M/s. Athani Sugars Limited At Vishnuanna Nagar, Post - , Tal. Athani, Dist Karnatka-591234

REVISED ENVIRONMENTAL IMPACT ASSESSMENT AND ENVIRONMENTAL MANAGEMENT PLAN FOR Sugar plant Expansion from 4500 to 12000 TCD, Distillery plant Expansion from 60 to 90 KLPD & Cogeneration plant Expansion from 24 to 54 MW At Vishnuanna Nagar, Post- Navalihal, Tal. Athani, District Belgaum,

AUGUST, 2015

Prepared by: MIN MEC CONSULTANCY PVT. LTD. A-121, Paryavaran Complex, IGNOU Road, New Delhi – 110 030

Ph : 29534777, 29532236, 29535891 ; Fax: 091-11-29532568 An ISO 9001:2008 Estb. 1983 Email :[email protected]; Web site : www.minmec.co.in approved company M/s. Athani Sugars Limited At Vishnuanna Nagar, Post - Navalihal, Tal. Athani, Dist Belgaum Karnatka-591234

REVISED ENVIRONMENTAL IMPACT ASSESSMENT AND ENVIRONMENTAL MANAGEMENT PLAN FOR Sugar plant Expansion from 4500 to 12000 TCD, Distillery plant Expansion from 60 to 90 KLPD & Cogeneration plant Expansion from 24 to 54 MW At Vishnuanna Nagar, Post- Navalihal, Tal. Athani, District Belgaum, Karnataka

ISSUE 1 REV. 0 AUGUST, 2015 (Post PH)

Prepared by: MIN MEC CONSULTANCY PVT. LTD. A-121, Paryavaran Complex, IGNOU Road, New Delhi – 110 030

Ph : 29534777, 29532236, 29535891 ; Fax: 091-11-29532568 An ISO 9001:2008 Estb. 1983 Email :[email protected]; Web site : www.minmec.co.in approved company

Athani Sugars Limited Athani Sugars Limited

CONTENTS CHAPTER 3 : DESCRIPTION OF THE ENVIRONMENT

Sl. Description Page 3.1 General 3-1 No. No. 3.2 Topography & drainage 3-1 CHAPTER 1 : INTRODUCTION 3.3 Climate 3-6 1.1 Purpose of the report 1-1 3.4 Micro meteorology 3-12 1.2 Identification of the project 1-2 3.5 Air quality 3-14 1.3 Project proponent 1-3 3.6 Water resources 3-18 1.4 Brief description of the project 1-3 3.7 Noise level 3-25 1.5 Scope of study-details of regulatory scoping carried out as per 1-8 terms of reference 3.8 Traffic density 3-26 1.6 Status of litigations 1-12 3.9 Land use 3-26 1.7 Regulatory requirements 1-12 3.10 Soil quality 3-31 1.8 Compliance of terms of reference (TOR) 1-12 3.11 Ecology 3-34 CHAPTER 2 : PROJECT DETAILS 3.12 Socio-economic conditions 3-39 2.1 Products and capacity 2-1 3.13 Seismicity 3-44 2.2 Plant layout 2-1 3.14 Industries around the project area 3-44 2.3 Process description 2-4 3.15 Places of tourist/ religious/ historical interest 3-45 2.4 Co-Gen power plant 2-16 CHAPTER 4 : ANTICIPATED ENVIRONMENTAL IMPACTS & 2.5 Distillery plant 2-18 MITIGATION MEASURES 4.1 General aspects 4-1 2.6 Process modifications in alcohol fermentation for better yield 2-27 4.2 Topography and drainage 4-2 2.7 Raw material, power and water 2-29 4.3 Climate 4-3 2.8 Man power 2-35 4.4 Air environment 4-4 2.9 Mass balance of integrated unit 2-35 4.5 Noise environment 4-12 2.10 Site facilities 2-35 4.6 Traffic density 4-15

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka i EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka ii Athani Sugars Limited Athani Sugars Limited

4.7 Water environment 4-16 8.3 CSR provision by ASL 8-3

4.8 Land environment - impact & mitigation 4-27 8.4 Budgetary commitment of CSR 8-5

4.9 Solid waste - impact and management 4-28 CHAPTER 9 : ENVIRONMENTAL COST BENEFIT ANALYSIS 9-1

4.10 Ecology 4-30 CHAPTER 10 : ENVIRONMENTAL MANAGEMENT PLAN

4.11 Socio-economic environment 4-35 10.1 Corporate responsibility for environment protection (CREP) 10-7 guidelines implementation 4.12 Occupational health and safety 4-36 10.2 Corporate environment policy 10-9

4.13 Exposure pathways 4-45 CHAPTER 11 : EXECUTIVE SUMMARY OF EIA/EMP

CHAPTER 5 : ANALYSIS OF ALTERNATIVES 11.1 Introduction 11-1

5.1 Site alternatives 5-1 11.2 Project description 11-1

5.2 Technology alternatives 5-1 11.3 Description of the environment 11-2

CHAPTER 6 : ENVIRONMENTAL MONITORING PROGRAM 11.4 Environmental impact assessment and mitigation 11-6

6.1 Introduction 6-1 11.5 Analysis of alternatives 11-10

6.2 Proposed set up 6-1 11.6 Environmental control and monitoring organisation 11-10

6.3 Monitoring schedule and parameters 6-3 11.7 Disaster management plan 11-10

6.4 Budgetary provision for environment management 6-4 11.8 Project benefits 11-10

CHAPTER 7 : ADDITIONAL STUDIES: DISASTER 11.9 Project consultants 11-11 MANAGEMENT PLAN SUMMARY OF PUBLIC CONSULTATION CHAPTER 12 : DISCLOSURE OF CONSULTANTS 12-1 7.1 Risk analysis and disaster management plan 7-1 ENGAGED

7.2 Risk assessment 7-1

7.3 Disaster management plan 7-2

7.4 Summary of the proceeding of public consultation 7-8

CHAPTER 8 : PROJECT BENEFITS

8.1 Employment potential 8-1

8.2 Physical & social infrastructure 8-2

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka iii EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka iv Athani Sugars Limited Athani Sugars Limited

LIST OF TABLES 3.7 Procedure for determining various air quality parameters 3-17

Table Particulars Page 3.8 Summary of ambient air quality monitoring results 3-17 No. No. 3 3.9 Standard of ambient air quality (concentrations in μg/m ) 3-18

1.1 Salient features of the project 1-2 3.10 Location of water sampling stations 3-24

1.2 Coordinates of the project 1-4 3.11 Location of noise monitoring stations 3-25

1.3 Standards for wastewater discharges from distilleries 1-12 3.12 Ambient noise levels 3-25

1.4 Point wise compliance to terms of reference 1-13 3.13 Traffic density 3-26

2.1 Proposed land use within project area after expansion 2-1 3.14 Present land use within project area 3-27

2.2 Design parameters of sugar plant 2-4 3.15 Land use details of study area as per (census 2001) 3-27

2.3 Steam balance 2-16 3.16 Land use based on satellite imagery 3-28

2.4 Power balance 2-16 3.17 Soil sampling stations 3-33

2.5 List of equipments for cogen and brief technical 2-17 3.18 Soil test result 3-33 specifications 3.19 List of flora in buffer zone 3-35 2.6 Design parameters of the total ethanol plant 2-18 3.20 List of fauna in the buffer zone 3-38 2.7 Raw material, quantity, source and transportation 2-29 3.21 District & Tehsilwise population (Census 2001) 3-40 2.8 Characteristics of captive molasses 2-29 3.22 Demographic details of the study area (as per census 2011) 3-40 2.9 Existing water balance 2-30 3.23 Employment pattern within the study area (Census 2011) 3-43 2.10 Proposed water balance 2-33 4.1 Stack details of existing plant 4-6 3.1 Streams/ water bodies present in 10 km radius 3-6 4.2 Stack details of proposed plant 4-6 3.2 Monthly average maximum and minimum temperature at 3-7 IMD station, Belgaum (1961-90) 4.3 Maximum ground level concentration with control measures 4-10 3.3 Monthly average rainfall (mm) at IMD station, Belgaum 3-8 (μg/m3) (1961-1990) 4.4 Cumulative impacts on air quality 4-10 3.4 Average monthly relative humidity at IMD station, Belgaum 3-9 (1961-1990) 4.5 Recommended measures for control of fugitive emissions 4-11 3.5 Summary of monitored micrometeorological data (March to 3-12 during construction May 2014) 4.6 Noise attenuation with distance on flat bare ground without 4-14 3.6 Location of air sampling stations 3-14 and with green belt

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka v EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka vi Athani Sugars Limited Athani Sugars Limited

4.7 Proposed land use within project area after expansion 4-28 LIST OF FIGURES

4.8 Solid waste - impact and management 4-29 Figure Particulars Page No. No. 4.9 Exposure pathway 4-45 1.1 Location plan 1-5

6.1 Monitoring schedule and parameters 6-4 2.1 Plant layout plan 2-2

6.2 Estimated capital investment on environmental management 6-5 2.2 Photographs of plant area 2-3

7.1 Issues raised during public hearing and replies by project 7-8 2.3 Flow sheet for sugar plant 2-6 proponent 10.1 Environment management measures 10-1 2.4 Flow sheet for power co-generation 2-7

10.2 Compliance to crep guidelines for sugar industry 10-7 2.5 Flow diagram of rectified spirit plant 2-8

10.3 Compliance to crep guidelines for cogen power plant 10-7 2.6 Process flow for steam generating unit 2-17

10.4 Compliance to crep guidelines for distilleries 10-8 2.7 Process flow for power generation & distribution 2-18

2.8 Continuous cascade fermentation system 2-22

2.9 Water balance diagram for existing sugar 4500 TCD + cogen 2-31 plant 24 MW season 2.10 Water balance diagram for existing distillery 60 KLPD season 2-32

2.11 Water balance diagram for proposed sugar 12000 TCD + 2-33 cogen plant 54 MW season 2.12 Water balance diagram for proposed sugar 12000 TCD + 2-34 Cogen Plant 54 MW off season 2.13 Water balance diagram for proposed distillery 90 KLPD 2-34 season 3.1 Project & its vicinity on topography and drainage map 3-3

3.2 Map of buffer zone (10 km radius around the project) 3-4

3.3 Digital elevation map of study area 3-5

3.4 Monthly avg. max & min. temperature (°C) IMD station, 3-7 Belgaum, (1961-1990) 3.5 Monthly average rainfall (mm) IMD station Belgaum, (1961- 3-8 1990) 3.6 Monthly relative humidity (%) IMD station, Belgaum (1961- 3-9 1990) 3.7 Windrose diagram for IMD, Belgaum at 08.30 hrs 3-10

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka vii EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka viii Athani Sugars Limited Athani Sugars Limited

3.8 Windrose diagram for IMD, Belgaum at 17.30 hrs 3-11

3.9 Wind rose diagram of monitored data 3-13

3.10 Location of sampling stations 3-15

3.11 Hydrogeology in Belgaum 3-20

3.12 Depth to water level pre-monsoon (May 2006) 3-21

3.13 Depth to water level post-monsoon (Nov. 2006) 3-21

3.14 Land use pattern in the study area (Census 2001) 3-28

3.15 10 km radius land use map based on satellite imagery, 2013 3-30

3.16 Soil map of Belgaum district 3-32

3.17 Literacy level in the study area (Census 2011) 3-40

3.18 Break up of SC & ST in the study area (Census 2011) 3-41

3.19 Employment pattern in the study area (Census 2011) 3-42

3.20 Break up of main workers in the study area (Census 2011) 3-42

3.21 Break up of marginal workers in the study area (Census 3-42 2011) 4.1 Impact of existing operation 4-7

4.2 Impact of proposed operation 4-8

4.3 Impact of cumulative operation 4-9

4.4 Noise attenuation with distance in all directions over flat open 4-13 bare ground 4.5 ETP of sugar cogen complex 4-19

4.6 Typical rain water harvesting structure at buildings 4-26

4.7 Rain water oil trap and desilting chamber prior to surface 4-27 reservoir 4.8 Personal protection equipment 4-43

6.1 Organisational chart for environmental management 6-2

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka ix EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka x Athani Sugars Limited Athani Sugars Limited

LIST OF ANNEXURES ABBREVIATION

Annex. No. Particulars AMSL - Above Mean Sea Level BF - Bag Filter °C - Degree Centigrade I TOR issued by MoEF CW System - Cooling Water System CPCB - Central Pollution Control Board II Environmental Clearance of existing plant vide Letter no. F. No. J- 11011/189/2009-IA-II(I) dt. 01-09-2009 CPP - Captive Power Plant DM - Demineralization Plant III Comprehensive list of legal instruments applicable to distilleries dB - Decibels IV Climatological data recorded at IMD Belgaun, (1961-1990) EIA - Environmental Impact Assessment ESP - Electrostatic Precipitator V Micro-meteorological monitored data (March-April 2014) EMD - Environmental Management Division VI Ambient air quality test results E - East VII National ambient air quality standards (NAAQS) FGD - Flue Gas Desulphurisation GLC - Ground Level Concentration VIII Water quality test results HFO - Heavy Fuel Oil IX Test characteristics for drinking water (IS 10500 : 2012) IDCT - Induced draft cooling tower X Ambient air quality standards in respect of Noise IMD - Meteorological Department IS - Indian Standard XI Damage risk criteria for hearing loss occupational safety & health KW - Kilowatt administration (OSHA) KWH - Kilo watt hour XII List of khasras mentioned in letter of KIADB KM - Kilo metre LDO - Light Diesel Oil XIII Land use pattern in the study area as per Census 2001 MT - Million Tonne XIV Village wise population, literacy and employment pattern within the MTPA - Million Tonne Per Annum study area (Census 2011) MW - Mega watt XV Village wise amenities in the study area as per (Census 2011) MWH - Mega watt Hour MVA - Mega Volt Ampere XVI Caline4: California Line Source Dispersion Model MOEF - Ministry of Environment & Forests XVII Water withdrawal permission letter MOU - Memorandum of Understanding XVIII Sample Medical record MPN - Maximum Probable Number M3 / cum - Cubic Metre XIX Safety, Health & Environment Policy N - North XX Public hearing documents NH - National Highway XXI Court Orders NOx - Oxides of Nitrogen PF - Protected forest XXII Compliance Report of Consent to operate PM2.5 - Particulate Matter less than 2.5 XXIII EC Compliance Report microns PM10 - Particulate Matter less than 10 microns XXIV Land Agreement Papers RPM - Respirable Particulate Matter XXV Questionnaire RF - Reserve Forest SH - State Highway SPM - Suspended Particulate Matter Sq. Km - Square Kilometre TG - Turbine Generator

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka xi EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka xii Athani Sugars Limited Athani Sugars Limited

CHAPTER 1 1.2 IDENTIFICATION OF THE PROJECT

INTRODUCTION ASL proposes to expand sugar crushing capacity from 4500 to 12000 TCD, distillery from 60 to 90 KLPD and set up 24 to 54 MW biomass power plant for making RS/ENA/Ethanol at village, Taluka Athani, Dist. Belgaum, Karnataka. 1.1 PURPOSE OF THE REPORT ASL has already obtained environmental clearance for distillery (60 KLPD) and M/s. Athani Sugars Ltd. (ASL) proposes to expand its existing integrated sugar, Cogeneration Power Plant (24 MW) vide MoEF’s letter no. J-11011/189/2009-IA-II (I) dated cogeneration power project & Distillery at Kempwad village, Vishnuanna Nagar, Post 1st September, 2009 (copy given in Annexure II). ASL has also obtained consent for Navalihal, Taluka Athani, District Belgaum, Karnataka. The factory was established for a expansion of Distillery plant from 30 KLD to 60 KLD from Karnataka State Pollution Control capacity of 2500 TCD sugar, 24 MW cogen plant. The factory had expanded capacity from Board vide letter No. PCB/148/HPI/2013/1100 dated 26.10.2013. 2500 to 4500, 24 MW cogen power and 60 KLPD distilleries in year 2008. ASL proposes to expand sugar crushing capacity from 4500 to 12000 TCD, distillery from 60 to 90 KLPD and The expansion plant is proposed in the existing project area of 24 acres. No additional land set up 24 to 54 MW biomass power plant for making RS/ENA/Ethanol. The present sugar, will be acquired for the expansion phase. The entire land is owned by the company and the distillery & cogen plant has been constructed over an area of 24 acres (9.71 ha), wherein operation of the existing plant is ongoing from 2006. the proposed expansion will also take place. The company has an additional area of 96.5 acres for plantation, composting, spentwash lagoon & other non-plant activities, thus, Salient features of the project are shown in Table 1.1. having total area of 120.5 acres (48.76 ha) under its ownership. This Environmental Impact Assessment (EIA) / Environment Management Plan (EMP) report has been prepared in line TABLE 1.1 with the Terms of References (TOR) issued by MoEF, New Delhi to obtain environmental SALIENT FEATURES OF THE PROJECT clearance for the integrated sugar, cogeneration power project & Distillery. Existing Proposed additional Total Project Integrated project Same Same Environmental clearance is a statutory requirement as per EIA Notification (S.O. 1533) Plant Sugar plant 4500 TCD, Sugar plant 7500 Sugar plant 12000 dated 14th September 2006. Since the capacity of the proposed expansion of distillery plant Capacity Distillery plant 60 TCD, TCD, is more than 30 KLD, it is covered under Serial 5 (j) of Schedule and category ‘A’ and the KLPD and Distillery plant 30 Distillery plant 90 capacity of the proposed expansion of cogen power plant is less than 50 MW, it is covered Power plant 24 MW KLPD and KLPD and under Serial No. 1(d) of Schedule and category ‘B’ of the EIA Notification. All molasses Power plant 30 MW Power plant 54 MW based distillery and cane juice/non-molasses based distillery (>30 KLD) are listed at Location Kempwad village, Same Same S.N. 5(g) (i) (ii) under category ‘A’ and appraised at Central level. It is also required to get Vishnuanna Nagar, the Consent to Establish from Karnataka State Pollution Control Board (KSPCB). Post Navalihal, Taluka Athani, Dist Belgaum Form-1, Pre-feasibility report for Sugar, cogen power plant & Distillery unit was submitted Latitude 16°46' 24"N Same Same vide letter no. ASL/MoEF/3016/2013-14 dated 06.11.2013 for consideration of EAC, Longitude 74°55'27.6"E Industries (MOEF&CC). The proposal was considered by the Reconstituted Expert Land Plant - 24 acres No additional land Plant - 24 acres Appraisal Committee (Industry) (EAC (I)) in its 16th Meeting held on 20th-21st February Requirement Project– 120.5 acres Project–120.5 acres 2014. The Terms of Reference (TOR) for preparation of EIA/EMP were issued vide letter Fresh water 2,45,360 29,760 2,75,120 no. J-11011/373 /2013 –IAII (I) dated April 30, 2014. (copy given in Annexure I) requirement, KL/annum Thereafter, conforming with MOEF circular dated 24.12.2010, EIA/EMP report was Source at 13 km Same Same prepared and public hearing was conducted on 22.08.2014. Being a Category ‘A’ project (permission obtained) due to the presence of distillery, although the co-gen unit & sugar unit is Category ‘B’, the Fuel, TPA Bagasse : 2,16,000 Bagasse: 3,60,000 Bagasse: 5,76,000 EIA report is being submitted for clearance to MOEF, New Delhi. Estimated Already completed Rs. 161.53 crore Project Cost

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 1-1 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 1-2 Athani Sugars Limited Athani Sugars Limited

1.4.4 Communication 1.3 PROJECT PROPONENT Road Link M/s. Athani Sugars Ltd. (ASL) is a limited company registered under the Companies Act, 1956 under registration no. 08/17806 of 1995 dated 12th May 1995. The nearest State Highway to the site is SH-12 at 2.3 km, aerially in South. State Highway runs from Athani to Kagwad. SH-72 is at a distance of 10.0 km SW from the project. It runs Shri Shrimant Balasaheb Patil is the Chairman and Managing Director of the Factory. He from to Khurd. The following roads are near the site and in study area: initially devoted himself towards establishment of Co-op Lift irrigation Schemes and brought hundreds of acres of dry land under irrigation, enabling the farmers to grow commercial and to Road 4.3 E food crops and raise their standard of living. During the year 1993- 94 & 94-95, he observed Athani to Ainapur Road 8.7 SE that the abundant quantity of cane grown in Athani Taluka was not entirely crushed by Ugar Sugar Works Ltd, as a result the farmers were terribly suffering to find alternative sugar The nearest town is Athani at 15 kms, SSW and nearest District Headquarters is Belgaum factory to send their cane. To overcome this problem he boldly took the decision to at 108 km, SSW. establish a sugar factory in Athani Taluka. Mr. Patil, with the kind co-operation of the farmers and with the help of devoted workers successfully established a 2500 TCD sugar Rail Link plant at Madbhavi in Athani Taluka during 2001. The nearest railway station is Belunki at a distance of 10 km, SW, aerially from the project 1.4 BRIEF DESCRIPTION OF THE PROJECT site.

1.4.1 Nature of project Air Link

The proposed project is an expansion of integrated sugar, distillery and power plant. The nearest airport is Kolhapur at a distance of about 68 km, WSW. Bidar AFS is the nearest defence installation at 300 km, ENE and Belgaum Contonement area is 108 km, 1.4.2 Size SSW.

The proposed project is an expansion of sugar crushing capacity from 4500 to 12000 TCD, distillery from 60 to 90 KLPD and set up 24 to 54 MW biomass power plant for making RS/ENA/Ethanol. The expansion plant is proposed to be set up in existing 48.8 ha of land.

1.4.3 Location

The proposed expansion plant will be located at Vishnuanna Nagar, Post - Navalihal, Taluka Athani, Dist. Belgaum, Karnataka. The location map of the area is shown in Fig 1.1. The study area of the proposed project falls in Survey of India Toposheet No. 47 L/13, 47 L/14, 47P/1 and 47P/2. The coordinates of the corners (as per toposheet) of the plant is given in Table 1.2.

TABLE 1.2 COORDINATES OF THE PROJECT Latitude Longitude A 16q46’ 24’’ N 74q55’ 21’’E B 16q46’ 33’’ N 74q55’17’ E C 16q46’ 29’’ N 74q55’ 07’’E D 16q46’ 22’’N 74q55’ 09’’E E 16q46’ 09’’N 74q54’ 55’’E F 16q46’ 03’’N 74q54’ 56’’E G 16q46’ 02’’N 74q55’ 27.6’’E

Interstate Boundary of is at a distance of 0.05 Km, NW from Project site.

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 1-3 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 1-4 Athani Sugars Limited

FIG 1.1 : LOCATION PLAN

Village : Vishnunagar Navlihal Tal: Athani , Dist: Belgaum

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 1-5 Growth of sugar industry in the State started prior to independence in the private the in to independence prior started State the in industry sugar of Growth MW, 18061 was in Karnataka capacity generation thepower 2007, April 30, of As incentives from interest The for Ministryspecific include subsidy the commercial Regulatory State Electricity and Commission Regulatory Electricity Central The in the will continue energy generation renewable for offered incentives The fiscal de- provides Parliament, of houses both by the approved 2003 Bill Electricity The and ofpower supply deficiency overall acknowledged the of India has The Govt. National Scenario- Integrated Cogen AndEthanol Project region& to country Importance 1.4.5 cane growing, good quality of soil for cultivation and adequate irrigation facilities. adequate irrigation and for cultivation quality of soil good growing, cane sugar for conditions environmental todue conductive the state in growth crop cash major the been has cane Sugar Govt. Central the with line in is Karnataka in industry The in for the policy sugar 1950 onwards. and sector since sector co-operative the country. for 33% average to compared beenabout 35%, have T&D The losses sector. from Central balance the and sector private the by contributed 20% sector, state from the contributed 56% etc. efforts, promotional for undertaking associations industry consultants, Nodal Agencies, State for assistance financial loans, project for of andof detailed assistance reports preparation in subsidy syndication pressure configuration, and the temperature on depending from 1-3% projects sector. this to incentives fiscal and promotional beenseveral offering the Ministry has projects, frompower such of exportable for purchase States tothe lines guide providing from Apart 1994-95. since Power /Cogeneration Program Biomass National on the under efforts promotional been undertaking Ministry has India, the in cogeneration In order to mill about5000MW thepotential fromplants. achieve of sugar power co-gen set up to units new and sugar the existing all encourages (MNRE), Sources Energy Conventional Ministryof Non the through India, of Govt. The hearings. from inputs public and the theMNRE, policies and State ofPower Ministry from the lines guidethe on based renewable, including sources from all SEBs by electricity of purchase the for tariffs fixed commissions regulatory The sector. electricity oversee the tariffs and force to establish have into come Commission tax. duty &Central sales excise Central of exemption concessions, duty forcustoms 5 years), next exemption tax holiday with 30% year (5 income holiday accelerated tax Theydepreciation, include period. coming primarily 10%. minimum to the been this their to increase have up in bill and States guided share focused been have sources from renewable generation and power sources energy renewable the throughout The and country. distribution, of power generation licensing the situation. away improve as to accepted has been generation, renewable sources of fuel, for complimenting centralized fossil from energy generation of decentralized fuel importance The the country. basedin quality power I/M o xaso fSgr itley&CgnPati it egu,Kraaa 1-6 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka Athani Sugars Limited Athani Sugars Limited Athani Sugars Limited

utilization levels, except for draught periods. It is essential for ASL to accelerate cane As of March 2006, a total of 1189 Lols/licenses were issued in different parts of the development in the study area. The proposed state-of -art equipment in the sugar State (between 1998 till 2006) for expanding their existing capabilities and / or for plant will ensure the performance in terms of recovery, plant efficiencies and lowest installing new sugar factories. steam & power consumption for the sugar process. Due to Electricity Act, 2003 opportunities for trade of power are available and ASL should explore them to sell In India, after protection granted to the sugar industry in 1932, a large number of power at higher tariff and improve economic viability of the project. Hence, ASL will sugar factories were established in the country. Increase in sugar production have no problems to market all its surplus power. resulted in accumulation of molasses, caused unmanageable environmental problem. In 1938 UP and Bihar established a joint committee to overcome this The plant is already present at the site and it has been selected keeping the various problem by developing alcohol based industries. Today, the distillery industry of India factors in view viz. vicinity to the source of raw material and availability of other uses only molasses for the manufacturing of alcohol. infrastructural facilities e.g. land, power, water, transport, communication, approach road and access distances from the nearest highway, railway station, etc. The plant Future demand & sugar pricing is established in 24 acres from the total Athani owned area of 120.5 acres. The open land will be used to grow sugarcane for the plant. A sugar mill of 5000 TCD capacity, will be installed for manufacture of refined sugar of good quality. The sugar market in India is quite up-beat and is expected to 1.5 SCOPE OF STUDY- DETAILS OF REGULATORY SCOPING CARRIED continue for a foreseeable future. The current net price of sugar for the factories has OUT AS PER TERMS OF REFERENCE been around Rs. 22.00 per Kg. Command area has excellent sugar cane availability with about 11.5% sugar recovery. ASL has also in process to make tie-ups with the The Environmental Impact Assessment and Environment Management Plan for the big malls in the metro cities along with Mumbai for sale of branded sugar and also project addressing the environment related issues are prepared in accordance with exploring possibilities of exporting refined sugar. the requirements of terms of reference prescribed by Ministry of Environment and Forest, Govt. of India. Objectives for sugar manufacturing The study evaluates the prevailing environmental conditions. The adverse impacts The objectives of the sugar plant of the proposed integrated project are mainly to have been identified and possible mitigation measures have been drawn in order to manufacture quality sugar for national & international markets at optimum operating protect the environment. In order to carry out the study, the baseline environmental and energy efficiency, as well as to provide raw materials for cogen power plant. The scenario has been established at the first instance. integrated project will push the product, which has highest realization in the market at any given time, either sugar or power. The design of the sugar mill and the cogen The main objectives of the present EIA study are briefly summarized below: power plant would match the latest and modern technologies being employed. At the same time, the flexibility of operation, expansion and diversification, also will be ¾ To establish the baseline environmental scenario. available. ¾ To identify, predict and assess the impacts of proposed expansion project on 1.4.6 Justification for the site the environment. ¾ To prepare a detailed action plan for implementation of mitigative measures. The promoters have extensively and carefully analyzed the present and future scenario of sugar, ethanol and power industries. They studied carefully the present ¾ To suggest preventive measures to minimize adverse impacts and to maximize irrigation facilities and surplus cane availability in the command area, as well as beneficial impacts. future potential of irrigation and additional cane availability. ¾ To suggest a monitoring programme to evaluate the effectiveness of mitigative measures. By virtue of company’s business sugar manufacturing, the company is closely associated with the farmers in the surrounding area. The company’s growth and ¾ To suggest the formation of a core group responsible for implementation of the progress largely depends on the growth and progress of these farmers. This project EMP. will further add value to the sugarcane and will assist the company in sustaining and improving the cane price. ¾ To prepare a capital cost estimate for environment management plan. ¾ To address the concerns of disaster management, CSR and points raised in Most of the villages in the study area are in Athani Taluka of Belgaum district. The public hearing. existing sugar cane availability in the study area, existing and proposed irrigation facilities, cane development program underway, as well as agro-climatic conditions, Any industrial project is expected to cause environmental impacts near the project are considered adequate for sustained cane supply for the envisaged capacity site during its operation phase. The type and intensity of impacts on various

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 1-7 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 1-8 Athani Sugars Limited Athani Sugars Limited components of the environment vary depending upon the nature and size of the (including associated activities required by or for the project), proposed schedule for project as well as its geographical location. The net impacts from individual project approval and implementation, technology and process description. can be quantified through Environmental Impact Assessment studies of various components of environment such as noise, air, water, land, biological and socio- ™ Chapter 3 : Present Baseline Scenario economic aspects. EIA studies form a basis for preparing an Environment Management Plan (EMP) to conserve the environment of the area. The total EIA The base line data generated and collected will be used to establish the present study for a particular project site can be divided into three phases. The first is environmental scenario. This will cover the study area, period, components & identification of significant environmental parameters and then assessing the existing methodology, establishment of baseline for valued environmental components, as (pre-project/ pre-expansion) status within the impact zone with respect to identified in the scope and base maps of applicable environmental components. environmental descriptors. The second phase is prediction of impacts from proposed project/ expansion on identified environmental parameters based on experience of ™ Chapter 4 : Environmental Impacts & Mitigation other projects. The third phase includes the evaluation of total impacts after superimposing the predicted impacts over baseline data. This helps in incorporating (Identification, prediction and evaluation of Anticipated Environmental Impacts due to proper mitigation measures wherever necessary for preventing deterioration in the proposed plant and related facilities) environmental quality. The impact assessment and mitigation is proposed for: The scope of the present study is to conduct EIA covering all the disciplines of * Ambient Air Quality * Surface and Ground Water Quality environment and field monitoring in relevant disciplines over one full season of 3 (three) months (excluding monsoon months). The draft EIA report is prepared as per * Noise levels * Soil Quality the MoEF Notification dated 14.09.2006. After completion of the Public Consultation, all the environmental concerns expressed during the Public Consultation process * Topography * Ecology have been addressed and appropriate changes in the draft EIA Report have been made accordingly to formulate the Final EIA Report. The final EIA Report is being * Land use * Socio-economic conditions submitted to be presented to the Expert Committee (EC) of MoEF. Any queries * Traffic density * Hydro-geological Regime raised by will be clarified and replies will be submitted to them. * Occupational health and safety The project area is termed as "core zone". The area within 10 km radius around the periphery of the project boundary has been considered as the “buffer zone” for * Sensitive Places/Historical Monuments identifying and assessing impact with respect to air, water, noise, land use, ecology and socio-economic environment. The core zone and buffer zone together comprise Environmental Management plan suggesting the environmental safeguards, the "study area". The studies covering all individual components of environment are abatement technology and pollution control measures as follows: described in detail in subsequent chapters. The preparation of the EIA/EMP was proposed as per the generic structure x Air, water, noise pollution control measures prescribed in EIA Notification dated 14th September 2006, as follows: x Solid waste management ™ Chapter 1 : Introduction x Traffic management

This covers Purpose of the report, Identification of project & project proponent, Brief x Land use changes and mitigation description of nature, size, location of the project and its importance to the country, region and scope of the study – details of regulatory scoping carried out as per x Pronounce the improvement in socio-economic conditions and benefits the Terms of Reference people will get on implementation of the project. Outlining corporate social responsibility. ™ Chapter 2 : Project Description x Green belt development Plan & Reclamation Plan. (Based on study of the reports like Pre-feasibility Report or Techno-economic Feasibility Report) x Environmental monitoring, implementation organization and feedback mechanism to effect mid course corrections. This includes Condensed description of those aspects of the project (based on x Cost for Environmental Protection measure project feasibility study), likely to cause environmental impacts. Details such as type of project, project boundary & project site, layout, size or magnitude of operation

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™ Chapter 5: Analysis of Alternatives (Technology & Site) A comprehensive list of legal instruments applicable to distilleries are given in Annexure III. The standard for SPM concentration is 150 mg/Nm3 irrespective In case, the scoping exercise results in need for alternatives then description of each of the type of boiler. Standards for wastewater discharges from distilleries are given alternative, summary of adverse impacts of each alternative and selection of in Table 1.3. alternative is done. TABLE 1.3 ™ Chapter 6: Environmental Monitoring Program. STANDARDS FOR WASTEWATER DISCHARGES FROM DISTILLERIES Sl. Parameter Standard for Fermentation Technical aspects of monitoring the effectiveness of mitigation measures including No. (Distilleries, Matrices & Breweries) measurement methodologies, frequency, location and detailed budget. 1. PH 5.5-9.0 2. Suspended Solids, mg/l 100 ™ Chapter 7 : Additional Studies 3. BOD, mg/l (27qC for 3 days) 30 (disposal into inland water) 100 (disposal on land) This shall comprise of public consultation, risk assessment, social Impact 4. Colour, hazen unit All efforts should be made to remove assessment and R&R action plans or any other studies specified by MoEF. colour, odour as far as practicable.

™ Chapter 8 : Project benefits 1.8 COMPLIANCE OF TERMS OF REFERENCE (TOR)

This comprises of the improvements in the physical infrastructure, improvements in The proposed Terms of Reference (TOR) for preparation of EIA/EMP were issued J- the social infrastructure, employment potential –skilled; semi-skilled and unskilled 11011/373 /2013–IAII (I) dated April 30, 2014 (copy given in Annexure I). Table 1.4 and other tangible benefits and proposed CSR by the project proponent. gives the compliance of Terms of Reference (TOR)

™ Chapter 9 : Environmental Cost Benefit Analysis

If recommended at the Scoping stage. In this case, it has not been prescribed.

™ Chapter 10 : Environmental Management Plan

Description of the administrative aspects of ensuring that mitigative measures are implemented and their effectiveness monitored, after approval of the EIA

™ Chapter 11 : Executive Summary of EIA/EMP

This will constitute the summary of the EIA Report

™ Chapter 12 : Disclosure of Consultants engaged

The names of the Consultants engaged with their brief resume and nature of Consultancy rendered

1.6 STATUS OF LITIGATIONS

There are no litigations/ court cases pending against the project as on 28.02.2015.

1.7 REGULATORY REQUIREMENTS

There are well-defined regulatory requirements, which imply that the government must regulate various aspects of the operations and construction of distillery units to reduce their environmental and social impacts.

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 1-11 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 1-12 Athani Sugars Limited Athani Sugars Limited

TABLE 1.4 Sl. Description as per MoEF Covered in EIA as per details POINT WISE COMPLIANCE TO TERMS OF REFERENCE No. Sl. Description as per MoEF Covered in EIA as per details sharpened etc for the 10 km radius of Chapter 3. No. from area from proposed site. The Executive Summary of the project Executive Summary of the project is same shall be used for land used along with justification for the given Chapter 11 and justification for the /land-cover mapping of the area. project. project is given in para 1.4.6, page 1-7 Present land use – agricultural land, of Chapter 1 forestland wasteland, water bodies, settlements etc shall be prepared Photographs of proposed and Photographs of the plant is given in Fig based on satellite imagery. existing (if applicable) plant site 2.2, page 2-3 of Chapter 2 Topography of the area shall be As can be seen from the photographs of A line diagram/flow sheet for the Process flow sheet sugar, distillery and given clearly indicating whether the the area for expansion in Fig 2.2, page 2- process and EMP co-gen plant is given in Fig 2.3, 2.4 and 2.5 page 2-6, 2-7, 2-8 of Chapter 2. site requires any filling. Is so details 3 of Chapter 2, the land is flat and only of filling, quantity of fill material minor leveling shall be required. No filling EMP is given in Chapter 10. required, its source, transportation will be required. The site is not present in In case of existing projects seeking Certified copy of the Monitoring Report of etc. shall be given. In case the site the hilly area. expansion (i) A certified copy of the the Regional Office of the ministry of is located on a hilly terrain, a 3 – No critically polluted area and eco Monitoring Report of the Regional Environment and Forest as per circular dimentional view of the location vis- th sensitive area is present within study Office of the ministry of dated 30 May, 2012, on the status of à-vis major landuse features and area. The nearest Sanctuary and National Environment and Forest as per compliance of the conditions stipulated in locations such as Critically Polluted th Park are Sanctuary (188 circular dated 30 May, 2012, on the environmental clearance is given in Area(s) and Eco-sensitive Area (s) km, SW) and Bhagwan Mahavir N.P. (265 the status of compliance of the Annexure XXIII. found within the study area, km, SW) and critically polluted area is conditions stipulated in the Compliance of Consent to Operate is indicating shortest (aerial) distance MIDC Industrial Area, Miraj (30 km, environmental clearance and (ii) given in Annexure XXII from critically/ severely polluted WNW). status of compliance of Consent to area (s) and Eco-sensitive area(s) Operate for the ongoing existing found within the study area, operation of the project from SPCB, indicating shortest distance from the which shall include data on AAQ site shall be provided. water quality, solid waste etc shall Map showing location of Eco- There is no eco-sensitive area such as be submitted. sensitive areas such as National national park / wildlife sanctuary / A toposheet of the study area and The site location map is given in Chapter Parks / Wild Sanctuary/ Reserve biosphere reserves within 10 km radius of site location map on Indian map of 1, Fig 1.1, page 1-5. Forests within 10km. radius (study project area. The nearest Sanctuary and 1:10,00,000 scale followed by The 10 kms radius digitized from area) shall specifically be National Park are Ghataprabha 1:50,000/1:25,000 scale on and toposheet is given in Fig 3.2, page 3-4, mentioned. A map showing lanuse Sanctuary (188 km, SW) and Bhagwan A3/A2 sheet of a circle of radius 10 Chapter 3 in A3 size showing the /landcover, reserved forests, wildlife Mahavir N.P. (265 km, SW) respectively. km and further 10 kms on A3/A2 longitude, latitude and elevation contours. sanctuaries, national parks, tiger sheets with proper A Digital Elevation Model for the 10 km reserve etc in 10 km of the project longitude/latitude/height with radius is given in Fig 3.3, page 3-5, site and shortest (aerial) distance minimum 100/200 m contour shall Chapter 3. from critically/severely polluted area be included. A 3-D view i.e. DEM MRL details of project site and RL of (s) and Eco-sensitive areas. (Digital Elevation Model) for the nearby sources of water are shown in Fig Project site layout plan to scale area in 10 km radius from the The project site layout plan is shown in fig 3.3, page 3-5, Chapter 3. using AutoCAD of the project site 2.1, page 2-2, Chapter 2 while the break proposal site. showing plant details, raw up of the proposed land use is given in MRL details of project site and RL materials, fly ash and other storage Table 2.1, page 2-1 giving the required of nearby sources of water shall be plans, ash pond and water details. indicated. harvesting structures, bore well or High resolution satellite image data Satellite image is shown in Fig. 3.15, water storage, aquifers (within having 1m-5m spatial resolution like page 3-30 and landuse as per satellite 1km), dumping waste disposal, quickbird, Ikonos, IRS P-6 pan imagery is given in Table 3.16, page 3-28 greenbelt (areas), water bodies,

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Sl. Description as per MoEF Covered in EIA as per details Sl. Description as per MoEF Covered in EIA as per details No. No. rivers/drainage passing covered with tarpaulin, maintained, through/near the project area shall optimally loaded and have PUC be included. certificates. Coordinates of the plant site with Coordinates of the plant including the ash Action plan for excavation and Refer Chapter 4, para 4.9, page 4-28. topo sheet co-ordinates shall also pond within it are given in para 1.4.3, muck disposal during construction be included. page 1-3 of Chapter 1 phase. Details and classification of total Details and classification of total land Studies for fly ash, muck, slurry, Refer Chapter 4, para 4.9, page 4-28. land (identified and acquired) shall (identified and acquired) is given in Table sludge material disposal and solid be included. 3.14, page 3-27 of Chapter 3. waste generated from the plant A copy of the mutual agreement for Mutual agreement for land acquisition operations and processes and land acquisition signed with land signed with land oustees is given in environmental control measures. If oustees. Annexure XXIV. the raw materials used have trace elements, an environment Proposal shall be submitted to the The entire land is in possession of the management plan shall also be Ministry for environment clearance company. The documents of land included. only after acquiring total land. acquisition is given in Annexure XXIV. Necessary documents indicating Manufacturing process details shall The manufacturing process of sugar is acquisition of land shall be included. be included. given in para 2.3.2, page 2-5, co-gen plant is given in para 2.4, page 2-16 and Permission and approval for the use There is no forest land in the project area, distillery is given in para 2.5, page 2-18 of of forest land (forestry clearance), if hence, no permission has been sought Chapter 2 any, and recommendations of the from the State Forest Department. The manufacturing process flow sheets State Forest Department, in case for sugar, distillery and co-gen plant is the project involves forestland. given in Fig 2.3, 2.4 and 2.5, page 2-6, 2- If the project falls within 10km of an There are no eco-sensitive area within 10 7 and 2-8 of Chapter 2. eco-sensitive area, present km radius of project area. Hence, no Mass balance for the raw material Please refer Chapter 2, para 2.9, page 2- status/approval from the Standing permission has been sought from and products shall be included. 35. Committee on Wildlife of the NBWL Standing Committee on Wildlife of the shall be furnished. NBWL Energy balance data for all the Cogen plant will produce 54 MW power. components of steel plant including Out of this, about 18 MW will be utilised in Rehabilitation & Resettlement (R & No displacement is involved therefore proposed power plant shall be house and additional power generated R) shall be as per the R&R Policy of detailed R&R policy has not been incorporated . will be supplied to grid. the State Govt. and a detailed prepared. Entire land is in possession of action plan shall be included. the company One season site-specific micro- Ambient air quality data is given in meteorological data using Annexure VI. Monitoring stations have A list of major industries with name There are no industries within the study temperature, relative humidity, taken into account the pre-dominant wind and type within study area (10km area. Please refer Chapter 3, para 3.14, hourly wind speed and direction and direction, population zone and sensitive radius) shall be incorporated. page no. 3-44 rainfall and AAQ data (except receptors including reserved forests. List of raw material required, The raw material required has been monsoon) shall be collected. The analysis of all the raw materials and described in respective sections of monitoring stations shall take into source along with mode of various units in Chapter 2 and collated in account the pre-dominant wind transportation shall be included. All Para 2.5.1, page 2-20 of Chapter 2. Raw direction, population zone and the trucks for raw material and material i.e. Sugarcane will be sensitive receptors including finished product transportation must transported by trucks, cart and tractor reserved forests. be "Environmentally Compliant". trolley and the finished product i.e. Sugar One season data for gaseous Data for gaseous emissions is given in will be transported by truck and ethanol emissions other than monsoon Table 3.8, page 3- 17 of Chapter 3 by tanker. All trucks used for season is necessary. transportation of raw material and finished product are being and will be Ambient air quality monitoring at 8 The ambient air quality monitoring has

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Sl. Description as per MoEF Covered in EIA as per details Sl. Description as per MoEF Covered in EIA as per details No. No. locations within the study area of 10 been carried out at eight locations in 10 ii) Meteorological inputs (wind speed, Meteorological inputs are based on km, aerial coverage from project km radius. The sampling stations are m/s), wind direction, ambient air monitored data which is given in site with one AAQMS in downwind tabulated in Table 3.6, page 3-14 and temperature cloud cover, relative Annexure VI. direction shall be carried out. shown in Fig 3.10, page 3-15 of Chapter humidity & mixing height using 3. SODAR on hourly basis. Suspended particulate matter One PM10 sample from the core zone iii) Model input options for terrain, The model input options are given in para present in the ambient air must be has been analysed for presence of PAH plume rise, deposition, etc. 4.4.1 (i), page 4-4 analysed for source analysis – and is BDL. The ambient air quality data iv) Print-out of model input and output The model output is given in para 4.4.1 natural dust/generated from plant for PM10, PM2.5, SO and NOx is given 2 on hourly and daily average basis (i), page 4-4 operations (for eg. Cement in Annexure VI and summarized in Table dust)/flyash/etc. The SPM shall also 3.8, page 3-17, Chapter 3 v) A graph of daily averaged The required graph is given in Fig 4.1 for be analysed for presence of poly- concentration (MGLC scenario) with impact of existing operation, Fig 4.2 of aromatic hydrocarbons (PAH), i.e. downwind distance at every 500 m proposed operation and Fig 4.3 for Benzene soluble fraction, where interval covering the exact location cumulative operation. applicable. Chemical of GLC characterization of RSPM. vi) Details of air pollution control The details of the air pollution control Determination of atmospheric The atmospheric inversion level at site methods used with percentage measures are given in para 4.4.2, page 4- inversion level at the project site has been determined and given in Table efficiency that are used for emission 11 of Chapter 4 and summarized in Table and assessment of ground level 4.4.1, page 4-4 of Chapter 4. rate estimation with respect to each 4.5, page 4-11 of chapter 4 concentration of pollutants from the The ground level concentration of pollutant stack emission based on site- pollutants from the stack emission based vii) Applicable air quality standards as The air quality prediction exercise carried specific meteorological features. In on site-specific meteorological data has per LULC covered in the study area out for existing & expansion plant, case the project is located on a hilly been calculated and given in in Table and % contribution of the proposed together is given para 4.4.1 (i), page 4-4. terrain/elevation, the AQIP 4.3, page 4-10 of Chapter 4. Based on plant to the applicable air quality The summary has been given in Table Modeling shall be done using inputs CPCB’s documents “Assessment of standard. In case of expansion 4.3 page 4-10 of Chapter 4. of the specific terrain characteristics Impact to Air Environment : Guidelines for project, the contribution should be of the project for determining the Conducting Air Quality Modelling” inclusive of both existing and potential impacts of the project on (PROBES/70/1997-98) expanded capacity. the AAQ. viii) No. I-VII are to be repeated for Air quality prediction exercise has been Action plan to implement National The air pollution control measures are fugitive emissions and any other carried out for road transport and is given Ambient Air Quality Emission given in Para 4.4.2, page 4-11, Chapter source type relevant and used for in Annexure XVI. Standards issued by the Ministry 4. The sources of secondary emissions, industry vide G.S.R. No. 826(E) dated 16`h its control and monitoring as per CPCB ix) Graphs of monthly average daily The graph is also given in Annexure XVI. November, 2009 shall be included. guidelines is given in Chapter 4, para concentration with down-wind 4.4.2 A, page 4-11 along with fugitive distance emissions and control technologies x) Specify when and where the As given in point (vii) above Ambient air quality monitoring Please refer Chapter 4, para 4.4.1, page ambient air quality standards are modeling along with cumulative 4-4 for air quality prediction modeling exceeded either due to the impact should be included for the details. proposed plant alone or when the day (24 hrs) for maximum GLC plant contribution is added to the along with following : background air quality. Emissions (g/second) with and The emission will remain same because it i xi) Fugitive dust protection or dust Please refer para 4.4.2, page 4-11 of without the air pollution control is essential to install an ESP, which will reduction technology for workers chapter 4 for EIA/EMP. measures. always reduce the concentration of within 30 m of the plant active particulate matter less than 50 mg/Nm3 areas.

