ENVIRONMENTAL IMPACT ASSESSMENT REPORT “M/S VITTHAL REFINED SUGARS LTD.”

ENVIRONMENTAL IMPACT ASSESSMENT REPORT (WITH ENVIRONMENTAL MANAGEMENT PLAN)

FOR ESTABLISHMENT OF INTEGRATED SUGAR INDUSTRY (Sugar 5000 TCD, Co-generation 29.5 MW, Grain based distillery 45 KLPD & Molasses/sugarcane juice/ Sugar Beet based distillery 60 KLPD)

AT A/p – Pande, Taluka – Karmala, District – Solapur, Maharashtra

PROJECT PROPONENT

“M/s VITTHAL REFINED SUGARS LTD.”

PREPARED BY

SGM Corporate Consultants Pvt. Ltd NABET/QCI Accredited Consultant An ISO 9001:2008 Certified. 206,207 Sai Chambers, Wakadewadi, Pune E-Mail: [email protected]

FOR THE PERIOD 1st DECEMBER 2014 – 28th FENRUARY 2015 CONTENTS

Sr. No. Particulars Page No.

EXECUTIVE SUMMARY 1-17

CHAPTER 1: BACKGROUND 1.1 Brief Description of the Project Proponent 18-19 1.2 Brief thoughts on project 19-20 1.3 Justification and Need of the project 20 1.4 Brief summary of the peculiarities 20-21 1.5 Sugar industry scenario in Solapur District 21-22 1.6 Environmental Policy 23 1.7 Track Records 23 1.8 Chapter Conclusion 23 CHAPTER 2: INTRODUCTION 2.1 Objectives of Environment Impact Assessment 24 2.2 Materials, Method and Approach 24-26 2.2.1 Material 24-25 2.2.2 Method 25 2.2.3 Approach 25 2.2.4 Technique 25-26 2.3 Indian Environmental Laws 26-27 2.3.1 Environmental Protection Rules, 1986 26 2.3.2 Environmental Guidelines 26 2.3.3 Coastal Regulation Zone (CRZ) 26 2.3.4 Hazardous Site Guidelines 26-27 2.3.5 Government Notification 27 2.4 Intended Use of this EIA 27-29 2.5 Scope of Document 29-30 2.6 Brief Description of Nature, Size, Location of the project 30-32 2.7 Need and importance of the project to the Country & Region 33-34 2.7.1 Need & Importance to the Country 33 2.7.2 Need & Importance to the Region 33-34 2.7.3 Employment generation due to the project 34 2.8 Terms of References (ToR) from MoEF and their Compliances 34-41 CHAPTER 3 – PROJECT DESCRIPTION 3.1 Introduction 42 3.2 Need for the project 42-43 3.2.1 Demand Supply Gap 43 3.2.2 Domestic/ Export market & Export possibility 43 3.3 Location of the project 43-46 3.3.1 General Location 43 3.4 Basis for selecting the site 47 3.5 Size and Magnitude of Operation 47-54 3.5.1 Land Requirement 47-50 3.5.2 Manpower 51 3.5.3 Housing facilities 51 3.5.4 Civil works during construction phase 51 3.5.5 Resources consumed 51 3.5.6 Sugarcane cultivation area 51 3.5.7 Traffic Density and its Impacts 51-53 3.5.8 Bulk Storage Facilities 53 3.5.9 Waste Generation 53 3.5.10 Employment Generation due to the project 54 3.6 Technology and Process Description 54-68 3.7 Raw Materials and Products 69-70 3.8 Power and Steam Requirement 71 3.9 Source and Utilization of Water 71-76 3.10 Power Requirement 77 3.11 Green Belt Development 77 3.12 Socio- Economic Benefit 77 3.13 Pollution Mitigation Measures 77-78 3.13.1 Built in Pollution Control Mitigation Measures 77-78 3.14 Assessment of New and Untested Technology for the risk of technology failure 78 CHAPTER 4 – BASELINE ENVIRONMENTAL STATUS 4.1 Introduction 79 4.2 Study area, period, components & methodology 79-80 4.3 Establishment of Baseline 81-86 4.3.1 Meteorological data 81-85 4.3.2 Baseline Monitoring 86 4.4 Ambient Air Quality 87-91 4.5 Noise environment 92-93 4.6 Water environment 93-99 4.7 Study Area – Geographical Aspects 99-105 4.7.1 Hydrology and hydrogeology 99 4.7.2 Soil & Geology 100 4.7.3 Soil Sampling 100-103 4.7.4 Land Use Pattern 104-105 4.7.4.1 Land Use Pattern of Solapur District 104 4.7.4.2 Land Use Pattern of Operational Area i.e. Karmala Taluka 104-105 4.8 Ecology 105-109 4.8.1 Flora in the Study Area 105-107 4.8.2 Fauna in the Study Area 107-109 4.9 Socio – Economic Environment 110-111 4.10 Social Infrastructure Available 111-112 4.11 Connectivity from the Project Site 112-113 4.12 Surrounding Sugar Industries 114 CHAPTER 5: ANTICIPATED ENVIRONMENTAL IMPACTS AND MITIGATION MEASURES 5.1 Introduction 115 5.2 Control Measures (Natural Environment) 115-123 5.2.1 Air Environment 115 5.2.1.1 Key Control Legislation 116 5.2.1.2 Ambient Air Quality at VRSL core zone 116-117 5.2.1.3 Emission Control Equipment 117 5.2.1.4 Air Pollution Control Facilities 118-119 5.2.1.5 Impact on Air Quality 119-122 5.2.1.6 Fugitive Measures 121-122 5.3 Water Environment 122-124 5.3.1 Water Quality & Quantity 124-125 5.3.2 Brief Description of Cleaner Technology 125-135 5.3.2.1 Treatment of Sugar & Co-gen effluent 125-128 5.3.2.2 Molasses based distillery spent wash Treatment 128-130 5.3.2.3 Stillage treatment of Grain based distillery unit 130-135 5.4 Solid Waste Management 136-137 5.4.1 Non hazardous solid waste 136 5.4.2 Hazardous waste 136-137 5.5 Noise Environment 137-139 5.6 Odour Environment 139-140 5.7 Socio Economic Environment 140-142 5.8 Work Environment 142 5.9 Disaster Management Plan 142-148 5.10 Chapter Conclusion 148 CHAPTER 6 : ANALYSIS OF ALTERNATIVES FOR TECHNOLOGY AND PROJECT SITE 6.1 Alternatives 149 6.2 Raw Material Alternative 149-150 6.2.1 Sugar Production Unit 149 6.2.2 Co-generation Unit 149 6.2.3 Molasses/ cane juice based distillery 149 6.2.4 Grain based distillery 149 6.2.5 CO 2 Recovery Plant 149 6.2.6 Malt Spirit 149 6.2.7 Grape Spirit 149 6.2.8 Cyclo dextrin 149 6.2.9 Country Liquor 149 6.2.10 Indian made foreign liquor 150 6.3 Technology Alternatives 150 6.4 Engineering & Hardware options 150 6.5 Site Alternatives 150-152 6.6 “No – Project” Option 152 6.7 Conclusion 152 CHAPTER 7 ENVIRONMENTAL MONITORING PROGRAM 7.1 Introduction 153 7.2 Monitoring Plan 153-154 7.2.1 Air Pollution & Meteorological Aspects 153 7.2.2 Water & Wastewater Quality 154 7.2.3 Noise Levels 154 7.3 Sampling Schedule & Locations 154 7.4 Laboratory Facilities 154-155 7.5 Compliances to Environmental Statutes 155 7.6 Monitoring of Compliances to Statutory Conditions 155 7.7 Success Indicators 155 CHAPTER 8 ADDITIONAL STUDIES 8.1 Public Hearing and Consultation 156 Risk Assessment for the storage & handling of alcohol & mitigation measures due to fire 8.2 156-157 & Explosion & handling 8.3 Disaster management plan 157 8.4 Hazard analysis 157-161 8.5 Occupational health & safety 161 8.6 Heat radiation 162 8.6.1 Distance from the fire 162 8.6.2 Effects of pool fire 162 8.7 Risk assessment for 60 KLPD Molasses based distillery unit 163-166 8.7.1 RS/ENA leakage through catastrophic failure 163 8.7.2 RS/ENA leak. 164 8.7.3 Unconfined Vapour cloud Exposure 165 8.7.4 Domino Effect 165 8.7.5 RS/ENA leakage through 50 mm pipe line failure 165-166 8.8 Risk assessment for 45KLPD Grain based Distillery unit 166-169 8.9 Estimation of plant risk assessment 169 8.10 Risk Assessment for Product Bagasse 170-172 CHAPTER 9: PROJECT BENEFITS 9.1 Availability of Quality Power and Alcohol 173 9.2 Improvement in the Physical Infrastructure 173 9.3 Improving the Economy of farming community 173 9.4 Improvement in the Social Infrastructure 173-174 9.5 Employment Potential 174 CHAPTER 10: ENVIRONMENTAL COST BENEFIT ANALYSIS 175

CHAPTER 11: ENVIRONMENT MANAGEMENT PLAN 11.1 Corporate Environmental policy (CEP) 176 11.2 Environment Components 176-177 11.2.1 Air Environment 176 11.2.2 Water Environment 177 11.2.3 Aesthetic (Noise and Odour) Environment 177 11.2.4 Biological Environment 177 11.2.5 Work-zone Comfort Environment 177 11.2.6 Socio-Economic Environment 177 11.3 Environment Management Hierarchy 177-178 11.4 Checklist for Statutory Obligations 179-181 11.5 Environmental Organization 181-185 11.5.1 Environment Management Cell (EMC) 182 11.5.2 Monitoring System 182-183 11.5.2.1 Schedules 183 11.5.2.2 Daily Compliance 183 11.5.2.3 Monthly Compliance 183 11.5.2.4 Quarterly Compliance 183 11.5.2.5 Yearly Compliance 183-184 11.5.3 Watch-dog committee 184 11.5.4 Monitoring and Reporting Mechanism 184-185 11.5.4.1 Construction Phase Management 185 11.6 Green Belt Development 185-186 11.7 Rain Water Harvesting System 187 11.8 Storm Water Management 187-188 11.9 Cost Provision for Environmental Measures 188-189 11.10 Chapter Conclusion 189 CHAPTER 12: EPILOGUE 190

CHAPTER 13: DISCLOSURE OF CONSULTANTS ENGAGED 191-207 TABLES

Page No. Table no. Particulars 1.1 Sugar Factories & cane crushed in Solapur District (Season 2014- 2015, Up to May 5, 21-22 2015) 1.2 Highlights of Distilleries in Solapur District 22 1.3 Various activities under Chairman and his Directors 23 2.1 Summary of Sampling 24 2.2 Present status and permissions available 30 2.3 Salient features of the project 30-32 2.4 Terms of Reference (TOR) 34-40 3.1 List of proposed units 42 3.2 Location features of the project 44 3.3 Detailed breakup of the land 48 3.4 Transportation of raw materials and products 52 3.5 List of liquid, gaseous and solid wastes generated from co-gen sugar and distillery units 53 3.6 Project Investment 53-54 3.7 Design parameter of the proposed sugar plant 57 3.8 Brief design parameters for the co-generation power plant 58 3.9 Raw materials and products for sugar unit 69 3.10 Raw materials and products for Co-generation unit 70 3.11 Raw materials and products for distillery units 70 3.12 Source and quantity of water, m3/day 71 3.13 Water requirement and waste generation in 45 KLPD grain based distillery unit & 72-73 IMFL bottling m3/day 3.14 Water requirement and waste generation in 60 KLPD distillery unit & country liquor 73-74 m3/day 3.15 Details of entire project in brief 75-76 4.1 Temperature Data of Karmala Taluka for year 2014 81 4.2 Micro- meteorological data of Project site during study period from December 2014 to 82 February 2015 4.3 Measured wind direction % of time (for study period December 2014 to February 2015) 84-85 4.4 Sampling and Analytical Techniques 86 4.5 Air Quality Monitoring Stations 87 4.6 Ambient Air Quality Standards – MoEF as per the notification dated 16th November 88 2009 for industrial, residential & rural areas 4.7 Ambient Air Quality Parameter Observations 89 4.8 Noise Level Monitoring Stations 92 4.9 Noise Level Limits as per Environmental Protection Rules 93 4.10 Summary of Noise Level during study period 93 4.11 Surface water sampling stations 94 4.12 Ground water sampling stations 95 4.13 Ground water quality Monitoring Results 96-97 4.14 Surface water quality Monitoring Results 98 4.15 Soil sampling locations 101 4.16 Soil Quality Monitoring Results 102 4.17 Standard Soil Parameter Classification 103 4.18 List of Terrestrial flora in study area 106-107 4.19 List of Terrestrial fauna in study area 107-108 4.20 Percentage wise population density of Zooplankton (per ml) at river Sina 108 4.21 Percentage wise population density of Phytoplankton river Sina 108 4.22 Percentage wise population density of Zooplankton (per ml) at Mangi Lake 108 4.23 Percentage wise population density of Phytoplankton (per ml) at Mangi Lake 109 4.24 Percentage wise population density of Zooplankton (per ml ) at Mhaisewadi Lake 109 4.25 Percentage (%) wise Population Density of Phytoplankton’s (per ml) at Mhaisewadi 109 Lake 4.26 The Socio- economic data in 28 villages of influential zone of 10 km radius from 110 project site 4.27 Socio Economic data of study area compared with Solapur District and Maharashtra 111 4.28 List of infrastructural facilities in the surroundings 112 4.29 Connectivity from the project site 112 4.30 Sugar Industries surrounding the project site 114 4.31 Schools near project site 114 5.1 National Ambient Air quality Standards (2009) 117 5.2 Emission Control Equipments for Proposed Integrated Sugar- Co gen- Distillery Units 117 5.3 Details of Capital Cost and Recurring cost 117 5.4 Air Pollution generation & its mitigation measures 118 5.5 Stack Details 120 5.6 Predicted 24 Hourly Short Term Maximum Incremental Concentrations 120 5.7 Resultant Concentrations Due To Incremental GLC's 120 5.8 Sources of wastewater generation and control option to reduce wastewater quantity in 124-125 Sugar Factory 5.9 Characteristics of Combined sugar & Co-gen effluent 125 5.10 Details of water balance - Molasses Based Distillery (60 KLPD) & CL Unit 127-128 5.11 Water balance details - Grain based Distillery (45 KLPD) & IMFL Bottling 130 5.12 Effluent Treatment Plant – Details of liquid effluent stream 131 5.13 Components of ETP units 131-132 5.14 Area utilization 134-135 5.15 Solid Waste details 136 5.16 Noise mitigation efforts 138 5.17 Summary of Noise level during study period 138 5.18 Odour mitigation efforts 139-140 5.19 The efforts taken w.r.t dust and free work environment is maintained in view of worker 142 safety, health and hygiene 5.20 Attributes & Sensitive Index 144-145 5.21 Attribute wise score is arrived at by multiplying the sensitivity index and the weight-age 146 of each attribute 6.1 List of villages around the Project Site (influential zone of 10 Km Radius) 151-152 7.1 Post Project Monitoring Schedule 154 7.2 Financial Allocation for Environmental Aspects 155 8.1 Properties of Ethanol 158 8.2 Hazard rating of alcohol based on flammability, reactivity and toxicity 158 8.3 Threshold Quantity 158 8.4 Degree of Hazard based on Fire explosion and toxicity indices for the storage 158 8.5 Minimum preventive & protective measures 159 8.6 Emergency organization 160-161 8.7 Health Evaluation 161 8.8 Pool fire Scenarios & radiation distances. 162 8.9 Scenario description & emergency planning.(60 KLPD distillery) 165-166 8.10 Scenario description & emergency planning.(45 KLPD distillery) 168-169 8.11 Pump house details 172 11.1 Schedule for small activity 183 11.2 Consent Compliance 184 11.3 List of Proposed trees 186 11.4 Cost provision for Environment Measures 189 13.1 List of Experts 198-199 FIGURES Fig. no. Particulars Page No. 2.1 Notification Logic 27 2.2 Location map project site in Solapur District 32 3.1 Map showing project site location 44 3.2 Google Image of Project Site 45 3.3 Plant Layout 46 3.4 Water requirement & waste generation in sugar mills, 5000 TCD sugar plant & 26 72 MW Co-generation power plant, CMD 4.1 Topo map showing the study area of 10 km radius 80 4.2 Graphical representation of Temperature observed in Study period (Dec. 2014 to Feb. 82 2015) 4.3 Graphical representation of Relative Humidity observed in Study period (Dec. 2014 to 83 Feb. 2015) 4.4 Graphical representation of Rainfall recorded in Study period (Dec. 2014 to Feb. 84 2015) 4.5 Wind rose diagram for study period (December 2014 to February 2015) 85 4.6 Map Depicting AAQM Stations 88 4.7 Variation of PM10 during the study period (Dec-14 to Feb-15) 90 4.8 Variation of PM2.5 during the study period (Dec-14 to Feb-15) 90 4.9 Variation of SO2 during the study period (Dec-14 to Feb-15) 90 4.10 Variation of NOx during the study period (Dec-14 to Feb-15) 91 4.11 Variation of CO during the study period (Dec-14 to Feb-15) 91 4.12 Map Depicting Noise Monitoring Locations 92 4.13 Variation of Noise level during the study period (Dec -14 to Feb -15) 93 4.14 Map Depicting Surface Water Locations 94 4.15 Map Depicting Ground Water Locations 95 4.16 Map Depicting Soil Quality Monitoring Locations 101 4.17 Land Use Pattern of Solapur District 104 4.18 Land Use Pattern of Karmala Taluka 104 4.19 Map Depicting terrestrial flora & fauna sampling Locations 109 4.20 Socio Economic data of 10 km radius with respect to project site 110 4.21 Google map depicting Infrastructural facilities 112 4.22 Google map depicting connectivity 113 4.23 Google Map depicting Sugar Industries surrounding the project site 113 5.1 Short Term 24 Hourly Incremental GLC’s PM 121 5.2 Short Term 24 Hourly Incremental GLCS of SO2 121 5.3 Short Term 24 Hourly Incremental GLCS OF NOx 122 5.4 Holding Tank Details 129 5.5 Block Diagram of MBBR Process for Sewage 133 5.6 Organization Chart 143 11.1 EMP Hierarchy 178 11.2 Table Structure 178 11.3 Environment Management Cell 182 11.4 Typical Plan and Section of Deep Well Recharge Pits 188 ANNEXURES

Annexure Particulars I. Copy of Terms of Reference Letter and Compliance II. Plant Layout III. 7/12 Extract IV. Certificate Of Registration (Incorporation) V. Certificate Of Commencement VI. Gram Panchayat NOC VII. Application for Water Permission VIII. Aerial Distance IX. Mining NOC X. CA Certificate XI. IEM 29.5 MW Co-Generation & IEM Sugar Factory 5000 TCD XII. Molasses Sparing Letter XIII. Coal Agreement (MoU) XIV. Socio economic data within 10 km radius of project site XV. Meteorological Data of Project Site (for Study period of Dec 2014 – Feb. 2015 ) XVI. Stack Height Calculations XVII. Monitoring Reports XVIII. Copy of Consent To Establish of (Sugar & Co-Generation Unit) & (Distillery Unit) Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

EXECUTIVE SUMMARY

1 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra 1.0 Background This is a proposal to establish a modern Integrated Sugar Complex by M/S Vitthal Refined Sugars ltd (VRSL) located A/P- Pande, Tal- Karmala, Dist- Solapur, State – Maharashtra. The proposed Sugar complex consists of Sugar unit (5000TCD), Co-generation (29.5 MW), Distillery Units (Molasses based- 60 KLPD & grain based- 45 KLPD), Malt spirit & grape spirit (Each-5 KLPD), Carbon-di-oxide recovery plant (50 TPD), Cyclodextrin (2.5 TPD), IMFL (1Lakh cases/Month), Country liquor (2Lakh cases/Month).

About Vitthal Refined Sugars Ltd. VRSL is a Public Limited Company registered under the Companies Act, 1956 (No.1 of 1956) on the 4th February 2010 with Corporate Identity Number- U15421 PN2010PLC135465. Its mailing address is Vitthal Refined Sugars Limited, A/P- Nimgaon, Tal- Madha, Dist- Solapur 413 208, Maharashtra, India. Its Board of Directors is as follows-

 Mr. Vikramsinh Babanrao Shinde, Chairman  Mr. Santosh Vyankatesh Garad, Director  Mr. Nitin Dattatray Shinde, Director The Chairman and members of Board of Directors have wide experience of setting up of sugar unit, primary credit societies, Educational Institutions, operating co-operative banks and financial institutions.

2.0 INTRODUCTION M/s. Vitthal Refined Sugars Ltd. (VRSL) has proposed to establish a fully integrated sugar complex at A/p - Pande, Tal. -Karmala, Dist. - Solapur, Maharashtra. Table 2.1: The project consists of following units Sr. No. Unit Production Capacity 1 Sugar unit 5000 TCD Bagasse based co-gen sugar 29.5MW (26 MW from Co-gen & 3.5 MW from spent 2 power plant wash incineration boiler) Molasses/ Sugarcane juice based 3 60 KLPD distillery unit 4 Grain based distillery 45 KLPD 5 Malt spirit 5 KLPD 6 Grape spirit 5 KLPD 7 Distillery CO2 recovery plant 50 TPD 8 Cyclodextrin plant 2.5 TPD 9 IMFL bottling One Lac cases/ Month 10 Country liquor bottling Two Lac cases/ Month

1.1 Land Requirement The land requirement for different applications for the proposed industry consisting of sugar, power and distillery units Total Plot Area – 44.33 Ha Own land in name of VRSL – 20.80 Ha Land on lease (33years lease) – 23.53 Ha Built up area – 27.71 Ha Green Belt area – 14.98 Ha

2 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra 3.0 PROJECT DESCRIPTION 3.1 Justification Man needs sugar, electricity as well as ethanol for day to day purpose. The sugar requirement is increasing in proportion to population of country as well as world. According to FAO Report, 4% growth in sugar consumption is expected. The Government policy is also favorable. India has not exploited its huge potential like other countries like Hawaii, Mauritius etc. where co-generation of power from sugar mills has become a dependable source for supply of power. Producing alcohol for various downstream chemicals (like ethyl acetate, ethylene oxide, butanol, vinyl acetate monomer, ethylene glycol, styrene etc.), for potable (IMFL & CL) and medicinal liquor and for admixing ethanol in petrol. Government of India has already taken steps to blend 10 per cent ethanol in petrol all over country.

3.2 Scope of the Study Expert Appraisal Committee (EAC), MoEF for the Environmental Appraisal of its 28th meeting held during December 1-2, 2014, has issued ToR for the preparation of the EIA report, based on the documents submitted and presentation made by the project proponent. ToR issued by MoEF as per vide letter no. J- 11011/107/2014 –IA II (I) as per the EIA notification dated 14th September 2006 of the Ministry of Environment & Forests (MoEF), New Delhi EIA report is prepared. VRSL entrusted SGM Corporate Consultants Pvt. Ltd., Pune to carry out EIA/EMP studies as per CPCB & MoEF Norms.

3.3 Project Location The proposed project is located at Gat No 238, 247, 248, 252, 254 & 256 A/p - Pande, Tal. -Karmala, Dist. - Solapur, Maharashtra. The site is located adjacent to State Highway no. 67 – 4 Km towards west.

Fig. 3.1 Location of the Project Site

3 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra Table 3.1 Location features of the project site

Sr. No. Particulars Details 1 Latitude 18024’17.91” N 2 Longitude 75013’02.69” E 3 Elevation above MSL 552 m above Mean Sea Level Maximum Temperature : 43.50C Minimum Temperature : 10.50C 4 Climatic Conditions Mean Annual Rainfall :488 mm (Rainfall Based on 15 years average ) 5 Present land use at the proposed site Barren land 6 Transport Connectivity Road A Nearest Highway State Highway no. 67 – 4 Km towards West B Nearest Railway Station Jeur Railway station – 20 Km towards South C Nearest Road Karmala – Pande road 1 Km 7 Social Aspect A Nearest School Annasaheb Jagtap Vidyalaya – 4 Km B Nearest Hospital District Hospital Karmala – 5 Km Sina River -5 Km 8 Nearest Water Body Mangi lake- 7.5 Km 9 Hills/Valleys Nil 10 Ecologically sensitive zones within 15 – Nil km distance 11 Historical/ Archaeological places Not Applicable 12 Nearest Defense and other Establishments Nil

Table 3.2 Salient Features of proposed Units of Integrated Sugar Complex by VRSL.

Sr. No. Particulars Details 1 New/expansion/ modernization New project 2 Constitution of the organization Public Limited Company Sugar Plant : 160 Days/ annum Cogeneration Power Plant : 160 Days/ annum 3 No. of working days in a year Molasses/ cane juice Based Distillery : 300 Days/ annum Grain Based Distillery : 300 Days/ annum Products & Co-products Unit Quantity Sugar Unit (5000 TCD)

Sugar (sugar [email protected]%) TPD 575 Molasses TPD 200 4 Products & capacity of industry Press Mud TPD 200 Bagasse Generation TPD 1500 Total Power Plants Capacity (29.5 MW) Co-generation / Spent wash MW 26/3.5 Incineration Boiler

4 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

Molasses based distillery Unit (60 KLPD) R S & IS / ENA & TA /Fuel KLPD 60 Alcohol Fusel oil KLPD 0.18 Grain based distillery Unit (45 KLPD) Rectified Spirit & IS/ENA &TA KLPD 45 Fusel oil KLPD 0.135 DDGS TPD 33 Malt Spirit KLPD 5 Grape Spirit KLPD 5

Distillery CO2 Recovery Plant TPD 50 Cyclodextrin Plant TPD 2.5 IMFL Bottling plant Cases/M One lac Country liquor bottling plant Cases/M Two lac

#. Raw Material Unit Qty Sugar Unit

Sugar cane TPD 5000 1 Lubricant (oil & grease) Kg/d 150 Lime TPD 8 Sulphur TPD 2.50 Power generation Unit

Bagasse for co-gen. unit TPD 1387.20 2 Concentrated Spent wash TPD 175 (55%) for incineration boiler Coal for incineration boiler TPD 138 5 List of Raw Material Molasses based distillery Unit

Molasses (FS- 42%) TPD 243 3 Nutrient Kg/D 60 TRO Kg/D 120 Sulphuric acid Kg/D 90 Grain based distillery Unit

Grains – Maize, jowar, broken TPD 104 4 rice etc ( 68 % starch) Alpha- Amylase Kg/D 56.25 Gluco- amylase Kg/D 56.25 5 Barley for malting TPD 13 6 Grapes for grape spirit TPD 78

During Construction: 200 Nos. 6 Manpower During Operation : 460 Nos. 7 Transportation During Construction – Construction material such as Gravels,

5 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra sand, boulders, bricks etc. will transport to the construction site through covered trucks and lorries. During Operation - Raw materials (sugarcane, molasses, grains, grapes, barley), fuels (coal) will be procured from various locations and transported to the factory through

Lorries/ Trucks. Similarly sugar/alcohol/ CO2 produced in the factory will be transported to various consumers through Truck and tankers. Boiler – 150 TPH – For Sugar & Co-generation Unit Boiler capacity Sugar & Co-gen sugar 8 Incineration Boiler – 35 TPH – For Molasses /cane juice based unit, Distillery unit & grain based Distillery Units Co–gen Boiler (150 TPH), Bagasse – 1387.20 MT/Day Boiler fuel (2,21,952 MT/annum) 9 1. 150 TPH boiler Incineration Boiler (35 TPH), Conc. Spent Wash – 175 TPD 2. 35 TPH incineration boiler + Coal – 138 TPD D.G. Set (500 KVA) – HSD – 65 lit/hr. Item Unit Value Co –gen Unit 10 Steam Generation Steam through 18 MW BP TPH 112.27 Steam through 8 MW DEC TPH 30.50 Distillery Boiler Unit TPH 35

Sr. Particular Steam (TPH) No. 1 Sugar Unit (5000 TCD ) 112.27 Co-generation / Incineration Boiler 2 (Capacity – 26 / 3.5 MW ) Cogeneration – steam to sugar 102.27 2a Auxiliary Unit 10.00 2b Co–gen. – Distillery

3 Distillery Units

11 Steam Requirement Molasses based (60KLPD) (ENA, 3A 13.80 Evaporator & ethanol) Grain based (45 KLPD) 3B (liquefaction, evaporator, dryer, 13 ENA) 4 Malt Spirit (5KLPD) 1.05 5 Grape Spirit (5KLPD) 0.875 3 TPD (alternate 6 CO Plant (50 TPD) 2 day) 7 Cyclodextrin Plant (2.5 MT/day) 6.25 TPD

1. Storage yards for storage of 30,000 Tons surplus Bagasse, 12 Bulk Storage Facility 4,500 Tons coal (one months’ storage) and 12,000 Tons press

6 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra mud (2 months’ storage) and 6292 Tons boiler ash (2 months storage) 2. Sugar godown for storage of 40,000 T of sugar 3. Molasses storage tanks- 3no’s, each of 7500 T capacity 4. Grain storage system- 3000 T 5. Ethanol storage tanks-12 no’s, both for molasses and grain based distillery units-total 6,300 m3 capacity 6. For concentrated spent wash storage tank- 1 no., impervious in nature, for 15 days storage – 2187.50 Cu.M. 7. Water reservoir- 10,000 Cu.M. 1. For 150 TPH boiler: ESP & 58 m stack 13 APC measures for boiler 2. For 35 TPH spent wash boiler: ESP and 70 m stack Turbine Capacity & Type – 14 Turbine for Co- Gen 1. 18 MW – Back Pressure 2. 8 MW – Double Extraction cum condensing

Sr. No. Particular Power 1 Co-gen Unit capacity 26 MW 2 Cogeneration- power to sugar unit 5 MW 2a Cogeneration- power to grid 20 MW Spent wash based Co gen. Capacity 2b 3.50 MW for Distillery units 3 Distillery Units

Molasses based (60KLPD) (ENA, 3A Evaporator & ethanol) Grain based (45 KLPD) 2.8 MW 15 Power Requirement 3B (liquefaction , evaporator, dryer, ENA) 4 Malt Spirit (5KLPD) 150 KW 5 Grape Spirit (5KLPD)

6 CO2 Plant (50 TPD) 450 KW Cyclodextrin Plant 7 75 KW (2.5 MT/day) IMFL Bottling plant 8 40 KW (One Lac cases/Month) Country liquor bottling 9 60 KW (2 Lac cases/ Month)

Exportable power from co-gen sugar Season: a) Power generation capacity: 26 MW 16 power unit b) Exportable Power : 20 MW Fresh water requirement Source: Sina 1.5000 TCD Sugar plant & Co-gen Unit : 517.44 m3/day 17 Kolegaon Dam & Mangi Talav 2.Molasses based (60 KLPD ) (ENA, Evaporator & ethanol) & (1812.44 Cu.M/day) Country liquor bottling plant (2 lac cases/month) : 517 m3/day

7 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra 3.Grain based (45 KLPD) (Liquefaction, evaporator, dryer, ENA) & IMFL Bottling plant (one lac cases/ Month ): 406 m3/day 4. Malt Spirit based (5 KLPD) : 75 m3/day 5.Grape spirit based (KLPD) : 60 m3/day 3 6.CO2 Plant (50 TPD): 12 m /day 7.Cyclo dextrin plant (2.5 MT/day): 25 m3/day 8. Domestic Use – 200 m3/day 1. Sugar unit: Primary clarifier & two stages ASP (Activated Sludge Process) treated to irrigation standards. 18 Effluent Treatment facility 2 Distillery units: Spent wash concentration in evaporator and then mixed with Bagasse/husk and utilization as fuel in boiler. 19 Project cost Rs. 305.86 Crores Investment towards pollution control & 20 Rs. 12.95 Crores environmental protection measures a) Sugar industry: 5(j) – B Category of project according to EIA b) Molasses/ Cane Juice based Distillery Unit (60 KLPD) & 21 notification dated 14th September 2006 Grain based Distillery Unit (45 KLPD): 5(g) – A and as Amended? c) 29.5 MW cogeneration Plant: 1(d) – A

4.0 DESCRIPTION OF THE ENVIRONMENT

Description of the existing environment conditions for the study area with respect to prominent environmental attributes. The data was collected from both primary and secondary sources. Primary data was collected through environmental monitoring & survey in the study area. The environmental influence due to the project is likely to be restricted to 10 km region around the factory site which covers 28 villages. Proposed site area covers the 10 KM radial study area in Survey of India (SOI) toposheet no. 47 J. The studies were conducted during the post-monsoon period of the 1st Dec 2014 – 28th February 2015.

4.1 Baseline Environment

The Region enjoys a tropical monsoon climate, the hot scorching summer from March onwards yet to the rainy monsoon in early June. Seasonal variation in temperature quite large from March onwards is a period of continuous increase in day temperature, the night remaining cool. Relative Humidity is Moderate to dry. The climate of Karmala is characterized with hot summers and dry winters. The cold season which last to February, the air is dry and invigorating. It is too hot in summer. Karmala summer highest day temperature is 42.30C.The Mean Maximum and Minimum temperature of Karmala Taluka is 37.780C and 17.810C respectively. Annual Rainfall for the year 2014 is 384.6 mm.

8 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra Table 4.1: Summary of Sampling Sr. No. Particulars No. of stations Parameters Frequency 1 Surface Water 8 33 Once in study period 2 Ground Water 8 31 Once in study period 3 Ambient Air 8 5 Twice in a week, 12 weeks 4 Ambient Noise 5 1 Once in study period 5 Soil 5 22 Once in study period

4.2 Air Environment The meteorological data was collected at the site by installing an automatic weather monitoring station (AWS) during study period (1st December 2014 – 28th February 2015). It shows that predominant wind direction is North (i.e. South to North). During study period maximum wind blow 4-6 Kmph from NNE, NE, East and SE directions. In study period, 20.7 % calm wind found.

Table 4.2: Description of Ambient Air Quality Monitoring Stations

Name of Distance in Km w.r.t Direction w.r.t Project Sr. No. location Project Site Site 1 Project site 0 0 2 Pande 2.4 SE 3 Mangi- 8.4 NW 4 Bhalewadi 7.0 NE 5 Deolali 5.6 SW 6 Pothare 5.3 N 7 Karmala 2.5 NW 8 Gulsadi 6.6 S

9 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra Table 4.3: The monitored values are within the limits specified by MoEF (as per the notification dated 16th November 2009 for industrial, residential & rural areas).

3 3 3 3 3 PM10 (µg/m ) PM 2.5 (µg/m ) SO2(µg/m ) NOx (µg/m ) CO (mg/m ) 98 98 98 Location Min Max % Avg. Min Max 98 % Avg. Min Max 98 % Avg. Min Max % Avg. Min Max % Avg. At plant site 35.4 47.2 46.96 41.4 11.3 19.3 19.14 15.08 3 7 6.92 4.80 11.2 15.2 15.12 13 0.11 0.22 0.218 0.157 Pande- 43.5 49.8 49.67 46.68 12.4 18.7 18.57 15.67 3 7.8 7.704 5.16 11.1 15.9 15.80 13.26 0.118 0.286 0.283 0.187 Mangi 44.4 51.8 51.65 47.52 13.7 19.7 19.58 16.54 3 7.5 7.41 5.20 11.5 15.9 15.81 13.61 0.12 0.289 0.286 0.194 Bhalewadi 45.5 53.8 53.63 49.45 15.3 22.2 22.06 19.04 4 7.8 7.724 5.67 13 16.9 16.82 14.65 0.152 0.298 0.295 0.21 Deolali 44.5 55.8 55.57 49.71 10 19.9 19.70 14.5 3 6.7 6.626 4.60 16.5 20.1 20.03 18.02 0.101 0.22 0.218 0.153 Pothare 48.1 55.2 55.06 52.02 13.5 20.8 20.65 17.54 3 7.5 7.41 5.16 13.1 17.7 17.61 15.3 0.227 0.31 0.308 0.268 Karmala 51.4 61.8 61.59 55.37 16.4 29.5 29.24 23.14 13.5 18.2 18.106 16..0 13.8 20.7 20.56 17.31 0.253 0.303 0.302 0.276 Gulsadi- 43.5 49.8 49.67 47.17 12.6 19.5 19.36 16.73 3 6.1 6.038 4.20 9.6 12.9 12.83 10.9 0.108 0.268 0.265 0.188

The existing ambient air quality status (AAQ) has been monitored for PM10, SO2 and NOx at each station at IST 8.30 hr. and IST 17.30 hr as per

the approved methods of Central Pollution Control Board (CPCB). In general, the average values of Particulate Matter PM10 & PM2.5 ranging from 3 3 3 3 41.4 g/m to 55.37 g/m and 23.14 g/m to 14.5 g/m respectively which is within NAAQ. The monitored values of ambient gases SO2, NOx and CO average, in the 10 Km radius of the proposed project remain at 16.27 g/m3 to 4.20 g/m3 , 18.02 g/m3 to 10.9 g/m3 and 0.276 mg/m3 to 0.153 mg/m3 respectively. Hydrocarbon concentration found below detection level.  Mathematical Modeling Prediction of impacts on air environment has been carried out by employing a mathematical model. In the present case, Industrial Source Complex Short – Term (ISCST3) dispersion model based on steady state Gaussian plume dispersion, designed for multiple point sources for short term has been used for predicting the ground level concentrations. The computations deal with major pollutants like Sulphur dioxide and Suspended Particulate Matter and Oxides of Nitrogen.

