per day Total Fresh Water Input Table 3: Fuel Balance for crushing season Sr. No. 1. 2. 3 4 5 6 7 Item Crushing rate (Maximum @6,250 TCD for 22h) Bagasse generation at 28% on cane Biogas (600m3/h) to be used in season, equivalent bagasse Cane Trash to be used in season, equivalent bagasse Net bagasse available Bagasse consumption by boilers Bagasse saved (considering average season of 160 days) Unit TCH TPH TPH TPH TPH TPH TPH MT Value 284 79.52 1.82 1.85 83.19 50.48 32.71 125,606 1,080 100 50 1230 595 1,080 100 550 20 25 50 1825 550 25 20 1825

Executi ve Summa ry: Expansion of Suga r, Dis tillery and Cogenera tion Project Dr. Babasaheb Ambedka r SSK Limi ted, Osmanadba d

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Bagasse available for off season days operation 8 Bagasse required for off-season cogeneration and distillery project 9 10 Therefore, off-season operational days (Considering 300 days of cogeneration) Bagasse saving even after cogeneration TCH TCD Day MT 19.15 459.6 140 61,262

Table 4: Boiler details Sr. no. 1 Boiler Air Pollution Control Equipment Steam generation 47.00 TPH

2.

New 50 TPH @ 72ATA Pressure and Electrostatic temperature 515 5 0C precipitator Bagasse to steam ratio 1:2.35 Existing three boilers Mechanical dust (32TPH x2 and 30TPH x 1) each @ collector followed by 45ATA Pressure and temperature 510 wet scrubber 50C Bagasse to steam ratio 1:2.1 Total Steam generation during crushing season Table 5: Power balance (Season)

64.00 TPH

111.00 TPH

Power Generation From 10 MW DEC type STG set From 10MW SEC type old STG TOTAL Power Consumption Sugar Factory Distillery Office, Colony, Workshop, Other Cogeneration auxiliary Total Captive Consumption

Unit (MW) 9.000 15.500 24.500

6.590 0.600 0.400 0.910 8.500

Executi ve Summa ry: Expansion of Suga r, Dis tillery and Cogenera tion Project Dr. Babasaheb Ambedka r SSK Limi ted, Osmanadba d

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Surplus exportable power (During season only) Table 6: Power balance (off-Season) Generation/Consumption Power generation Power consumption Cogen auxiliaries Sugar process Distillery / ENA / ethanol Colony Total captive consumption Power export 1.00 0.10 0.60 0.15 1.85 8.15 Table 7: Cogeneration Expansion Scheme Particulars steam turbine generator (STG) Type Existing 3MW x 2 Nos. 10 MWX1 No. Back pressure 32 TPH x 2 boilers for two Steam supplying boilers 3MW STG 30TPHx1 boiler for 10MW STG Steam pressure Steam temperature Bagass to steam ratio 45kg/cm2 5100C 2.15 16.00 MW Existing air pollution control device on each of the boiler Stack Height and its connectivity with boiler Mechanical Dust collector followed by wet scrubber 65 m; Connected to existing boilers

16.000

Unit (MW) 10.00

Proposed 10 MW -1 No.

Double Extraction cum condensing (DEC)

New boiler of 50TPH

72kg/cm2 5100c 2.40 26.00MW ESP 72 m; Connected to proposed boiler

Executi ve Summa ry: Expansion of Suga r, Dis tillery and Cogenera tion Project Dr. Babasaheb Ambedka r SSK Limi ted, Osmanadba d

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Operational days Power generation

300 Days During crushing season During off-season Season 24.5 MW 10MW

Bagasse :1,163MT/day Biogas: 600m 3/h Bagasse= 467MT/day

Fuel Off season

Biogas = 600m3/h Cane Trash: 7,000MT/annum Imported coal as an auxiliary during offseason (if required): ~70MT/day