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Sl. Description as per MoEF Covered in EIA as per details Sl. Description as per MoEF Covered in EIA as per details No. No. A plan for the utilisation of Plan for the utilisation of waste is given in water is given in Annexure XVII waste/flue gases (if applicable) for para 4.9 , page 4-28 of Chapter 4 Water balance data including The effluent treatment system is shown in generating power shall be quantity of effluent generated, Fig. 4.5, page 4-19, Chapter 4 along with presented. recycled and reused and the scheme of zero discharge. Impact of the transport of the raw Air quality prediction exercise has been discharged is to be provided. materials and end products on the carried out for road transport and is given Methods adopted/to be adopted for surrounding environment shall be in Annexure XVI. And summarized in the water conservation shall be assessed and provided. The chapter 4, para 4.4.1 (ii), page 4-10. included. Zero discharge effluent alternate method of raw material concepts to be adopted and end product transportation shall Source of surface/ground water The water quality analysis has been also be studied and details level, site (GPS), cation, anion (Ion summarized in Para 3.6.6, page 3-24, included. Chromatograph), metal trace Chapter 3. Detailed Water quality An action plan to control and Please refer chapter 4, para 4.4.2, page element (as above) chemical analysis for anions, cations and heavy monitor secondary fugitive 4-11 analysis for water to be used. If metals is given in Annexure VIII. emissions from all the sources as surface water is used from river, Water source is Krishna river and the per the latest permissible limits rainfall, discharge rate, quantity, note on it discharge rate, quantity, issued by the Ministry vide G.S.R. drainage and distance from project drainage and distance from project site is 414(E) dated 30th May, 2008. site shall also be included. included in para 4.7.2, page 4-18 of Information regarding surface Presence of aquifer(s) within 1 km The hydrogeology is given in para 3.6.3, Chapter 4. hydrology and water regime shall of the project boundaries and page 3-19 of Chapter 3. Rain water be included. management plan for recharging harvesting measures have been outlined the aquifer shall be included. in Para 4.7.4, page 4-25 of Chapter 4. Ground water analysis with bore Ground water quality has been analyzed well data, litho-logs, drawdown and and given in Annexure VIII. There is no If the site is within 1 km radius of No major river flowing within study area recovery tests to quantify the area intent to draw ground water for either any major river, Flood Hazard only Krishna river is flowing in the study and volume of aquifer and its domestic or industrial purposes for the Zonation Mapping is required at area. Flood hazard has been discussed in management. project, therefore, detailed drawdown and 1:5000 to 1:10,000 scale indicating Chapter 3, para 3.6.1, page 3-18. recovery tests have not been carried out. the peak and lean River discharge The aquifers are shallow and localized in as well as flood occurrence this area as described in para 3.6.3, page frequency. 3-19 of Chapter 3. Details of water requirement, water Details of water requirement, water Ground water monitoring minimum The water quality analysis has been balance chart for new unit or for balance chart for existing is given in at 8 locations and near solid waste summarized in Para 3.6.6, page 3-24, existing unit as well as proposed Table 2.9, page 2-30, Fig. 2.9 and 2.10, dump zone, Geological features Chapter 3. Detailed Water quality expansion (if expansion). Measures page 2-31 & 2.32 and proposed and Geo-hydrological status of the analysis for anions, cations and heavy for conservation water by recycling expansion is given in Table 2.10, page 2- study area are essential as also. metals is given in Annexure VIII. and reuse to minimize the fresh 33 and shown in Fig. 2.11, 2.12 and 2.13, Ecological status (Terrestrial and water requirement. page 2-33 and 2-34 respectively is given Aquatic) is vital. in chapter 2. Please refer Chapter 3, para 3.11 page 3-34 for ecology. Measures for water conservation by Ground water modelling showing Please refer para 3.6.3, page 3-19 of recycling and reuse to minimize the fresh the pathways of the pollutants shall Chapter 3. water requirement are given in Chapter 4, be included para 4.7.5, page 4-27 Action plan for rainwater harvesting Action plan for rainwater harvesting Source of water supply and The water will be source from Krishna measures at plant site shall be measures at plant site is given in para permission of withdrawal of water River. `Permission’ from concerned submitted to harvest rainwater from 4.7.4, page 4-25 of Chapter 4. from Competent Authority. Department/Authority for the drawl of the roof tops and storm water drains

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Sl. Description as per MoEF Covered in EIA as per details Sl. Description as per MoEF Covered in EIA as per details No. No. to recharge the ground water and shall be included also to use for the various activities The pathways for pollution via Please refer chapter 4 para 4.7.3 page 4- at the project site to conserve fresh seepages, evaporation, residual 18. water and reduce the water remains are to be studied for requirement from other sources. surface water (drainage, rivers, Rain water harvesting and ponds, and lakes), sub-surface and groundwater recharge structures ground water with a monitoring and may also be constructed outside the management plans. plant premises in consultation with local Gram Panchayat and Village Action plan for solid/hazardous Please refer chapter 4, para 4.9, page 4- Heads to augment the ground water waste generation, storage, 28 along with ash utilization plan. level. Incorporation of water utilisation and disposal from all the harvesting plan for the project is sources and fly ash. EMP shall necessary, if source of water is bore include the concept of waste- well. minimization, recycle/reuse/recover techniques, Energy conservation, A note on the impact of drawl of Refer para 4.7.2, page 4-18 of Chapter 4. and natural resource conservation. water on the nearby River Water withdrawal permission letter is Details of evacuation of ash, details Please refer chapter 4, para 4.9, page 4- particularly during lean season. given in Annexure XVII. Permission of competent authority regarding pond impermeability and 28 for details about the ash pond for withdrawal of river/groundwater. whether it would be lined, if so details of the lining etc. need to be Surface water quality of nearby The surface water quality is given in addressed. Copies of MOU River (60 m upstream and Annexure VIII and summarized in Table regarding utilisation of ash shall downstream) and other surface 3.10, Page 3-24of Chapter 3. also be included. drains at eight locations to be provided in and around the project End use of solid waste and its Please refer chapter 4, para 4.9, page 4- site. composition shall be covered. Toxic 28 metal content in the waste material A note on treatment of wastewater Refer para 4.7.3, page 4-18 of Chapter 4 and its composition shall also be from different plants, recycle and incorporated. reuse for different purposes shall be included. Complete scheme of All stock piles will have to be on top Please refer chapter 4, para 4.9, page 4- effluent treatment. Characteristics of a stable liner to avoid leaching of 28 of untreated and treated effluent to materials to ground water. meet the prescribed standards. Action plan for the green belt Please refer chapter 4, para 4.10.2, page Provision of traps and treatment Refer para 4.7.3, page 4-18 of Chapter 4 development plan in 33 % area i.e. 4-31 plants are to be made, if water is land with not less than 1,500 trees getting mixed with oil, grease and per ha. Giving details of species, cleaning agents width of plantation, planning schedule etc. shall be included. The If the water is mixed with solid Refer para 4.7.3, page 4-18 of Chapter 4 green belt shall be around the particulates, proposal for sediment project boundary and a scheme for pond before further transport shall greening of the roads used for the be included. The sediment pond project shall also be incorporated. capacity shall be 100 times the All rooftops/terraces shall have transport capacity. some green cover. Wastewater characteristics (heavy Refer para 4.7.3, page 4-18 of Chapter 4 Detailed description on flora and Refer para 3.11, page 3-34 of Chapter 3 metals, anions and cations, trace for waste water characteristics fauna (terrestrial and aquatic) exists for flora and fauna in the core area and metals, PAH) from any other source

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Sl. Description as per MoEF Covered in EIA as per details Sl. Description as per MoEF Covered in EIA as per details No. No. in the study area shall be given with study area, respectively. No Schedule I workers. special reference to rare, endemic specie is found within the study area. Corporate Environment Policy and endangered species. If Schedule-I fauna are found within (i) Does the company has a well laid Please refer chapter 10, para 10.3, page the study area, a Wildlife down Environment Policy approved 10-9 Conservation Plan shall be by its Board of directors? If so, it prepared and furnished. may be detailed in the EIA report. Risk Assessment and Disaster Refer Chapter 7 (ii) Does the Environment Policy Please refer chapter 10, para 10.3, page (Emergency) Preparedness and prescribe for standard operating 10-9. Management Plan including process/ procedures to bring into damage control needs to be focus any infringement/ addressed and included. deviation/violation/ of the environmental or forest norms/ Occupational health: conditions? If so, it may be detailed a. Details of existing Occupational Refer para 4.12, page 4-36 of Chapter 4. in EIA. Health and Safety hazards and (iii) What is the hierarchical system or Please refer chapter 10, para 10.3, page whether they are within Permissible Administrative order of the company 10-9. Exposure Level (PEL). If these are to deal with the environmental not within PEL, what measures the issues and for ensuring compliance company has adopted to keep them with the Environmental clearance within PEL so that health of the conditions? Details of this system workers can be preserved. may be given. b. Details of exposure specific health Refer para 4.12.1, page 4-37 of Chapter (iv). Does the company have system of Please refer chapter 10, para 10.3, page status evaluation of worker. If the 4. reporting of non 10-9. worker’s health is being evaluated compliances/violations of by pre-designed format, chest x- environmental norms to the Board rays, Audiometry, Spirometry, of Directors of the company and /or Vision Testing (FAR and Near shareholders or stakeholders at vision, colour vision and any other large? This reporting mechanism ocular defect) ECG, during pre- should be detailed in the EIA report. placement and periodical examinations give the details of the Details regarding infrastructure Please refer chapter 2, para 2.10, page 2- same. Details regarding last month facilities such as sanitation, fuel, 35 analyzed data of above mentioned restroom etc. to be provided to the parameters as per age, sex, labour force during construction as duration of exposure and well as to the casual workers department wise. including truck drivers during operation phase. c. Annual report of health status of Refer para 4.12, page 4-36 of Chapter 4. workers with special reference to Impact of the project on local Please refer chapter 2, para 2.10, page 2- Occupational Health and Safety. infrastructure of the area such as 35 road network and whether any d. Action plan for implementation of Refer para 4.12, page 4-36 of Chapter 4. additional infrastructure needs to be OHS standards as per constructed and the agency OSHAS/USEPA. responsible for the same with time e. Plan and fund allocation to ensure Refer para 4.12, page 4-36 of Chapter 4. frame. the occupational health and safety Environment Management Plan Refer Chapter 10 for EMP in brief and of all contract and sub-contract (EMP) to mitigate the adverse Chapter 4 for EMP in detail.

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 1-23 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 1-24 Athani Sugars Limited Athani Sugars Limited

Sl. Description as per MoEF Covered in EIA as per details Sl. Description as per MoEF Covered in EIA as per details No. No. impacts due to the project along Refer Chapter 6, Table 6.2, page 6-5 for of EIA-EMP report for the project in with item wise cost of its capital & recurring cost. addition to all the relevant implementation. Total capital cost information as per the 'Generic and recurring cost/annum for Structure of EIA' given in Appendix environmental pollution control III and IIIA in the EIA Notification, measures shall be included. 2006. Where the documents Plan for the implementation of the Refer para 10.1, page 10-7 of Chapter provided are in a language other recommendations made for the 10. than English, an English translation Sector in the CREP guidelines must shall be provided. The draft EIA- be prepared. EMP report shall be submitted to the State Pollution Control Board of At least 5 % of the total cost of the Refer para 8.4, page 8-5 of Chapter 8 the concerned State for conduct of project shall be earmarked for the Public Hearing. The SPCB shall initial 5 years towards the conduct the Public Hearing/public Enterprise Social Commitment and consultation, district-wise, as per 2% of retain profit thereafter for life the provisions of EIA notification, of the project towards CSR based 2006. The issues raised in the on public hearing issues and item- Public Hearing and during the wise details along with time bound consultation process and the action plan shall be included. Socio- commitments made by the project economic development activities proponent on the same shall be need to be elaborated upon. included separately in EIA-EMP A note on identification and Refer para 4.3.1, page 4-3, of chapter 4. Report in the form of tabular chart implementation of Carbon Credit with financial budget (capital and project shall be included. revenue) along with time-schedule Any litigation pending against the No litigation as on 20.03.2015 of implementation for complying project and/or any direction/order with the commitments made. The passed by any Court of Law against final EIA report shall be submitted the project, if so, details thereof to the Ministry for obtaining shall also be included. Has the unit environmental clearance. received any notice under the The TORs prescribed shall be valid Section 5 of Environment for a period of two years for (Protection) Act, 1986 or relevant submission of the EIA-EMP reports Sections of Air and Water Acts? If along with Public Hearing so, details thereof and Proceedings (wherever stipulated). compliance/ATR to the notice(s) The following general points shall These have been followed. and present status of the case. be noted: A tabular chart with index for point It has been followed All documents shall be properly wise compliance of above TORs. indexed, page numbered. The questionnaire for industry Questionnaire is given in Annexure---- Period/date of data collection shall sector (available on MOEF website) be clearly indicated. shall be submitted while submitting Authenticated English translation of EIA- EMP. all material in Regional languages 'TORs' prescribed by the Expert It has been followed shall be provided. Appraisal Committee (Industry) The letter/application for shall be considered for preparation environmental clearance shall quote

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 1-25 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 1-26 Athani Sugars Limited Athani Sugars Limited

Sl. Description as per MoEF Covered in EIA as per details Sl. Description as per MoEF Covered in EIA as per details No. No. the MOEF file No. and also attach a Measures to take care of SO2 copy of the letter. emission. A copy of Memorandum The copy of the letter received from of Understanding (MoU) signed with the Ministry shall be also attached the coal suppliers should be as an annexure to the final EIA- submitted. EMP Report. Storage facility for raw materials, Storage facilities are shown in Fig. 2.1, The index of the final EIA-EMP prepared alcohol, fuel and fly ash. page 2-2 of Chapter 2. report must indicate the specific An action plan prepared by SPCB An action plan to control and monitor chapter and page no. of the EIA- to control and monitor secondary secondary fugitive emissions from all the EMP Report fugitive emissions from all the sources is given in para 4.4.2 , page While preparing the EIA report, the sources. 4-11 of Chapter 4. instructions for the proponents and instructions for the consultants Details of the use of steam from the Use of steam from the boiler is given issued by MoEF vide O.M. No. J- boiler. 11013/41/2006-IA.II (I) dated 4th Ground water quality around Ground water quality is given in August, 2009, which are available proposed spent wash storage Annexure VIII and summarized in para on the website of this Ministry shall lagoon and the project area. 3.6.6, page 3-24 of Chapter 3. also be followed. Details of water requirement, water Details of water requirement, water The consultants involved in the balance chart for existing unit as balance chart for existing and proposed preparation of EIA-EMP report after well as proposed expansion. expansion is given in chapter 2, para accreditation with Quality Council of Measures for conservation water by 2.7.4, page 2-30. India (QCI) /National Accreditation recycling and reuse to minimize the Measures for water conservation by Board of Education and Training fresh water requirement. recycling and reuse to minimize the fresh (NABET) would need to include a water requirement are given in Chapter 4, certificate in this regard in the EIA- section 4.7.3, page 4-18. EMP reports prepared by them and data provided by other Source of water supply and The water will be source from Krishna organization/Laboratories including permission of withdrawal of water River. their status of approvals etc. from Competent Authority. `Permission’ from concerned Department/Authority for the drawl of ADDITIONAL TORS FOR water is given in Annexure XVII DISTILLERY WITH CO- GENERATION UNIT Proposed effluent treatment system The effluent treatment system is given in for molasses based distillery (spent section 4.7.3, page 4-18 and Fig 4.5, List of existing distillery units in the There are no existing distillery present wash and spent lees) as well as Chapter 4. study area along with their capacity within 10 km radius domestic sewage and scheme for and sourcing of raw material. achieving zero discharge. Details of proposed products along Details of proposed products along with Spent wash generation should not Details of the spent wash treatment is with manufacturing capacity. manufacturing capacity is given in para exceed 8 KL/KL of alcohol given in para 4.7.3(iii), page 4-20 of 2.3, page 2-4 of Chapter 2. production. Details of the spent Chapter 4. Number of working days of the 160 days wash treatment for molasses based distillery unit. distillery. Details of raw materials, its source Details of raw materials, its source with Capacity for spent wash holding Details of the spent wash treatment is with availability of all raw materials. availability of all raw materials is given in tank and action plan to control given in para 47.3 (iii). , page 4-20 of Table 2.7, page 2-29 of Chapter 2. ground water pollution. Chapter 4. Sources and quantity of fuel (rice Not applicable Layout for storage of Layout for storage of bagasse is given in husk/coal etc.) for the boiler. bagasse/biomass/coal. Fig. 2.1, page 2-2 of Chapter 2.

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 1-27 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 1-28 Athani Sugars Limited

Athani Sugars Limited CHAPTER 2

Sl. Description as per MoEF Covered in EIA as per details PROJECT DETAILS No. Details of solid waste management Details of solid waste management is including management of boiler given in para 4.8, page 4-29 of Chapter 2.1 PRODUCTS AND CAPACITY ash. 4. EMP should also include the Refer Chapter 10 M/s. Athani Sugars Ltd. (ASL) proposes to expand its existing integrated sugar, concept of waste-minimization, cogeneration power project & Distillery at Vishnuanna Nagar, Post- Navalihal, Tal. Athani, recycle/reuse/ recover techniques, Dist Belgaum, Karnataka. ASL proposes to expand sugar crushing capacity from 4500 to Energy conservation, and natural 12000 TCD, distillery from 60 to 90 KLPD and set up 24 to 54 MW biomass power plant for resource conservation making RS/ENA/Ethanol. Risk assessment for storage and Refer Chapter 7 handling of alcohol and mitigation 2.2 PLANT LAYOUT measure due to fire and explosion and handling areas. ASL proposes to expand sugar crushing capacity from 4500 to 12000 TCD, distillery from Alcohol storage and handling area Refer Chapter 7 60 to 90 KLPD and set up 24 to 54 MW biomass power plant in the existing area of 20 fire fighting facility as per norms. acres. Provision of Foam System for fire fighting to control fire from the The plant layout is shown in Fig 2.1 and the areas proposed under different uses are given alcohol storage tank. in Table 2.1. The total plant area is 24 acres. In addition to that, the company owns 96.5 ADDITIONAL TOR acres of land outside the plant area for various purposes, as shown in Table 2.1. (i) Odour Management Plan (ii) Spent Wash lagoon of a capacity of TABLE 2.1 30 days (after evaporation+bio PROPOSED LAND USE WITHIN PROJECT AREA AFTER EXPANSION methanation). Examine use of steel Land Use Area (Acres) % of total tanks for storage (i) Area inside plant boundary (iii) Monitoring reports of RO is required Sugar Factory 12 50.0 (iv) Permission obtained to use water from River Krishna Distillery Plant 4 16.7 Cogen Plant 8 33.3 Total Plant area 24 100.0 (ii) Area owned outside plant Biodigestor and Compost Yard 15 Green Belt 48 Caneyard 15 Employee quarter 10 Vacant Land 8.0 Total area outside plant 96.0 Total Project area 120.0

The plant layout with proposed units, quarter, greenbelt, utilities, etc. is shown in Fig 2.1. Photographs of the plant site are shown in Fig 2.2.

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 1-29

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 2-1 Athani Sugars Limited Athani Sugars Limited

FIG 2.1: PLANT LAYOUT PLAN FIG 2.2: PHOTOGRAPHS OF PLANT AREA

Compost Spent wash tank

Biodigester

Godown

Molasses tank Co-gen unit

Bagasse yard

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 2-2 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 2-3 Athani Sugars Limited Athani Sugars Limited

2.3 PROCESS DESCRIPTION Sl. Performance Parameters Performance Values No. expected 2.3.1 Sugar alcohol and cogeneration process 1 Cane preparatory index 90 + 2 Imbibition water % of fibre 250 + Cane from nearby area will be crushed to get sugar cane juice which will further be 3 Mixed juice % cane 100 concentrated to get quality sugar crystals. Uncrystallised sugar collected in molasses will be 4 Primary pol extraction, % 75 fermented to form alcohol with Yeast cells. 5 Mill extraction, % 96

C12H22O11 + H2 O Enzyme Invertase 2 C6H12O6 6 Reduced mill extraction, % 96.50+ C6H12O6 Enzyme zymase 2 C2H5OH + 2 CO2 7 Reduced boiling house extraction, % 91.00+ 8 Total sugar loss, % cane Less than 1.6 On a theoretical basis 342 kg of sugar yields 184 kg of 100% alcohol and 176 kg of CO2. 9 Process steam required % on cane Less than 40 % Usual commercial efficiency obtained are in the range of 85% fermentation and 98 to 99% 10 Power required for plant Less than 23 kWh/TCH distillation, contributing to a total efficiency of 83 to 84%. The manufacturing process flow sheets for sugar, distillery and co-gen plant is given in Fig Ethanol or ethyl alcohol, CH3-CH2-OH is a volatile, flammable, clear, colourless liquid which 2.3, 2.4 and 2.5. finds many applications as a raw material for acetone, acetaldehyde, acetic acid, acetic anhydride, ethyl acetate, other esters, and syntheses along with its main use due to 2.3.2 Manufacturing process for sugar associated oxygen from hydroxyl group in fuel blending in gasoline. 2.3.2.1 Sugarcane Alcohol distillation will yield quality rectified alcohol. Spent wash will be used along with press mud for composting. Bagasse from cane crushing will be burnt in 130 T/H boiler for Cane is harvested at the field quality cleaned cane is transported to the factory cane yard. cogeneration of 24 MW power with turbo generator. Press mud from cane juice filtration will be used in composting and the same will be supplied to cane farmers. Ash from boiler will 2.3.2.2 Cane Yard be sold to brick producers or used in Biocopmposting. Cane is weighed at the yard without error. Yard balance is maintained as equal to 2-3 hours Following parameters and their basis are considered while designing the plant. as indicated crushing rate with respect to the factory capacity. Spillage of cane may be avoided. If tops in the following Table 2.2. are more, it may be removed. If there is any error in cane weighment, it should be corrected then and there. TABLE 2.2 DESIGN PARAMETERS OF SUGAR PLANT 2.3.2.3 Cane Carrier Sl. Design Parameters Designed Values No. Weighed cane is unloading into the cane carrier by mechanical means. Overload to the 1 Crushing capacity of the plant 12000 TCD on 24 hour basis cane carrier may be avoided by using feeder table for uniform feeding. 2 Crushing capacity of the plant 500 TCH on 24 hour basis 2.3.2.4 Mill House 3 Number of operating days 160 The weighed cane is fed to cane carrier with the help of cane un loaders. The cane carrier 4 Total crushing per annum 19.2 Lakh MT takes the cane to milling units via kicker, chopper, leveler, and fibrizor. The kicker controls 5 Sugar recovery More than 11.50% the height of cane blanket in the carrier. The chopper and leveler cut the cane in to small (220800 MT @11.5%) pieces. And finally the fibrizor or shreds the cane pieces. This is called prepared cane. The milling unit has four mill tandem each mill consist of three rollers namely feed, top and the 6 Bagasse generation % on cane 30 (576000 MT) discharge. Prepared cane is fed to first mill and from first mill primary juice (without any 7 Molasses generation % on cane 4 (76800 MT) addition of water) is extracted. The bagasse coming out from the first mill is fed to second 8 Press mud generation % on cane 4 (76800 MT) mill and so on.

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 2-4 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 2-5 Athani Sugars Limited Athani Sugars Limited

FIG 2.3: FLOW SHEET FOR SUGAR PLANT FIG 2.4 : FLOW SHEET FOR POWER CO-GENERATION

CANE WEIGHING RAW WATER ETP

CANE UPLOADING REGENER- COOLING ATION WASHIN DM TOWER WATER G PLANT Baggase CANE PREPARATION Hot Water MANUFACTURING

MILLING

JUICE WEIGHING SOFT WATER WATER SOFT COOLED WATER STEAM RECEIVER Phosphate FUEL BOILER STEAM 1 X 140 TPH TURBINE 25 MW AGROWASTE JUICE HEATING GEN GSC SO2 gas and JUICE SULPHITOR milk of lime CONDENSED STEAM USED IN OTHER UNIT JUICE HEATING

Press Mud CLARIFIER

JUICE HEATING ESP FLY ASH Seed EVAPORATOR Crystallizer

SYRUP SULPHITOR USED FOR BIO STACK COMPOSTING / BRICK MANUFACTURING SYRUP

FLOW SHEET FOR SUGAR PLANT CLEAN FLUE GAS SYRUP +SEED

PAN

CRYSATLLIZER

White Sugar Cooling Grading Weighing Bag Stitching Godown

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 2-6 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 2-7 Athani Sugars Limited

(DISTILLERY DIVISION) RECTIFIED SPIRIT MANUFACTURING PROCESS

Condensers

Beer Heater Filtered Air Condensers

R E Dilution water C T AL II F DE A II E Impure Spirit Molasses HY N R F E DE R M A L Cold Water in Sludge Y S E N setting tank Rectified Spirit T E Impure E R R Spirit Steam in REB OILE R EX HA US T REB Pump OILE Steam in R Hot Water Sludge out Fermented wash Condensate Pump to reboiler bil Spent wash Spent leese to Bio-gas plant to fermenter Condensate to boiler

FIG 2.5: FLOW DIAGRAM OF RECTIFIED SPIRIT PLANT

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 2-8 raw juiceintheraw juicetank. discharged intoraw receiving vacuum Filteredjuicefrom juice isalsoadded time. with filter accuratelyweighed Mixedwith the juiceform is mills automaticjuiceweighing scaleand a) JuiceWeighing Scale: 1. Clarification: Clarification, Evaporation and Crystallizations aretaking placein the Boiling House. 2.3.2.5 Boiling sugar and 50% moisture. Thisbagasse to the issupplied boiler unit through rake elevators. house outputDSM screens.Thefinal section through bagasse fromcontains fourthmill 2.2% of thefrom cane. The final solid called Bagasse goes toboilers andjuice goes toprocessing The roller RPM is maintainedThe rollerRPM 4.5 system isknown ascompound imbibition system isfollowed getting for good mill extraction. The lastbutone mill theimbibition water on with fiber at therate 250-275% of previous and mill the juice extracted inthat mill. the millThus ispassed tothe previous temperature °Cisadded.Thelighter 65-70 extracted juice thelastmill from isaddedto I/M o xaso fSgr itley&CgnPati it egu,Kraaa 2-9 EIA/EMPSugar, forExpansionof Distillery &Cogen Plant Dist.Belgaun, in Karnataka Raw is juiceat65-70°C lime mixed with toraise the milk of pH to - 9.5and then9.2 SO c) JuiceSulphiter (ReactionVessel): more. maximum absorption coloringof matter and other with non-sugar calcium sulphate may be maximum formation ifcalcium sulphate may bemoreatthistemperature and thereby content in burnt lime should be above 70%. Gritshould be below 2%. juice may bein the range brix. lime 8-10 of of should Milk be free grid.from Calcium oxide sulphitation 10-12 minutes. may of be in therange Brix the milk of of thelimeadded intothe maximum non-sugar and coloring matter from the juice. The retention time of the juice is passed to reduce the- 7.4. This condition pHto 7.3 should be maintained to remove microorganisms and betterreactionfor with lime of and SO Raw- 70°C. juiceisheated to by65 second or thirdvapor inorderto avoid Inversion, tokill b) Rawjuice heater (Primary juice heater): clarification.before process. Ortho phosphoric acidisadded ppm to of maintain phosphate275-325 inraw juice deposited inthe raw tankshould juice be removed to avoid carryover the sandto of the time permit apart clearingfrom period, rawjuice tankshould be washed and sand getclear juiceto produce better quality sugar minimum molassesfinal purity. the Whenever isnothingClarification butremoval of maximum and coloring matter raw juiceto from correctTo the inweighmenterror juice of weight juice of per tip ischecked every day. 200 kg/cm 1. 2. 2 g for better extraction. About 95-96% of sucrose isextracted better sucrose of g extraction. for inthemill juice About95-96% Mixed juice pH -5.2Mixed juicepH Mixed juicedirt%-0.30-0.40% ± ± 5.4 5.00 and thehydraulic pressureismaintained at108 2 gas at the reaction vessel i.e., Athani SugarsLimited 2 gas gas ± Athani Sugars Limited Athani Sugars Limited d) Treated juice heater (secondary juice heater): a) Clear juice Heater:

Treated juice from juice sulphiter is again heated to 1.2 - 1.4°C to get its point at the treated Clear juice is at 97-98 °C is heated in clear juice heater to 110-115 °C. by exhaust before juice heater by vapor from SK 1 and if necessary by exhaust as correction heater. taken to semikestner in order to maintain before evaporation i.e. semikestner to produce Depending upon the brix % of the mixed juice, the temperature may be maintained in the maximum vapors at higher temperature 110-112 °C to using for juice heater and pan boiling juice heater. without using exhaust. It is for better steam economy. e) Clarifier (Dorr): b) Semi-kestner (1):

Juice from treated juice heater is pumped through splitter box into the clarifier for setting is Clear juice from clear juice heater is heated by exhaust to around 120°C and the vapor nothing but removal of coloring matters and non-sugar as solids (Flocks) from juice to get produced in SK-1 may be having 0.3-0.4 Kg/cm2 g. pressure at 110-112 °C. This vapor is clear juice. Splitter box is used to reduce the velocity of juice before going to the clarifier taken for C massecuite boiling in pars and for treated juice heater nearly 28-30% water is and to release the air from the juice. Settling aid 0.4-0.8 ppm (magno flock) is also added evaporated in SK-1. into the clarifier to increase the settling rate of mud and to get the better quality clear juice. Clear juice is taken as overflow method to avoid the carryover of mud through the clear c) Quadruple Evaporators: juice. Outlet clear juice pH may be maintained 7.0 - 7.1 with the temperature of 97-98°C. Clear juice should be free from colloids (suspended matter) and bagacillio (or) any mud i. Evaporator: SK juice is heated in first evaporator by exhaust. The temperature of particles and it may be highly transparent and golden yellow color. vapor inside the body may be 102-103 °C nearly 12-14% of water is evaporator in first evaporator. This vapor is used to heat the juice from second evaporator. If phosphate content is below 100 ppm in clear juice, Ortho phosphoric acid may be added externally in the clear juice to maintain 100 - 110 ppm of phosphate in order to get spongy ii. Evaporator: Juice form first evaporator is heated in II evaporator by first evaporator nature of scales in the evaporations, for easy removal. vapor. The vapor temperature in second evaporator may be 92-94 °C. This vapor is again used to heat the juice in third evaporator. Nearly 12-14% water is evaporated here. Muddy juice from the bottom of the clarifier may be taken continuously to the vacuum filter mud level in the clarifier should not be above 2 cores. When the setting problem occurs in iii. Evaporator: Juice from second evaporator is heated in third evaporator by the vapor the clarifier, rate of crushing should be reduced and after satisfying the settling problem, from second evaporator. The temperature of vapor in the third evaporator may 82-83 °C. crushing may be continued. The vacuum in the body may be 12-14 inches. The vapor is used to heat the juice from fourth body. Nearly 12-14% water is evaporated in third evaporator. f) Vacuum Filter: iv. Evaporator (Last Body): The juice from third evaporator is heated in fourth Muddy juice is taken to the vacuum filter to remove juice and mud as filter cake. This is evaporator at 25-26 inches Vacuum to reduce the boiling point of syrup thereby to reduce done by proper washing with hot water of 65-70 °C and with 16-20 inches of vacuum. The the color formation and to reduce inversion losses. Third evaporator vapor is used to heat filter juice is turbid in nature and taken to raw juice tank for processing. The moisture % the juice in fourth evaporator. The concentrated juice from fourth evaporator is called as un- filter cake may be 70-75% and pol% may be 1.8 - 22% addition of bagacillo to the muddy sulphited syrup. juice should be free from sucrose. Brix % un sulphited syrup may be 55-60° Brix pH of un sulphited syrup may be 6.4-6.6 pH. The vapor at 56-60 °C from fourth body evaporator is going to condenser to condense and 2. Evaporation: thereby to spray pond through injection pit.

Evaporation is nothing but the maximum removal of wash water from clear juice to To avoid the entrainment of juice, nearly 1:3rd calendria level (tube light) may be the boiling concentrate the clear juice from 12-13 brix to 55-60° brix %. level in all the evaporators. Clear juice is having 12.5-13.5% solids and 86.5-87.5% water. Out of 87% water nearly 75- 80% of water has to be removed as vapors in the evaporators which consist as follows: Retention time of the evaporators may be 25-35 mts.

Double effect vapor cell - quadruple effect evaporator (or) Quadruple effect evaporator (or) d) Syrup Sulphitation: Quintuple effect evaporators. Un-sulphited syrup may be having high coloring matter and coloring content. In order to It is possible to evaporate nearly 80% water from clear juice only when juice evaporated in reduce this to the minimum un-sulphited syrup should be sulphited by SO2 gas as double multistage evaporators in a serious manner. sulphitation for better bleaching. The sulphited syrup should be with pH 4.6-4.8, Brix 55- 60% and color - Golden yellow, free from colloids (or) any suspended matter to be highly transparent. The retention time of syrup sulphitor may be 8-10 mts for better

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 2-10 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 2-11 Athani Sugars Limited Athani Sugars Limited bleaching. In order to have uniform bleaching of syrup chocking of SO2 gas lines if occurs (iii) C-Massecuite Boiling: It contains two steps. should be cleaned then and there. Sulphited syrup is taken to supply tank for storage before use it for pan boiling. Sulphur purity should be above 99.5%. a) C-Grain preparation b) C-Massecuite Boiling 3. Crystalisation: Crystallization is nothing but the formation and developing of purse sucrose Crystals by a) C-Grain Preparation: One third of A-heavy molasses and two third of C-light taking sucrose molasses from the syrup (or) any other molasses. In order to get pure sugar molasses may be taken through molasses conditioner and may be concentrated in the pans crystals to the required grade and to get the minimum final molasses purity multi to 86-88 Brix%. After attaining the concentration required quantity of slurry may be massecuite boiling is practiced. Based on crystal size massecuite purity. A-massecuite, B- introduced into the pall sucrose nuclio seed from the slurry may be formed as grain and the massecuite and C-massecuite are boiled as standard three massecuite boiling. formed grain is to be harden. After establishing the grains, movement water (hot water or calendria water) is to be fed until the grains are to be well harder. Movement water is used (i) A-Massecuite Boiling: It consists of two steps to maintain the same super saturation co-efficient in the meta-stable zone throughout the a) A-Footing preparation hardening the process. During hardening except movement other molasses should not be b) A-Massecuite preparation given to the pans. After hardening the grains, C-light molasses if available or B-heavy molasses may be fed. After getting the required C-grain size 80-100 microns and after a) A-Footing preparation: A-Light molasses, melt, syrup and B-Seed magma is taken reaching the capacity of the pan the feeding material is to be stopped. The moss is to be to prepared A-Footing material while curing A-Footing may be having Brix 88-90%, Purity concentrated to 90-92 brix%. Then two third of C-grain may be transferred into C-Vacuum 88-90 and Crystal Size of 350-450 microns with uniform crystal size. A - Footing may be crystaliser. One third of C-grain may be kept in the same C - pan for further boiling. The prepared for boiling three (or) four A - Massecuite Boiling. cutting grain should have Brix 90-92%, purity 50-52 and grain size 80-100 microns with uniform grains. b) A - Massecuite preparation : One third of A-Footing may be taken and boiled with A-Light molasses melt and syrup to get A-Massecuite. At the feed stage, A - massecuite (b) C-Massecuite Boiling : One-third the C-grain in the C-pan may be developed may be having Brix 93-95%, Purity 84-86 and crystal size 700-800 microns with uniform further by taking B-heavy molasses to 140 -160 microns. After attaining 140-160 microns crystal. crystals, B-heavy should be stopped and the boiling moss may be concentrated to 100 - 101 brix% then the C-massecuite may be dropped into receiving C-massecuite crystallizer. (ii) B-Massecuite Boiling: It consists of two steps The C - massecuite is having Brix 100-101%, purity 48-50% and Grain size 140-160 microns with uniform grains. a) B-grain preparation Note: b) B-Massecuite preparation 1. Pan boiling should be done only in meta-stable zone. a) B-Grain Preparation: A - heavy molasses is taken through conditioner and concentrated to 86-88 Brix and calculated quantity of slurry is fed into the pans. Sucrose nuclear form 2. If falls grains are formed during, it should be dissolved by water and then boiling may be developed as grains. After forming grains, graining should be established and should be continued. should be hardened with movement water. Movement water may be hot water at 75-80°C or calendria water at 95-98° C. During hardening feeding materials except hot water should 3. Required quantity of C-grain from vacuum crystallizers may be again taken to C- pan be avoided. After hardening movement water should be stopped. Feeding material of A- to boil C - massecuite. heavy molasses may be taking for further boiling. After attaining the required grain size 160 - 180 microns and after reaching the capacity of the pan, the mass is to be concentrated to 4. Required quantity of B- grain from vacuum crystallizers may be again taken to B-pan 90-92-brix%. Then two third of grain may be transferred into B-Vacuum crystallizer for to boil B - massecuite. further boiling and one third of the grain may be kept in the same pan for B-massecuite boiling. 5. Required quantity of A- grain from vacuum crystallizers may be again taken to A-pan to boil A - massecuite. b) B - Massecuite Boiling: A-heavy molasses may be cut as mother liquor to develop the B-grain to the required size of B-massecuite crystals to 275-325 microns. After getting 6. Crystal % A - massecuite may be 50-52% the required size of the crystals after reaching the pan capacity-feeding materials may be stopped and the moss may be concentrated to 96-98-brix%. Then B-assecuite may be 7. Crystal % B - massecuite may be 40-42% developed into B- Massecuite Cristalisers. B-Massecuite may be having Brix 96-98%, Purity 68-70 and Crystal Size 275-325 microns. 8. Crystal % C - massecuite may be 30-35%

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2.3.2.6 Crystallizers adopted in B - massecuite curing. According to the quality load may be adjusted. A - heavy molasses is separated then. Massecuite dropped from pans are having 62-65°C, which contains more sucrose in mother liquor. The sucrose from the mother liquor has to be defused and deposit on the exiting (iii) C-Massecuite for curing: Cooled C-massecuite from vertical crystaliser at 40-42°C is crystals for the further growth of crystals in order to get more crystal yield and minimum re-heated by transient heated before curing to its saturation temperature 52-54°C. This is molasses purity. for better purging (Separation) of final molasses from the crystals. Continuous centrifugal is used at 2000 RPM to separate final molasses from the crystal. Hot water at 50-55°C or A-Massecuite Crystallizers : A-Massecuite Crystallizers from pan is dropped as 60-65 °C diluted final molasses at 20-25° brix or cold water at 30°C is used as lubrication for C- in to A-massecuite crystallizer and cooled by air to 56-58°C for 4-5 hours. Then the cooled massecuite curing. In order to separate the final molasses in a better manner and to get massecuite is taken to A-centrifugal. During cooling of massecuite sterring should be there. better quality C-fore sugar and minimum final molasses purity. A-massecuite cooling is done to increase the bagging % massecuite and to reduce the A - heavy molasses purity. Optimum load may be maintained for better purging. C-fore sugar at 78-80 purity is mixed with C-light molasses at 56-58 purity to get C-fore magma mixture for C - after curing. Mesh B-Massecuite Crystallizers : A -Massecuite from B - pan at 62-65°C is dropped into B - size used may be 0.05 to 0.06 mm for C-fore centrifugal machine. massecuite crystallizer and cooled by air cum cooled water to increase exhaustion i.e., to increase crystal yield and to reduce the heavy molasses purity in order to avoid re- C - After curing: Continuous centrifugal is used at around 1800 RPM to separate C - circulation of molasses. B - massecuite may be cooled to around 8 hours to get the light molasses from magma and to get C seed purity above 97. Hot water at 75 - 80°C or temperature of B - massecuite to 52-54 °C stirring should be continued. superheated wash water at 115 - 120°C is used to wash the sucrose crystals completely and easily to maintain the C- seed purity to above 97. C light molasses may be in the range C-Massecuite Crystallizers : Massecuite from pans at 60-65°C is dropped into receiving of 56 - 58. Mesh size used for after centrifugal may be 0.06 mm. C-massecuite crystallizer for air-cooling to 6-8 hours to get 56-58°C. Then this massecuite is pumped to vertical srystaliser for further cooling. Stirring should be continued. C - Seed obtained may be completely melt and taken for A - massecuite boiling.

Vertical Crystallizer: Vertical is used to cool the C-massecuite further to 40-42°C by cold 2.3.2.8 Sugar Hopper water in order to improve exhaustion i.e. to get more crystallizers and to reduce final molasses purity to the minimum. Stirring should be continued. Sugar discharged from the machine is having higher temperature and moisture content. This may not be bagged as it is. Hence, this sugar is to be dried and cooled to 38 - 40°C. 2.3.2.7 Centrifugal Section Hot air blower at 90 - 95°C is used to dry the sugar crystal and cold air blower is used to cool the sugar to 38 - 40°C. Lumps breaker is used in the second hopper to break the lump Centrifugal are used to separate the molasses from massecuite, to wash the sugar crystals sugar is there, it should be removed from the end of the hopper before going to the sugar and to dry the sugar crystals. elevator.

Based on massecuite quality different types of centrifugal are used for curing. 2.3.2.9 Sugar Elevator

(i) A-Heavy massecuite curing: Single curing is adopted in A-massecuite boiling first Cooled sugar from the hopper is taken to the sugar grader by sugar elevator buckets. superheated wash water at 120 - 125°C with 5-6 kg/cm2 g. Crusher is used for complete washing of molasses layer around the sucrose crystals. The molasses obtained by washing 2.3.2.10 Sugar Grader is known as A-light molasses. A-light and A-heavy molasses separator should be all right. Otherwise mixing of these molasses finally take place. This may affect the quality of B - Sugar is distributed over distribution box and sieved through grader to get different size of massecuite or A-massecuite. Superheated wash water is used not only for washing and crystals for bagging separately with respect to its grade. Mesh size 8, 14, 20, 26 or 28 mesh purifying of crystals but also self-drying of sucrose crystals. The sugar discharge from the may be used in the grader. A-machine may be having the temperature of 75 - 80°C and massecuite of 0.5 - 2.0%. 2.3.2.11 Sugar Bin (ii) B-Massecuite Curing: Continuous centrifugal is used at around 1600 RPM. Hot water at 75 - 80°C superheated wash water at 115 - 120°C for washing of sucrose crystal. B - Sugar from the grader is grader is stored in the sugar bin before bagging. heavy molasses purity may be maintained in the range of 46 - 48 and B - seed purity may be maintained above 98 nearly 25% of B - seed may be used for A- boiling and remaining 2.3.2.12 Sugar Weighment 75% of B - seed may be crystallized completely and taken for A - massecuite boiling. Mesh size used for B - centrifugal may be 0.06 mm or 0.09 mm. Now a days, single curing is Sugar from the sugar bin is weighed automatically and bagged. The bagged sugar is stitched and taken to sugar go-down.