10 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

The predicted incremental Ground Level Concentrations (GLCs) for PM10, SO2 and NOx likely to be contributed by the proposed plant are presented in Table – 5.7

The maximum incremental GLCs due to the proposed project for PM10, SO2 and NOX are superimposed on the maximum baseline PM10, SO2 and NOx concentrations recorded during the study period in the downwind direction to arrive at the likely resultant concentrations during the same period after implementation of the proposed project. The cumulative concentrations (baseline+ incremental) after implementation of the project are tabulated in Table-5.1. The isopleths for pollutants PM10, SO2 and NOx are presented in Figure – 5.2 to Figure – 5.3

4.3 Noise Environment A sound level meter was used for measuring the noise level at one hour interval continuously for 24 hrs at 1.5 m above ground level for 5 stations. The noise levels in the study area vary between 33.12 – 45 dB (A) during night time & 36.56 – 51.93 dB (A) during day time. It has been observed that the maximum noise levels at all the locations are within the limits specified for residential areas. Refer Annexure XVI for Noise Level Monitoring Report.

3.4 Water Environment Water parameter analyzed as per the procedure specified in standard methods for examination of water and wastewater published by American Public Health Association and Bureau of Indian Standards (APHA/BIS). The water requirement for the proposed integrated sugar complex will be sourced from Mangi Lake & Sina Kolegaon Dam. The physico -chemical quality of the surface and ground water sources (8 stations each) at and around the plant site have been analyzed, which indicates that almost all the parameters except total hardness in case of ground water (as CaCO3) analyzed are within “Maximum Acceptable Limits As per IS: 10500-2012. Refer Annexure XVI for Surface water and Ground water Quality Monitoring Reports.

4.5 Land Environment Karmala Taluka falls under Western Zone of Solapur District. Shallow and poor type of soil, not retentive of moisture marks this part. Region shows Scanty and uncertain rainfall. The agriculture land in Karmala Taluka is 525 Sq. Km. which is 33 percent of the total geographical area. Karmala Taluka is noted for jawar, sugarcane, groundnut, safflower, wheat, maize, gram, bajara, and tur and fruits combination.

4.6 Socio – Economic Environment The information collected from the secondary sources is from the district census statistical hand books 2001. The Study area covers total 28 nos. of Villages. Total Population of the study area is found to be 58457, out of which 30245 no. of male (51.73%) and 28212 no. of female (48.27%). The sex ratio of the study area on an average has 925 females per 1000 males. Population Density area works out to about145 persons per km2. The literacy rate found 62.10% of total population in the study area. SC and ST Population observed as 15.54% and 1.58% respectively of total population in the study area. Workers (Main & Marginal) observed 46.71% of the total population in the study area and Non Workers (include students, house wives, and children above 6 years also) 53.30% indicating that the problem of unemployment in the region.

11 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra 4.7 Ecology There is no endangered species of flora and fauna noticed in this area. The area does not shelter any specific wildlife. The study area mostly comprises of un-urbanized area. The area includes few villages comprising of agricultural and barren land where most of the vegetation is aggregated on agricultural bunds and open area. Apparently it is covered by vegetation of Kadu Neem, Teak and Acacia species. The agricultural land in the study area, mainly cultivation is sugarcane, bajara, jawar, groundnut, maize etc. The faunal species found in the study area are of domestic type such as cow, buffalo, and cattle.

5.0 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURE Prediction of impacts depends on the nature and size of activity being undertaken and also on the type of pollution control measures that are envisaged as part of the project proposal. However, the good management practices would be followed to ensure that the environmental pollutants concentrations remain within the limits. The proposed plant may cause impact on the surrounding environment in two phases.  During construction phase  During Operation phase

5.1 Social Aspects • This project is very necessary in view of production of sugar, power generation especially renewable power, producing Ethanol, a useful foreign exchange saver. • The candidate site is suitable from availability of water, power, raw material, Filler Material and Market is assured. • Full precautions for Pollution Control, Resource Conservation and Environmental Protection • The project will generate employment opportunities during operational phase. • The standard of living of local people due to employment is likely to be better, so we may say that it is positive socio-economic impact. • Farmers will get better price to their produce. • This is cost effective and Sustainable Development.

6.0 ALTERNATIVES FOR TECHNOLOGY & PROJECT SITE Any proposed human activity is never a simple straightforward matter. A number of decisions are required to be taken and for each step a number of alternatives are available. Selection is thus all the more critical in an industrial development where time, money and natural resources are in stake. Although the present case is not a production of such chemicals, pharmaceuticals, pesticides etc. which will threaten by mammalian toxicity and toxicity to fish, VRSL decided to undertake an Alternative Analysis (AA) for this project. The various alternatives were:

 Raw Materials  Technology  Engineering & hardware  Site  No Project

7.0 ENVIRONMENTAL MONITORING PROGRAMME The environment, safety and health-monitoring programme in the factory shall be implemented as follows:  Regular monitoring of stack emissions  Daily monitoring of water and wastewater  Quality monitoring of ambient air, noise and work place air  Monitoring of occupational safety

12 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

The project management, being aware and conscious of its responsibilities to environment, is committed that the project operations will be made keeping in line with the internationally accepted sustainable measures/practices and methods thus leaving negligible adverse impacts on any segment of environment due to proposed activity.

8.0 ADDITIONAL STUDIES

8.1 RISK ASSESSMENT An industry with its complex nature of activities involving various plant machineries, raw materials, products, operations, intermediates and environmental discharge has a number of associated hazards. A minor failure can lead to major failure resulting into a disaster causing heavy losses to life, property and environment. Risk assessment studies are being conducted to ensure safety and reliability of any new plant, through systematic and scientific methods to identify possible failures and prevent their occurrences before they actually cause disasters and production loss.

8.2 FIRE FIGHTING FACILITIES IN ETHANOL PLANT 8.2.1 Possible Fire Hazards  Fire in fuel/bio-mass storage yard.  Fire in alcohol storage tanks electric, static electricity and consequent fire accident.

8.2.2 Fire Fighting Facilities a. Water hydrant system b. Fire extinguishers c. Fire protective appliances d. Fire brigade facilities available at Karmala will be utilized whenever need arises.

8.3 DISASTER MANAGEMENT PLAN (DMP) A comprehensive DMP that will be implemented in the industry as presented below.

8.3.1 Objectives • To localize the emergency • To minimize the consequences • To ensure that following concepts are considered, namely rescue, first aid, evacuation, rehabilitation, spreading the information.

8.3.2 Elements of On-Site Emergency Plan  Assess the size of event  Plan formulation and liason  Actions like: Raise alarm, communication within and outside  Appoint key personnel and deploy. Appoint Controller.  Emergency Control Center  Action on site  Action off-site.  Alarm and visual signals at strategic points, first alert sent to Incidence Controller.

13 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

9.0 PROJECT BENEFIT Proposed integrated sugar complex will result in considerable growth of stimulating the industrial and commercial activities in the Karmala tehsil of Solapur district. VRSL will be beneficial in reducing the existing and ever escalating demand of electricity to some extent.

In operation phase, the proposed plant would require considerable work-force both technical and non- technical persons. Migration of experienced persons with better education will result in increase of population and literacy in surrounding villages.

 Improvement in the Physical Structure  Improving the Economy of Farming Community  Improvement in the Social Infrastructure  Employment Potential

10.0 ENVIRONMENTAL COST BENEFIT ANALYSIS

In proposed integrated sugar complex, various environmental cost beneficial techniques will be used for water conservation, to improve performance of sugar plant, co-gen power plant.

11.0 ENVIRONMENTAL MANAGEMENT PLAN

11.1 CORPORATE ENVIRONMENTAL POLICY (CEP) VRSL commit to improve our Environmental Management System and minimize the impact of our manufacturing activity on the environment, on continual basis, by:  Complying with applicable environmental laws and regulations,  Establishing systems and processes which minimize /prevent pollution and foster conservation of resources.  Improving efficiency of all the operations through our proactive efforts in environmental management and incorporating cleaner technologies in the projects.  Establishing objectives and targets and the review of policy.  Enhancing the skills and competence of our employees to ensure sound environmental management.

VRSL will be set up a high power watch dog committee which will have a power of sudden spot inspection, checking of documents and listening of complaints if any. This committee will supervise over the monitoring and environmental management cell as may be necessary, generally over the following facets of works: 1. Permit management 2. Construction management 3. Treatment and emission management 4. Transport management 5. Disposal management 6. Monitoring

11.2 EMP for Construction Phase

Increase in PM10, Sulphur di-oxide (SO2), Oxides of Nitrogen (NOx), & Carbon Monoxide (CO) levels in environment due to construction activities and movement of vehicles. Frequent water sprinkling in the vicinity of the construction sites will be undertaken. During construction phase SVSSKL will be taken care to provide all necessary facilities to construction workers such as water supply, sanitary facilities, temporary housing, sewage treatment facilities, drainage facilities and domestic fuels; to nullify adverse

14 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra impact on environment. The impacts will be localized in nature and the areas outside the project boundary are not likely to have any major adverse impact with respect to ambient air quality.

11.3 EMP for Operation phase

11.3.1 Air Environment

 The major pollutants from boilers during operation phase are PM10 & PM2.5, SO2 (Sulphur dioxide) and NOx (Oxides of Nitrogen).These pollutant will be nullify by adopting following measure.  Stack emissions will be regularly monitored by SVSSKL/external agencies on periodic basis to check the efficiency of air polluting control devices and necessary action.  To control of the airborne fugitive emissions from the ash handling area will be achieved through regular water sprinkling in this area.  Avenue plantation and green belt development will be undertaken in the operation phase.  The air pollution generation from the proposed project is given in table below:

Table 11.1: Air Pollution generation & its mitigation measures

Sr. No. Area of Operation Air Pollution Mitigation Measures 1. Boiler – 150 TPH Stack height – 60 M, As per CPCB with ESP 2. Incineration Boiler – 35 TPH Stack height – 70 M, As per CPCB with ESP 3. D.G. Set (1000 & 500 KVA) Adequate stack height will be provided as per CPCB norms

11.3.2 Noise Environment  All rotating items will be well lubricated and provided with enclosures as far as possible to reduce noise transmission. Vibration isolators will be provided to reduce vibration and noise wherever possible  Manufacturers and suppliers of machine/equipment like compressors, STG turbines and generators will be manufactured as per OHSAS/MoEF guidelines.  The personnel safety such as ear muffs, ear plugs and industrial helmets shall be provide to workers which act as noise reducers

11.3.3 Water Environment The total fresh water requirement for the proposed activity will be 1812.44 m3 /day. And waste water generation will be 765 m3/ day. The continuous efforts will be made to reduce the water consumption and thereby reduce wastewater generation. Flow meters will be installed on all major water inlets and the flow rates will be continuously monitored. Periodic water audits will be conducted to explore the possibilities of minimizing water consumption. The wastewater generated from the different units such as cooling tower blow down, boiler blow down, DM plant, sugar process unit waste and sanitary waste of proposed activity shall be treated in ETP having capacity 1000 m3/day.

Effluent Treatment  The effluents generated from sugar unit, co-gen, distillery and other auxiliary units are treated in an ETP Comprising of anaerobic digestion followed by aeration system Treated effluent will be recycled / reused within factory premises.  The RO plant will be installed in the Sugar & co-gen power plant. After RO treatment, the DM water will be used in Boiler. RO reject water is send to Kardali plantation.  The spent wash from molasses based distillery will be concentrated in Multiple Effect Evaporators and incinerated in incineration Boiler (35 TPH) to achieve zero discharge.  Domestic effluent will be treated in Soak Pit & Septic Tank will be provided at the site.

15 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra Storm Water Management The Integrated sugar complex water management system will be designed to minimize the potential for storm water contamination occurring at the site. This will be achieved by incorporating the following features into the storm water management system:  Run off from upstream areas will be diverted around the plant site;  The quantity of contaminated run off generated will be minimized by diverting run off from areas external to the plant to storm water discharge points.  Hazardous material and fuel storage areas will be bunded and drains will be provided around these facilities to prevent entering of runoff water ; and  Runoff from area external to process areas of the plant will be contained within a storage system.

11.3.4 Solid Waste Management Table 11.2: Details of solid waste generation Sr. No. Particular Solid waste ETP sludge – 325 Kg/day 1 Sugar 5000 TCD Oil & grease recovery – 146 Kg/day 2 Co-generation Unit (Cap.- 26 MW), DECC Bagasse Ash-20.81 MT/day * Coal and spent wash Ash from Incineration 3 Distillery Co-gen Unit (Cap 3.5 MW, ECC) boiler-84.06 MT/day 3 Distillery Molasses based (60KLPD) (ENA, 3A * Yeast sludge from molasses distillery – 15 Evaporator & ethanol) MT/day Grain based (45 KLPD) 3B * Distillery ETP sludge – 250Kg/day (liquefaction , evaporator, dryer, ENA) 4 Malt Spirit based (5KLPD) Residue as cattle feed –3.90 MT /day Grape residue for composting – 19.5 MT 5 Grape Spirit based (5KLPD) /day 6 Cyclodextrane Plant (2.5 MT/day) Grain residue as cattle feed 750Kg/day

Solid by-products such as bagasse, press mud and molasses are generated as process co- products (byproducts) from the industry. Press mud is supplied to member farmers for their used as bio–manure and molasses is used in own distillery for its use as raw material in manufacture of ethanol. Bagasse produced from the sugar factory is used as a fuel in the boilers for production of process steam. Solid wastes such as boiler ash & ETP sludge are also produced from the proposed unit. These are disposed to farmers for their use as soil conditioner in agricultural field. For siting of an activity, “Delphi Technique” is advised by MOEF. The Government of India has recommended this technique in the book on Siting of Hazardous Waste Disposal Areas prepared by NEERI, Nagpur and published by the Ministry of Environment and Forest (MOEF) in 1991. The same is proposed to be used with due improvisation, mutatis mutandis, covering other media of environment.

11.3.5 Occupational Health & Safety During operation stage, dust is the main health hazard. Other health hazards are due to gas cutting, welding, noise and high temperature and micro ambient conditions especially near the boiler and platforms which may lead to adverse effects (Heat cramps, heat exhaustion and heat stress reaction) leading to local and systemic disorders.  Adequate arrangements for preventing generation of dust by providing the chutes at transfer points to reduce the falling height of material, preventing spillage of material by maintaining the handling equipment, isolating the high dust generating areas by enclosing them in appropriate housing and appropriately de-dusting through high efficiency bag filters

16 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra  All workers engaged in material handling system will be regularly examined through PFT (Pulmonary Function Test) tests for lung diseases.

11.4 Ecology Flora and fauna inventories within the project area will be monitored on a twice yearly basis, as well as before and during the construction and early operating activities. This may involve the use of specific indicators, such as the occurrence of nests or nesting bird species of importance. It is intended that the implementation of the monitoring program will be conducted on a co-operative basis by the various stakeholders in the area

11.5 Green Belt Development The total plot area is 110 acres (~44Ha). The green belt will be developed to the tune of 37.45 Acres (14.98 ha). There under, about 8000 no. of trees will be planted.

11.6 Budgetary Provision for Environmental management plan  Cost of EMP is Rs. 1295.25 Lakh.  A Total capital & recurring cost EMP are presented below: Table 11.3: Details of Capital Cost and Recurring cost Recurring Cost, Rs Sr. No. Description of Item Capital Cost, Rs Lacs Lacs/ annum 1 Electrostatic precipitators 500 15.00 2 Stacks 170 3.00 Effluent treatment plants (ETP), Sewage 3 450 12.50 collection, treatment & disposal (STP) 4 Fire fighting system 75 2.25 5 Noise Abatement 0.25 0.10 Env. Lab equipment & on line 6 50 5.00 monitoring system 7 Rain water harvesting 15 4.50 8 Green Belt Development 35 5.00 Total 1295.25 47.35

12.0 CONCLUSION This industry will provide sugar, power as useful material for India, which will save foreign exchange in these days. This will not disturb the present land use because our area occupied will be only small % of Influence zone 10 km. Compatible Architecture will be adopted and No Prime Agriculture Land will be put to this industrial use. Trees will be maintained and not razed down. No Rehabilitation is involved. The problematic waste materials of sugar mills like molasses, press mud and bagasse will be utilized within the existing project. People will get some jobs here and the sugar, power and organic compost generated here will be useful for farming and some incidental small employment like eatery, canteen, tyre repairs, and garage too will become available to genuine people. This will be beneficial to the society. Due to this project, farmer will get more prices for sugarcane.  This project is very necessary in view of converting waste bagasse, molasses into useful steam, power and foreign exchange saver product.  The local people desire that this industry will be welcome in their area.  The candidate site is suitable from general MoEF expectations.  Water, power, Raw material and Market is assured and found available with ease.  Full precautions will be taken for Pollution Control, Resource Conservation and Environmental Protection.  This is cost effective and Sustainable Development.

17 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

CHAPTER-1 BACKGROUND

1.1 BRIEF DESCRIPTION OF THE PROJECT PROPONENT i. This is a proposal to establish a modern Integrated Sugar Complex by M/s Vitthal Refined Sugars ltd. (VRSL) located A/p- Pande, Tal- Karmala, and Dist- Solapur, in Maharashtra state. The proposed Sugar complex consists of Sugar unit (5000TCD), Co-generation (29.5 MW), Distillery Units (Molasses based- 60 KLPD & grain based- 45 KLPD), Malt spirit & grape spirit (Each-5 KLPD), Carbon-di-oxide recovery plant (50 TPD), Cyclodextrin (2.5 TPD), IMFL (1Lakh cases/Month), Country liquor (2Lakh cases/Month).

VRSL is a Public Limited Company registered under the Companies Act, 1956 (No.1 of 1956) on the 4th February 2010 with Corporate Identity Number- U15421 PN2010PLC135465. Its mailing address is Vitthal Refined Sugars Limited, A/p – Nimgaon, Tal – Madha, Dist – Solapur 413 208, Maharashtra, India

Its Board of Directors is as follows –

 Mr. Vikramsinh Babanrao Shinde, Chairman  Mr. Santosh Vyankatesh Garad, Director  Mr. Nitin Dattatray Shinde, Director

Chairman of the Board of Director is a most experienced person and entrepreneur of the Solapur district. He is a sitting Director of Vitthalrao Shinde Sahakari Sakhar Karkhana Ltd., Tal- Madha, Dist- Solapur (Maharashtra). Also he was a Director of Indian Sugar Mfg Co Ltd for a period of 5 years. The day to day management of the company (VRSL) shall be looked after by Shri. Vikramsinh B. Shinde with the due consultation of other Board members.

The team of VRSL shall be working under the most able guidance. VRSL is in the process of appointing technical / managerial team of qualified engineers, contract & arbitration experts, agricultural officers and managerial personnel for implementation and operation of the proposed integrated project.

The team members have wide experience of setting up of primary credit societies, Educational Institutions, operating co-operative banks and financial institutions.

There are number of sugar units attached with Co-generation and distillery in Maharashtra State. However, it is will of top management of VRSL to take environment challenges seriously as far as molasses based distillery project is concerned. Specific areas in which efforts are needed are-

 Improvement of process efficiency and product quality  Effective utilization of waste materials  Emphasis on process cost reduction  Monitoring and Controlling pollution  Technology up gradation  Process control by Instrumentation and computers and more importantly converting sugarcane in to sugar, by–products/wastes such as bagasse in to co-generation, molasses in to useful alcohol, press

18 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra Mud as soil conditioner, Carbon-di-oxide recovery and make use of it for industrial purposes, rectified spirit and extra neutral alcohol for Indian Made Foreign Liquor (IMFL) and Country liquor (CL) respectively. The Sholapur district is famous for jawar and other cereals as well as for grapes and therefore it is proposed to go for grain based distillery and grape and malt spirit.

The VRSL will continue their efforts in making the proposed VRSL plant IDEAL with state of Art Hardware and same responsible working as other enterprises of the Chairman’s’ group.

1.2 BRIEF THOUGHTS ON PROJECT

Government of India stated in the World Conference at Rio that India has 16.1 percent of world population to be supported on only 2.3 % of the global land mass, on a background of low per capita income and low energy reserves. Designers of the five-year plans of India have been struggling hard to meet the gap of essential commodities, and balance of Foreign Exchange. Man needs sugar, electricity as well as ethanol for day to day production of downstream industrial chemicals, also for potable and medicinal usages and potentially as petrol additive to oxygenate replacing tetra ethyl lead. Government of India has already taken steps to blend 10 per cent ethanol in petrol all over country.

Learning from experiences from the West and from their own Co – operative units, VRSL management has taken initiatives to undertake,” Production with zero discharge and conversion WASTE IN TO WEALTH.

VRSL has already obtained various Permits/NOC such as –

 Certificate of Incorporation of Company  Industrial Entrepreneurial Memorandum (IEM) from Govt. Of India, Ministry of Industry, New Delhi  Sale Deed and Lease of land  NOC from Local body/Gram Panchayat  Building Plan(Planning Phase)  Consent to Establishment for Sugar and Co-gen power plant and Distillery Units

VRSL has made SWOT Analysis and finds the overall summation encouraging. The SWOT (Strength, Weakness, Opportunity and Threat) analysis is made as follows-

 Strength Raw materials (Sugarcane, grains) are available in Tahsil/District. Surrounding areas good Agro –climatic zone. Area comes under traditional Cane & cereals growing area. Good Market potential in State in general and in India particular. Treated as priority sector project Government appreciates this venture which is in rural backward area/region.

 Weakness Medium sugar recovery compared to western Maharashtra (Kolhapur region of Maharashtra) occasionally may not be able to pay optimum price to the farmers in the initial years as compared to existing well established units in Kolhapur region.

 Opportunities Bringing an Integrated Sugar Complex project for the benefit of farmers of the surrounding area

19 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra Use of waste residuals for downstream benefits

 Threats Competition from existing units as regards to cane pricing Changes in Government policy Non availability/ less availability of raw material, a possibility due to drastic climate changes

All this goes to suggest that the Project Proponent has made a serious homework and have seen that the environmental impact will be minimal.

1.3 JUSTIFICATION AND NEED OF THE PROJECT : The man is struggling for growing needs of mankind, which is compounded by the continuously increasing world population. This is in every field of consumer goods, food, additives, energy etc. The sugar requirement is increasing in proportion to population of country as well as world. According to FAO Report, 4% growth in sugar consumption is expected. The Government policy is also favorable. The sugar cane crop has been in growth mode till date though there has been a fluctuation.

Bagasse is used as captive fuel in the mill as power. Most efficient as well as balanced mills should be able to save bagasse to the extent of 10% of its production. The potential for co-generation and export of power to the grid after meeting mills own requirement of energy is estimated by expert bodies, at 7000 MW (650 Sugar mills). India has not exploited its huge potential like other countries like Hawaii, Mauritius etc. where co-generation of power from sugar mills has become a dependable source for supply of power.

Producing alcohol for various downstream chemicals (like ethyl acetate, ethylene oxide, butanol, vinyl acetate monomer, ethylene glycol, styrene etc.) for potable (IMFL & CL) and medicinal liquor and for admixing ethanol in petrol. The objective of power alcohol ethanol is best summarized in a paper published by Hon’ble Ram Naik, the ex- union petroleum Minister, GOI. According to him, this type of plant is likely to be more viable in view of present situation , when sugar has low demand in the market, molasses is an environmental risk (of pollution and auto-combustion) and ethanol has a foreign saving potential. In brief the objective of ethanol project is:

1. To help Indian citizens to have a useful petrol additive, ethanol 2. To make optimum utilization of natural resources 3. To incorporate modern state – of – art gadgets for production, waste minimization and pollution control. 4. To keep the work environment healthy for the workers with periodic checks. 5. To keep the external environment safe. 6. To make provisions of pollution control expected right from the project proposal stage itself.

1.4 BRIEF SUMMARY OF THE PECULIARITIES –

 The first peculiarity is this, that the project Management has made a provision of about Rs 12.95 Crores of their capital outlay for pollution control and greening drive in the outset itself.  The existing sugar factories from Karmala Tehsil (3 in number) have a crushing capacity of 7500 TCD and can crush annually about 15 lakh tons. The area under sugarcane in Karmala Tehsil is 38800 ha. Considering 100 MT/ha sugarcane yield, the cane availability is more than 38 lakh tons indicating that there is no problem of sugarcane for this proposed factory.

20 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra  The quality of cane will be excellent and brought to mill within few hours so as to minimize the inversion of sugar.  The optimum efficiency will be maintained in every process of sugar production, generation of electricity and alcohol production based on both molasses and grain as raw materials.  Selection of correct quality molasses is possible because in addition to our own molasses, there is one other unit namely M/s Babanrao Shinde Sugar & Allied Industries Ltd, A/p – Turk- Pimpari, Tal – Barshi, Dist- Solapur (5000 TCD, Molasses @ 4% of cane crushed) in reachable distances who agreed to provide molasses as this unit does not have distillery unit. Thus molasses availability no problem. Solapur District and especially Karmala and adjoining tahsils are known for sorghum (Hybrid jawar) and therefore availability of grains for grain based distillery is no problem.  Waste heat (exhaust steam) and waste water (hot condensate and treated effluent) too is reused/recycled

1.5 SUGAR INDUSTRY SCENARIO IN SOLAPUR DISTRICT There were 32 sugar units in Solapur district which were in operation during crushing season of 2014-15. The details are-

Table 1.1 Sugar Factories & cane crushed in Solapur District (Season 2014- 2015, Up to May 5, 2015) Name of Sugar Unit & Co-op./ Cap./Day Cane Sugar Sugar Sr. No. Taluka Private TCD crushed Production Recovery, % Lakh MT ton 1 Sahakar Maharshi , Akluj Co-op. 7500 14.85 1,67,540 11.28 2 Shankar, Malshiras Co-op. 2500 4.339 45,885.50 10.57 3 Shidheshwar, Solapur Co-op. 5000 9.41 99,475 10.57 4 Vitthal, Pandharpur Co-op. 5000 10.219 1,08,695 10.57 5 Bhogavati, Barshi Co-op. 1250 Not in operation 6 Bhima-Takli, Pandharpur Co-op. 5000 6.07 67,873 11.18 7 Pandurang, Malshiras Co-op. 4500 10.983 120,849.5 11.00 8 Sant Damaji, Mangalvedha Co-op. 2500 5.637 63,235 11.22 9 Adinath, Karmala Co-op. 2500 4.3697 46,420 10.62 10 Sangola Taluka, Sangola Co-op. 2500 Not in operation 11 Swami Samarth, Akkalkot Co-op. 2500 2.86 28,300 9.90 12 Chandabhaga, Pandharpur Co-op. 2500 5.507 58,345 10.59 13 Vithalrao Shinde, Madha Co-op. 8500 17.56 1,95,000 11.10 14 Makai, Karmala Co-op. 2500 3.019 32,310 10.70 15 Kurmadas, Madha Co-op. 2500 2.002 21,035 10.51 L.B.patil Agro India, 16 Co-op. 2500 7.965 87,450 10.98 Mohol 17 Saswadmali, malshiras Private 3500 5.674 63,275 11.15 18 Lokmangal Agro, Solapur Private 2500 3.791 39,580 10.44 19 Vitthal Corporation, Madha Private 3500 5.905 62,405 10.57 20 Sidhanath Sugar, solapur Private 2500 7.153 75,895 10.10 21 Jakraya Sugar,Mohol Private 2500 5.441 59,760 10.98 22 Bhairavnath Sugar2karmala Private 2500 5.89 59,630 10.12 23 Indreshwar Sugar, Barshi Private 2500 5.89 61,433 10.43 24 Aryan Sugar, Barshi Private 2500 1.38 12,622 9.14 25 Matoshri Lakshi ,Akkalkot Private 3500 6.043 71,072 11.76 26 Vijay Sugars, Pandharpur Private 2500 4.113 41,474 10.08 27 Lokmangal Sugar, Solapur Private 6000 9.129 93,540 10.25 Sitaram Maharaj, 28 Private 2500 3.503 37,490 10.70 Pandharpur

21 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra Shetkari Chandapuri, 29 Private 2500 2.307 25,591 11.09 Malshiras 30 Fabtech Sugar Mangalveda Private 2500 6.793 76,340 11.24 Ethopian Sugar 31 Private 3500 4.517 48,158 10.66 Mangalveda Bhairavnath Sugar3 32 Private 2500 4.396 40,920 9.31 Mangalveda 33 Shivratna Udyog, Madha Private 2500 2.00 21,435 10.72 Babanrao Shinde 34 Private 5000 2.035 20,920 10.28 Sugars,Barshi High lights of Solapur District (crushing season 2014-15) Sr. No. Particulars Private Co-operative Total 1 No. of Factories in Operation 19 13 32 2 Daily Crushing Capacity, TCD 60,000 55,000 115,000 3 Total Cane crushed in 2014-15, Lakh Ton 94.293 96.827 191.12 4 Total sugar produced in 2014 – 15, Ton 9,98,990 10,54,963 20,53,935 5 Average Sugar recovery, percent 10.59 10.90 10.75 6 Molasses Production @4 % cane crushed , Lakh Ton 7.6648

From the table, it may be seen that there are 3 existing sugar units operating in Karmala Taluka of Solapur district. The availability of cane is no problem. There is very good potential to set up a new unit of 5000 TCD capacity.

Table 1.2: Highlights of Distilleries in Solapur District Sr. Name of Distillery * Daily Capacity, Annual licensed Annual Molasses, No KLPD Cap. Lakh Lit TON @ 250 Lit/Mt 1 Sahakar Maharshi , Akluj 60 180 72,000 2 Shankar, Malshiras 30 90 36,000 3 Shidheshwar, Solapur 20 135 54,000 4 Vitthal, Pandharpur 30 90 36,000 5 Pandurang, Malshiras 45 135 54,000 6 Chandabhaga, Pandharpur 30 90 36,000 7 Vithalrao Shinde, Madha 60 180 72,000 8 Saswadmali, malshiras 30 90 36,000 9 Lokmangal Agro, Solapur 80 240 81,600 10 Vitthal Corporation, Madha 30 90 36,000 Total 415 1320 5,13,600 Highlights 1 Distillery’s in operation(2014 – 15) 10 2 Their Annual Licensed Capacity, Lakh Lit 1320 3 Maximum Annual Molasses Required, Lakh Tons 5.136 *Note- Above distilleries are attached with the sugar mills

The availability of molasses is no problem (Table 1.1 & 1.2) at all as the production of molasses is very much on high side in Solapur district. Moreover, VRSL will receive molasses from one sugar factory namely M/s Babanrao Shinde Sugar & Allied Industries Ltd, A/p – Turk – Pimpari, Tal – Barshi, dist – Solapur ( 5000 TCD, Molasses @ 4% of cane crushed) (Letters for molasses sparing from these industries are attached as Annexure XII)

22 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

1.6 ENVIRONMENTAL POLICY In order to fulfill the promise, an Environmental Policy will be in place and adopted for practice. It reads as –  Prevent pollution in its all activities associated with manufacturing of sugar, co-generation, alcohol (Industrial, Potable & fuel Purpose), IMFL & CL and related various ancillary units.  Continuous efforts to improve the environmental performance.  Comply with environmental legislation and regulations.

These shall be implemented by  Conserving resources such as water, energy (steam & electricity) and other resources through optimum utilization and adopting principles of reduce/reuse/recycle so as to minimize the waste.  Reducing the spillage and fugitive emissions through extensive monitoring.  Training and active participation of employees for development of Clean and Green Environment.

1.7 TRACK RECORDS The Chairman of the proposed project is known for his track record of honest and transparent businesses. He and his team is law abiding and goes much beyond mere obedience to the letters. They go to the spirit of law. The track record of merit and honesty is evident from the various activities the chairman is associated as Director with Vitthalrao Shinde Sahakari Sakhar Karkhana Ltd. (VSSSKL), Tal – Madha, Dist – Solapur (Maharashtra) and Indian Sugar Mfg Co Ltd.

The VSSSKL is working properly and the effluents are treated well. The same good work will be continued with an aim, “Production without pollution achieving Zero discharge in inland surface water” for all the units. Table 1.3: Various activities under Chairman and his Directors Sr. No. Organization Merit Is run professionally and has also shown service to the 1 The local bodies people by cutting red tapes. All the environmental obligations are brought to the notice. Has mentioned an excellent teaching quality and is a centre 2 Educational Institutes of attraction to students and parents 3 The credit societies Is receiving good remarks from Auditors Farmers are trained and they are given all agricultural inputs 4 Agricultural Produce with scientific approach for adoption of innovative agricultural techniques Like sugar, milk collection & its processing. Kept fair 5 Industrial Activity practice, congenial environment and sustainable development. The project proponent will attempt hard to keep the same track record as per earlier units.

1.8 CHAPTER CONCLUSION

The project proponent has a history of social service. VRSL will have integrated Sugar unit, Co–gen unit, Distillery units (Molasses & grain based), IMFL Plant & CL plant, grape and malt spirit plants,

malt dextrin and CO2 Recovery Plant. It proposes to establish a modern state-of- art units at a site, near Pande village, Tal- Karmala, Dist- Solapur and by making full utilization of its capacity wishes to feed the demand in the vicinity. For fulfilling all this, the process of Impact Assessment is undertaken and reported in the following chapters.

23 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

CHAPTER – 2 INTRODUCTION

2.1 OBJECTIVES OF ENVIRONMENT IMPACT ASSESSMENT

Any human activity creates a change in the environment. Whether it is noticeable or marginal depends on a number of factors. There can be a number of situations like – 1) A new industry getting established 2) An existing industry continuing the same production at the same place. 3) An existing industry, establishing a parallel unit at new place 4) An existing industry, under expansion with same product 5) An existing industry under diversification at the same place.

The present VRSL case under discussion is a proposed agro-based green industry, coming under type (1) above. The proponents have good experience for handling industrial activity. All the same, a prior impact assessment must be done with the same protocol and without compromise. This is attempted here keeping the following objectives –

 To know the existing environmental status  To estimate the pollution load  To design preventive and curative steps so that any probable significant impact can be turned insignificant first by control measures and inconsequential next by further mitigation measures.  To superimpose the resultant pollution load on existing environmental conditions due to the proposed activity.  To understand the views of other departments and incorporate measures to fulfill the statutory requirements.  To prepare an environmental management plan (EMP) including monitoring schedule to serve as “Watch-Dog”

2.2 MATERIALS, METHOD AND APPROACH VRSL believes strongly in, “Production without Pollution” and has taken the work of examining the project environmentally.

2.2.1 Material- The work involves three activities VIZ 1) collection of dry data and statistics by literature survey, interviewing the resource institutes and general public 2) Wet studies by sampling and laboratory analysis of ambient air, surface water and ground water, noise, soil etc. and logically analyzing the findings of dry and wet studies for interpretation, extrapolation and inference. A number of offices/officers were contacted in the course of this study. Samples were collected in 2014 – 15 vide Table No. 2.1 Table 2.1: Summary of Sampling

Sr. No. Particulars No. of stations Parameters Frequency 1 Surface Water 8 33 Once in study period 2 Ground Water 8 31 Once in study period 3 Ambient Air 8 5 Twice in a week, 12 weeks 4 Ambient Noise 5 1 Once in study period 5 Soil 5 22 Once in study period

24 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra All the samples were collected by Standard Practices and analyzed as per the Indian Standard Specifications or by APHA (USA).

2.2.2 Method An eleven step sequence model will generally be adopted in this study while covering every facet of environment.