Table 8: Summary of proposed distillery expansion project # 1 2 3 4 5 6 7 Particulars Installed capacity Spentwash generation (L per L of Alcohol) Primary treatment to spentwash Secondary treatment Disposal Compost yard Ratio of pressmud : spentwash Existing 30KLPD 10L Biomethanation Composting 6.75 acres RCC 1:2:4 1:2.5 Proposed 30 KLPD (total 60KPD) 10L Biomethanation Multi-Effect Evaporation (MEE) - After expansion for 60KLPD Composting additional 2 acres = 8.75 acres , RCC 1:2:4 1.25:1

Executi ve Summa ry: Expansion of Suga r, Dis tillery and Cogenera tion Project Dr. Babasaheb Ambedka r SSK Limi ted, Osmanadba d

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Molasses 150m3 Dilution Water 550m3

Steam 204MT/d from sugar Soft water 180m
3

Fermentation

CO 2 74m /day

Sludge 16m3/day

Distillation
Spent wash 600m
3

RS/ENA/AA + IS = 60KL

Lees 40 m + process condensate 500m

3

Biomethanation
Cooling water 360m3/h
Steam 120MT from sugar Spent wash 600m
3

Polishing unit

Steam condensate recycled

ME Evaporation
Spent wash 100m
3

Press mud

Biocomposting
Recycled water Spentlees 90m to distillation column Treated water Molasses dilution: 500m
3 3

Figure 2: Process and Water Balance for 60KLPD Unit

CO2 scrubber: 40m

Executi ve Summa ry: Expansion of Suga r, Dis tillery and Cogenera tion Project Dr. Babasaheb Ambedka r SSK Limi ted, Osmanadba d

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Table 9: Summary of Environmental Setting in 10km radius area Facet Characterized Rainfall Precipitation Temperature In brief General dryness, except monsoon Average 700 mm Mainly in July-Aug Summer temp 240 C to 380 C. Sometimes + 40 0C. Winter temp 140 C to 220 C rarely <80 C Humidity Wind Air Quality Noise Soil Within 10km Area High in Monsoon 85 %, In summer it decreases up to 30 % Calm 22.6%, Predominant direction East, North- East Within NAAQS Within Noise standards prescribed by CPCB Brown (Various tings), Texture clay to loam There is no tropical forest, or biosphere reserve, or national park Or wildlife sanctuary Table 10: Pollution sources and types Environ ment Air Bagasse as fuel Ash and bagasse handling Biogas Fermenters Bio-composting Water Process Mainly particulate matter (fly ash as SPM) Minor fugitive dust Methane and CO2 CO2 Odour, methane Sugar Effluent = 600 -650 m3/day sent to ETP Spent wash from distillery 600m3 treated by biomethanation followed by multi-effect evaporation followed by composting Spent lees, process condensate & other ~ 550m3 excess condensate overflow blow down from Condensate of 1,200m3 day cooled and recycled other sources ~750 m3/day - mildly polluted Activity/Process/Source Pollutant/measures if any

Executi ve Summa ry: Expansion of Suga r, Dis tillery and Cogenera tion Project Dr. Babasaheb Ambedka r SSK Limi ted, Osmanadba d

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Environ ment

Activity/Process/Source cooling tower and boiler Sewage

Pollutant/measures if any effluent recycled after treatment Sewage = 16 m3/day disposed by septic tanks and Sock pit Ash 24.24 MT/day Non-toxic; non-hazardous Mixed with biocompost Scrap oil from DG set- very minor since DG will be used only in case of captive power failure Collectively 200-250MT per month Mixed with biocompost Effluent of 650 m3/day treated in sugar ETP used for irrigation Noise levels between 80-90 dB(A) at few work places

Land

Boiler ash Hazardous oil Sludge from biodigester, fermenter, ETP units Wastewater discharge

Noise

Mill house, Bagasse & Ash handballing, Power house and boiling house, Sugar house, transportation etc.