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2.3.2.13 Sugar Go-down TABLE 2.5 LIST OF EQUIPMENTS FOR COGEN AND BRIEF TECHNICAL SPECIFICATIONS Bagged sugars are stored in the godown for storage the humidity of godown should be 55 - Sl. Description Capacity Brief Specifications 60° humidity. No. 1 Boiler with ESP, TPH 140.00 87 kg and 515 deg C temp Sugar should have color below 100 ICUMSA 2 Turbine, MW with single HP 30.00 85 kg and 505 deg C temp Sucrose % above 99.5% heater Ash% 0.04 - 0.05 3 Generator and Auxiliaries 30.00 To suit steam turbine configuration 4 Total electrical distribution system Preferably with same capacity along with distribution transformers as existing 2.4 CO-GEN POWER PLANT transformers for sugar & Distillery 5 Power evacuation system To suit power evacuation of 32.26 Presently cogen plant of 24 MW to suit 4500 TCD sugar plant is established. New plant MW in season and 22.34 in off- details are given in Table 2.3, 2.4 and 2.5 respectively for steam balance, power balance season and list of equipments that will be suitable to provide steam and power for 12000 TCD 6 Water treatment plant Addition of suitable capacity as per sugar crushing and 90 KLPD distillery plant. requirement 7 Cooling tower 6900 3 cells of 2300 m3/hr The additional power generated will be supplied to grid. New power plant of 30 MW along cum/hr with 140 TPH boiler will be erected. Steam and power from the power plant will be supplied 8 Plant DCS system Shall be added to the level of to the sugar expansion unit and new distillery ethanol plant. The steam balance & power automation required balance is given in Table 2.3 & 2.4. 9 Fuel and Ash handling system Addition /modification to suit additional boiler TABLE 2.3 STEAM BALANCE Cogeneration is a process that simultaneously produces two or more forms of useful Sl. Description Season Off-Season energy, such as electric power and steam. It harnesses the thermal and electrical energy No. Operation Operation that is released as part of the production process in various industries. 1 Total steam Generated 270.00 117.60 2 Steam utilization 2.4.1 Steam generating unit Sugar process 200.00 0.00 The process flow for steam generating unit is given in Fig 2.6. FIG 2.6: PROCESS FLOW FOR STEAM GENERATING UNIT Distillery process 25.00 25.00 Steam to auxiliaries 36.35 20.93 To Turbine unit Water addition if any (4.90) (0.90) Steam Steam to Condenser 13.55 72.57 3 Total Utilization 270.00 117.60

TABLE 2.4 Bagasses Boiler Flue gas POWER BALANCE Sl. Description Season Off-Season No. Operation Operation 1 Total Power Generated 54.00 30.00 Air pre heater 2 Power utilization Hot air Sugar process 12.50 0.30 Distillery process 2.50 2.50 Power to auxiliaries 2.24 2.66 Forced draft ESP Power to Others (Office, 0.50 0.20 quarter etc) 3 Power Export 36.26 24.34 Cold air Chimney The list of equipment for cogen and brief technical specification is given in Table 2.5.

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Sl. Item Ethanol Plant on 2.4.2 Power generation and distribution No. Own/Procured Molasses ENA capacity, KLPD 84.6 The process flow for power generation and distribution is given in Fig 2.7. Ethanol capacity, KLPD 45 7 Molasses, % cane 4.0 FIG 2.7: PROCESS FLOW FOR POWER GENERATION & DISTRIBUTION 8 Molasses MT 76800 9 Filter cake, % cane 4 Bagasse Feed Water Cold Air Chimney 10 Filter cake, MT 76800 11 RS Recovery 247 ENA Recovery 242 Ethanol recovery, liters / MT of 235 Boilers Economizer Forced Draft Flue Gas molasses 12 No. of days on Own molasses days 213 Air Pre-heater Induced Draft Procured molasses days 57 High Pressure Total 270 Steam 13 Quantities Molasses required MTPD 360 Molasses required MTPA 97200 Preparatory Power Turbine Multi Turbine Devices Own Molasses, MT 76800 Procured Molasses, MT 20400 14 MP Steam, TPH 14.00 15 Power, kW 600 Exhaust 16 Water, KL/day @ 8 m3/KL 720 17 Spent wash generation per lit of RS 2.0 Sulphur melting㸾 with seven stage evaporation Process Export to Grid To Process & centrifugal 18 Total spent wash generation / day 180 station 19 Total spent wash generation per 48600 2.5 DISTILLERY PLANT annum 20 Percent solids available in Spent wash 32 The proposed distillery/ethanol plant will have manufacturing additional capacity of 30 21 Percent solids available in Spent wash 57.6 KLPD (existing 60 KLPD). The ethanol plant will be operated using steam and power that per day will be generated from the integrated project. 22 1 MT of press mud treats 2.5 m3 of 72 spent wash. Press mud required per Distillery will operate on molasses as feed stock during season and on saved / purchased day molasses as feed stock during off-season. With 45% fermentable sugar in molasses one 23 Press mud required for bio-earth 19440 ton of molasses, will yield 247 lit of total spirit and 235 lit of ethanol. Molasses required per production day and the design parameters of the total ethanol plant are given in the Table 2.6. Culture required (Micro 110 only) 1 Total Culture required TABLE 2.6 (With prescribed proportion of 0.5 1.25 DESIGN PARAMETERS OF THE TOTAL ETHANOL PLANT Kg/MT of PM + 0.1 kg/kl of SW Sl. Item Ethanol Plant on 2 Culture quantity required per annum 40000 No. Own/Procured Molasses kg 1 Cane crushing, TCH 12000 Compost Production 2 No. of hrs. per day 24 1 Annual raw material 3 No. of season days 160 Press Mud 76800 4 Cane crushing, MT 1920000 Spent wash 48600 5 No. of days of operation 270 2 Solid Contents 6 Distillery capacity, KLPD 90 Press Mud 30

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Sl. Item Ethanol Plant on The yeast propagation section is meant for generating an active yeast biomass of selective No. Own/Procured Molasses yeast breed by way of reproductive multiplication. Spent wash 32 3 Total Solids This section serves as yeast catering unit for fermenters. The section includes a set of four Press Mud 76800 vessels progressively connected in series namely yeast culture propagation vessel number Spent wash 48600 1, vessel number 2, number 3 and fourth and final vessel called a pre-fermenter. All of Annual Compost Production, MT 28200 these vessels are equipped with supply of clean sterile air, water and molasses feed. All these utilities are to be added in a measured quantity to each vessel as the vessels are 2.5.1 Raw materials, products, waste formation in alcohol fermentation equipped with individual flow metres for the same. Also a cooling jacket and plate heat cooler is provided to cool the contents of these vessels. Yeast acts best at temperature A. Raw Material Handling range 27q c to 32q c in our case.

Molasses from the bulk storage tank located in the sugar manufacturing unit premises is Pure and cultured yeast of precisely defined characteristic grown/preserved in the test pumped into a molasses day storage tank T-WRHDUPDUNDQGHQVXUHDGD\¶VSURYLVLRQ. tubes holding slanted synthetic media is used. The yeast formed as colonies on this slanted Between the passages of these two tanks it is filtered to remove any grit or macro size medium is further propagated in the laboratory under strict sterile condition successively in foreign substances by a basket filter/strainer. T-108 tank bottom is connected to the suction a 500 ml, 1000 ml and 2500 ml. culture flasks using an ideal synthetic medium. The final of a pump no. P 101-A/B via lines 13016-MOL no.13018-MOL, 13019-MOL. It is delivered and finished culture flask from the laboratory culture preparation is transferred aseptically to to tank no.T-109 by this pump via lines.13023-MOL, 13024-MOL. T-108 has a dedicated the yeast culture vessel no.1 in the plant which is holding around 100 litres of clean and low bottom drain via line no.13016-MOL. sugar content molasses medium. Clean and sterile air is passed through the vessel content continuously as yeast needs oxygen for reproduction process. Yeast multiplies in this Tank T-109 is meant for weighing the molasses in batches before it is delivered in the vessel. After around 12 to 18 hours it can obtain the desired concentration of yeast cells in process. The 24 hours count of molasses used and alcohol produced will give us the figure the molasses broth say some 300-450 million cells per ml of broth. The broth rich in cell of overall process efficiency. A flow control valve FCV-1 is located on this delivery lines. mass from vessel no.1 is now transferred to culture vessel no.2 holding around 750 litres of This valve shall switch ON/OFF to deliver a determined quantity of molasses in the tank clean and low sugar content molasses medium. Clean and sterile air is passed through the no.T-109 / process per hour. From tank T-109 weighed quantity of molasses shall be sent vessel content continuously. After around 12 to 18 hours it can obtain the desired to Tank T-11O called weighed molasses receiving tank via line 13025-MOL. concentration of yeast cells in the molasses broth say some 300-450 million cells per ml of broth. The vessel no.2 contents are now transferred to culture vessel no.3 having capacity The bottom of the tank T-110 is connected to the suction of the pump P-101 C via a line around 1500 litres. Clean and sterile air is passed through the vessel content continuously. no.13026-MOL. By this pump the weighed molasses shall be served in the process via line After around 12 to 18 hours we can obtain the desired concentration of yeast cells in the no.13027-MOL. This line joins a common header line 13028-MOL which distributes molasses broth say some 300-450 million cells per ml of broth. Finally the contents of third molasses to yeast propagation section and line 13027-MOL meeting the molasses demand vessel are passed to the prefermenter to achieve similar cell concentration. Prefermenter of fermentation section. volume is around 18000 litres. The loaded prefermenter rich with fresh yeast cell mass is transferred to the main fermenter. The cell mass continuous to grow in fermenter and B. Yeast Propagation Section attains a desired cell concentration. This cell mass is maintained in the fermenter throughout during the continuous cascade fermentation mode operation. Propagation in this As explained earlier that the molasses is diluted with water to achieve a specific desired mode is carried out only at the initial start up or inception of the process or after a prolong sugar concentration and it is subjected to the action of yeast in the fermenters. Yeast cells shut down resulting in emptying of fermenters. secret enzymes which convert these sugars in molasses to ethyl alcohol. In order to fulfil the fullest capacity of a given alcohol plant the yeast employed has to process many tonnes During the batch fermentation mode we can distribute the finished pre-fermenter between 2 of molasses into alcohol in shortest time. The width of a single yeast cell is around 1-5 main fermenters. We can recharge the pre-fermenter again immediately and cater the next microns and the length is around 20-30 microns. It is practically found that we have to two fermenters. maintain a population of around 300-450 million live and viable yeast cells per mili-litre of molasses broth in the fermenters. It is not feasible and economic to add the required huge mass of yeast externally on day to day basis.

Yeast cell has got an inherent property to multiply (reproduce) itself asexually by forming buds on its cell wall in shortest time. These buds detach, form a new adult cell and give rise to multiple cells by budding. This property of yeast to meet the required yeast population in molasses broth in the fermenters is utilized.

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FIG 2.8: CONTINUOUS CASCADE FERMENTATION SYSTEM The fermenters are cleaned and kept ready. The first fermenter T-104 is filled 1/10th of its MOLASSES total volume with dilute molasses of around 1040 S.G. Now the matured pre-fermenter is transferred to this T-104.The contents of the fermenter are kept undisturbed for around 2 hours to allow the nascent yeast cells of pre-fermenter to adapt itself. This is called as log phase. After two hours we start feeding this fermenter with molasses and water slowly. Process water Yeast starts fermenting the molasses and simultaneously growing and multiplying itself now. The feed of molasses and water is so adjusted that around 4-5% residual sugar = concentration is maintained thought in the fermenter broth. Air is supplied to the WST propagation broth continuously. The rate of feed is so employed that it shall take around 26- 30 hours to fill the tank to its full capacity. This retention is given to generate the yeast mass to the desired count of 400-600 million cells per ml. of broth in all the fermenters. The contents of T-104 are now with slow rate transferred to T-105 with adopting the same procedure followed for first fermenter. This is followed till the last fermenter (except the last fermenter is not fed with substrate).

From the last fermenter the final wash is drawn in the wash holding tank. After filling the F 1 wash holding tank the wash is sent for distillation at slow feed rate. This rate is gradually F 2 F 3 F 4 increased and set to desired feed rate for full capacity production. Concurrently the dilute molasses feed to the first three fermenters is increased to keep the fermenters and wash holding tank full to the capacity throughout. The sugar concentration of the molasses feed is so selected that it shall generate around 5.5% v/v alcohol in T-104 and around 2% v/v in T- 105 and around 1.5%v/v alcohol in the third T-106 fermenter. Final wash shall have around 8.5%v/v alcohol concentration. Please note that contents of each fermenter are overflown to next fermenter. This operation of generation of yeast cells in the fermenter broth and IHUPHQWDWLRQRIPRODVVHVWRDOFRKRODFKLHYHVDVWHDG\VWDWHDQGVKDOOODVWPRQWK¶VWRJHWKHU ALCOHOL CONC. : 6.5 We shall corroborate the yeast population by serving intermittent doses of matured ALCOHOL CONC. : 5 ± 6 ALCOHOL CONC. : 7.5 ALCOHOL CONC. : 8.5 %production 45% %production 45% % production 10% %production 0% prefermenter to the T-104.

Additives like urea and Di- ammonium Phosphate as a source of nitrogen are added in the In the outset itself we have discussed what fermentation section stands for. Four no. fermenter as and when required. Nitrogen addition favours fermentation rate and also fermenters T-104, T-105, T-106 and T-107 have been installed in series. Each fermenter is prevents formation of impurities like higher alcohol during the fermentation. The upsurge of equipped with sloping bottom and bottom drain, bottom and top manhole, sight glass, foam in the fermenter head space is controlled by addition of surfactants like surface breather valve to release excess pressure, vent to release the gases evolved during tension. Every litre of alcohol produced generates about 270 Kcal of heat in the fermenters. fermentation process, individual plate heat cooler with pump to cool the fermenter contents This excess heat is removed by continuous circulation of the fermenting wash through and nozzles to feed molasses, water, air (in metered quantity through flow metres), external plate heat exchangers PHE 102/3/4/5 called the Fermenter Cooler. The fermenter antifoaming agent, nutrient etc. Fermenter section is connected to a yeast propagation temperature is always maintained between 32°C, and 34°C, the range optimum for efficient section to receive the propagated yeast mass. The fermentation tanks are in progressive fermentation. series, that is, the contents of first fermenter T-104 flow to T-105 to T-106 so on. However a provision is made to isolate these four tanks from each other to use each tank in a The carbon Dioxide which is generated in the fermentation process carries along traces of standalone status. ethyl alcohol up to 0.8% to 1% v/v. Before letting it in the atmosphere or recovering by purification it is passed through a carbon dioxide scrubber C-11 whereby it is scrubbed by The fermentation process can be brought about in two modes. (We have made this water. This water containing ethyl alcohol is returned back to the fermenter. This minimises provision in the design) By continuous cascade type (recommended and preferred) or by the alcohol loss in the atmosphere via carbon dioxide evolution. batch type (route chosen if raw material molasses, water etc. is scanty)

Continuous Cascade Method

In this mode the substrate i.e. molasses is fed and fermented continuously into the first three of four fermenters placed in series and the outflow of one fermenter is allowed to flow in the next fermenter progressively. Yeast mass is generated continuously in the first two fermenters. The diagram shown on the previous page illustrates this mode.

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Batch fermentation Flexibility:

This is the old and out-dated method of fermentation. However it is followed under some This process accords tremendous flexibility to the operator. Process conditions and plant exceptional conditions even now. design can be varied to suit individual requirements of alcohol quality, effluent concentration and characteristics. This unit can give spent wash suitable for use in any effluent treatment We have made our fermentation section design versatile. It can handle the batch mode process. More details of this feature of process flexibility can be supplied on request. also. E. Multi Pressure, Multi-Product Distillation (EQRS, EQENA, AA ± Molecular A clean and standalone fermenter is filled with dilute molasses to its around 1/10th Sieve) capacity. A matured pre-fermenter is transferred to this. Contents are left undisturbed for around 1-2 hours. Then the fermenter is filled rapidly to its full capacity within a span of 3-4 The Distillation Plant offered is a Multi pressure Multi product distillation system with all hours maintaining molasses gravity 1100 SG throughout, the fermenter is left alone. The prescribed auxiliary equipment and services as required to produce, as a minimum, the fermentation will conclude within a span of 32 to 38 hours producing 8.5% v/v alcohol. This desired ethanol quality. The system consists of total 4 nos. column along with related fermenter is distilled by drawing the wash directly to distillation. condenser, coolers, pump, piping, etc.

C. Fermentation The distillation columns provided are as follows:

Cane Molasses, a waste generated from cane sugar manufacturing process is used for the ¾ Analyser column production of ethyl alcohol. Molasses contains about 50% total sugars, of which 30 to 33% is cane sugar & the rest are other reducing sugar. These sugars present in the molasses ¾ Extractive distillation (Hydroselection) column are subjected to the action of yeast of the species Saccharomyces cerevisiae, a living unicellular microorganism belonging to class fungi. Diameric sucrose undergoes ¾ Rectifier column & Recovery column decomposition due to metabolic activities of yeast and monomeric invert sugars such as glucose and fructose are produced in inversion process. Fermentation of these total invert The above distillation system is run as below for following products: sugars in the molasses broth gives ethyl alcohol and carbon dioxide. This is an exothermic (heat evolving), biochemical reaction brought about by the action of certain enzymes Export Quality RS : Analyzer Column (Atmospheric) secreted by the yeast. For bringing out above biochemical reaction requires proper & Hydroselection column (Atmospheric) careful handling of yeast, optimum parameters like pH, temperature & substrate Rectifier (Pressure) Recovery column (Atmospheric) concentration to be maintained in the fermenter vessels which results into effective conversion of sugars to alcohol. While producing Export Quality RS, the hydroselection column is run at lower dilution. The analyser and Extractive Distillation column are run in vacuum. The overhead vapours of D. Post clarification system of fermented wash by gravity settling system and Rectifier are fed to the Analyzer re-boiler. The product is drawn from the top of the Rectifier decanter Column. The operation of Rectifier under pressure enables to operate the Analyzer under vacuum. The direct benefit of such Pressure Vacuum system results in energy saving and The post clarification of fermented wash is brought about by well-designed gravity settlers reduces down time in plant operation (cleaning of scales in Analyser Column). This further system. The fermented wash from the last fermenter (in case of continuous cascade ensures very good quality of product. fermentation) is collected in a sludge settling tank no.T-111.This.tank has large conical bottom. The sludge and used yeast in the wash settles at the bottom cone of T-111. The ENA Column: Analyzer Column (Atmospheric) Hydroselection column (Atmospheric) clear wash is drawn by overflow from the top of this tank (leaving the bottom contents of Rectifier (Pressure) tank undisturbed) to a buffer tank to send to distillation section. The settled mass at the bottom of T-111 is diluted with water and sent to a sludge washing tank T-112.From this The system is operated in the same manner as detailed for EQRS operation. However, the tank it is fed to a sludge decanter centrifuge D-101. The decanter separates the sludge Extractive column is operated under higher dilution rate. In order to ensure the ENA quality, mass which is discarded. The sludge free liquid from decanter recycled in the system for the refining column is used in the system for further removal of traces of impurities. alcohol recovery. Recovery column is used in the system for further removal of traces of impurities. This helps in reducing the sludge in fermented wash allowing clear liquid to enter the distillation. This will minimize the scaling of the distillation columns as well as other equipment. This also avoids a caramalisation and charring of wash under distillation which imparts burnt and other off flavors to final product.

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 2-24 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 2-25 Athani Sugars Limited Athani Sugars Limited

Anhydrous Alcohol: Analyzer Column (Atmospheric) Rectifier (Atmospheric) 2.6 PROCESS MODIFICATIONS IN ALCOHOL FERMENTATION FOR BETTER YIELD The rectifier is operated under pressure. The overhead vapours of the Rectifier are used to heat the reboiler of the Analyzer. Part of the vapours of the rectifier are sent to the Special features, Performance and Efficiencies of the project based on this process superheater of the Molecular sieve plant. Superheated vapours are passed through the are as follows : molecular sieve plant. Superheated vapours are passed through the molecular sieve beds for dehydration. a) Distillery project

The vapour passes through a bed of molecular sieve beds and water in the incoming ¾ Truly continuous fermentation process with yeast recycling vapour stream is adsorbed on the molecular sieve material and anhydrous ethanol vapour exists from the Mol Sieve Unit. ¾ Higher yields ± yield of 247 ltrs of alcohol per ton of molasses containing 45% F.S. is guaranteed Hot anhydrous ethanol vapour from the Mol Sieve Units is condensed in the Mol Sieve Condenser. The anhydrous ethanol product is then further cooled down in the product ¾ Lower effluent generation ± the process generates only 8 to 10 ltrs of effluent per ltr cooler, to bring it close to the ambient temperature. of alcohol produced (as against 14 to 15 ltrs per ltr of alcohol produced in case of other conventional processes) The two Mol Sieve Units operate sequentially and are cycled so that one is under regeneration while the other is under operation, adsorbing water from the vapour stream. ¾ Yeast recycle ± In this process, the yeast is efficiently separated and fed back to The regeneration is accomplished by applying vacuum to the bed undergoing regeneration. fermenter. Therefore no fresh yeast is required to add every day. This also avoids The adsorbed water from the molecular sieve material desorbs and evaporates into the loss of sugar due to yeast growth. ethanol vapour stream. The mixture of ethanol and water is condensed and cooled against cooling tower water in the Mol Sieve Regenerant Condenser. Any uncondensed vapour and ¾ Weak beer recycle ± this unique feature allows higher dissolved solid level in the entrained liquid leaving the Mol Sieve Regenerant Condenser enters the Mol Sieve fermenter broth which not only makes process infection resistant but also reduces Regenerant Drum, where it is contacted with cooled regenerant liquid. water and steam consumption.

The cooled regenerant liquid is weak in ethanol concentration, as it contains all the water ¾ Requires only on fermenter and hence very less floor area for the plan desrobed from the Molecular Sieve Beds. This low strength liquid is recycled back to the Stripper / Rectifier Column for recovering the ethanol. The water leaves from the bottom of Performance and Efficiencies the column and contains only traces of alcohol. The capacity offered will produce min. 81000 lit of spirit (94.68% v/v) per 24 hrs, conforming Bio-fertiliser to IS 323, 1959 grade I. Impure sprit production will not exceed 4050 ltrs per 24 hours. The total spirit production shall be 76950 ltrs per 24 hrs. This process has been specifically developed to treat distillery effluent- spent wash with organic matter like press mud. This process not only helps you in solving your effluent Fermentation efficiency will be between 90% and the distillation efficiency will be 98.5%. treatment problem, but also produces valuable Biofertilizer. The process does not give any These efficiencies are based on stable operating conditions and quality of raw material liquid discharge after the treatment. This is a zero pollution process in real terms. This used. process produces good quality compost which is a valuable product for farmers. Extra Neutral Alcohol The process mainly uses a machine called ³$(527,//(5´which is manufactured by Alfa Laval in India. The machine aerates the mass of press mud and spent wash to treat the The ENA produced will be of quality better than IS 6613-1972, specs for neutral spirit for mixture aerobically. Alfa Laval also supply bioculture, namely, Micro 110 for speedy alcoholic drinks. Rectified spirit as per IS 323 Grade I will be the raw material. Re-distillation decomposition of organic matter. Besides this, they supply complete knowhow for practicing efficiency will be 98.5%. Bioearth Scientific Composting process. Anhydrous Alcohol This process has been approved by Pollution Control Boards in Maharashtra, Andhra Pradesh, Tamil Nadu and Maharashtra. There is also a consent from Central Pollution It is a mature and reliable technology capable of producing a very dry product. However, its Control Board for this process. There are 16 plants in India who have been quite high capital cost, energy consumption, reliance on toxic chemicals like benzene, and successfully practicing this process and have also generated sizeable revenue from the sensitivity to feedstock impurities, has virtually eliminated the use of azeotropic distillation in sale of Biofertilizer. modern ethanol plants. Benzene has been used as entrainer of choice for ethanol dehydration but it is now known to be a powerful carcinogen.

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 2-26 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 2-27 Athani Sugars Limited Athani Sugars Limited

b) Bio-Fertiliser Some of the advantages of Molecular sieve technology for ethanol dehydration are as follows:- ¾ Total abatement of pollution as per existing rules of Water Pollution Control Board

¾ The basic process if very simple, making it easy to automate which reduces labour ¾ pH will be between 6.5 to 7.5 and training requirements, ¾ No spent wash colour will elute. The supernatant of 1% solution will have a murky appearance similar to 1% solution of black earth. ¾ The process is inert. Since no chemicals are used, there are no material handling or liability problems which might endanger workers, ¾ This process will not have repulsive odour. The effluent / spent wash odour will be completely destroyed. ¾ Molecular sieves can easily process ethanol-containing contaminants, which would cause immediate upset in an azeotropic distillation system. In addition to 2.7 RAW MATERIAL, POWER AND WATER ethanol, a properly designed sieve can dehydrate a wide variety of other chemicals, thereby providing added flexibility in future operating options, 2.7.1 Raw material The molecular sieve desiccant material has a very long potential service life, with ¾ The source of sugarcane will be from own farms and any shortfall to be met from the failure occurring only due to fouling of the media or by mechanical destruction. A nearby farmers for the sugar plant whereas the molasses and bagasse with be used from properly designed system should exhibit a desiccant service life in excess of 5 within the plant. The transportation shall be done through tractor trolleys, trucks and carts, years, as per the mode available with the farmer. Annual requirement of various raw materials for the proposed is tabulated in Table 2.7. ¾ It can be configured to function as a stand-alone system or to be integrated with the distillation system. This lets the customer make the trade-off between TABLE 2.7 maximum operating flexibility versus maximum energy efficiency, RAW MATERIAL, QUANTITY, SOURCE AND TRANSPORTATION ¾ If fully integrated with the distillation system, a steam consumption rate only slightly above the absolute theoretical minimum for the separation can be Unit Raw material Quantity Source Mode of achieved, transportation Sugar Sugarcane 500 TCH Own, nearby Truck, Tractor ¾ A properly designed molecular sieve can reliably dehydrate 160 ± proof ethanol to farmers 190 + proof, making strict control of rectifier overhead product quality Co-gen Total Baggase 150 TPH Self Not applicable unnecessary. plant generated (peak) Distillery Molasses 20 TPH Self Not applicable Advantages of System: 2.7.2 Raw material analysis ¾ Minimal Labour. Captive molasses from sugar process will have characteristic as given in Table 2.8. ¾ Stable operation. TABLE 2.8 ¾ Near theoretical recovery. CHARACTERISTICS OF CAPTIVE MOLASSES ¾ Steam consumption minimized by multi-stage preheating to permit substantial heat 1. Water 18 - 20% recovery and reuse. 2. pH 5.5 ± 6.0% 3. Colour Dark Brown ¾ An advanced control system, developed through years of experience, to provide 4. Total Dissolved Solids 82% sustained, stable, automatic operation. 5. Sucrose 35% ¾ Consistent excellent product quality maintain 6. Reduced Sugar 20% 7. Unfermented Sugar 6% ¾ The AA produced will be of quality 99.8% v/v. 8. Protein 2% 9. Sulphated ash 10% ¾ The feedstock quality, ethanol 95% v/v. 10. Specific gravity 1.4 11. Calorific value 3050 Kcal/Kg.

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 2-28 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 2-29 Athani Sugars Limited Athani Sugars Limited

3 12. SO3 1.5% Unit Fresh water Recycled (m /day) Total 3 3 13. K2O 4.8% (m /day) (m /day) 14. SiO2 0.4% 15. MgO 0.8% 16. Fe2O3 0.3% Sugar Plant Nil Nil Operation closed in 2.7.3 Power offseason

Company proposes to have power supply from 440 V, 50 cycles from in house captive Cogen Plant 935 Nil 935 power plant of sugar mill. Hence the power supply from the grid is not proposed as the Distillery 432 638 (From Evaporate condensate from 1070 power supply will be available from the cogen power plant. Distillery Unit) Total 1367 638 2005

The estimated power requirement is as under: FIG 2.9: WATER BALANCE DIAGRAM FOR EXISTING SUGAR 4500 TCD + COGEN PLANT 24 MW SEASON. x RS - @ 130 kwh/KL x ENA - @ 139 kwh/KL x Ethanol - @ 140 kwh/KL Sugar Plant It is inclusive of power consumption in plant, off-site equipment, factory lighting, etc. Currently using one DG set & its capacity is 1250 KVA. 500 m3/d to sugar unit Condensate polishing unit 1320 m3/day (Evaporator 2.7.4 Water requirement condensate available from Sugar Plant

Total fresh water requirement is 189472 KL/annum, out of which the existing fresh water requirement is 245360 KL/annum and proposed additional is -55888 (reduction by 22.78%). 820 m3/d The water will be sourced from Krishna river for which the permission has been obtained. The existing water balance is given in Table 2.9 and depicted in Fig 2.9 & 2.10. Cogen plant 1238 m3/day Fresh water source TABLE 2.9 418 m3/d EXISTING WATER BALANCE Unit Fresh water Recycled (m3/day) Total (m3/day) (m3/day)

Boiler Blow Down 62.4 Cooling Tower Blow Down Season (160 days) m3/day 230.4 m3/day Sugar Plant Nil 500 (Evaporator condensate available 500 from Sugar Plant) Cogen Plant 418 820 (Evaporator condensate available 1238 from Sugar Plant) Total Effluent Generated 292.8m3/day Distillery 432 638 (From Evaporate condensate from 1070 ETP Green Belt Distillery Unit) Total 850 1958 2808 Offseason (80 days)

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 2-30 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 2-31 Athani Sugars Limited Athani Sugars Limited

The proposed water balance is given in Table 2.10 and depicted in Fig 2.11, 2.12 & 2.13 FIG 2.10: WATER BALANCE DIAGRAM FOR EXISTING DISTILLERY 60 KLPD for peak and off seasons. The peak water requirement shall be 189,472 KL/annum. SEASON TABLE 2.10 Recycle water form evaporation PROPOSED WATER BALANCE Fresh water 432m3/d condensate 638 m3/d Unit Fresh water Recycled (m3/day) Total (m3/day) (m3/day) Season (160 days) Sugar Plant Nil 1200 (Evaporator condensate available 1200 Distillery plant from Sugar Plant) Cogen Plant 448 1220 (Evaporator condensate available 1668 Total water 1070 m3/d from Sugar Plant) Distillery 535 865 (From Evaporate condensate & 1400 return condensate from Distillery Unit) Total 983 3285 4268 Process 548 m3/d Distillery condensate Offseason (80 days) 238m3/d Sugar Plant Nil Nil Operation closed in offseason Cogen Plant 938 Nil 938 Concentrate BMSW 120 Evaporate condensate m3/d water 400 m3/d Distillery 535 865 (From Evaporate condensate & 1400 return condensate from Distillery Unit) Total 1473 865 2338

FIG 2.11: Water balance diagram for Proposed Sugar 12000 TCD + Cogen Plant 54 MW Bio composting Season Sugar Plant

3285 m3/d (Evaporator condensate available from sugar plant and distillery return condensate ) 1220m3/d

1200m3/d 1668 m3/d Cogen Plant 448 fresh water

Boiler blow down Cooling tower blow 139.2 m3/d down 230.4 m3/d

Total effluent generated 369.6 m3/d ETP gardening

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 2-32 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 2-33 Athani Sugars Limited Athani Sugars Limited

FIG 2.12: WATER BALANCE DIAGRAM FOR PROPOSED SUGAR 12000 TCD + 2.8 MAN POWER COGEN PLANT 54 MW OFF SEASON Total existing manpower of the sugar factory is 500 and additional 300 employees will be required for expansion. Total 140 rooms are available,100 rooms for family & 40 for 938 fresh water Cogen Plant 938 m3/d bachelors. Septic tank & soaking pit provided to treat domestic waste generated from colony.

2.9 MASS BALANCE OF INTEGRATED UNIT

(i) Sugar Plant Boiler blow down Cooling tower blow Cooling tower evaporation 4.4m3/d down 155.52 m3/d Make Up 777.6 m3/d Crushing capacity per day 12000 tons sugar cane --> 3600 tonnes baggase + 1440 tonnes crystal sugar + 6000 tonnes (moisture) + 480 tonnes (press mud) + 480 tonnes molasses

(ii) Distillery plant Total Effluent generated ETP 159.92 m3/d Gardenin Chemistry

C6H12O6 (Glucose) --> 2C2H5OH + 2CO2 FIG 2.13: WATER BALANCE DIAGRAM FOR PROPOSED DISTILLERY 90 KLPD 180 --> 92 + 88 SEASON AND OFF SEASON 1 ton of molasses = 45 % sugar (Glucose)

Fresh water 535 m3/d 865 m3/d From Evaporate condensate & return Therefore, condensate from Distillery 450 kg of sugar = 247 kg(litr) Alcohol + 203 kg CO2

In a year 97200 ton of molasses used as raw material = 43740 ton of sugar (glucose)

total water for Distillery unit 43740 Tons Sugar (Glucose) --> 24008 Tons KL of alcohol + 19731 Ton of CO2. 265m3/d 1400m3/d

2.10 SITE FACILITIES

Process 822 m3/d Distillery condensate x Details regarding infrastructure facilities such as sanitation fuel, restrooms, 578 m3/d medical facilities, safety during construction phase etc have been provided to the labour force during construction as well as to the causal workers including truck drivers during operation phase has been adequately catered for and details furnished. Conc BMSW Evaporator Condensate x Employees of the company provided apartments having flat systems and 180 m3/d 642 m3/da colony. It is located about 1 km from factory premises. 600 m3/d x Work shop with all modern maintenance facilities have been provided. Communication facilities such as telephone, telefax and Internet are available in vicinity of the proposed plant site. composting x All employees have been provided canteen facility, rest room, locker room, sanitation facility, entertainment and sport tournament in our industry premises. Note : No Fresh water required for proposed distillery unit in Season

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 2-34 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 2-35 Athani Sugars Limited Athani Sugars Limited

The company has purchased its own well equipment ambulance and also CHAPTER 3 appointed three drivers to provide 24*7 ambulance service to all employees. x A suitable technical office & administrative office has been constructed for the DESCRIPTION OF THE ENVIRONMENT project activities and operation phase 3.1 GENERAL

3.1.1 Sources of environmental data

The baseline information on micro-meteorological data, ambient air quality, water quality, noise levels, soil quality, floristic descriptions and traffic density have been generated by M/s JV Analytical Services, Pune. Long term meteorological data available from the nearest IMD station at Belgaum, about 108 km aerial distance from plant site towards SSW direction. Apart from these, secondary data have been collected from Census Handbook, Revenue Records, Forest Department, etc. The generation of primary data as well as collection of secondary data and information from the site and surroundings was carried out during summer season from March to May 2014. The data was generated after the receipt of the Terms of Reference from Ministry of Environment and Forests in line with the requirements of the MoEF.

3.1.2 Study area

For the description of baseline environmental scenario, the plant area has been considered as the core zone. The area falling within a distance of 10 km from the boundary of the core zone has been considered as the buffer zone. It falls within Maharashtra & Belgaum District of Karnataka. The core zone and the buffer zone, combined together, form the study area for determination of baseline status and for assessment of impacts.

Belgaum district is located in the north-western part of Karnataka state. It is a frontier district of the State and is bounded on the south-west by Goa, on the west north-west and north by the district of the Ratnagiri, Kolhapur and Sangli of Maharashtra State, on the east by Belgaum district, and on the south by the district of Dharwad and Uttar Kannad. It may be incidentally noted that the jurisdiction of this district extends over 2 villages (of Belgaum taluka) which are located a few kilometers away from the district borders.

3.2 TOPOGRAPHY & DRAINAGE

The landscape of Belgaum district mainly consist of vast stretches of plains studded with solitary hills, most of which are flat topped and are adorned with fortifications. The western fringe particularly in the south is at a relatively higher elevations. The district may be divided into four natural divisions. The western belt which is quite narrow, is characterized by rugged terrain. The extreme west is in fact a succession of valleys running between the spurs that stretch out from the Sahyadri range. In this zone, the rainfall is moderate to heavy and the climate is damp and cool and the vegetation is abundant. The northern belt consists of plateau of poor soils and is characterized by a dry climate. Amidst the plains there are some low rolling hills which are generally devoid of tree growth. The banks of the rivers and streams are however flanked with rich black cotton soil. The central belt is separated by the Belgaum hills on the west and further east by succession low sand stone ranges. The Ghatprapha valley which has its origin in the Western Ghat changes here into the waving plains broken by lines of low hills.

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 2-36 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 3-1 Athani Sugars Limited

The southern belt presents a mixed landscape, while the lands of west of Maharashtra valley are covered by rugged hills and forest, the lands in the eastern zone are more open and consist of level ground broken by gentle slopes and an occasional mass of granite. Black cotton soil is the predominant type of soil noticeable in this belt. Towards the east the terrain is broken by low hills on which stand the remnants of old forts. The slopes of most of these hills are covered with brush wood and prickly pear and at several places these slopes

have been brought under cultivation as well. Limited Sugars Athani

3.2.1 Topography

Core zone: The topography of the proposed plant location area is plain and already having industrial structure. The average elevation of the plant area is 590 m above mean sea level, as seen in google earth. The slope is towards South. The site superimposed on the digitized topographical and drainage map of Survey of India (which cannot be reproduced since it is restricted) is shown in Fig 3.1.

Buffer zone: The topography of the study area is generally plain with less undulation. The general slope in the study area is towards the drainage channels, which are spread out across the study area as seen in Fig 3.2. The elevation of the study area varies between 532 m to 640 m above MSL. The topography of the region is such that it has well developed drainage system. The Digital Elevation Map of 10 km radius is given in Fig 3.3.

3.2.2 Drainage

Core zone: As per the toposheet, no stream is passing or originating from the plant area. There are no water bodies within the plant site area. Rain water run off is through sheet flow from plot area joining the natural drainage.

Buffer zone: There are few water bodies present in the study area. Drainage of the study area is dendritic.

Streams/ Water bodies present in 10 km radius are given in Table 3.1. FIG 3.1: PROJECT & ITS VICINITY ON TOPOGRAPHY AND DRAINAGE MAP DRAINAGE ON TOPOGRAPHY AND ITS VICINITY PROJECT & FIG 3.1:

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 3-2 Karnataka in Dist. Belgaun, Plant & Cogen Distillery for Expansion of Sugar, EIA/EMP 3-3 Athani Sugars Limited

FIG 3.2: MAP OF BUFFER ZONE (10 KM RADIUS AROUND THE PROJECT)

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 3-4

Athani Sugars Limited

FIG 3.3: DIGITAL ELEVATION MAP OF STUDY AREA

Source : M/s Yogiraja Industrial Consultant, Pune

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 3-5 Athani Sugars Limited Athani Sugars Limited

TABLE 3.1 STREAMS/ WATER BODIES PRESENT IN 10 KM RADIUS TABLE 3.2 Name of Streams/ Water body Distance (km) Direction wrt plant MONTHLY AVERAGE MAXIMUM AND MINIMUM TEMPERATURE Agrani River 7.4 SE AT IMD STATION, BELGAUM (1961-90) Lingnur Tank 8.1 NW Months Temperature (°C) Kalakati Nala 8.0 E Maximum Minimum Lingnur Minor 6.0 NW January 30.30 14.10 February 32.80 15.50 Beyond Buffer Zone: The Krishna, the Ghataprabha and the Malalprabha are the principal March 35.40 18.30 rivers which flow across the district from west to east and drain the waters in its northern, April 36.40 20.70 central and southern tracts respectively. The river, which has a total length of 1400 May 34.50 21.50 traverses through the States of Maharashtra, Karnataka and Andhra Pradesh. Within June 28.40 21.20 Belgaum district, however, the river flows for a distance of about 70 km only. On entering July 25.70 20.50 the district near the north-eastern corner of Yedur village, the river flows south-west and August 25.70 20.30 then takes a U turn, receives the waters of the Dudhganga flows from the west and flows September 28.00 19.70 eastwards along the southern borders of Yedur, Manjari and villages of October 30.20 19.20 taluka. Thereafter, the river forms the natural boundary between the taluks and Athani and November 29.80 16.90 cuts across Athni taluka and the again it forms the natural boundary between Athni December 29.40 15.00 taluka and then again it forms the natural boundary between Athni taluk and Jamakhandi Mean 30.55 18.58 taluk of Belgaum district. The mean of monthly minimum temperatures recorded at IMD station Belgaum 3.3 CLIMATE ranges from 14.10°C in January to 21.50°C in May. The mean of monthly maximum temperatures ranges from 25.70°C in July to 36.40°C in April. Belgaum is well known for its pleasant climate throughout the year, but the last few years, summers (April through June) have been warmer than usual. It is at its coldest in winter FIG 3.4: MONTHLY AVG. MAX. & MIN. TEMPERATURE (November through February), and experiences continuous monsoon of medium intensity during July to September. The annual average rainfall is 50". The climate of Belgaum (°C) district is, by and large, quite healthy and agreeable. Within the district, the eastern zone IMD STATION, BELGAUM (1961-1990) has a dry climate characterized by a hot summer. The -Belgaum zone has a more 40 moist climate. The year is usually divided into four seasons. 35 30 The period from March to May is reckoned as the summer season and usually April happens to be the hottest month. During this month, the mean maximum temperature 25 reaches 35.7 degrees Celsius and the mean minimum touches 19.5 degrees Celsius. On 20 individual days, at times the mercury touches the mark of 41 degrees Celsius. During May, 15 the oppressive heat is relieved by sharp showers. The rainy season starts during June and 10 lasts till the end of September. During May and June, the nights are warmer than in April. Temperature (°C) 5 The months of October and November are regarded as the months constituting the post- 0 monsoon season which is noted for heavy fogs and misty mornings. Winter sets in during Jan. Feb. Mar. Apr. May Jun. Jul. Aug. Sep. Oct. Nov. Dec. December and lasts till the end of February. December is the coldest month of the year and on individual days the minimum temperature would be as low as 7 degrees Celsius. This Months period coincides with the driest part of the year and the skies are usually bright and clear. Max. Avg. max. Min. Avg. min. The data in respect of various parameters are briefly discussed in the following paragraphs. 3.3.2 Rainfall 3.3.1 Temperature Belgaum district receives an average annual rainfall of 748.7 mm. The amount of rainfall Month-wise average maximum and minimum temperatures from 1961-1990 period as decreases as one moves from west to east. At Khanapur in the west, the average rainfall is recorded at IMD station Belgaum, (Source: Climatological Normals-1961-1990 Issued by 1683.6 mm whereas at Raybag in the east, the average annual rainfall is 509.5 mm. The Office of The Additional Director General of Meteorology (Research) IMD, Pune) have been average number of rainy days too decreases as one moves from west to east. About 68 per furnished in Table 3.2 and visualised in Fig 3.4. The detailed data is given in Annexure IV.

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 3-6 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 3-7 Athani Sugars Limited Athani Sugars Limited cent of the annual rainfall precipitates during the south-west monsoon season which lasts TABLE 3.4 from June to September, July happens to be the month with the heaviest downpour. In the AVERAGE MONTHLY RELATIVE HUMIDITY AT IMD STATION, BELGAUM (1961-1990) western portion of the district the rainfall is reliable and the seasonal conditions are fairly Month Relative Humidity (%) god and are helpful to agriculturists. In the eastern sector, however, the rainfall is not only 0830 Hrs 1730 Hrs scarce but also capricious. A redeeming feature is that these tracts are endowed with black January 72 40 soils which have a high moisture-retentive capacity. Furthermore, in these parts, under the February 64 34 Ghataklprabha and the Malaprabha projects, large tracts of lands have, in recent years, March 61 42 been provided with assured canal irrigation facilities. Monthly average rainfall at IMD station April 66 51 Belgaum is given in Table 3.3 and shown in Fig 3.5. May 75 61 June 88 78 TABLE 3.3 July 93 88 MONTHLY AVERAGE RAINFALL (MM) AT IMD STATION, BELGAUM (1961-1990) August 93 87 September 90 81 Months Average rainfall (mm) October 83 68 January 0.30 November 73 51 February 1.70 December 73 45 March 11.50 Average 78 61 April 42.30 May 94.30 June 230.30 FIG 3.6 : MONTHLY RELATIVE HUMIDITY (%) July 416.20 IMD STATION, BELGAUM (1961-1990) August 261.60 September 119.10 100 October 100.30 November 45.80 80 December 7.40 Total 1330.8 60

FIG 3.5: MONTHLY AVERAGE RAINFALL (mm) 40 IMD STATION, BELGAUM (1961-1990) 20 Relative Humidity (%) Humidity Relative 500 0 400 Jan. Feb. Mar. Apr. May Jun. Jul. Aug. Sep. Oct. Nov. Dec.

300 Months 200 Rel. hum. at 0830 hrs Average Rel. hum. at 1730 hrs Average

Rainfall (mm) 100 0 It is seen from the above that relative humidity is higher during the period of Jan. Feb. Mar. Apr. May Jun. Jul. Aug. Sep. Oct. Nov. Dec. monsoon and lower during other months. Months 3.3.4 Wind speed and wind rose

3.3.3 Humidity As the wind rose diagram for IMD station Belgaum, are presented in Fig 3.7 & 3.8 for 8.30 hrs and 17.30 hrs respectively. The average monthly relative humidity data recorded at Belgaum IMD station during the period 1961-1990 is given in Annexure IV and summarised in Table 3.4 and graphically represented in Fig 3.6.

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FIG 3.7: WINDROSE DIAGRAM FOR IMD, BELGAUM AT 08.30 HRS FIG 3.8: WINDROSE DIAGRAM FOR IMD, BELGAUM AT 17.30 HRS

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3.4 MICRO METEOROLOGY FIG 3.9: WIND ROSE DIAGRAM OF MONITORED DATA

The micro-meteorological data of the study area have been recorded with an automatic weather station during summer season March to May 2014 at plant site. The frequency of occurrence of wind in various speed categories was calculated on the basis of total number of observations recorded and the windrose prepared and given in Fig 3.9.

The daily average of the monitored micro-meteorological data is given in Annexure V and summarized in Table 3.5. The various parameters are discussed in subsequent paragraphs.

TABLE 3.5 SUMMARY OF MONITORED MICROMETEOROLOGICAL DATA (MARCH TO MAY 2014) Parameter Maximum Minimum Mean

Temperature (°C) (Dry bulb) 38 10 27

Relative humidity (%) 100 6 51

Wind speed (km/hr) 32 Calm 5

Predominant wind direction WSW (23% Readings)

The above table depicts that during monitoring season, temperature ranged between 10- 38°C and relative humidity varied from 6% to 38 %. The hourly average of micro- meteorological data is given in Annexure V.