1) To fix up the scope of work (Purpose and need of study) 2) The present human activities within 10 Km radius and prepare environmental inventory (EI). 3) The present environmental status by sampling. 4) Establishing correlation between cause effects of step 2 & 3 above. 5) To know the carrying capacity of environment and to know as to how much more pollution it can absorb, if any 6) Extent of proposed activities in the influence zone and ancillaries especially with respect to pollution 7) How much will be the pollution created by the above said activity, totally after the provision of effluent treatment plant (ETP) and emission control equipments (ECE) 8) Whether the carrying capacity has capability of absorbing the pollution stated at step no.7. 9) What mitigation measures be thought as last line of defense 10) The legal provisions required to be obeyed 11) Probable public acceptability

2.2.3 Approach For a stream-line work, a standard six-step model of working is adopted for this VRSL work. The six generic steps associated with environment impacts are –

1) Identification of pollutants emission and impact concern related to construction and operation of the development work 2) Description of environmental setting in terms of existing environmental quality, emission inventory and natural data in the project study area. 3) Procurement of relevant laws, regulations or criteria related environmental quality and/or pollution emission effluent standards. 4) Conduction of impact prediction activities, including the use of simple dilution calculations, qualitative predictions based on case study and professional judgment. 5) Use of pertinent information from step 3 along with professional judgment and public input to assess the significance of anticipated beneficial detrimental impacts and 6) Identification, development and incorporation of appropriate mitigation measures for the adverse impacts.

2.2.4 Technique For siting of an activity, “Delphi Technique” is advised by MOEF. The Government of India has recommended this technique in the book on Siting of Hazardous Waste Disposal Areas prepared by NEERI, Nagpur and published by the Ministry of Environment and Forest (MOEF) in 1991. The same is proposed to be used with due improvisation, mutatis mutandis, covering other media of environment.

A) The Delphi Technique considered the following 34 attributes and four weight – ages i.e. 7 attributes, receptor related 10 attributes pathway related 8 attributes, pollution related 9 attributes, waste management related

25 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

B) The modified technique used here considers 23 attributes and 4 Weight – ages i.e.- 7 attributes, receptor related 5 attributes pathway related 4 attributes, pollution related 2 attributes, waste management related

1. Four types of marks for each attributes like 0-0.25, 0.25-0.5, 0.5 to 0.75 and 0.75 to 1.0 depending on facts of situations, chemical properties of pollutants and quantification are considered. These marks are known as Sensitivity Index (SI).

2. Combined consideration of 1) and 2) together gives attributes-wise weight-ages. These are the negative marks out of 1000 and ranking of candidate sites is based on comparison of these marks.

2.3 INDIAN ENVIRONMENTAL LAWS

The site selection is taken seriously by many Indian Statutes and Guidelines such as those narrated below.

2.3.1 Environmental Protection Rules, 1986: The Environmental (Protection) Rules, 1986 provides certain frame work on this subject. The parent Act, viz. The Environment (Protection) Act, 1986 in its section 3(V) provides a function as: Section 3(V) - restriction of areas in which any industries, operation or process or class of industries, operations or process shall not be carried out or shall be carried out subject to certain safeguards.

This section is further elaborated by Rule 5:

Rule5: Prohibition and restriction on the location of industries and carrying on of processes and operations in different areas.

2.3.2 Environmental Guidelines A MOEF stipulation for siting of industries is:

1 Ecologically and/or otherwise sensitive area at least 25 Km 2 Coastal areas: At least 0.5 Km from high tide line. 3 Flood plains of the riverine systems: At least 0.5 Km from flood plain 4 Transport/Communication System: At least 0.50 Km from highway & railway. 5. Major Settlements (3 Lac population): Considering urban sprawl, at the time of siting of the industry if any notified limit of any major settlement is within 50 Km, the spatial direction of growth of the settlement for at least a decade must be assessed and the industry shall be sited at least 25 Km from the projected growth boundary of the settlement.

2.3.3 Coastal Regulation Zone(CRZ): A notification No. S.O. 114 (E) is published on 19th Feb 1991 under the Environment (Protection) Act and Rules, 1986. It is influenced by tidal action (in the landward side) up to 500 M from the high tide line (HDL) and the land between Low Tide Line (LTL) and HTL as CRZ.

2.3.4 Hazardous Site Guidelines: Goals for siting the proposed facilities should be to: 1. Minimize health risk

26 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra 2. Minimize adverse environmental impacts 3. Minimize the costs, and 4. Maximize the public acceptability.

2.3.5 Government Notification: The Central Government has exercised powers conferred under Section 3(1) (V) and Section 3(2) of the Environment (Protection) Act, 1986 and Rule 5 (3) (d) of Environment (protection) Rules, 1986; and published a Notification S.O. 60 (E) in Official gazette dated 27.1.1994.This is now a rigid statutory requirement of clearance through Impact Assessment Agency (IAA), to undertake certain projects in any part of India. The latest 1994 Notification provides for a sequenced approach as to which one of industries/ human activities will need Environmental Site Clearance from Govt. Of India and who are exempted. This can be prescribed in the figure No. 2.1 Notification Logic:

No Whether the proposed activity is covered in the 29 categories of Notification

Yes Yes Whether it is one within 16 such Yes Whether the Capital Outlay less categories that is exempted? than Rs. 100 crores?

No No Whether obtained certificate Yes Does this activity increase the from SPCB to that effect? And existing pollution load? so informed to MoEF?

Yes No Environmental Clearance from Environmental Clearance from GOI needed apply? GOI not needed

Fig. 2.1 Notification Logic

Cognizance of all above is taken while making the present study and recommendations. The proposed activity is production of crystalline sugar from the agricultural raw material such as sugarcane, Use of bagasse and spent wash for power generation, molasses/ sugar cane juice and grains for alcohol production (Distillery Units) grape and malt for potable spirit, maize for Cyclodextrin Plant, IMFL Bottling & Country Liquor from ENA & R.S. respectively and recovery of carbon di-oxide for industrial purpose.

2.4 INTENDED USE OF THIS EIA This EIA is not undertaken as an idle exercise. It is not intended to be just a plan on paper to satisfy the statutory requirement. VRSL desires to use this work as a tool that can become handy for many decision making processes. Content of this report will be relayed to many other Government, Semi-Government, and Non- Government organizations and of course will be used by VRSL for forward financial planning and budget provisions.

27 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra 1. VRSL can examine from this EIA the resources such as water, bagasse & coal, steam, electricity, pollution loan, designed performance of control measures, VRSL may put this use for specifying such measures for mitigation, tree plantation, rain water harvesting, minimum monitoring schedule, annual budgetary provision as recurring expenses towards Environment Management. 2. The relevant local authorities for this purpose will know from this EIA, the facilities RVSL proposes to include for fire fighting, medical or hospital establishments, Number of labor force employment and generation of sewage. 3. Chief Inspectorate of Factories (CIF) is an authority that looks after the workers welfare from point of noise, ventilation and toilet facilities as also disaster management. 4. The VRSL production will incidentally offer economic benefits to the society as well. More labor employment will also mean more purchasing capacity, more jobs in ancillaries, more transportation and more opening for garages. The Chamber of Commerce of Industries (CCI), the business community, the labor force, senior citizens who are well wishers of Tahsil and district residents and NGOs can get full information on these aspects by using this EIA.

SPCB- State Pollution control Board CIF- Chief Inspector of Factories CCI- Chamber of Commerce and Industries NGO- Non-governmental Organization EMP- Environmental Management Plan MOEF- Ministry of Environment & Forest ED – Environmental Department, State Government VRSL- Vitthal Refined Sugar Ltd.

Location, Control conditions, Tree requirements

Social benefit, Fire fighting, Water Supply, Transport, Building Financial Planning, Budget Compatibility, Aesthetics Provision, Law abiding SPCB

VRSL Local Body

This EIA and its users

MoEF & ED CIF

CCI, NGO Citizens

Watch dog, Monitoring, EMP Accidents, Occupational Health, Onsite, Offsite Disaster Economic benefits, Employment, Management Plan Ancillary growth

28 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra 5. The Environment Department and MOEF do not look at the project only from tunnel vision of pollution control. They in fact keep a broader compass of Environmental Protection, bio-diversity, ecological balance and resource conservation. The land- use pattern too is under their watch. By this EIA, they can examine as to whether more production available at a very marginal use of land, building construction and transportation. The EMP, watch-dog committee (WDC) and monitoring schedule are the specific considerations which MOEF can examine as also the production possibility without increasing the pollution load. 6. VRSL on their own use will use this EIA for a number of points, the first being whether alternate site or “No Project” alternative is more attractive. A Management Commitment for a continual progress, which is basis for ISO 14000, will be included by VRSL on the background of this EIA. The cost estimate and time table for fund availability can be predicted by this report.

2.5 SCOPE OF DOCUMENT

This is an attempt where environment information is used for planning, development and decision making. Every step is required to be systematically documented. Starting point of documentation is preparation of Environmental Inventory (EI) considering the activity of the proponent as also the other activities in the zone of influence. The document shall reflect the attempt of finding any other alternatives and the best option. The plan emerges as recommended one which will predict the Environmental impact and effects (short and long term, cumulative and growth inducing). There is a scope of binding ourselves by self-discipline to undertake certain EMP and monitoring schedule and commitment to obey all the conditions being laid by consent (Air/water), Authorization (Hazardous Waste), siting clearance conditions. In short, the scope of document will entirely synchronize the Planning Program.

Environmental Alternatives for Impact around in Inventory EI VRSL the region Management Action

Planning  Environment  Technical  Selection  Obey Consent Process for Natural  Collaborators  Project conditions VRSL  Environment  Environ. Description  EMP, self Project Manmade Engg  Significant discipline  Environmenta  Economics load but  Monitoring l goals Scope of  Construction insignificant  Watch-dog  Indian Laws Correspondin  Siting impact efforts g Documents  Local  No-project 2.6 IDENTIFICATIONcompulsions OF OJ

M/s Vitthal Refined Sugars Ltd. has proposed to establish a fully integrated sugar industry complex located at A/p - Pande, Taluka – Karmala, District - Solapur, State – Maharashtra. The project consists of following units. 1. Sugar unit 5000 TCD 2. Bagasse based co-gen sugar power plant – 29.5 MW (26 MW from Co-gen & 3.5 MW from spent wash incineration boiler)

29 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra 3. Molasses / Sugarcane Juice based Distillery Unit – 60 KLPD 4. Grain Based Distillery Unit – 45 KLPD 5. Malt spirit – 5 KLPD 6. Grape spirit – 5 KLPD 7. Distillery CO2 Recovery Plant – 50 TPD 8. Cyclodextrane plant – 2.5 TPD 9. IMFL bottling – One lac cases/ Month 10. Country liquor bottling – Two lac cases/ Month The proposed project is an integrated sugar industrial complex with facilities to manufacture white sugar, co – gen power and alcohol. Sugar plant is based on sugarcane which is an agriculture resource. Co –gen power plant mainly uses bagasse as fuel and distillery is based on molasses as raw material. Bagasse and molasses are the waste or by-products of sugar plant. The project is basically an agro based rural industry. Present status and permissions available for the project are given in Table 2.2.

Table 2.2: Present status and permissions available 1 Land availability 44.33 hectares land suitable for the industry is procured. Water drawl permission Water drawl permission from Water 2 Applied for Resource from Sina- Kolegaon Dam & Mangi Talav Public hearing conducted 3 Public Hearing on 17/06/2017 at Karkhana site The command area comprises of total four Tehsil, Karmala from Solapur District, Karjat and Jamkhed from Ahmednagar 4 Cane area allotment and Paranda from Osmanabad District. The total area under sugarcane cultivation of these four Tehsil is 17,583 ha, with total sugarcane production of 15, 08,970 MT. MPCB has issued Consent to Establish for Sugar & Cogeneration unit under Red Category in the year 2014. (Ref: MPCB letter no. Format 1.0/BO/CAC-CELL/PN-21215- Earlier Consent for Establishment from 14/E/CAC-4702 dated 19.05.2014) 5 MPCB MPCB has issued Consent to Establish for 60 KLPD molasses based, 45 KLPD grain base Distillery & IMFL Unit under Red Category. (Ref: MPCB letter No: Format – 1.0/BO/CAC- CELL/ EIC No. PN-22063-14/E/CAC-9891 dated 27.10.2014 MoEF has granted ToR (Terms f Reference) for EIA studies. 6 Environmental Clearance from MoEF EC is yet to be received for the project. (F. No. J – 11011/107/2014-IAII(I) ) – dated 16.12.2014)

2.6 BRIEF DESCRIPTION OF NATURE, SIZE, LOCATION OF THE PROJECT

M/s Vitthal Refined Sugars Ltd is an agro based industry focused on manufacture of sugar and allied products like power, alcohol and bio –manure. Salient Features of the Project given in Table 2.3. Table 2.3: Salient features of the project M/s. Vitthal Refined Sugars Ltd., Village - Pande, Taluka- 1 Name and address of project proponent Karmala, District- Solapur, and Maharashtra State. Industry consisting of Project Establishment of an integrated 1. Sugar Unit – 5000 TCD sugar 2. Bagasse based co-gen sugar power plant – 29.5 MW (26 2 29.5 MW co-gen power and 60 KLPD MW from Co-gen & 3.5 MW from spent wash incineration molasses based distillery & 45 KLPD boiler) Grain based distillery 3. Molasses / Sugarcane based Distillery Unit – 60 KLPD 4. Grain based Distillery Unit – 45 KLPD

30 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra 5. Malt spirit- 5 KLPD 6. Grape Spirit- 5 KLPD 7. CO2 Recovery Plant- 50 MT/Day 8. Cyclodextrane Plant- 2.5 MT/Day 9. IMFL Bottling- One lac cases/Month 10.Country Liquor Bottling- Two lac cases/ Month 3 New/expansion/ modernization It is a New Project Village - Pande, Taluka- Karmala, District – Solapur, State – 4 Location of the site Maharashtra. 5 Constitution of the organization Public Limited Company Sugar Plant : 160 Days Cogeneration Power Plant : 160 Days 6 No. of working days in a year Molasses/ Cane Juice Based Distillery : 300 Days Grain Based Distillery : 300 Days Products & Co-products Unit Qty Sugar Unit (5000 TCD)

Sugar (sugar recovery @ 11.5%) TPD 575 Molasses TPD 200 Press Mud TPD 200 Bagasse Generation TPD 1500 Total Power Plants Capacity (29.5 MW) Co-generation / Spent wash MW 26/3.5 Incineration Boiler Molasses based distillery Unit (60 KLPD) R S & IS / ENA & TA /Fuel 7 Products & capacity of industry KLPD 60 Alcohol Fusel oil KLPD 0.18 Grain based distillery Unit (45 KLPD) Rectified Spirit & IS/ENA &TA KLPD 45 Fusel oil KLPD 0.135 DWGS/DDGS TPD 92/33 Malt Spirit KLPD 5 Grape Spirit KLPD 5 Distillery CO2 Recovery Plant TPD 50 Cyclodextrin Plant TPD 2.5 IMFL Bottling plant Cases/M One lac Country Liquor Bottling plant Cases/M Two lac

8 Extent of land area Total Plot Area: 44.33 Ha During Construction: 200 Nos. 9 Manpower During Operation : 460 Nos. 1. Boiler - 150 TPH - For Sugar & Co-generation Unit Boiler capacity Sugar & Co-gen sugar 10 2. Incineration Boiler - 35 TPH – For Molasses /Cane Juice unit, Distillery unit based Distillery Unit 1. Co-gen Boiler (150 TPH) – Bagasse – 1387.20 MT/Day Boiler fuel (2,21,952 MT/annum) 11 1. 150 TPH boiler 2. Incineration Boiler (35 TPH) – Concentrated Spent Wash- 2. 35 TPH incineration boiler 175 TPD + Coal- 138 TPD 3. D.G. Set (500 KVA) – HSD – 65 lit/hr. Item Unit Value 12 Steam Generation Co-gen Unit

31 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra Steam through 18 MW BP TPH 112.27 Steam through 8 MW DEC TPH 30.50 Distillery Boiler Unit TPH 35

1. 150 TPH boiler: ESP &58 m stack height will be provided 13 APC measures for boiler 2. 35 TPH concentrated spent wash incineration boiler: ESP and 70 m stack height will be provided. Exportable power from co-gen sugar Season: a) Average Power generation: 25 MW 14 power unit b) Exportable Power : 23.5 MW 1.Sugar plant & Co-gen Unit (5000 TCD) : 517.44 m3/day 2.Molasses based (60 KLPD ) (ENA, Evaporator & ethanol) & Country liquor bottling plant (2 lac cases/month) : 517 m3/day 3.Grain based (45 KLPD) (Liquefaction, evaporator, dryer, Fresh water requirement Source: Sina ENA) & IMFL Bottling plant (one lac cases/ Month ): 406 15 Kolegaon Dam & Mangi Talav m3/day 4. Malt Spirit based (5 KLPD) : 75 m3/day 5.Grape spirit based (KLPD) : 60 m3/day 3 6.CO2 Plant (50 TPD): 12 m /day 7.Cyclo dextrin plant (2.5 MT/day): 25 m3/day 8.Domestic Use/Colony – 200 m3/day 1. Sugar & co-gen unit: Primary clarifier & two stages ASP (Activated Sludge Process) treated to irrigation standards. 16 Effluent Treatment facility 2 Distillery units: Spent wash concentration in evaporator and then mixed with Bagasse/husk and utilization as fuel in boiler. 17 Project cost Rs. 305.86 Crores Investment towards pollution control & 18 Rs. 12.95 Crores environmental protection measures a) Sugar industry: 5(j) – B Category of project according to EIA b) Molasses/ Cane Juice based Distillery Unit (60 KLPD) & 19 notification dated 14th September 2006 Grain based Distillery Unit (45 KLPD): 5(g) – A and as Amended? c) 29.5MW cogeneration Power Plant: 1(d) – A

32 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

Figure 2.2: Location map project site in Solapur District

2.7 NEED & IMPORTANCE OF THE PROJECT TO THE COUNTRY & REGION

2.7.1 Need & Importance to the Country Sugar is an essential food product for mankind. Sugarcane is the raw material for manufacturing of sugar which is obtained from agricultural source. Bagasse, press mud and molasses are the by-products of the sugar industry. Once thought to be unwanted waste products, these by-products are now advantageously utilized as a valuable resource for profitable applications

Sugarcane is one of the important cash crops of India. The industry based on sugarcane and its allied products help farmers to realize higher economic returns and provide employment to the rural mass. After independence, the sugar industry has steadily grown and became the backbone of the agricultural and rural economy in the country.

Today, sugar industry is the second largest agro-processing industry in the country, next to the textile industry. India is the largest producer of sugar in the world, with a production of over 18 million tones. About 45 million farmers and their families depend directly on sugar industry. 2.5 % of the total cultivable land area in the country is under sugarcane crop. Sugar industries are located mostly in the rural parts of the country. They act as centre’s of development, provide largest direct employment in the rural areas and contribute substantially to the Central and State exchequers. The prospects of earning foreign exchange from export of sugar are also quite high.

In India the annual per capita consumption of white crystal sugar is 15 kg per annum. This is much below the consumption in advanced countries. Thus, there is vast untapped potential for growth of sugar industries in the country. The Central and State Governments have envisaged the policy to encourage sugar industries along with generation of power and alcohol with various incentives.

33 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

Alcohol has assumed very important place in the country’s economy. It is vital raw material for a number of chemicals. It has been a source of large amount of revenue by way of Excise Duty levied by State Government. Ethanol has a potentiality as fuel in the Form of “power alcohol” for blending with petrol in the ratio of 20:80. This trend is continuing and will continue in view of the fact that potable liquor has larger revenue generating potential for the Governments. The demand for alcohol will always be there for industrial purposes. Further the use of alcohol in automobile fuel will enhance the demand for alcohol. Other than the above mentioned major requirement, alcohol is also being used in the production of many downstream chemicals including drugs, polymers, plastic, etc.

2.7.2 Need & Importance to the Region The Government of Maharashtra envisaged the policy to encourage sugar industries along with cogeneration of power and alcohol in the state with various incentives. The total area under sugarcane cultivation in the command area is 17,583 ha with total sugarcane production of 15.09 lakh MT. Sugar cultivation gives higher economical returns to the farmers. The Government of Maharashtra envisaged the policy to encourage co-gen sugar industries in the state with various incentives including power purchase agreement. The industry will be located in the rural backward region of the state and has a good scope for development of sugarcane with suitable climatic conditions and assured source of underground and surface water. At present there is few number of sugar industries in the region. Sugarcane cultivated in the region is presently transported through 30 – 60 km and supplied to existing factories in Solapur district. As compared to other crops sugarcane cultivation gives higher economical returns to the farmers. There is good potential to develop more than 20,000 hectares of sugarcane cultivable land in about 20 km distance from the proposed site. Hence, with the proposed industry more agricultural land would be brought under sugarcane cultivation and it benefits the farmers in the local region. The establishment of the integrated sugar industry will thus meet the national interest of economical power and food through sustainable development. Further it helps to uplift the rural mass.

2.7.3 Employment Generation due to the Project The total direct employment potential of the proposed industry is about 460 people. However, the commencement of this industry will create direct and indirect employment opportunities to more than 2,000 people in terms of factory employment, transportation, vehicle maintenance, petty shops etc. In addition, about 2,000 workers will be indirectly benefitted through harvesting and other sugarcane cultivation work.

2.8 TERMS OF REFERENCES (ToR) FROM MOEF AND THEIR COMPLIANCES: Terms of References for conduct of EIA studies were issued by MoEF, Delhi .The EIA studies were conducted based on these ToR and accordingly the EIA report is prepared. The list of TOR and their compliances is appended in the table below: Table 2.4: Terms of Reference (ToR) Sr. ToR issued by MoEF Compliance No. Executive Summary is attached and submitted along with 1. Executive summary of the project. EIA Report. Page No. 1-17. Justification & Need of the project given in Chapter 1, 2. Justification of the project Section 1.3, Page No 20. Total Plot Area – 44.33 Ha Detailed break-up of the land area along with latest 3. Built up area – 27.71 Ha photograph of the area. Green Belt area – 14.98 Ha

34 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra Detailed breakup of the land along with latest photograph of the area is given in Chapter 3, Section 3.5, and Table 3.3 for Detailed breakup of the land. Page No. 47-50. Present land use based on satellite imagery and details 44.33 hectares land suitable for the industry is procured. 4. of land availability for the project along with Satellite image of proposed project land is shown in supporting document. Chapter 3, Fig. 3.2 and Page No. 45. Details of site and information related to Details of site and information related to environmental 5. environmental setting within 10 km radius of the setting within 10 km radius of the project site are given in project site. Chapter 3, Section 3.3, Table No. 3.2, Page No. 44 There are no eco-sensitive locations such as national Information regarding eco-sensitive areas such as park, wild life sanctuary, bio-sphere reserve in the 6. national park/wildlife sanctuary/biosphere reserves vicinity of the proposed project site. within 10 km radius of project area. For details refer Chapter 3, Section 3.3, Table No. 3.2 and Page No. 44. Total project Cost is Rs. 305.86 Cr. Details of Project Investment given in Chapter 3, Table 3.6, Page No. 53 (CA Certificate attached as an Total cost of the project along with total capital cost Annexure X) 7. and recurring cost/annum for environmental pollution Estimated EMP Capital cost will be Rs. 1295.25 lakh & control measures. Recurring cost will be Rs. 47.35 Lakh/ annum. Detailed break up of EMP cost mentioned in Chapter 5, Table 5.3, Page No. 117. Total Plot Area of proposed project is 44.33 Ha, out of A copy of lease deed or allotment letter, if land is which, Own land in name of VRSL is 20.80 Ha & Land 8. already acquired. on lease (33 years lease) is 23.53 Ha. Copy of Lease Deed is attached as an Annexure III. List of existing distillery units in the study area along Refer Chapter 1, Table 1.2 for Distilleries in Solapur 9. with their capacity and sourcing of raw material. District, Page No. 22 Layout maps indicating existing unit as well as Layout Plan showing proposed units indicating storage 10. proposed unit indicating storage area, plant area, area, plant area, greenbelt area, utilities etc. is attached. greenbelt area, utilities etc. Refer Chapter 3, Fig. 3.3, Page No. 46 Industry consisting of 1. Sugar unit – 5000 TCD 2. Total Power generation Capacity – 29.5 MW (26 MW from bagasse based Co-gen & 3.5 MW from spent wash incineration boiler) 3.Molasses / Cane Juice based distillery unit – 60 KLPD 4. Grain based distillery unit – 45 KLPD Details of proposed products along with 5. Malt spirit – 5 KLPD 11. manufacturing capacity. 6. Grape Spirit – 5 KLPD 7. CO2 recovery plant – 50 MT/Day 8. Cyclodextrin plant – 2.5 MT/Day 9. IMFL bottling – One lac cases/Month 10.Country liquor bottling – 2 lac cases/ Month Refer Chapter 3, Section 3.1, and Table 3.1, page No. 41 For Manufacturing process refer Chapter 3, Section 3.6 Page No. 54-68 Sugar Plant : 160 Days/annum Cogeneration Power Plant : 160 Days/annum Number of working days of the sugar unit, distillery Molasses/ cane juice Based Distillery : 300 Days/annum 12. unit and CPP. Grain Based Distillery : 300 Days/annum Included in Chapter 2, Section 2.6, Table 2.3, Sr. No. 6, Page No. 31 Details of raw materials, its source with availability of Details of raw materials, its source with availability given 13. all raw materials including cereal grains requirement Chapter 1, Section 1.4, Page No. 20-22

35 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra in case of grain based distillery. If molasses based VRSL will receive molasses from one sugar factory distillery, then give source and quantity available for namely M/s Babanrao Shinde Sugar & Allied Industries molasses. Ltd, A/p – Turk – Pimpari, Tal – Barshi, dist – Solapur ( 5000 TCD, Molasses @ 4% of cane crushed) Refer Annexure XII for letters for molasses sparing from other industries Manufacturing process details of Sugar, distillery and Manufacturing process details of Sugar, distillery and CPP along with process flow chart are given in Chapter 14. CPP along with process flow chart. 3, Section 3.6 and Page No. 54-68 (Latest Technology And Process Description) The coal will be provided by M/s Krishna Transport, Kurduwadi, Tal- Madha, and Dist- Solapur in covered Sources and quantity of fuel (rice husk/ bagasse/ coal coal transporting vehicles. VRSL has made agreement etc.) for the boiler. Measures to take care of SO 2 with M/s Krishna Transport. A copy of Memorandum of 15. emission. A copy of Memorandum of Understanding Understanding (MoU) signed with the coal supplier is (MoU) signed with the coal suppliers should be enclosed as an Annexure XIII. submitted. Control Measures of SO2 emission is given in Chapter 5, Section 5.2, Sub Section 5.2.1 Pg No. 114 Storage facilities for raw materials, prepared alcohol, Storage facilities for raw materials, prepared alcohol, fuels and fly ash given in Chapter 3, Area required for 16. fuels and fly ash. storage given in Table 3.3, Page No. 48 & Section 3.7, Table 3.9, 3.10 & 3.11. Page No. 69-70 To control impact of PM10, PM2.5, SO2 and NOX emission to the environment, VRSL make Action plan for Action plan for ambient air quality parameters as per ambient air quality parameters as per NAAQS Standards 17. NAAQ S Standards for PM10, PM2.5, SO2 and NOX as for PM , PM , SO and NO as per GSR 826(E) dated per GSR 826(E) dated 16th November, 2009. 10 2.5 2 X 16th November, 2009 are mentioned in Chapter 5, Section 5.2, Sub section 5.2.1 Page No.115. Baseline study in Environmental Impact Assessment report was conducted for a period of three months during December 2014 to February 2015. Details given in Chapter 4. One season site-specific micro-meteorological data AAQ sampling locations (8 Locations) are decided based using temperature, relative humidity, hourly wind on predominant wind direction, population zone and speed, direction, rainfall and AAQ data (except sensitive receptors including reserved forests. For details monsoon) for PM , PM , SO , NO , CO and HC 10 2.5 2 X refer Chapter 4, Section 4.4, Table 4.5, Fig 4.6, Page (methane & non methane) shall be collected. The 18. no.87 & 88 monitoring stations should take into account the pre- Monitoring for Surface & Ground water analysis (at 8 dominant wind direction, population zone and stations each) was carried out. Refer Chapter 4, Section sensitive receptors including reserved forests. Data 4.6, Table 4.11, 4.12, Fig. 4.14 & 4.15. Page No. 93-99 for water and noise monitoring should also be and Noise monitoring at five locations was conducted. included. Refer Chapter 4, Section 4.5, Table 4.8, Fig 4.12, Page no. 92-93 Refer Annexure XVII For Environmental Monitoring Reports. Particulate Matter, Sulphur dioxide (SO2) and Oxides of Nitrogen (NOx) emissions will be the main pollutants in the proposed plant. The incremental ground level Mathematical modeling for calculating the dispersion concentrations from the proposed facilities have been 19. of air pollutants and ground level concentration along estimated by using dispersion modeling along with the with the emissions from the boiler’s stack. emissions from the boiler’s stack. Details given Chapter 5, Section 5.2, Sub Section 5.2.1 (5.2.1.5), Table 5.6 & 5.7, Fig 5.1, 5.2 & 5.3 Page No. 119-122 20. An action plan to control and monitor secondary Details of an action Plan to control & monitor secondary

36 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra fugitive emissions from all the sources. fugitive emissions from all the sources mentioned in Chapter 5, Section 5.2, Sub Section 5.2.1 (5.2.1.6), and Page No. 122-123 An action plan prepared by SPCB to control and Details are given in Chapter 5, Section 5.2, Sub Section 21. monitor secondary fugitive emissions from all the 5.2.1 (5.2.1.6), and Page No. 122-123 sources. 3. Co-gen Boiler – 150 TPH – For Sugar & Co-generation Unit Details of boiler and its capacity. Details of the use of 4. Incineration Boiler – 35 TPH – For Molasses /cane 22. steam from the boiler. juice based Distillery Unit. Details given in Chapter 2, Section 2.6, and Table 2.3, Sr. No. 10, 11 and 12. Page No. 31 Ground Water Quality Monitoring at Project site was Ground water quality around proposed spent wash 23. carried out. Refer Chapter 4, Table 4.3, Page No. 95 & storage lagoon and the project area. report of the same is attached as an Annexure XVII. Details of water requirement, water balance chart for existing unit as well as proposed expansion (as Total water requirement of the project will be 1812.44 24. applicable). Measures for conservation water by m3/day Water Balance for proposed units given in recycling and reuse to minimize the fresh water Chapter 3, Section 3.9, Table 3.12 Page No.71 requirement. Sources of water supply will be Sina Kolegaon Dam & Mangi Talav located at about 21 km and 7 Km Source of water supply and permission of withdrawal respectively from the site. The industry has applied for 25. of water from Competent Authority. permission for drawl of water from Sina Kolegaon Dam & Mangi Talav. Copy of application is enclosed as an Annexure VII Proposed effluent treatment system for grain/molasses based distillery (spent wash and spent lees) along with utility wastewater including CPP/Co-gen Unit Details of Process & Technology of Effluent Treatment 26. (wherever applicable) as well as domestic sewage and Plant are given in Chapter 5, Section 5.3.2, Page No. 125 scheme for achieving zero discharge. Details of treatment of effluent generation from sugar unit. Spent wash generation will be 2.92 KL/KL of Alcohol Spent wash generation should not exceed 8 KL/KL of Production. Refer Chapter 3 27. alcohol production. Details of the spent wash Details of the spent wash treatment for molasses based treatment for molasses based distillery. distillery given in Chapter 5, section 5.3, Sub section 5.3.2, Point 5.3.2.2 Page No. 128 For concentrated spent wash storage tank 1 no., impervious in nature, for 15 days storage-2187.50 CuM. For Storage of spent wash MS epoxy coated tank will be provided and transportation will be done through closed SS pipes to avoid spillage and accordingly ground water Capacity for spent wash holding tank and action plan 28. pollution. For details, Refer chapter 3, Section 3.7, Table to control ground water pollution. (3.10) Also refer section 3.5, sub section 3.5.8 (Point No. 5) Page No. 53 & 70. Also refer Chapter 5, Section 5.3.2.2 for treatment of spent wash & Capacity of holding tank. Page No. 128- 129 Storage yards for storage of 30,000 Tons surplus Bagasse, 4,500 Tons coal (one months’ storage) will be 29. Layout for storage of Bagasse/biomass/coal. provided. Layout showing storage yard given in Chapter 3, Figure 3.3, Page No. 46. For concentrated spent wash storage tank 1 no., Capacity for spent wash holding tank and action plan 30. impervious in nature, for 15 days storage-2187.50 CuM. to control ground water pollution. For Storage of spent wash MS epoxy coated tank will be

37 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra provided and transportation will be done through closed SS pipes to avoid spillage and accordingly ground water pollution. For details, Refer chapter 3, Section 3.7, Table (3.10) Also refer section 3.5, sub section 3.5.8 (Point No. 5) Page No. 52 & 70. Also refer Chapter 5, Section 5.3.2.2 for treatment of spent wash & Capacity of holding tank. Page No. 128- 129. Dryer will be installed in order to dry Distillers’ wet 31. Dryer shall be installed to dry DWGS. grain soluble(DWGS) Storage yards for storage of 30,000 Tons surplus Bagasse, 4,500 Tons coal (one months’ storage) will be 32. Layout for storage of rice husk/biomass/coal. provided. Layout showing storage yard given in Chapter 3, Figure 3.3, Page No. 46 VRSL will follow mitigation practice policy to Management & Minimization of solid wastes generated from co-gen, sugar and distillery units. Management of Details of solid waste management including hazardous solid waste will be done as per hazardous 33. management of boiler ash. waste (Management & Handling) Rules of 1989 as amended in 2000. Details of Solid waste generation & its management given in Chapter 5, Section 5.4, Page no. 136 Risk assessment for storage and handling of alcohol 34. and mitigation measure due to fire and explosion and Details included in Chapter 8, Section 8.2, Page No. 155 handling areas. Alcohol storage and handling area fire fighting facility as per norms. Provision of Foam System for 35. Details included in Chapter 8, Page No. 156-172. fire fighting to control fire from the alcohol storage tank. Total greenbelt area is around 14.52 Ha which covers Action plan for development of green belt over 33 % over 33% of the total plot area. Details of Green Belt of the total project area within plant premises with at Area and tree plantation given in Chapter 11, Table 11.3, 36. least 10 meter wide green belt on all sides along the Page No. 186. periphery of the project area, in downward direction, Layout showing proposed Green Belt cover given in and along road sides etc. Chapter 3, Figure 3.3, Page No. 46 Ecology of the study area includes the flora and fauna 37. List of flora and fauna in the study area. studies within the study zone. List of Flora and Fauna given in Chapter 4, Section 4.8, Page No. 105-109 Noise Level Monitoring was carried out at five locations within study area. For details, Refer Chapter 4, Section Noise levels monitoring at five locations within the 38. 4.5, Page No. 92-93 study area. Noise Level Monitoring Reports attached as an Annexure XVII. Environmental Management Plan (EMP) prepared by Detailed Environment management Plan (EMP) with VRSL to minimize the impact of manufacturing activity specific reference to details of air pollution control on the environment w.r.t Environmental Components system, water & wastewater management, monitoring 39. such as Air Environment, Water Environment, Noise & frequency, responsibility and time bound Odour Environment, Biological Environment as well as implementation plan for mitigation measure should be Socio Economic Environment of the region. For detailed provided. EMP, refer Chapter 11, Page No. 176-189 EMP should also include the concept of waste- EMP includes the concept of waste minimization, minimization, recycle/reuse/recover techniques, recycle/reuse/recover techniques, Energy Conservation, 40. Energy Conservation, and natural resource and natural resource conservation. For detailed EMP conservation. refer Chapter 11, Page No. 176-189