Bagasse feeding Boiler feed water

Boiler blow down from cooling tower

Sugar Cane Turbin Fly Ash and e

bottom ash (Max. 24. 24 MT/Day) Ash to compos t or Brick manufacturi ng

Mill House
24.5 MW Electricity

Boiler/Furnac e

Steam

Sluice water from the bottom ash handling system, boiler chemical cleaning water

Neutralized Recycled or used for irrigation

Effluent from Mill house, Boiling House, 600m3 /day

Sent to ETP sugar factory

Figure 3: Schematic of waste management at sugar and cogeneration project

Executi ve Summa ry: Expansion of Suga r, Dis tillery and Cogenera tion Project Dr. Babasaheb Ambedka r SSK Limi ted, Osmanadba d

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Reducing fresh water intake by

Waste generation

Rain water harvesting

Efficient use of water/steam

Already minimized in existing plant

From roof top areas

Recycling of non or less polluted streams

Proper treatment to all effluent sttreams

Mainly by storage method

Reusing treated water

Figure 4: Schematic of water management 3.0 CREP Guidelines and its compliance mechanism

The sugar factory has implemented Bio-methanation as primary treatment followed by bio composting for the safe disposal of spent wash in its existing 30KLPD unit. For the proposed distillery expansion it has decided to install multi-effect evaporation as a secondary treatment after biomethantion. By this the factory not only going to reduce spentwash volume but also it will help to meet press mud balance. The guidelines recommended through CREP, which will be implemented by the project proponent, are as follows. Spentwash storage lagoon of 30 days and five days capacity Impervious lagoons, constructed leak-proof, lined with HDPE sheets and protected by brick lining The compost yard of 6.5 acres lined with HDPE sheets and protected with Reinforced cement concrete(RCC), it will be extended by two acres with RCC Provisions for leachate collection gutter and sump well as well as spentwash sprinkling pipeline network. Provision of modern machinery for turning of wind rows and spraying of spentwash 3.1 Polishing Unit for Condensate, spent lees and other minor distillery effluents

Executi ve Summa ry: Expansion of Suga r, Dis tillery and Cogenera tion Project Dr. Babasaheb Ambedka r SSK Limi ted, Osmanadba d

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Wastewater sources such as spent lees, steam condensate and blow-down water will be treated through polishing unit. Treated water will be reused for dilution of molasses, cooling tower make-up water, water for the gardening/irrigation activity. Steam condensate will be recycled back as a boiler feed water to sugar factory. Thus, the industry is determined to put its sincere efforts for the recycle/reuse of water. Table 11: Polishing unit for condensate and other minor distillery effluents # 1 Unit Primary Settling Tank Purpose To remove suspended and colloidal settle able solids and BOD 2 3 Buffer Tank Aeration Tank To adjust pH by recycling alkaline returns sludge For final oxidation of Organic matter using suspended growth principle 4 Final Clarifier To settle and return the Bio-Sludge for efficient Aerobic performance

Sludge from Fermenters, ETP units, bio-digesters

Bottom and fly ash from furnace

Press-mud from sugar unit

BioComposting

Figure 5: Schematic of waste management

Executi ve Summa ry: Expansion of Suga r, Dis tillery and Cogenera tion Project Dr. Babasaheb Ambedka r SSK Limi ted, Osmanadba d

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4.0

Greenbelt development

The Major objectives of the proposed green belt development will be Mitigate impact due to fugitive emissions Control the noise levels Create an aesthetic environment Enhance the bio-diversity of the vicinity Prevent soil erosion and surface run-off Trees interspacing 3 x 3m tree density per 100m2 25 Shrubs and small trees Boundary of sugar and cogeneration, Garden/landscape areas 5 x 5m 09 medium to large size trees 10 x 10m 04 Large size trees Road side large size trees Boundary of plot area Size/type Location

There is already a good green belt developed around 5,000 trees present around the factory premises. The greenbelt development for proposed actvity will be done as per the requirement i.e. type of activity performed at a particular area/plot, thus the tree spacing will vary from plot to plot. Therefore, an average 2500 3,000 plants (including shrubs and trees) are proposed for the greenbelt development.