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3.5 AIR QUALITY

The ambient air quality study has been carried out continuously for three months during the summer season i.e. from March to May, 2014.

3.5.1 Location of ambient air sampling stations

Ambient air quality monitoring was undertaken at 8 different stations within the study area Limited Sugars Athani including 1 station at core zone during summer season of 2014. The sampling stations were set up on terraces of single floor residential buildings. The locations were selected considering upwind, down wind and cross wind directions from the project site. The sampling station locations are given in Table 3.6 and the same are marked in Fig 3.10.

TABLE 3.6 LOCATION OF AIR SAMPLING STATIONS Station Name of the Distance from Justification for selection Code village project site (km), of site Direction CA1 Core zone Within Within activity area (Project site) BA1 Kempwad 2.7, SW 1st predominant upwind BA2 Madhbhavi 4.7, NE 1st predominant downwind BA3 Mole 5.9, S Crosswind BA4 Khatav 3.9, NW 4th predominant upwind BA5 Kidgedi 4.4, SW 1st predominant upwind BA6 Shiddhewadi 2.3, E 3rd predominant downwind BA7 Vishnuwadi 5.5, NNE 1st predominant downwind

3.5.2 Sampling schedule and air quality parameters

The study was for 3 months with frequency of twice a week at each site. 24-hour average samples were collected from each station. These samples were analysed in laboratory by STATIONS OF SAMPLING LOCATION FIG 3.10: adopting the methods specified in National Ambient Air Quality Standards. The following parameters were determined for each sample:

- Respirable Particulate Matter (RPM or PM 10) - Fine Particulate Matter (PM 2.5)

- Sulphur dioxide (SO2) - Oxides of nitrogen (NOx)

Carbon Monoxide (CO) was monitored for one month. The sampling and testing of ambient air quality parameters were carried out as per relevant parts of IS 5182.

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3.5.3 Methodology Carbon monoxide The method of determining carbon monoxide is by hand held CO detector tubes. Respirable Particulate Matter (PM 10) A summary of the methodology is given in Table 3.7. The sampling of ambient air was performed with Respirable Dust Sampler, which is primarily a High Volume Sampler fitted with a cyclone separator for pre-separation of TABLE 3.7 particles larger than 10 microns diameter. Air exiting from the separator is drawn at a PROCEDURE FOR DETERMINING VARIOUS AIR QUALITY PARAMETERS measured rate through the separator followed by a pre-weighed glass fibre sheet of 20 cm Parameters Testing Procedure x 25 cm sizes (Whatman, EPM-2000). The RPM concentrations are determined PM 10 Respirable Dust Sampler (RDS) gravimetrically from the average airflow rate, sampling period and the mass of particulate PM 2.5 Fine particulate sampler matter collected over the GF filter surface. SO2 Absorption in Sodium Tetra Chloro-mercurate followed by Colorimetric estimation using P-Rosaniline hydrochloride and Fine Particulate Matter (PM 2.5) Formaldehyde (IS : 5182 Part. II. 1969) NOx Absorption in dil. NaOH and then estimated calorimetrically with The sampling of ambient air was performed with Fine Particulate Sampler for particles less sulphanilamide and N(I-Nepthyle) Ethylene diamine Dihydrochloride than 2.5 microns diameter. The PM concentrations are determined gravimetrically from the and Hydrogen Peroxide (IS:5182 1975, Part VI) average airflow rate, sampling period and the mass of particulate matter collected over the CO Detection by hand held CO detector tubes PTFE filter surface.

Analysis results with respect to PM2.5, PM10, SO2 and NOx are presented in Annexure VI Sulphur dioxide and summarized in Table 3.8. TABLE 3.8 The sampling of ambient air for evaluating SO2 concentrations was performed with a SUMMARY OF AMBIENT AIR QUALITY MONITORING RESULTS Multigas Sampler, using the vacuum created by the Respirable Dust Sampler for drawing Sl. Location Grade 24 hourly average concentration (μg/m3) the air samples through the impingers. Air is drawn at a measured and controlled rate of No. PM 10 PM 2.5 SO2 NOx 300 ml/min through a solution of sodium tetra-chloromercurate. 1 Project site Min. 40.8 10.6 5.6 14.2 Max. 51.0 14.3 11.8 18.6 After completion of the sampling, the used absorbing reagent is treated with dilute solutions of sulfamic acid, formaldehyde and para rosaniline hydrochloride. The absorbance of the 98%tile 50.68 15.07 11.71 18.60 intensely coloured para rosaniline methyl sulphonic acid is measured and the amount of 2 Kempwad Min. 50.2 14.8 11.3 9.4 SO2 in the sample is computed from graphs prepared with standard solutions. The ambient Max. 62.3 19.3 15.3 20.3 SO2 concentrations were computed from the amount of SO2 collected and the volume of air 98% tile 61.06 19.12 14.98 20.3 sampled. 3 Madbhavi Min. 32.4 15.3 5.2 7.6 Max. 49.2 28.6 10.4 15.7 Oxides of Nitrogen 98% tile 48.65 28.46 10.31 15.52 4 Khatav Min. 30.2 15.5 4.2 9.2 The sampling of ambient air for evaluating NOx concentrations was performed with a Max. 42.4 21.0 7.9 13.6 Multigas Sampler, using the vacuum created by the Respirable Dust Sampler for drawing 98% tile 41.85 21.38 7.90 13.28 the air samples through the impingers. Air is drawn at a measured and controlled rate of 5 Kidgedi Min. 40.2 12.1 4.2 10.4 about 300 ml/minute through an orifice-tipped impinger containing solutions of sodium Max. 50.1 16.9 9.7 19.7 hydroxide and sodium arsenite. After completion of the sampling, an aliquot of the used 98% tile 50.01 16.26 9.52 19.47 absorbing solution was treated with solutions of H2O2, sulphanilamide and NEDA. The 6 Vishnuwadi Min. 45.8 12.8 3.6 5.6 nitrite ion present in the impinger was calculated from the absorbance of the resulting Max. 59.2 19.5 9.8 11.8 solution and from the graphs prepared with standard solutions. The ambient NOx 98% tile 58.92 19.04 9.71 11.80 concentrations were computed from the total nitrite ion present in the impingers, overall 7 Mole Min. 40.2 20.5 4.7 8.6 efficiency of the impinger and the procedure, and the volume of air sampled. Max. 52.4 24.8 7.9 13.6 98% tile 51.39 24.40 7.90 13.6 8. Siddhewadi Min. 45.2 7.5 4.7 8.6 Max. 59.9 25.8 7.9 13.6 98% tile 56.45 26.47 7.90 13.28

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3 Twenty four hour average PM10 level was found to range from 30.2 to 62.3 μg/m , PM 2.5 The Sogal stream rises near Sogal in Parasgad taluka, passes through a depression in 3 3 was found to vary from 7.5 to 28.6 μg/m , SO2 from 4.2 to 15.3 μg/m and NOx from 5.6 to quartzite ridge and forms what is popularly know as the Sogal Falls before it joins the 20.3 to μg/m3. CO is found to be lower than < 3 μg/m3 at all the locations. All the values are Malaprabha. Mahadayi is the only west-flowing river of the district. It has its origin near on the lower side at all the locations. village of Khanapur taluka, receives the waters of Bhandurnala before it enters the Goa territory, where it assumes the name Mandovi and finally flows into the Arabian Sea. The National Ambient Air Quality Standards dated 18th November 2009, which give the The distance and direction of various water bodies in the study area is already given in limits for industrial as well as residential & rural area is attached in Annexure VII. Results of Table 3.1. monitoring are compared with the standards laid down by Central Pollution Control Board in Table 3.9. Flood hazard zonation : A perusal of Fig 3.1 shows that there are only seasonal drainage TABLE 3.9 in around the plant and the nearest Lingnur Minor is at a distance of 6 km from the project STANDARD OF AMBIENT AIR QUALITY (CONCENTRATIONS IN μg/m3) site. Krishna river is at a distance of approximately 13 km. Thus, there is no risk of flooding Pollutants Standard laid down by CPCB (18/11/2009) Maximum due to inundation of surface streams and river during normal monsoons. Industrial, Ecologically Sensitive values Residential, Rural area (notified by Central monitored in 3.6.2 Geology and other area Government) study area Annual (24 hrs. avg.) Annual (24 hrs. avg.) The rock formations of the district chiefly consist of the Dharwars, gneisses, Kaladgi series PM10 60 100 60 100 62.3 and the Deccan trap. The Dharwars are mostly seen in the western parts of Khanapur and PM2.5 40 60 40 60 28.6 also in the taluka of Belgaum and Sampgaon. These rocks are represented by schists, SO2 50 80 20 80 15.3 phyllites, quartzites and banded ferrugenours quartzites. The gneissic system consists of NOX 40 80 30 80 20.3 different types of granite and gneisses which ultimately give rise to clay. Rock formations belonging to this system are found in the southern parts of the district. From the above table it can be concluded that the maximum value of ambient air quality monitored in the study area does not exceed the limit laid down by CPCB for all the The Kaladgi series are represented by sandstone, quartzite, conglomerates, haematite, parameters. The concentrations of SO2 and NOx are considerably low compared to the 80 dolomite and lime stone. Sandstone and quartzite are particularly noticeable in the taluka of μg/m3 NAAQS permissible limit for residential, rural and other areas. The concentrations of , Parasgad, and Belgaum in the form of low ridges. The Deccan Traps 3 PM2.5 are within limits of 60 μg/m as per National Ambient Air Quality Standard. occupy a major portion of the district, especially in the northern and eastern parts. The chief varieties found here are the basalt, amygdaloid trap, vasicular trap and the clayey trap. One PM 10 sample from the core zone has been analysed for presence of PAH. Particulate laden PAH sample have been collected on Whatman glass fibre filter (EPM 2000) using The upper layers of the trap are generally capped by beds of laterite and clay. The Respirable Dust Sampler at a flow rate of more than one meter cube per minute for a period economic minerals found in the district include iron, manganese, bauxite, limestone and of 24 hours. Sample was extracted with toluene using soxhlet extraction apparatus for clay besides sand and stone which too are being commercially exploited. about 8 hours. Extracted sample was pooled & concentrated using rotary evaporator and analysed on gas chromatograph (GC) using capillary column and flame ionisation detector 3.6.3 Hydrogeology (FID). The total PAH was found to be below detectable limit. Water table generally follows the topography of the area and is at greater depths in the 3.6 WATER RESOURCES water divides and topographic highs, but becomes shallower in the valleys and topographic lows and therefore, groundwater moves down and follows the gradient from the higher to 3.6.1 Surface water lower elevations, that is, from recharge area to discharge area. Therefore, locally direction of flow from higher elevations is towards the rivers. Overall, the general flow direction of The Krishna, the Ghataprabha and the Malalprabha are the principal rivers which flow ground water in the district is generally towards the east. across the district from west to east and drain the waters in its northern, central and southern tracts respectively. The district is underlain by gneisses, schist, limestone, sandstone, basalts, alluvium, etc. of Archaean to Recent age. Deccan basalts cover an area of 7,650 Sq.Kms. in the northern The Krishna river has its fountain head in the temple of Mahadev at the foot of the steep part of the district and have a maximum thickness of around 256 m, which gradually thins hills that form the Mahadev range in the range in the Western Ghats north of out in the southern direction as shown in Fig 3.11. Mahabaleshvar. In addition to these three major rivers, the district has several small rivers and streams of considerable importance. Markandeya river which rises near in Khannakpur taluka is an important tributary of the Ghataprabha. Dudhganga which originates in the Western Ghats in joined by Vedganga and finally flows into the Krishan near Yedur.

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FIG 3.11: HYDROGEOLOGY IN BELGAUM Athani Sugars Limited Limited Sugars Athani MONSOON (NOV. 2006) MONSOON (NOV. 2006) DEPTH TO WATER LEVEL POST- FIG 3.13:

(Source: http://cgwb.gov.in/district_profile/karnataka/belgaum_brochure.pdf)

The percentage of safe area in the district is 39.5% and the rest 60.5% is the over exploited area. No area comes under the category of semi-critical or critical stage of development. 2006)

In the major parts of the district, the decadal mean of depth to water level generally ranged between 5 to 20 m bgl (Fig 3.12). During pre-monsoon period i.e. May 2014, 8%, 28%, 37%, and 27% of the wells had depth to water level ranges between 0-2, 2-5, 5-10 and 10- 20m bgl respectively (Fig 3.13). There was a rise of water level in 30%, 20% and 30% of the wells during post monsoon period i.e. in the range of 0-2, 2-4 and more than 4m respectively.

(Source: http://cgwb.gov.in/district_profile/karnataka/belgaum_brochure.pdf) FIG 3.12: DEPTH TO WATER LEVEL PRE-MONSOON (MAY (MAY DEPTH TO WATER LEVEL PRE-MONSOON FIG 3.12:

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On the other hand 12%, 5% and 3% of the wells showed a fall in water levels in the ranges method. If it is greater than +20%, then recharge is taken as equal to 1.2 times the value of 0-2, 2-4 and more than 4m respectively. Therefore, more than half of the district had estimated by the rainfall infiltration factor method. depth to water level between 2-5m bgl during post-monsoon period and the overall depth to water level in the district was between 0 to 10m bgl, except in a small strip towards The difference between the two is 0.2%, thus, recharge is taken as the value estimated by southern part of Ramdurg taluk where it is more than 10m bgl. the water table fluctuation method. Thus, 87.69 MCM per annum is the estimated annual ground water resource. The long-term pre-monsoon water level trend (1996-2010) shows a rise in 53% of the wells, while there is a fall in 47% of the wells. On the other hand during post-monsoon period, Ground water use 68% of the wells show falling trend, while there is a rising trend in 32% of the wells. Over all There are three major consumer of ground water in the area (i) Domestic (ii) Irrigation (iii) the annualised trend shows a fall in 61% of the wells and rise in 39% of the wells. Livestock. The ground water use by the three users is worked out as under

Belgaum District can be categorized as a low to moderately yielding area (1000 lph to 8000 A. Domestic lph) 72.2% of district falling in this category. From considerable part of the district (9%) poor yielding (less than 1000 lph sources) or non ± feasible areas have been reported. The Total population as per Census 2011 - 105413 talukas having largest poor yielding area, are Muddebihal (19%) followed by Indi (15%), Per capita domestic need - 70 LPD Belgaum and sindagi (13% each), Basavan (4%). Low yielding areas (1000lph to 4000lph source) in the district constitute about 40% of the district, with the largest being Total annual ground water use - 2.69 MCM Basavan Bagewadi (54%) and smallest in Indi taluka Moderate yields (4000 lph to 8000 lph source ) are reported from 36% of the district, highest being in Belgaum with 70% of the B. Irrigation area, and lowest being in Sindagi with 19% of the taluka. High yielding areas (more than 8000 lph sources) over 15% of the district. The smallest area under this category are in Total area irrigated by ground water - 11330.91 Ha Sindagi Taluka (2% each) and largest is in muddebihal (29% each) where very lengthy contact zones occurs between traps and other formations. Gross irrigation (50 cm/ha) - 5665.4 ha m Annual consumption - 56.65 MCM The ground water recharge potential in the area has been estimated by using rainfall- infiltration and water table fluctuation methods. Ground water is used for 6353.24 ha i.e. 56.07% of irrigation, thus, ground water A. By rainfall infiltration method used for irrigation is i.e. 31.76 MCM.

C. Livestock Total study area - 438.47 Sq.km. Annual Average Rainfall (IMD Belgaum 1961- - 1330.8 mm The water consumption for livestock has been empirically considered as 5% of 1990) human consumption, which comes to 0.13 MCM. Rainfall infiltration index as per GEC - 15% recommendation for alluvial area (Areas with Annual ground water use higher clay content) Monsoon groundwater recharge - 87.52 MCM 2.69 + 31.76 + 0.13 = 34.58 MCM

B. By water table fluctuation method Ground water balance

Sl. Particulars Million Total study area - 438.47 Sq.km No. Cubic Meter Average seasonal change of water table - 4 m (MCM) Specific yield - 5% 1. Total annual replenishable recharge Monsoon groundwater recharge - 87.69 MCM x By rainfall infiltration factor method (million m3/year) 87.52 As per the recommendations on ground water resource estimation methodology, if the x By groundwater table fluctuation method (million m3/year) 87.69 difference between the above two, expressed as a percentage of the rainfall infiltration 2. Estimate Annual draft (million m3/year) 34.58 method, is greater than or equal to -20%, and less than or equal to +20%, then the 3. Net annual ground water availability (million m3/year) 53.11 recharge is taken as the value estimated by the water table fluctuation method. If it is less 4. Stage of ground water development in % 39.43% than -20%, then it is taken as 0.8 times the value estimated by the rainfall infiltration factor 5. Category as per GEC White

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3.6.4 Water quality All the physio-chemical parameters present in ground water as well as surface water are within the permissible limits specified by IS: 10500 for drinking purposes. Thus it can be Ten water samples including two surface water and eight ground water samples concluded from the analysis that surface as well as ground water samples is potable and fit were collected from various locations within the study area and were analyzed. The details for human consumption after treatment. The drinking water standards as per IS 10500: of water monitoring stations are shown in Fig 3.10 and given in Table 3.10. 2012, has been given in Annexure IX.

TABLE 3.10 3.7 NOISE LEVEL LOCATION OF WATER SAMPLING STATIONS 3.7.1 Monitoring locations Sl. Station Location of water sampling Distance from Direction No. code stations project site from project Eight monitoring locations including one in the core zone, were selected so as to represent (km) site the entire study area. The locations of monitoring stations are indicated in Fig 3.10 and Surface water given in Table 3.11. 1. SW1 Krishna River at Jackwell 13.2 km SSW TABLE 3.11 2. SW2 Krishna River at Ainapur 13.2 km SSW LOCATION OF NOISE MONITORING STATIONS Ground water Code Name of Monitoring Distance (km) and Direction 1. GW1 Core zone (Project site) Within - Station from the plant 2. GW2 Kempwad 2.7 SW N1 Core zone (Project site) Within 3. GW3 Mole 5.9 S N2 Kempwad 2.7, SW 4. GW4 Madhbhavi 4.7 NE N3 Madhbhavi 4.7, NE 5. GW5 Kidgedi 4.4 SW N4 Mole 5.9, S 6. GW6 Shiddhewadi 2.3 E N5 Kidgedi 4.4, SW 7. GW7 Khatav 3.9 NW N6 Shiddhewadi 2.3, E 8. GW8 Vishnuwadi 5.5 NNE N7 Khatav 3.9, NW N8 Vishnuwadi 5.5, NNE 3.6.5 Methodology 3.7.2 Methodology Samples from surface and ground water sources were collected by adopting grab sampling. For measurement of ambient noise level, a Digital Sound Level Meter was used. The meter The samples collected in polyethylene sampling bottles. In case of surface water, sample was calibrated with a standard Acoustic calibrator before using in the field. The ZDVFROOHFWHGIURPDSRLQW´EHORZWKHVXUIDFH measurements were carried out continuously for the 24-hour period to obtain hourly equivalent sound pressure level. From these values, day and night time as well as 24-hour The physico-chemical quality of water samples were characterized by adopting the relevant Leq values were also calculated. The Leq is the equivalent continuous sound level, which is SDUWVRI,6³6WDQGDUG0HWKRGVIRU:DWHU$QDO\VLV´and the parameters prescribed in equivalent to the same sound energy as the fluctuating sound measured during observation IS:10500. For analysis, the samples were brought to JV Analytical Services, Pune, after period. addition of proper preservatives. 3.7.3 Observations 3.6.6 Observations Results of ambient noise measurements are summarized in Table 3.12. The Ambient Air The analysis results of ground water and surface water quality of the study area and core Quality Standards in respect of Noise and Damage risk criteria for hearing loss zone are presented in Annexure VIII respectively. The analysis of ground and surface occupational safety & health administration (OSHA) is given in Annexure X and XI water samples shows following results: respectively. TABLE 3.12 a. The pH value is found to vary from 7.6-7.8 for the ground water collected samples AMBIENT NOISE LEVELS (dB(A)) and 7.3 to 7.8 in surface water samples. Sl. Monitoring Observed Values Permissible limits No. Station Day Leq. Night Leq. Day Night b. The total hardness is found to be 380-688 mg/l in the samples from the groundwater 1. Core zone 59.0 44.1 75.0 70.0 sources and 106-139 mg/l in surface water samples. (Project site) c. The total dissolved solids concentration is found between 226-276 mg/l in surface 2. Kempwad 54.0 43.8 55.0 45.0 water sources and 424-585 mg/l in ground water samples. 3. Madhbhawi 52.2 40.2 55.0 45.0 d. Total alkalinity is found between 76-110 in surface water samples and 176-210 mg/l 4. Mole 51.8 38.2 55.0 45.0 in ground water samples. 5. Kidgedi 48.2 37.1 55.0 45.0 6. Shiddhewadi 54.2 41.2 55.0 45.0 e. Arsenic is not detected in all the ground and surface water samples. 7. Khatav 53.7 40.1 55.0 45.0

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Sl. Monitoring Observed Values Permissible limits TABLE 3.14 No. Station Day Leq. Night Leq. Day Night PRESENT LAND USE WITHIN PROJECT AREA 8. Vishnuwadi 52.8 41.0 55.0 45.0 Land Use Area (Acres) (i) Area inside plant boundary % of plant The noise levels observed on all locations were in range of 48.2 to 59.0 dBA during Sugar Factory 12 50.0 day time and 37.1-44.1 dBA during night time. The day and night time Leq values noted Distillery Plant 4 16.7 from the eight (8) noise monitoring stations in the study area indicate that the noise levels are well within the limits prescribed for the noise level in the residential zone. Cogen Plant 8 33.3 Total Plant area 24 100.03 3.8 TRAFFIC DENSITY (19.92% of project) (ii) Area owned outside plant % of project 3.8.1 Monitoring locations Biodigestor and Compost Yard 15 12.45 Green Belt 48 39.83 A traffic density survey was conducted round the clock from 19-20.04.2014 on Purshottam Caneyard 15 12.45 Road at a distance of about 2.0 km, S from the project site. The traffic monitoring station is Employee Colony 10 8.3 shown in Fig 3.10. Vacant Land 8.5 7.05 Total area outside plant 80.08 3.8.2 Methodology 96.5 Grand total- project area 120.5 100 Traffic density measurements were made continuously for 24 hours by visual observation and counting of vehicles under four categories, viz., heavy motor vehicles, light motor The terrain of the plant site is generally flat with minor undulations. The entire land is in vehicles, two/three wheelers and others. As traffic density on the road is low, one skilled possession of the company and the registration of the land documents has been done. The person was deployed simultaneously during each shift for counting the traffic. At the end of khasras falling under the project are mentioned in letter dated 01.08.2000 of Karnataka each hour, fresh counting and recording was undertaken. Thus, the total number of vehicles Industrial Areas Development Board in Annexure XII. per hour under the four categories was determined. 3.9.2 Buffer zone 3.8.3 Observations The land use pattern of study area falling within 10.0 km of project site has been assessed Table 3.13 shows the summary of the movement of the various types of vehicles during the on the basis of Census data of 2001 and given in Fig 3.14, Annexure XIII and summarized survey period. in Table 3.15. As on 15.03.2015, the Census office in New Delhi had been contacted and the land use data was still not available for 2011 nor was available on their website. TABLE 3.13 TRAFFIC DENSITY TABLE 3.15 Traffic Vehicle Total No. of traffic LAND USE DETAILS OF STUDY AREA AS PER (CENSUS 2001) H.M.V 238 Land use Area (Ha.) % of Total Area L.M.V 83 Irrigated agricultural land 11330.91 25.84 Two/Three wheeler 254 Unirrigated agricultural land 29027.08 66.20 Others 118 Culturable waste 1255.11 2.86 Total 693 Area not available for cultivation 2234.17 5.10 Forest 0.0 0.0 The movement of heavy motor vehicles are almost uniform through out the 24 hour Total 43847.27 100.00 period. The movement of light motor vehicles is low during the night hours. A perusal of above table shows that 25.84% of the total area is occupied by irrigated 3.9 LAND USE agricultural land while unirrigated agricultural land is more than half i.e. 66.20% and culturable waste land 2.86%. The area not available for cultivation is 5.10% and forests 3.9.1 Core zone constitute 0% of the total study area.

The total plant area is 24 acres. In addition to that, the company owns 96.5 acres of land outside the plant area for various purposes, as shown in Table 3.14.

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Sl. No. Type of landuse Area in % 5 Barren Land 2.33 6 Fallow Land 39.59 7 Built-up 0.62 8 Shrub 0.62 Total 100.00 Source : Satellite Image, USGS EROS, Sioux Falls, USA.

3.9.3 Land use based on satellite imagery

Land use / land cover information relates to the status, spatial distribution & area extent of different land use categories.

Data Source

USGS EROS, Sioux Falls, USA.

Collateral data

Survey of India topographical map

Ground truth information

The satellite data has been used for digital classification of land use categories. The satellite data has been geo-referenced with survey of India topographical map of the area. The 10 km area has been stratified by generating forest mask from topographical map. In non forest area the supervised classification of maximum likelihood procedure has been used to classify land use classes. Imagery based Land Use / Land Cover Map has been shown in Fig 3.15 and break up of land use is given in Table 3.16.

TABLE 3.16 LAND USE BASED ON SATELLITE IMAGERY Sl. No. Type of landuse Area in % 1 Water 1.10 2 Agriculture(Current) 35.29 3 Agriculture(Harvested) 18.74 4 Grassland 1.71

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 3-28 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 3-29 Athani Sugars Limited

FIG 3.15: 10 KM RADIUS LAND USE MAP BASED ON SATELLITE IMAGERY, 2013

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 3-30 shallow blacksoilsand 234,000 hadeep black soils. Black soils constitute 90% of the area with 400,000 ha of medium black soils, 262,000 ha of good nature. in loamtexture toclay. varies from infiltration characteristicsThe these of soilsare moderate to district. These are dark greyish brown and dark brown to dark reddish brown in colour. Their limestones and sandstones inMuddebial andBasavanaBelgaum Bagewadi taluks of Mixed soils arederived the from fringe areas Deccan of traps and granites, gneisses, range 2.6 from to 3.8 cm/hr. found insouthern part Muddebial of taluk of the district. infiltrationThe rates of these soils Red soils, which aresandy innature derived granites, and from sandstones, gneisses are moisture holding capacity andon drying upthese soils develop open cracks. Black cotton soils with high clay andhumus content areas.They inlow-lying have high nitrogen. and potassium in low nature, in alkaline are soils These cm/hr. 2.5 to 0.75 from varies characteristicsinfiltration arepoor to moderate. constantThe rate of infiltration inthese soils deepof blackcotton west soilsstretchingfrom toeastinthe central the partof district. The are deeper invalley portions. DonRiverThe valley hasplainsand richconsisting of tracks Black soils arederived basaltic from bedrock. These soils inupland areas areshallower and nature. bedrocks, vegetative decay andcirculation water. of Soils precipitated aremostly insitu soils. Formation of various types soilsof is a complex function of chemical weathering of The district isoccupied by threetypes soils of viz. Blacksoils, Redsandy soils and mixed 3.10.1 Soil ofBelgaum District 3.10 SOIL QUALITY I/M o xaso fSgr itley&CgnPati it egu,Kraaa 3-31 EIA/EMPSugar, forExpansion of Distillery &Cogen Plant Dist. Belgaun, in Karnataka Athani Sugars Limited Athani Sugars Limited Athani Sugars Limited

Major soil in the Belgaum District is shown in Fig 3.16. 3.10.2 Soil analysis

Top soil samples were collected from 8 locations in the study area including one from the FIG 3.16: core zone. The location of soil sampling stations are given in Table 3.17 and shown in Fig 3.10. TABLE 3.17 SOIL SAMPLING STATIONS Station Location Distance Direction No. (km) S1 Project site Within Within S2 Agriculture Land Kempwad village 2.7 SW S3 Agriculture Land Madhbhavi village 4.7 NE S4 Agriculture Land in Mole village 5.9 S S5 Agriculture Land in Kidgedi village 4.4 SW S6 Agriculture Land in Shiddhewadi village 2.3 E S7 Agriculture Land in Khatav village 3.9 NW S8 Agricultural land in Vishnuwadi village 5.5 NNE

Detailed soil test results are given in Table 3.18. TABLE 3.18 SOIL TEST RESULT Parameters of Analysis Unit Soil Sample Identity Project Kempwad Madhbhavi Mole site village village village pH of 10%suspension pH 7.5 7.2 7.6 7.2 Moisture content at 105qC % 10.3 13.3 09.2 07.2 Water holding capacity % 42.1 45.2 28.3 24.9 Organic carbon % 0.5 0.44 0.61 0.35 Total Nitrogen mg/kg 17 20 14 08 Potassium as K Mg/kg 68 80 48 59 Phosphorous as P Mg/kg 10 13 15 14 Copper as Cu ppm 0.5 1.1 1.3 1.5 Particle size distribution Sand % 25.1 28.3 28.1 32.4 Silt % 34.7 40.3 34.6 28.6 Clay % 40.2 31.4 37.3 39.0

Kidgedi Shiddhew Khatav Vishnuwa village village village di village pH of 10%suspension pH 8.6 8.4 7.8 7.4 Moisture content at 105qC % 7.8 6.9 10.2 9.7 Water holding capacity % 37.8 43.6 472 32.1 Organic carbon % 0.6 0.7 0.5 0.72 Total Nitrogen mg/kg 13.0 21.0 16.9 15.1 Potassium as K Mg/kg 90.2 108.0 124.2 87.0 Phosphorous as P Mg/kg 5.6 10.4 12.5 8.4 Copper as Cu ppm 0.2 0.1 0.15 0.09 Particle size distribution Sand % 26.0 25.1 34.1 21.4 Silt % 30.1 44.1 24.7 20.6 Clay % 43.9 30.8 41.2 59.0

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 3-32 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 3-33 Athani Sugars Limited Athani Sugars Limited

3.11 ECOLOGY x As the plants are static, they have been identified based on their specific diagonistic An ecological assessment was conducted in and around the proposed site for assessing characters of Family, Genus and Species using available floral, other related literature the diversity pattern of the floral species. Faunistic pattern of the area was studied based on and herbarium Botanical Survey of India. inquiries from the local population, personal observation and forest officials. x Besides the collection of plant species, information is collected on the vernacular names The specific aims of the Ecological Assessment component are to provide: and uses of plants made by local inhabitants. x Account of the Flora and Fauna types present within the project area and within 10 km radius of buffer zone, including significance status under The Wildlife (Protection) x Qualitative analysis of vegetation is made by floristic method (by simple studying various Act, 1972, if necessary, recommendations for conservation plan for Schedule I genera and species of various plant groups i.e. herbs, shrubs, trees and climbers etc). species; List of flora in the buffer zone is given in Table 3.19. x Evaluation and comment on the presence or absence of any at-risk, migratory or otherwise significant species of flora and fauna of the area; TABLE 3.19 LIST OF FLORA IN BUFFER ZONE x Assessment and comment on any significant habitats within the project site, Sl. No. Common Name Scientific Name Family including their contribution to faunal movement corridors; 1 Amba Mangifera indica Anacardiaceae 2 Sitaphal Annona squamosa L. Annonaceae 3.11.1 Flora 3 Ashok Polyalthia longifolia Annonaceae 4 Saptaparni Alstonia scholaris Apocynaceae The vegetation of Belgaum district is of two types. The moist occurs in the south-western 5 Kaner Nerium indicum Apocynaceae portion where the district touches the crest line of the western ghats. The second, found 6 Sadaphuli Vinca rosea Apocynaceae towards the east of Belgaum city stretches from the northern areas around Athani, Chikodi 7 Tad Borassus fabellifer Arecaceae and Gokak right down to Sampagaon and in the south. It is of the dry type. 8 Coconut Cocos nucifera Arecaceae 9 Rui Calotropis gigantea Asclepiadaceae The moist vegetation is sustained by the heavy seasonal precipitation from the south-west 10 Dagadipala Tridax procumbens Asteraceae monsoon which is active from June to October. The duration of the monsoon decreases 11 Neel Gulmohor Jacaranda mimosefolia Bignoniaceae from south to north. As there is a long dry spell from late October to early June the plant 12 Shalmali Bombax ceiba Bombacaceae cover has to survive despite the rainless period. 13 Bahava Cassia fistula Caesalpiniaceae 14 Cassia Cassia javanica Caesalpiniaceae Natural moist forests in Belgaum district have felt the pressure of over exploitation 15 Cassia Cassia siamea Caesalpiniaceae especially in recent years. The natural vegetation has been replaced by forest plantations. 16 Takla Cassia tora Caesalpiniaceae The eastern part of the district is crossed by three main rivers, the Krishna, the 17 Gulmohar Delonix regia Caesalpiniaceae Ghataprabha & the Malaprabha. Ridges of sandstone hills separate the three river basins. It 18 Copper pod Peltophorum ferruginium Caesalpiniaceae is mostly on these hills that remnants of the native flora continue to survive. Dry forest is made up of small trees, mostly slow growing, with either broad or reduced leaves. Similarly 19 Chinch Tamarindus indica Caesalpiniaceae there are no important medicinal plants that are uncommon to other areas. 20 Motha Cyperus spp. Cyperaceae 21 Palash Butea monosperma Fabaceae (a) Flora in core zone 22 Gokarna Clitoria ternatea Fabaceae 22 Karanj Pongamia pinnata Fabaceae In the project area, sugarcane is grown. Besides this plantation of trees such as Mango, 23 Mehndi Lawsonia inermis Lythraceae Neem, Karanj, Gulmohar, Kaner etc. are also done in the project area. 24 Jaswand Hibiscus rosasinensis Malvaceae 25 Bakan neem Melia azedarach Meliaceae (b) Flora in buffer zone 26 Ausrtalian babool Acacia auriculiformis Mimosaceae 27 Kala shirish Albizia lebbeck Mimosaceae In the study area trees like Mango, Ashok, Coconut, Cassia, Gulmohar etc. are commonly 28 Vad Ficus benghalensis Moraceae observed. The ecological study was undertaken to understand the present status of 29 Umbar Ficus glomerata Moraceae ecosystem of the area, to predict changes as a result of proposed activities and to suggest 30 Pimpal Ficus religiosa Moraceae measures for maintaining the conditions. This was carried through secondary data collected 31 Shevga Moringa oleifera Moringaceae from various Govt. agencies like Forest Department, Agriculture Department etc. 32 Nilgiri Eucalyptus globulus Myrtaceae

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 3-34 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 3-35 Athani Sugars Limited Athani Sugars Limited

Sl. No. Common Name Scientific Name Family Classification of Forest Types RI ,QGLD´ E\ &KDPSLRQ DQG 6HWK   WKH IRUHVW RI WKH 33 Jambhul Eugenia jambolana Myrtaceae study has been observed as sub group 3C/C2 as Sal bearing forest under the major sub 34 Boganvel Bouganvillea spectabilis Nyctaginaceae group 3C as Tropical Dry Deciduous Forest. Forests within revenue villages account for 35 Surwal Andropogan contortus Poaceae only 0.31% of the study area. There is only one Reserve Forest at a distance of 13.0 km, 36 Rohis Andropogon martinii Poaceae NNW within the study area. 37 Dub Cynodon dactylon Poaceae 38 Bordi Zizyphus jujuba Rhamnaceae Cultivation crops 39 Bor Zizyphus mauritiana Rhamnaceae 40 Bakul Mimusops elengi Sapotaceae In Athani agricuture is the main occupation the main crops are , Wheat, Sunflower, 41 Rukhdo Ailanthus excelsa Simaroubaceae toordal, kushbi, etc are cultivated. The commercial crops are grapes, cotton are cultivated 42 Pankanis Typha angustata Typhaceae here the main commercial crop is Sugarcane. Most of the farmers cultivates Sugarcane. Athani is one of largest sugarcane cultivation taluk in Karnataka Irrigation facilities of berrage of is their in Athani taluk. It is very helpful for Economically important Flora of the study area cultivation sugarcane and grapes. The most part of taluk is fertile land. By Hipparagi project Agricultural crops: There are 25% irrigation facility in the area and the agriculture in the there were canals constructed in Athani which are useful for agriculture. area is predominantly rain fed- 66%. The principal agricultural crop is Paddy. But other crops like maize and vegetables are also grown in pockets, where water is available for Belgaum district as such was described as cultivated area from the view of agricultural. At irrigation. Sugarcane is the preferred crop around sugar mill. The soil is mostly red. the beginning the crops like, Jawar, Wheat, Bajara, Groundnut, Chilli, were grown. Due to availability of river water the sugarcane growers increased to the large extent. The survey Minor forest produce: Most of the population depends on the forest for raw material for conducted in the project area indicated that there is no competing crop for sugarcane. High their traditional occupation apart from fodder, honey and wood. There is less modern value crops like chillies, fruits and vegetables are grown in few villages. However, area cooking energy source and the villagers mainly depend on fuel wood. under these crops is very meager. Jawar, wheat, bajra, safflower, sunflower and groundnut are other important crops that provide a source of income. Farmers reported that they are Medicinal plant species: The nearby area is also endowed with several medicinal plants not happy with private traders about the payment received and the price offered to them for which are commonly available in the shrub forest and waste lands. The common medicinal these products. Moreover, there is an certainty of the payment from traders and is generally plants of the region are Eucalyptus globulus (Nilgiri), Ocimum basilicum (Ban Tulsi), etc. delayed. In case of sugarcane, the first installment is assured within the first 15 days from the date of sugar cane supplied to the sugar factory. Farmers also feel that soyabean, Fuel wood plant species: Forest is a major source of fuel wood for the local villagers. jawar, groundnut, sunflower and wheat fetch less income as compared to sugarcane. They use to collect dry leaves, stems and log to fulfill their daily need for fuel wood Soyabean and groundnut crops are also affected due to rains during September and late requirement. Polyalthia longifolia (Ashok), Mangifera indica (Mango) etc. are the species August. Moreover, in spite of adopting recommended package of practices, the entire crop used for fuel wood collection from the surrounding forest area. is lost most of the time leading to loss of income. The agro- climatic conditions and soil type prevailing in the operational area of ASL are very much congenial for healthy growth of Rare and endangered floral species: During the vegetation survey of both core zone and good quality sugarcane. Sufficient irrigation facility is also available from irrigation Schemes buffer zones of the plant area did not encounter any such species which are endangered or as well as tube wells existing in the area. Water level of existing wells are reportedly threatened under IUCN (International Union for Conservation of Nature and Natural increased because of regular monsoon during past few years and hence there is resources) guidelines. considerable scope to improve the cultivation practices and shift over to sugarcane. It is also observed that cultivators in command area are progressive and are aware of Vegetation in the hamlets: The species composition near the hamlets is different from sugarcane cultivation practices. In view of above, local farmers other crops wish to switch those found in the natural environmental conditions. The vegetation structure surrounding over to sugarcane cultivation. the hamlets reflects a typical character of habitation. The trees in the settlement area are catering to the needs of local population such as fodder, fuel-wood, fruit, and timber and for religious purposes. Some of the common species found in the hamlets comprise Mangifera indica, Ficus religiosa, Zizyphus jujuba etc.

3.11.2 Forests

There is no forest in the core zone. There is no National Park/ Wildlife Sanctuary/ Tiger Reserve within 10 km radius of proposed plant site. The nearest National Park is Bhagwan Mahavir National Park at a distance of 176 km, SSW and nearest Wildlife sanctuary is Ghataprabha at a distance of 105 km, SSW from the project Site. $FFRUGLQJWRWKH³5HYLVHG

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 3-36 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 3-37 Athani Sugars Limited Athani Sugars Limited

3.11.3 Fauna Sl. Scientific Name Common Name Family Reference to schedule as No. per Wild Life Protection Act Methodology 1972, as amended upto 2006 Schedule Part Serial ¾ Ground surveys have been carried out by trekking the study area for identification of 6. Presbetis entellus Common Langur important animal groups such as birds, mammals and reptiles. A linear transect of 1 7. Cannis lypuspallipes Wolf km each is chosen for sampling at each site. Each transect was trekked for more 8 Sus-screfa Wild Pig than 90 minutes for sampling of animals through the following methods. Aves 1. Acridotheres tristis Myna Sturnidae IV - 11(45) ¾ For sampling ELUGVµSRLQWVDPSOLQJ¶ along the fixed transects (foot trails) was done 2. Accipitter nisus Sparrow hawk Accipitridae 3. Common Blue Alcedinidae to record all the species of birds with the help of binoculars; field guides and Alcedo atthis Kingfisher photography for more than 1 hour on each transect (n=4). 4. Columba livia Blue rock pigeon Columbidae - - - 5. Centropus sinensis Crow pheasant Cuculidae V - 1 ¾ For sampling maPPDOVµGLUHFWFRXQWRQRSHQZLGWK P WUDQVHFW¶ was used on 6. Corvus splendens House crow Corvidae V - 1 the same transects. Besides, information on recent sightings/records of mammals by 7. Copsychus saularis Magpie robin Muscicapinae the locals was also be collected from the study areas. 8. Dicrurus adsimilis Black Drongo Dicruridae 9. Eudynamys scolopacea Koel Cuculidae ¾ 5HSWLOHVPDLQO\OL]DUGVZHUHVDPSOHGE\µGLUHFWFRXQW RQRSHQZLGWKWUDQVHFWV¶ 10. Egretta garzetta Little Egret Ardeidai 11. White breasted Alcedinidae Halcyon smyrnensis List of the endangered and endemic species as per the schedule of The Wildlife Protection Kingfisher Act, 1972. 12. Hirundo rustica Swallow Hirundinidae 13. Nectarinia asiatica Purple Sunbird Nectariniidae Emphasis is given to identify avifauna and mammals to determine the presence and 14. Nectarinia zeylonica Purple rumped Sunbird Nectariniidae absence of Schedule-1 species, listed in Wildlife Protection Act-1972, as well as in Red 15. Megalaima Crimson breasted Capitonidae Data Book of IUCN. haenacephala Barbet 16. Milvus migrans Pariah Kite Accipitridae a) Core zone 17. Motacilla flava Yellow Wag Tail Motacillidae 18. Passer domesticus House sparrow Passerinae - - - Fauna in core zone is in the form of common mammals such as cat, rat, squirrel; aves such 19. Psittacula krameri Roseringed parakeet Psittacidae IV - 11(50) as pigeon, sparrow, house crow, myna, drongo and reptiles such as lizard, etc. 20. Ploceus philippinus Baya Ploceidae 21. Pycnonotus cafer Red vented Bulbul Pyconotidae b) Buffer zone 22. Saxicoloides fulicata Indian Robin Muscicapinae 23. Streptopelia decaocto Ring Dove Columbidae IV - 11(19) The list of fauna species generally present within 10 km of the plant is given in Table 3.20 24. Tringa hypoleucos Common Sandpiper Cacanidae 25. Vanellus indicus Redwattled Lapwing Cacanidae along with their reference to Schedule of Wildlife Protection Act 1972 amended in 2006. As Reptiles regards fauna is concerned, Squirrel, Mangoose, Indian Hare etc. are the common 1. Calotes versicolor Lizard Agamidae - - - mammals found, while amongst repltiles Naja-Naja, Viper, etc were noticed. Among the 2. Naja naja Cobra Elapidae avifauna, drongo, parakeet, crow, and green bee eater were are found. 3. Vipera russeli Russel viper Viperidae 4. Ptyas mucosus Indian ratsnake Colubridae TABLE 3.20 LIST OF FAUNA IN THE BUFFER ZONE 3.12 SOCIO-ECONOMIC CONDITIONS Sl. Scientific Name Common Name Family Reference to schedule as No. per Wild Life Protection Act The socio-economic conditions of the area are described in the following paragraphs. 1972, as amended upto 2006 Schedule Part Serial Mammals 3.12.1 Demographic details 1. Funambulus pennanti Palm squirrel Sciuridae IV - 3-A 2. Herpestes edwardsi Mongoose Herpestidae II II 16 There is no village habitation within the core zone and no displacement shall take place. 3. Lepus nigricollis Indian hare Leporidae IV - 4 The study area consists of 26 villages. The total population within the study area is 105413 4. Pteropus vampyrus Fruit bat Pteropopidae V - 3 with 54181 males and 51232 females. The total literate in study area is 62.75%. The district 5. Cannis aureus Common Jackal and taluk wise population as per Census 2011 records are given in Table 3.21.

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 3-38 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 3-39 Athani Sugars Limited Athani Sugars Limited

TABLE 3.21 DISTRICT & TEHSILWISE POPULATION (CENSUS 2001) District CD Block No. of No. of Total Males Females villages households population Sangli Miraj 6 4534 20634 10748 9886 Belgaum Athani 20 17070 84779 43433 41346

The village wise demographic details including population of males, females, schedule cast, schedule tribe, literacy level are given in Annexure XIV and summarised in Table 3.22. The population of SC & ST and sex wise break-up of literacy levels are shown in Fig 3.17 and 3.18 respectively.