38 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

Rain water harvesting structures are proposed to recharge Action plan for rainwater harvesting measures at plant the ground water resources in the region calculating peak site should be included to harvest rainwater from the run - off 1225.35 m3/ hr collected from roof top area and 41. roof tops and storm water drains to recharge the storm water drains. Details of Rain water Harvesting ground water. system & calculation of Runoff given in Chapter 11, Section 11.7, and Page No. 187 Details of occupational health surveillance Details of occupational health are given Chapter 8, 42. programme. Section 8.5 and Page No. 161. Details of socio – economic welfare activities given in 43. Details of socio-economic welfare activities. Chapter 5, Section 5.7, Page No. 140-141 Transportation of raw materials and finalized products Transportation of raw materials and products in respect for the project (proposed / expansion) in respect of of existing traffic, type of vehicles, frequency of vehicles existing traffic, type of vehicles, frequency of for transportation of materials, additional traffic due to 44. vehicles for transportation of materials, additional proposed project parking arrangements etc. given in traffic due to proposed project parking arrangements Chapter 3, Section 3.5, Sub section 3.5.7, Table 3.4, Page etc. No. 52. An environmental cell will be set up for pollution control Action plan for post-project environmental and post project routine environmental monitoring. 45. monitoring. Details are given in Chapter 11, Section 11.5, Page No. 181 VRSL commit to improve Environmental Management System and minimize the impact of manufacturing activity on the environment, for such purpose VRSL will 46. Corporate Environmental Responsibility. set up Environment Management Cell, EMP Hierarchy. For details refer Chapter 11 (Environment Management Plan), Page No. 176-189 a) Does the company have a well laid down Environment Policy approved by its Board of VRSL will lay down Environmental Policy to Manage Directors? If so, it may be detailed in the EIA report. and minimize the impact of manufacturing activity on the b) Does the Environmental Policy prescribe for standard environment. operating process/procedures to bring into focus any infringement / deviation / violation of the VRSL will adopt Environmental Management structure environmental or forest norms / conditions? If so, it and hierarchy, which is akin to principles and may be detailed in the EIA report. Environmental management practice. 47.c) What is the hierarchical system or Administrative order of the company to deal with the environmental A high power watch dog committee will be set up which issues and for ensuring compliance with the EC will supervise and monitor the working of Environmental conditions? Details of this system may be given. Management Cell and give its report to Board of d) Does the company have a system of reporting of non- Directors (BOD) every three months. compliance / violations of environmental norms to the Board of Directors of the company and / or Details are included in Chapter 11 (Environment shareholders or stakeholders at large? This reporting Management Plan), Page No. 176-189 mechanism should be detailed in the EIA report. At least 5 % of the total cost of the project should be earmarked towards the Enterprise Social Commitment 48. based on Public Hearing issues and item-wise details Public Hearing conducted on 17.06.2017 at Karkhana site along with time bound action plan should be prepared and incorporated. EMP Capital cost is Rs. 1295.25 lakh & Recurring cost is Total capital cost and recurring cost/annum for 49. Rs. 47.35 Lakh/ annum mentioned in Chapter 5, Table environmental pollution control measures. 5.3, and Page No. 117. B Additional TOR

39 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra Public hearing to be conducted and issues raised and commitments made by the project proponent on the 1. same should be included in EIA/EMP Report in the Public Hearing conducted on 17.06.2017 at Karkhana Site form of tabular chart with financial budget for complying with the commitments made. Total project Cost is 305.86 Cr. Details of Project Investment given in Chapter 3 Total project cost to be re-casted with component Refer Table 3.6, Page No. 53 (CA Certificate attached as 2. wise details. Accordingly, expenditure on pollution an Annexure X) control measures to be incorporated. Capital cost of EMP will be 1295.25 Lakh & Recurring cost will be 47.35 Lakh/ annum. Details are mentioned in Chapter 5, Table 5.3, and Page No. 117. The following general points shall be noted: All documents shall be properly indexed, page i. Complied. numbered. Period/ date of data collection shall be clearly Data collected during Dec. 2014 to Feb. 2015 for ii. indicated. preparation of EIA and it is indicated in Chapter 4. Authenticated English translation of all material in the iii. Complied. Regional languages shall be provided. The letter/ application for Environmental Clearance iv. shall quote the MoEF file No. and also attach a copy Letter Attached of letter. The copy of letter regarding ToRs given by Ministry of The copy of letter received from the Ministry shall be Environment, Forests and Climate Change (I.A. v. also attached as an annexure to the final EIA/ EMP Division), Govt. of India. Vide letter No. J – Report. 11011/107/2014 – IA II (I) is attached as an annexure I. The index of the final EIA- EMP report must indicate vi. the specific chapter and page no. of the EIA – EMP Complied. Report. While preparing the EIA Report, the instructions for the proponents and instructions for the consultants vii.issued by MoEF vide O.M. No. J – 11013/41/2006- Complied IA.II (I) dated 4th August, 2009, which are available on the website of this Ministry shall also be followed. The EIA/ EMP report prepared by M/s. SGM Corporate The consultants involved in the preparation of EIA – Consultants Pvt. Ltd., which is an ISO 9001:2008 EMP report after accreditation with Quality Council certified company with QCI-NABET Accreditation of of India/ National Accreditation Board of Education category ‘A’ for the various project sectors for obtaining and Training (NABET) would need to include a Environmental Clearances from authorities like viii. certificate in this regard in the EIA – EMP reports Ministry of Environment and Forests (MoEF), State prepared by them and data provided by other level Environment Impact Assessment Authority organization/ laboratories including their status of [SEIAA] etc. approvals etc. Consultancy and Laboratory details are given in Chapter 13. These ToRs should be considered for the preparation of EIA/ EMP for sugar (5000 TCD), Molasses/ sugarcane juice/ sugar beet based distillery (60 KLPD)/ Grain based (45 KLPD) and cogeneration EIA Report is prepared on the basis of ToRs given by power plant (29.5 MW) at village A/p – Pande, Tehsil Ministry of Environment, Forests and Climate Change 3. – Karmala, Dist. – Solapur, Maharashtra by M/s (I.A. Division), Govt. of India. Vide letter No. J – Vitthal Refined sugars Ltd. in addition to all the 11011/107/2014 – IA II (I) relevant information as per the “General Structure of EIA” given in Appendix III and III A in the EIA Notification, 2006. The EIA/ EMP as per ToRs should be submitted to the Chairman, Maharashtra

40 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra Pollution Control Board, for public consultation. The SPCB shall conduct the public hearing or public consultation as per provisions of EIA notification, 2006. You are requested to kindly submit the final EIA/ EMP prepared as per ToRs and incorporating all the issues raised during Public Hearing/ Public 4. Consultation to the Ministry for considering the Public Hearing conducted on 17.06.2017 at Karkhana site proposal for environmental clearance within 3 years as per MoEF O. M. No. J- 11013/41/2006-IA.II (I) dated 8th October 2014. The EIA/ EMP report prepared by M/s. SGM Corporate The consultants involved in the preparation of EIA/ Consultants Pvt. Ltd., which is an ISO 9001:2008 EMP report after accreditation with Quality Council certified company with QCI-NABET Accreditation of of India/ National Accreditation Board of Education category ‘A’ for the various project sectors for obtaining and Training (QCI/ NABET) would need to include a Environmental Clearances from authorities like 5. certificate in this regard in the EIA/ EMP reports Ministry of Environment and Forests (MoEF), State prepared by them and data provided by other level Environment Impact Assessment Authority organization(s)/ Laboratories including their status of [SEIAA] etc. approvals etc. Consultancy and Laboratory details are given in Chapter 13

41 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

CHAPTER – 3

PROJECT DESCRIPTION

3.1 INTRODUCTION : M/s Vitthal Refined Sugars Ltd. has proposed to establish a fully integrated sugar industry at Pande Village, Karmala Taluka and Solapur District in Maharashtra State. The project consists of following units.

The proposed integrated sugar industrial complex consists of following associated Manufacturing units. Table 3.1: List of Proposed units Sr. No. Units Capacity 1 Sugar Plant 5000 TCD 29.5 MW (26 MW from Co-gen & 3.5 2 Cogeneration Power Plant MW from spent wash incineration) 3 Molasses / Sugarcane juice based distillery unit 60 KLPD Ethanol 4 Grain Based Distillery 45 KLPD 5 Malt Spirit 5 KLPD 6 Grape Spirit 5 KLPD 7 CO2 Recovery Plant 50 MT/day 8 Cyclodextrin Plant 2.5 MT/day 9 IMFL Bottling One lac cases/Month 10 Country liquor bottling Two lac cases/Month

The proposed project is an integrated sugar industrial complex with facilities to manufacture white sugar, co-gen power and alcohol. Sugar plant is based on sugarcane which is an agriculture resource. Co-gen power plant is based mainly on Bagasse as fuel and distillery is based on molasses as raw material. Bagasse and molasses are the waste or by-products of sugar plant. In addition, it is proposed to set up grain based distillery unit, grape and malt spirit, Cyclodextrane and Country liquor and IMFL Bottling Plant. The project is basically an agro based rural industry.

3.2 NEED FOR THE PROJECT India is the second largest producer of sugar over the globe. With more than 45 millions of sugar cane growers in the country, the bulk of the rural population in India depends on this industry. One of the agro- based industries in India, the sugar industry is the second largest agricultural industry followed after the textile industry. Maharashtra Sugar Industry is one of the most notable and large-scale sugar manufacturing sectors in the country.

Electricity is the most essential input for growth and development of any sector. Rapid growth in India is the consequent result of such availability of power in the past and the present rising trend of power demand is the consequent result of the desire of keeping pace with the past progress. This is true for an advanced State like Maharashtra. As per the approach paper of the Planning Commission meant for formulating the 11th Five Year Plan, the growth of power sector needs to be at least 10% to support the expected GDP growth of 7 per cent per annum.  Maharashtra State has the largest power system (power generation and distribution) in India, with 100% rural electrification (as per the earlier definition of rural electrification with at least one light connection per village). Power situation in Maharashtra is better than many of the other States, but still suffers huge demand and energy shortages.

42 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra  Maharashtra faces a power shortfall of 5000-5500 MW. The peak demand increased from 13697 MW in 2002-03 to 17934 MW in 2012 –13 registering rise of 31%, due to increase in industrial & commercial activities.  The Government of Maharashtra recently has taken several steps to improve power situation in the State. Expansion of existing capacities, setting up new projects including private sector, promoting captive power plants, promoting energy efficiency and of course promoting renewable energy based power generation, have been the major areas.

Alcohol has assumed a very important place in the country’s economy. It is a vital raw material for a number of chemicals. It has been a source of revenue by way of excise duty levied by the State Government on alcoholic liquors. It has potential as a fuel in the form of power alcohol for blending with petrol in the ratio of 20:80. The use of alcohol for the purpose of potable liquor is as higher as its use for industrial purposes. Alcohol is used for manufacture of country liquor consumed by common masses. Alcohol is produced by fermenting sugar and is used in industry as industrial alcohol or power alcohol or for drinking purpose as potable alcohol. The basic raw material used is molasses (sugar) or grain (starch). Potable alcohol produced from grain has better quality, smoother taste and better flavor. The potable segment is growing by almost 10% to 15 % per year. Grain based alcohol is much more preferred base material for potable liquor than molasses alcohol because of silent and smoother flavor and taste. Most of the IMFL brands in the prestige segment are now made from grain sprit.

3.2.1 Demand Supply Gap The power situation in India is characterized by continued demand supply gap, despite large capacity additions. The installed capacity of 1,350 MW in the year 1947 has increased to 2, 28,722 MW, as on September 2013. The generation capacity is expected to add by 88,537 MW, as per the CEA and Planning Commission estimates for the 12th Five Year Plan. We have been able to achieve 25,240 MW (as on Sept 2013.) i.e. 28.71 % of the planned target. (Source – CEA)

3.2.2 Domestic/Export Market & Export Possibility Local as well as international market is available for sugar and molasses. Electricity will be used in in- house & exported to the local grid of MSEDCL.

3.3 LOCATION OF THE PROJECT

3.3.1 General Location The industry is proposed to be located at Village- Pande, Taluka- Karmala, and District- Solapur in Maharashtra State. The site is located adjacent to State Highway no. 67 – 4 Km towards West from the proposed project site. The location features of site are given in Table-3.1. Google map of the site is given in Figure- 3.1 and 3.2. The area has dry tropical climate with hot summer and cold winter with scanty rainfall. The surrounding area of the project site is rural agrarian. River Sina, the perennial river located at a distance of about 5 km from the site in the eastern direction. Rainwater streams are present in the region and they carry water only during rainy days. The region is nearly a plain land sloping south towards river Sina. There are no hillocks or valleys in the region. There are no eco-sensitive locations such as national park, wild life sanctuary, biosphere reserve in the vicinity of the proposed project site. The site and its vicinity are generally barren with small patches of agricultural lands growing rain fed crops such as Jawar, maize and groundnut. Few patches of agricultural lands cultivated through lift irrigation also exist in the region. The site and the surrounding region are devoid of forest or major trees except scanty bushes and shrubs. Greenery is observed only on the banks of the river and streams.

43 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra Table 3.2: Location features of the project site

Sr. No. Particulars Details 1 Latitude 180 24’17.19 ”N 2 Longitude 750 13’02.69”E 3 Elevation above MSL 552 m above Mean Sea Level Maximum Temperature : 43.5oc Minimum Temperature : 10.50c 4 Climatic Conditions Mean Annual Rainfall :488 mm (Rainfall Based on 15 years average ) 5 Present land use at the proposed site Barren land 6 Transport Connectivity Road A Nearest Highway State Highway no. 67 – 4 Km towards West direction B Nearest Railway Station Jeur Railway station – 20 Km towards NE direction C Nearest Road Karmala

In 10 Km radius study area No Tropical Forest No Coral Formation No Biosphere Reserve Sina River : 5 Km No National Park Mangi lake : 7.14 Km No wild life Sanctuary Connectivity : Good No nearest Defense establishment

Figure 3.1: Map showing project site location

44 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

Fig 3.2 Google Image of Project Site

45 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

Fig 3.3 PLANT LAYOUT

46 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

3.4 BASIS FOR SELECTING THE SITE The selection of site location for the industry depends mainly on the availability of resources such as raw materials, fuel, power, water, manpower, connectivity for transportation of man and materials, market for the product and more importantly environmental compatibility and sustainability. The industry is proposed to be established in Village- Pande, Taluka- Karmala, District- Solapur in Maharashtra State. The choice of the land confers several advantages, which are summarized below.

 The site is well connected by roadways State Highway No.67, 4Km towards West direction of the proposed project site  Water requirement is proposed to be met by Sina Kolegaon Dam & Mangi Talav for which permission has been obtained. VRSL applied for the permission.  The main raw material viz. sugarcane is locally cultivated in that area. The location has good scope for development of sugarcane with suitable climatic conditions and assured source of underground and surface water. The entire project area is blessed with adequate irrigation potential by virtue of location Sina- Kolegaon dam which is at a distance of 21 km from the proposed project site in the eastern direction. Also sugar cultivation gives higher economical returns to the farmers.  Nearest railway station to the site is Jeur located at a distance of 20 km from the site towards north eastern direction.  It will generate about 96.00 million KWh and export about 76.80 million KWH through MSEDCL grid for sale to MSEDCL or to third party consumers, as per prevailing tariff. All steam and power requirements of the sugar mill and cogeneration auxiliaries and colony during season period will be met internally from the cogeneration power plant.  No incidence of cyclones, earthquake, floods or landslides in the region has been reported.  There are no eco-sensitive locations within 10 km radius around the proposed project site.

3.5 SIZE AND MAGNITUDE OF OPERATION

The industry “M/s Vitthal Refined Sugars Ltd.” is a large scale industrial unit with a total capital investment of Rs. 305.86 Crores.

3.5.1 Land Requirement The land requirement for different applications for the proposed industry consisting of sugar, power and distillery units

Total Plot Area – 44.33 Ha Own land in name of VRSL – 20.80 Ha Land on lease (33years lease) – 23.53 Ha Built up area – 27.71 Ha Green Belt area – 14.98 Ha

Detailed breakup of the land along with latest photograph with different angles of the plot area is given below:

47 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

Table 3.3 Detailed breakup of the land Sr. No. Particulars Area in m2 1 Sugar Factory Campus 6000 2 Co-gen Plant 5200 3 Chimney -- 4 WTP 1350 5 11 KV/ 440 substation 2500 6 Store Building 216 7 Water Storage Tank 1350 8 Admin Building 1100 9 Switch Yard 2304 10 Sugar Godown 16800 11 Cane Yard 3500 12 Fly Ash Storage 2500 13 Spent wash fire Boiler 4080 14 Chimney -- 15 Coal Storage 4582 16 Bagasse Yard 10000 17 Molasses Tank 400 18 Molasses Tank 400 19 Molasses based distillery 60 KLPD 4032 20 Grain based distillery 45 KLPD 7140 21 Bottling plant, Country liquor plant 3600 22 IMFL Plant 3600 23 WTP 609 24 CO2 Plant 864 25 Grapes spirit plant 600 26 Cyclodextrane plant 600 27 Spent wash lagoon 1260 28 ETP 5000 29 Lawn & Greenery plantation Area 149813 30 Colony 10530 31 Temple 182 32 Work shop 120 33 FA Storage 696 34 Alcohol storage 2035 35 ENA Storage 1855 36 Parking -- 37 Security 120 38 Time office 120 39 Weigh bridge 50 40 Cooling Tower 1400 41 Rain water harvesting 1350 42 Press mud storage 5000 Total Built up Area 272234 Lawn & Greenery plantation Area 149813 Plot Area 443300

48 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

Location: North Side of the Plot

Location: South Side of the Plot

49 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

Location: East Side of the Plot

Location: West Side of the Plot

50 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

3.5.2 Manpower: The skilled manpower required for operation of sugar and co-gen power plants will be easily available from Karmala town and surrounding areas. VRSL will require about 460 people for operation of proposed integrated project. VRSL is in a process of appointing required manpower and has already appointed key top management positions for the purpose. Manpower requirement during construction will be 50. Skilled and unskilled labors and supervisory staff are available within the vicinity of the industry. The company has a policy of providing residential accommodation on-site for the essential employees.

3.5.3 Housing facilities The company will provide residential facilities to the essential workers and staff. Most of the workers come from nearby villages. A total of 200 quarters will be provided for the operation phase. These quarters will be provided with all the civic amenities. No. of residential quarters: 200 Nos. Persons residing in quarters: 1000 Nos.

3.5.4 Civil works during construction phase 1. Building & other construction: sugar plant, boiler house, turbine house, distillery plant, sugar godowns and cooling tower. 2. above ground building / structures: 6 to 25 m height for buildings/structures. 3. Excavations: 1 to 3 m excavations for foundations of machinery such as turbine, mills and for water storage tanks. 4. Stack height: For Co-gen boiler- 58.2 M and for spent wash incineration boiler as 70 M & as per CPCB Norms for DGs are required in the project.

3.5.5 Resources Consumed 1. Sugarcane: 8.00 lakh T/crushing season 2. Water from Sina Kolegaon Dam & Mangi Talav: Average 1812.44 m3/day 3. Molasses (42 % Fermentable Sugars): 72,900 T/annum 4. Grains: 31200 T/annum 5. Fuel  Bagasse : 2,21,952 T/annum  D.G. Set (500 KVA) HSD during emergency only: 65 lit/hr  Concentrated spent wash : 175 T/day  Coal : 41,400 T/annum

3.5.6 Sugarcane Cultivation Area  Sugarcane as a raw material will be made available from the 4 tehsils namely Karmala of Solapur district, Karjat & Jamkhed of Ahmednagar district & Paranda tehsil of Osmanabad District.  The existing sugar factories from Karmala Tehsil (3 in number) have a crushing capacity of 7500TCD and can crush annually about 15 lakh tons. The area under sugarcane in Karmala Tehsil is 38800 ha. Considering 100 MT/ha sugarcane yield, the cane availability is more than 38 lakh tons indicating that there is no problem of sugarcane for this proposed factory.

3.5.7 Traffic density and its impacts

a. During construction phase The material required for construction work will be provided by Trucks. Maximum 50 people from the local area will be taken for construction works. Temporary sheds with sanitary blocks will be provided for accommodation of workers taken from outside of the local or nearby area. During construction phase, People visiting the industry including construction works, suppliers of material and related activities will use company vehicle facilities, public transportation and own vehicles.

51 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

 Construction Material Construction material such as Gravels, sand, boulders, bricks etc. will transport to the construction site through trucks and Lorries. b. During operation phase The Sugar Unit of the company is very ideally located, it is in the mid of traditional cane growing area and is surrounded by large sugarcane growing area where the transportation cost of sugarcane from farm to factory site would be lowest. Sugarcane is harvested in the fields, dressed and bundled in small bundles, stacked in lorries, Tractor, trailers or bullock carts and will be supply to factory. All transportation has been considered by road.

 Traffic due to project activities 1. Personnel Residential quarters (200) are proposed within the project site & most of the employees are expected to reside within the project site itself. However assuming maximum of about 1000 people (inclusive of employees and others) is attending the industry. A total of about 10 visits by four wheelers and 30 visits by two wheelers will made to the industry for transportation of personnel. 2. Material Bagasse and molasses are the main inputs to the proposed project and they are available from the captive source and transported through pipeline and covered mechanical conveyor. Shortage of these materials will be met from external source. Raw materials (molasses), fuels (bagasse/agro-waste/coal) will be procured from various locations and transported to the factory through Lorries/ Trucks. Similarly alcohol produced in the factory is transported to various consumers through Truck and tankers. The vehicles will move mainly through State and National highways which are tarred roads. Movement of heavy vehicles for transportation of material during operation phase is given below. Table 3.4: Transportation of Raw Materials & Products A) Sugar Unit – (5000 TCD, 160 days/annum) Sr. No. Mode of Transport No. i. Sugarcane a) Bullock Cart (10 % of cane) 2 Ton/trip 250 b) Trucks/ Tractors 450 ii. Sugar – 575 TPD x 160days per season (250 Days/annum) Average Trucks/day 35 iii. Press mud [200 x 160 – 32000 (20% weight loss – 25600 MT) Average trucks per day 10 iv. Bagasse saved & sold – 1297.6 Tons/annum Ave. Trucks required per day @ 5 tons/truck 1

B) Distillery Unit Particular No. of Vehicle 1. Molasses based Distillery – 50% from outside Molasses Tankers/day (14 Tons/tanker) 9 2. Grain Based Distillery Grains Trucks/day 10 3. Alcohol A. 60 KLPD Molasses based distillery Alcohol Tankers (20KL/tanker) 3 B. 45 KLPD grain based distillery Alcohol Tankers (20 KL/tanker) 2 4. IMFL - 8000 cases/day (600 cases/truck) 13 5. Country liquor - 4000 cases/day (600 cases/truck) 7 6. CO2 Recovery Tankers (20 Tons/tanker) 3

52 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

 Traffic impacts and mitigation measures The transportation density on the road is likely to increase due to multi-products to be manufactured in Integrated Sugar Complex. The road will be a tarred wide road and will have adequate capacity to take the additional vehicular load. Lorries carrying solid material will be covered with tarpaulin. The industry will take measures for additional plantation on road sides. Bell mouth shape geometry will be provided at entry and gates to the industry. Considering the facilities as above, the impact of additional transportation on road will be minimized.

3.5.8 Bulk Storage Facilities 1. Storage yards for storage of 30,000 Tons surplus Bagasse, 4,500 Tons coal (one months’ storage) and 12,000 Tons press mud (2 months’ storage) and 6292 Tons boiler ash (2 months storage) 2. Sugar godown for storage of 40,000 T of sugar 3. Molasses storage tanks 3no’s, each of 7500 T capacity 4. Grain (Grains like Maize, Jawar, and broken Rice) storage system- 3000 T storage Capacity 5. Ethanol storage tanks 13 no’s, both for molasses and grain based distillery units-total 6,000 m3 storage capacity 6. For concentrated spent wash storage tank 1 no., impervious in nature, for 15 days storage-2187.50 CuM. 7. Water reservoir 10,000 CU.M.

3.5.9 Waste Generation Table 3.5: Liquid, gaseous and solid wastes generated from co-gen sugar and distillery units are listed below: Management of these wastes is discussed in later chapters. CO-GEN SUGAR UNIT DISTILLERY UNIT Domestic wastewater Domestic wastewater 1. Wastewater Industrial wastewater Spent wash Excess condensate water Miscellaneous wastewater CO-GEN SUGAR UNIT DISTILLERY UNIT 2. Gaseous Boiler flue gases Boiler flue gases emissions Smoke from diesel generator Smoke from diesel generator Fugitive emissions Fermented emissions CO-GEN SUGAR UNIT Bagasse DISTILLERY UNIT Press mud 3. Solid wastes Yeast sludge Molasses Boiler ash Boiler ash Lime sludge

Table 3.6: Project Investment Rs. Lakh Molasses Sugar Grain Based Co-Gen Based Total In Sr. no. Particulars Plant Distillery & 29.5 MW Distillery Lakh, Rs 5000 TCD other units 60KLPD Land & Land 1 300 200 100 100 700 Development Building & Civil 2 2035 400 694 710 3839 Works 3 Plant & Machinery a Grain based distillery 1698.95 b Country Liquor 400 c IMFL 400

53 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

d CO2 plant 200 e Grape spirit plant 200 f Cyclodextrane plant 200 Total Plant & 6802 8686 3595 3098.95 22181.95 machinery Miscellaneous Fixed 4 613 100 255.60 100 1068.60 Assets Provision For 5 236 230 114 98 469 Contingencies Preliminary & Pre 6 Operative & Other 596 532 444 287 1859 Expenses Margin Money For 7 100 10 50 100 260 Working Capital Total 10682 10158 5252.60 4493.95 30586.55

3.5.10 Employment Generation Due To the Project The total direct employment potential of the proposed industry is about 460 people. However, the commencement of this industry will create direct and indirect employment opportunities to more than 1,000 persons in terms of factory employment, transportation, vehicle maintenance, petty shops etc. in addition to about 2,000 workers in harvesting of sugarcane work.

3.6 TECHNOLOGY AND PROCESS DESCRIPTION

3.6.1 SUGAR PLANT (5000 TCD)

Technology- Most of the sugar factories in India follow Double Sulphitation Process and produce plantation white sugar. The major unit operations are given below. These are – 1. Extraction of Juice 2. Clarification 3. Evaporation 4. Crystallization 5. Centrifugation

Extraction of Juice The sugarcane is passed through preparatory devices like knives for cutting the stalks into fine chips before being subjected to crushing in a milling tandem comprising 4 to 6 three roller mills. Fine preparation with its impact on final extraction, is receiving special attention and shredders and particularly the fibrizers are gaining popularly. The mills are of modern design, being equipped with turbine drive, special feeding devices, efficient compound imbibitions system etc. In the best milling practice, more than 95% of the sugar in the cane goes into the juice, this percentage being called the sucrose extraction or more simply, the extraction. A fibrous residue called Bagasse; with a low sucrose content is produced about 25 to 30% of cane, which contains 45 to 55% moisture.

Clarification The dark-green juice from the mills is acidic (pH-4.5) and turbid, called raw juice or mixed juice. The mixed juice after being heated to 65 to 75 oC is treated with phosphoric acid, sulphur dioxide and milk of lime for removal of impurities in suspension in a continuously working apparatus. The treated juice on boiling fed to continuous clarifier from which the clear juice is decanted while the settled impurities known as mud is sent to rotary drum vacuum filter for removal of unwanted stuff called filter cake is discarded or returned to the field as fertilizer. The clear juice goes to the evaporators without further treatment.

54 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

Evaporation The clarified juice contains about 85% water. About 75% of this water is evaporated in vacuum multiple effects consisting of a succeeding (Generally four) of vacuum-boiling cells arranged in series so that each succeeding body has higher vacuum. The vapours from the final body go to condenser. The syrup leaves the last body continuously with about 60% solids and 40% water.

Crystallization The syrup is again treated with sulphur dioxide before being sent to the pan station for crystallization of sugar. Crystallization takes place in single-effect vacuum pans, where the syrup is evaporated until saturated with sugar. At this point “seed grain” is added to serve as a nucleus for the sugar crystals, and more syrup is added as water evaporates. The growth of the crystals continues until the pan is full. Given a skilled sugar boiler (or adequate instrumentation) the original crystals can be grown without the formation of additional crystals, so that when the pan is just full, the crystals are all of desired size, and the crystals and syrup form a dense mass known as “massecuite”. The “strike” is then discharged through a foot valve into a crystallizer.

Centrifugation The massecuite from crystallizer is drawn into revolving machines called centrifuges. The perforated lining retains the sugar crystals, which may be washed with water, if desired. The mother liquor “molasses” passes through the lining because of the centrifugal force exerted and after the sugar is “purged” it is cut down leaving the centrifuge ready for another charge of massecuite. Continuous centrifuges may purge low grades. The mother liquor separated from commercial sugar is again sent to pan for boiling and re-crystallization. Three stage of re-crystallization are adopted to ensure maximum recovery of sugar in crystal form. The final mother liquor referred to as final molasses is sent out the factory as waste being unsuitable for recovery of sugar under commercial condition from economical point of view.

55 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

MANUFACTURING PROCESS FOR SUGAR Condensate Boilers Cane Steam

Cane preparation

Imbibition water

Milling Bagasse Bagasse Saving 85 o C

Milk of lime Raw Juice heating

SO2 gas Juice sulphiter

Juice sulphur burner Sulphited juice Sulphur heating

Syrup sulphur burner Dorr clarifier Filter cake

Clear juice heating Rotary Vacuum Filter

Evaporator Bagacillo

SO2 gas Syrup sulphiter

Vacuum pans

Desugarisation in Crystallizers steps

To distillery Centrifugals

Hopper

Grader

Godown Bagging

56 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

Table 3.7: Design parameters of the proposed sugar plant have been indicated below:

Sr. No. Item Unit Value Season Operation 1 Avg. cane crushing TCD 5000 2 Net season days Nos. 160 3 Hrs. / day Nos. 22 4 Normal cane crushing TCH 227.27 5 Cane crushed Lakh MT 8.00 6 Bagasse generation % cane 30 7 Bagasse generation TPH 68.18 8 % cane 1.00 Bagasse for bagacillo / handling loss TPH 2.27 9 Bagasse available for boiler TPH 65.91 10 Total equivalent Bagasse available for boiler TPH 65.91 11 TPH 57.80 Bagasse used by boiler MT/Annum 2,21,952 14 Steam generation TPH 142.77 Steam consumption through 18 MW BP TPH 112.27 Steam consumption through 8 MW DEC TPH 30.50 15 Steam consumption for sugar process As 45 % of cane 90.91 16 Power generation, Average MW 25.00

3.6.2 Process Description of Cogeneration Power Plant

Co-generation Power Plant process in Brief – Cogeneration denotes generation of surplus power mainly with a view to supplying power to the grid. The process of manufacturing of crystal sugar requires steam. However by producing steam at higher pressure and higher temperature, electricity can be generated in addition to the main manufactured product i.e. Sugar is known as Cogeneration.

The sugarcane stalk consists of around 73 % water and 27% solids. Solids in turn comprise soluble solids mainly sucrose and fiber. The woody fiber of the cane is known as Bagasse and is about 30 % of the weight of the sugarcane. From the inception sugar factories are equipped with the capacity to generate power for captive consumption and surplus power of 14 MW. Normally a standard sugar plant of 3500 TCD would be provided with one boiler of 90 tones with 87 kg/sq. cm. pressure and suitable turbo-alternator set etc. the sugar units of the capacity would consume of about 35 % of steam for processing.

The factory crushing at 146 tons per hour by adopting the new special methods can reduce the process steam consumption from 32% to 35% and also by increasing the boiler pressure at 87 kg/sq. cm. at 510 degree C would enable generation of excess power of 9.47 mw. That is to say it would be possible to export 9.47 MW of surplus power after considering a captive consumption of 4.53MW.

Co-generation for the sugar factory has been a very attractive option in view of the potential for improving the financial health. On the other hand it helps in reducing ecological damage, by promoting the use of renewable fuels like Bagasse. Bagasse based cogeneration of power for export to the grid is a technology used in many countries; this is very beneficial to both the Sugar unit and to the Government. This concept is born out of the fact the sugar plant cogeneration holds the promise of narrowing the ever widening gap between the power supply and demand at low incremental cost. The present potential are estimated for the surplus exportable power to the grid from the sugar factories is around 5000 MW in the country.

57 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

The fuel for the boilers of the cane sugar industry is Bagasse; however the storage of large quantity of combustible Bagasse in the premise of the sugar factory is problematic. Most of the boilers of sugar factory are designed in such a way as to use the entire quantity of Bagasse in cane as it is crushed daily. There is thus inbuilt energy inefficiency in the factory using all the Bagasse produced as fuel for the low pressure boilers, which could be otherwise used in a more efficient manner by making alteration in the specifications of boiler and producing high pressure steam which can be utilized for generation of Power. Thus there is no any need of additional raw material for running this plant only need is to increase the efficiency of the existing procedure and plant and machinery.

MANUFACTURING PROCESS FOR CO-GENERATION POWER PLANT

Sugar Cane

Milling Cane Juice for sugar production

Bagasse Feed Water

Boiler

Superheated Steam

Turbo generator Steam to sugar process

Condensate

De-aerator Make up water

26 MW

Table 3.8: Brief design parameters for the cogeneration power plant will be as follows:

Boiler capacity, TPH : 1 x 150 Pressure, kg/cm2 : 87.00 Temperature, 0C : 515 Turbine capacity, MW : 1 x 18 1 x 8 Turbine type : Back Pressure Double extraction - cum condensing Season operation, days : 160 Fuels used for season operation : Bagasse Boiler efficiency, % - On Bagasse / bio-mass / cane trash : 70.00,± 2 - On imported coal : 80.00, ± 2 Feed water temperature, 0C : 165 Turbo-generator efficiency, % : 96.0

58 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

3.6.3 Process Description Molasses/Cane Juice Based Distillery (60KLPD)

The proposed distillery project (Molasses and Cane Juice based of 60 KLPD Capacity) will adopt the best technology available for converting molasses into ethanol. The present trend is to adopt continuous fermentation/Fed batch method to ferment molasses into alcohol, which is distilled in a multistage distillation/pressure vacuum column, system.

Extra Neutral Alcohol is manufactured from Rectified Spirit. The impurities in Rectified Spirit are reduced to considerable extent by properly diluting and redistilling the spirit. The impurities like aldehydes, acids, Esters, higher alcohols are minimized by controlled condition and tapping impurities at appropriate points during distillation. The eco-friendly Molecular Sieve Technology will be used for production of Fuel Ethanol. The integrated and independent evaporation system will be used for concentration of effluent.

Machinery and Hardware: 1. Continuous/Fed batch Fermentation process which consists of Yeast Propagation System, Sludge Washing and Decantation System, Spent wash and Spent Lees recycling system. 2. Pressure – Vacuum Distillation system with integrated evaporation system where in the Steam Economy will be obtained considerably. Simultaneously recovering steam condensate which will be recycled back to Steam Generating Unit. 3. ETP system – It will be based on modern concept to obtain Zero Discharge. The system consists of further concentration of effluent in multiple evaporation system followed by burning of concentrated effluent in specially designed boiler. Auxiliary fuel coal will be used as per need of process. 4. Plant shall be more water / energy conservative i.e. Spent Lees / Part of Spent Wash will be recycled for the process, low steam consumption for MPR distillation system. 5. Avoidance of scaling problem due to use of MPR distillation system. 6. Simultaneous generation of steam and power for the process and distillery project

TECHNOLOGY AND PROCESS DESCRIPTION

Technology: Continuous Fermentation Process Fermentation Process Molasses is the chief raw material used for production of alcohol. Molasses contains about 50% total sugars, of which 30 to 33% are cane sugar and the rest are reducing sugar. During the fermentation, yeast strains to the species Saccharomyces Cerevisiae, a living microorganism belonging to class fungi converts sugar present in the molasses such as sucrose or glucose in to alcohol. Chemically this transformation for sucrose to alcohol can be approximated by the equation: -

I) C12H22O11 + H2O Invertase 2C6H12O6 Cane Sugar Glucose + Fructose

ii) C6H12O6 Zymase 2C2H5OH + 2 CO2 180 2 x 46 + 2 x 44 Glucose/Fructose Ethyl alcohol + Carbon di-oxide Thus 180 gm. of sugars on reaction gives 92 gms of alcohol. Therefore, 1 MT of sugar gives 511.1 kgs of alcohol. The specific gravity of alcohol is 0.7934, therefore, 511.1 kg. Of alcohol is equivalent to 511.1 /

59 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

0.7934 = 644.19 litres of Alcohol. During Fermentation of other by-products like glycerin, succinic acids etc. also are formed from sugars. Therefore, actually 94.5% total fermentable sugars are available for alcohol conversion. Thus, one MT of sugar will give only 644 x 0.945 = 608.6 litres of alcohol, under ideal condition theoretically. Normally only 88 to 90 % efficiencies are realized in Continuous type plant. One MT of molasses containing 47 % fermentable sugars gave an alcoholic yield of 283 litres per MT. Process of manufacture of Extra Neutral Alcohol Extra Neutral Alcohol is manufactured from Rectified Spirit. The impurities in Rectified Spirit are reduced to considerable extent by properly diluting and redistilling the spirit. The impurities like aldehydes, acids, Esters, higher alcohols are minimized by controlled condition and tapping impurities at appropriate points during distillation. Process of manufacture of Fuel Alcohol The latest technology of Molecular Sieve will be used for production of Fuel Ethanol

MANUFACTURING PROCESS FOR MOLASSES BASED DISTILLERY

Raw material Arrives Weighed & Diluted

Yeast Propagated in sterilized separate vessel

Fermentation CO2

Clarified Wash Tank Analyzer Column

Pre-Rectifier column if

required

Rectifier column Exhaust column

Boiler

Fusel oil separated & alcohol Fusel Oil returned Rectified Spirit/ENA/ absolute alcohol

60 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

3.6.4 Process Description for Grain Based Distillery (45KLPD) –

Grain Handling and Milling Section Grain is lifted and unloaded by bucket elevator into grain silos. Grain from hopper is transferred continuously to feed bin of intermediate bucket elevator. This bucket elevator lifts the grains and feeds to vibratory pre- cleaner. The Pre cleaner removes light impurities like Straws, Stem and fine dust. Grain from vibrator is fed by gravity to magnetic separator to remove iron particles. From magnetic separator the grain is fed by gravity to de-stoner. This machine removes heavier particles like stones and supplies almost stone free grains. From de-stoner the grain is fed by gravity to hammer mill. The milled flour from hammer mill is fed by bucket elevator to a vibratory sifter from a small hopper. The vent losses are minimized by a bag filter on vent lines. Flour is unloaded from hopper to vibratory sifter through rotary valve. The sifter classifies flour into fine and course. The coarse particles are recycled by gravity to mill through duct. A specially designed of mill facilitates of air escaping through Aspiration Section. Front opening of our Hammer Mill facilitates easy change of Screen & Hammers. Provide versatility of this Mill for all types of grinding of grains like Maize, Sorghum, Broken Rice and Millets. The Flour coming from mill of desired size of particles is conveyed through Screw Conveyor and Bucket Elevator is Stores is Flour Storage Silo. THE avg. Bulk Density of 0.5/0.6 Gm. /Cc. and Capacity of Silo is around Four Hours production of Hammer Mill.. The flour bins are mounted on load cell for weighment. Once the flour bin is full the actuated diversion valve stops feeding, the bin under feeding and diverts feed to other bin, which is empty. At a time one bin is getting filled and other bin is feeding to further section. The flour from either of bin is fed to next section, i.e., liquefaction section through a screw conveyor, which works through loss in weight feeder.