5.0 Safety, occupational health management

Suitable operating procedures shall be adhered for overall safety and health Use of flameproof electrics Smoking and igniting activities shall be strictly prohibited in the entire unit The plant and buildings should meet the corresponding provisions of statutes regarding inter-distances, exits, ventilation, illumination, etc. Fire fighting system shall be provided as per the statutory requirement

Executi ve Summa ry: Expansion of Suga r, Dis tillery and Cogenera tion Project Dr. Babasaheb Ambedka r SSK Limi ted, Osmanadba d

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Regular medical checkup of workers, contractual workers and employees Regular medical check-up, Group insurance and medical aid facilities should be provided as per the statutory requirement 6.0 Social environmental Aspects No rehabilitation/resettlement issues are involved The proposed project on implementation will generate 90-100 direct employment opportunities The project proponent is a cooperative sugar factory, which is owned by about 10,000 farmers, hence the revenue generated through proposed project will directly beneficial to all share holders and their families Activities such as primary school, school for cane harvesting labours, etc will be continued Compost produced from the spentwash, pressmud and other filler material will be sold to member farmers at very nominal cost; it will help in recycling the soil nutrients and help in improving the soil conditions Project proponents are already engaged with many activities under various sectors such as public health educational, cultural as well as welfare activities, they will continue their activities with updated mechanisms Table 12: Budgetary allocations for environment management for sugar and cogeneration project Sr. No. 1 2. 3. 4. 5. 6. Category Air pollution control equipments (ESP) Ash & bagasse handling Fire protection FD/ID fans Greenbelt ETP Up-gradation Total (Sugar and Cogen) Sr. No. Distillery unit Cost (in lakhs Rupees) Capital 150.00 250.00 25.00 25.00 10.00 90.00 550.00

Executi ve Summa ry: Expansion of Suga r, Dis tillery and Cogenera tion Project Dr. Babasaheb Ambedka r SSK Limi ted, Osmanadba d

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1 2. 3. 4. 5. 6. 7.

Multi-effect evaporator Bio gas plant and machineries Condensate polishing unit (mechanical) Molasses storage tank Spent wash storage lagoons Bio-compost yard Fire protection system TOTAL (distillery unit) GRAND TOTAL

400.00 300.00 125.00 97.50 115.50 135.00 25.00 1,198.00 1,748.00 Recurring cost (Rs. In Lakhs) 17.00 24.50 1.50 5.00 0.50 8.00 1.0 15.00 72.50

1. Air, noise and odour Pollution Control 2. Water Pollution Control 3. Environment Monitoring and Management 4. Occupational Health 5. Greenbelt 6. Solid waste management 7. Others Fire Protection Ash handling and disposal Total

Executi ve Summa ry: Expansion of Suga r, Dis tillery and Cogenera tion Project Dr. Babasaheb Ambedka r SSK Limi ted, Osmanadba d

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Table 13: Summary of Impact Assessment and mitigation measures Source AIR ENVIRONMENT Main pollutant SPM Stack emissions due to burning of bagasse, biogas SOx , NOx and H 2S Stacks 72 m height (for proposed boiler) ESP to control fly ash particles (for new boiler) Greenbelt of 33% of the plot area i.e. 2.5 acres Bagasse contains traces of N and S In bagasse fired boilers, the temperature encountered is <10000C due to 50% moisture in the bagasse; hence NOx emissions from combustion in the form of NO2 will be in traces H2S scrubbers for biogas Mechanized system for handling of bagasse and ash Asphalted internal roads, Adequate parking places for goods and private vehicles Pollutant Control/Mitigation Impact Assessment

Minor negative impact due to stack emissions

Negligible impact due to installation of H2S scrubber

Handling and transport of bagasse and ash

SPM

Minor negative impact due to fugitive dust

Executi ve Summa ry: Expansion of Suga r, Dis tillery and Cogenera tion Project Dr. Babasaheb Ambedka r SSK Limi ted, Osmanadba d