TABLE 3.22 DEMOGRAPHIC DETAILS OF THE STUDY AREA (as per Census 2011) Description Population Percentage Total Population 105413 100.00 Male Population 54181 51.40 Female Population 51232 48.60 Females/1000 males 946 - Mostly the population is rural and the percentage of Scheduled Castes is 14.84% and No. of households 21604 - Schedule Tribes is 2.86% of the total population. The male population exceeds female Family size, persons/family 5 - population. The average family size is 5 persons per family. More than half population is Schedule caste 15645 14.84 literate (62.75%). The literacy level is lower among females (26.63%). Schedule Tribe 3019 2.86 3.12.2 Employment pattern Total literates 66146 62.75 Male literates 38074 36.12 The village wise employment pattern within the study area including their break-up is given Female literates 28072 26.63 in Annexure XIV and summarised in Table 3.23. The employment pattern, break-up of main workers and break-up of marginal workers are graphically depicted in Fig 3.19, 3.20 and 3.21 respectively. FIG 3.17: LITERACY LEVEL IN THE STUDY AREA (CENSUS 2011)

Literates 26.63 Literates 36.12 % %

Illiterates 21.97 Males 51.4 % Females 48.6 % Illiterates 15.28 % %

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 3-40 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 3-41 Athani Sugars Limited Athani Sugars Limited

TABLE 3.23 EMPLOYMENT PATTERN WITHIN THE STUDY AREA (CENSUS 2011) Description No. of people Percentage Main workers 42279 40.11 Marginal workers 10376 9.84 Total workers 52655 49.95 Non workers 52758 50.05 Break-up of main workers 1. Cultivators 22392 52.96 2. Agricultural labours 12797 30.27 3. House hold industries 1184 2.80 4. Other workers 5906 13.97 Break-up of marginal workers

FIG 3.20: BREAK UP OF MAIN WORKERS IN THE STUDY AREA 1. Cultivators 4421 42.62 (CENSUS 2011) 2. Agricultural labours 4252 40.98 3. House hold industries 451 4.35 Cultivators 4. Other workers 1252 12.07 52.96% 3.12.3 Amenities

As on 15.03.2015, the Census office in New Delhi had been contacted and the amenities data was still not available for 2011 nor was available on their website. The details of amenities based on Census 2001 are given in Annexure XV and summarised below:

Other workers Agriculture labour ƒ Educational facilities comprising of 72 primary schools, 42 middle schools, 12 13.97% Household 30.27% Industries Secondary schools, 4 senior secondary schools, 1 Graduate colleges and 36 adult 2.80% literacy centres and 18 other institutions are present within the villages of study area.

FIG 3.21: BREAK UP OF MARGINAL WORKERS IN THE STUDY ƒ Medical facilities comprise of 1, allopathic hospital, 10 allopathic dispensary, 2 AREA (CENSUS 2011) Ayurvedic dispensary, 4 Maternity and child welfares, 5 Primary health centres, 11 Primary health sub centres, 5 Family welfare centres, 20 Regd. Pvt. Medical practitioners, 2 subsidised medical practitioners and 10 community health workers are Agriculture labour there in villages of the study area. 40.98% ƒ For drinking purpose, the villages within the study area has 17 tap water, 20 well water, 4 tank water, 16 tube well water, 5 river water, 1 lake water, 24 hand pumps and 1 other water source.

ƒ As per Census 2001 records, the villages within the study area are enjoying the power supply of 1 connection each for domestic and agriculture and 25 for all purposes. Cultivators Household 42.61% Other workers Industries ƒ As per the communication and approaches is concerned, the villages within the study 12.07% 4.35% area are connected through 24 pucca roads, 17 mud roads and 4 footpaths. There are 18 post offices, 7 telegraph offices, 7 post & telegram offices and 568 telephones

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 3-42 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 3-43 Athani Sugars Limited Athani Sugars Limited

within the villages of study area. There are 23 bus stops and 1 railway station. There is 3.15 PLACES OF TOURIST/ RELIGIOUS/ HISTORICAL INTEREST 1 cinema/video hall within the villages of study area. Belgaum lies in the Deccan region of India. Belgaum is famous in history for the Adil Shahi Health and medical care dynasty. There are ten mosques here, of which the Jamma Mosque is a fine representation of Adil Shah's period. There are some places of religious importance used by the local Common diseases prevalent in the area are Abscess, Acidity, Asthma, Backache related villagers in the study area. These are Shri Mangsuli Mallaya Temple (11.1 km, WSW), Shri problems, Diabetes, Eye diseases, Female reproductive disorders, Fever, Kasa, Piles, Malakarsiddeswar Temple (2.4 km, SW) and Jain Temple (5.5 km, S). Athani is also Pregnancy related problems, Skin diseases, Vata etc. 57% of the practitioners follow famous for it's Amritalingeshwara temple. During the annual jatra in January there is huge Ayurvedic system only and rest of the practitioners practice other systems of medicine like volume of trade at the cattle fair. The Mahadeva Temple with it's massive lathe turned Allopathy, Homeopathy, Siddha, Yoga etc., along with Ayurveda. Ayurvedic practitioners pillars is another tourist attraction. Mangsuli, 26 Kms from Athani, is a Celebrated Pilgrim prescribe animal products, herbal medicine, mineral based products and also Bhasmas. Centre of the Mailare (Khandoba) worship. The huge temple complex of Mallaiah has other (Source: Survey On Usage, Availability And Utility Of Traditional Medicines/ Formulations In Belgaum Region shrines like Malachi, Ambabai, Bana. by 'U6'.KRONXWH6FLHQWLVWµ)¶ 2IILFHU-in- Charge, RMRC (ICMR), Belgaum) Athani is very famous for it's Leather Industries. The famous "Kolhapuri" slippers are 3.13 SEISMICITY actually made at of this taluka. The slippers manufactured here are exported to countries like Thailand, Netherlands and Bangkok. The area lies in one of the moderate seismic zones in the country. The area falls in Zone III of the seismic zoning map of India prepared under the auspices of Bureau of Indian Standards (BIS Code : IS 1893 : Part-I : 2002).

3.14 INDUSTRIES AROUND THE PROJECT AREA

There is no industry within 10 km radius.

The nearest critically polluted area is MIDC Industrial area, Miraj at a distance of 30 km, WNW from the project site.

However, as a district, Belgaum has always been at the forefront of industrial growth in India. With its inherent capabilities coupled with its enterprising citizens, Belgaum provides the ideal choice for investment opportunities. Belgaum is one of the fastest growing cities with a very good Industrial Scenario in the northwestern part of Karnataka. Belgaum has several large industries, important among them are the INDAL Aluminium Factory and the Polyhydron Pvt. Ltd. Belgaum acts as a trade centre for food grains, sugarcane, cotton, tobacco, oilseed, and milk products. Industries include leather, clay, pottery, soap, cotton, and precious metals. It is very famous for it's Power Loom Industries which provide employment for many weavers. The Hydraulic Industry started here was first of it's kind in Belgaum District. Besides, Belgaum also provides excellent opportunities for businessmen in almost all sections of the Society and thus is said to be an important Industrial and Business Centre.

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 3-44 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 3-45 Athani Sugars Ltd. Athani Sugars Ltd.

CHAPTER 4 - Places of archaelogical, religious or tourist interest

ANTICIPATED ENVIRONMENTAL IMPACTS The beneficial impacts anticipated from an industrial project, irrespective of & MITIGATION MEASURES their relevance to the proposed project, would be the employment opportunity available. 4.1 GENERAL ASPECTS 4.2 TOPOGRAPHY AND DRAINAGE Environment management plan has been prepared for the proposed Sugar 4.2.1 Topography - impact & mitigation plant expansion from 4500 to 12000 TCD, Distillery plant Expansion from 60 to 90 KLPD and Cogeneration plant expansion from 24 to 54 MW at Vishnuanna Nagar, Impact: The topography of the proposed site is plane with gentle slope and slightly Post- Navalihal, Tal. Athani, Dist Belgaum, Karnataka as per the EIA Notification undulation. The agriculture land was converted to industrial purpose at the first stage 2006 issued by Ministry of Environment & Forests, Government of India. The plant of installation of the plant.Thereafter an expansion was undertaken and currently a will have an impact on land, air, water, noise, soil, ecology, socio-economics, etc. second expansion is proposed in this report in the same premises and area. Thus, no significant changes in topography in the core zone are anticipated since majority The environment management plan includes the evaluation of total impacts of the construction of the buildings such as walls, buildings, stock yards etc. have after superimposing the project activities over base line data. This helps in already occurred. The ground has already achieved a requisite level during previous incorporating proper mitigation measures wherever necessary for preventing construction phases. There will be no impact on topography of the buffer zone. deterioration in environmental quality. Keeping in mind the environmental baseline scenario as detailed in Chapter 3 and the proposed project activities described in Management: The additional change in topography in the core zone will not lead to Chapter 2, it is attempted to assess the likely impact and its extent on various additional changes in the sheet flow pattern of rain water within the core zone since environmental parameters in this chapter. most of the construction has been carried out in the previous phases of construction. Moreover, a network of planned storm water drainage is provided and maintained. The important environmental parameters likely to be affected due to industrial The additional construction is expected to be completed in one year. projects and which have been incorporated into this chapter are as follows: 4.2.2 Drainage - impact & mitigation - Topography and drainage Impact: The nearest water body from project site is Lingnur Minor at distance of 6 - Climate km in North West Direction. As no stream or water body is traversing through or originating from the plant site area, therefore no impact on stream flow will be there - Air environment due to the project. As discussed in the section related to topography, the sheet flow of rain water shall not get additionally affected within the core zone since most - Noise environment installations & buildings are already existing. As the sheet flow runoff from plant site is going into natural drain at present, there will be marginal change in the volume of - Traffic density flow as some of the water from the plant area will get captured and harvested and recharged to ground. - Water environment

- Impact on the drainage in the buffer zone is not anticipated as no construction will be Land environment taking place outside plant boundary. - Solid waste Management: As explained in topography, the sheet flow will be managed through the storm water drainage. Rain water Harvesting will be carried out to reduce the - Ecology load on fresh water uptake from river. It will also recharge & raise the ground water table. - Socio-economic environment

- Occupational health and safety

- Other industries

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 4-1 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 4-2 Athani Sugars Ltd. Athani Sugars Ltd.

4.3 CLIMATE 4.3.2 Mitigation measures

4.3.1 Impact on climate The operations are to be carried out in a limited area, as a result no large scale climatological impacts are anticipated. Development of greenbelt in the plant area The climatic conditions including temperature variations, wind direction and speed, will contribute in a positive manner towards mitigation of greenhouse gases as well rainfall and humidity are governed by regional factors and the monsoons. As such as reducing temperature due to the urban heat island effect. Global warming is a plant operations and other allied activities will not tend to influence the climate. global concern and hence, the company will be undertaking all possible measures to Further, carbon dioxide (green house gas) contributing fuel in the form of bagasse in minimise the CO2 emissions. Since part of the transportation is through trucks, it will boilers will be used and diesel to operate the trucks and tractors, which will be a be ensured that the vehLFOHV DUH KDYLQJ WKHLU ³3ROOXWLRQ 8QGHU &RQWURO´ 38&  necessity. certificates. The trucks will be maintained in order to ensure optimum fuel utilization.

During the construction phase, the activities will be restricted to construction of Urban heat island can be reduced by using environment friendly building material. additional buildings and erection of structures, plants and machinery. Due to the Plantation of trees, low heat gain layouts of the buildings and creation of shades and existing & proposed construction of buildings, an urban heat island effect will get water bodies over which wind can blow to cool down, are some measures to reduce created locally which raises the temperature at the buildings and its immediate the impact of urban heat island effect. vicinity. 4.3.3 Micro climate The major impact on global scenario of climate change will be in terms of contribution of carbon dioxide into the atmosphere during operation. Carbon dioxide In the project site, the micro climate at different parts of the plot will not be same. is formed due to combustion of the bagasse which contains carbon and releases The area of green belt will be cooler than the infrastructure area and remaining part CO2 as a combustion product. of the plant. The boiler and associated area will be hotter as compared to other areas of the plant. The storage yard for the cane would have warm and humid In case of cogen plant, the carbon dioxide emissions are a global concern since it is climate. The emission sources like stack will also be hot due to release of gases. a green house gas (GHG). The CO2 emissions anticipated per MWH of energy has been calculated as follows: Micro-climate modification involves the best use of structural and landscape design elements to maximize or limit sunlight, shade and air movement. Structural x For 54 MW X 330 days X 24 hours = 4,27,680 MWH energy, bagasse modifications involve the design of the building and associated construction required is 576000 MTPA (driveway, walkways, fences, etc). Landscape modifications involve the use of plants to further increase or decrease the impact of sun and wind upon the local x For 1 MWH energy, bagasse required is 1.35 T. environment. This will decrease the energy costs associated with maintaining interior comfort. These are components of building design and as such have been x Based on the techno economic feasibility report of proposed Plant, the incorporated in the architecture and layout of the plant & buildings passively. analysis of bagasse fixed carbon is 22.7%. One tonne of bagasse contains 227 kg of carbon. Therefore, 1.35 T contains 306.45 kgs of carbon 4.4 AIR ENVIRONMENT

Molecular weight of carbon = 12 and of CO2=44 x 4.4.1 Impact on air quality

x Hence, for generating 1 MWH energy, CO2 emitted = 1306.45 X 44/12 = 1123.65 kg or 1.12 T/MWH A. Construction Phase Sources of air pollution, during the construction phase will be: As such, there is no viable and feasible technology to sequester this CO2 at present although pilot research projects have been undertaken in China and Europe. However, research underway across the world and any such technology available in - Vehicle exhausts for transport of materials the future shall be taken up. Plantation is a suitable method to sequester carbon and - Dust generation during construction due to excavation work, shifting of 48 acres of plantation has been carried out outside the plant area. construction materials (cement, sand and gravel), vehicle movement on unpaved roads and concrete preparation plant. - Exhaust from construction equipment like compressors, DG sets, etc.

Primary impact from these sources on air quality will be high dust generation resulting into increased SPM levels in the surrounding areas. Possibility of

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 4-3 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 4-4 Athani Sugars Ltd. Athani Sugars Ltd. impairment of visibility of the dust may arise if control measures are not The stack details of exiting and proposed plant is presented in the Table 4.1 and implemented. Further movement of construction equipment for these operations as Table 4.2. Meteorological data is present in Annexure V. well as for transport of material will lead to increased level of SPM, SO2, NOx and CO in the surrounding areas. Thus, adverse impacts on air quality are envisaged. TABLE 4.1 The secondary impacts of air emissions dust as well as other emission will be the STACK DETAILS OF EXISTING PLANT effect on the health of the labour force working in close vicinity. Secondary impacts Sl. Stack Fuel Emission Stack Ht Diameter Exit Gas Velocity of air emission could also effect the flora, crops and nearby residents due to dust No. (T/Hr) Rate (g/s) (m) (m) Temp. (m/s) deposition, if proper control measures are not adopted. (K) 1 Boiler 130 0.055 70 3.5 413 16 B. Operation Phase (ESP will be used of 99%) The project has air pollution point source in the form of boiler stack. The air environment gets polluted due to emission of suspended particulate matter having TABLE 4.2 particle size less than 50 microns. It can also affect the crops grown in the nearby STACK DETAILS OF PROPOSED PLANT areas. So it can have negative impact on the health of people. Sl. Stack Fuel Emission Stack Diameter Exit Velocity No. (T/Hr) Rate (g/s) Ht (m) (m) Gas (m/s) Due to existing state highways & less distances for carts, tractors & trucks to reach Temp. mill site the suspended particulate matter generation is anticipated to be within (K) specified limits. 1 Boiler 140 0.070 75 3.5 413 16 (ESP will be During operation phase, emissions from various types of industries vary from one used of 99%) another in terms of quality and quantity of emissions, production capacity of the plant, type of fuel used, type and complexity of the process employed, use of air Predicted SPM Concentration in Ambient Air as per Gaussian Model is shown in the pollution control measures and degree of maintenance enforced. The cogen power Table 4.3. The isopleths are presented in the Fig 4.1, Fig 4.2 and Fig 4.3 for generation will be proposed to expand capacity. Presently 24 MW power generation existing, proposed and cumulative operation impact. The maximum GLCs is exist at the plant, the fuel for boiler is bagasse it requires 2,16,000 TPA. The calculated for existing scenario is 0.0086 ȝJP3 NE Direction. Incremental rise due to proposed cogen power project is planned to be implemented as 54 MW, bagasse proposed unit power plant will be 0.011 ȝJP3 NE Direction. The cumulative impact requirement for proposed unit is 3,60,000 TPA. Total requirement for bagasse for due to existing and proposed operation will be 0.014 ȝJP3 NE Direction. plant is 5,76,000 TPA. This cogen project meets the heat & power needs of ASL and Stack Monitoring Data exports balance power to the grid. March Feb Jan Dec Parameters Jan 2015 Dec2014 2014 2014 2014 2014 i. Air Emissions from Cogen plant 130 18 130 18 130 130 130 130 TPH TPH TPH TPH TPH TPH TPH TPH Air quality modeling has been carried out for both existing and proposed scenarios. Particulate Matter 40.0 The major pollutant from the activity is PM. In the present study, the major source 33.4 36.7 46.37 33.11 22.0 81.0 88.0 mg/Nm3 has been considered as the stack attached to boiler. The estimation of emission Nitrogen dioxide rates based on rate of fuel consumption and characteristics has been calculated. 25.91 22.34 26.28 21.63 9.17 19.49 23.39 33.24 Also, the meteorological data at the site has been collected during study period. After mg/Nm3 calculation and collection of data, assessment of impact on ambient air quality using Sulphur dioxide 22.40 19.20 24.69 22.40 13.71 22.40 26.88 36.41 ISCST3 model of USEPA for emissions from existing 24 MW power plant and mg/Nm3 proposed 54 MW power plant have been carried out. The bagasse is used as fuel in the plant.

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 4-5 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 4-6 Athani Sugars Ltd. Athani Sugars Ltd.

FIG 4.1: IMPACT OF EXISTING OPERATION FIG 4.2: IMPACT OF PROPOSED OPERATION

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 4-7 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 4-8 Athani Sugars Ltd. Athani Sugars Ltd.

FIG 4.3: IMPACT OF CUMULATIVE OPERATION The maximum ground level concentration recorded is summarised in Table 4.3.

TABLE 4.3 MAXIMUM GROUND LEVEL CONCENTRATION WITH CONTROL MEASURES (μg/m3) Scenario Max. GLC Distance Distance from Concentration from source source in Y (μg/m3) in X direction direction Existing Operation 0.0086 12 km 12 km Proposed Operation 0.011 13 km 13 km Cumulative Operation 0.014 20 km 20 km

ii. Transportation

As a matter of fact of Co-generation Power Plant does not invite heavy vehicular traffic at the site, however due to sugar production activities at ASL, there will be an increase in the traffic to and from the site. Vehicles used for transportation of sugar cane as well as finished product would be a bullock cart, Tractors and Trucks where as, utility vehicles used for various purposes would be buses, Jeeps, cars and cycles. The transportation route will be the highway and the connecting road from the highway to the plant for the purpose of the evacuation of sugar while the bullock carts will bring raw material (cane) through internal roads of ASL and village roads from nearby fields.

All trucks proposed to be used for transportation will be covered with tarpaulin, maintained, optimally loaded and have PUC certificates.

In order to predict the possible impacts of vehicular transportation, CALINE4 model has been used. It is based on the Gaussian diffusion equation and employs a mixing zone concept to characterize pollutant dispersion over the roadway. The purpose of the model is to assess air quality impacts near transportation facilities. Given source strength, meteorology and site geometry, CALINE4 can predict pollutant concentrations for receptors located within 500 meters of the roadway. In addition to predicting concentrations of relatively inert pollutants such as carbon monoxide (CO), the model can predict nitrogen dioxide (NO2) and suspended particle concentrations. It also has special options for modeling air quality near intersections, street canyons and parking facilities. The findings of the predicted incremental cumulative impact are given in Table 4.4. The detailed calculations, assumptions and results are given in Annexure XVI. TABLE 4.4 CUMULATIVE IMPACTS ON AIR QUALITY Pollutant Highest Maximum Maximum Total resultant NAAQS, concentration Incremental Incremental concentration 2009 observed in anticipated anticipated GLC (Pg/m3) study area GLC from from road (Pg/m3) (Pg/m3) plant (Pg/m3) PM10 62.3 0.014 1.8 64.114 100 NOx 20.3 - 27.8 48.1 80 CO < 3 - 19.75 23 (approx.) 2000

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 4-9 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 4-10 Athani Sugars Ltd. Athani Sugars Ltd.

It can be seen that the resultant GLCs will remain within the stipulated norms after B. Operation Phase expansion of the plants. The operation of the proposed DG set during emergency will During operation phase assessment the mitigation of air pollution emissions and release emissions into air, however, they will be low concentration and temporary. their control are outlined below:

4.4.2 Mitigation measures ¾ The only major source of air pollution from the ASL manufacturing process is emission from stack attached to boilers used for steam generation and A. Construction phase subsequently power. However, has chimney of 3.5 diameter up to 75 m height and the stack height designed on the basis of CPCB guidelines to ensure proper During construction phase certain mitigating measures need to be adopted to reduce disposal of gas emissions. the primary impact on air environment to the minimum. Water spraying on material to ¾ Fugitive emissions from raw material storage yards, loading and unloading be handled before beginning work and spraying on unpaved surfaces twice a day will operations, will be controlled water sprinkling system, if applicable. improve the working conditions and minimise dust pollution. The designated areas for roads and parking spaces shall be black topped at the earliest. Welding ¾ Electrostatic precipitator (ESP) will be provided in the additional boiler stack. operations shall be carried out within cordoned areas. ¾ Water sprinkling system will also be provided in strategic area for control of fugitive emissions. During dry weather condition, the dust created by excavation, leveling and transportation activities will be easily controllable by sprinkling of water. Construction ¾ Use of bullock carts, which are environmental friendly, for transportation of equipment and transport vehicle will be maintained properly to minimize source sugarcane from the villages to the plant site as far as possible. emissions and spillage. Regular maintenance schedule will be adopted. ¾ Ensure that all vehicles (trucks & tractors) used in transportation have PUC Certificate. As per AP-42 of US EPA, the recommended measures for various activities during construction phase are summarised in Table 4.5. ¾ As far as possible all internal roads shall be constructed as tar roads and regular water sprinkling shall be carried out on all the kucha roads for preventing fugitive TABLE 4.5 dust emissions. RECOMMENDED MEASURES FOR CONTROL OF FUGITIVE EMISSIONS Construction of speed breakers on roads at regular intervals all over the plant DURING CONSTRUCTION ¾ area and / or attachment of speed locking system to the accelerators of all Emission Source Recommended Control Method(s) vehicles used for maintaining a speed limit of 20 km/h.Construction of vehicle Debris handling Wind speed reduction, Wet suppression# parking area having at least brick on edge flooring. Truck transport## Wet suppression, Paving Chemical stabilization^ ¾ No overloading of trucks used in transporting sugar from the plant. Bulldozers Wet suppression^^ ¾ Carry out tree plantation around plant area for minimizing environmental impacts Pan scrapers Wet suppression of travel routes of the proposed activities over a period of time. Plantation program shall be Cut/fill material handling Wind speed reduction, Wet suppression designed and a budget should be allocated for this purpose every year. 33% of Cut/fill haulage Wet suppression, Paving the area owned by ASL is planned for greening. Chemical stabilization General construction Wind speed reduction, Wet suppression ¾ Moreover, the garden development and tree plantation activities of ASL during Early paving of permanent roads operational face would ensure minimal impact of fugitive dust emissions. # Dust control plans should contain precautions against watering programs that ¾ In addition to above, ASL promised to maintain good house-keeping in all the confound trackout problems. ## Loads could be covered to avoid loss of material in transport, especially if material is departments of their sugar manufacturing and power generation departments in transported offsite. order to keep the entire complex clean and free of dust. ^ Chemical stabilization usually cost-effective for relatively long-term or semipermanent unpaved roads. 4.5 NOISE ENVIRONMENT ^^ - Excavated materials may already be moist and not require additional wetting. Furthermore, most soils are associated with an "optimum moisture" for compaction. 4.5.1 Impact on noise level

During Construction phase: Noise levels in the vicinity of any construction activity increase due to running of bull-dozers, excavators, transport vehicles, pile drivers, portable generators, mechanical machinery such as cranes, riveting machines, hammering etc. These activities will run round the clock. Noise pollution thus

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 4-11 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 4-12 Athani Sugars Ltd. Athani Sugars Ltd. created, particularly during the night, could affect the human habitation. The primary A perusal of graph shows that the sound levels attenuate to value as shown in Table impact of noise level would be mainly on workers engaged on high noise generating 4.6. machines. TABLE 4.6 NOISE ATTENUATION WITH DISTANCE ON FLAT BARE GROUND WITHOUT During operation phase: The noise levels near the sources such as Sugarcane AND WITH GREEN BELT cutting, Crushing, Lime addition, Clarification, Evaporation, Sugar separation, Steam COMBINED NOISE OF MORE THAN ONE SOURCE = 103 dB(A) Production, Noise making Equipments such as cutters, crushers, mixers, pumps, Distance from Noise level reduced from 103 dB(A) boilers etc. will be higher. The traffic involved for transportation of raw material and source (m) Without green belt, dB(A) With green belt, dB(A) finished product by road will also cause noise pollution and affect habitation along 20 70.0 68.5 the roads. 60 60.0 55.5 100 56.0 49.0 The noise levels at machinery sources are anticipated to go as high as 100-105 150 52.0 41.0 dB(A) based on experience of similar plants. The general noise levels within core 180 50.0 33.0 zone are expected to remain below 75 dB(A). 300 45.0 <33.0

Noise propagation have been studied by mathematical model and impacts of noise It means that after distance of about 300 m, the machine noise will merge into the on surrounding area have been brought out below. As the equipment generate noise background noise in the day time average around 45 dB(A). This noise level is same generally not higher than 100 dB(A) at source it can be safely assumed that the as the limit [ 45 dB(A) ] prescribed by GSR 742 (E) dt. 30th August 1990 at night ambient noise levels on any point of boundary line of the plant are not higher than time for residential areas. With plantation around the plant site, it will be possible to 100 dB(A). It has, also been assumed that the area within the core zone within an further lower the noise levels below the prescribed limits. It may be noted that the imaginary line running at a distance of 3-5 m (say) from noise generating machines combined noise from all the three plants cannot be more than 103 dB(A) at any point will be termed as point noise source to avoid complication in the absence of considering the distance between their relative locations. availability of exact location of various noise generating units, their arrangements and shapes. Taking extreme case of two machines each generating 100 dB(A) Several noise suppression and attenuation features shall be designed in the plant for working at a point will add upto 103 dB(A) overall noise level. Such source noise the protection of personnel at all normally accessible locations within the plant level has been considered here for anticipating the impacts. Noise attenuation with boundary, both inside and outside different buildings, and for the protection of the distance in all directions over flat open bare ground is given by inhabitants living in the vicinity of the plant.

Sound level dB(A) = Lw ± 20 log r2/r1 The damage risk criteria as enforced by OSHA and CPCB to reduce hearing loss, stipulates the noise levels up to 90 dB(A) as acceptable limits for 8 hour working shift Where : LW = Sound level of source, dB(A) assumed 100 dB(A) per day. Noise levels may, however, exceed the prescribed limits in certain work r1,r2 = distance from source(m) places. At these work places, workers will be posted for shorter durations only. Operations and maintenance personnel will not be exposed to the high levels for The same has been plotted in Fig 4.4. Assuming source noise level as 103 dB(A) reasons of the control operations conducted from sealed cabins. The OSHA damage risk criteria are reproduced in Annexure XI and the Ambient Air Quality Standard in FIG 4.4: NOISE ATTENUATION WITH DISTANCE IN ALL DIRECTIONS OVER respect of noise is given in Annexure X. FLAT OPEN BARE GROUND 4.5.2 Mitigation measures

The following measures will be taken up to keep the noise levels with in permissible limits:

a. Provision and maintenance of green belt. The proposed green belt will also help to prevent noise generated within the plant from spreading beyond the plant boundary.

b. Proper maintenance of noise generating machinery including transportation vehicles

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 4-13 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 4-14 Athani Sugars Ltd. Athani Sugars Ltd. c. The noise generation will be reduced at source by erecting noise dampening 4.6.2 Impact on traffic density enclosures, by maintaining the machines and greasing them regularly. Following control measures will be adopted to reduce the impact of increase in traffic d. Provision of air silencers to modulate the noise generated by the density: machines/equipments 1. Erection of traffic signals at strategic locations e. The equipments will be provided with acoustic shields or enclosures to limit the sound level inside the plant. 2. Employment of only experienced drivers with good records 3. Regular training to drivers f. Provision made for special vibration dampness and monitoring to prevent propagation of vibration to surrounding areas. 4. Maintenance of roads from time to time 5. Roads and intersections upgradation g. Use rubber packing in the foundations of machineries to prevent noise transmission to the surrounding. 6. 'Pollution Under Control' (PUC) certificates for each and every vehicle. 7. Cleaning of air filter and oil filter regularly. Cleaning the carbon deposit from h. Noise from safety valves, start up vents, steam jet ejectors of condenser etc. will silencer. Maintaining recommended tyre pressure. Maintenance of vehicle as per be reduced by providing silencers at the outlet of down steam piping. manufacturers specification i. All the workers engaged at and around high noise generating sources will be 8. Covering of trucks with tarpaulin to avoid spillage provided with ear protection devices like ear mufflers/plugs. Their place of 9. Water sprinkling on roads leading to plant and within plant attending the work will be changed regularly so as to reduce their exposure duration to high levels. They will be regularly subjected to medical check-up for 10. No overloading. Optimum loading of the trucks and cross checking at weigh detecting any adverse impact on the ears.Proper encasement of noise generating bridge sources to control noise level. Besides, ear muffs/plugs provided to the workers 11. Avenue plantation in the close vicinity of noise source.

4.6 TRAFFIC DENSITY 4.7 WATER ENVIRONMENT

4.6.1 Impact on traffic density 4.7.1 Impact

Incoming raw material is sugarcane only, grown in the adjoining area of the plant. A. Construction Phase These plantations are owned by the company itself and hence, no public road will be used to transfer the sugarcane from the field to the plant. The transportation shall be During construction phase the requirement of water will be on account of concrete carried out by bullock cart. If case of any shortfall, due to unforeseen circumstance, it mixing, curing and tank preparation, usage in sprays and sprinklers for dust suppression, irrigation for plantation and for landscaping with decorative plants and will be fulfilled from nearby farms using bullock carts. Hence, additional impact on air 3 due to vehicular emission for incoming raw material is not anticipated. lawns. During construction hardly 35 m water will be required for curing. The construction activity will not have any effect on ground as well as surface water. However, there will be increase in trucks, tractors as well as bullock carts due to the Even the domestic waste water generated in the labour camp is also very low. The evacuation of sugar. The pathway of transportation is given in Annexure XVI. The fresh water requirement during the construction phase will be procured from nearby additional peak traffic load anticipated is 50 trucks per hours and 42 tractors per hour water sources. There shall be approximately 80 workers requiring 15 l/capita/day i.e. on a peak work day besides bullock carts whose numbers will vary due to varying 1.2 KLD. It is assumed about 50% of the labour will stay at site in temporary individual carrying capacity. The bullock carts are anticipated to transport 3000 TPD. structures and with both parents working and two children, a family of four would Impacts on Air Quality due to vehicle transportation is already given in Table 4.4 require 160 X 135 = 21.6 KLD. Thus, daily construction phase domestic water above, which shows that increase in number of trucks and tractors would lead to requirement shall be to the tune of 22.8 KLD. increase in the concentration of pollutants at ground level, however, on adding to the existing highest concentrations observed in study area, the resultant GLCs still shall B. Operation Phase remain within permissible limits. The plant will derive its water from the Krishna River, which is located at distance of about 13 km. The water requirement will be increased from 850 cum/day to 1298 cum/day after expansion for sugar plant. However, total water requirement on annual basis will be reducing by 22.78% from 245360 KL/A to 189472 KL/A. Necessary

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 4-15 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 4-16 Athani Sugars Ltd. Athani Sugars Ltd. pumping and piping system has been installed for water withdrawal from the 4.7.2 Impact of drawl of water on the nearby River during lean season proposed source. Water will be stored in a surface water reservoir for the plant and in an overhead (OH) tank for potable purposes. The copy of the water withdrawal The lean season for Krishna river is in the month of May. However, sugar factory permission is given in Annexure XVII. crushing season is closed in the April end. The other unit like distillery which is running requires only 534.8 m3/day drawl of water. For cogen 937.6 m3/day water is This raw water will be used as a make up for the losses in the process steam, boiler required. During the lean season Krishna river is never dried as it is perennial and blow down, auxiliary cooling tower blow down, service water, etc. As the sugar plant the water flow in the river near drawl point always more than 5 cum per secs (0.432 is an already operating unit, the complete raw water supply system from the MCD). Hence there is no significant impact on drawl of water during April and May reservoir to the sugar mill already exists. After expansion, ASL will need 4268 KLD of month i.e. lean season since the total water withdrawal of 1472.4 cum/day is 0.34 % water during season and 2337.6 KLD during off-season to fulfill the needs of mill, of the total flow. distillery & co-generation plant, residential colony. Out of this, the fresh water requirement of 448 KLD during season and 1472.6 KLD during off-season shall be 4.7.3 Mitigation measures drawn from River Krishna, while the rest shall be recycled water from evaporator condensate of Sugar and distillery units. Air Cooled Condenser has been proposed, A. Construction Phase hence, the water requirement for Cogen Plant is also going to reduce. Waste water generated during construction is insignificant. Proper sanitation facility The spent wash generated shall be 720 KLD then fed to Biodigester for will be provided with septic tank so that there will be no negative impact on water. biomethanazation followed by evaporation( seven effect) to reduce and concentrate biomethanated spent wash to 180 KLD . This spent wash is further bio methanated B. Operation Phase send to seven effect multiple Evaporator and then converted to bio compost using press mud available from the sugar factory. Hence impact on surface and ground (i) Sugar Mill water is negligible as zero discharge scheme is planned. Septic tank has been provided to treat domestic effluent. Treated effluent will be used for green belt Wastewater from Sugar mill will not have significant BOD/ COD levels. All waste development, sprinkling, etc. water will be collected in effluent treatment chambers and neutralized prior to discharge in the existing sugar plants. The treatment scheme incorporates Aerobic Currently 500 employees are working in sugar factory and 300 employees need for treatment method for the wastewater with state of the art Bio-Aeration Technologies. expansion plant. Accommodation is available in total of 140 rooms, out of which 100 The flow diagram of the ETP is given in Fig 4.5. In sugar mill maximum due rooms are for family and 40 rooms for bachelors. The domestic requirement shall be water conservation will be achieved with precise equipment selection. approximately 73 cum of fresh water per day. Septic tank and soaking pit provided to treat the domestic waste generated from colony. (ii) Cogen plant

Sources of waste water: In co-generation also precise design parameters will enhance target of water conservation & power production. Maximum attention is paid to recycle the water in During operation of power plant, there shall be various effluents. Acidic and alkaline each unit/equipment. effluents will be generated during regeneration of various ion exchange units in the RO water plant. Cooling water system for auxiliary circuit operates in a closed cycle Effluent Treatment Plant for Cogen with a cooling tower for heat rejection. In order to keep the concentration of dissolved The quantity and quality of waste water will be controlled using following measures : solids within the limits a blow down is maintained from the system. For inhibition of corrosion/ scaling in the circulating cooling water system, a chemical treatment ¾ Recycle of process water including vapor condensate and reuse of treated water system for dozing of inhibiting chemical shall be provided. ¾ Control of water tap, washing water, leakage from pump gland and overflow Since waste waters from plant are proposed for reutilisation within plant for sprinkling ¾ Dry floor cleaning and irrigation, no discharge is anticipated from the plant premises to outside on normal working days. Hence, no impact is envisaged on the surface water bodies and on the fresh water eco-system and ground water.

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 4-17 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 4-18 Athani Sugars Ltd. Athani Sugars Ltd.

FIG 4.5: ETP OF SUGAR COGEN COMPLEX (iii) Distillery

SUGAR UNIT EFFLUENT EFFLUENT OF COGEN Single stage evaporation technology during alcohol concentration & recovery reduces spent wash quantity. Thus, spent wash generation will be minimum. The treated wastewater will be utilized for plant floor washing, make up water for cooling tower, green belt in the area and captive irrigation. Thus, impact on ground & surface BAR SCREEN CHAMBER water shall be negligible and zero wastewater discharge scheme involves conversion of spent wash after evaporation to bio-compost using press mud.

Spent Wash Treatment Management for Distillery OIL SKIMMER The characteristics of the spent wash are given below:

EQUALIZATION TANK Characteristics Raw Spent Wash (Value in PME mg/l except pH and temp) Sludge Odour Jaggery - PRE CLARIFIER Colour Dark Brown Greenish Brown/Black pH 4.0 - 5.0 7.2 - 7.5 COD 1,20,000 - 1,60,000 35,000 - 42,000 BIO-AERATION TANK- I BOD 40,000 - 60,000 6,000 - 9,000 Total Solids 1,00,000 - 1,50,000 1,00,000 - 1,50,000 Chloride (Cl) 6,000 - 10,000 - Sludge CLARIFIER Sulphate (SO4) 4,000 - 6,000 - Nitrogen (TKN) 1,500 - 3,000 - Potassium(K2O) 10,000 - 15,000 - Sodium (Na) 300 ± 600 - BIO-AERATION TANK- II Phosphate(PO4) 400 - 4,000 - Calcium (Ca) 3,000 - 5,000 - Sludge Return Sludge CLARIFIERCLARIFIER Environmental management system for distillery has components like biomethanation, evaporation & concentration followed with biocomposting of Sludge pressmud with primary treated spent wash. FILTERATIONFILTERATION UNIT UNIT SLUDGE DRYING BED The process involves the following stages;

TREATED EFFLUENT COLLECTION TANK ¾ Day Storage of Spent wash.

¾ Biomethanisation Reactor

¾ Seven Effect Falling Film Evaporation Unit GARDENING GREEN BELT DEVELOPMENT ±R&D FARM ¾ Concentrated Spentwash storage tank

Effluent generated by cogen plant will be treated in existing sugar Plant having ¾ Transportation and windrowing of pressmud. Preliminary and Secondary treatment. In the secondary treatment stage wise activated sludge treatment process will be carried out. Each stage consist of the ¾ Composting of pressmud aeration tank with fixed aerators and secondary clarifiers. The clear effluent from ¾ Preparation of Bio-Compost Yard clarifier will be collected in polishing pond and water will be used for irrigation. ¾ Harvesting of Bio-compost after the respective cycle & sale of product ¾ The above steps have been detailed below:

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 4-19 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 4-20 Athani Sugars Ltd. Athani Sugars Ltd.

The Feed from the Feed balance tank is taken to the High Heater for removal of non- (a) Preparation of spent wash storage tanks condensible gases and passing to PHE-1 to make the best heat recovery. There will be Two spent wash storage tanks which will be made impervious by interior living with 100 mm thick concrete slab. Size of the storage tank and The Feed after getting heated to the predetermined temperature in preheater is fed capacity is given below; from the of the second effect evaporator which is Falling Film Evaporator -1 ¾ Storage tank no.1 (5 days capacity for Raw spent wash): 56 m X 12 m X 3 m = 2016 M3 + 1m free board. Then the feed from High heater is given to first effect evaporator and follows the flow ¾ Storage tank no.2 (25 days capacity for biomethanated spent wash): 56 m X path given below. 64 m X 3 m = 10752 M3 + 1m free ¾ Inlet Feed -HH- HE ± Flash Vessel- E1 - E2 - E3 ± Outlet (b) Biomethanisation Reactor ¾ Vapors generated in 1st effect VLS (Vapor Liquid Separator) are used as heat source in the 2nd effect. The primary treatment of spent wash & anaerobic digester specification are given below: ¾ Vapors generated in the 2nd effect VLS are subsequently used as heat source for 3rd effect. Digester Anaerobic Dig. Finally Vapors from 3rd effect are condensed on shell side of Surface Condenser Spent wash COD Kg/M3 160 ¾ for Evaporator. Spent flow rate m3/d 450 COD reduction in digester 65% ¾ The product at the desired concentration of 24 - 25 % w/w TS is obtained at the Total COD fed to Digester (450 x 160) Kg/d 72,000 Kg/d outlet of the third effect, which is a Falling Film evaporator. COD removal in Digester at 65% of feed 46,800 kg/d ¾ A Shell & tube type Multi-pass Surface condenser is employed for condensing Bio-gas production (0.5 Nm3/Kg of COD removal) 23,400 the shell side vapors. Nm3/d Composition of Bio-gas ¾ The Pure and the process condensate are collected in receiving vessels. Highly CH4% 60-65 efficient operating pumps have been provided for pumping the required fluid. CO2% 35-40 ¾ The operation of the plant is under vacuum. Vacuum is created with the help of a H2S% 1-2 water ring vacuum pump. Calorific value of bio-gas in K.cal/Nm3 4800 ± 5600 Type of digester CSTR ¾ The plant is having high level of automation to get consistent output at required Volume of digester 13,050 cum concentration. Spent wash feed/day 450 cum ¾ The system operates under vacuum. Water-ring vacuum pumps are used to Retention time 29 days maintain a desired vacuum. Diameter 32.2 m Height 16 m ¾ Cooling water from cooling tower is used in the surface condensers for condensing the vapors. (c) Seven Effect Falling Film Evaporation Unit ¾ Concentrated Spentwash storage tank The suggested treatment scheme is a SEVEN EFFECT Evaporation Plant for Bio- (d) Transportation and windrowing of pressmud Methanated Spent Wash Evaporation. The following points will elucidate the basic working principle: The first step is to assess the land and pressmud requirement of composting as given below: Shell & Tube type Evaporators with highly efficient liquid distributor working on the principle of Falling Film Evaporation have been used, with Shell & Tube type 1. Capacity of distillery : 90 KLPD Preheaters for preheating of FEED stream which serves the purpose of energy conservation. 2. Quantity of spent wash from Distillation : 720 cum/day 3. Quantity of spent wash after Evaporation : 180 cum/day Steam is fed to the first effect evaporator shell side at the given pressure and temperature as the heating medium. 4. Spent wash consumption/Kg of pressmud : 2.5 Liters 5. Requirement of pressmud/day : 72 MT/day

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 4-21 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 4-22 Athani Sugars Ltd. Athani Sugars Ltd.

5. Size of each composting windrow : 100 x 3 x 1.0 5. P205 2 ± 3% 6. Capacity of each windrow By volume : 300 cum 6. K2O 0.5 ± 1.0% By weight : 180 MT 7. CaO 3 - 4% 7. Composting cycle : 60 days 8. N 1.2 ± 2.0% 8. Composting cycle/year : 4 cycles/year 9. Ash 8 ± 10% 9. Spent wash production/year 180x 270 : 48,600 cum 10. Micronutrients 2 ± 3% 10. Pressmud required/year 72 x 270 : 19,440 MT 11. Others 15 ± 20% 11. Quantity of pressmud in the : 4,860 MT yard/cycle(19,440/4) All parameter except pH are expressed as percentage on dry basis 12. No. of windrows in the compost yard : 27 (4860/180) (f) Preparation of Bio-Compost Yard : 13. Area occupied by windrows 21 x 100 x 10 : 27,000 m2 say 6.8 acres The bio-compost yard of size 190 x 126 m and area 24000 sq. M is proposed. ETP, Effluent Storage, Vehicular : 4.0 acres i.e. total of movement and other contingencies 10 acres is provided Entire bio-compost yard area will be made leak proof by constructing it with 300 mm 14. Availability of molasses for distillery : 90 KLD thick stone soling followed by 200 mm thick base concrete and 150 mm R.C.C. 0.5 capacity mt. height brick wall will be built around the compost yard with provision for incoming 15. Requirement of molasses (90 x 4 x 270) : 97,200 MT and outgoing of vehicles. The water collection tank of 2,400 m3 will be constructed to collect during the rainy days storm water from the yard. The water thus will be The requirement of press mud for its utilization of spent wash in composting process recycled in composting process. is estimated below: Land requirement details for 90 KLPD operation is estimated below: Spent wash utilization in composting of : 2.5 cum/tonne pressmud Capacity 90 KLPD Total spent wash produced per day : 180 cum/day Process Continuous fermentation with Multipressure 90 m3 x < 2.0 Vacumn distillation process. No. of working days : 270 days/year Effluent treatment Anaerobic Biodigester for primary Press mud requirement per year (270 x : 19,440 MT/year treatment and concentration by seven 180)/2.5 effect falling film Evaporators, Storage tanks for 5 days and 25 days capacity & 1 No.IBF Enviro-700 machine used for Bio- The press mud required for composting shall be received from FRPSDQ\¶V own sugar composting system. mill. The quantity of press mud produced in the sugar unit is estimated as: Spentwash generation 8.0 lts. Of spentwash per liter of alcohol. Annual crushing rate : 19.20 Lakh MT/year Press mud production rate per tonne of Spentwash generation per : 0.04 tonnes day after evaporation & 180 m3 cane crushed concentration Total quantity of pressmud produced from : 76,800 tonnes/year Distillery operation days 270 days per annum our Sugar industry (19,20,000 x 0.04) Maximum quantity of 48,600 m3 @ 180 m3/day effluent generated per Thus, the required quantity of press mud is available in excess from our captive annum sugar factory only which is owned by the same management.

(e) Composting of pressmud (i) Compost yard requirement calculation as per CPCB guidelines The characteristics of pressmud (% on dry wt. basis) is given below: 1 : 2.5 ratio for 60 days composting cycle (maximum 4 cycles per annum) or 1. Sugar 6 ± 8% 2. As fibre 20 ± 25% 1 : 2.5 ratio for 45 days composting cycle (maximum 5 cycles per annum) 3. As raw protein 8 ± 10% Pressmud quantity per acre, per cycle (maximum 850 tonnes per annum) Consumption of spentwash per acre per annum (for 4 cycles) 4. Crude wax 6 ± 8%

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 4-23 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 4-24 Athani Sugars Ltd. Athani Sugars Ltd.