Slurry Preparation and Liquefaction Process – The flour from mill is mixed homogenously in blunging tank where process water with process condensate from evaporator and thin Stillage is used for dilution. Some quantity of Alfa amylase and viscosity reducing enzyme is also added here. The slurry is then pumped from mixing retention tank thru jet cooker where steam is added through for instantly raising the temperature of slurry to >1050 C. The slurry is cooked for specific period by allowing specific retention time in coil by centrifugal pump to liquefaction tank 1. The heat recovery is done by using heat in flash steam from liquefaction tank 1. The blunging vessel is a very high flow and high shear mixer ensuring no untreated mash clusters are passed to jet cooker. Efficient mixing is done by using agitators in mixing and liquefaction tanks. Gluco amylase is added in specific amount for Saccharification. After this it is cooled and sent to fermentation. The whole process is well monitored via instrumentation to get high conversion efficiency.

Yeast Propagation and Fermentation In this process, the genetically marked, highly efficient yeast strain under aseptic conditions, in Yeast vessels is prepared. The ready yeast Culture is then transferred from Pre-Fermented to Fermenters. The glucose in media gets converted to ethanol, in each of the 6 Fermenters operating in batch mode for grain based fermentation. CO2 liberated during reaction is sent to CO2 scrubber for recovery of ethanol before venting to atmosphere. The equipment is well designed to achieve enhanced efficiencies through better sugar / yeast contact by shearing and mixing, efficient oxygen transfer etc. Oxygen transfer at optimum efficiency is ensured by jet educators inside Fermenters.

Multipressure Distillation Concept Note on Distillation – The distillation system is designed for the production of potable alcohol. The distillation system comprises seven columns namely Analyzer/Degasifying column, Prerectifier Column, Extraction Column, Second Rectifier Column & Refining Column. The Fusel Oil Column, Head Concentration Column are used for concentrating & removal of Fusel Oil & impurities. After separation of impurities the recovered alcohol is recycled back to the pre rectifier column system.

61 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

Rectification column and pre-rectifier column works under positive pressure. The top vapours from rectifier column are condensed in stripper column for giving heat to stripper re-boiler. Most of the other columns work under vacuum. The Distillation process is operated through PLC.

Stillage Processing The Stillage from Distillation section is then passed through decanter where cake and thin stillage are separated. The recovered thin stillage from decanter is concentrated in the evaporator till 38% concentration. The evaporator uses heat from distillation column for desired final concentration of stillage. The product from the evaporator is mixed with cake recovered from decanter. The mixture is sent to the dryer and the dried product is used as cattle feed. Part of the thin stillage [approximately 40% to 50%] is recycled to liquefaction section and Fermenters

Dryer will be installed in order to dry DWGS from distillation. MANUFACTURING PROCESS FOR GRAIN BASED DISTILLERY (45 KLPD)

Grain handling & Storage

Grain Cleaning

Grain Milling

Flour

Pre-mashing & slurry preparation

Flour Recycle steam

slurry Initial liquefaction

Pre liquefied Low pressure steam slurry Cooking

Cooked slurry High pressure steam

Final liquefaction

Partial Saccharification

Saccharified slurry Simultaneous Saccharification CO2 & Fermentation

Distillation

Rectified spirit/ENA Fusel Oil DWGS

62 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

3.6.5 Description of Manufacturing Process for Malt Spirit: Barley is softened by steeping it in water & allowing it to germinate; the resulting malt is then used in brewing and distilling spirits. The enzyme diastase which is produced by the malting process helps starch in the grains turns into sugar and eventually into alcohol.

MANUFACTURING PROCESS FOR MALT SPIRIT

Barley

Malting (Stipping in water for germination)

Drying in the Kiln

Mashing/Brewing

Yeast added Fermentation

Pot still distillation

Maturation of malt spirit in oak wooden casks

Blending of Malt spirit for IMFL bottling

Water requirement and waste generation in Malt Spirit, 05 KLPD: The fresh water requirement for Malt Spirit, 05 KLPD will be 75.00 Cu.M/Day & effluent generation will be 15.00 Cu.M/Day

3.6.6 Description of Manufacturing Process for Grape Spirit: First we are harvesting the Grapes & Destemming of grapes is carried out by hand. The next phase is designed to crush the grapes to release their juice and allow the primary fermentation to start. Fermentation is the process whereby grape juice is turned into wine. Micro-organisms called Yeasts turn the natural sugar in the grape juice into alcohol. During fermentation the skins of the Grapes release aromatic compounds, natural coloring matter and tannins into the wine. Once the grapes have been crushed, the second phase of treading keeps the skins in constant contact with the fermenting wine so that the required amount of flavor, colour and tannin is extracted. The ageing can take place in wood (normally oak) or in bottle and then filtered & clarified the juice. Finally the Distillation & Packing of Wine is carried out.

63 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

MANUFACTURING PROCESS FOR GRAPE SPIRIT

Harvesting of grapes

Destemming of grapes

Crushing & primary fermentation (alcoholic)

Cold Stabilization

Secondary fermentation & bulk aging

Filtration & clarification

Distillation of wine

Packing

Water requirement and waste generation in Grape Spirit, 05 KLPD: The fresh water requirement for Grape Spirit, 05 KLPD will be 60.00 Cu.M/Day & effluent generation will be 15.00 Cu.M/Day

3.6.7 Description of Manufacturing Process for CO2 Recovery Plant: First we are getting raw gas from Fomenters and then we will take this gas in to our system then we take gas in foam trap where we remove the foams come along the gas and then with the help of booster blower we will

push the gas in to the chain/series of scrubbing systems consists of pre water scrubber, KMnO4 scrubber with

dosing facilities and then after water scrubber. In this chain of scrubber we wash the CO2 gas by means of

water and then raw gas gets buffer in a buffer vessel and then it goes to two stage CO2 compressor where it compresses up to a desired pressure and then raw gas goes DRYER & then goes to the Dual tower activated carbon Bed where the odor of raw gas removed and then raw gas enters into the high pressure precooler and

then enters into the Dual Tower CO2 dryer and then into the liquefaction system and then the liquid goes

directly to the Storage tank where the gas stores for a particular period of time. Liquid CO2 used in formation of Dry Ice, in cylinder filling & in tanker.

Water requirement and waste generation in CO2 RECOVERY PLANT, 50 TPD:

The fresh water requirement for CO2 RECOVERY PLANT, 50 TPD will be 12.00 Cu.M/Day & effluent generation will be 2.00 Cu.M /Day.

64 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

MANUFACTURING PROCESS FOR CO2 PLANT:

CO2

SCRUBBER FREMENTERS

BLOWERS CO2 MAIN COMPRESSOR

GAS CO2

PURIFICAT LIQUID CO2 AT 22 KG/CM2

ION TRAIN

REFRIGERATION CIRCUIT

CYLINDER FILLING

DRY ICE

TANKER 65 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

F) MANUFACTURING PROCESS FOR CYCLODEXTRIN

Grain handling & Storage

Grain

Cleaning

Grain

Milling

Flour

Pre-mashing & slurry preparation

Flour slurry

Liquefaction

Pre liquefied slurry Enzymatic degradation of starch to Cyclodextrane

Crystallization

Cyclodextrane

Water requirement and waste generation in CYCLODEXTRIN PLANT, 2.5 MT /Day: The fresh water requirement for CYCLODEXTRIN PLANT, 2.5 MT/Day will be 25.00 Cu.M/Day & effluent generation will be 7.5 Cu.M/Day.

66 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

3.6.8 Description of Manufacturing Process for IMFL Bottling : The process would involve ENA spirit which is stored in tanks it will be transfer to reduction vats & then mixing of ENA with DM water for dilution, blends with different liquor essence in the blending tank. It will be treated with Activated Carbon which stabilizes biological systems against upsets and shock loading, controls color and odor. It undergoes maturing & aging process for long period of time. Then addition of flavoring agents, caramel & colors in stainless steel blending tanks. The blend would be subjected to physical filtration. Subsequently, the blend would be filled in bottles. The bottles would be labeled, packed, and stored for final dispatch.

MANUFACTURING PROCESS FOR IMFL BOTTLING

ENA spirit in storage tank

Transfer to reduction vats

Dilution with DM water

Blending with different spirits

Treatment with activated carbon

Maturing & aging

Addition of flavoring agent

Addition of caramel

Circulation of blends

Filtration & bottling

Packing

67 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

3.6.9 Description of Manufacturing Process for Country Liquor Bottling: The process would involve rectified spirit transfer to reduction vats & then mixing of ENA with DM water along with liquor essence blends, caramels, and colors in stainless steel blending tanks. The ratio of spirit to DM water would be controlled by proof requirements in the end product. The blend would be subjected to physical filtration. Subsequently, the blend would be filled in bottles. The bottles would be labeled, packed, and stored for final dispatch.

MANUFACTURING PROCESS FOR COUNTRY LIQUOR BOTTLING

Rectified spirit in storage tank

Transfer to reduction vats

Dilution with soft water/ DM water

Activated carbon treatment

Addition of flavoring agents

Addition of caramel

Circulation of blends

Filtration & bottling

Packing

68 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

3.7 RAW MATERIALS AND PRODUCTS

1. Sugar Unit:

The main raw material required for manufacture of sugar is sugarcane, which is obtained from agricultural source existing in the region of the factory. Chemicals such as lime, phosphoric acid etc. are used in the process for purification of sugarcane juice. Common salt, hydrochloric acid and caustic soda are used in water treatment plant. Lubricating oil and grease are also used as consumables in the industry. Chemicals and consumables are locally available in the country. The details of raw materials and products are given in Table 3.9

Sugar is the main product in the industry. However, Bagasse, molasses and press mud are also produced as by-products in the process. Bagasse is used as fuel in the boiler for production of high-pressure steam, which in turn is used in generation of captive electric power. Major part of the Bagasse produced in the industry is consumed as fuel in the boiler. Other products viz., press mud and molasses, which once thought to be waste products, are now advantageously utilized for profitable applications. Press mud is used as manure in agriculture. Molasses is used as raw material for manufacture of ethanol and other products.

Table 3.9: Raw materials and products for sugar unit

Sr. No. Raw Material Unit Quantity Storage facility Transportation Sugar Unit

Sugar cane TPD 5000 Cane Yard Lorry & bullock cart 1 Lubricant(oil & grease) Kg/d 150 MS tank Drums by trucks Lime TPD 8 Lime store house Trucks Sulphur TPD 2.50 Gunny bags in store By truck

Sr. No. Products & Co-products Unit Quantity Sugar Unit (5000 TCD) Sugar (sugar recovery @ 11.5%) TPD 575 1 Molasses TPD 200 Press Mud TPD 200 Bagasse Generation TPD 1500

69 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

1. Co-generation unit:

Table 3.10: Raw materials and products for co-gen unit Storage Sr. no Raw Material Quantity Unit Transportation facility Power generation Unit Bagasse for co-gen unit 1387.20 TPD Bagasse Yard RBC Carrier 1 Conc. Spent wash (55 -60 %) MS epoxy 175 TPD Closed SS pipes for incineration boiler coated tank Coal for incineration boiler 100 TPD Coal Yard Covered trucks

Sr. No. Products & Co-products Unit Quantity Total Power Plants Capacity (29.5 MW) 1 Co-generation / Spent wash Incineration Boiler MW 26/3.5

2. Distillery unit Molasses obtained as by-product from sugar plant is the main raw material for manufacture of alcohol. Urea and DAP are used as nutrients in fermentation process. Microbial culture is used in the Fermenters as bio-catalyst for production of alcohol. The Company has proposed to manufacture ethanol of RS, ENA and fuel ethanol grades. The fusel oil and aldehydes are produced in small quantities as by-products in the process. They are useful as solvent in paints, pesticides etc. and will be sold in the market. Ethanol with a chemical formula CH3CH2OH is commonly known as ethyl alcohol. It is also simply referred as alcohol or spirit in practice. The list and quantity of raw materials and products including consumables, chemicals, by products and waste products is given in Table 3.11 Table 3.11: Raw materials and products for distillery units Sr. no Raw Material Quantity Unit Storage facility Transportation Molasses based distillery Unit (60 KLPD) Molasses (FS – 42%) 243 TPD Molasses tanks Lorry tanker 1 Nutrient 60 Kg/d Bags in Godown Lorry TRO 120 Kg/d Drums in Godown Lorry Sulphuric acid 90 Kg/d Lined tank Drums in Lorry Grain based distillery Unit (45 KLPD) Grains-Jawar, Maize, broken 104 TPD Silo / godown Lorry 2 rice etc. (68% starch) Alpha- Amylase 56.25 Kg/d Drums in godown Lorry Gluco- Amylase 56.25 Kg/d Drums in godown Lorry 3 Barley for malting 13 TPD Bags in godown Lorry 4 Grapes for grape spirit 78 TPD Cold storage Crates in Lorry

Sr. No. Products & Co-products Unit Quantity Molasses based distillery Unit (60 KLPD) 1 R S & IS / ENA & TA /Fuel Alcohol KLPD 60 Fusel oil KLPD 0.18 Grain based distillery Unit (45 KLPD) Rectified Spirit & IS/ENA &TA KLPD 45 2 Fusel oil KLPD 0.135 DDGS TPD 33 3 Malt Spirit KLPD 5 4 Grape Spirit KLPD 5 5 Distillery CO2 Recovery Plant TPD 50 6 Cyclodextrane Plant TPD 2.5 7 IMFL Bottling plant Cases/M One lac 8 Country liquor bottling plant Cases/M Two lac

70 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

3.8 POWER AND STEAM REQUIREMENT

1. Co-gen sugar unit Total power requirement to the unit will be 5 MW during crushing season. A high pressure boiler of 150 T/hr will be provided to meet the steam requirement of co-gen power plant and sugar plant. Co-gen power to the tune of 20 MW is supplied through a T.G. set of 26 MW capacities. The information on generation and utilization power and steam is given in operating parameters of the co-gen sugar unit.

Distillery unit Power requirement to the distillery will be met from the distillery spent wash & coal based power plant of 3.5 MW capacities. Steam generated from high pressure boiler (45 bar pressure) is passed through ECC turbine to generate electric power

Diesel generator To meet the emergency requirement of power during power failure, two diesel generators of 1,000 kVA & 500 kVA will be provided in the co-gen sugar unit. Diesel generators will be used to run essential services only during the emergency of power failure from the regular source. Gen set will be utilized for a maximum period of about 30 hours per month.

3.9 SOURCE AND UTILIZATION OF WATER Source of water for the proposed integrated industry Fresh water requirement to the industry will be met from the Sina Kolegaon Dam & Mangi Talav located at about 21 km and 7 Km respectively from the site. The industry has applied for permission for drawl of water from Sina Kolegaon Dam & Mangi Talav. Sugarcane utilized as raw material in the sugar unit contains 73% of its weight as water. The water will be recovered by evaporation of juice and reused in the process. Similarly, the spent wash obtained as wastewater in distillery is concentrated by evaporation and condensate water obtained from the evaporation will be reused in the process. The quantity of fresh and recycled condensate water is given in Table 3.12. Table 3.12: Source and quantity of water, m3/day Sr. No. Particular Fresh Water Requirement, m3/day Sugar & Co-generation Unit (Cap- 26 MW), 1. 517.44 DECC Molasses/ Sugarcane juice based (60 KLPD) 2. (ENA, Evaporator & ethanol) & Country 517 liquor bottling plant (two lac cases/ Month) Grain based (45 KLPD) & IMFL bottling 3. 406 plant (one lac cases/Month) 4. Malt Spirit based (5 KLPD) 75 5. Grape spirit based (5 KLPD) 60 6. CO2 Plant (TPD) 12 7. Cyclodextrane Plant (2.5 MT/day) 25 8. Domestic use including colony 200 Total 1812.44

71 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

Fig 3.4: Water requirement and waste generation in sugar mills, 5000 TCD Sugar Plant & 26 MW Co- generation Power plants, Cu.M/day

Table 3.13: Water requirement and waste generation in 45 KLPD Grain based Distillery unit & IMFL Bottling, Cu.M/day Water Input Table S. No. Section Water Quantity (m3/day) 1 Water in Grain 11 2 Process Water In Fermentation & Liquefication 347 3 DM water for RS dilution 400 4 Soft water for vacuum pump & others 132 5 Soft water makeup for cooling tower 368 6 Bottling 50 7 Misc. water 58 8 Other domestic usage 10 9 DM Water for Boiler & DS 376 TOTAL WATER INPUT 1752

Water Input Table S. No. Section Water Quantity (m3/day) 1 Spent Lees 477 2 Water in Raw Stillage 314 3 Vacuum Pump & Others 127 4 Vacuum Pump loss 5 5 Water in Product 3 6 Bottling waste 10 7 CT Evaporation & Drift Losses, Blow Down 368

72 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

8 Washing Water 5 9 Domestic Consumption Waste 2 10 Blow Down Water & Reject Streams 96 11 Steam Condensate 300 12 Water in Waste Stream 45 TOTAL WATER OUTPUT 1752

Recycling and utilization stream S. No. Section Water Quantity (m3/day) 1 Thin Stillage & Spent Lees Recycle in Liquefication 140 2 Spent Lees Recycle for RS Dilution 348 3 Vacuum Pump Recycle 127 4 Treated Effluent 431 5 Steam Condensate Recycle 300 TOTAL WATER 1346 406 m3/day TOTAL FRESH WATER REQUIREMENT 9.02 lit/lit

Input to ETP 1 Process Condensate 197 m3/day 2 Spent Lees 129 m3/day 3 WTP Blow down & Boiler Blow Down 85 m3/day 4 Cooling Tower Blow down 47 m3/day TOTAL 458 m3/day

Table 3.14: Water requirement and waste generation in 60 KLPD Distillery unit & Country liquor, Cu.M/day Water Input Table S. No. Section Water Quantity (m3/day) 1 Water in Molasses 36 2 Process Water In Fermentation 521 3 DM water for RS dilution 494 4 Soft water for vacuum pump & others 180 5 Soft water makeup for cooling tower 359 6 Bottling 60 7 Misc. water 65 8 Other domestic usage 10 9 DM Water for Boiler & DS 425 TOTAL WATER INPUT 2150

Water Output Table S. No. Section Water Quantity (m3/day) 1 Spent Lees 608 2 Water in Spent Wash 466 3 Water in sludge 18 4 Vacuum Pump & Others 173 5 Vacuum Pump loss 7 6 Water in Product 4 7 Bottling Waste 20 CT Evaporation & Drift Losses, Blow 8 359 Down 9 Washing Water 5

73 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

10 Domestic Consumption Waste 2 11 Blow Down Water & Reject Streams 84 12 Steam Condensate 350 13 ETP Waste 54 TOTAL WATER OUTPUT 2150

Recycling and Utilization streams S. No. Section Water Quantity (m3/day) 1 Spent Lees Recycle for RS Dilution 449 2 Vacuum Pump Recycle 173 3 Treated Effluent 661 4 Steam Condensate Recycle 350 TOTAL WATER 1633 517 TOTAL FRESH WATER REQUIREMENT 8.62 lit/lit

Input to ETP Process Condensate 392 m3/day Spent Lees 160 m3/day WTP Blow down & Boiler Blow Down 109 m3/day Cooling Tower Blow down 36 m3/day TOTAL 697 m3/day

74 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

Table 3.15: DETAILS OF ENTIRE PROJECT IN BRIEF

Fresh Water input to Effluent Sr. No. Particular Steam Power process after recycling Solid waste CMD CMD ETP sludge – Exhaust steam – 325Kg/day Sugar 5 MW 1 112.27 TPH (sugar & 5000 TCD Consumed ethanol) Oil & grease recovery – 146 Kg/day 26 MW Cap. *Sugar Effluent – Co-generation Unit (Cap.- 26 Steam (5 MW- Sugar 517.44 CuM/day Bagasse Ash – 20.81 2 545.28 CuM/day MW), DECC 142.77 TPH & others, 20 MT/day MW Export)

*Coal and spent wash Distillery Co-gen Unit (Cap 3.5 Ash from Incineration 3 Steam – 30.5 TPH 3.5 MW MW, ECC) boiler – 84.06 MT/day 3 Distillery * Yeast sludge from Molasses based (60KLPD) (ENA, * Conc. Spent wash to 3A Steam – 13.80 TPH 2.8 MW molasses distillery – Evaporator & ethanol) boiler – 175 TPD 517 CuM/day 15 MT/day Country liquor bottling plant -- 60 KW -- -- (2 Lac cases/ Month)

Grain based (45 KLPD) * combined spent lees, *Distillery ETP 3B (liquefaction , evaporator, dryer, Steam-13.00 MT/hr vapor condensate & sludge – 250Kg/day ENA) RO reject – 1168 TPD 406 CuM/day

IMFL Bottling plant(0ne Lac -- 40 KW cases/Month)

75 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

Residue as cattle 4 Malt Spirit based (5KLPD) Steam – 1.05 MT/hr 75 CuM/day 15 CuM/day feed-3.90 MT /day 150 KW Grape residue for 5 Grape Spirit based (5KLPD) 0.875 MT/hr 60 CuM/day 15 CuM/day composting -19.5 MT /day 3TPD 6 CO Plant (50 TPD) 450 KW 12 CuM/day 2 CuM/day -- 2 (alternate day) Cyclodextrane Plant Grain residue as cattle 7 6.25 TPD 75 KW 25 CuM/day 7.5 CuM/day (2.5 MT/day) feed 750Kg/day 8 Domestic use including colony -- -- 200 CuM/day 180 CuM

 Water Requirement and Source:

The total water required for the project i.e. 1812.44 CMD will be taken from Sina- Kolegaon dam & Mangi Lake. Distillery Water Consumption= (1035/105) = 9.86 KL/KL of Alcohol production (Norms < 10 KL/KL) Total Industrial Effluent Generation from sugar and Co-gen = 545.28 KLD = 0.109 CM/Ton cane crushed (Norms < 0.4 CM/Ton) Spent Wash Generation from molasses based distillery = (175/60) = 2.92 KL/KL of Alcohol Production (Norms < 08KL/KL) Total Sewage Generation = 180CMD

76 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

3.10 POWER REQUIREMENT: Electricity required for plant operation shall be in-house generated. Total power requirement will be 8.5 MW. D.G. Sets having 1000 KVA & 500 KVA capacities in case of power failure.

3.11 GREEN BELT DEVELOPMENT: The total plot area is 110 acres (~44Ha). The green belt will be developed to the tune of 37.45 Acres (14.98 ha). There under, about 8000 no. of trees will be planted.

3.12 SOCIO-ECONOMIC BENEFIT: The project will generate a fair amount of direct and indirect employment in the study region as a result of which the local economy is expected to receive a boost due to employee spending and services generated by industry. Migration at the existing area is insignificant.

3.13 POLLUTION MITIGATION MEASURES: The main objective of mitigation measures is to conserve the resources, minimize the waste generation, treatment of wastes, recovery of by-products and recycling of material. It also incorporates greenery and landscape development of open area and the post project monitoring of environmental quality. The measures under mitigation plan are classified as

 Measures built in the process  Measures during construction phase  Measures during operation phase

The main objective is to follow environment friendly process, with efficient utilization of resources, minimum waste generation, built in waste treatment and operation safety. The measures adopted are

3.13.1 BUILT IN POLLUTION CONTROL MITIGATION MEASURES

1. Sugar & Co-gen unit

1. Recovery and reuse of inherent water present in sugarcane. 2. Complete recycle of vapor condensate water with cooling water. 3. Use of hydrated lime instead of lime to avoid lime sludge. 4. Treatment and reuse of vapor condensate for reuse as boiler feed. 5. ESP and stack for air pollution. 6. Dust control in sugar grader unit. 7. Spent oil and grease recovery in mill plant. 8. Use of hot vapor-condensate for imbibitions in mill. 9. Use of mechanical seals in pumps to avoid liquid leakages and noise.

SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

2. Distillery Units 1. Separation, recovery and recycle of yeast present in Fermenters wash for reuse in Fermenters. This reduces the use of fresh culture and nutrients and also improves ethanol yield. 2. Use of live steam is avoided by employing re-boiler in distillation columns. This reduces the generation of wastewater. 3. Multi pressure distillation system is used to reduce the consumption of steam and quantity of effluent. 4. Use of pumps with mechanical seals to avoid liquid leakages.

5. Scrubbing of Fermenters vent gases containing CO2 to recover traces of alcohol present in it.

3.14 ASSESSMENT OF NEW & UNTESTED TECHNOLOGY FOR THE RISK OF TECHNOLOGICAL FAILURE The proposed project is a fully integrated sugar industry consisting of fully integrated sugar industry consisting of 5000 TCD sugar plant, 29.5 MW (26 MW from Co-gen & 3.5 MW from spent wash incineration boiler) co-gen power plant and 60 KLPD molasses based & 45 KLPD grain based distillery plant, Malt spirit- 5 KLPD, Grape Spirit- 5 KLPD, CO2 recovery plant- 50 MT/Day, Cyclodextrane plant- 2.5 MT/Day, IMFL bottling- one lac cases /Month, Country liquor bottling- 2 lac cases/ Month at Village – Pande, Taluka – Karmala, District – Solapur in Maharashtra State. The manufacturing process is a tried & tested method & therefore there is no risk of technological failure.

SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

CHAPTER-4 DESCRIPTION OF ENVIRONMENT 4.1 INTRODUCTION

This chapter covers the description of existing environmental conditions of the study area with respect to the prominent environmental attributes. The data was collected from both primary and secondary sources. Primary data was collected through environmental monitoring & survey in the study area.

4.2 STUDY AREA, PERIOD, COMPONENTS & METHODOLOGY

STUDY AREA: An area, covering 10 km radial distance around the project site is considered as the study area for conducting baseline studies.

PERIOD: Baseline study in this Environmental Impact Assessment report was conducted for a period of three months during 1st December 2014 to 28th February 2015.

COMPONENTS: Air, noise, water & soil analysis studies were carried out. Survey of the flora & fauna in the surroundings & demographic pattern of the survey area were also studied.

METHODOLOGY: The data was collected from both primary and secondary sources.

Primary data sources include the data collected through environmental monitoring/ survey of the study area. The studies involved conducting field studies and analyzing various parameters that might be affected due to the industry and conducting socio-economic survey among the people.

The sampling locations were identified based on:

• Existing topography and meteorological conditions

• Locations of water intake and waste disposal points

• Location of human habilitation and other sensitive areas present in the vicinity of the proposed project site

• Representative areas for baseline conditions

• Accessibility for sampling

Secondary data was collected from various organizations to substantiate the primary data. The data thus collected was compared with the standards prescribed for the respective environmental parameters.

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Project Site

Fig 4.1: Topo map showing the study area of 10 km radius

Source: Survey of India;

STUDY AREA – This study area is in Gat. No. 238, 247, 248, 252, 254, 256, Village – Pande, Taluka – Karmala, Dist – Solapur, State – Maharashtra. For the present study, an area covered in 10 Km radius from the project location has been considered and marked as per the guidelines. The study area lies between Latitude – 180 24’17.91” N & Longitude – 75013’02.69” E Project site and the 10 km radius study area falls in the survey of India Toposheet no. 47 J.

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4.3 ESTABLISHMENT OF BASELINE

4.3.1 Meteorological Data

Assessment of the micro and macro meteorology is important from the standpoint of understanding the nature and extent of air pollution in the study area. Climate has an important role in the build-up of pollution levels. The climatic condition of the area may be classified as moderately or seasonally dry, tropical or temperate savanna climate with four seasons in a year. Winter is critical for air pollution build- up because of frequent calm conditions with temperature inversions resulting in poor atmospheric mixing, natural ventilation and high emission loads.

The classification of months according to the seasons is given in the following table

Season Period Summer March to May Monsoon June to September Post monsoon October to November Winter December to February

The meteorological data for various parameters from both primary & secondary sources are detailed subsequently.

Source of meteorological data:- The meteorological data for Solapur District was obtained from IMD Mumbai 4.1: Temperature Data of Karmala Taluka for year 2014

Month Temperature in 0C Maximum Minimum January 33.8 13.9 February 34.7 14.1 March 40.9 15.5 April 42.3 21.6 May 43.5 22.1 June 41.9 22.3 July 37.9 21.6 August 37.1 21.0 September 34.9 20.6 October 37.4 16.0 November 35.4 14.5 December 33.5 10.5 Average 37.78 17.81 Source – IMD, Mumbai

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Karmala Taluka enjoys a tropical monsoon climate, the hot scorching summer from March onwards yet to the rainy monsoon in early June. Seasonal variation in temperature quite large from March onwards is a period of continuous increase in day temperature, the night remaining cool. The climate of Karmala is characterized with hot summers and dry winters. The cold season which last to February, the air is dry and invigorating. It is too hot in summer. Karmala summer highest day temperature is 42.30C.The Mean Maximum and Minimum temperature of Karmala Taluka is 37.780C & 17.810C respectively.

Table 4.2: Micro-meteorological data of Project Site during Study period from December 2014 to February 2015 Temperature(0C) Relative humidity (%) Total rainfall Rainy Month Min Max Min Max (mm) days IST 17.30 IST 8.30 Dec 2014 10.8 33.5 36.03 74.16 0 0 Jan 2015 14.7 33.1 37.51 68.25 0 0 Feb 2015 14.1 35.1 33.82 59.75 34.8 2 Average 13.2 33.9 67.39 35.79

1. TEMPERATURE :- Temperature is important in all fields of natural science, including physics, geology, chemistry, atmospheric sciences, medicine, and biology as well as most aspects of daily life. A temperature is an objective comparative measure of hot or cold.

 Methodology Temperature was measured by using Thermometer. 60

50 C o 40 30 Temperature(0C) Max 20 Temp in Temp 10 Temperature(0C) Min 0 déc.-14 janv.-15 févr.-15 Month

Fig. 4.2: Graphical representation of Temperature observed in Study period (Dec. 2014 to Feb. 2015)

 Observations:- The temperature data collected at the site is presented as monthly maximum and minimum values. The maximum temperature is observed at (35.1°C) in the month of February and the minimum temperature at (10.8°C) is observed in the month of December. It is found moderate temperature at project site. The Values are appended in table 4.2

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2. RELATIVE HUMIDITY :-

Relative humidity is the ratio of the partial pressure of water vapor to the equilibrium vapor pressure of water at the same temperature. Relative humidity depends on temperature and the pressure of the system of interest.

 Methodology A hygrometer is an instrument used for measuring the moisture content in the atmosphere. Humidity measurement instruments usually rely on measurements of some other quantity such as temperature, pressure, mass or a mechanical or electrical change in a substance as moisture is absorbed. By calibration and calculation, these measured quantities can lead to a measurement of humidity

Relative Humidity (%) 80 74,16 68,25 70 59,75 60 50 37,51 40 36,03 33,82 RH (%) Min RH (%) RH 30 20 RH (%) Max 10 0 déc.-14 janv.-15 févr.-15 Month

Fig. 4.3: Graphical representation of Relative Humidity observed in Study period (Dec. 2014 to Feb. 2015)

 Observations: - Minimum and maximum values of relative humidity have been recorded. The maximum Relative Humidity is 74.16 %, observed in the month of December. The minimum Relative Humidity is 33.82%, observed in the month of February. During the study period the air is observed to be moderately humid to dry. The values are presented in table 4.2

4. RAINFALL Rain, also known as precipitation, involves the condensation of water in the air. When the air can longer hold the weight of the water it falls to the earth in the form of hail, rain, snow or sleet. Rain is part of the never-ending water cycle, where fallen rain eventually evaporates, becomes stored by clouds and falls to the earth again to repeat the process. The advantages seen in rainfall contribute to the earth's weather systems, seasons and the survival of all plant and animal life.

 Methodology A rain gauge (also known as a udometer, pluviometer, or an ombrometer) is a type of instrument used by meteorologists and hydrologists to gather and measure the amount of liquid precipitation over a set period of time. According to 15 years study of rainfall of Solapur District, the average rainfall recorded as 522.74 mm which is 9.02% less as compared to the total district’s average rainfall. It is found that low rainfall in Karmala Tehsil (Refer Annexure XV)

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Also, rainfall data for the year of 2014 collected from IMD, Mumbai, it is observed that annual rainfall of Karmala Taluka is 573 mm. in 82 rainy days. (Refer Annexure XV)

Rainfall (mm) 40

20 Rainfall (mm) 0 Rainfall (mm) Rainfall déc.-14 janv.-15 févr.-15 Month

Fig. 4.4: Graphical representation of Rainfall recorded in Study period (Dec. 2014 to Feb. 2015)

 Observations: - The study period was mainly of winter season. 34.8 mm rainfall recorded in month of February. The values are presented in Table No. 4.2

5. WIND Wind speed describes how fast the air is moving past a certain point. This may be an averaged over a given unit of time, such as miles per hour, or an instantaneous speed, which is reported as a peak wind speed, wind gust or squall. Wind speed and direction are important for monitoring and predicting weather patterns and global climate.

 Methodology Wind speed is typically reported in miles per hour, knots, or meters per second. One mile per hour is equal to 0.45 meters per second, and 0.87 knots. Wind direction is typically reported in degrees, and describes the direction from which the wind emanates The measurement of wind speed is usually done using a cup or propeller anemometer, which is an instrument with three cups or propellers on a vertical axis. The force of the wind causes the cups or propellers to spin. The spinning rate is proportional to the wind speed. Wind direction is measured by a wind vane that aligns itself with the direction of the wind. Table 4.3: Measured wind direction % of time (For study period December 2014 to February 2015) Wind Speed (KMPH) (%) Direction No. of Days 0-2 2-4 4-6 Total Calm 15 8.3 4.5 7.9 20.7 NNE 3 1.1 0 0 1.1 NE 29 2.2 8.5 0.5 11.2 ENE 6 2.2 1.2 0 3.4 E 12 1.1 0.5 0 1.6 ESE 3 3.5 2.7 0.5 6.7 SE 36 4.5 14.5 0 19 SSE 2 0.5 0.6 0 1.1 S 61 12.2 15.5 0 27.7 SSW 3 0 1.6 0 1.6

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SW 2 1 0.7 0 1.7 WSW 0 0 0 0 0 W 0 0 0 0 0 WNW 0 0 0 0 0 NW 2 0 1.1 0 1.1 NNW 1 0 0.5 0 0.5 N 4 1.1 1.1 0 2.2

Wind rose based on data collected at IST 8.30 hr and IST 17.30 hr readings of wind speed and direction monitored during monitoring period at the factory site for the month of December 2014, January 2015, and February 2015 is presented in Figure – 4.3. In general, the primary meteorological data obtained at the project site are in agreement with the data of previous years available from secondary source. During study period, the highest wind speed recorded is 27.9% towards North direction (i.e. from South to North)

Fig 4.5: Wind rose diagram for study period (December 2014 to February 2015)

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4.3.2 Baseline Monitoring

Table 4.4: Sampling and Analytical Techniques Sr. Components Parameters Frequency of Monitoring Methodology adopted No 1. PM10 and PM2.5: Gravimetric Method (IS: 5182, Part IV) 2. SO2: Modified West and PM2.5,PM10,Sulphur di- Ambient air quality samples are Geake Method (IS: 5182, Part Ambient air oxide (SO ), Oxides of monitored at 8 locations for 24 II)(Sodium 1 2 quality Nitrogen (NOx), Carbon hours twice a week for the study Tetrachloromercurate) Monoxide (CO) period 3. NOx: Jacobs and Hochheiser Method (IS: 5182, Part VI) 4. CO: Dragger gas tubes (IS: 5182, Part X). Secondary data collected from Surface : Wind speed and Primary data: Wind Speed & IMD, Pune for Karmala Tehsil direction , temperature, Temperature data collected at IST 2 Meteorology & Solapur observatory relative humidity and 8.30 hr & IST 17.30 hr during the Monitoring data for primary rainfall study period at plant site data IS:8829 Primary data :- Ground water Standard methods for Physical, Chemical and samples were collected from 8 Examination of Water and 3 Water quality Bacteriological locations and surface water samples Wastewater published by parameters. were collected from 8 American Public Health locations Association (APHA) Field survey conducted once during Terrestrial fauna and flora the study period from 7 locations Rau and Wooten 1980) have 4 Ecology and River ecology and the data collected from been followed and measured secondary sources. Noise levels measured in Continuous 24 – hourly monitoring 5 Noise dB(A) at 5 locations once during the study IS: 4954 as adopted by CPCB. period Sampling at 5 locations around 6 Soil Physicochemical project site once during the study BIS specifications period. Land use Based on data published in Primary Land use for different Toposheet Satellite imageries 7 pattern Census Abstract and satellite categories imagery LISS –III Socio – Socio – economic Based on data collected from the 8 economic Characteristics of local Based on Census Data 2001 year 2001 Census Abstract aspects Population Geology and Based on data collected from field Hydro geological study 9 Geology hydrogeology of the area survey once during the study period conducted and from secondary sources.