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Source

Pollutant

Control/Mitigation Less utilized due to captive power Regular maintenance; compliance of statute and guidelines Tank covered Provision of CO2 scrubber Mechanized system for aeration and spentwash spraying Proper operation process Proper operation process

Impact Assessment

D.G. sets

NOx, HC CO

Insignificant impact

Fermentation unit Bio-compost unit ETP unit WATER ENVIRONMENT

Insignificant impact Use of modern machines for maintaining oxygen supply will reduce the odour; hence minor negative impact Minor negative impact

CH H S Odour
4; 2

HC

Manufacturing Process

Major source Distillery Spentwash Minor effluent from sugar & cogen unit, Spent lees, steam condensate, Blow down from, cooling tower, Pump Sealing, floor

Biomethanation followed by Multiple effect Evaporation (MEE) followed by Bio-composting Steam will be utilized twice, before condensing and condensate will be recycled Other effluents will be treated in ETP and treated water will be reused Process condensate from sugar as well as distillery unit will be

Minor negative impact

Overall impact reduction due to recycle and reuse of water, rain water harvesting scheme, hence minor negative impact

Executi ve Summa ry: Expansion of Suga r, Dis tillery and Cogenera tion Project Dr. Babasaheb Ambedka r SSK Limi ted, Osmanadba d

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Source

Pollutant washing and other cleaning activities Thermal pollution Sources: boiler blow down and cooling tower blow down.

Control/Mitigation recycled; due to which the fresh water drawl will get reduced considerably spent lees and other distillery effluents will betreated in Condensate Polishing Unit (CPU) Hot water will be collected and cooled in separate ponds/tanks and recycled after cooling Zero Liquid Discharge will be achieved for sugar, distillery as well as cogeneration Treated water will be reused as a cooling tower make-up or gardening Local acceptable practice of septic tank and soak pit system will be followed Enriches soil as a source of Potash hence mixed with bio compost Dust generation will be localized and dust particles will get arrested due to the greenbelt

Impact Assessment

Sewage SOLID WASTE Boiler

Domestic wastewater

Minor negative impact Minor negative impact on air quality, positive impact on soil due to return of nutrients Mechanized handling will reduce the impact, significantly

Ash

Executi ve Summa ry: Expansion of Suga r, Dis tillery and Cogenera tion Project Dr. Babasaheb Ambedka r SSK Limi ted, Osmanadba d

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Source Process

Pollutant Pressmud (from sugar) Yeas sludge from fermentation unit of distillery Sludge

Control/Mitigation Used for making compost as a basic material for spraying spent wash Organic and degradable hence, mixed with compost Organic and degradable hence, mixed with compost

Impact Assessment Improve soil organic matter hence positive impact on soil Improve soil organic matter hence positive impact on soil Improve soil organic matter hence positive impact on soil

ETP (Sugar& Cogen), Bio-digesters and CPU(distillery) OTHER WASTE

Process

Molasses

Though, it is a waste, it is considered as a by-product since it is used as a raw Proper storage and use in distillery will material for distillery. Utilized fully in reduce the negative impact own distillery for production of RS/ENA/AA Noise sources/ noise generating activities will be under roof/covered area Regular maintenance of machinery Provisions of personal protective equipments Job rotation at high noise work places Regular health check up Walls, trees, and ample open space in surrounding will support to mitigate noise propagation to outside area

NOISE

Process machineries

Mainly Boiler, milling, STG, pumps and motors

Minor negative impact

Executi ve Summa ry: Expansion of Suga r, Dis tillery and Cogenera tion Project Dr. Babasaheb Ambedka r SSK Limi ted, Osmanadba d

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Source

Pollutant

Control/Mitigation Greenbelt development

Impact Assessment

Transportation

Regular maintenance of vehicles Well maintained internal roads and adequate parking will reduce traffic congestion and noise due to it

Minor negative impact

Executi ve Summa ry: Expansion of Suga r, Dis tillery and Cogenera tion Project Dr. Babasaheb Ambedka r SSK Limi ted, Osmanadba d

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