Annual Rainfall in the area is = 0.5 m/year A. 850 tonnes pressmud x 2.5 times of spentwash x 4 cycles = 8500 m3/acre. B. Maximum effluent generated for 90 KLPD operation 270 days = 48,600 m3 Available roof top area for rainwater harvesting = 1279.24 m2 Roof Run off coefficient = 0.8 The extent of compost yard required to B 48,600 consume 48,600 m3 of spentwash = ---- = ------= 5.71 acres. S = R x A x Cr produced at ASL A 8,500 = 0.5 x 1279.24 x 0.8 = 511.69 m3 / season Hence we would be constructing a lined compost yard of 6.00 acres(max) Where, S = Mean rainwater supply in m3 Out of 10 acres earmarked for Pollution control activities, the usage for various R = Annual rainfall in mm/year purposes shall be: A = Surface area of catchment in m2 Cr = Run-off coefficient A] Biodigester & associated treatment units = 0.50 acres B] Multiple effect Evaporator section = 0.25 acres C] Concentrated effluent storage tank = 0.75 acres D] RCC lined Biocompost yard = 5.00 acres E] Biocompost Sieving & packing plant = 0.25 acres F] Finished compost storage godown = 1.25 acres H] Area for Vehicle movement & other contingencies = 2.00 acres

Total Land area Provided = 10.00 acres

Leakages will be collected from molasses tank will be collected in small pits. Cooling tower used is having closed system hence only make up water is required. 4.7.4 Rain water harvesting FIG 4.6: TYPICAL RAIN WATER HARVESTING STRUCTURE AT BUILDINGS In addition to the above, surface run off water harvesting from plant premises will be There are number of ways recharging the ground water such as- done into surface water reservoir. The surface water harvesting into surface reservoir will decrease water requirement during rainy days. Prior to entering into the ¾ Recharging of bore wells surface water reservoir, a silt trap shall be provided in the storm water drain. Surface run off from roads, green and open area shall be led to the surface water reservoir. ¾ Recharge pits The water shall be passing through settling chambers before reaching the reservoir to reduce suspended particulate load. The mechanism of settlement of contaminants Recharge trenches ¾ from rain water prior to reaching the surface reservoir is shown in Fig 4.7. ¾ Roof top rain water harvesting

Roof top rain water harvesting has been considered for the present case for recharge into pits. The typical rainwater harvesting structure layout at the building is proposed as given in Fig 4.6. It should be noted that process of recharging is a continuous and slow process. The results can be observed after a period of 3 to 4 years. The rain water likely to be recharge is calculated below:

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 4-25 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 4-26 Athani Sugars Ltd. Athani Sugars Ltd.

FIG 4.7: RAIN WATER OIL TRAP AND DESILTING CHAMBER PRIOR TO SURFACE The existing integrated sugar plant is already in operation and is spread over an area RESERVOIR of 24 acres. No additional area is proposed. The company owns a total of 120.4 acres where plantation, composting, etc is carried out. So, there is no change in the land use of the core area since the expansion units will come up in the existing plant area of 24 acres. The resultant land uses within the plot is shown in Table 4.7.

TABLE 4.7 PROPOSED LAND USE WITHIN PROJECT AREA AFTER EXPANSION Land Use Area (Acres) % of total (i) Area inside plant boundary Sugar Factory 12 50.0 Distillery Plant 4 16.7 Cogen Plant 8 33.3 Total Plant area 24 100.0 (ii) Area owned outside plant Biodigestor and Compost Yard 15 4.7.5 Water conservation measures Green Belt 48 Caneyard 15 Methods to be adopted for water conservation are: Employee Colony 10 Vacant Land 8.5 x Recycle of process water including vapor condensate and reuse of treated water Total area 96.5 x Evaporator condensate available from Sugar Plant will be reused in sugar plant The plant layout with proposed units, colony, greenbelt, utilities, etc. is shown in Fig and co gen plant 2.1. Photographs of the plant site are shown in Fig 2.2. x From Evaporate condensate from Distillery Unit will be reused in distillery unit During operation phase, the landuse pattern will remain same as constructed/ used. itself The quality can land & soil degradation can be a matter of concern due to waste water & solid waste disposal on land. The same shall be addressed as follows: x Effluent generated by cogen plant will be treated in existing sugar Plant having Preliminary and Secondary treatment. In the secondary treatment stage wise ¾ There shall be waste water from the power plant will be neutralised and used for activated sludge treatment process will be carried out. Each stage consist of the sprinkling and horticulture. The quality of the water shall be monitored to ensure aeration tank with fixed aerators and secondary clarifiers. The clear effluent from that it is within norms for disposal land. clarifier will be collected in polishing pond and water will be used for irrigation. ¾ The solid waste generation for disposal will be negligible and will be stored in x Rain water harvesting designated areas with impervious bases, thus, the impact on land shall be minimal. 4.8 LAND ENVIRONMENT - IMPACT & MITIGATION ¾ The majority of the solid waste i.e. fly shall be used composting since it is rich in potash. During construction, some excavation, land filling and development aspects may be needed for leveling of the ground During site clearance there may also be some . 4.9 SOLID WASTE - IMPACT AND MANAGEMENT accumulation of boulders at site. However, this disturbance be done only on temporary basis. At the end of the construction, the soil will be stabilized at the A. Construction Phase unpaved areas with the help of plantation activities. More than 33% of the 120.5 acres land owned by ASL has been envisaged to be covered with plantation During Construction phase, there will be development of a shanty town with including green belt. Since the plant species will be capable of checking soil erosion, temporary establishment of residential and commercial nature. Therefore, there will the soil will be fully stabilised without any adverse change in erosion potential of the be generation of solid waste. For, say, 500 persons involved in construction, it is area. assumed that both parents of a family would work while on an average two children would be non-working. Therefore, for 2000 persons residing/ visiting the site, at an

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 4-27 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 4-28 Athani Sugars Ltd. Athani Sugars Ltd.

average rate of 100 gm/capita/day, atleast 0.2 TPD of solid waste will get generated. ii. Pressmud Storage Yard : The pressmud storage yard of 75 m x 50 m will be These will have to be segregated. The organic matter can be composted and non- made impervious by constructing it with 300 mm thick stone soling. 200 mm thick biodegradables can be incincerated in the boiler. The recyclable will be sold to base garland canal to collect any leachate are rainy days water. The same water will recycling vendors although components like paper & plastic serve as high calorific be collected in a collection tank of 10 m x 10 m x 5 m and the same will be recycled. wastes for incineration in boiler. iii) Yeast sludge management : ASL will adopt the state of the art continuous fermentation process with Multipressure Vacumn Distillation such that the generation B. Operation Phase of solid waste such as, yeast sludge is very less as compared to conventional batch process. The volume of sludge is only 0.5 ± 1% of the total quantity of fermented The various types of solid waste along with their impact and management is wash. For 90 KLPD Rectified Spirit Plant the maximum quantity of sludge produced summarised in Table 4.8. is 2,500 ± 5,000Lt./day (wet basis). The sludge is dried and will be used for composting. TABLE 4.8 iv) Details of waste generated other than Fly ash SOLID WASTE - IMPACT AND MANAGEMENT Boiler ash generated in co- generation used in biocompositing and some quantity Unit Solid Waste Quantity (MT) Source Management sold to brick manufacture. Name Generate Reuse Yeast sludge and ETP Generation sludge also mixed with press mud for bio d composting. Sugar 1) Bagasse 1,66,080 From Process Used in boiler Distillery spent wash treated in 2 nos of Biodigester having each capacity 450 2) Press mud 23,334.5 19,837 From Process Composted m3/day and biomethanated spent wash (BMSW) further fed to seven effect falling .5 film evaporation system to increase concentration and reduce quantity of BMSW. 3) Biological 16.5 16.5 FromPollution Composted Sludge control Equipment Conc BMSW then spraying on press mud for composting to achieve zero discharge. Cogen Boiler Ash 2826.5 2,826 From Process Due to high potash content, used with press 4.10 ECOLOGY mud to convert to compost 4.10.1 Impacts Distillery Yeast Sludge 1300 1300 From Process Compost A. During Construction Hence, it can be see that in this plant as all solid wastes generated will be recycled During construction phase, there will be less negative impacts on terrestrial eco- in the process or composted and given/ sold to farmers due to high nutrient content. system comprising birds and animals as the area proposed for construction has less No net-solid wastes generated will be available for disposal. trees. Despite attempts to minimise the cutting / felling to the extent possible, if trees Fly ash, press mud and yeast sludge management are described below: will have to be felled, due permission will be taken from the Forest Department and compensatory tree plantation undertaken within the plant premises. With progressive i. Ash handling and storage : Fly ash collected from the ESP hoppers and the growth of greenery, terrestrial eco-system will improve in course of time. Presence of air-heater hoppers and the ash collected from the furnace bottom hoppers can be water and food wastes during day time will attract some birds and small animals used as landfill, during the seasonal operation of the plant, when bagasse will be the (squirrels, mongoose, etc) towards the site. main and only fuel for the operation. The ash content in bagasse is less than two percent. In cane trash and the other biomass fuels proposed to be used the ash B. During Operation percentage will not exceed 10%. The total fly ash collected during off season could During operation phase, the impact zone is part of landscape involving rural areas. be used as a landfill. The high potash content in the bagasse ash makes the ash, a Impacts on biological environment in the buffer zone will be low during the good manure. As the filter press mud from the sugar plant also has a good land operational phase as the overall emissions shall remain well within the permissible nutrient value, it is possible to mix the ash and the press mud and sell the same to limits. the farmers to be used in the cane fields. The maximum ash generated using bagasse, biomass and cane trash as fuels will be about 8640 M TPA. The general adverse impacts, usually in case of such an industry are: This ash generated will be given freely to entrepreneur to convert to Bio compost as Dust emission from plant and due to transportation, which affects the effective well as it will be used with press mud to convert to compost in own distillery. ¾ photosynthesis by covering the plant/tree leaves by thin dust layer during dry months which however will be washed away in rainy months.

¾ Roadkill due to traffic

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 4-29 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 4-30 Athani Sugars Ltd. Athani Sugars Ltd.

¾ Disturbance to birds and animals due to bright light and unusual noise during Company has planted several trees around factory premises operation activity. No. Scientific name of tree Common Name No. of trees 1 Azadirachta indica Neem 100 Contamination of water bodies on which animals and birds are dependent or ¾ 2 Tamarindus indica. Linn Gulmohor 70 contamination of ground water due to effluents and sewage. However, in this 3 Manilkara zapota Chikko 50 case, the waste water from domestic and and industrial sources will be treated in septic tanks and ETP, respectively, and will be used for irrigation of plantation 4 Pongamia pinnata Karanj 100 areas. Thus, there will not be any discharge of effluent from the plant. So, no 5 Magnifera indica Mango 500 impact is envisaged on the surface water bodies and on the fresh water eco- 6 Saraca asoca Ashoka 100 system or ground water quality. 7 Tamarindus indica. Linn Chinch 160 8 Cocos nucifera coconut tree 350 C. Impact on cropping pattern Total 1430

Belgaum District as such was described as cultivated area from the view of In addition to the trees, a variety of small flowering shrubs and plants will be planted agriculture. At the beginning the crops like, Jawar, Wheat, Bajara, Groundnut, Chilli, in the gardens and lawns. These flowering plants will improve the aesthetics of the were grown. Due to availability of river water the sugarcane growers increased to a area. The selection of trees for plantation will be done judiciously keeping in mind the large extent. The survey conducted in the project area indicated that there is no adaptability of trees to the climate of the region. Consultation with the forest officers competing crop for sugarcane. High value crops like chillies, fruits and vegetables and experts in the field will be done to identify the exact species to be planted. Thus, are grown in few villages. However, area under these crops is very meager. Jawar, a positive impact will be there due to plantation within the plant premises. The green wheat, bajra, safflower, sunflower and groundnut are other important crops that belt is proposed to constitute of fast growing native species. provide a source of income. Farmers reported that they are not happy with private traders about the payment received and the price offered to them for these products. 33% of the total 120.0 acres land under the ownership of ASL is proposed for Moreover, there is an certainty of the payment from traders and is generally delayed. plantation. In case of sugarcane, the first installment is assured within the first 15 days from the date of sugar cane supplied to the sugar factory. Farmers also feel that soyabean, ii. Wildlife protection measures jawar, groundnut, sunflower and wheat fetch less income as compared to sugarcane. Soyabean and groundnut crops are also affected due to rains during September and There is no Schedule-I species in the study area. As regards fauna is concerned, late August. Moreover, in spite of adopting recommended package of practices, the Squirrel, Mangoose, Indian Hare etc. are the mammals besides various species of entire crop is lost most of the time leading to loss of income. The agro- climatic ambhipians, aves and reptiles. The plant in the centre does not intend to interfere conditions and soil type prevailing in the operational area of ASL are very much with the fauna. However, precautionary measures can be taken as mentioned below: congenial for healthy growth of good quality sugarcane. sufficient irrigation facility is also available from irrigation Schemes as well as Tube wells existing in the area. 1. Construction of boundary or fence along the plant perimeter to prevent wild Water level of existing wells are reportedly increased because of regular monsoon animals from straying into the plant area and getting harmed. during past few years and, hence, there is considerable scope to improve the 2. Establishment of greenbelt along the facilities periphery to act as a natural buffer cultivation practices and shift over to sugarcane. It is also observed that cultivators in between the surrounding area and the facilities. The greenbelt establishment command area are progressive and are aware of sugarcane cultivation practices. In around facilities and along roads will result in small sized fauna such as squirrels, view of above, local farmers other crops wish to switch over to sugarcane cultivation. hare, etc., reptiles and birds in finding a favorable habitat. 4.10.2 Mitigation measures 3. The roads leading to and from the plant shall be having caution boards warning drivers to slow down for animal crossings, if any develop in the future Although the impacts are very limited or negligible, it is proposed to improve 4. The drivers shall be sensitized not to hit stray animals on the road. the general ecology within the plant premises. Therefore, the following measures are proposed: 5. The emissions from the plant shall always be kept within the norms so the surrounding environment is always clean and comfortable for human and wildlife i. Plantation programme vegetation. 6. Care shall be taken that no food or degradable waste is openly disposed. This To reduce the impact of air pollution, particularly the PM content, the creation and could attract wild animals near to human habitation and create man-animal maintenance of a green belt and plantations within and around the plant is being and conflict. Hence, disposal of wastes shall always be on the designated and will be undertaken. protected place.

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 4-31 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 4-32 Athani Sugars Ltd. Athani Sugars Ltd.

7. The company shall interact with the Divisional Forest Officer and find out whether plan to plant fuel wood or other biomass plantation in the area of the factory can any schemes are ongoing for the protection of the wildlife. If such schemes are cover this. This can be a stopgap arrangement for the fuel for boilers to produce ongoing, then monetary or logistic support shall be extended by the company. power for around 300 days in the year. For example, the company can supply water to watering holes in the forests in study area during dry season Plantation in the forest blanks to increase the Based on the farmers survey carried out in the command area, it is recommended to fodder availability in the forest. undertake following activities in order to ensure uninterrupted sugarcane supply 8. While carrying out social welfare activities, awareness about the variety of faunal during the crushing season: species, their status of protection and awareness of their behavior will be spread It is recommended to develop seed nursery for through posters/ seminars or discussions to sensitize the villagers. By gaining ¾ Development of Seed Nursery : sugar cane and fuel wood or other biomass varieties for distribution of the same correct scientific information, the villagers will be in a better position to protect to the farmers in the command area themselves from animals and in return not harm them. Such situation reduces man-animal conflict, which usually arise due to myths and fear or hatred of ¾ Seed Distribution : ASL will have to raise quality seed material and meet the animals. demand so that old seed is replaced after every five years. Sufficient seeds of new high yielding varieties should also be multiplied in the seed farm. These 9. Plantation in the villages is also a part of the social welfare proposal, which may varieties should be systematically distributed to help the farmers to plan their be done in a manner that it acts as a natural buffer between the villages and cropping pattern and cultivation of early / mid late / late varieties surrounding areas. Also, the choice of the species to be planted can not only be natural but also economic yielding trees such as those for firewood, fruits, gum, ¾ Water Management : ASL will have to take due care to water management leaves, seeds or timber. Such schemes would be called social-forestry schemes especially in the heavy soil region. Care should also be taken for proper drainage and create a community resource due to which villagers need not go further to system. The region has natural slope and the higher region is free from water the jungles to get firewood, fruit, etc. When their visits to the forests reduce, the logging. pressure on the forests reduces and makes it not only safer for the flora but also ¾ The inputs like pesticide, insecticide, fungicide, micro ± nutrient fertilizers, seeds fauna. The impacts therefore can be mitigated with appropriate control measures of green manure, organic compost are easily available. There is no difficulty in 10. Water sprinklers and fire hydrants of adequate specification will be provisioned at procuring crop loans and M T Loans from PACs. strategic locations to deal with any emergency. ¾ For implementing the above mentioned programs in the command area, training 11. The treated effluent released from the plant will be utilized for raising plantation programs, Kisan-mela etc. could be conducted in various parts of the operational and maintenance of garden. area. Thus, the gap between potential yield actual yield could be reduced.

12. It will be ensured and monitored that noise level is not exceeded beyond 60 dBA. It is to be noted that due to the developmental activities already introduced by ASL, Noise level beyond work place will be reduced by planting green belt around the sugarcane cultivation has improved. Many new cane varieties have been introduced plant. and hence it can be concluded that systematic as well as sustained efforts would 13. Air pollution will be kept minimum at work place and negligible beyond the plant help to increase the yields of sugarcane. premises by providing green belt in plant area, sprinkling water, etc. Ultimately, farmers would undertake sugarcane cultivation and the responsibility of 14. Company has earmarked separate budget for environmental protection. the promotional activity of cane cultivation has to be played effectively by the 15. Plantation of fodder grass can bH FDUULHG RXW DW WKH FRPSDQ\¶V H[SHQVH LQ WKH proposed ASL. Farmers are anxious about ASL expanding the sugar factory at the nearby forests, as per directions of the Forest Department so that the animals proposed site. Non-member of ASL should be attended to properly and even better stay back in the forests and do not enter the villages in search of food. than the present SSKs. Farmers are of the view that the area of sugarcane has been 16. Awareness programmes will be conducted with the help of different voluntary increasing steadily for the last few years as some irrigation projects have come up in organizations involved in conservation through various means like film, video the command area. However, following expectations from the proposed ASL shall be shows, street plays, story telling etc. taken care of: 1. Cane price should be paid as per FRP calculations. iii. Command Area Development 2. Good quality seed material of sugarcane should be provided by ASL, as there is no source for good seed material in the command area. The availability of bagasse is entirely placed on the quantity of sugarcane present in the ASL area. Although the project is based on the bagasse which is sourced from 3. At the time of plantation, crop loan and basal dose of fertilizer should be linked so sugar unit. It may be foreseen that due to marginal rainfall quantity of bagasse shall that farmers apply the basal dose of fertilizer be reduced. As a consequence power plant may have acute shortage of fuel. having

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 4-33 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 4-34 Athani Sugars Ltd. Athani Sugars Ltd.

4. ASL should make arrangement for soil testing and accordingly fertilizer doses timely harvesting, as they have to wait till their round of harvesting comes because of should be recommended. It should be done not only for members of SSK but also which they loose time and cannot take up another crop. With the setting up of ASL, for all farmers who supply sugarcane to ASL the demand of sugarcane will increase in the local area because of which there would be timely harvesting of sugarcane and the farmers are also likely to get a 5. ASL should provide the seeds of green manure. It is reported by a number of better price to the existing one thereby improving the economy of the local area farmers that organic fertilizer coupled with chemical fertilizers if applied in projected in the proposals, ASL will be able to supply 12 MW surplus power balanced quantity, give a considerably higher yield of sugarcane particularly in generated in Phase I and 12 MW at the end of Phase II implementation to KV MSEB medium and light soils. Thus, it is necessary that organic fertilizer be utilized to substation, from ASL site location. The production of power will resolve power crises increase the sugar yield. and will enhance earning to village people. The consumption of bagasse for power generation will make ASL free from its disposal. The adjoining sugar factories 6. Presently sugarcane growers face great difficulty due to lack of road facility from marginal bagasse shall be diverted to ASL, which will reduce the load of its proper the main road to farm. These roads are small in breadth and during rainy seas, disposal. Encouraging the farmers in the ASL vicinity to plant more and more of fuel these roads become unsuitable for transportation of sugarcane vehicles every wood for cogeneration unit will substantially increase income level of the farmers. year. Thus, there is concerted demand from the farmers that small roads should be developed into pacca roads. The socio-economic benefits shall be as follows: 7. Due to benefits accrued from the irrigation project, the number of electric pumps operating in the area as well as new pump connections would increase and there x Ample power will be available from local grid due to decentralization of power would be a long waiting list for electricity shortage and low voltage problems. generation SSSKL would ensure constant and continuous electricity supply for agricultural operations. x Power from grid on no charge basis or low charge basis can be available in this area. 8. Farmers should be imparted training in sugarcane cultivation. x This can be an initiative for many units to start. 9. All studies, which are made available by the existing SSKs to their own members, should be provided to other sugarcane growers also. x Many sorts of direct as well as indirect job opportunities will be on the horizon due to expansion sugar, distillery and co-generation complex. 10. Press mud and bio-FRPSRVWVKRXOGEHPDGHDYDLODEOHDWWKHIDUPHU¶V field. x This will result in an increase in income level of the employees, subsequent 11. Interest rates on NRD and RD should be uniform in case of non-members as well commercial as well as social infrastructure establishment. as members. x Supplementary type units can be initiated in the area like cattle preservation & 12. In some of the villages, new lift irrigations schemes should be promoted. protection, poultry, herbal medicinal plants, spices, pickles, papad and other food items, milk producer group co-operative small saving groups. 13. Timely payment should be made to farmers. A detailed CSR plan has been prepared by the company to improve the socio- 4.11 SOCIO-ECONOMIC ENVIRONMENT economic status of the surrounding people and is given in Chapter 9. Like other sugar factories ASL is located in an isolated area. ASL management 4.12 OCCUPATIONAL HEALTH AND SAFETY thought that it would be advantageous to improve the living conditions of people in Occupational safety and health is very closely related to productivity and good and around the plant site. It also proposes to employ local skilled and unskilled employer employee relationship. The main factors of occupational health in workers for expansion stage also. It will therefore generate additional employment in proposed site are fugitive dust and noise. To avoid any adverse affects on the health the local area. ASL is also planning to setup additional 30 MW cogeneration plant for of workers due to dust, heat, noise sufficient measures have been provided in the power production. It will resolve power crisis and will enhance earnings for village proposed project. These include: people. In turn local people can avoid uncertainty of job, raise their living standard, do supplementary jobs of cane & other farming, cattle, poultry, brick making unit etc. x Provision of rest shelters for workers with amenities like drinking water, fans, thus to stabilize & prosper in life. This will surely be a positive impact. toilets, etc. The existing production of sugarcane is much more than the requirement of these Provision of personal protection devices to the workers. sugar factories. The balance sugarcane is presently sold to different sugar units in x Belgaum district. In view of more availability of sugarcane than the demand of existing sugar factories, there is no certainty of getting a good price for the can and x First-aid facilities on the site the sale price keeps varying. Moreover farmers are also not very happy about its

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 4-35 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 4-36 Athani Sugars Ltd. Athani Sugars Ltd.

x Mobile toilets will be provided during construction Sl. Type Effects Remedy No. x Ambulance will be provided for taking patient to the nearby hospital in case of dermatitis gloves, use of body lotions emergency or medical. 12 Cold weather Skin cracks and damage Proper cloths, Use of due to exposure to proper skin covers 4.12.1 Occupational & Safety hazards and protection measures severe cold climate, dermatitis Hazards associated with human body are of 3 types, physical, chemical, biological. 13 Wind & storms Skin damage, wound do A. Physical hazard formation on exposed skin Sl. Type Effects Remedy 14 SPM and dust Damage from nostrils to Avoid / lessen exposure No. matter lungs part, Pneumonia, Use masks, screens 1 Lifting heavy Temporary or permanent Maximum capacity for a Temporary or permanent Minimize / avoid source loads bone damage & man to lift a load fixed as 15 Excess pressure Effect on O2 intake Stepwise change over to fragments, Weakness of 50 kg, Automation of carts, area conditions capacity And N2 normal air pressure, Keep bone & spinal cord, new trolleys, Prefer sliding than deep sea associated with it less exposure period RBC & WBC forming lifting exploration, ship damage to heart and lung process building muscles 2 UV, IR Ionization Vision damage, skin Proper cover to source of radiations damage, skin cancer glare, use of colored In the project, the above impacts are possible with the exception of points 2 & glasses 3. 3 Nuclear radiation Do Do B. Chemical hazards 4 Light glare Damage to vision, lens Do opacity, Myopia Sl. Compound Effect Remedy 5 Poor illumination Less accuracy in work Provide proper light No. 6 Excess Heat exhaustion, fatigue, Distance be more from 1 Metals Fe, Co, Combine with body tissue, Safe distance from temperature / cramps, stroke, muscle heat source, to give Ni, Mn, Zn, Pb, form metabolites, affect source, shielding, Heat stress cramps, fainting, dry skin, drinking water & milk, Cd, Cr, Al, As, blood, nervous, protective equipment, heat rash, [prickly heat], Limited exposure, cool rest Hg, Cu, Fe. respiratory, neuro, change in operation, loss of hair rooms, Asbestos lined excretory, reproductive, automation clothing and gloves, digestive systems adjustment of work and 2 Asphyxiant CO, Chemically combine with Safe distance from rest period HCN, NCO, H,N Haemoglobin can cause source, shielding, cross 7 Cold stress Cracks in skin Proper clothing, gloves, death in short time ventilation aprons, body lotion 3 Anaestatics Chemically combine with Do 8 Vibrations and Vibration induced joint Absorption of excess shock gasoline, ethers, tissues, damage & rupture shocks impairment, Arthritis, waves with clad medium, ester, alcohol, them Parkinson disease rubber pads, exact C6H6, CCl4. maintence, proper 4 Irritants NH3, Damage nostrils to air Do lubrication SO2, Cl2, H2S, sack path, affect 9 Noise Temporary or permanent Minimum exposure, air CS2 respiratory ability hearing disability, loss of plugs, muffs, reducing 5 Solvents, Petrol, Damage body parts, Protective equipment peace of mind noise frequency kerosene cracks in skin, Dermatitis 10 Dry air Lack of natural lubrication Proper skin lotion and skin to skin, scaling, nourishment use of proper The most applicable on this project is point no. 2. dermatitis, soricis gloves 11 Humid climate Skin damage due growth Correct draining of all C. Biological hazards of some microorganisms water from work place, due to wet nature, Proper aprons, rain coat, These cover all sorts of micro organisms, bacteria, fungi, viruses, insects, particles initiating via air, water, soil, cotton, wool, leather, silk, milk, rubber, bagasse, plastics,

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 4-37 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 4-38 Athani Sugars Ltd. Athani Sugars Ltd. jute, meat, fish, slaughter, paper, dry biomass etc. They affect whole body and can Thus probable routes to mitigate such damages can be: cause death. Remedy is to isolate, kill and avoid them to enter in body. 1. Precise man power selection 4.12.2 Guidelines on Specific Occupational Health Issues- prevention & protective measures 2. Adequate pre employment training 3. Optimum supervision at all levels Persons working in bagasse based power generation plant are always exposed to solids, particularly fine dust of bagasse, trash and other fuel components. PM10 and 4. Precise equipment selection PM2.5 enter air sacks after entering respiratory track where they settle. Due to precise size they are difficult to be removed from there. Moisture in fresh air and 5. Periodic and exact lubrication of the equipment, machines. constant body temperature make them to build microbial colonies. Treatment in such cases to curtail the infection in respiratory track is a hail of a job for medical experts. 6. Advance planning of substitution of equipment Micro organisms have short life span and have to adopt consistently for the survival. 7. Prevention of solids to enter in respiratory track. Thus they develop capability to resist the drugs / therapeutic agents / antibiotics etc. It is a battle at global level for decades together. No correct curing agent / exact or 8. As far as possible closed condition operation. permanent solution exist. 9. Use of natural and forced fresh air supply at work place Persons working in bagasse based power generation area can get exposed to : 10. Adequate natural and forced air circulation as per needs 1. Excess air pressure zones and SPM prone area. 11. Proper bonding and earthing of the machinery 2. Higher temperature to follow heat exhaustion, cramps, stress, stroke 12. Proper insulation & core cover for power supply cables 3. Moist / humid and dry weather area where skin damage may occur 13. Proper selection for material movement 4. Lifting of excess load can lead to damage to bones & spinal cord 14. Provision for cages, trolleys, carts, fork lifts, cranes, shuttles for movement of 5. 9LEUDWLRQLQGXFHGERQHMRLQWGDPDJH $UWKULWLV3DUNLQVRQ¶VGLVHDVHFDQRFFXU material and men 6. To lessen SPM, sprinkled water can lead to moist air. Such condition can lead 15. Automation of material handling to growth of mosquito, insects, flies population to lead to Malaria & other epidemic diseases 16. Sprinkling of enough water to mitigate SPM 7. Electric shocks in case of short circuit 17. Sufficient enlightening in work area when persons are inside

Various extents of the damages to different body parts can be: 18. Provision to keep shop floor dry 19. Provision of enough drinking water when needed. 1. Permanent or temporary deafness 2. Slight or severe damage to bones & spinal cord, joints 20. Provision of rest rooms / shelters to working staff 3. Anemic condition due to less RBC, WBC & lacking of new blood formation 21. Prevention of fly, mosquito, insects in spread water to mitigate SPM 4. Affect initial correct vision due to poor light as well as due to small particles 22. Provision of primary health center / first aid booths with adequate drugs, 5. Damage to skin due to humid climate & water sprinkling, dermatitis / soricis, lotions, eye washers etc. and attendants. cracks to skin, dry skin 23. Strict control to follow use of personal protective equipment like goggles, ear 6. Damage to respiratory track to lead to businosis, pneumokosis, pneumonia plugs, air muffs, aprons, helmets, rain coats, respiratory kits / air pipes, safety 7. Heat exhaustion, fatigue, stroke, rash, cramps, damage to muscles belts etc. 8. Excess heat exposure may lead to damage to reproductive system 24. Periodic replacement of new / fresh teams to complete time scheduled task 9. Electric shocks can lead to partial paralysis 10. Damage to eye due to incident light particles.

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 4-39 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 4-40 Athani Sugars Ltd. Athani Sugars Ltd.

Noise and Vibration 7. Manage the safety team (committee)

Relevant noise emitters at ASL are noise-making equipments such as Cutters, 8. Conduct or coordinate all site safety inspections Crushers, Mixers, Compressors, Pumps, Centrifuges, Heat exchangers, Vacuum 9. Manage safety violation and award program Filters, Boilers, and Turbines, D.G. Sets etc. All the equipments produce continuous noise. As deliberated in Chapter ±IV, noise level impacts of ASL operations are 10. Provide and/or coordinate safety training for all new employees significant only on the operators of machinery and are negligible within buffer zone. This is because the noise produced by these machinery gets dissipated due to wave 11. Be notified immediately regarding accidents and/or injuries divergence, atmospheric absorption and absorption by noise barriers before being 12. Eliminate all hazardous practices performed by employees even felt in the buffer zone. 13. Assign and train a replacement in the event he/she is unavailable for duty The continuous hammering of noise on the ears of the staff working in the factory premises may lead to some health problem, it can be circumvented by having small A detailed safety plan shall be prepared to cover the safety hazards and their cabins with polycarbonate sheet or glass partition where in officers can carry out prevention. The plan shall clearly describe what people are expected to do for safety, day-to-day work peacefully. will make safety a line management responsibility and accountable and will incorporates safety into the business process as an operational strategy. It will use Following measures are proposed for controlling noise level impacts on machinery proactive health and safety measurements. operators and within core and buffer zone of ASL. Workshop audits and inspections will be planned and take place on a regular basis. x Proper lubrication and regular maintenance of all the machinery used. They will be reported and give rise to corrective and preventative actions, which will x Development of greenery / barriers / landscaping of trees/ bushes and shrubs. be managed in the same way as injury analysis. These inspections and audits will be x Reduced noise exposure to the operators of machinery by work scheduling conducted by the line management, trained for the purpose, including the Top and by providing ear protective equipment. Management. Personnel will be involved as much as possible in these audits and x Use rubber packing in the foundations of machineries to prevent noise inspections. transmission to the surrounding. Personal Protection Equipment 4.12.3 Safety hazards along with prevention & protective measures Personal protection equipment for work shall be identified, the circumstances in Company will work as per The Factories Act, 1948. The law contains provisions which it should be worn defined, and suitable arrangements made including training regulating the health of workers in an establishment. Whereas the Employees State & supervision to ensure it is worn. The use of safety helmet and shoes will be made ,QVXUDQFH $FW  DQG WKH :RUNPHQ¶V &RPSHQVDWLRQ $FW  ZLOO EH mandatory in the plant area while the use of glasses, face shield, dust mask, ear compensatory in nature. muff shall be advisable in many parts of the plant depending on the hazard nature. Some of the safety gears are shown in Fig 4.8. It will be the responsibility of the management to ensure safety in the the premises of the company. The duties of the management will be as follows:

1. Lead in the establishment of rules and policies designed to promote safety and health, accident prevention and hazard awareness 2. Maintaining the safety policy, safety manual, the proper safety and health training documentation and the necessary recordkeeping 3. Make all employees aware of the established safety and health rules of the safety policy 4. Hold each employee responsible and accountable 5. Monitor all aspects of the safety policy and safety manual 6. Promote and ensure proper safety training, worksite audits, accident investigations, and hazard control.

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 4-41 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 4-42 Athani Sugars Ltd. Athani Sugars Ltd.

¾ Use of PPE (masks & respirators) ¾ Use of mobile vacuum cleaning systems ¾ Water spray systems, where applicable ¾ Plantation ¾ Regular housekeeping ¾ Providing pollution control equipment like ESPs

x The company will establish its own occupational health and safety centre with MBBS doctor and support staff.

x The proposed medical facility will:-

¾ All primary, secondary and essential life saving drugs and injections. ¾ Laboratory for blood testing. ¾ Oxygen cylinder including central oxygen cylinder. ¾ Nebulisation Machine. FIG 4.8 : PERSONAL PROTECTION EQUIPMENT ¾ One ordinary ambulance for referral centre with certain primary facilities to help the patient while in transit. 4.12.4 Occupational health monitoring system Surrounding population Regular medical examination of employees will be done for the occupational diseases. The medical examination will be carried out by a qualified Medical Officer Weekly medical camps will be arranged for detection of diseases in the nearby rural appointed by the Company. The following measures relating to safety and health population, wherein the local people can take free medicines and health check ups. shall be practiced: 4.12.5 OHS monitoring ± planning & findings x Provision of rest shelters for plant workers with amenities like drinking water, etc. The company shall strive to maintain public health in the area by way of conducting or sponsoring programs such as free eye camps, diabetes and cancer detection x All safety measures like use of safety appliances, safety awards, posters, camps, inoculation and vaccination programs etc. it shall also offer the services of slogans related to safety, etc. Ambulance or any other such vehicle in case of emergencies to the needy locals. x Training of employees for use of safety appliances and first aid. The workers will be medically examined at the time of employment to observe the x 5HJXODU PDLQWHQDQFH DQG WHVWLQJ RI DOO HTXLSPHQW DV SHU PDQXIDFWXUHUV¶ physical fitness and to know any ailment which may need care while placing him in guidelines. some hazardous area. Regular medical examination by a qualified Medical Officer of x Periodical Medical Examination (PME) of all workers by a medical specialist employees on annual basis will be done for the occupational diseases. The sample so that any adverse effect may be detected in its early stage. Medical Format for pre placement and post placement of employees is given in Annexure XVIII. x First Aid Cell in plant including training and retraining of First Aiders. x Close surveillance of the factors in working environment and work practices, The industry has and will keep health records of all its employees starting from ZKLFKPD\DIIHFWHQYLURQPHQWDQGZRUNHU¶VKHDOWK0RQLWRULng of the values of employment date till their retirement. The medical records have and will be analysed various factors, which may lead to occupational health hazards. annually to know the trend of employee health. In case some serious trend is noted then suitable action will be taken to address such health issues. x Fugitive dust protection or dust reduction technology for workers within 30 m Some typical health record analyses to be maintained are given in subsequent of the plant active areas will be used as follows : paragraphs as illustration:

¾ Use of dust extraction and recycling systems to remove dust from work areas, Chest X Ray: The chest X-Ray is conducted to reveal the health problems specially in grinding mill associated with dust. This data may be useful to provide medical attention to the ¾ Use of air conditioner/ local exhaust ventilation systems, enclosures, hoods

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 4-43 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 4-44 Athani Sugars Ltd. Athani Sugars Ltd.

affected persons and if the number increases with time attention would be required Media Pathways Comment to improve the working environment. Sediment (solids Benthic animals absorb Processes are very complicated and Spirometry Test: Spirometry (meaning the measuring of breath) is the most and pore water) chemicals, respire pore usually simplifying assumptions are water or food or food from required. However, these will not be common of the Pulmonary Function Tests (PFTs), measuring lung function, the water column. Plants applicable in proposed plant due absence specifically the measurement of the amount (volume) and/or speed (flow) of air that rooted in the sediment may of heavily contaminated effluents can be inhaled and exhaled. Pulmonary function tests are done to diagnose certain take up material from types of lung disease (especially asthma, bronchitis, and emphysema), find the sediments, surface water cause of shortness of breath, measure whether exposure to contaminants at work and air affects lung function, assess the effect of medication, measure progress in disease treatment etc. Soil (solids, pore Organisms in soils may Processes are very complicated and water and pore air) absorb material from soil, usually simplifying assumptions are pore water, pore air, ingest required. The solid waste is all Electrocardiogram (ECG) Test: The ECG is a diagnostic tool that measures and soil, soil- associated food compostable and even the fly ash is rich in records the electrical activity of the heart in exquisite detail. The annual analysis potash, thereby increasing the nutrient helps in keeping track of heart related illness caused due to several occupational value of the soil on which this compost & reasons. flyash shall be used. The air emissions anticipated are also so low that they will Audiometry Test: Audiometry is the testing of hearing ability, involving thresh-holds have negligible impact and differing frequencies. Results of audiometric tests are used to diagnose hearing Ingested Food and Consumption by fish and Assume the test animal consumption rates loss or diseases of the ear, and often make use of an Audiogram. Water wildlife in laboratory for a given availability of food or water are the same as those occuring Vision Test: Eye examinations may detect potentially treatable blinding eye naturally in the environment. In case of diseases, ocular manifestations of systemic disease, or signs of tumours or other this plant, there will be no discharges to a anomalies of the brain. surface water body, thus, fish and wildlife are not anticipated to get affected 4.13 EXPOSURE PATHWAYS Multimedia More than one of the It is often possible to assume one pathway above pathways is dominant. In some cases, it will be Exposure pathway is the path due to which exposure of the receptor takes place. necessary to estimate the combined 7KH³H[SRVXUH´KDVEHHQGHILQHGDVFRQWDFWZLWKDFKHPLFDORUSK\VLFDODJHQW,WLV dosage. In this project, such a pathway the process by which an organism acquires a dose. Table 4.9 identifies some of the will be through the use of composted solid major exposure pathways. There is are effluent and solid waste generated in the waste and use of treated effluent for plant which is managed by using for irrigation and as manure, respectively. irrigation, both on soil. Source : Adapted from Table 3-5, Technical EIA Guidance Manual (COP) by IL&FS Ecosmart Limited, Hyderabad TABLE 4.9 EXPOSURE PATHWAYS Emissions from sugar mill and cogeneration plant can cause damage to human health, aquatic and terrestrial ecology as well as material due to mainly the soil Media Pathways Comment exposure routes For example, adverse effects of the plants on human health can Air- Gases and Respiration Assuming accurate fate model estimates, derive from the direct impact of suspended particulate matter and combustion gases Aerosols exposure is relatively predictable based on emission on the organism and/ or their direct impact via the food chain and changes assumption of homogenous distribution in in the environment. But this impact will not be as high in comparison to any air. The air quality prediction model shows contamination that might occur due to contaminated effluent or comtaminated solid that this exposure pathway will be low waste applied on soil and thereafter, on uptake by plants, finding its way into the impact for emissions from boiler. animal food chain. The duration of exposure is decisive. Injurious heavy metals (e.g. Water- Soluble Respiration Assuming accurate fate model estimates, lead, mercury, cadmium, etc) can enter the food chain and thereafter, the human Chemicals exposure is relatively predictable based on organism by way of drinking water and consuming vegetables and animal products. assumption of homogenous distribution in Thus, monitoring of both effluent as well as solid waste quality shall be done, even water. However, these will not be though both are well extablished as nutrient rich and beneficial to plant growth. applicable in proposed plant due to absence of heavily contaminated effluents

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 4-45 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 4-46 Athani Sugars Limited Athani Sugars Limited

CHAPTER 5 Benefits of Cogeneration

ANALYSIS OF ALTERNATIVES Cogeneration offers higher efficiency and lower waste on the one hand, and greater fuel flexibility and lower costs on the other. However, with the benefit of new technology a much wider range of industries, from sugar to chemicals to textiles, is employing cogeneration. Its 5.1 SITE ALTERNATIVES potential is just beginning to be realized.

M/s. Athani Sugars Ltd. (ASL) proposes to expand its integrated sugar, cogeneration power Cogeneration utilize the available energy in more than one form, they use significantly less project & Distillery at Kempwad village, Taluka Athani Dist. Belgaum, Karnataka in existing fuel input. The cogeneration reduces energy costs and offers fuel flexibility. It also protects units. The proposed project is an expansion of sugar crushing capacity from 4500 to 12000 a company from the effects of power cuts and improves the quality of power. And finally, it TCD, distillery from 60 to 90 KLPD and set up 24 to 54 MW biomass power plant for making reduces wastes. RS/ENA/Ethanol. The expansion plant is being set up in the existing 120.5 acres of land. Technologies of Cogeneration The site had been selected because of the following reasons: Cogeneration can be implemented in many ways. Small diesel engines, gas turbine plants ¾ Availability of uninhabited, non-forest land at reasonable cost; with waste heat boilers, combined cycle cogeneration stations, biomass-based plants can ¾ Proximity to water source; be used to provide heat as well as generate electricity. There are two types of cogeneration ¾ Proximity to raw material source and cost-effective transportation logistics; plants. ¾ Availability of infrastructural facility including road connection; Topping cycle: Primary fuel is used to produce electricity, and thermal energy which is the No alternative site was considered for the proposed expansion phase as the plant exist at by-product is then used for process heating. the present site. There are no eco-sensitive locations such as bio-sphere, mangrove, protected forest, National parks etc. or environmental sensitive locations such as protected Bottoming cycle: Primary fuel is used to produce heat which is required for the process at monuments, historical places within 10 km from the site. high temperatures and hence, power is generated through a suitable waste heat recovery system. 5.2 TECHNOLOGY ALTERNATIVES 5.2.2 Distillery The process selection is done based on the following considerations: Fermentation process is Hi-Ferm GR. continuous fermentation with two-fermenter system i. Least stress on resources including raw materials and utilities various input raw molasses, process water, nutrient solution and concentrated sulphuric ii. Reduce, Recycle and Reuse of wastes acid are feed to the fermenter in a fixed proportion. iii. Least or no pollution from the industry iv. Least or no risk to human and property Carbon dioxide gas generated during reaction is scrubbed in a carbon dioxide scrubber is v. Least or no adverse impacts on environment fitting with sieve trays and scrubbing is done with process water. Using anti-foaming agent TRO controls foaming during fermentation. Anti foam is continuously circulated with the The technology options for the proposed plant were considered based on efficient utilization help of pumps. The temperature of fermentation wash is maintained by plate type heat of raw materials, fuel and water along with efficiency in power generation. exchanger by cooling water.