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4.4 AMBIENT AIR QUALITY Ambient air quality refers to the quality of outdoor air in our surrounding environment. It is typically measured near ground level, away from direct sources of pollution. The term “air quality” means the state of the air around us. Good air quality refers to clean, clear, unpolluted air. Clean air is essential to maintaining the delicate balance of life on this planet — not just for humans, but wildlife, vegetation, water and soil.

 Sampling Methodology

The existing ambient air quality status (AAQ) has been monitored for PM10, PM2.5, SO2 and NOx at each station at IST 8.30 hr. and IST 17.30 hr. The monitoring was done as per the approved methods of Central Pollution Control Board (CPCB). Various statistical parameters like 98th percentile, Maximum, minimum and average values have been computed from the data collected at all individual sampling stations to represent the ambient air quality status. The Ambient Air Quality Monitoring Analysis results for the study period are presented in detail in Annexure XVII.

 Sampling Locations

The status of the existing ambient air quality in the study region has been assessed through a network of eight air sampling stations during the study period within a radial distance of 10 km distance from the project site. The monitoring network was so designed that a representative baseline scenario is obtained in upwind, downwind and crosswind directions. These monitoring sites have been established keeping in view the available data on predominant wind direction and wind speed of this particular region. The list of sampling locations are given below (Table No. 4.5)

Table 4.5: Air Quality Monitoring Stations

Distance in Km Direction w.r.t Sr. No. Name of location w.r.t Project Site Project Site 1 Project site 0 0 2 Pande 2.4 SE 3 Mangi 8.4 NW 4 Bhalewadi 7.0 NE 5 Deolali 5.6 SW 6 Pothare 5.3 N 7 Karmala 2.5 NW 8 Gulsadi 6.6 S

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Fig 4.6 Map Depicting AAQM Stations

Table 4.6: Ambient air quality standards – MoEF as per the notification dated 16th November 2009 for industrial, residential & rural areas Time National Ambient Air Quality Standards Sr. Pollutants Weighted Industrial, residential Ecologically No. Average and other area μg/m3 sensitive area μg /m3 1 Sulphur di-oxide (SO2) 24 hours 80 80 2 Oxides of Nitrogen (NOx) 24 hours 80 80 3 PM2.5 24 hours 60 60 4 PM10 24 hours 100 100 Carbon Monoxide CO 5 8 hours 04 04 (mg/m3)

Note: ♦ 8 hourly or hourly monitored values, as applicable, shall be complied with 98% of the time in a year. 2% of the time, they may exceed the limits but not on two consecutive days of monitoring. ♦ Whenever and wherever monitoring results on two constitutive days of monitoring exceed the limits specified above for the respective category, it shall be considered adequate reason to institute regular or continuous monitoring and further investigation

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Table 4.7: Ambient Air Quality Parameter Observations during Study Period The monitored values are within the limits specified by MoEF (as per the notification dated 16th November 2009 for industrial, residential & rural areas).

3 3 3 3 3 PM10 (µg/m ) PM 2.5 (µg/m ) SO2(µg/m ) NOx (µg/m ) CO (mg/m ) 98 98 98 Location Min Max % Avg. Min Max 98 % Avg. Min Max 98 % Avg. Min Max % Avg. Min Max % Avg. At plant 35.4 47.2 41.35 41.4 11.3 19.3 15.076 15.08 3 7 4.7 4.80 11.2 15.2 12.9 13 0.11 0.22 0.218 0.145 site Pande- 43.5 49.8 46.36 46.68 12.4 18.7 15.28 15.67 3 7.8 5.02 5.16 11.1 15.9 13.04 13.26 0.118 0.286 0.179 0.187 Mangi 44.4 51.8 47.10 47.52 13.7 19.7 16.37 16.54 3 7.5 5.04 5.20 11.5 15.9 13.24 13.61 0.12 0.289 0.187 0.194 Bhalewadi 45.5 53.8 49.04 49.45 15.3 22.2 19.00 19.04 4 7.8 5.63 5.67 13 16.9 14.35 14.65 0.152 0.298 0.194 0.21 Deolali 44.5 55.8 49.5 49.71 10 19.9 14.04 14.5 3 6.7 4.5 4.60 16.5 20.1 18 18.02 0.101 0.22 0.147 0.153 Pothare 48.1 55.2 52.01 52.02 13.5 20.8 17.18 17.54 3 7.5 5.03 5.16 13.1 17.7 15.13 15.3 0.227 0.31 0.265 0.268 Karmala 51.4 61.8 55.1 55.37 16.4 29.5 22.41 23.14 13.5 18.2 16.04 16..0 13.8 20.7 17.15 17.31 0.253 0.303 0.273 0.276 Gulsadi 43.5 49.8 47.24 47.17 12.6 19.5 16.74 16.73 3 6.1 4.1 4.20 9.6 12.9 10.8 10.9 0.108 0.268 0.183 0.188

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Variation of PM during the study period 3 70 10 60

50 in µg/m in

10 40 30 20 PM10 (µg/m3) Min 10 PM10 (µg/m3) Max 0

Values Values PM of PM10 (µg/m3) Avg.

Locations

Fig. 4.7 Variation of PM10 during the study period (Dec – 14 to Feb –15)

Variation of PM2.5 during Study Period

35 3 30

25 inµg/m

2.5 20 15 PM 2.5 (µg/m3) Min 10 PM 2.5 (µg/m3) Max 5 PM 2.5 (µg/m3) Avg.

Values ofPM 0

Locations

Fig. 4.8 Variation of PM2.5 during the study period (Dec – 14 to Feb – 15)

Variation of SO2 during Study Period 35

3 30

25 µg/m 2 2 20 15 SO2(µg/m3) Min 10 SO2(µg/m3) Max 5 Values SO of SO2(µg/m3) Avg. 0

Locations

Fig. 4.9 Variation of SO2 during the study period (Dec – 14 to Feb –15)

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Variation of NOx during Study Period

3 25 20 15

10 Nox (µg/m3) Min 5 Nox (µg/m3) Max

0 Nox (µg/m3) Avg. Values of NOx µg/m NOx of Values

Locations

Fig. 4.10 Variation of NOx during the study period (Dec – 14 to Feb – 15)

Variation of CO during Study Period

3 0,35 0,3 0,25 0,2 0,15 CO (mg/m3) Min 0,1 CO (mg/m3) Max 0,05

0 CO (mg/m3) Avg. Values of CO in mg/m in CO of Values

Locations

Fig. 4.11 Variation of CO during the study period (Dec – 14 to Feb – 15)

 Observations 3 PM10 – A maximum value of 61.8 g/m was observed at location Karmala which is residential area and minimum value of 35.4 was observed at Project Site. Observed values are well within the NAAQ specific standards of 100 g/m3 for rural/ residential areas. The average values ranged from 41.4 g/m3 to 55.37 g/m3. 3 PM2.5 – The maximum value of 29.5 g/m was observed at Karmala and minimum value observed 10.0g/m3 at Deolali village. Both are residential areas. The values are within the permissible limits of NAAQ specified standards of 60 g/m3 for rural/ residential areas. The average values ranged from 23.14 g/m3 to 14.5 g/m3. 3 SO2 – Maximum concentration of SO2 observed 18.2 g/m at Karmala which is residential area and minimum value of 3.0 g/m3 at six locations in the study area viz. Project Site, Pande, Mangi, Deolali, Pothare and Gulsadi. All are residential areas. Observed values are well within the NAAQ specified standards of 80 g/m3 for rural/ residential areas. The average values ranged from 16.27 m3 to 4.20 g/m3. 3 NOX – Maximum concentration of NOX was observed 20.7 g/m at Karmala and minimum value of 9.6 g/m3 observed at Gulsadi village. Both are residential areas hence the observed values are well within the NAAQ specified standards of 80 g/m3 for rural/ residential areas. The average values ranged from 18.02 g/m3 to 10.9 g/m3. CO – Maximum and minimum CO concentrations in the study region observed 0.310 mg/m3 and 0.108 mg/m3. The average values ranged from 0.153 mg/m3 to 0.268 mg/m3.

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4.5 NOISE ENVIRONMENT Environmental noise is the summary of noise pollution from outside, caused by transport, industrial and recreational activities. Noise is frequently described as 'unwanted sound', and, within this context, environmental noise is generally present in some form in all areas of human activity. The effects in humans of exposure to environmental noise may vary from emotional to physiological and psychological. The proposed project is an integrated sugar industry and hence requires movement of raw materials, chemicals, fuels, tools & tackles required for its manufacturing process and also transportation of finished products to its destination. The movement of personnel from their residence to industry would also result in a moderate increase in the traffic, which would not result in any drastic change in either the existing traffic pattern or noise levels of the area as accommodation facilities are proposed within the project site for most of the employees.  Sampling Methodology A sound level meter was used for measuring the noise level at one hour interval continuously for 24 hrs at 1.5 m above ground level, about 3 m from walls, buildings or other sound reflecting sources. The measurements were carried out in such a way that the monitoring locations were 1 m away from the sources and 1 m away from the edge of the roads. The lowest and highest noise levels are presented in table 4.10 and the limits as per Environmental Protection Rules, 1986 for industrial, commercial & residential areas are presented in Table 4.9 as under. During each hour parameters like L10, L50, L90, and Leq were directly computed by the instrument based on the sound pressure levels.  Sampling Locations Background noise levels were measured in 5 locations (Table 4.8), monitoring locations depicted in map attached (Fig 4.12) in human settlements within the study area Table 4.8: Noise level Monitoring Stations Sr. No. Name of location Distance in Km w.r.t Project Site Direction w.r.t Project Site 1 Project site 0 0 2 Pande 2.4 SE 3 Karmala 2.5 NW 4 Bhalewadi 7.0 NE 5 Deolali 5.6 SW

Fig. 4.12: Map Depicting Noise Monitoring Locations

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Table 4.9: Noise Level Limits as per Environmental Protection Rules Limits In dB ( A ) Category of Area Day Time (6 am – 9 pm) Night Time (9 pm – 6 am) Industrial Area 75 70 Commercial Area 65 55 Residential Area 55 45 Silence Zone 50 40

Table 4.10: Summary of Noise Level during Study Period Sr. No. Location (Zone) Leq (day)dB ( A ) Leq (Night) dB ( A ) Description i.e., Zone 1 Project site 36.56 33.12 Residential 2 Pande 43.75 37.75 Residential 3 Karmala 51.93 45 Residential 4 Bhalewadi 44.06 36.87 Residential 5 Deolali 41.12 37.25 Residential

Variation of Noise Level during Study Period 60 50 40 30 20 Leq (day)dB ( A )

Values in dB(A) Values 10 Leq (Night) dB ( A ) 0

Locations Fig. 4.13: Variation of Noise level during the study period (Dec -14 to Feb -15)

 Observations: The baseline noise levels have been monitored at different locations as indicated in the table above. The noise levels in the study area vary between 33.12 – 45 dB (A) during night time & 36.56 – 51.93 dB (A) during day time. It has been observed that the maximum noise levels at all the locations are within the limits specified for residential areas. Refer Annexure XVII for Noise Level Monitoring Report.

4.6 WATER ENVIRONMENT Water is one of the most important substances on earth. All plants and animals must have water to survive. If there was no water there would be no life on earth. Water on Earth moves continually through the water cycle of evaporation and transpiration (evapotranspiration), condensation, precipitation, and runoff, usually reaching the sea Evaporation and transpiration contribute to the precipitation over land. Safe drinking water is essential to humans and other life forms even though it provides no calories or organic nutrients.

 Sampling Methodology Water parameter analyzed as per the procedure specified in standard methods for examination of water and wastewater published by American Public Health Association and Bureau of Indian Standards (APHA/BIS). Samples for the analysis were collected in polyethylene containers. Samples collected for

metal content were acidified with 1 ml HNO3. Samples for biological analysis were collected in sterilized glass bottles. Selected physico -chemical and biological parameters have been analyzed for projecting the existing water quality status in the study area. Parameters like temperature, Dissolved Oxygen (DO), and pH were analyzed at the time of sample collection. Name of the locations, orientation with respect to the

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project site are listed in below table. The analytical data for surface water quality has been tabulated in table 4.14. Also Refer Annexure XVII for Surface Water Analysis Report.

 Sampling Locations The impact has been assessed on randomly selected surface and ground water sources falling within the impact zone. In order to assess the existing water quality, the water samples were collected from eight different locations within the study area (fig 4.14 & 4.15) Table 4.11: Surface Water sampling stations Sr. No. Name of location Distance in Km w.r.t Project Site Direction w.r.t. Project Site 1 Project site 0 0 2 Pande 2.4 SE 3 Karmala 2.5 NW 4 Bhalewadi 7.0 NE 5 Deolali 5.6 SW 6 Mangi lake 7.4 NW 7 Sina river 5.0 NE 8 Mhaisewadi lake 4.5 SE

Fig. 4.14: Map Depicting Surface Water Locations

The major fresh water source within the study zone is Sina River. The water requirement for the proposed integrated sugar complex will be sourced from Mangi Lake and Sina Kolegaon Dam. The supply of water to the industry will be metered for its quantification.

Ground water Ground water occurs under water table conditions in the weathered mantle of granite gneisses and in the joints, cracks and crevices of the basement rock. The depth of water is also dependent on topography and varies depending on the depth of weathering. The results of the analysis of Ground water samples are tabulated in Table 4.13.Also refer Annexure XVII (Ground Water Analysis Report)

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Table 4.12 Ground Water Sampling Stations Sr. No. Name of location Distance in Km w.r.t project Site Direction w.r.t. Project Site 1 Project Site 0 0 2 Pande 2.4 SE 3 Mangi 8.4 NW 4 Bhalewadi 7.0 NE 5 Deolali 5.6 SW 6 Pothare 5.3 N 7 Gulsadi 6.6 S 8 Karmala 2.5 NW

Fig. 4.15 Map Depicting Ground Water Locations

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Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

Table 4.13: Ground Water Quality Monitoring Results

Desirable Limits Sr. As Per Parameters Unit Project Site Pande Mangi Bhalewadi Deolali Pothare Karmala Gulsadi No. IS 10500:2012 [Max] 1 Colour, Hazen <5 <5 <5 <5 <5 <5 <5 <5 5 2 Odour Unobjectionable Unobjectionable Unobjectionable Unobjectionable Unobjectionable Unobjectionable Unobjectionable Unobjectionable Unobjectionable --- 3 pH --- 7.88 7.32 6.75 7.98 7.88 7.32 6.75 7.98 6.5 to 8.5 4 Taste ---- Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Turbidity 5 NTU 0.3 0.2 0.4 0.1 0.2 0.1 0.3 0.2 1 [NTU] 6 TDS mg/lit 480 450 485 490 490 460 500 490 500 Calcium 7 mg/lit 68.4 71.65 74.31 70.8 70 69.6 72 70.5 75 [as Ca] Chlorides 8 mg/lit 47.9 65.5 52.7 58.4 65.4 45.8 55.9 49.1 250 [as Cl] 9 Fluoride mg/lit Nil Nil Nil Nil Nil Nil Nil Nil 1.0 Residual 10 Free mg/lit Nil Nil Nil Nil Nil Nil Nil Nil 0.2 [MIN] Chlorine 11 Iron [as Fe] mg/lit 0.021 0.025 0.020 0.022 0.021 0.025 0.020 0.022 0.3 Magnesium 12 mg/lit 28.9 31.4 29.7 32.3 31.2 33 30.1 32.3 30 [as Mg] 13 Nitrate mg/lit 8.18 7.16 8.74 14.7 8.18 7.16 8.74 14.7 45 Sulphates 14 mg/lit 27.1 38.2 40.9 43.9 32.6 27.1 23.3 41.2 200 [as SO4] Total 15 Alkalinity mg/lit 96.7 103.9 116.7 119.63 103.7 113.9 101.7 119.63 200 as CaCO3 Total 16 Hardness mg/lit 263.4 287.3 259.8 232.5 305.6 267.5 224.7 318.27 200 as CaCO3 17 Lead mg/lit Nil Nil Nil Nil Nil Nil Nil Nil 0.05 18 Cadmium mg/lit Nil Nil Nil Nil Nil Nil Nil Nil 0.01 19 Chromium mg/lit Nil Nil Nil Nil Nil Nil Nil Nil 0.05 20 Aluminium mg/lit Nil Nil Nil Nil Nil Nil Nil Nil 0.03 21 Zinc mg/lit Nil Nil Nil Nil Nil Nil Nil Nil 5 22 Manganese mg/lit Nil Nil Nil Nil Nil Nil Nil Nil 0.1

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23 Copper mg/lit Nil Nil Nil Nil Nil Nil Nil Nil 0.05 24 Arsenic mg/lit Nil Nil Nil Nil Nil Nil Nil Nil 0.05 25 Boron mg/lit Nil Nil Nil Nil Nil Nil Nil Nil 1 26 Phenol mg/lit Nil Nil Nil Nil Nil Nil Nil Nil 0.001 27 Cyanide mg/lit Nil Nil Nil Nil Nil Nil Nil Nil 0.05 28 Mercury mg/lit Nil Nil Nil Nil Nil Nil Nil Nil 0.001 29 Nickel mg/lit Nil Nil Nil Nil Nil Nil Nil Nil 0.02 No’s/100 30 E – Coli Absent Absent Absent Absent Absent Absent Absent Absent --- ml Total Coli form No’s/100 31 Absent Absent Absent Absent Absent Absent Absent Absent --- Bacteria / ml MPN

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Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

Table 4.14: Surface Water Quality Monitoring Results

Desirable LimitsAs Sr. Mhaisewadi Parameters Unit Project Site Pande Karmala Bhalewadi Sina River Mangi lake Deolali Per IS 10500:2012 No. lake [Max] 1 Colour, Hazen <5 <5 <5 <5 <5 <5 <5 <5 5 2 Odour --- Unobjectionable Unobjectionable Unobjectionable Unobjectionable Unobjectionable Unobjectionable Unobjectionable Unobjectionable Unobjectionable 3 pH -- 7.45 7.57 7.78 7.40 7.73 7.28 7.44 7.35 6.5 to 8.5 4 Taste --- Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable 5 Turbidity [NTU] NTU 0.5 0.8 0.7 0.6 0.8 0.9 0.7 0.65 1 6 TDS mg/lit 215.44 207.45 220.86 235.32 210 222.5 215.7 200.93 500 7 Calcium [as Ca] mg/lit 38.3 48.02 51.02 63.04 35.4 57.6 53.7 36.3 75 8 Chlorides [as Cl] mg/lit 89.4 92.33 82.45 86.33 108.2 74.3 69.5 79.8 250 9 Fluoride mg/lit Nil Nil Nil Nil Nil Nil Nil Nil 1.0 10 Residual Free Chlorine mg/lit Nil Nil Nil Nil Nil Nil Nil Nil 0.2 [MIN] 11 Iron [as Fe] mg/lit 0.011 0.013 0.016 0.012 0.009 0.014 0.011 0.013 0.3 12 Magnesium [as Mg] mg/lit 17.44 13.36 21.22 25.6 21.16 23.45 20.33 19.6 30 13 Nitrate mg/lit 8.36 8.83 10.21 7.44 7.43 10.11 9.63 6.78 45 14 Sulphates [as SO4] mg/lit 36.9 41.9 47.9 50.2 35.8 42.3 45.9 39.8 200 Total Alkalinity as 15 mg/lit 72.3 88.5 92.7 56.21 74.3 63.2 81.7 97.3 200 CaCO3 Total Hardness as 16 mg/lit 122.53 117.4 120.56 119.12 94.6 103.8 118.9 120.6 200 CaCO3 17 Lead mg/lit Nil Nil Nil Nil Nil Nil Nil Nil 0.05 18 Cadmium mg/lit Nil Nil Nil Nil Nil Nil Nil Nil 0.01 19 Chromium mg/lit Nil Nil Nil Nil Nil Nil Nil Nil 0.05 20 Aluminium mg/lit Nil Nil Nil Nil Nil Nil Nil Nil 0.03 21 Zinc mg/lit Nil Nil Nil Nil Nil Nil Nil Nil 5 22 Manganese mg/lit Nil Nil Nil Nil Nil Nil Nil Nil 0.1 23 Copper mg/lit Nil Nil Nil Nil Nil Nil Nil Nil 0.05 24 Arsenic mg/lit Nil Nil Nil Nil Nil Nil Nil Nil 0.05 25 Boron mg/lit Nil Nil Nil Nil Nil Nil Nil Nil 1 26 BOD mg/lit 3.1 3.3 2.0 2.5 1.5 3.4 3.0 2.4 --- 27 COD mg/lit 7.75 8.25 5.0 6.25 4.5 8.5 7.5 6 --- 28 Phenol mg/lit Nil Nil Nil Nil Nil Nil Nil Nil 0.001 29 Cyanide mg/lit Nil Nil Nil Nil Nil Nil Nil Nil 0.05 30 Mercury mg/lit Nil Nil Nil Nil Nil Nil Nil Nil 0.001 31 Nickel mg/lit Nil Nil Nil Nil Nil Nil Nil Nil 0.02 No’s/100 32 E – Coli Absent Absent Absent Absent Absent Absent Absent Absent Absent ml Total Coli form Bacteria No’s/100 33 Absent Absent Absent Absent Absent Absent Absent Absent Absent / MPN ml

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Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

Observations: Most of the villages in the project area have hand pumps and wells, as most of the residents of these villages make use of this water for drinking and other domestic uses. The physico -chemical quality of the surface and ground water sources at and around the plant site have been analyzed, which indicates that almost all the parameters except total hardness in case of ground water

(as CaCO3) analyzed are within “Maximum Acceptable Limits As per IS: 10500-2012. The analysis of samples collected from rivers & canals for various parameters also reveals that the quality of water is fairly potable to meet the quality requirement for human use

4.7 STUDY AREA-GEOGRAPHICAL ASPECTS

4.7.1 Hydrology and hydrogeology The Solapur district as a whole is mainly covered by Deccan Trap basaltic lava flows of Upper Cretaceous to Lower Eocene age, which in turn is covered by a thin mantle of soil almost everywhere. These flows due to differential weathering give rise to undulating topography. There are no prominent hill ranges in the district and the region is characterized by typical Deccan trap geomorphology. The lava flows in the district represent middle traps and attain a thickness of more than 1,200 m. The fine grained dark grey basalts and weathered vesicular and zeolitic basalts are generally observed. The flows consist of dark grey fine grained, hard and compact basalts. A few red bole beds, which are the ferruginous clayey substances of brick-red colour, have been noticed in between the successive flows.

The vesicles in basalt, which are around 4-5 mm. in diameters, are usually filled in by secondary minerals like zeolites, calcite etc. The maximum thickness of a flow in the area, observed is around 30 meters, while the average is generally of the order of 20 meters. The basalts display typical spherical weathering, the depth of the weathered zone varying between 3 to 8 meters. Veins of kankar filling up the fractures of the vesicular traps are quite common. Such vein fillings are absent in the fine grained compact basalt. There are no evidences of any structural disturbances like folding or faulting. The trap flows exhibit a general horizontal disposition. The fine-grained basalts show the typical hexagonal columnar type of jointing. The vesicular traps at places exhibit north-south and east-west striking joints, with vertical dips. Closely-spaced sheet jointing is also present.

The groundwater in district occurs in both confined and unconfined conditions. The individual trap flows in the southern part of Solapur district are observed to yield a discharge of about 5 to 10 liters per second (i.e., 4,000 to 9,000 gallons per hour) for a draw-down of 1 to 3 meters. The chemical quality of groundwater tapped from the vesicular zones is generally good and quite suitable for irrigation and domestic purposes. The North Solapur Taluka falls under safe category of watershed. The total net annual groundwater availability is 7067 Ham. The average pre monsoon water level in command area in North Solapur Taluka is 9 m below ground level (Below Ground Level) while post-monsoon water level is 4 m (Below Ground Level)

The area surrounding plant site is generally flat terrain with undulating topography. Small hillocks of 478 m elevation are observed in NW side of plant. General slope of the area is towards western direction. A nalla is present on western part at about 2.5 km flowing southerly. A prominent river Sina is flowing in West direction at about 8.0 km from plant site.

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4.7.2 Soil and Geology Geographically Solapur is located between 17.10 to 18.32 degrees north latitude and 74.42 to 76.15 degrees east longitude. The district is situated on the south east fringe of Maharashtra State and lies entirely in the Bhima and Sina basins. Whole of the district is drain either by Bhima river or its tributaries. The district is bounded on the north by Ahmednagar and Osmanabad districts, on the east by Osmanabad and Gulbarga (Karnataka State) districts, on the south by Sangli and Bijapur (Karnataka State) and on the west by Satara and Pune districts.

There is no important hill system in the district. Only in the north of Barshi Taluka several spurs of Balaghat range pass south for a few kilometers. There are also a few scattered hills in Karmala, Madha and Malshiras Taluka. The district in general has flat or undulating terrain. The low table land and small separate hills in Karmala and Madha Taluka act as a Watershed between Bhima and Sina rivers.

The district covers geographical area of 14844.6 sq. kms. This is 4.82% of the total area of Maharashtra State. Out of the total area of the district 338.8 sq. kms (2.28 %) is urban area whereas remaining 14505.8 sq. kms. (97.72%) is rural area. Area wise Karmala Taluka is biggest covering an area of 1609.7 sq.kms and North Solapur is smallest covering an area of 736..3 sq.kms.

The soils of the District can broadly be classified into three types.  Black  Coarse Gray  Reddish According to topography the district is divided in three natural zones.  Eastern Zone: This comprises of Barshi, North Solapur, South Solapur and Akkalkot Talukas. The soil is medium to deep black and of rich quality. Jawar, Bajra and Pulses are the main crops of this zone.  Central or Transitional Zone: Mohol, Mangalvedha, eastern part of Pandharpur and Madha Taluka are covered by this zone. Like to moderate soil and uncertain rainfall marks this zone. Both Kharif and Rabbi Crops are grown in this part.  Western Zone: Karmala, Sangola and Malshiras Taluka and western parts of Pandharpur comes under this zone. Shallow and poor type of soil, not retentive of moisture marks this part. There is Scanty and uncertain rainfall. Rabbi crops are mainly grown in Karmala, Pandharpur and Madha Taluka while Kharif crops like Bajara and Groundnut are grown in Sangola and parts of Malshiras Taluka.

4.7.3 Soil Sampling It is essential to determine the potential of soil in the area and identify the current impacts of urbanization and industrialization on soil quality and also predict impacts, which may arise due to the plant operations. Accordingly, a study of assessment of the baseline soil quality has been carried out.

 Sampling Methodology:- For studying soil profile of the region, sampling locations were selected to assess the existing soil conditions in and around the project area representing various land use conditions. The physical, chemical and heavy metal concentrations were determined. The samples were collected by ramming a core-cutter into the soil up to a depth of 90 cm. The present study of the soil profile establishes the baseline characteristics and this will help in future in identifying the incremental concentrations if any, due to the operation of the plant. The sampling locations have been identified with the following objectives:-  To determine the baseline soil characteristics of the study area.  To determine the impact of industrialization on soil characteristics; and  To determine the impact on soil more importantly on agricultural productivity point of view.

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 Sampling Locations:- Five locations Within 10 Km radius of the proposed plant boundary were selected for soil sampling. At each location, soil samples were collected from three different depths viz. 30 cm, 60 cm, 90 cm below the surface and are homogenized. This in line with IS: 2720 and methods of soil analysis, Part – 1, 2nd edition, 1986 of (American Society for Agronomy and soil science Society of America). The homogenized samples were analyzed for physical and chemical characteristics. The soil samples were collected during post-monsoon season. The samples have been analyzed as per established scientific methods for physico-chemical parameters. The heavy metals have been analyzed by using Atomic Absorption Spectrophotometer. The list of locations and the orientation with reference to the project site are listed in table 4.15. Soil sampling locations are shown in the map appended as fig 4.16. Soil samples were analyzed for physical and chemical parameters the results of which are given in Table 4.16. Also refer Annexure XVII for Soil sampling analysis report. Table 4.15: Soil Sampling Locations Sr. No. Name of location Distance in Km w.r.t. Project Site Direction w.r.t Project Site 1 Project site 0 0 2 Pande 2.4 SE 3 Bhalewadi 7.0 NE 4 Deolali 5.6 SW 5 Pothare 5.3 N

Fig. 4.16: Map Depicting Soil Quality Monitoring Locations

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Table 4.16 Soil Quality Monitoring Results Sampling Location Project Site Pande Bhalewadi Deolali Pothare Unit SR PARAMETERS A PHYSICAL PARAMETERS 1 pH of 1 % Solution --- 7.58 7.87 7.48 7.56 7.52 Conductivity of 1 % Micro 2 166 178 148 162 167 Solution mhos Soil Classification % 17.0 18.0 18.5 16.0 17.5 - Clay 3 % 79.5 77.5 79.7 79.0 77.0 - Silt % 3.5 4.5 1.8 5.0 5.5 - Loam 4 Moisture content % 29.15 29.60 30.10 30.05 28.6 5 Soil Texture Silt loam Silt loam Silt loam Silt loam Silt loam Water Retention 6 % 43.6 43.4 45.8 44.2 41.56 Capacity in C CHEMICAL PARAMETERS (BY WATER LEACHATE) Sulphate as SO mg/lit 355.10 392.74 332.7 330.12 388.7 4 7 Chlorides as Cl mg/lit 254.35 288.14 282.54 271.45 279.08 8 Calcium as Ca mg/lit 412.35 392.64 410.47 288.5 424.13 9 Sodium as Na ppm 4.52 4.01 4.23 3.58 4.86 Total Kjeldhal Nitrogen 10 mg/lit 1077 1162 1093 1148 1192 (N)

11 Total Phosphates as PO4 ppm 698 756 714 672 764 12 Potassium ( K) mg/lit 33.21 36.54 35.30 34.7 33.6 13 Organic matter % 0.83 0.79 0.81 0.86 0.74 14 Copper as Cu ppm Nil Nil Nil Nil Nil 15 Zinc as Zn ppm 4.38 4.82 5.8 5.1 3.2 16 Iron as Fe ppm 46.21 48.7 41.09 41.2 51.9 17 Manganese as Mn ppm Nil Nil Nil Nil Nil 18 Boron as B ppm 5.52 4.8 4.1 4.3 3.56 D HEAVY METALS (BY ACID LEACHATE) 18 Nickel as Ni ppm 1.92 1.67 1.76 1.97 1.56 19 Cadmium as Cd ppm Nil Nil Nil Nil Nil 20 Lead as Pb ppm Nil Nil Nil Nil Nil 21 Chromium ppm Nil Nil Nil Nil Nil

 Observations:-  It has been observed that the pH of the soil in the study area ranged from 7.48 to 7.87. The maximum pH value (7.87) was observed at Pande village, and where as the minimum value (4.48) was observed at Bhalewadi village  The electrical conductivity was observed to be in the range of 148 mhos/cm to178 mhos/cm, with the maximum observed at Pande village and the minimum observed in Bhalewadi.  The nitrogen value range between 1162 mg/lit to 1077 mg/lit. The nitrogen content in the study area falls in less to better category.  The phosphorus values range between 672 ppm to 764 ppm indicating that the phosphorus content in the study area falls to sufficient category.  The potassium values range between 33.21 mg/lit to 36.54 mg/lit. The potassium content in the study area falls to sufficient category.  The Chlorides were found to be in the range of 254.35 mg/lit to 288.14 mg/lit in the study area.

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Table 4.17: Standard Soil Parameter Classification Sr. No. Soil Test Parameter Classification < 4.50 Extremely acidic 4.51- 5.00 Very strongly acidic 5.51-6.00 moderately acidic 6.01-6.50 slightly acidic 1 pH 6.51-7.30 Neutral 7.31-7.80 slightly alkaline 7.81-8.50 moderately alkaline 8.51-9.00 strongly alkaline 9.01 very strongly alkaline Average Salinity Electrical Conductivity (ppm) 1.01-2.00 harmful to germination 2 (1 ppm = 640 mho/cm) Upto 1.00 2.01-3.00 harmful to crops (sensitive to salts) Up to 0.2: very less 0.21-0.4: less 0.41-0.5 medium, 3 Organic Carbon (%) 0.51-0.8: on an average sufficient 0.81-1.00: sufficient >1.0 more than sufficient Up to 50 very less 51-100 less 4 Nitrogen (Kg/ha) 101-150 good 151-300 Better >300 sufficient Up to 15 very less 16-30 less 31-50 medium, 5 Phosphorus (Kg/ha) 51-65 on an average sufficient 66-80 sufficient >80 more than sufficient 0 -120 very less 120-180 less 181-240 medium 6 Potash (Kg/ha) 241-300 average 301-360 better >360 more than sufficient

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4.7.4 Land Use Pattern

4.7.4.1 Land Use Pattern of Solapur District ► Agricultural Area – 11480 Km2 ► Cultivable not in use – 380 Km2 ► Non-agricultural – 690 Km2 ► Grass Lands and Herbs – 720 Km2 ► Forest Cover – 350 Km2 ► Wastelands – 1260 Km2 ► Draught prone areas (All eleven Taluka) – 14844.6 Km2

Fig. 4.17: Land Use Pattern of Solapur District

4.7.4.2 Land use pattern of the Operational Area (i.e.) Karmala Taluka 1) Karmala Taluka: Particulars Area, Sq. Kms Percent Agricultural Area 525 32.91 Shrub Land 501 31.41 Fallow Land 389 24.39 Settlement 24 1.51 water body 156 9.78 Total 1595 100

Land Use Pattern of Karmala Taluka water body Agricultural Settlement 10% Area 2% 33%

Fallow Land 24%

Shrub Land 31%

Fig. 4.18: Land Use Pattern of Karmala Taluka

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 Agriculture & Irrigation 1.0 Agriculture

Need of Agriculture Land use Study • To feed the man’s requirement. • To study the land use problem. • For keeping social and ecological balance. • For best use of land. • For optimum use of land. The agriculture land in Karmala Taluka is 525 Sq.Km. which is 33 percent of the total geographical area. Karmala Taluka is noted for jawar, sugarcane, groundnut, safflower, wheat, maize, gram, bajara, tur and fruits combination.

2.0 Irrigation Soil Irrigation means to provide water for sustainable crop production in agriculture with the help of artificial sources without rain water. For ex. Dam, Well, Canal, Tube well, etc. in artificial irrigation, canal irrigation plays vital role. Karmala tehsil is benefited by back water on lift irrigation of the Ujjani irrigation project

District Taluka No. of Benefited village Area under irrigation (Ha) Percentage Solapur Madha 11 4884 26.41 Solapur Karmala 45 13604 73.59 56 18488 100 Source – Bhima Project, salient feature Bhima (Ujjani) irrigation Division Pandharpur District – Solapur 2004

There is maximum shares of Karmala Taluka (Dist Solapur) in which the maximum share of (73.59 %) Lift irrigation has been observed by Karmala Taluka. Minimum share of Madha tehsil is (26.41 %) to the total lift irrigation of Bhima (Ujjani) Irrigation Project.

4.8 ECOLOGY

Natural flora and fauna are important features of the environment. They are organized into natural communities with mutual dependencies among their members and show various responses and sensitivities to physical innocence. The integrated ecological thinking and planning process is an urgent need in the context of natural environment's deterioration which has a direct bearing on socioeconomic development.

Ecology of the study area includes the flora and fauna studies within the study zone. The investigation included field observations, discussions with local people, forest officials etc.

4.8.1 Flora in the Study Area Flora: The scope of study is to know the prevalence of living forms (plants and animal) in the study area and the impact if any, due to existence of the industry. The impact could be visible damage, increased mortality, reduction in growth and reproduction and possibility of extinction of some species. There are numerous species of plants and animals and it is just impossible to study all the species. Higher animals and plants were chosen for study.

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Table 4.18: List of Terrestrial flora in study area Sr. No. Botanical name Local Name Family Status Trees, herbs and shrubs 1 Polyalthia longifolia Ashoka Annonaceae Cultivated 2 Santalum album Chandan Santalaceae Common 3 Tamarindus indica Chinch Caesalpiniaceae Common 4 Terminalia catappa Bahada Combretaceae Common 5 Terminalia catappa Jangli Badam Combretaceae Common 6 Ziziphus mauritiana Bor Rhamnaceae Common 7 Aloe vera Korphad Liliaceae Cultivated 8 Annona squamosa Sitaphal Annonaceae Cultivated 9 Calotropis gingaea Rui Asclepiadaceae Common 10 Carissa carandas Karvand Apocynaceae Common 11 Crossandra infundibuliformis Aboli Acanthaceae Cultivated 12 Hibiscus hispidissimus Kateri bhendi Malvaceae Cultivated 13 Ipomoea carnea Besharam Convolvulaceae Common 14 Malachra capitata Ran-Bhendi Malvaceae Common 15 Maytenus senegalensis Henkal Celastraceae Common 16 Mimosa hamata Borkhad Mimosaceae Common 17 Nerium indicum Kanher Apocynaceae Cultivated 18 Opuntia elatior Nivdung Cactaceae Common 19 Psidium guajava Guava Myrtaceae Cultivated 20 Punica granatum Pomegranate Punicaceae Cultivated 21 Pupalia lappacea Chikta Amaranthaceae Common 22 Vitex negundo Nirgudi Verbenaceae Common 23 Ziziphus mauritiana Jangli-bor Rhamnaceae Common 24 Datura metal Dhotra Solanaceae Common 25 Eclipta prostrata Maka Asteraoeae Common 26 Ocimum sanctum Ran-Tulas Lamiaceae Common 27 Ocimum sanctum Tulas Lamiaceae Cultivated 28 28 Solanum indicum Kamoni Solanaceae Common 29 Typha angustata Pan-kanis Typhaceae Common 30 Vernonia cinerea Sahadevi Asteraceae Common 31 Acacia nilotica ssp.indica Babhul Mimosaceae Common 32 Acacia nilotica Spp. astringens Vedi-Babhul Mimosaceae Common 33 Aegle marmelos Bel Rutaceae Common 34 Azadirachta indica Neem Meliaceae Common 35 Bauhinia racemosa Aapta Caesalpiniaceae Common 36 Phanera variegata Kanchan Caesalpiniaceae Common 37 Butea monosperma Palas Febaceae Common 38 Ricinus communis Castor Euphorbiaceae Common 39 Dalbergia sisoo Shisvi Fabaceae Frequently 40 Delonix regia Gulmohar Caesalpiniaceae Cultivated 41 Phyllanthus emblica Aavla Euphorbiaceae Cultivated 42 Syzygium cumini Jambhul Myrtaceae Cultivated 43 Eucalyptus globulus Nilgiri Myrtaceae Cultivated 44 Ficus benghalensis Wad Moraceae Frequently 45 Ficus racemosa Umbar Frequently 46 Ficus religiosa Pimpal Moraceae Common 47 Limonia acidissima Kavath Rubiaceae Scarce 48 Mangifera indica Aamba Anacardiaceae Cultivated 49 Pithecellobium dulce Vilayati chinch Mimosaceae Cultivated

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50 Prosopic spicigera Saundad (Shami) Fabaceae Frequently Climbers 1 Clematis gouriana Morvel Ranunculaceae Common 2 Clitoria ternatea Gokarna Fabaceae Common 3 Cuscuta hyalina Amarvel Cuscutaceae Common 4 Momordica dioica Kartoli Cucurbitaceae Common 5 Pergularia daemia Utaran Araceaeae Common 6 Tinospora cordifolia Gulvel Menispermaceae Common 7 Vigna sublobata Welmoog Fabaceae Common 8 Abrus precatorius Gunj Fabaceae Frequently 9 Asparagus racemosus Shatavari Liliaceae Frequently Grasses 1 Ischaemum pilsum Kunda Poeceae Common 2 Aristida redacta Kusal Poaceae Common 3 Cynadon dactylon Durva Poaceae Common 4 Dichanthium annulatum Marvel Poeceae Common 5 Aristida funiculata Pandhri-kusal Poaceae Common Lichens 1 Calopaca marina Crustose Teloschistaceae Frequently Source – Department of Forest, Tahsil – Karmala

4.8.2 Fauna in the Study Area A significantly large populations of cow, buffaloes, goats are present the study area. On the Basis of interviewers of villagers it was reported that there was increase in cows & buffaloes. This is due to the increased demand of milk. The animals found healthy and no special diseases were reported. Pet animals like dog, cats, goats were observed in general. Pet birds like parrots are also observed in some houses. The poultry business is also a major business in this area. No any killing due to pollution of the factory detected so far. Thus it can be said that there has been no adverse impact on domestic animals. The common species of animals found in the study area are as follows: Table: 4.19: List of Terrestrial fauna in study area Sr. No Common Name Scientific Name Mammals 1 Cow Bos taurus 2 Domestic buffalo Bubalus bubalis 3 goat Capra hircus aegagrus 4 Squirrel Funambulus palmarum 5 Indian palm squirrel Funambulus palmarum 6 Indian grey mongoose Herpested edwardsil 7 Common cat Felis silvestris catus 8 Common dog Canis lupus familiaries Amphibians 1 common tree frog Polypedates leucomystax 2 Indian bullfrog Hoplobatrachus tigerinus 3 Common Indian toad Duttaphrynus melanostictus Reptiles 1 Common garden lizard Calotes versicolor 2 House gecko Hemidactylus frenatus 3 Rock lizard Petrosaurus mearnsi Insects - Butterfly 1 Chocolate pansy Junonia iphita 2 Common evening brown Melanitis leda 3 Common grass yellow Eurema hecabe

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4 Common Indian crow Euploea core 5 Red pierrot Talicada nyseus 6 Blue mormon Papilio polymnestor 7 Blue pansy Junonia orithya Dragonflies and Damselflies 1 Long legged Marsh Skimmer Trithemis pallidinerries 2 Ditch jewel Brachythemis contaminata 3 Senegal golden dartlet Ischnura senegalensis 4 Yellow bush dart Copera marginipes 5 Crimson marsh glider Trithemis aurora Birds 1 Darter Anhinga melanigaster 2 Pond heron ardeola grayii 3 River tern Sterna aurantia 4 Cotton teal Etapus coromandelisanus 5 Black ibis Pseudibis papillosa 6 Purple sunbird Cinnyris asiaticus 7 Baya weaver Ploceus philippinus 8 Pigeons Columbidae 9 Myna Acridotheres tristis 10 Painted partridge Francolinus pictus 11 Black kite Milvus migrans 12 Cattle egret Bubulcus ibis 13 Kingfisher Alcedines 14 Grey heron Ardea cinerca 15 Indian robin Saxicoloides fulicatus 16 Little cormorant Microcarbo niger 17 Jungle crow Corvus macrorhynchos Source – Department of Forest, Tahsil – Karmala

Table 4.20: Percentage (%) wise Population Density of Zooplankton (per ml) at river Sina

Sr. No. Zooplankton No of species Percentage 1 Rotifera 36 (31.58%)

2 Cladocera 24 (21.05%) 3 Copepoda 37 (32.46%) 4 Ostracoda 17 (14.91%) Total 114 100 %

Table 4.21: Percentage (%) wise Population Density of Phytoplankton (per ml) at river Sina Sr. No. Zooplankton No of species Percentage 1 Chlorophyceae 53 (38.97%) 2 Bacillariophyceae 33 (24.26%) 3 Cynophyceae 29 (21.32%) 4 Euglenophyceae 21 (15.44%) Total 136 100 %

Table 4.22: Percentage (%) wise Population Density of Zooplankton (per ml) at Mangi Lake Sr. No. Zooplankton No of species Percentage 1 Rotifera 10 (62.5%) 2 Cladocera 03 (18.75%) 3 Copepoda 03 (18.75%) 4 Ostracoda Nil --- Total 16 100 %

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Table 4.23: Percentage (%) wise Population Density of Phytoplankton’s (per ml) at Mangi Lake Sr. No. Zooplankton No of species Percentage 1 Chlorophyceae 01 (7.7%) 2 Bacillariophyceae 03 (23%) 3 Myxophyceae 06 (46.3%) 4 Euglenophyceae 03 (23%) Total 13 100 %

Table 4.24: Percentage (%) wise Population Density of Zooplankton (per ml) at Mhaisewadi Lake

Sr. No. Zooplankton No of species Percentage 1 Rotifera 09 (42.9%) 2 Cladocera 05 (23.80%) 3 Copepoda 05 (23.80%) 4 Ostracoda 02 (9.5%) Total 21 100 %

Table 4.25: Percentage (%) wise Population Density of Phytoplankton’s (per ml) at Mhaisewadi Lake Sr. No. Zooplankton No of species Percentage 1 Chlorophyceae 04 (28.6%) 2 Bacillariophyceae 02 (14.29%) 3 Cynophyceae 05 (35.71%) 4 Euglenophyceae 03 (21.4%) Total 14 100 %

Fig. 4.19: Map Depicting Terrestrial Flora & Fauna Sampling Locations

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4.9 SOCIO-ECONOMIC ENVIRONMENT The baseline data referring to the socio-economic environment is collected by way of secondary sources such as census records, statistical hand book and relevant official records with the government agencies and primary sources such as the socio-economic surveys conducted by different Govt. & Non Govt. Agencies.

The growth of industrial sectors and infrastructure development in and around the agricultural area i.e. villages and semi-urban settings and towns is bound to create certain socio-economic impacts on the local populace. The impacts may be either positive or negative depending on the nature of development. To assess such impact it is necessary to know the existing socio-economic order of the study area, which will be helpful in improving the overall quality of life.

Demographic structure The information collected from the secondary sources are from the district census statistical hand books and the records of the National Informatics Center, New Delhi in respect of the population, infrastructure facilities available and the occupational structures of the study area. The socio-ecological aspect of the study include the agro based economy, industry based economy and occupational structure of the workers. The study has been divided in to three zones which include the core and buffer zones which are presented in below given Table No. 4.26.

Table 4.26: The Socio- economic data in 30 villages of influential zone of 10 km radius from project site In Figures In Percentage (%) Sr. No. Contents Male Female Total Male Female Total 1 Population 30245 28212 58457 51.73 48.27 100 2 Literates 21378 14927 36305 36.57 25.53 62.10 3 Illiterates 8867 13285 22152 15.17 22.73 37.90 4 SC 4628 4457 9085 7.92 7.62 15.54 5 ST 475 451 926 0.81 0.77 1.58 6 Workers A Main Workers 15378 7972 23350 26.31 13.63 39.94 B Marginal Workers 1330 2631 3961 2.27 4.50 6.77 Total Workers 16708 10603 27311 28.58 18.13 46.70 7 Non Workers 13537 17609 31146 23.16 30.14 53.30 Source – 2001 Census of India

Socio economic Data

53,30% 100% Population 46,71% Literates Illiterates SC 37,90% 62,10% ST Total Workers 15,54% Non Workers 1,58%

Fig. 4.20: Diagram showing Socio Economic data of 10 km radius with respect to project site

110 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

Observations:- 1. Average House hold size: - The study area had an average family size of 5.4 persons per house hold. 2. Population Density: - The density of population in the study area works out to about145 persons per km2. 3. Sex Ratio: - The configuration of male and female indicates that the male constitute to about 51.73% and 48.27 % females to the total population. The sex ratio i.e. the number of female per 1000 males indirectly reveals certain sociological aspects in relation with female birth, infant mortality among female children and single person family structure, a resultant of migration of industrial workers. The study area on an average has 925 females per 1000 males. 4. Literacy: - To know development in a society, Literacy is proper indicator of Social and economic development. The literacy rate found 62.10% of total population in the study area. Female literacy rate is lower than the male literacy rate i.e. Female Literacy rate is 25.53% and that of male is 36.57%. 6. SC and ST Population – SC and ST Population observed as 15.54% and 1.58% respectively of total population in the study area, indicating that about 17.12% of the population in the study area belongs to socially weaker sections. 7. Occupational Structure- The occupational structure of residents in the study area is studied with reference to main workers, marginal workers and non marginal workers. Workers (Main & Marginal) observed 46.71% of the total population in the study area and Non Workers (include students, house wives, and children above 6 years also) 53.30%. It concluded that the number of non workers in this area is greater than that of workers. They will be benefited by getting opportunity of employment through this proposed project.

Table 4.27: Socio Economic data of study area compared with Solapur District and Maharashtra

Sr. No. Particular Study Area (Influential Solapur District Maharashtra zone of 10 km radius) 1 Population (Nos.) 58457 43,18,000 11,23,74,000 2 Male (%) 51.73 51.60 51.82 3 Female (%) 48.27 48.40 48.18 4 Population Density (Nos.) 145 290 365 5 Sex Ratio (Females per 1000 males) 925 938 929 4 Literacy (%) 62.10 77.02 82.30 5 SC (%) 15.54 15.04 11.81 6 ST (%) 1.58 1.78 9.35

4.10 SOCIAL INFRASTRUCTURE AVAILABLE Infrastructure is the basic physical and organizational structures needed for the operation of a society or enterprise or the services and facilities necessary for an economy to function. The term typically refers to the technical structures that support a society, such as roads, water supply, sewers, electrical grids, telecommunications and so forth and can be defined as "the physical components of interrelated systems providing commodities and services essential to enable, sustain or enhance societal living conditions.

Viewed functionally, infrastructure facilitates for example, roads enable the transport of raw materials to a factory. The basic social services such as schools and hospitals are also very essential.

The list of hospitals & other infrastructural facilities available in the vicinity of the proposed industry is given in below Table No. 4.28

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Table 4.28: List of infrastructural facilities in the surroundings Distance from the Direction from the Sr. No. Hospital industry (km) industry (km) 1 District Hospital, Karmala 3 North West 2 Krushna Hospital, Karmala 3.2 North West 3 Crhp Julia’s Hospital 36 North East 4 Jeur Railway Station 16 South West 5 Kem Railway Station 25 South East 6 Jinti Railway Station 36 South West 7 Baramati Airport 70 South West 8 Osmanabad Airport 90 South East Note: All distances mentioned are aerial

Fig. 4.21: Google map depicting Infrastructural facilities

4.11 CONNECTIVITY FROM THE PROJECT SITE Connectivity to the project site is detailed in the following table. Google map showing the same is appended subsequently. Table 4.29: Connectivity from the project site (Distance in Km) Sr. No. Road Distance Direction 1 SH 143 2.5 North 2 SH 141 1.7 South West 3 SH 67 1.5 West 4 SH 149 16.9 South East 5 Jeur Railway station 16 South West 6 Kem railway Station 25 South East 7 Jinti railway station 36 South West 8 Baramati Airport 70 South West 9 Osmanabad Airport 90 South East

112 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

Fig. 4.22: Google map depicting connectivity

Fig. 4.23 Google Map depicting Sugar Industries surrounding the project site

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4.12 SURROUNDING SUGAR INDUSTRIES

Table 4.30: Sugar Industries surrounding the project site

Distance from the Direction w.r.t. Sr. No. Industry project site (km) the project site Adinath SSK , Adinath Nagar , Shelgaon 1 21 South West Bhalwani, Tal: Karmala, Dist:Solapur Bhairavnath Sugar Pvt Ltd , Sonari, 2 21 South East Paranda Dist: Solapur Vitthalrao Shinde SSK ltd, Gangamai 3 40 South Nagar, Pimpalner , Madha Dist: Solapur Makai SSK ltd, Bhilarewadi , Karmala 4 35 South West Dist: Solapur

Table 4.31: Schools near Project Site

Distance from the Direction w.r.t. Sr. No. Name project site (km) the project site 1 Gurukul Public School, Karmala 2.5 West 2 ZPPS, Pnade 2.4 South East Maharashtra Madhyamic Vidyalaya, 3 5.3 North Pothare

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CHAPTER – 5 ANTICIPATED ENVIRONMENTAL IMPACTS AND MITIGATION MEASURES

5.1 INTRODUCTION It is said that the only constant thing in the Universe is change. Every activity is bound to bring about some change. The change in case of careless working can be significant. This may result in making significant effect on environment. California Environment Quality Act defines this qualitative term. Guideline sin section 15382, state as under: “Significant effect on the environment means a substantial or potentially substantial, adverse change in any of the physical conditions within the area affected by the project including land, air, water, minerals, flora, fauna, ambient noise, and objects of historic or aesthetic significance. An economic or social change by itself shall not be considered a significant effect on the environment. A social or economic change related to a physical change may be considered in determining whether the physical change is significant. Any activity making a significant effect is not permissible. This “significant effect” is required to be neutralized to a level of ‘’insignificance”. This can be brought about by various tools like: in plant measures, segregation, environment friendly process and collectively termed as pollution control say be providing Effluent Treatment Plant (ETP) and Emission Control Equipments (ECE), etc. This will simultaneously satisfy the provisions of environmental statutes automatically. However, meeting the standards may not be adequate view point of some sensitive group of the community like say aged people, NGOs or young exposed kids. For them, even the “insignificant effect” may be large enough. It is then necessary to work out and take supplementary mitigation measures and neutralize the situation further to a “low or no consequences”. If this can be successfully done, impact is not felt from the proposed activities and hence is indeed permissible.

Industry VRSL Produc t

Pollution

Significant Effect Control measures Insignificant Low / no consequence Supplementary mitigation measures

Target

5.2 CONTROL MEASURES (NATURAL ENVIRONMENT): 5.2.1 Air Environment: It will be a logical analysis of the situation if the following study is undertaken:  Present ambient air quality in the fifteen-kilometer influence zone  Proposed air pollution load  Proposed ECE efforts  Proposed mitigation measures  Likely ambient air quality thereafter

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5.2.1.1 Key Control Legislation: A comprehensive statute viz., Air (Prevention and Control of Pollution) Act stands promulgated in India in 1981. Its corresponding Statement of Object and Reasons have provided an insight of the driving force viz, ‘With the increasing industrialization and the tendency of majority of industries to congregate in area which is already heavily industrialized, the problem of air pollution has begun to be felt in the country. The problem is more acute in those heavily industrialized areas which are also densely populated. The presence of air, beyond certain limits of various pollutants discharged through industrial emissions and from certain human activities connected with traffic, heating, use of domestic fuel, refuse incineration, etc. has a detrimental effect on the health of the people as also on animal life, vegetation and property’. A definition of air pollution and air pollutant is provided by Section 2(a) and (b) and read as under: (a) ‘Air pollutant’ means any solid, liquid or gaseous substance (including noise) present in the atmosphere in such concentration as may be or tend to be injurious to human beings or other living creatures or plants or property or environment’. (b) ‘Air pollution’ means the presence in the atmosphere of any air pollutant’ The Act provides that the Water Pollution Control Board will also enforce the Air Act, as an integrated effort. Consent management under Section 21 controls the activities. Sampling activity is permitted to the Board under Section 26 to 30. The breach is criminal offence and is punishable under Sections 37, 38 and 39 by following the procedures under Sections 40 to 46. The Environment protection Act, 1986 under its Sections 3 & 24 have recognized the powers of the Air (P & CP) Act, 1981, and its amendments. Monitoring: Materials and Methods Ambient air quality survey has been carried out for three months, at eight locations.

Pollutants sampled and analyzed were for SPM, SO2 and NOx on eight hourly basis. Discussions

All the four parameters viz. PM10, PM2.5 SO2 and NOX are found to be within ambient quality limits. The vehicular traffic though scanty, may contribute to these values at some points.

The ground level concentration values on an average for SPM, RSPM, SO2 and NOX are found to be low in g/m3 respectively and represent the satisfactory background values.

5.2.1.2 Ambient Air Quality at VRSL Core Zone: Track Record: This is a new and proposed unit. As such question of monitoring the work zone and finding the status doesn’t arise at this stage. However, VRSL has designed the plant layout by studying similar units elsewhere in the country by taking help of the machinery suppliers who have a large interface with sugar-distillery and allied industry sector over last more than 25 years. Even orientation of Boiler, bagasse-baling yard is taken into consideration, so that the location is downloaded and away from factory workers breathing zone. The VRSL units will be monitored for the air pollutants at certain stations inside the work environment also at regular intervals. It may not be out of place to mention that the people who are behind this Enterprise have an excellent record of abiding of law and using best available technology (BAT) for all their other vocations, whether to run the technical and academic institutes, banking corporation or religious responsibilities. At VRSL too similar honesty of purpose will be kept and persons of professional acumen will be engaged.

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Table 5.1: National Ambient Air quality Standards (2009) National Ambient Air Quality Standards Time Sr. No. Pollutants Industrial, residential Ecologically Weighted Average and other area μg/m3 sensitive area μg /m3 1 SO2 24 hours 80 80 2 NOx 24 hours 80 80 3 PM2.5 24 hours 60 60 4 PM10 24 hours 100 100 5 CO 8 hours 04 04

5.2.1.3 Emission Control Equipments (ECE): Further, regarding new product looking to the description of manufacturing operations and the corresponding flow sheet, VRSL knows from which unit operation or process, air pollutants are expected. For the purpose of arresting and capturing the pollutants, measures are proposed and designed. The following is discussed and mentioned in Table 5.2 Table 5.2: Emission Control Equipments for Proposed Integrated Sugar- Co gen- Distillery Units Source Pollutant In-plant measures Proposed Control equipment 1 Cane yard PM10, PM2.5, Leveled roads & land - road dust, rubber tire, slow speed juice, HC less waiting 2 Boilers PM10, PM2.5, Feed bagasse more dry, Dampers, ID Fan, CO CO2 meter, fly-ash arrestor and ESP. 3 Fermentation CO2 Tank covered Scrubbed in water & CO2 taken to CO2 recovery unit 4 Distillation HC Closed circuit 5 Spentless, bottle washings H2O, - Treated & reused In addition, other attendant efforts like water spraying, tree plantations and covered storage etc shall be adopted, wherever feasible and needed. Totally the pollution control may cost Rs. 12.95 Cr. with O & M anticipated at 3.65 % of it per annum. The details of it are given in following Table No. 5.3. Table 5.3: Details of Capital Cost and Recurring cost Capital Cost, Recurring Cost, Sr. No. Description of Item Rs Lakh Rs Lakh/ annum 1 Electrostatic precipitators 500 15.00 2 Stacks 170 3.00 Effluent treatment plants (ETP), Sewage 3 450 12.50 collection, treatment & disposal (STP) 4 Fire fighting system 75 2.25 5 Noise Abatement 0.25 0.10 Env. Lab equipment & on line monitoring 6 50 5.00 system 7 Rain water harvesting 15 4.50 8 Green belt 35 5.00 Total 1295.25 47.35

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Dispersion: 5.2.1.4 Air Pollution Control Facilities: Gaseous emission from the boiler will be passed through systems to control the emission level of pollutants

like SO2, NOx and SPM within the stipulated limits. The air pollution generation from the proposed project is given in below Table No. 5.4.

Table 5.4: Air Pollution Generation & its Mitigation Measures Sr. No. Area of Operation Air Pollution Mitigation Measures 1. Boiler - 150 TPH Stack height – 60 M, As per CPCB with ESP 2. Incineration Boiler -35 TPH Stack height – 70 M, As per CPCB with ESP Adequate stack height will be provided as per CPCB 3. D.G. Set (1000 & 500 KVA) norms

1) Sugar Factory Co-gen Boiler- 150 TPH, 87 Kg/cm2(g), 515 C Daily Requirement of Bagasse for sugar & co-gen boiler - 57.8 TPH, with ash content as 1.5% and GCV as 2250 Kcal/Kg Details of stack, for Proposed Sugar/co-gen Division Attached to Boiler- 150 bagasse fired boiler, 87Bar(g), 515 C Height (m) 58 M (Say 60 M) Diameter at bottom and top 2 M Emitting gas temperature (0 C) 135 Exit gas velocity m/sec 20

The stack will be fitted with port-holes, ladder and platform for facility of taking samples The total ash generated per hr will be 0.867 TPH or 20.81 TPD. The bottom ash will be 60% and will be 0.52TPH; the fly ash will be 40% and will be 0.347TPH. The suitable capacity of Electrostatic precipitator will be installed to achieve maximum efficiency of collection of fly ash. The bagasse ash will be mixed in press mud cake and distributed to farmers as soil conditioner. For Detailed Calculations of Stack Height; please refer Annexure XVI (Stack Height Calculations)

1) Spent wash incinerated boiler with supplementary fuel as coal- 35 TPH, 45 Kg/cm2(g), 440 C In VRSL project, about 175 T/day concentrated spent wash (55 – 60 % w/w) and 138 T/day coal will be used. The coal will be provided by M/S Krishna Transport, Kurduwadi, Tal- Madha, Dist- Solapur in covered coal transporting vehicles. VRSL has made agreement with M/S Krishna Transport. As per data from M/s Thermax Company who is spent wash incinerated boiler manufacturer, for generation of required steam and power for distillery units, the 175TPD concentrated spent wash and 138 TPD coal will be used. The sulfur content in concentrated spent wash and coal is assumed as 0.90 and 0.40 percent respectively. A separate incineration boiler is proposed for distillery projects

Details of stack, for Proposed Sugar/co-gen Division Attached to Boiler- 35 TPH, spent wash fired boiler, 45Bar(g), 440 C Height (M) 70 M Diameter at bottom and top 2.5 M Emitting gas temperature (0 C) 135 Exit gas velocity, m/sec 21 For Detailed Calculations of Stack Height; please refer Annexure XVI (Stack Height Calculations)

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Considering ash content of spentwash powder and coal as 18.66 and 37.25 percent respectively, the

The ash generated/day = 84.06 T/day or 25,218 T/annum

Assuming bottom ash and fly ash as 60% and 40% respectively, the bottom ash and fly ash will be 50.44 T/d and 33.62 T/d respectively. The suitable capacity of Electrostatic precipitator will be installed to achieve maximum efficiency of collection of fly ash.

The ash will be sold and used for bricks manufacturing.

5.2.1.5 Impact on Air Quality The sources of air pollution in the process due to the proposed plant facilities have been identified and quantified. The contribution from the existing activities has been captured in the ambient air quality during baseline monitoring studies.

Particulate Matter (PM10), Sulphur dioxide (SO2) and Oxides of Nitrogen (NOx) emissions will be the main pollutants in the proposed plant. The incremental ground level concentrations from the proposed facilities have been estimated by using dispersion modeling.

 Details of Mathematical Modeling Prediction of impacts on air environment has been carried out by employing a mathematical model. In the present case, Industrial Source Complex Short-Term (ISCST3) dispersion model based on steady state Gaussian plume dispersion, designed for multiple point sources for short term has been used for predicting the ground level concentrations. The computations deal with major pollutants like Sulphur dioxide and Suspended Particulate Matter and Oxides of Nitrogen.

 Model Options used for Computations The options used for short-term computations are:  The plume rise is estimated by Briggs formulae, but the final rise is always limited to that of the mixing layer;  Stack tip down wash is not considered;  Buoyancy induced dispersion is used to describe the increasing plume dispersion during the ascension phase;  Calms processing routine is used by default;  Wind profile exponents are used by default, ‘Irwin’;  Flat terrain is used for computations;  It is assumed that the pollutants do not undergo any physico-chemical transformations and that there is no pollutant removal by dry deposition;  Washout by rain is not considered; and  Cartesian co-ordinate system has been used for computations.

 Meteorological Input Data to the Model The hourly meteorological data recorded at site is converted to the mean hourly meteorological data as specified by CPCB and the same has been used in the mode. In absence of site specific mixing depths, mixing depths published in “Spatial Distribution of hourly Mixing Depths over Indian Region” by Mr. R.N. Gupta and recommended by CPCB have been used.

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 Model Input Data The air pollution modeling carried out represents the worst case and normal operating scenarios. The pollutants considered for modeling include suspended particulate matter, sulphur dioxide and oxides of nitrogen. The details of the stack and emissions envisaged from the proposed plant are given in below Table 5.5 Table 5.5: Stack Details Details Co generation Plant Spent wash incineration Boiler Stack Height (m) 58.0 70 Flue gas velocity (m/s) 20 21 Stack flue gas temp. (0C) 135 135 Dia of stack (m) 2.0 2.5 Flow rate (Nm3/sec) 45.91 75.32 Bagasse Requirement (TPH) 57.8 Spent wash – 175 TPD Indian coal – 138 TPD SPM (g/sec) @ 50 mg/Nm3 2.30 3.77 SO2 (g/sec) 32.1 From coal – 12.78 From spent wash – 36.46 NOx (g/sec) 16.7 26.36

 Presentation of Results

The simulations were done to evaluate PM10, SO2 and NOX likely to be contributed by the proposed plant. For the short term simulations, the concentrations were estimated around 1200 receptor points chosen to obtain an optimum description of variations in concentrations over the site in 10-km radius covering 16 directions. The predicted incremental Ground Level Concentrations (GLCs) for PM10, SO2 and NOx likely to be contributed by the proposed plant are presented in below given Table 5.6 Table 5.6: Predicted 24 Hourly Short Term Maximum Incremental Concentrations Parameters Concentration Distance Direction (µg/m3) (Km) PM10 0.58 1 North SO2 7.9 1 North NOx 4.1 1 North

Resultant Concentrations after Implementation of the Project

The maximum incremental GLCs due to the proposed project for PM10, SO2 and NOX are superimposed on the maximum baseline PM10, SO2 and NOx concentrations recorded during the study period in the downwind direction to arrive at the likely resultant concentrations during the same period after implementation of the proposed project. The cumulative concentrations (baseline+ incremental) after implementation of the project are given in below Table No. 5.7. The isopleths for pollutants PM10, SO2 and NOx are presented in Figure 5.1 to Figure 5.3 Table 5.7: Resultant Concentrations Due To Incremental GLC's Parameter Baseline Conc.(g/m3) Incremental Conc. (g/m3) Resultant Conc. (g/m3) PM10 47.2 0.58 47.78 SO2 7.0 7.9 14.9 NOx 15.2 4.1 19.3

The predictions indicate that the PM10, SO2 and NOx concentrations are likely to be well within the prescribed limit after plant comes into operation.

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FIGURE 5.2: SHORT TERM 24 HOURLY INCREMENTAL GLCS OF SO2

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FIGURE 5.3: SHORT TERM 24 HOURLY INCREMENTAL GLCS OF NOx

Discussions on Results of Assessment A perusal of previous subsection reveals that the maximum short incremental short term ground level 3 concentrations for PM10, SO2, and NOx after implementation of the proposed project are 0.58 g/m , 7.9 g/m3 and 4.1 g/m3 respectively occurring at a distance of 1.0 Km in the north direction.

The maximum resultant 24 hourly concentrations for PM10, SO2 and NOx after implementation of the proposed project are 47.78 g/m3, 14.90 g/m3 and 19.30 g/m3 respectively. According to the above presented results, it may be stated that the impact of PM from the proposed plant would be negligible in core or buffer zone of the project.

Even though the incremental concentrations of SO2 and NOx are considerable, they are well within the NAAQ limits and hence the AAQ levels after implementation of the proposed project will remain within permissible limits.

5.2.1.6 Fugitive Measures A number of mitigation measures are taken to control fugitive emissions, the presence of which will be noticeable by plain vision if not controlled. The measures are thus taken seriously and continuously such as:  Pucca approach road to project site shall be constructed prior to commencing construction activity of the integrated sugar plant so as to avoid fugitive emissions and regular water sprinkling shall be carried out on all the rough roads for preventing fugitive dust emissions.  Construction of speed breakers on roads at regular intervals all over the plant area and /or attachment of speed locking system to the accelerators of all the vehicles used for maintaining a speed limit of 20Km/hr.  Construction of vehicle parking area having at least brick on edge flooring.

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 Rubber wheel carts/ tractors/ trucks to bring in cane, not filled high, sides cladded, slow speed travel, avoiding vibrations en route  Ensure that all vehicles used in transportation have PUC certificate. It is proposed to have an auto exhaust emission monitoring equipments and trained manpower to carry out PUC checks at regular intervals.  Engineering the plant layout in such a way so as to virtually eliminate need of using heavy equipment for material handling in the main plant  Internal roads paved, leveled, no undulations, no sharp curves, slow speed  No open storage of molasses, or sugar bags involved. Provided steel tank for finished product.  In plant, control measures for checking fugitive emissions from all the vulnerable sources shall be provided. Fugitive emissions shall be controlled by providing closed storage, closed handling & conveyance of chemicals/materials, multi cyclone separator and water sprinkling system. Dust suppression system including water sprinkling system shall be provided at loading and unloading areas to control dust emissions. Fugitive emissions in the work zone environment, product, raw materials storage area etc. shall be regularly monitored and records shall be maintained.  Gaseous emissions from DG sets shall be dispersed through the adequate stack height as per the CPCB guidelines. Acoustic enclosures shall be provided to mitigate the noise pollution.  Tree plantation on surrounding available area  Bagasse where excess is baled and auctioned swiftly.  Coal storage shall be done in such a way that it does not get air borne or fly around, for this; it shall be kept in wet form.  Separate storage for fly ash is proposed which will be as per CPCB guidelines so that it shall not adversely affect air quality, becoming air borne by wind. It will be disposed off before rainy season starts so as to avoid its flowing with storm water.  Dedicated parking facility for loading & unloading shall be provided in the integrated sugar complex.

Monitoring: During the proposed activity monitoring will be periodically done by MPCB as well as by the industry through reputed third party. The industry proposes to continue the efforts of air pollution control and remain inside the limits

5.3 WATER ENVIRONMENT: It will be a logical analysis of any situation if a study is undertaken in following way:  Incoming water quality  Water budgeting to estimate effluent quantity and quality  ETP and its performance evaluation  Expected impact Here we shall have to consider both (1) the proposed sugar factory & co- gen water regime and (2) proposed Distillery units & other ancillary units’ water reg

Central Legislation: A comprehensive statute viz., water (Prevention and Control of Pollution) Act stands promulgated in 1974 (amended twice in 1978 & 1988). The Statement of Object and Reasons annexed to the Bill interalla states: ‘Having considered the relevant local provisions existing in the country and recommendations of the aforesaid Committee, the Government came to the conclusion that the existing local provisions are neither adequate nor satisfactory. There is, therefore, an urgent need of introducing a comprehensive legislation

123 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra which will establish unitary agencies in the Center and States to provide for the prevention, abatement and control of pollution of rivers and streams, for maintaining and restoring wholesomeness of such water courses and for controlling the existing and new discharges of domestic and industrial wastes’. The scope of the Act is quite wide. The object of this Water Act, 1974 is (1) to prevent and control of pollution of water as defined therein and (2) to maintain or restore wholesomeness of water. The objective also appears to provide penalties after conviction that it will be deterrent to others who might indulge or tend to indulge in polluting the waters. The definition of water pollution, therefore, is kept quite wide and encompasses welfare of not only human beings but also the plants, animals and aquatic organisms. The definition is too comprehensive to allow anyone to escape the hands of this Act on pure technicalities. This Act considers the principle of vicarious liability in Section 47, and thus where the offense has been committed by a company (a body corporate, a firm or association of individuals), every person who at the time of offense was committed, was in charge of and was responsible to the company, as well as the company, shall be deemed to be guilty of the offense. Furthermore, if it is proved that the offense has been committed with consent or connivance of or is attributable to any neglect on the part of any director, manager, secretary or other officer of the company then such person also shall be deemed to be guilty of the offense and shall be liable to be proceeded against. The scope of this Act is kept quite wide as to cover in Section 48, the offenses by the Government departments or undertakings and the head of the department shall be in normal course deemed to be guilty of offence, where an offense under this Act is committed. With the sole object to empower the Pollution Boards, (establishment of which is yet another object of this enactment), to keep the waters wholesome, the legislature have offered a wide scope under Section 60 which sanctions an over-riding status viz. ‘The provisions of the Act shall have effect not-with-standing anything inconsistent therewith contained in any other enactment other than this Act’. Therefore, in conclusion it can be said that in order to prevent and control pollution of water, to avoid nuisance, harm, injury to public health and safety and to maintain or restore quality of water, this Act confers a number of powers on Pollution Control Boards and expects specific functions from them. To protect a guilty person against double jeopardy, the Act puts a bar by Section 49 on cognizance of offense under this Act except; (1) on a complaint made by or (2) or on a complaint made with previous sanction in writing of the State Board. By a recent amendment public participation is encouraged and prior sanction is not insisted.