5.2.1 Cogeneration process The fermented wash overflows line given to fermenter No. 1 to fermenter No. 2. 30 % spent wash recycle to fermentation process and remaining spent wash is send to composting. In Cogeneration is a process that simultaneously produces two or more forms of useful this process yeast activation tank is plays an important role. This is used for an aerobic energy, such as electric power and steam. It harnesses the thermal and electrical energy condition for maximum growth of yeast side. Then continuously feed to fermenter No.1 for that is released as part of the production process in various industries. When a fuel is burnt yeast activation tank Sp. Gr. is adjusted at 1.050. to generate heat, and that heat is exploited in a thermo dynamic cycle to produce electricity, a great deal of energy is wasted. This wasted energy (which can be up to two-thirds of the In fermentation section 2 nos of fermenters are in series having capacity 340m3 each. energy content of the fuel) emerges as heat. If that heat can be utilized for space heating, Fresh biomass propagated in yeast propagation section is seeded in first fermenter. Then for making hot water or in a manufacturing process, it could reduce the amount of additional start 25 % (of flow chart) molasses and process water feeding to the fermenter the feedings energy needed for those purposes. This makes the economics of cogeneration extremely of molasses and process water increases up to 100 % by observing & maintaining the favorable. fermenters parameters. After filling of the first fermenter, overflow of this fermenter is transferred to second fermenter. Here also given molasses and process water feeding as

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 5-1 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 5-2 Athani Sugars Limited Athani Sugars Limited per the flow charts. Yeast converts fermentable sugars to alcohol and carbon dioxide under Extractive Distillation Column (E.D.) optimum conditions. As alcohol fermentation is exothermic process, heat is released during the process. Dedicated forced re-circulation fermented wash coolers for each fermenter Alcohol drawn from Pre-rectifier column is feed to Extractive Distillation column (ED) middle cools the wash to maintain optimum temperature in between 30 - 32qC, which is required plate. To remove low boiling point impurities from alcohol deminarilised water (D.M water) for yeast activity. The fermented wash is then transferred to the yeast settling tank. + spent lees (1:3) feed to ED column mixing bottle. ED column liquid is heated through Fermented wash from wash charger is feed to analyzer column with centrifugal pump. steam by thermo-siphon reboiler. The top vapors of ED column goes to simmering column reboiler & bottom liquid of ED column is pre-heated in PHE by spent lees of rectifier column Manufacturing process of wash to ENA on Multipressure Vacuum Distillation with & goes to Rectifier column. E.D. column is operates at atmospheric pressure. DCS ccontrol system plant Rectifier cum Exhaust Column After completion of fermentation process the next stage in the manufacture of wash to ENA is to separate alcohol from fermented wash and to concentrate it upto 96% alcohol by Rectifier cum Exhaust column is operated under pressure (2.1 to 2.2 A). Top vapours of removing all traces of impurities like aldehydes, ketones & higher alcohols etc. is called as rectifier goes to analyzer reboiler shell side. Here, these vapours are exchange heat to µ(1$¶ )RU WKLV SXUSRVH PHWKRG RI GLVWLOODWLRQ LV HPSOR\HG 7KLV V\VWHP FRQVLVWV RI analyzer spent wash. Then spent wash vapours are collected in flash tank. These vapours following equipments. reheats analyser column bottom. The reboiler shell side condensate are collects in the rectifier reflux tank & refeed to the rectifier column top plate No.72 by pump. Alcohol is Analyser Column enriched on plate No. 68 & is drawn out as Rectified spirit (96%). This RS feeds to simmering column middle plate. This column liquid is heated through steam by thermo- The main purpose of this column is to extract total alcohol from the fermented wash. The siphon reboiler. Fusel oil build up is avoided in the Rectifier column by withdrawing out side fermented wash first feeds to analyzer through spent wash PHE (Plate type heat streams of Fusel oil LFO & HFO. These LFO & HFO feeds to fusel oil concentration exchanger) where fermented wash is heated by means of spent wash. Hot fermented wash column. from PHE goes to Analyzer column top tray. Analyzer column operates under vacuum. The top alcohol & water vapours of this column feeds to Pre-rectifier column bottom. Rest of the Simmering Column fermented wash flows down & it is drain as spent wash from Analyzer column bottom. The simmering column is most important column in ENA production. This column helps to Pre-rectifier column minimize the volatile acids contents from R.S. which is drawn from Rectifier column. This column is totally fabricated in de-oxidized copper. The principle behind that to react the The top vapours of Analyser column having temperature 73qC are feed to bottom of pre- impurities in the alcohol with copper & neutralize it. This column is operates at atmospheric rectifier column. Pre-rectifier bottom liquid is heated by these vapours. The Pre-rectifier pressure. This column liquid is heated by top vapors of ED column through reboiler which is column operates under vacuum. The vacuum is created in second condenser through situated at bottom of simmering column. The top vapors of this column are reflux through Ist alcohol scrubber. During creation of vacuum some alcohol vapours are sucked in the & IInd condensers. The technical alcohol cut is drawn from same condensers. Condensed Alcohol scrubber. In this scrubber, alcohol from the vapours are scrubbed by using soft alcohol water liquid from reboiler fed to recovery column. The salient pure Extra Neutral water & scrubbed alcohol mix in the water is collected in to fusel oil washing tank. The top alcohol (ENA) product is drawn from bottom of simmering column & sent to tester through vapors of Pre-rectifier column are condensate & reflux through Ist, IInd & IIIrd condensers. ENA cooler. This column is operates at atmospheric pressure. The Technical Alcohol cut is drawn from same condensers. Low boiling impurities are concentrated in the Pre-rectifier column. The Alcohol water liquid from bottom of Pre- Fusel Oil Concentration Column / Recovery Column rectifier column is sent to stripper. Fusel oil build up is avoided in the Pre-rectifier column by withdrawing out side streams of Fusel oil as LFO & HFO. The Rectified spirit drawn from Fusel Oil Concentration (FOC) column basically works for concentrating the fusel oil Pre-rectifier column is fed to Extractive Distillation column. received from the rectifier column, Pre-rectifier column so as have effective separation of heavy fusel oils and recovering the alcohol from the FO decanter. Simmering column Stripper column reboiler condensed liquid is also fed to this column. Steam is given to this column through reboiler. The top vapors of recovery column are refluxed through Ist & IInd condensers, Stripper column is fitted with thermo-siphon reboiler. The steam applied to the stripper Technical alcohol cut is drawn from same condensers. LFO & HFO drawn from same column through reboiler. Stripper column also operates under vacuum. The Alcohol water column & which cooled through double pipe heat exchanger & sent to decanter for further liquid from bottom of Pre-rectifier column is sent to stripper. The top vapours of this column separation the fusel oil wash water is fed to stripping column. This column is operates at feeds to Pre-rectifier column bottom. Stripper column bottom liquid drain as spent lees atmospheric pressure. which is alcohol free.

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 5-3 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 5-4 Athani Sugars Limited Athani Sugars Limited

CHAPTER 6 FIG 6.1 ORGANISATIONAL CHART FOR ENVIRONMENTAL MANAGEMENT ENVIRONMENTAL MONITORING PROGRAM Chairman

6.1 INTRODUCTION

Success of any environment management programme depends upon the efficiency G.M. Sugar of the organisational set up responsible for the implementation of the programme. Regular G.M. Co-gen G.M. Distillery monitoring of the various environmental parameters is also necessary to evaluate the effectiveness of the management programme so that necessary corrective measures can be taken in case there are some drawbacks in the proposed programme. Since Prod. Manager environmental quality parameters at work zone are important for maintaining safety, the Prod. Manager Prod. Manager monitoring work forms part of safety measures also.

6.2 PROPOSED SET UP

Keeping the utility of monitoring results in the implementation of the environment management programme in view, an organisational set up for is present in the existing unit as shown in Fig 6.1 and the same shall operate for the expansion phase. The Environmental Management Cell team is and shall be responsible for the environmental management, monitoring and implementation activities of the proposed unit. Environmental Management Cell (EMC) will carry out various activity of environment under supervision of E.M.C. Coordinator the Head of the plant. The EMC will meet at lease once a month and take stock of progress of work relating to decisions taken and targets set in the previous meeting.

The said team will be responsible for:

x Monitoring activities within core and buffer zone of ASL as per program Environmental Officer x Monitoring of efficiency of pollution control schemes. (Sugar+ Co gen+ Distillery) x Preparation of maintenances schedule of pollution control equipment and treatment plants and see that it is followed strictly.

x Inspection and regular cleaning of setting tanks, drainage system etc. Env.Lab. Incharge x Green ±belt development

x Water and energy conservation Chemist

x Good housekeeping

x Appraising EMC on regular basis

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 6-1 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 6-2 Athani Sugars Limited Athani Sugars Limited

6.3 MONITORING SCHEDULE AND PARAMETERS The schedule, duration and parameters as per the latest norms are shown in Table 6.1. TABLE 6.1 Monitoring schedule given by KSPCB will be strictly followed to ensure the success of MONITORING SCHEDULE AND PARAMETERS environmental management activities. In general, the monitoring schedule shall be as Particulars Location Frequency follows: Ambient Air 2 samples down wind direction at 24 hr sample half Quality 500m and 1000m yearly a. Ambient air monitoring 1 sample at up wind direction at 500m Flue gas from Sampling port of chimney Monthly x Monitoring of ambient air quality within 10 km radius of ASL at 8 stations. Chimney for flow rate SPM, x Pollutants monitored shall be Suspended Particulate Matter, Sulphur Dioxide and RSPM, SO2, Oxides of Nitrogen. Monitoring shall be carried out on alternate days throughout the NOX year. Meteorological Site Daily data b. Meteorology Ground Water 1 Km from spent wash tank and Half Yearly compost yard Monitoring of meteorological data (Wind Speed, Wind Direction, Maximum and Minimum 2 location on downward drainage Temperature, Relative Humidity and Cloud Cover) at any single representative station pattern location on ambient air monitoring days. 1 on upward drainage 3 location in buffer zone c. Water monitoring River water 1 each down and upstream Quarterly Soil Farm using Biocompost Pre and post Surface Water Sources : Sampling of Krishna River water located within buffer zone of Monsoon ASL shall be carried out once in 6 months. Three grab samples shall be collected at the Waste Water At site final discharge point Daily rate of one sample each on 3different days. The environmental monitoring activities will be recorded and the following documents are Ground Water Sources : Sampling of ground water from 8 existing open-wells located proposed to be maintained: within 10 km buffer zone of ASL shall be carried out once in 3 months. 1. Log sheets of operation and maintenance of pollution control facilities/ equipment Analysis of samples collected from effluent, surface and ground water sources shall be such as ETP operation and test results of inlet and outlet water carried out for parameters stated in the consent issued by Karnataka State Pollution Control 2. Instruction manuals for operation and maintenance of pollution control facilities/ Board. equipment like ETP as well as for manual for monitoring of water, solid and gaseous parameter discharged from the project. Soil testing 3. Statutory records as per the environment related legislation. Soil samples from various agriculture fields in the command area shall be regularly collect and analysed in order to confirm optimum doses of fertilisers to be used by the farmers in 4. Monthly and annual progress report. order to ensure maximum sugarcane yield. 5. Bi-annual compliance statement for Regional office, MoEF. Noise monitoring 6. Annual Environmental audit statements and compliance to NOC/ Consent conditions for State Pollution Control Board/ Regional Office, MoEF. Hourly noise levels shall be monitored near all the noise making equipments for a period of 8 hours. Hourly noise level shall also be monitored for 8 hours in situated near ASL site. 6.4 BUDGETARY PROVISION FOR ENVIRONMENT MANAGEMENT

Adequate budgetary provisions have been made by the Company for execution of Environment Management Plan. The Table 6.2 give overall investment on the environmental safeguards and recurring expenditure for successful monitoring and implementation of the control measures.

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 6-3 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 6-4 Athani Sugars Limited Athani Sugars Limited

TABLE 6.2 CHAPTER 7 ESTIMATED CAPITAL INVESTMENT ON ENVIRONMENTAL MANAGEMENT Sl. Particulars Capital cost Recurring ADDITIONAL STUDIES: No. (Rs. Lakhs) Cost DISASTER MANAGEMENT PLAN (Rs. lakh) SUMMARY OF PUBLIC CONSULTATION 1. Air Pollution Control 250 20 2. Water Pollution control 140 10 3. Composting 250 25 Additional study on disaster management plan has been included out in this chapter along with summary of public consultation. 4. Noise pollution control 10 - Enclosures for DG set 7.1 RISK ANALYSIS AND DISASTER MANAGEMENT PLAN 5. Occupational health 2 - 6. Environment monitoring and 15 ASL will be a new growth oriented center in the Athani taluka. Such unit can pose threat of management danger / hazard due to storage of hazardous materials. The power plant also poses 7. Green Belt development 20 2 electrocution, fire, and explosion hazards. When the full fledged activities of sugar, alcohol & co-generation will gear up, they will have to follow Factories Act 1948 with all 8. Others-Consultation and -2 amendments till today and any directives from Director Safety, Health & Environment [SHE] training will automatically be binding on ASL. In such condition to appoint a qualified Safety Officer 9. Community development - 115 is a must & will be an adequate, wise step in such direction. On site and off site disaster Total 673 179 control plans and their perfect implementation will be part and parcel of the management & such safety officer. To lessen the probability of hazard to occur & avoid the consequent damage, a disaster management and control plan has to be worked out for whole complex in anticipation to the threat.

7.2 RISK ASSESSMENT

The main objective of the risk assessment study is to propose a comprehensive but simple approach to carry out risk analysis and conducting feasibility studies for industries and planning and management of industrial prototype hazard analysis study in Indian context.

Risk analysis and risk assessment should provide details on Quantitative Risk Assessment (QRA) techniques used world-over to determine risk posed to people who work inside or live near hazardous facilities, and to aid in preparing effective emergency response plans by delineating a Disaster Management Plan (DMP) to handle onsite and offsite emergencies. Hence, QRA is an invaluable method for making informed risk-based process safety and environmental impact planning decisions, as well as being fundamental to any facility-siting decision-making. QRA whether, site-specific or risk-specific for any plant is complex and needs extensive study that involves process understanding, hazard identification, consequence modeling, probability data, vulnerability models/data, local weather and terrain conditions and local population data. QRA may be carried out to serve the following objectives.

1. Identification of safety areas

2. Identification of hazard sources

3. Generation of accidental release scenarios for escape of hazardous materials from the facility

4. Identification of vulnerable units with recourse to hazard indices

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 6-5 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 7-1 Athani Sugars Limited Athani Sugars Limited

5. Estimation of damage distances for the accidental release scenarios with recourse times in a calendar year, reports for the same to DISH & due amendments for the perfect to Maximum Credible Accident (MCA) analysis implementation.

6. Hazard and Operability studies (HAZOP) in order to identify potential failure cases of 7.3.1 Level of Accident significant consequences If there is any disaster in any part of plant/work place due to any reason the level of 7. Estimation of probability of occurrences of hazardous event through fault tree accidents from damage point of view may vary. Accordingly accident prevention program analysis and computation of reliability of various control paths will have to be initiated by safety department simultaneously.

8. Assessment of risk on the basis of above evaluation against the risk acceptability 7.3.2 Critical Targets During Emergency criteria relevant to the situation Level I Accidents 9. Suggest risk mitigation measures based on engineering judgement, reliability and risk analysis approaches Under this level disaster may happen due to electrocution, fire explosion, alcohol spillage 10. Delineation / up-gradation of Disaster Management Plan (DMP). and spontaneous ignition of combustible material. This level has probability of occurrence affecting persons inside the plant. Various hazardous areas identified in the plant are 11. Safety Reports: with external safety report/ occupational safety report potential areas to be affected due to level ± I accidents.

7.3 DISASTER MANAGEMENT PLAN Level II Accidents

Disaster can occur as on site or off site variety i.e. disaster on campus or disaster in nearby Disaster of this level can occur in case of sabotage and complete failure of all automatic area causing indirect damage to site area & the complex. control/warning systems, and also if the alcohol stored in tank and covered by tank bunds leaks out. However, probability of occurrence of this is very low due to the proposed Disaster may occur due to two categories, natural and manmade calamities: adequate security training, and education level of plant personnel for the captive power plant. ¾ Natural calamities cover Flood, Storm / typhoon, Earthquake, Heavy mist, fog, hail storm, Land slide 7.3.3 Site Emergency Control Room (SECR) & Site Main Controller In each segment of work, from domestic level to war fighting team level approach always ¾ Man made calamities involve Fire & Explosion, All types of leakages & spillage, Electrocution, excavation, construction, erection, Sabotage, rail & road accidents, helps. If the concerned man is aware of his duty at his place & need of the time, he can mass agitation, Looting, Morcha, war complement the huge task of lessening the damage of the disaster. To overcome the emergency in its occurrence, the strategy is to be prepared in advance, plan for the team The identified hazardous areas in the complex are : effort, educate others and reduce all effects of disaster.

1. Boiler area - Explosion In case of any disaster main responsibility lies with the Chairman and Board of Directors, where they can nominate one fellow to be responsible person who will be Chief Incidence 2. Turbine section - Explosion Controller (IC). In case of disaster key person like Chief engineer, Chief chemist, Distillery manager will be the site main incidence controller and will commence respective duties in 3. Electrical rooms - Fire and electrocution that capacity to curtail the emergency & minimize the losses may be occurring.

4. Transformer area - Fire and electrocution People in all departments can assist in contacting external persons, district, state & central 5. Cable - Fire and electrocution authorities, hospital & ambulance contact and evacuation, if needed, for people in the vicinity with assistance of state transport buses. People from maintenance department can 6. Storage facilities ± Fire / spillage for alcohol help in rectifying the fault in system. Security persons assist in fire fighting & material movement operation to avoid losses. It is utmost necessary to prepare the control plan & to Considering various probabilities the management & safety department has to create safety involve all staff in factory to get any sort of external help / assistance in time to lessen all awareness & preparedness in all employees and people in vicinity area in case of any sort sorts of damage. of emergency to occur & a chalked out attempt to surely overcome the disaster in time. This includes preparation of onsite and offsite disaster control plans, their mock drills at least 2 To assist the disaster control more effectively a site emergency control room (SECR) will be established at the plant site. The SECR may be provided with following sections:

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 7-2 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 7-3 Athani Sugars Limited Athani Sugars Limited

7.3.4 Disaster Preventive Measures ¾ All site plant layout The proposed power plant will have following preventive measures to avoid occurrence of ¾ List of important telephone numbers of Chairman & Directors ASL, Chief Engineer, disasters: Chief Chemist, Distillery Manager, Administration Manager. ¾ Specification & marking of safe area to gather in emergency. ¾ Telephone numbers of Navanihal Gram Panchayat, Athani Tehsil, Tehsildar of Athani, Belgaum District collector, Belgaum State transport depot office, Belgaum District & ¾ Design, manufacture and construction of plant, machinery and buildings will be as per local fire brigade station, home guard, civil defense, N.C.C. unit, State crisis group, national and international codes as applicable in specific cases and laid down by Karnatka crisis group, CGO complex, MoEF statutory authorities.

¾ All material handling & incoming vehicle traffic to be stopped temporarily. ¾ Provision of adequate access ways for movement of equipment and personnel shall be kept. ¾ All outgoing lines to be used to contact above authorities. ¾ Minimum two numbers of gates to escape during disaster shall be provided. ¾ Captive power plant layout showing inventories and locations of fuel ¾ Alcohol storage shall be in protected and fenced. The tank will be housed in a dyke ¾ Oil / furnace oil storage tanks, Bagasse/alcohol storage yard etc. wall. As per regulations of CCOE its testing & certification will be performed each 5 years regularly. ¾ Hazard identification chart, maximum number of people working at a time, assembly Proper colour coding for all process water, air & steam lines will be done. points, etc. ¾ ¾ Proper insulation for all steam & condensate, hot water lines will be done. ¾ List of village and their population in the vicinity of proposed captive power plant ¾ Provision of circuit brakers, isolation switches, signals will be provided as per electricity ¾ Public address system like loud speaker, battery operated speaker, sirens, act & rules.

¾ Whistles, batteries, signaling flags etc. ¾ Proper & rigid bonding and earthing to all equipment will be arranged.

¾ Rechargeable and battery operated torch lights and invertors. ¾ Earthing connections will be checked each 6 months and the same record will be available. ¾ Tie up with nearest hospital for medical assistance and facility for stretchers, chairs, etc. ¾ System of fire hydrants comprising of electrical motor driven fire pumps is planned. The ¾ List of registered medical practitioners in vicinity. fire hydrant system will have electrical motor and a generator driven jockey pump to keep the fire hydrant system properly pressurized. ¾ Study map showing various villages and towns in the vicinity of captive power plant. ¾ Automatic water sprinkling system is planned for all transformers. ¾ Muster Roll of all present employees. 7.3.5 Fire Fighting Arrangements ¾ Note pads and ball pens to record message received and instructions to be passed to concerned persons BIS 2190 provides Indian standards for firefighting equipment. All firefighting equipment and extinguishers have to be planned according to this standard. There are 4 classes of a fire ¾ The blow up copy of Layout plan showing areas where accident could occur. that can occur:

¾ Accident mock drill for at least 2 times in a calendar year is to be a part of routine Class Materials Extinguisher exercise. The report bf such drill has to be submitted to DISH for his information & A Cotton, Cloth, paper, wood Water type approval. B Oils, Hydrocarbons, Alcohol, Greases CO2 type C Gases, CNG, LPG, Acetylene, Foam type D Electrical & metals Foam

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 7-4 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 7-5 Athani Sugars Limited Athani Sugars Limited

Location type of fire extinguishers contact with heat, sparks and flame. Avoid ingestion and inhalation. Do not pressurize, cut, weld, braze, solder, drill, grind, or expose empty containers to heat, sparks or open flames. ¾ Turbo-generator area CO2 Type, Foam Type Dry chemical powder ii. Storage: Keep away from heat, sparks, and flame. Keep away from sources of ignition. ¾ Cable galleries CO2 Type, Foam Type Dry chemical powder Store in a tightly closed container. Keep from contact with oxidizing materials. Store in a ¾ High voltage panel CO2 Type, Foam Type Dry chemical powder cool, dry, well-ventilated area away from incompatible substances. Flammables-area. Do not store near perchlorates, peroxides, chromic acid or nitric acid. ¾ Control rooms CO2 Type, Foam Type Dry chemical powder

¾ MCC rooms CO2 Type, Foam Type Dry chemical powder 7.3.8 Emission Mechanisms And Control Considering Storage Tanks

¾ Pump houses CO2 Type, Foam type dry chemical powder Emissions from organic liquids in storage occur because of evaporative loss of the liquid during its storage and as a result of changes in the liquid level. The emission sources vary ¾ Tank Area CO2 type, Foam Type Dry chemical powder Sand Basket with tank design, as does the relative contribution of each type of emission source. ¾ Offices & Godowns Foam or Dry chemical powder Type Emissions from fixed roof tanks are a result of evaporative losses during storage (known as breathing losses or standing storage losses) and evaporative losses during filling and ¾ Crushers house CO2 Type, Foam Type dry chemical powder emptying operations (known as working losses). External and internal floating roof tanks are emission sources because of evaporative losses that occur during standing storage and 7.3.6 Alarm System to be followed During Disaster withdrawal of liquid from the tank. Standing storage losses are a result of evaporative losses through rim seals, deck fittings, and/or deck seams. The loss mechanisms for fixed 2QUHFHLYLQJWKHPHVVDJHRIµ'LVDVWHUIURP6LWH0DLQ&RQWUROOHUILUHVWDWLRQFRQWUROURRP roof and external and internal floating roof tanks are described in more detail in this section. DWWHQGDQWZLOOVRXQG6LUHQµ:$ILI1*7<3(¶IRUPLQXWHV,QFLGHQWFRQWUROOHUZLOODUUDQJHWR Variable vapor space tanks are also emission sources because of evaporative losses that broad cast disaster message through public address system. On receiving the message of result during filling operations. ³(PHUJHQF\2YHU´IURPLQFLGHQW&RQWUROOHUWKHILUHVWDWLRQFRQWUROURRPDWWHQGDQWZLOOJLYH ³$OO&OHDU6LJQDO´E\VRXQGLQJDODUPVWUDLJKWIRUWZRPLQXWHV7KHIHDWXUHVRIDODUm system i. Fixed Roof Tanks: A typical vertical fixed roof tank is type of tank consists of a cylindrical will be explained to one and all to avoid panic or misunderstanding during disaster. steel shell with a permanently affixed roof, which may vary in design from cone- or domeshaped to flat. Losses from fixed roof tanks are caused by changes in temperature, It is necessary to take one trial for perfect functioning of the siren at least once in one week pressure, and liquid level. Fixed roof tanks are either freely vented or equipped with a with prior intimation to Belgaum District Collector. pressure/vacuum vent. The latter allows the tanks to operate at a slight internal pressure or vacuum to prevent the release of vapors during very small changes in temperature, 7.3.7 Storage of Flammable Liquids pressure, or liquid level. Of current tank designs, the fixed roof tank is the least expensive to construct and is generally considered the minimum acceptable equipment for storing The Dangerous Substances and Explosive Atmospheres create risks from the indoor organic liquids. storage of Dangerous Substances to be controlled by elimination or by reducing the quantities of such substances in the workplace to a minimum and providing mitigation to ii. Floating Roof Tanks : There are two types of floating roof tanks External and Internal. A protect against foreseeable incidents. typical external floating roof tank (EFRT) consists of an open- topped cylindrical steel shell equipped with a roof that floats on the surface of the stored liquid. The floating roof consists These should be located in designated areas that are wherever possible away from the of a deck, fittings, and rim seal system. Floating decks that are currently in use are immediate processing area and do not jeopardise the means of escape from the constructed of welded steel plate and are of two general types: pontoon or double-deck. An workroom/working area. The flammable liquids should be stored separately from other internal floating roof tank (IFRT) has both a permanent fixed roof and a floating roof inside. dangerous substances that may enhance the risk of fire or compromise the integrity of the There are two basic types of internal floating roof tanks: tanks in which the fixed roof is container. supported by vertical columns within the tank, and tanks with a self-supporting fixed roof and no internal support columns. The ethanol is flammable liquid and to handle properly as per the guidelines. This project is having storage of ethanol of about 90 KLPD. The storage involves 4 no of bulk storage available. The plant having capacity of 330 days storage capacity. Accidental Release Measures i. Handling: Wash thoroughly after handling. Use only in a well-ventilated area. Ground x General Information: Use proper personal protective equipment as mentioned below: and bond containers when transferring material. Use spark-proof tools and explosion proof equipment. Avoid contact with eyes, skin, and clothing. Empty containers retain product x Eyes: Wear appropriate protective eyeglasses or chemical safety goggles as described by OSHA's eye and face protection regulations in 29 CFR 1910.133 or European residue, (liquid and/or vapor), and can be dangerous. Keep container tightly closed. Avoid Standard EN166.

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 7-6 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 7-7 Athani Sugars Limited Athani Sugars Limited x Skin: Wear appropriate protective gloves to prevent skin exposure. Regional Officer, Karnataka State Pollution Control Board, Belgaum (Chikoddi Centre). About 250 people attended the Public Hearing. Various points were raised by the local x Clothing: Wear appropriate protective clothing to prevent skin exposure. people and during the public hearing. The same were replied to and the points requiring action from the Company were clearly addressed and their execution outlined. x Respirators: A respiratory protection program that meets OSHA's 29 CFR 1910.134 and ANSI Z88.2 requirements or European Standard EN 149 must be followed Documents related to PH including minutes of public hearing, list of attendees, written whenever workplace conditions warrant a respirator's use. suggestions, objections and comments, notice in the newspaper etc. are given in Annexure XX. The replies have been updated as per the latest situation, activities executed, x Spills/Leaks: Absorb spill with inert material (e.g. vermiculite, sand or earth), then place in suitable container. Remove all sources of ignition. Use a spark-proof tool. Provide information received, etc. and given in Table 7.1. ventilation. A vapor suppressing foam may be used to reduce vapors.

Fire Fighting Measures :

General Information: Containers can build up pressure if exposed to heat and/or fire. As in any fire, wear a self-contained breathing apparatus in pressure-demand, MSHA/NIOSH (approved or equivalent), and full protective gear. Vapors may form an explosive mixture with air. Vapors can travel to a source of ignition and flash back. Will burn if involved in a fire. Flammable Liquid Can release vapors that form explosive mixtures at temperatures above the flashpoint. Use water spray to keep fire-exposed containers cool. Containers may explode in the heat of a fire.

Extinguishing Media: For small fires, use dry chemical, carbon dioxide, water spray or alcohol resistant foam. For large fires, use water spray, fog, or alcohol-resistant foam. Use water spray to cool fire-exposed containers. Water may be ineffective. Do NOT use straight streams of water.

Flash Point: 16.6 deg C ( 61.88 deg F) Autoignition Temperature: 363 deg C ( 685.40 deg F) Explosion Limits, Lower:3.3 vol % Upper: 19.0 vol %

7.4 SUMMARY OF THE PROCEEDING OF PUBLIC CONSULTATION

The public hearing for the proposed expansion phase for sugar (4500 to 12000 TCD), cogeneration power project (24 MW to 54 MW) & Distillery (60 KLPD to 90 KLPD) was held inside the premises of existing industryb of Athani Sugar Ltd. at village Kempwad, Taluka Athani, District Belgaum, Karnataka on August 22, 2014 at 10.30 am as per EIA Notification S. No. 1533 14.09.2006 and amendment dated 1.12.2009 of MoEF on the basis of the prepared draft EIA report, which included the Terms of References prescribed by the Ministry of Environment and Forests. As per stipulations in the Notification, notice for the Public Hearing was published in National Newspaper, The Times of India and State level newspaper Prabha (Kannada) dated July 21, 2014, and local newspaper Kannadamma (Kannada) dated August 01, 2014. Beside this photography and videography was also done.

Public Hearing was held under the chairmanship of Shri N. Jayaram, Deputy Commissioner District Magistrate, District Belgaum. Besides this, Shri C M Satish, Regional Senior Environmental Officer, Karnataka State Pollution Control Board, Dharwad, Shri K P Parmeshwarappa, Joint Director, District Industries Centre, Belgaum, Smt. Rajshiri J Kulli,

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 7-8 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 7-9 Min Mec Consultancy Pvt. Ltd.

TABLE 7.1 ISSUES RAISED DURING PUBLIC HEARING AND REPLIES BY PROJECT PROPONENT Sl. Name suggestions, objections and Answers given by Action proposed Budgetary Provision No. comments Project proponent (Rs. lakhs) 1. Deputy The sound generated from Provision of ear plugs are Acoustic Only maintenance cost Commissioner steam turbine, boiler, DG set is there for people working Measurement is about 70-90 dB or more. This near the boiler area. already provided. will have impact on people. If we Acoustic enclosures and hear continuously, it may affect sound proof are provided the ears of the public to all the equipments and existing DG sets. Lubricants will be put to sound generating equipments regularly. Give the details of 16 irrigation 16 irrigation projects are Irrigation projects in Capital investment of projects being taken by the the villages. Rs. 100 lakh for green company in the villages belt development and Kempwadi, Madhbhavi, Rs. 5 lakh per annum Tevareti, Jambgi, will be recurring Sambargi, Kalauti, expenditure. Parthanhalli, Gundewaddi, Arallikatti, , Jakaratti, Raderhatti and Mole near the project site.

3000 acres of area has been made irrigated at a cost of RS. 40 crores.

How much will be the Existing employment is It is also proposed As regards direct employment generation? Why 500 and the expansion to provide Capacity employment by the the population is not doubled? phase will provide Building Training for company, Wages, PF EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 7-10

Min Mec Consultancy Pvt. Ltd. Sl. Name suggestions, objections and Answers given by Action proposed Budgetary Provision No. comments Project proponent (Rs. lakhs) employment to 300 more vocational Courses. and bonus will be given people. Employment as per Labour Laws. increase is not directly proportional to production increase What is the water requirement Treated water from Sugar Will increase for 42 acres green belt as ETP will be used for greenbelt area in mentioned by you. greenbelt development its factory premises required around 300m3 using ETP treated water . Average rainfall is 822 mm. Since it is dry area, we do Company will take Expenditure of Rs. not receive much rains. various activities of 132.25 lakhs during 5 rain water years of construction harvesting works, period and Rs. 1 crore wells, ponds, hand pumps and tube per year for post wells under CSR commissioning of the scheme. plant for various CSR activities.

Government is giving 90% We have sent proposal - - subsidy. but has not been approved yet. Government is giving subsidy only for drip. Why do you say that you have We have done by - - done, although government has spending our own. Also done. the subsidy amount is not remitted although we have given subsidy application signed by everyone.

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 7-11 Min Mec Consultancy Pvt. Ltd. Sl. Name suggestions, objections and Answers given by Action proposed Budgetary Provision No. comments Project proponent (Rs. lakhs) How much you have to spend Even though we do not CSR initiatives will Expenditure of Rs. for CSR? come under CSR, we are be continued 132.25 lakhs during 5 spending from little profit years of construction we are earning from period and Rs. 1 crore factory. We have constructed a per year for post check dam in Murgundi commissioning of the village. plant for various CSR In the middle, river water activities. conservation scheme has been done at Murgundi village. A school has been CSR initiatives will Expenditure of Rs. opened within the colony be continued 132.25 lakhs during 5 premises at a cost of Rs. years of construction 15 lakhs. period and Rs. 1 crore Water facility to cattle of per year for post draught affected villages commissioning of the at a cost of Rs. 25 lakh in plant for various CSR 2013 has been done by activities. the company.

Suitable employment opportunities is being provided to people. :KDW LV WKH LQGXVWU\¶V SURILW IRU About Rs. 8 to 9 Crores. - - the last year? According to CSR, how much Less than 2%. CSR has been Expenditure of Rs. you should spend from profit? increased from Rs. 132.25 lakhs during 5 CSR activities should be 115 laksh to Rs. years of construction increased. 132.25 lakhs during EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 7-12

Min Mec Consultancy Pvt. Ltd. Sl. Name suggestions, objections and Answers given by Action proposed Budgetary Provision No. comments Project proponent (Rs. lakhs) construction phase. period and Rs. 1 crore per year for post commissioning of the plant for various CSR activities. 2. Shri Vijay baburao Earlier we had drinking water Company conveys thanks - - Wali, farmer, and employment problems. But Kempwad village today in our village, everybody is traveling by motor cycle or by car. We express our gratitude to the chairman and managing director of the factory. The company has planted many - Will be continued as Company will spend Rs. mango trees to combat the per environment 673 lakhs as capital cost damage caused to the conservation for environmental environment due to factory measures. protection measures and wastes. Rs. 179 lakhs per year as recurring cost. The waste generated from this - The waste industry by crushing the sugar generated from cane of 4500 tonnes has been crushing the sugar converted into compost manure cane will not be and given to the farmers. used for co generation of power. From this industry, there is no - Will be continued as Capital expenditure of odour problems and sound per environment Rs. 673 lakhs for pollution. conservation environmental protection measures. measures and Rs. 179 lakhs per year as

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 7-13 Min Mec Consultancy Pvt. Ltd. Sl. Name suggestions, objections and Answers given by Action proposed Budgetary Provision No. comments Project proponent (Rs. lakhs) recurring cost. Good trainings have been - Will be continued as provided to the industry labours. per disaster In the history of factory, no management plan accidents took place till today. formulated for the factory. The industry has provided drip - - - irrigation for our 3000 acres farm land. In this my 2.5 acres land has also been covered. I have not spent any money for this till today. 4. Shri Ramesh We are benefited by the Company conveys thanks Basappa Teli, establishment of this industry as Member, gram this industry had purchased my Panchayat, sugarcane because it is of low Kempwad village sugarcane recovery. I wholeheartedly give my consent to this industry for expansion. 5. Shri. Prakash This industry had purchased low - - - Hullolli, farmer, sugar content sugarcane from Mole village the poor farmers thereby benefiting the farmers of this area. The industry also suffered a loss of Rs. 3 crore for the sake of poor farmers. The industry has also made drinking water facility to this area. Also there is no emission from - Will be continued as Capital investment of the factory chimney. per environment Rs. 250 lakh for air conservation pollution control and Rs.

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 7-14

Min Mec Consultancy Pvt. Ltd. Sl. Name suggestions, objections and Answers given by Action proposed Budgetary Provision No. comments Project proponent (Rs. lakhs) measures. 20 lakh will be spend as recurring expenditure per annum. The financial conditions of the Company conveys thanks - - farmers have improved and also the area has been more developed. Therefore, the permission for the increase in production may be given. 6. Shri Mallappa People of the area are leading CSR shall be Budgetary provision of Kenchappa Chung comfortable life due to this Company conveys thanks continued Rs. 1 crore per year for farmer, Kempwad industry. Good atmosphere is various CSR activities. village created to the school going children. Factory owners are paying for patients. The factory is providing all types of cooperation. I am in this factory and have full devotion. 7. Shri Sanjay By increasing the capacity of the Company conveys thanks Employment shall As regards direct Rajaram Parakatte, industry, we will get job be given as employment by the ZP member, opportunities. Due to this, mentioned earlier company, Wages, PF Ugarkhurud village people of this area as well as and bonus will be given nearby area will get benefited. Therefore, I request to give the as per Labour Laws. permission to open the factory. People from Ugar comes here to work in this factory.

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 7-15 Athani Sugars Limited Athani Sugars Limited

CHAPTER 8 After selecting the youth they will be provided ITI training in the following areas

PROJECT BENEFITS 1. Fitters 2. Welders 3. Carpenters All organisations have an impact on the society and the environment through their 4. bar bending operations, products or services, and through their interactions with key stakeholder groups 5. Mason including employees, customers/clients, suppliers, investors and the local community. Generally speaking, it can be stated that Corporate Social Responsibility (CSR) was born 6. Maintenance of Pumps and other mechanical equipments as a response to a growing gap between two societies in terms of economic, social and 7. Electrical Maintenance environmental development. 8. Environment Monitoring ASL has identified 6 key principles of CSR, as follows: 9. Green belt Development ( Gardner Training) 10. Laboratory Chemist (Water Testing) ¾ Must take care of their employees and investors 11. Brick Manufacturing ¾ Must satisfy market demands and gain new customers 12. Vehicle Driver ¾ Must improve their relationships with providers After successful training the youths will be appointed at appropriate position in ASL. ¾ Must listen to community expectations 8.1.2 Capacity Building and Training for vocational Courses ¾ Must be concerned about the environment ASL will provide the vocational training for youth as per their qualification and interest. This ¾ Must promote and facilitate intercultural dialogue will enable them to get employment at proposed power plant. It will increase their social and economical status. In order to incorporate each of those principles into their everyday activities, ASL shall include them in every project activity as well. ASL will implement this by hiring the proper and renowned institute from near by area (possibly Nagpur) to arrange the trainings. ASL will form a supervisory committee to inspect 8.1 EMPLOYMENT POTENTIAL all the activities and also take care of the requirement for the training program.

Currently 500 employees are working and additional 300 will get employment during 8.2 PHYSICAL & SOCIAL INFRASTRUCTURE expansion. In addition to these, indirect workers will be several times and the farmers supplying sugarcane is surrounding areas will benefit. For employment, preference will be The amenities within the plant and residential units such as drinking water, sanitation, STP, given to local population for employment in the semi-skilled and unskilled category. Hence, solid waste management, first etc have been provided. The same are available for the the company has also envisaged various skill-building programmes for locals. Therefore, employees to avail. In the surrounding villages, CSR activities have been undertaken in the the significant positive impact on employment and occupation is envisaged on account of past for social and physical infrastructure development. better economic status of the community due to better earnings, higher inputs towards infrastructural facilities due to establishment of plant and enhancement of literacy due to ASL shall support villagers in Road, sanitation facilities, shopping centers, solar lighting, educational facilities available in the surroundings. community development, construct school building, primary health centers etc. Due to the establishment of the proposed plant, there will be development of communication facilities 8.1.1 Employee youth for training in skill in the area. The plant office and workers rest shelters will be equipped with sufficient infrastructural facilities including drinking water, toilets, sanitation facilities, health centre, Employee youth for training in skill relevant to the project for eventual employment in the etc. Education and medical facilities will be provided to the employees and to their family project itself shall be as under ± members and will also be extended to the villagers. Shopping complex and banks will come ASL will continuously have interactions with Schools, Junior Colleges, Industrial Training up in the locality, which will be beneficial for local villagers also. Schools located in Athani taluka. Training Division of ASL will have campus interview in the Schools, Junior College, Industrial training Schools located in Athani taluka.

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 8-1 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 8-2 Athani Sugars Limited Athani Sugars Limited

Drinking water facility : ASL has proposed to make provision for drinking water at the said 8.3.4 Agriculture Development Program villages. ASL will meet this requirement by constructing water storage tank, bore wells and hand pumps. Training on agriculture extension service e.g fertilizer application, paste management, agri clinic, and will regularly be conducted by reputed agriculture institutes. 8.3 CSR PROVISION BY ASL 8.3.5 Other benefits from the project In addition to the above, ASL is planning for the following: ¾ Near the Navanihal and other areas in Athani Taluka the irrigation schemes and ASL is planning for developing nearby villages as per the identified requirement of the sugarcane growing will be sufficient to fulfill the requirement of ASL. region under CSR activity. This will increase the social and economical sector of the region. ASL has decided to adopt three near by villages to implement CSR. The identified villages ¾ This project will have long run benefits in Indi taluka of Bijapur district. Sugar mill is an are Kempwad, Madhbhavi, Khatav ,Siddhewadi. These villages were selected on the basis agro based project using Sugar cane as sole raw material. Sugar cane cultivators i.e. of shortfall of basic amenities. Majorly these villages are depending on the agriculture. Farmers will receive many benefits such as transport, education, community center etc. Following are the identified provision for the area: ¾ In the first stroke due to less distance from the farms they will get good price for cane. ¾ Capacity Building and Training for vocational Courses Next, farmers will get compost from waste streams to be used as nutrients on farms. Thus, they will achieve good returns for cane. ¾ Village infrastructure ¾ At the same time utilizing conservation plan they will get precious nutrients at merely ¾ Sustainable power development throw away price. In this area crops like cotton, tur, jawar, bajra are cultivated, which will also fetch profits to the farmers. ¾ Drinking water facility ¾ Waste of sugar mill i. e Bagasse and imported coal are useful for power generation and ¾ Women Empowerment trough training and financial support molasses is utilized for Ethanol production. ¾ Education Support through Extension of Building, Scholarship, Books ¾ There will be remarkable reduction in the waste from the complex. Thus such an attempt ¾ Primary Health Centers through health camps, upgradation of Building, New Building of use of waste material will also provide ASL an opportunity to pay higher price to etc sugarcane grower.

¾ Agriculture Development Program ¾ ASL plans to produce anhydrous ethanol to provide precious fuel to automobiles and contribute to save Petrol, thereby foreign exchange. Indian Oil sector obtains fuel 8.3.1 Women Empowerment trough training and financial support ethanol from sugar sector with good price.

ASL has proposed to develop the training center as handy craft making, household goods ¾ Power shortage is a crucial issue in the Country. A decision to opt for co-generation by making, tailoring etc. It will increase the economic level of the region. ASL using bagasse will provide power for self consumption and also other parts of villages under rural electrification plan. 8.3.2 Education Support through Extension of Building, Scholarship, Books ¾ This will raise funds to pay good price to farmers. This industry will provide revenue to ASL is planning to improve educational level of the region. It will be implemented by helping State and Central Government. school building construction, providing books to poor student, scholarship to financially poor ¾ At village Athani of Belgaum district, good scope exists to provide facilities like road, students per year as per their previous academic record. This will motivate the student in power, health care centers and educational institutes in the area. MSPSL has already education. ASL will give opportunity to educated youth to work in plant. initiated socioeconomic development of the nearby villages.

8.3.3 Primary Health Centers through health camps, up-gradation of Building, New ¾ It will be a nucleus for forecasted accelerated growth in the region. As cash money will Building etc. be available to the farmers cooperative supplementary units to farms like poultry, cattle ASL is willing to help in setup of primary health center, running free checkup camps, help in growing and milk products and other food items, silkworm growing and silk weaving, building hospitals and buying machineries, funding to health centers etc. Edible seeds crushing to yield oils, hand made paper units can be initiated. ASL decides profoundly to initiate this plan amongst the villagers and farmers jointly.

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 8-3 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 8-4 Athani Sugars Limited Athani Sugars Limited

¾ Both direct and indirect employment is next important issue at the door step. ASL has x Paying monthly expendiWXUHRIRQHVFKRROLQYLOODJHµ6KLQDO¶$WKDQLWDOXND%HOJDXP initiated recruitment of senior staff and persons needed in construction phase to dist. minimize migration from village to city. Proposals or planning for future CSR activities At the national and the state levels the benefits include decentralized power generation, ¾ x CBSE pattern school have been open nearby factory for the children of employee reduction in T&D loss, reduced emissions, reduction in the imports of petroleum and farmer products, increased tax revenues and reduction in the transportation cost. The project will have excellent multiplier effect and will become truly a win-win situation for all the x Soil testing lab will be established. stakeholders and for local people. x 4000 Acres of land will be irrigated with 100% micro irrigation during next 2-3 years.

8.4 BUDGETARY COMMITMENT OF CSR

8.4.1 Construction Phase

Details of expenditure estimates during construction period of 5 years are given below:

Sl. Activity Rs, in No. lakhs 1 Capacity Building Training for vocational Courses 25.0 2 Village infrastructure 30.0 3 Drinking water facility in villages nearby 10.0 4 Women Empowerment trough training and 10.0 financial support 5 Education Support through Extension of Building, 10.0 Scholarship, Books 6 Primary Health Centers through health camps, 10.0 upgradation of Building, New Building etc 7 Agriculture Development Program 20.0 8 Total 115.00 9 Cost of implementation 5% of 1 to 7 5.75 10 Administrative and Misc. Expenses for monitoring 5.75 and evaluation 5% of 1 to 7 11 Contingency @5 % of 1 to 7 5.75 Total 132.25

8.4.2 Operation Phase

The budget for CSR activities shall be Rs. 1 crore per year is earmarked for post commissioning of the plant.

Details of CSR activities with expenditure made till date

x ASL has opened new school expenditure of Rs.15 Lakhs x ASL has opened primary health care clinic for all employees and their family. x During 2013 draft situation, ASL provided fodder for animal to the near villages which cost around Rs.25 lakhs. x ASL constructed a Check Dam for Agrani River at Muragundi village for water conservation which cost around 45 lakhs.

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 8-5 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 8-6 Athani Sugars Limited

CHAPTER 9

ENVIRONMENTAL COST BENEFIT ANALYSIS . Parameters Parameters The scope of the EIA/EMP has been prescribed vide the Terms of Reference issued by Ministry of Environment and Forests vide Letter No. vide letter no. J-11011/373 /2013 ± Table 10.1 Table Athani Sugars Ltd. SugarsAthani Ltd. Measurement of material material of Measurement handling Checkingmaintainence of & reservoir surface of drains garland ofVerification settling tank system tank & septic IAII (I) dated April 30, 2014. (Annexure I). Waterquality from settling from & of overflow tank system septic tanks

As per SO 1533 dated 14th September 2006, this chapter is to be prepared if prescribed at scoping stage. Monitoring Monitoring

The prescribed scope does not require environmental cost benefit analysis. Finance Department Plant Manager Environmental Engineer Plant Manager Implementation Implementation Civil Department Environmental Engineer Civil Department Civil Department TABLE 10.1 TABLE CHAPTER 10 CHAPTER During Construction Phase During Construction ENVIRONMENT MANAGEMENT MEASURES ENVIRONMENTAL MANAGEMENT PLAN ENVIRONMENTAL the surface water harvesting pond through harvesting pond through water the surface system drainage site,thus, no disturbance will occur site,thus, no disturbance thus,road layouting, major construction, been drains have water & storm services runoff evacuation out. Thus,laid rainwater existingwill be continued system. through construction site will be routed to a site will construction for settlement tank sedimentation temporary of release before solids of suspended water. It is proposed that the runoff be diverted to to be diverted runoff the that It is proposed No natural drain is passing through the the No natural drain is passing through The existing plant is already constructed, constructed, already is plant The existing During monsoon season run off from from run off Duringmonsoon season ¾ ¾ ¾ ¾ The total land of and proposed The the existing total The existing project acres. is 120.5 expansion major thus, constructed, is already plant & storm services road construction, layouting, out. The been laid land is drains have water levelled, thus,digging no major or fillingby will be required. drains flow flow (sewage) from from (sewage) to soil run-off during during run-off to soil precipitation. heavy Domestic waste water water waste Domestic Disturbance to sheet sheet to Disturbance natural to Disturbance Suspended solids due ¾ ¾ due to expansion due to expansion of Sugar, Distillery and Cogen Plant. ¾ ¾ Source Proposed management measures for pollution control and environmental management in the mine are given in are given mine in the management environmental and control for pollution measures management Proposed Karnataka in Dist. Belgaun, Plant & Cogen Distillery for Expansion of Sugar, EIA/EMP 10-1 Discipline Potential impacts and and measures impacts Mitigation Potential Discipline Aspect Administrative Monitoring

EIA/EMP for expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 9-1 Topography Change in topography Drainage Water quality Athani Sugars Ltd.

Discipline Potential impacts and Mitigation measures Administrative Aspect Monitoring Source Implementation Monitoring Parameters workers in plant & ¾ Domestic waste water shall be treated in residential areas septic tank- soak pit system. Air quality ¾ Increase in dust ¾ Isolate the construction area with flexible ¾ Civil ¾ Environme ¾ Verifying construction concentration due to enclosures/ curtains so that the air department ntal of enclosures construction vehicular emissions will not spread in the engineer ¾ Verification of log of movement, surroundings. sprinkling & actual site excavation and ¾ Sprinkling of water in the construction area conditions material handling and unpaved roads. Proper maintenance of ¾ Verifying cover on activities vehicles shall be done. trucks and ¾ Cover heavy vehicles moving offsite. construction of speed ¾ Restrict vehicles speed on construction breakers roads and ensure vehicles use only ¾ Records of PUC of dedicated construction roads and access vehicles points. ¾ Ensure PUC for vehicle and carryout regular maintenance on all plant and equipment. Noise Increase in noise level ¾ Equipment to be kept in maintained ¾ Civil ¾ Environme ¾ Noise levels at site due to construction condition to keep the noise level within 90 Department ntal ¾ Verification of PPE of equipment. dB(A). engineer workers through ¾ Develop and implement a construction surprise checks noise management plan. ¾ Limit hours of construction where practical. Workers will be provided with necessary protective equipment e.g. earplug, earmuffs. Terrestrial Clearing of vegetation Landscaping and extensive plantation shall be Civil department Environmental Verification by observation ecology due to soil handling done. engineer activities Excavated Loss of excavated top soil The top soil shall be properly stored and used Civil department Environmental Verification by observation soil in green belt and for leveling in the low lying engineer area within areas to be constructed.

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 10-2

Athani Sugars Ltd.

Discipline Potential impacts and Mitigation measures Administrative Aspect Monitoring Source Implementation Monitoring Parameters During Operational phase Air quality ¾ SPM, SO2 and NOx ¾ The resultant air quality will conform to the ¾ Analysts & ¾ EMC ¾ Online monitoring in levels in ambient air stipulated standards. environmental coordinato stack for PM, SO2, due to stack emission ¾ 75 m height stack will be provided for the engineers of r NOx, CO, etc due to operation of proper dispersion of pollutants. Environmental ¾ Plant head ¾ Third party periodical additional boiler ¾ Particulate emission from stacks expected Management ambient air quality ¾ Increase in ground to be below standards Department monitoring for PM2.5, level concentrations ¾ Dust suppression by sprinkling water will be PM10, SO2, NOx, CO, (GLC) during vehicle implemented in storage yards, as etc movement for applicable. ¾ Verification of cover of evacuation of product ¾ Vehicles used for transportation of sugar trucks, tractors, dust cane as well as finished product would be a suppression measures bullock cart, Tractors and Trucks and will be & plantation ensures for PUC, in case of motorised vehicle. ¾ Greenbelt/ green cover development programs will be undertaken around the plant in the available area. Terrestrial ¾ Impact on plant ¾ Control and disperse emission through and ¾ Housekeeping ¾ HOD, ¾ Inventory of trees ecology species due appropriate ESP & stack height. As & Gardeners EMD planted with species emission from stack ambient air quality will be within limits, no ¾ Plant head and survival rate ¾ Planting trees within active injury to the vegetation is expected ¾ Area under plantation premises ¾ Extensive tree plantation will be carried out ¾ Height and girth to be ¾ Impact on fauna and and proposed and any tree cut will get annually measured flora compensated manifold ¾ Inspection of ¾ Boundary wall will be developed around the boundary wall plant so that there is no interaction with the fauna of the surrounding except birds and small mammals who make their way into the planted areas of the industry. The air emissions also reduce to a level that has negligible impact

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 10-3 Athani Sugars Ltd.

Discipline Potential impacts and Mitigation measures Administrative Aspect Monitoring Source Implementation Monitoring Parameters Noise ¾ Noise levels in the ¾ Equipment will be designed to conform to ¾ Civil ¾ EMC ¾ Noise level plant area due to noise levels prescribed by regulatory department coordinato ¾ Vibration level equipment in main agencies ¾ Housekeeping r ¾ Tree inventory as in plant and auxiliaries. ¾ High noise generating equipment would be & Gardeners ¾ Plant head previous point ¾ Noise due to traffic acoustically shrouded or housed in acoustic ¾ Safety Officer ¾ Verification of PPE movement enclosure & provided with vibration ¾ Drivers/ dampners. vehicle ¾ Provision of green belt and plantation would contractors further help in attenuating noise. ¾ Employees working in high noise areas are provided with earplugs/earmuffs as protective device. ¾ Vehicles will be maintained as per manufacturers schedule Traffic Impact on infrastructure ¾ Provision of the proper parking yard and Housekeeping EMC Verification by observation impacts and impact on air quality maintenance of roads and transportation coordinator and noise due to vehicles. vehicular movement ¾ Use of covered trucks for transportation of products to make spill-proof. Demography During the construction ¾ Plant will generate direct employment. The ¾ Human ¾ Plant head ¾ Employment and and socio- phase, no family will preference will be given to local population resources domicile records economics migrate from the core for employment in the semi-skilled and ¾ Welfare officer ¾ CSR compliances zone as there is no unskilled category. habitation. Therefore, no ¾ Indirect employment will be created by the impact on demographic plant for supply of daily domestic goods, profile of the area is sservices, transportation, etc. foreseen. The land is ¾ Additional facilities will be developed by the already in possession of project proponent in surrounding villages as the company, hence part of CSR. there are no land losers for expansion phase. There will be influx of operating personnel

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 10-4

Athani Sugars Ltd.

Discipline Potential impacts and Mitigation measures Administrative Aspect Monitoring Source Implementation Monitoring Parameters Greenbelt Air and noise pollution Green Belt will be provided all along the Housekeeping & EMC Verification by observation due to emissions from periphery of the project area and vacant areas Gardener coordinator Treated waste water stack and noise levels in the plant, along roads etc. Part of the treated reuse log books due to the equipment. wastewater from the plant will be used for greenbelt development. Fire and Accidents/disasters ¾ Prepare and implement Disaster ¾ Safety Officer ¾ Plant ¾ Verification of Safety related to fire and safety Management Plan (DMP). head approvals from factory ¾ A well-laid fire fighting system and fire inspector extinguishers will be installed as per fire ¾ Fire fighting approvals safety norms. ¾ Training and mock drill ¾ Regular fire safety training and mock drills records will be conducted. Solid Waste ¾ Management of ¾ Bagasse will be used in boiler for cogen ¾ Cogen plant ¾ Plant head ¾ Log of bagasse, press bagasse, press mud, ¾ Composting of pressmud, yeast sludge, incharge mud, fly ash yeast sludge, biological sludge, etc ¾ Housekeeping generation and biological sludge, etc ¾ Fly ash, due to high potash content, will be incharge utilisation ¾ Pollution of air due to used with press mud to convert to compost ¾ ETP operator ¾ Log of solid waste ash handling ¾ Municipal solid waste due to everyday handling and disposal ¾ Municipal solid waste sweeping, canteen and domestic activities ¾ Log books of ETP due to everyday will be used as manure. Non biodegradable ¾ Surprise checks sweeping, canteen products shall be sold to authorized ¾ Verification by and domestic vendors. observation activities ¾ The sludge from water and waste water ¾ Sludge from water treatment systems shall be composted and and waste water used as manure horticulture. Treated waste treatment systems water will be used for irrigation of green belt ¾ Miscellaneous wastes in project area. from plant Thermal Heating of receiving Since a re-circulating cooling system with ¾ Cogen plant EMC Periodic verification of pollution waters and air from Boiler cooling tower shall be adopted, no thermal incharge coordinator guard pond for maintained blow down, cooling tower pollution is anticipated. Guard pond shall be conditions blow down and stack there to receive and cool the water prior to use emissions. in horticulture, etc

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 10-5 Athani Sugars Ltd.

Discipline Potential impacts and Mitigation measures Administrative Aspect Monitoring Source Implementation Monitoring Parameters Liquid Effluent Pollution of surface and ¾ All waste water from different units within ¾ Unit operators ¾ Environme ¾ Quality parameters ground water, the plant are recirculated, reused and ntal ¾ Log books propagation of vectors, recycled completely engineer ¾ Inspection creation of odour due to ¾ All treated wastewater shall meet applicable ¾ EMC effluents from sugar unit, standards. coordinato distillery, cooling tower ¾ water from evaporator condensate of r blow down, boiler blow Sugar and distillery units shall be down, water treatment recycled systems, waste water ¾ Sewage will be treated in septic tank treatment systems, system domestic sewage, etc

Health and Injury ¾ Working as per approved plans. ¾ Safety officer ¾ Plant ¾ Examination records Safety ¾ Periodical Medical Examination. head as given in Annexure ¾ Extensive publicity and propaganda related XVIII to safety. ¾ Training records

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 10-6 2 Development of Authority toexamine possibility to SO 1 Emission minimization No. Sl. 10.4 The compliance to the CREP guidelines prescribed by CPCBisgiven in GUIDELINES IMPLEMENTION 10.1 CORPORATE RESPONSIBILITY FOR ENVIRONMENT PROTECTION (CREP) I/M o xaso fSgr itley&CgnPati it egu,Kraaa 10-7 EIA/EMPSugar, forExpansionof Distillery &Cogen Plant inDist.Belgaun, Karnataka Reducewastewater generation to 2 Asperguidelines Operation ETPof 1 Waste WaterManagement 5 To install /high ESP/bag To filter 5 Control Emission To provide 15 days storagecapacity 4 To achieve zero discharge ininland 3 No. Sl. . mg/Nm suggest the road mapto meet 100 standards to 100 mg/Nm reduce theparticulate matter emissions 100 litres per tonne of cane the operation one of mill. of the prescribed standards day from achieve desiredMLSS soastomeet before starting of to cane crushing shall bestarted atleast one month emission to<150 mg/Nm particulatematter standards for efficiency scrubberto comply with monsoon irrigationduring demand for for treated effluent to take care of no surface water bodies COMPLIANCE FOR TOCREPGUIDELINES COGENPOWER PLANT RPGieie yCC Implementation and expansion by Industry CREP GuidelinesbyCPCB COMPLIANCE FOR TOCREPGUIDELINES SUGAR INDUSTRY 3 RPGieie yCC Implementation and expansion by CREP Guidelines by CPCB wherever found feasible. 3 . The studies shall alsoshall . Thestudies 2 & NO 3 x emission TABLE 10.2 TABLE 10.3 discharged watering, etc.Hence, nowaste water is i.e. Indistillery,itself cogen, green belt Wastewater generated reuseintheproject requirement of Expansion of project. capacity itwill beenhanced asper ETP isalready inoperation for existing 15 days storageisprovided irrigation purpose reuse in theindustry itselfand provided for Generated wastewater treated and will be for existing plant ESP isalready installed and maintained SO Baggase content very negligible amount of generation PM vehicularfrom traffic. paved roads,therefore therewill not efficiency of 99.99% and roads are already stacklimit, from by installingESP with high willEmission bemaintained wellwithin the 2 & NO x Industry Industry Athani Sugars Ltd.Athani Sugars Table 10.2 , 10.3 & Athani Sugars Ltd. Athani Sugars Ltd.

Sl. CREP Guidelines by CPCB Implementation and expansion by Industry 10.2 CORPORATE ENVIRONMENT POLICY No. Maintenance The Corporate Environment Policy of M/s Athani Sugar Mills is given in Annexure XIX. The 3 Install/activate capacity meters/ Already exist salient point of which are: continuous monitoring system in all the units with proper calibration system x The company has a well laid down Environment Policy approved by its Board of 4 Development of guidelines/ standards Already exist directors. for mercury and other toxic heavy metals emissions. x The Environment Policy prescribes for standard operating process/ procedures to 5 Review of stack height requirement and Stack height for proposed plant is planned bring into focus any infringement/ deviation/violation/ of the environmental or forest guidelines for power plants based on 75m, which is calculated CPCB and MoEF norms/ conditions. micro meteorological data. approved guidelines x There is a hierarchical system or Administrative order of the company to deal with the environmental issues and for ensuring compliance with the Environmental 6 Power plants will sign fuel supply Fuel is own baggase. clearance conditions. agreement (FSA) 7 Dry ash to the users outside the Dry ash will be collected and send to cement x The company have system of reporting of non compliances/violations of premises or uninterrupted access to the manufacturing or send to compost. environmental norms to the Board of Directors of the company and /or shareholders users within six months or stakeholders at large.

10.2.1 Standard operating process / procedures to address deviation/ violation TABLE 10.4 COMPLIANCE TO CREP GUIDELINES FOR DISTILLERIES An Environmental Manual shall be prepared, either stand alone or as part of the Sl. No. CREP Guidelines by CPCB Implementation and expansion Environmental Management System such as ISO 14001, if the company will decide to by Industry implement it. The Manual shall be prepared to comply the Corporate Environmental Policy Waste disposal covering the following aspects: 1 Compost making with press Implemented (existing plant) 1. Environment clearance conditions/ stipulations/ norms mud/agricultural residue/ Municipal Waste 2. Consent to establish conditions / stipulations / norms 2 Utilization of spent wash by the Implemented in existing plant, and distilleries to achieve zero discharge will follow at expansion 3. Consent to operate conditions / stipulations / norms of spent wash in inland surface water 4. Monitoring mechanism for compliance through periodic audits courses 3 The 100% utilization of spentwash is Implemented in existing plant, and 5. Reporting of the audit results to Board of Directors achieved, controlled and restricted will follow at expansion discharge of treated effluent form 6. Corrective and Preventive Actions to be taken lined lagoons during rainy season will be allowed by SPCB/CPCB in such a 7. Self improvement measures way that the perceptible colouring of river water bodies does not occur. 10.2.2 Hierarchical systems to deal with the environmental issues and for ensuring compliance Maintenance 4 Monitoring Task Force consisting of Implemented in existing plant, and The Company has established an environmental cell at Company level for all projects, CPCB, SPCB, Experts and industry will follow at expansion which is responsible for the compliance of the environmental conditions. At the project level, shall be constituted for monitoring the an environmental manager will be operating under the GM, who is reporting to the implementation of action points. Chairman of the Company.

Further Environmental Manual shall be prepared and will define the roles and responsibilities of various members of the team in different hierarchical levels with respect

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 10-8 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 10-9 Athani Sugars Ltd. Athani Sugars Ltd. to adherence to the Environmental policy and compliance with Environmental Laws and CHAPTER 11 Regulations. EXECUTIVE SUMMARY OF EIA/EMP

11.1 INTRODUCTION

11.1.1 General background

M/s. Athani Sugars Ltd. (ASL) proposes to expand its existing integrated sugar, cogeneration power project & Distillery at Kempwad village, Vishnuanna Nagar, Post Navalihal, Taluka Athani, District Belgaum, Karnataka. The factory was established for a capacity of 2500 TCD sugar, 24 MW cogen plant. The factory had expanded capacity from 2500 to 4500, 24 MW cogen power and 60 KLPD distilleries in year 2008. ASL proposes to expand sugar crushing capacity from 4500 to 12000 TCD, distillery from 60 to 90 KLPD and set up 24 to 54 MW biomass power plant for making RS/ENA/Ethanol.

11.1.2 Location and communication

The proposed expansion plant will be located at Kempwad village, Vishnuanna Nagar, Post Navalihal, Taluka Athani, Dist. Belgaum, Karnataka. The location map of the area is shown in Fig 1.1 of chapter 1. The study area of the proposed project falls in Survey of India Toposheet No. 47 L/13, 47 L/14, 47P/1 and 47P/2. It is bound by latitudes 16q¶¶¶1 to 16q¶ ¶¶ 1 and longitude 74q¶ ¶¶( to 74q¶ ¶¶(. Interstate Boundary of Maharashtra is at a distance of 0.05 Km, NW from Project site.

The nearest State Highway to the site is SH-12 at 2.3 km, aerially in South. The nearest town is Athani at 15 kms, SSW and nearest District Headquarters is Belgaum at 108 km, SSW. The nearest railway station is Belunki at a distance of 10 km, SW, aerially from the project site. The nearest airport is Kolhapur at a distance of about 68 km, WSW.

Systems of reporting of non compliances/ violations 11.2 PROJECT DESCRIPTION 11.2.1 Plant layout Half yearly Progress Report to the conditions imposed by in Environmental Clearance of the project VKDOOEHXSORDGHGDW&RPSDQ\¶VZHEVLWHUHJXODUO\. Deviations from the policy and The present sugar, distillery & cogen plant has been constructed over an area of 24 acres, cases of violation of Environmental clearance conditions as well as Consent to operate as wherein the proposed expansion will also take place. The company has an additional area found by SPCB or other public authority will be reported to Board of Directors and of 96.5 acres for plantation, composting, spentwash lagoon & other non-plant activities, corrective as well as preventive action will be taken. thus, having total area of 120.0 acres under its ownership.

10.2.3 Corporate Social Responsibility 11.2.2 Process description x In Atahni sugar factory premises has opened new school expenditure of Rs.15 Lakhs. Cane from nearby area will be crushed to get sugarcane juice which will further be x ASL has opened primary health care clinic for all employees and their family. concentrated to get quality sugar crystals. Uncrystallised sugar collected in molasses will be x During 2013 draft situation ASL provided fodder for animal to the near villages which fermented to form alcohol with Yeast cells. cost around Rs.25 lakhs. C12H22O11 + H2 O Enzyme Invertase 2 C6H12O6 x ASL constructed a Check Dam for Agrani River at Muragundi village for water conservation which cost around 45 lakhs. C6H12O6 Enzyme zymase 2 C2H5OH + 2 CO2 x SD\LQJPRQWKO\H[SHQGLWXUHRIRQHVFKRROLQYLOODJHµVKLQDO¶$WKDQLWDOXND%elgaum dist.

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 10-10 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 11-1 Athani Sugars Ltd. Athani Sugars Ltd.

On a theoretical basis 342 kg of sugar yields 184 kg of 100% alcohol and 176 kg of CO2. Buffer zone: The topography of the study area is generally plain with less undulations. The Usual commercial efficiency obtained are in the range of 85% fermentation and 98 to 99% general slope in the study area is towards the drainage channels, which are spread out distillation, contributing to a total efficiency of 83 to 84%. across the study area. The elevation of the study area varies between 532 m to 640 m above MSL. The topography of the region is such that it has well developed dendritic Ethanol or ethyl alcohol, CH3-CH2-OH is a volatile, flammable, clear, colourless liquid which drainage system. There are few water bodies present in the study area. finds many applications as a raw material for acetone, acetaldehyde, acetic acid, acetic anhydride, ethyl acetate, other esters, and syntheses along with its main use due to 11.3.2 Climate and micro-meteorology associated oxygen from hydroxyl group in fuel blending in gasoline. Alcohol distillation will yield quality rectified alcohol. Spent wash will be used along with press mud for composting. Belgaum is well known for its pleasant climate throughout the year, but the last few years, summers (April through June) have been warmer than usual. It is at its coldest in winter Bagasse from cane crushing and coal will be burnt in 130 T/H boiler for cogeneration of 24 (November through February), and experiences continuous monsoon of medium intensity MW power with turbo generator. Press mud from cane juice filtration will be used in during July to September. The annual average rainfall is 50". The year is usually divided composting and the same will be supplied to cane farmers. Ash from boiler will be sold to into four seasons- summer, monsoon, post monsoon & winters. brick producers or used in land filling. The micro-meteorological data of the study area have been recorded with an automatic 11.2.3 Raw material, power and water weather station during summer season March to May 2014 at plant site. Temperature was recorded between 10 to 38°C, relative humidity between 6 to 100%. The wind speed varied 500 TCH of sugarcane required for sugar plant will be from own farms and any shortfall to between calm to 32 km/hr and the predominant wind direction was observed from WSW be met from the nearby farmers for the sugar plant whereas the molasses (76800 MT or with 23% of occurrences. 351.5 TPD) and bagasse (150 TPH) will be used from within the plant. The transportation shall be done through tractor trolleys, trucks and carts, as per the mode available with the 11.3.3 Ambient air quality farmer. Ambient air quality was monitored at eight locations, one in the core and seven in the buffer 3 Company proposes to have power supply from 440 V, 50 cycles from in house captive zone. Twenty four hour average PM10 level was found to range from 30.2 to 62.3 μg/m , PM 3 3 power plant of sugar mill. Hence the power supply from the grid is not proposed as the 2.5 was found to vary from 7.5 to 28.6 μg/m , SO2 from 4.2 to 15.3 μg/m and NOx from 5.6 3 3 power supply will be available from the cogen power plant. The estimated power to 20.3 μg/m . CO was found to be lower than < 3 μg/m at all the locations. All the values requirement will be 130 kwh/KL for RS, 139 kwh/KL for ENA and 140 kwh/KL for Ethanol.It ZHUHZLWKLQWKHDPELHQWDLUTXDOLW\VWDQGDUG¶VOLPLWV is inclusive of power consumption in plant, off-site equipment, factory lighting, etc. Backup generator of 1250 KVA is also provisioned for future. 11.3.4 Water resources

Total fresh water requirement shall reduce to 1,89,472 KL/annum after expansion from the The Krishna, the Ghataprabha and the Malalprabha are the principal rivers which flow existing 2,45,360 KL/annum. The reduction will be 55888 KL/ annum i.e. by 22.78%. The across the district from west to east and drain the waters in its northern, central and water will be sourced from Krishna river for which the permission has been obtained. southern tracts respectively.

11.2.4 Manpower In the major parts of the district, the decadal mean of depth to water level generally ranged between 5 to 20 m bgl. During pre-monsoon period i.e. May 2014, 8%, 28%, 37%, and 27% Total existing manpower the sugar factory is 500 and additional proposed manpower is 300 of the wells had depth to water level ranges between 0-2, 2-5, 5-10 and 10-20m bgl for expansion. respectively. There was a rise of water level in 30%, 20% and 30% of the wells during post monsoon period i.e. in the range of 0-2, 2-4 and more than 4 m respectively.

11.3 DESCRIPTION OF THE ENVIRONMENT Ten water samples including two surface water and eight ground water samples were collected from various locations within the study area and were analyzed. Surface water 11.3.1 Topography and drainage samples from Krishna River at Jackwell, Krishna River at Ainapur and ground water samples from project site, Kempwad village, Mole village, Madhbhavi village, Kidgedi Core zone: The topography of the proposed plant location area is plain and already having village, Shiddhewadi village, Khatav village and Vishnuwadi village in the study area were industrial structure. The average elevation of the plant area is 590 m above mean sea level, collected. All the physio-chemical parameters present in ground water as well as surface as seen in google earth. The slope is towards South. As per the toposheet, no stream is water are within the permissible limits specified by IS: 10500 for drinking purposes. passing or originating from the plant area. There are no water bodies within the plant site area. Rain water run off is through sheet flow from plot area joining the natural drainage.

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 11-2 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 11-3 Athani Sugars Ltd. Athani Sugars Ltd.

11.3.5 Noise and traffic density family. More than half population is literate (62.75%). The literacy level is lower among females (26.63%). Noise levels at eight stations (1 within the core area and seven within study area) were observed. The noise levels observed on all locations were in range of 48.2 to 59.0 dBA 11.3.9 Places of archaeological/ historical/ tourist/ religious importance/ industries during day time and 37.1-44.1 dBA during night time. Belgaum is famous in history for the Adil Shahi dynasty. There are ten mosques here, of A traffic density survey was conducted round the clock from 19-20.04.2014 on Purshottam which the Jamma Mosque is a fine representation of Adil Shah's period. There are some Road at a distance of about 2.0 km, S from the project site. Total numbers of vehicles were places of religious importance used by the local villagers in the study area. These are Shri found to be 693. Mangsuli Mallaya Temple (11.1 km, WSW), Shri Malakarsiddeswar Temple (2.4 km, SW) and Jain Temple (5.5 km, S). Athani is also famous for it's Amritalingeshwara temple. The 11.3.6 Land use pattern and soil quality Mahadeva Temple with it's massive lathe turned pillars is another tourist attraction. Mangsuli, 26 Kms from Athani, is a Celebrated Pilgrim Centre of the Mailare (Khandoba) The total plant area is 24 acres. In addition to that, the company owns 96.5 acres of land worship. The huge temple complex of Mallaiah has other shrines like Malachi, Ambabai, outside the plant area for various purposes. Bana.

The study area comprises 26 villages in Sangli district of Maharashtra and Athani district of Athani is very famous for it's Leather Industries. The famous "Kolhapuri" slippers are Karnataka. The land use has been assessed from satellite imagery interpretation, which actually made at Madabhavi of this taluka. The slippers manufactured here are exported to shows predominant fallow land (39.59%) followed by agricultural land (35.29%) and countries like Thailand, Netherlands and Bangkok. harvested agriculture land (18.74%). Barren, built-up and water bodies comprises remaining part of the study area.

8 top soil samples were collected and analysed from core and buffer zone. The soils are mostly black soils. The moisture content is around 7.2±13.3% and organic carbon is found as 0.35 and 0.72%.

11.3.7 Ecology

There is no forest in the core zone. There is no National Park/ Wildlife Sanctuary/ Tiger Reserve within 10 km radius of proposed plant site. The nearest National Park is Bhagwan Mahavir National Park at a distance of 176 km, SSW and nearest Wildlife sanctuary is Ghataprabha at a distance of 105 km, SSW from the project Site.

In the project area, sugarcane is grown. Besides this plantation of trees such as Mango, Neem, Karanj, Gulmohar, Kaner etc. are also done in the project area. In the study area trees like Mango, Ashok, Coconut, Cassia, Gulmohar etc. are commonly observed.

Fauna in core zone is in the form of common mammals such as cat, rat, squirrel; aves such as pigeon, sparrow, house crow, myna, drongo and reptiles such as lizard, etc. As regards fauna is concerned, Squirrel, Mangoose, Indian Hare etc. are the common mammals found, while amongst repltiles Naja-Naja, Viper, etc were noticed. Among the avifauna, drongo, parakeet, crow, and green bee eater were are found.

11.3.8 Socio-economic condition

There is no village habitation within the core zone and no displacement shall take place. The study area consists of 26 villages. The total population within the study area is 105413 with 54181 males and 51232 females. Mostly the population is rural and the percentage of Scheduled Castes is 14.84% and Schedule Tribes is 2.86% of the total population. The male population exceeds female population. The average family size is 5 persons per

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 11-4 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 11-5 Athani Sugars Ltd. Athani Sugars Ltd.

11.4 ENVIRONMENTAL IMPACT ASSESSMENT AND MITIGATION period of time. Plantation program shall be designed and a budget should be allocated for this purpose every year. 33% of the area owned by ASL is planned for greening. Moreover, 11.4.1 Topography and drainage the garden development and tree plantation activities of ASL during operational face would ensure minimal impact of fugitive dust emissions. In addition to above, ASL promised to Impact: The topography of the proposed site is plain with gentle slope and slightly maintain good house-keeping in all the departments of their sugar manufacturing and undulation. The agriculture land was converted to industrial purpose at the first stage of power generation departments in order to keep the entire complex clean and free of dust. installation of the plant.Thereafter an expansion was undertaken and currently a second expansion is proposed in this report in the same premises and area. Thus, no significant 11.4.3 Noise and traffic density changes in topography in the core zone are anticipated since majority of the construction of the buildings such as walls, buildings, stock yards etc. have already occurred. The ground Impact: During construction phase, noise levels in the vicinity of any construction has already achieved a requisite level during previous construction phases. There will be no activity increase due to running of bull-dozers, excavators, transport vehicles, pile drivers, impact on topography of the buffer zone. portable generators, mechanical machinery such as cranes, riveting machines, hammering etc. During operation phase, the noise levels near the sources such as Sugarcane cutting, Mitigation: The additional change in topography in the core zone will not lead to Crushing, Lime addition, Clarification, Evaporation, Sugar separation, Steam Production, additional changes in the sheet flow pattern of rain water within the core zone since most of cutters, crushers, mixers, pumps, boilers etc. will be higher. The traffic involved for the construction has been carried out in the previous phases of construction. Moreover, a transportation by road will also cause noise pollution and affect habitation along the roads. network of planned storm water drainage is provided and maintained. The additional construction is expected to be completed in one year. Mitigation: Provision and maintenance of green belt. Proper maintenance of noise generating machinery including transportation vehicles. The noise generation will be 11.4.2 Air environment reduced at source by erecting noise dampening enclosures, by maintaining the machines and greasing them regularly. Provision of air silencers to modulate the noise generated by Impact: During the construction phase, sources of air pollution will be vehicle the machines/ equipments. The equipment will be provided with acoustic shields or exhausts, dust generation due to excavation work and exhaust from construction equipment enclosures to limit the sound level inside the plant. Use of rubber packing in the foundations like compressors, DG sets, etc. of machineries to prevent noise transmission to the surrounding. Noise from safety valves, start up vents, steam jet ejectors of condenser etc. will be reduced by providing silencers at Primary impact will be high dust generation resulting into increased SPM levels in the outlet of down steam piping. Ear muffs/plugs provided to the workers in the close the surrounding areas. The project has air pollution point source in the form of boiler stack. vicinity of noise source. The air environment gets polluted due to emission of suspended particulate matter having particle size less than 50 microns and can have secondary impacts, if not managed. 11.4.4 Water environment

The major pollutant from the activity is PM. In the present study, the major source Impact: During construction phase the requirement of water will be on account of has been considered as the stack attached to boiler. The maximum GLCs is calculated for concrete mixing, curing and tank preparation, usage in sprays and sprinklers for dust existing scenario is 0.0086 ȝJP3 NE Direction. Incremental rise due to proposed unit suppression, irrigation for plantation and for landscaping with decorative plants and lawns. power plant will be 0.011 ȝJP3 NE Direction. The cumulative impact due to existing and During construction hardly 35 m3 water will be required for curing. The construction activity proposed operation will be 0.014 ȝJP3 NE Direction. will not have any effect on ground as well as surface water. The plant will derive its water from the Krishna River, which is located at distance of about 13 km. The water requirement Due to existing state highways & less distances for carts, tractors & trucks to reach will be increased from 850 cum/day to 1298 cum/day after expansion for sugar plant. mill site the suspended particulate matter generation is anticipated to be within specified However, total water requirement on annual basis will be reducing by 22.78% from 245360 limits. KL/A to 189472 KL/A. necessary pumping and piping system has been installed for water withdrawal from the proposed source. The lean season for Krishna river is in the month of Mitigation: During construction, welding operations shall be carried out within May. However, sugar factory crushing season is closed in the April end. Total fresh water cordoned areas. During dry weather condition, the dust created by excavation, leveling and requirement for cogen and distillery plant will be 850 cum/day in season and 1367 cum/day transportation activities will be easily controllable by sprinkling of water. Construction in off season. Treated water will be used for the sugar plant. During the lean season equipment and transport vehicle will be maintained properly to minimize source emissions Krishna river is never dried as it is perennial and the water flow in the river near drawl point and spillage. Regular maintenance schedule will be adopted. always more than 5 cum. Hence there is no significant impact on drawl of water during April and May month i.e. lean season. During operation, Electrostatic precipitator (ESP) will be provided in the additional boiler stack. Use of bullock carts, which are environmental friendly, for transportation of Mitigation: Waste water generated during construction is insignificant. Proper sugarcane from the villages to the plant site as far as possible. Carry out tree plantation sanitation facility will be provided with septic tank so that there will be no negative impact on around plant area for minimizing environmental impacts of the proposed activities over a water.

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 11-6 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 11-7 Athani Sugars Ltd. Athani Sugars Ltd.

in construction (& two more family members). These will have to be segregated. The Wastewater from Sugar mill will not have significant BOD/ COD levels. All waste organic matter can be composted and non-biodegradables can be incincerated in the boiler. water will be collected in effluent treatment chambers and neutralized prior to discharge in The recyclable will be sold to recycling vendors although components like paper & plastic the existing sugar plants. The treatment scheme incorporates Aerobic treatment method for serve as high calorific wastes for incineration in boiler. the wastewater with state of the art Bio-Aeration Technologies. In co-generation also precise design parameters will enhance target of water conservation & power production. During operation phase, Bagasse, Press mud and Biological Sludge will be Maximum attention is paid to recycle the water in each unit/equipment. generated form sugar plant. Bagasse will be used in boiler and press mud and biological sludge will be composted. Effluent generated by cogen plant will be treated in existing sugar Plant having Preliminary and Secondary treatment. In the secondary treatment stage wise activated Boiler ash will be generated from cogen which due to high potash content, will be sludge treatment process will be carried out. Each stage consist of the aeration tank with used with press mud to convert to compost. And yeast sludge which will be generated from fixed aerators and secondary clarifiers. The clear effluent from clarifier will be collected in the distillery will be composted. polishing pond and water will be used for irrigation. 114.7 Ecology Single stage evaporation technology during alcohol concentration & recovery reduces spent wash quantity. Thus, spent wash generation will be minimum. The treated Impact: During construction phase, there will be less negative impacts on terrestrial wastewater will be utilized for plant floor washing, make up water for cooling tower, green eco-system comprising birds and animals as the area proposed for construction has less belt and plantation in the area and captive irrigation. Thus, impact on ground & surface trees. Despite attempts to minimise the cutting / felling to the extent possible, if trees will water shall be negligible and zero wastewater discharge scheme involves conversion of have to be felled, due permission will be taken from the Forest Department and spent wash after evaporation to bio-compost using press mud. compensatory tree plantation undertaken within the plant premises. With progressive growth of greenery, terrestrial eco-system will improve in course of time. Presence of water 11.4.5 Land use and food wastes during day time will attract some birds and small animals (squirrels, mongoose, etc) towards the site. During operation phase, dust emission from plant and due Impact & Management: During construction, some excavation, land filling and to transportation, affects the effective photosynthesis by covering the plant/tree leaves by development aspects may be needed for leveling of the ground. However, this disturbance thin dust layer during dry months which however will be washed away in rainy months. be done only on temporary basis. At the end of the construction, the soil will be stabilized at There can be roadkill due to traffic, disturbance to birds and animals due to bright light and the unpaved areas with the help of plantation activities. More than 33% of the 120.5 acres unusual noise during operation activity and contamination of water bodies on which animals land owned by ASL has been envisaged to be covered with plantation including green belt. and birds are dependent or contamination of ground water due to effluents and sewage, if Since the plant species will be capable of checking soil erosion, the soil will be fully mitigation measures are not implemented. stabilised without any adverse change in erosion potential of the area. Mitigation: Company has planted several trees around factory premises such as in During operation phase, the landuse pattern will remain same as constructed/ used. front of guest house- 50 chiku trees, near cane yard- 70 Gulmor plants, 200 wind trees and The quality of land & soil degradation can be a matter of concern due to waste water & solid 500 mango trees in front of main gate and admin block. 100 ashok trees and 160 tamarind waste disposal on land. The same shall be addressed as follows: have been planted both sides of road leading to factory. Establishment of greenbelt along the facilities periphery to act as a natural buffer between the surrounding area and the ¾ There shall be waste water from the power plant, will be neutralised and used for facilities. Construction of boundary or fence along the plant perimeter to prevent wild sprinkling and horticulture. The quality of the water shall be monitored to ensure that it is animals from straying into the plant area and getting harmed. within norms for disposal land. 11.4.8 Socio-economics ¾ The solid waste generation for disposal will be negligible and will be stored in designated areas with impervious bases, thus, the impact on land shall be minimal. There will be additional 300 employment available with the expansion of the plant. Further indirect job opportunities will be on the horizon due to expansion sugar, distillery ¾ The majority of the solid waste i.e. fly shall be used in composting since it is rich in and co-generation complex. This will result in an increase in income level of the employees, potash. subsequent commercial as well as social infrastructure establishment. Several socio- economic benefits shall be there. Ample power will be available from local grid due to 11.4.6 Solid waste management decentralization of power generation and power from grid on no charge basis or low charge basis can be available in this area. This can be an initiative for many units to start. Impact & Mitigation: During Construction phase, there will be development of a Supplementary type units can be initiated in the area like cattle preservation & protection, shanty town with temporary establishment of residential and commercial nature. Therefore, poultry, herbal medicinal plants, spices, pickles, papad and other food items, milk producer there will be generation of solid waste to the tune of 0.2 TPD for, say, 500 persons involved group co-operative small saving groups.

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 11-8 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 11-9 Athani Sugars Ltd. Athani Sugars Ltd.

the significant positive impact on employment and occupation is envisaged on account of 11.5 ANALYSIS OF ALTERNATIVES better economic status of the community due to better earnings, higher inputs towards infrastructural facilities due to establishment of plant and enhancement of literacy due to No alternative site was considered for the proposed expansion phase as the plant educational facilities available in the surroundings. Better education facilities, proper health exist at the present site. The process selection is done based on the following care, road infrastructure and drinking water facilities are basic social amenities for better considerations: living standard of any human being which are aimed to be improved through proposed Corporate Social Responsibility Program (CSR). A sum of Rs. 132.25 lakhs had been i. Least stress on resources including raw materials and utilities planned during construction period of 5 years and Rs. 1 crore per year is earmarked for post commissioning of the plant. ii. Reduce, Recycle and Reuse of wastes iii. Least or no pollution from the industry 11.9 PROJECT CONSULTANTS The consultants engaged for the preparation of the EIA/EMP of the project are Min Mec iv. Least or no risk to human and property Consultancy Pvt. Ltd. Company. It was registered in July 1983 with the Registrar of Companies, Delhi & Haryana, India. In 1994, Min Mec established a modern R & D v. Least or no adverse impacts on environment laboratory. Min Mec is ISO 9001: 2008 certified under ANZ-JAS. In June 2006, the laboratory received accreditation from NABL (certificate no. T-1157), which has been The technology options for the proposed plant were considered based on efficient renewed as per procedure since. In 2012, lab has been accredited under Environment utilization of raw materials, fuel and water along with efficiency in power generation. Protection Act (EPA) by Ministry of Environment & Forests, Government of India (sl. No. 11.6 ENVIRONMENTAL CONTROL AND MONITORING ORGANISATION 97). M/s JV Analytical Services, Pune, an ISO 9001: 2008 and OHSAS 18001: 2007 certified laboratory, has collected the baseline data for air, water, soil, noise and micro- A environmental management department is existing to take care of pollution meteorology during March-May 2014. J P Mukherji & Associates Pvt. Ltd., Pune has monitoring aspects and implementation of control measures headed by an EMC coordinator prepared draft Detailed Project Report for expansion of sugar plant. Yogiraj Industrial and supported by Environmental Engineer. A schedule has been spelt out for periodical Consultant, Pune, An ISO 9001:2008 Certified & CRISIL Rated Company, is the Industrial monitoring of the important environmental parameters. The total initial capital investment on Consultant, with required laboratory facilities and man power. The firm was established on environmental improvement works is envisaged as Rs. 673 lakhs while the recurring 1994 and providing services to various industries. Yogiraja Industrial Consultant is expenditure during the stage of production is envisaged as Rs. 179 lakhs per year. empanelled by Maharashtra Pollution Control Board, Mumbai. 11.7 DISASTER MANAGEMENT PLAN

When the full fledged activities of sugar, alcohol & co-generation will gear up, they will have to follow Factories Act 1948 with all amendments till today and any directives from Director Safety, Health & Environment [SHE] will automatically be binding on ASL. In such condition to appoint a qualified Safety Officer is a must & will be an adequate, wise step in such direction. On site and off site disaster control plans and their implementation will be part and parcel of the management & such safety officer. To lessen the probability of hazard to occur & avoid the consequent damage, a disaster management and control plan has to be worked out for whole complex in anticipation to the threat.

To tackle the situation, a site emergency control room will be set up having links with all control rooms of the factory. An upto date communication facility will be provided to control rooms. The emergency organisation shall be headed by emergency leader called Site Main Controller (SMC) who will be factory manager.

11.8 PROJECT BENEFITS

Currently 500 employees are working and additional 300 will get employment during expansion. In addition to these, indirect workers will be several times and the farmers supplying sugarcane is surrounding areas will benefit. For employment, preference will be given to local population for employment in the semi-skilled and unskilled category. Hence, the company has also envisaged various skill-building programmes for locals. Therefore,

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 11-10 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 11-11 Athani Sugars Ltd. Athani Sugars Ltd.

CHAPTER 12 Personnel

DISCLOSURE OF CONSULTANTS ENGAGED Min Mec has a strong team of in-house experts in EIA, EMP, DMP, RA, EHS, mining, socio economics and software development. The team of experts is supported by a panel of experts comprising of over twenty specialists in various fields with an average experience of over 30 years. Min Mec provides services in the field of environmental impact assessment and management for all types of industries (chemical/ cement/ steel industries, power stations, Team engaged infrastructure projects, mines, etc), risk analysis, disaster management, environmental The team of Min Mec Consultancy Pvt. Ltd. and Min Mec R&D Laboratory involved in EIA health and safety auditing, socio-economic studies, R&R studies, mine planning and preparation was as follows: engineering software development. Min Mec conducts studies as per international requirements such as those for IFC (World Bank) and CIDA sponsored projects and of Role as per Expert Name Qualifications Experience national standards of MoEF. QCI

Min Mec Consultancy Pvt. Ltd was registered in July 1983 with the Registrar of Companies, EC & FAE Dr. Marisha Ph.D., M. Plan Since 2001, experience in land Delhi & Haryana, India. In 1994, Min Mec established a modern R&D laboratory which was Sharma (Env.), BE (Civil), use, mathematical modeling of recognised under Environment Protection Act (EPA) by Ministry of Environment and PG certificate in air and water pollution. Also Forests, Government of India. On 02.02.2003, Min Mec received ISO 9001:2008 Disaster experienced in waste water certification under ANZ-JAS. In June, 2006, the laboratory received certification from NABL Management treatment, resettlement and (Certificate No. T-1157). In 2012, lab has been again recognised under Environment rehabilitation studies. Certified Protection Act (EPA) by Ministry of Environment and Forests, Government of India (Sl. No. Energy auditor 97). FAE Parul Srivastava M. Tech (Env), Since 2011, experience in environmental impact Services and expertise B. Tech (Biotechnology) assessment, management and planning with over 10 projects Services are provided to the following sectors executed since x Infrastructure projects such as jetties, highways, water supply pipelines projects, power FAE Prasenjit Das B. Tech (Env), Since 2009, experience in stations, canals, minor dams, etc. environment impact assessment x Industries such as cement plants, smelters, steel, chemicals, pharmaceuticals, petrochemicals, salt works, pesticides and other hazardous and polluting industries. FAE Rashmi Gupta M.Sc. Since 2003, experience in ecology, environmental data x Mines-surface and under ground for all minerals and metals interpretation and preparation of EIA/EMP report As on 31.12.2014, the following projects have been executed:

Studies Numbers EIA, EMP & Environmental Studies 355 As per Circular no. F. No. J-11013/77/2004-IA II (I), dated 30th September 2011 of RA & DMP 17 0R() &&0LQ0HFLVOLVWHGDWVHULDOQRLQ/LVWµ%0LQ0HFLVSUHSDULQJDQGSUHVHQWLQJ EHS 4 reports as per the High Court of Delhi orders dated 03.02.2014, 14.03.2014, 13.05.2014, Socio Economics 13 14.08.2014, 13.11.2014 & 06.02.2015 in LPA 110/2014 and CM No.2175/2014 (stay) (Copy Feasibility studies (sponge iron & power plants) 40 given in Annexure XXI). Pre Feasibility studies (coal blocks) 43 Consultants for other reports Market surveys 8 Mine Planning and Detailed Project Report 114 Various reports have been prepared or are being prepared with respect to the project, from where various information has been sources for this report as follows: Regional Studies 2 Hydro- geological & hydrological studies 56 1. J P Mukherji & Associates Pvt. Ltd., Pune has prepared Draft Detailed Project Others (due diligence, land acquisition study, 21 Report for expansion of sugar plant. forest proposal, compliances, softwares etc.)

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 12-1 EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 12-2 Athani Sugars Ltd.

2. M/s JV Analytical Services, Pune, an ISO 9001: 2008 and OHSAS 18001: 2007 certified laboratory, has collected the baseline data for air, water, soil, noise and micro-meteorology during March-May 2014. 3. Yogiraj Industrial Consultant, Pune, An ISO 9001:2008 Certified & CRISIL Rated Company, is the Industrial Consultant, with required laboratory facilities and man power. The firm was established on 1994 and providing services to various industries. Yogiraja Industrial Consultant is empanelled by Maharashtra Pollution Control Board, Mumbai.

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 12-3