5.3.1 Water Quality & Quantity: The project proponent & his team are well versed with various techniques for conservation of water in sugar industry. The principle of 3 R s (Reduce, Reuse and Recycle) will be used to minimize plant water requirement. Further efforts will be made to identify the sources of waste water generation and measures will be taken to minimize the waste water generation (Table 5.8). Table 5.8: Sources of wastewater generation and control option to reduce wastewater quantity in Sugar Factory Sr. No. Source of waste water Control option to reduce wastewater quantity Water re-circulation system provided pumping and piping Mills bearing cooling 1. arrangement, after separation of oil, grease and suspended (externally) particles. Follow dry cleaning with bagasse as far as possible and hot 2. Mills washing water washing once a day. 3. Boiler blow down Use for spray pond Use spray pond water for pumps cooling, washing and 4. Spray pond overflow cleaning to reduce overflow. 5. Pumps glands cooling Install mechanical seal or adopt Recycling system. Collect all sugar content material samples in a separate 6. Laboratory use drum after analysis and send to process.

124 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

7. Boiling house floor washing Follow dry cleaning with bagasse as far as possible. Use soda boiling water for cleaning to reduce juice heater 8. Juice heater cleaning brushing and water requirement. Store soda boiling water in separate storage tank and use it 8. Periodical cleaning for spray pond to maintain pH. Construct common collection pit and reprocess sugar 9. Centrifugal section content materials with the help of pump and piping arrangement. Install cooling tower to reduce waste water and use it with 10. Excess Condensate raw water. 11. Domestic use Install spring-loaded cock to each water tap connection.

5.3.2 Brief Description Of Cleaner Technology-

5.3.2.1 Treatment of Sugar & Co-gen effluent The Sugar factory capacity and C-gen Capacity will be 5000 TCD and 26 MW respectively. Both plants will operate for 160 days per annum. The effluent generation will be 545.28 Cu M/day. The general effluent characteristics and effluent discharge standards for inland surface water has been indicated in the following table. Table 5.9: Characteristics of Combined sugar & Co-gen effluent Sr. No. Parameter Unit Inlet Effluent Effluent discharge standards for Irrigation Characteristics (CPCB/MPCB) 1 pH 4.5-5.0 5.5-9.0 2 Oil & grease Mg/l 40-60 < 10 3 TSS Mg/l 400-500 < 200 4 BOD Mg/l 1000-1500 < 100 5 COD Mg/l 2000-3000 < 250 The ETP system is provided such that maximum treated water will be recycled for process and will be used for green belt/garden & irrigating the experimental sugarcane plots etc. The details of Sugar & Co-gen ETP system will be as follows- ETP system proposed - Anaerobic Followed by Aerobic System Brief Flow Sheet Details: Sr. No. Type Units to be provided Flow measurement, screening, grit removal, oil and grease 1 Preliminary flotation, Averaging of flow quantity and homogenizing the flow 2 Equalization tank characteristics 3 Neutralization pH adjustment 4 Primary clarifier To remove suspended solids and to remove settable BOD Anaerobic digester For second stage BOD reduction using anaerobic digester 5 followed by Aeration tank followed by aeration tank and sludge recycle 6 Secondary clarifier Secondary clarification 7 Dewater Sludge drying beds 8 Holding Non-demand tank 9 Recycling of treated water

Screening: Coarse screen or rack is used for removal of large pieces of gunny bags, plastics, branches, rubbers, packing materials, gaskets, cotton waste and other floatable. It is used as protecting devices so that large suspended solids and floating material do not damage pumps, agitators, mixers and aerators. Coarse screens have

125 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra openings ranging from 75mm to 150 mm and racks are usually set at an angle of 450 – 600. The cleaning of screens is done either manually or mechanically. Oil & Grease Skimmer: Oil being is lighter than water, floats. This property is used to separate it out. However, if there is more turbulence or if the travel distance is high, gradient slop is more, or if boiler blows down, excess condensate, stream trap, cooling purging co-enters, the oil gets emulsified and then does not float out easily. It has to avoid such situations to the maximum extent possible by either providing the traps very near to the source, or by segregating the sub-streams. If the oil does not float and a thick film does not develop, the physical removal by big spoon becomes difficult. In such case, the oil & grease escapes out to further downstream units of the ETP to spoil the situation. In aeration tank the contents are further churned and the oil may cover the bacterial cell wall, stopping their work of adsorbing and absorbing the food (BOD) and utilizing the same in turn for their life and growth cycle. The BOD will not get utilized for removal, and the shining oil will escape out from the secondary clarifier to the disposal site. Removal of oil and grease is necessary to increase treat ability. In an industry oil and grease traps are situated close to the source of oil and grease. Various patterns are available for oil and grease trap. The most common is the one in which inlet is below the surface and outlet is at the bottom with sufficient retention period (10-30min). The floating material rises and remains on the surface of the wastewater. The oil & grease will be collected in a separate sump, by manually or mechanically, from where it can be removed with the help of a hand pump. Considering floating matter and oil & grease in the effluent. It is advised to provide oil & grease trap near mills as major oil & grease come from milling section.

V-Notch: The triangular or V-notch sharp-crested consist of an angular notch cut into a bulkhead in the flow channel. The apex of the notch is at the bottom, and the sides are set equally on either side of a vertical line from the apex. The angle of the notch most commonly used is 90o .The discharge equation of a free flowing triangular weir takes the form. 1/2 3 Q = 8 x (2 g) CD. H5/2/ 15 ------m /S Where, h (m) = head referred to the vortex of the notch g = 9.81 m/S2

CD = discharge coefficient, which is given by following table. Head, h(M) 0.050 0.075 0.100 0.125 0.150 0.200 0.300 Value of CD 0.608 0.598 0.588 0.588 0.586 0.585 0.585

Equalization Tank: Equalization is often used for smoothening out individual wastewater stream flow variations so that a composite stream of relatively constant flow rate is fed to the treatment plant and, also to even out variations in effluent feed BOD to the treatment facility. The equalization tank should not work as settling tank. The solids should be kept is suspension. For this, the water must be in motion. A stirrer, mixer, agitator, or diffused air is employed.

Primary Clarifier: Purpose of this process is to reduce settable suspended solids content of the wastewaters. When a liquid containing such solids is detained without disturbances for a time, particles of higher specific gravity will settle and those with lower specific gravity will float. About 50-65 % removal of suspended solids and 20- 40 % of the BOD removal can be achieved in a properly designed and operated primary clarifier. Common retention time is 90-150 minutes based on average rate of flow. If these precede a biological treatment unit, 30-60 minutes retention time is sufficient. Sugar factory effluent contains bagacillo particles as a suspended particle. These should to be separated out before the biological treatment.

Anaerobic Digester: The supernatant from primary clarifier is further subjected to anaerobic digester. It is submerged digester with plastic media. The microbial growth is retained on the plastic media making possible higher loading rates and efficient digestion. The BOD removal is about 80%. Advantages: 1) Higher degree of stabilization.

126 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

2) Little sludge production. 3) Low capital and operating cost. Aeration Tank: The effluent from anaerobic lagoon is further subjected to aeration tank. The biological treatment of effluent by aeration process with sludge culture is very sensitive. The efficiency depends on pH, temperature, air contact, suspended solids, culture growth, and concentration of floc that is optimum mixed liquor suspended solids concentration (MLSS). The microbial culture concentration is to be maintained in the range of 1500 to 4000 mg/l. Hence initial culture development and maintaining of activated sludge rate by re-circulation of sludge and addition of cow dung, urea, DAP and their mixing are essential. The nutrients are to be in liquid form. The ratio of BOD: N: P is 100:5:1 will be maintained. Care is to be taken not to destabilize the microbial culture.

Secondary Clarifier: It is a cylindrical concrete tank with conical bottom. There is a central well to which water is fed to avoid short-circuiting of water into the overflows. The central stirrer is rotated at 2 RPH. Sludge will be collected at the bottom from where it re-circulated to aeration tank and excess sludge is taken on sludge drying beds by pumping. There is circumferential overflow from which treated effluent is collected and sent for agricultural use.

Sludge Drying Beds: Sludge drying beds will be provided for the disposal of sludge from clarifier. The dried cakes will be scrapped off periodically and can be utilized as manure.

Recovery of treated water –  Distillery division The water input and wastewater output described stepwise are given in following Table 5.10.

Table 5.10: Details of water balance

B.1) Molasses Based Distillery (60 KLPD) & CL Unit Water Input Table S. No. Section Water Quantity (m3/day) 1 Water in Molasses 36 2 Process Water In Fermentation 521 3 DM water for RS dilution 494 4 Soft water for vacuum pump & others 180 5 Soft water makeup for cooling tower 359 6 Bottling 60 7 Misc. water 65 8 Other domestic usage 10 9 DM Water for Boiler & DS 425 TOTAL WATER INPUT 2150

127 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

CT Evaporation & Drift Losses, Blow 8 359 Down 9 Washing Water 5 10 Domestic Consumption Waste 2 11 Blow Down Water & Reject Streams 84 12 Steam Condensate 350 13 ETP Waste 54 TOTAL WATER OUTPUT 2150

Recycling & Utilization streams S. No. Section Water Quantity (m3/day) 1 Spent Lees Recycle for RS Dilution 449 2 Vacuum Pump Recycle 173 3 Treated Effluent 661 4 Steam Condensate Recycle 350 TOTAL WATER 1633 517 TOTAL FRESH WATER REQUIREMENT 8.62 lit/lit Input to ETP Process Condensate 392 m3/day Spent Lees 160 m3/day WTP Blow down & Boiler Blow Down 109 m3/day Cooling Tower Blow down 36 m3/day TOTAL 697 m3/day

The sober & polluted waste water-697 Cu.M/day and highly polluted water, spent wash - 169 Cu.M/day (175 TPD).

5.3.2.2 Molasses based Distillery spent wash Treatment-The spent wash generated from distillery unit will be concentrated in Multiple Effect Evaporator system to concentrate effluent up to 55 to 60 percent solids. The 60 KLPD distillery generates about 175 TPD concentrated Spent wash and it will be incinerated in 35 TPH Boiler using coal as supplementary fuel (138 TPD) to generate power simultaneously achieving achieve zero discharge. It is proposed to store concentrated spentwash during emergency and repair & maintenance of boiler unit. The spent wash storage capacity will be maximum 15 days (@175 T/d, 2625 Tons or ~ 2188 Cu.M.). It will be made impervious Pucca lagoon as shown in Figure 5.4.

128 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

Fig. 5.4: Holding Tank Details

Monitoring- VRSL will make efforts to consume daily spent wash generated by distillery unit. There may be emergency storage of spent wash only and efforts will be made to utilize the same. The bore wells will be installed on the periphery of the spent wash storage tank. In case there is storage, samples will be collected from the bore wells every 15 days and will be analysed for BOD and TDS. The increase in the value of these parameters shall not exceed 3PPM or 200 PPM, whichever is less, respectively. In the event of first observation that the prescribed limits are exceeding the stated value, it will be informed to SPCB immediately. First and foremost, the spentwash in lagoon will be utilized in boiler and the emptied storage tank will be observed for any leakage or otherwise and appropriate impervious coating will be applied on the surface of tank.

129 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

Table 5.11: Water balance details B.2) Grain based Distillery (45 KLPD) & IMFL Bottling Water Input Table S. No. Section Water Quantity (m3/day) 1 Water in Grain 11 2 Process Water In Fermentation & Liquefication 347 3 DM water for RS dilution 400 4 Soft water for vacuum pump & others 132 5 Soft water makeup for cooling tower 368 6 Bottling 50 7 Misc. water 58 8 Other domestic usage 10 9 DM Water for Boiler & DS 376 TOTAL WATER INPUT 1752

Water Output Table S. No. Section Water Quantity (m3/day) 1 Spent Lees 477 2 Water in Raw Stillage 314 3 Vacuum Pump & Others 127 4 Vacuum Pump loss 5 5 Water in Product 3 6 Bottling waste 10 7 CT Evaporation & Drift Losses, Blow Down 368 8 Washing Water 5 9 Domestic Consumption Waste 2 10 Blow Down Water & Reject Streams 96 11 Steam Condensate 300 12 Water in Waste Stream 45 TOTAL WATER OUTPUT 1752

Recycling & Utilization streams S. No. Section Water Quantity (m3/day) 1 Thin Stillage & Spent Lees Recycle in Liquefaction 140 2 Spent Lees Recycle for RS Dilution 348 3 Vacuum Pump Recycle 127 4 Treated Effluent 431 5 Steam Condensate Recycle 300 TOTAL WATER 1346 406 m3/day TOTAL FRESH WATER REQUIREMENT 9.02 lit/lit

Input to ETP 1 Process Condensate 197 m3/day 2 Spent Lees 129 m3/day 3 WTP Blow down & Boiler Blow Down 85 m3/day 4 Cooling Tower Blow down 47 m3/day TOTAL 458 m3/day

The sober & polluted waste water-458 Cu.M/day and final concentrated slop with 38% solids – 70.60 Cu.M/day

130 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

5.3.2.3 Stillage treatment of Grain Based distillery Unit – The stillage from Distillation section is then passed through decanter where cake and thin stillage are separated. The recovered thin stillage from decanter is concentrated in the Multiple Effect evaporator System (MEE) till 38% concentration. The product/thick syrup from the MEE is mixed with cake recovered from decanter to form Distillers’ Wet Grains Solubles (DWGS) to achieve zero discharge. The mixture is sent to the dryer and the dried product (DDGS) is used as cattle feed. Part of the thin stillage [approximately 40% to 50%] is recycled to liquefaction section and Fermenters

Dryer will be installed in order to dry DWGS from distillation. Generally, 30- 35% yield of DDGS (Distillers’ Dry Grain Solubles) is obtained on the basis of grains consumed. It is a good cattle feed as seen from the following analysis.

Sr. No. Particulars Values, Percent 1 Moisture 14.14 2 Protein, Crude 32.91 3 Fat 7.63 4 Crude Fibre 11.85 5 Nitrogen Free Extract 30.45 6 Total Ash 3.05 7 Acid insoluble ash 0.46 8 Calcium 3.22 9 Phosphorus 0.46 10 Salts as NaCl 0.03

B.3) Treatment of Distillery (Process condensate, spent lees) & auxiliary units (CO2, CL, IMFL, Malt/grape spirit, Cyclodextrane) - liquid waste Streams for Effluent Treatment Plant-

Table 5.12: Details of liquid effluent stream are as follows Cu.M/Day Sr. No. Particulars Type of stream Sober Moderately polluted 1 Molasses based distillery & CL 14 684 2 Grain based distillery & IMFL 12 446 3 Malt Spirit 15 4 Grape spirit 15 5 Cyclodextrin 7.5 6 Co2 Plant 2.0 Total 26 1169.50 Total effluent generation~ 1195.50 Cu.M/Day

Streams considered as feed to effluent treatment plant total as – 1195.50 Cu. M/day. 5.13: The components of ETP units are as follows Sr. No. Description Quantity Bar screen 1 1 Bar screen suitable for client’s concrete tank. Bar screen will be made of suitable size bars with 20 mm clear opening (Bar screen- MOC SS304) Air blowers (1 working + 1 stand bye) for equalization tank 1+1 2 Pressure: 0.4 kg/cm2, Accessories: Inlet filter, inlet silencer, pressure gauge, pressure relief valve, non-return valve, common base frame, V-belt, etc. Coarse air diffusers 1 3 An air grid with coarse air diffusers will be installed in the equalization tank. Grid will be made of HDPE/PVC 4 Lime agitators 1

131 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

Type: Pitched blade type, RPM:15-20, MOC: S.S. Raw effluent pumps 1+1 5 These will be horizontal, non-clog, open impeller pumps Head: 10 m, MOC: All C.I. Air blowers (1 working + 1 stand bye) for aeration tank 1+1 6 Pressure: 0.5 kg/cm2, Accessories: Inlet filter, inlet silencer, pressure gauge, pressure relief valve, non-return valve, common base frame, V-belt, etc. Fine air diffusers 1 For installation in aeration tank 7 The system will comprise of, a)2 m long retrievable, self closing diffusers b)Air supply pipe in HDPE/PVC construction 8 MBBR media Size: suitable, Area: suitable 1 Sludge pumps 1+1 These will be horizontal, non-clog, semi-open impeller type pumps 9 Capacity: Suitable, Head: 10 MWC, MOC: All C.I. Accessories: Each pump will complete with TEFC motor, base plate, couplings, coupling guards etc. Lamella media 1 10 Lamella media for installation in settling tank of suitable. Media will comprise of PVC components. Electrical for the plant Lot 11 Motor control centre (MCC) for treatment plant units. This will be a locally fabricated panel with Siemens/ L&T components Dual media filter Type of filter Dual media filter Mode of operation Manual Quantity 1 Operating time 22 hrs Design pressure 3.5 kg/cm2 (g) Max. pressure drop across the filter 1.0 kg/cm2 (g) MOC Vessel MS Activated Carbon Filter Type of filter Activated Carbon filter Mode of operation Manual Quantity 1 Operating time 22 hrs Design pressure 3.5 kg/cm2 (g) Max. pressure drop across the filter 1.0 kg/cm2 (g) MOC Vessel MS

Civil Work Sr. No. Unit Nos. MOC 1 Bar Screen Chamber 1 RCC 2 Equalization tank 1 RCC 3 Aeration tank 1 RCC 4 Settling Tank 1 RCC 5 Treated water tank 1 RCC 6 Sludge drying beds Suitable capacity BB masonry 7 Pump house 1 BB masonry 8 Miscellaneous .Pump foundation etc PCC/RCC

132 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

Fig 5.5: Block Diagram of MBBR Process for Sewage Treatment Plant

Recovery of treated water & its recycling – For recovery of water from waste water, the treated water from ETP may be sent to tertiary system consisting of polishing tank followed by dual media filtration, activated carbon system and disinfection by chlorination. After treatment, efforts will be made to recycle to maximum extent the treated effluent for the process.

C) Domestic effluent Domestic effluent is 180m3/d in quantity. The flow chart of effluent treatment plant is given in Figure 5.5 The domestic waste water (sewage effluent) is required to be treated to bring it to the quality of 100/100 (BOD/SS) standards, suitable for use on gardening, irrigation. This is best done traditionally by providing a sewage treatment plant. VRSL has so proposed. Sub-surface irrigation arrangement or disinfections at the end for freshening up, odour control, disinfections and safety for sewage farm workers shall be provided.

All above activities will be periodically monitored by MPCB as well as by the industry through reputed third party. Mitigation: As additional mitigation measures, VRSL proposes to take-up following:  To spread awareness to the workers about the importance of water quantity measurements and resource conservation.  Shop-floor supervisors are encouraged for mopping up, dry collection, good house-keeping by arranging lectures, and by conscious supervision

133 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

 The treated domestic and industrial waste water will be applied judiciously on land for gardening so that there will not be any flooding of excess water either to migrate to ground water table or get away as runoff to join surface water drains. Summary: From the foregoing it may be seen that the industry is without any such effluent which is hazardous, poisonous or non-biodegradable. It is not likely to create pollution from the point-of-view of water phase of environment. In fact the raw spent wash is concentrated to 55 Bx and burnt in boiler to generate steam and power. Soil and biological environment: Every industrial activity brings in some change to soil environment. The land-use pattern changes, eyesore buildings may come up, excavation and filling with borrow-pits get involved, and the soil gets paved by roads, buildings (terraces / roofs) and platforms. All this reduces areas for percolation into soil and increases storm run-off that leads to erosion of soil in channels down stream. Sometimes the rapid congregation of water becomes too high for the carrying capacity of channels/ nallas giving rise to build-up of back waters. Land – use: The land is outside the area of industrial restrictions such as that covered in any Fragile Zone or Coastal Regulation Zone (CRZ) Notifications. The land can be used for industrial purposes. The Area utilization is given in following Table No. 5.14. Table 5.14: Area utilization Sr. No. Particular Area in m2 % of total area 1 Sugar Factory 6000 2.16 2 Co-gen Plant 5200 1.87 3 Chimney 0 4 WTP 1350 0.49 5 11 KV/ 440 substation 2500 0.90 6 Store Building 216 0.08 Water Storage Tank 7 1350 0.49 8 Admin Building 1100 0.40 9 Switch Yard 2304 0.83 10 Sugar Godown 16800 6.04 11 Cane Yard 3500 1.26 12 Fly Ash Storage 2500 0.90 13 Spent wash fire Boiler 4080 1.47 14 Chimney 0 15 Coal Storage 4582 1.65 16 Bagasse Yard 10000 3.60 17 Molasses Tank 400 0.14 18 Molasses Tank 400 0.14 19 Molasses based distillery 60 KLPD 4032 1.45 20 Grain based distillery 45 KLPD 7140 2.57 21 Bottling plant, Country liquor plant 3600 1.29 22 IMFL Plant 3600 1.29 23 WTP 609 0.22 24 CO2 Plant 864 0.31 25 Grapes spirit plant 600 0.21 26 Cyclo dextrin plant 600 0.21 27 Spent wash lagoon 1260 0.45 28 ETP 5000 1.80 29 Lawn & Greenery plantation Area 149813 53.85 30 Colony 10530 3.79 31 Internal Roads 14328 5.15

134 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

32 Temple 182 0.07 33 Work shop 120 0.04 34 FA Storage 696 0.25 35 Alcohol storage 2035 0.73 36 ENA Storage 1855 0.67 37 Parking 1000 0.36 38 Security 120 0.04 39 Time office 120 0.04 40 Weigh bridge 50 0.02 41 Cooling Tower 1400 0.50 42 Rain water harvesting 1350 0.49 43 Press mud storage 5000 1.78 Total Built up Area 278186 100 53.85 % of built up Lawn & Greenery plantation Area 149813 (33.65% OF PLOT AREA) Plot Area 445157

No detrimental land-use change is proposed and local native biology will not be harmed and no more soil will be disturbed.

Borrow Pits: The present plot of VRSL has sober undulations. By good architectural practices, the flow of activities will be planned so as to make maximum use of gravity for the traffic of material. The buildings and the plinths will be so adjusted as the cutting should balance the embankments or filling. Indeed very little murum or any other material will be required to be borrowed from outside. The fear of erosion, nalla back-water, need of soil stabilization etc. are thus of no cause for anxiety by this proposal and hence no effect is expected on biological environment in developing this unit. Key Central Legislation: A number of Indian environmental and other statutes are promulgated which aim at preserving the soil and groundwater quality and quantity. The Water (P&CP) Act, 1974 which previously was addressing merely the state waters after amendment, has clearly encompassed ‘land and wells’ in many of its Sections. The land development and construction restrictions are included in Coastal Zone Regulations as well. Various activities are declared as prohibited within the CZR, such as (1) setting up of new industries and expansion of existing ones, (2) manufacture and handling of hazardous substances, (3) treatment and disposal of waste and effluents and of thermal ash, (4) harvesting sand or groundwater, (5) construction above a height of nine meters, etc. MoEF has also considered soil and groundwater in guidelines issued for siting of Hazardous Waste Rules 1989. None of the candidate sites should show any malefic potentially on: a) Existing zones of development b) Agricultural land preserves c) Areas of mineral development d) Freshwater wetlands e) Visual corridors of scenic rivers and f) Riverine and dam-related flood hazard areas

135 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

5.4 SOLID WASTE MANAGEMENT: It is said that every proposed activity is bound to create solid wastes along with some pollution of water, air, soil, groundwater, noise, etc. The solid waste can be classified in many ways such as (1) domestic/ commercial and industrial, (2) solid and semi – solid, (3) hazardous and non-hazardous, (4) medical/ hospital and non-contaminated, and (5) resalable and otherwise considering the activities as planned today Following mitigation practice is the policy for future: Minimization at all levels need be attempted for discarded products, empty containers (which are rare), packing surpluses, incoming raw material unloading spillages (which is rare) and fugitives. The factory has very little scrap materials. All these, however, be carefully stored on raised platform with dwarf toe walls all around, and a roof over-head. The contents should not be held in the premises for more than a fortnight. These measures can easily be taken by VRSL because (1) they have no discards or off-specification products, and (2) the waste is fully recycled both in green stage and in dry stage. Quantification in cubic meters per day for the sugar factory unit are presented in following given Table No. 5.15. 5.4.1 Non hazardous solid waste: Table 5.15: Solid Waste details No. Unit Waste & Quantity, TPD Treatment Disposal 1 Canteen 1.0 Compost Own Garden 2 Colony 2.0 Compost Factory farm Drying beds & ETP sludge 0.325 Own garden compost 3 Sugar Unit Mixed with Bagasse & Oil & grease 0.146 Flotation Technique burnt Press mud 32,000 Compost As soil conditioner Co-gen Units 4 Bagasse ash 20.81 Mixed with PMC As soil conditioner (sugar) Co-gen Units Incineration 5 84.06 To brick manufacturer (Distillery) Boiler Ash distillery Units Yeast sludge 15 Compost Factory farm 6 (Molasses & Grain) ETP Sludge 0.25 Compost Own garden 7 Office Waste Papers 0.50 Sale Non – Hazardous 8 Packing section Waste papers 0.50 Sale Non – Hazardous

1. The solid waste shown in the above table, will now serve as valuable material for the new product, bagasse as fuel, molasses as raw materials, press mud as valuable source of crop nutrients and acts as soil conditioner. 5.4.2 Hazardous waste: Hazardous solid waste is governed by hazardous waste (Management & Handling) Rules of 1989 as amended in 2000. The H.W. amendment is promulgated in 2000. It defines hazardous waste on a basis of different criteria. This is examined. The relevant summary of above reads as:

List of processes Waste stream Remark please S. No generating hazardous vide note waste 38.1 Chemicals containing No. 1 below Distillery Units- Cleaning of residues from barrel 1 barrels which have held cleaning chemical substances 38.2 Sludge form waste water purification 2 Sugar unit -Wastes/residue 34.4 The wastes/residue No. 2 below

136 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

containing oil containing oil at sugar ETP unit Note 1: The number of barrels containing Turkey Red Oil is only few, as the substance is not a raw material. It is merely an anti-foam agent. These are on returnable basis to suppliers. So, also can be said for the yeast supplement substances, like nutrients, which comes in bags only Note 2: The waste/residue containing oil in sugar unit (~ 146 Kg/day) would be mixed with bagasse and burnt in the boiler.

5.5 NOISE ENVIRONMENT: Noise is any undesired, unpleasant, irritating or harmful sound or a combination thereof. Noise pollution has been regarded among top ten environmental problems of the world. Sound is sensible in terms of pitch and frequency. The pitch of sound is the loudness or intensity whereas the frequency is the duration of sound- impulsive or continuous. The physiological and psychological effects of noise depend on the human exposure to the noise intensity and duration. It is an endeavor to have minimum noise level within the factory and work zone for the welfare of the workers and also at the four corners of the premises at the boundary wall for the comfort of general public at large. Society will not certainly like a high noise level. From noise point of view let us divide VRSL in four parts viz., (A) material unloading section, (B) manufacturing zone, (C) packing and loading sections and (D) waste treatment area. The four potentially noise generation stations are discussed. From incoming material unloading and handling: VRSL brings in sugar cane, molasses, grains, grapes during grape season etc. as the raw materials. The internal road surface is kept reasonably smooth and non- undulating so as to avoid any noise generation and more so the spillages and fugitive emissions. 1. A large inventory of chemical is always a hanging sword on the engineers, whether it is hazardous or non-hazardous material. VRSL therefore, made a policy of having a minimum storage capacity at hand so that inventory will be always limited. Except in critical times, the other raw material inventory is merely of four weeks only. 2. The success of inventory control depends also on the Supplier-Industry relations. VRSL has kept it smooth and hence there is a free flow and availability of raw materials. 3. Major raw materials sugarcane/ molasses/grains is brought in by vehicles, a very safe and environment friendly way of transportation. This saves in fugitive emissions, losses in transfer/ transit and undue exposure in the yard. This is procured from vicinity. 4. The unloading of raw materials is one of the weaker links in the manufacturing/ production chain. As the prominent raw materials arrive in slow speed vehicles, the closed protected transfer is possible. 5. As a result of these precautions, there is neither a possibility of fugitive emission nor a possibility of noise during transfer or at storage. This yard will be kept away from the road resulting in minimization of any propagation to the boundary. Manufacturing area: The manufacturing activity can be another source of noise generation. The generation is expected to be more, especially in such industries when there are a number of reaction vessels, transfer operations, open vessels, hammering or product cleaning, multiple pumps, ejectors, pulverizes, etc. This particular manufacturing activity involves only three steps simple unit operations and processes. By experience VRSL knows from where the noise problem may get generated. The causes are identified and so are the solutions. The foundation is strong by good civil engineering practices and offers no vibrations.

137 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

Table 5.16: Noise mitigation efforts Source of noise Attenuation by 1 Cane yard Avoided by adopting smooth roads and yard Avoided by adopting good foundation, good alignment, well 2 Milling plant lubricated machinery 3 Generators & DG sets Fitted silencers and separate room provided Mild humming sound, but is not make-and-break type. This is inside the respective sugar unit & distillery column. The Steam in juice respective sugar unit/column is closed and jacketed by fiber 4 heater/evaporator/Pans & wool all around (though basically foe thermal loss, also distillation process serves as barrier for noise, incidentally). The Sugar units/ distillery column itself is in closed building/sugar unit shed. Only occasional and for a small duration of time. Line is not 5 Release of steam too long. 7 Aeration in ETP/CPU Most efficient Diffused aeration system has been provided This machine is in open. However, smooth oiling, periodical Yeast sludge& ETP sludge 8 overhauling, imported gears and level internal service roads composting are provided Proper sturdy foundation provided for all the machines and 9 Vibrations equipments

The finished goods stored under supervision: The alcohol (absolute or extra neutral or rectified spirit) is loaded in tankers by pump-pipe arrangement. Spring cushioning is provided below the floor of the truck to prevent noise, breakage, loss and spillage.

As per applicable schedule and rule of factories Rules prescribed under Section 87 of factories Act, general noise levels will be within the limit. Sound propagation outside any building or structure is also a part of study of environmental noise problems. This becomes specific in cases where noise generating source falls near sensitive area. Here side cladding is provided, the distance from boundary is far and the adjoining area is not occupied by habitation. Sound levels will be measured using digital sound level meter. The readings were recorded in Leq, since it combines noise level, frequency content and duration into one unit. The representative readings will be taken and recorded near all the three activities mentioned above. The existing noise levels in the five villages are recorded and found to be in the range of 33.12 to 51.93 dB (A). Table 5.17: Summary of Noise Level during Study Period Sr. No. Location (Zone) Leq (day)dB ( A ) Leq (Night) dB ( A ) Description i.e., Zone 1 Project site 36.56 33.12 Residential 2 Pande 43.75 37.75 Residential 3 Karmala 51.93 45 Residential 4 Bhalewadi 44.06 36.87 Residential 5 Deolali 41.12 37.25 Residential

Key central legislation: The environment (Protection) Rules 1986, promulgated under environment (Protection) Act, 1986 have described certain noise levels as mandatory maximum. Standard limits, Sound pressure level, dB (A) Areas Day time Night time Industrial area 75 70 Commercial area 65 55 Residential area 55 45

138 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

The noise levels expressed as dB (A) are stringent in case of residential areas while somewhat higher levels are allowed in the industrial areas. This is predominantly an agricultural area. The factory Act, 1948 provides restriction in the interest of worker’s health in the vicinity while the environment Act limits are addressed by keeping the public at large in consideration. Mitigation measures: The control measures as described above have given sufficient satisfaction, so as to make the consequent noise levels very low. There is no need of designing further mitigation measures beyond this. However, training is given to the staff and workers to see that no noise-increasing activities are undertaken and also to report if they notice any abnormality high noises in any section or sub-activity. A watch-dog committee (WDC) proposed under environment management plan (EMP) keeps a watch on its monthly round to judge this. Following measures are proposed for controlling noise level impacts on machinery operators and within core and buffer zone of VRSL  In order to avoid noise during transport, the surface quality of internal roads is kept smooth in engineering like manner. Loading is done mechanically.  Development of greenery/barriers/landscaping of trees /bushes and shrubs. Trees of special varieties with large number of small leaves are planned.  Reduce noise exposures to the operators of machinery by work scheduling and by providing ear protective equipments.  Use rubber packing in the foundations of machineries to prevent noise transmission to the surroundings.

5.6 ODOUR ENVIRONMENT: Odour is an undesired, unpleasant, irritating or harmful experience or a combination thereof. Odour pollution has been regarded among top environmental problems in certain situations. Odour is variously described as ‘unpleasant, disagreeable, pungent, characteristic, Odourless’ and yes even as ‘sweet or pleasing’. Odour is sensible only in terms of organolyptic test. The physiological and psychological effects of odour depend on the human exposure to the odour intensity and duration. It is our endeavor to have or low odour level within the factory work zone for the welfare of the workers and also at the four corners of the premises at the boundary wall and much beyond for the comfort of general public at large. Society will not certainly like any odour. From odour point of view let us divide VRSL in four parts viz., (A) material unloading section, (B) manufacturing zone, (C) packing and loading sections and (D) waste treatment. The potentially odour generation stations are discussed in following given Table No. 5.18. Table 5.18: Odour mitigation efforts Sr. No. Probable source of odour Attenuation by 1 Milling plant, detention of effluent Quick draining, aerobic condition 2 Stale press mud Consume quickly to compost yard Covered, CO captured and scrubbed and 3 Fermentation 2 recovered. Avoids odour escape 4 Distillation column Now multi pressure- vacuum improved hardware. A closed system, continuous feeding of 5 Spent wash incineration system concentrated spent wash & no question of odour Now only 15 days storage, that too in the 6 Concentrated Spent wash storage emergency for repairs/ maintenance of machinery. 7 Spentwash in evaporation ponds Not provided. Office, colony-guest house septic 8 Remove and compost it sludge 9 Reusable effluent plant sludge Oxidize by bleaching powder or reagents 10 Moderately polluted stream effluent No over detention. No anaerobic condition to set

139 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

treatment in Moderately polluted spent lees 11 effluent treated satisfactorily and Apply wastewater judiciously. recycled Fully aerobic by special turning machine, viable 12 Press mud - Composting yard dedicated culture and fine spraying of water getting immediately absorbed.

The manufacturing area of proposed integrated sugar complex, Sugar Division is more than 2.40 Km away from the village Pande and the ETP is still farthest. The ETP is provided with aeration system and hence no anaerobic odour will get generated as is associated with open lagoons of distilleries. In distillery too exposure to air is reduced.

Mitigation measures:

The control measures as described above have given sufficient satisfaction, so as to make the consequent odour levels very low. There is no need of designing further mitigation measures beyond this. However, training is given to the staff and workers to see that no odour increasing activities are undertaken and also to report if they notice any abnormally high odour in any section or sub-activity. A watch-dog committee (WDC) proposed under environment management plan (EMP) keeps a watch on its monthly round to judge this. In order to avoid odour during transport, the surface quality of internal roads is kept smooth in engineering like manner, and trees of special varieties with large number of small leaves are planned. Loading is done mechanically. Temperature: The heat can get generated mainly at two places viz., (A) at the manufacturing section, and (B) at utility section (Boiler and cooling tower) The VRSL working is a simple operation. Though the manufacturing is done at raised temperature, there are no exothermic reactions, except at Fermenters. The utilities like boiler or cooling system (or exchange of heat) is a requirement. However, the waste heat is being recycled fully internally, leaving no waste and thus no treatment. There is incineration boiler. Hot condensate water too is reused over again and does not find a way in the environment to raise its temperature. All the hot lines and vessels are insulated and jacketed. This is checked every month, by taking a shutdown for a day. All this indicates that there is no possibility of any thermal environmental shock. The mitigation will be done by providing excellent ventilation (natural), shielding of hot object area, good head way and by increasing the greenery outside.

5.7 SOCIO ECONOMIC ENVIRONMENT: The proposal is for production of sugar, ethanol, grape and malt spirit, IMFL, Country liquor unit, malto dextrin unit. It is big activity and provides good job opportunities. This industrial unit is likely to offer about 460 new jobs of various hierarchies. On the background of the district population, the figure of fresh employment of 460 people is hardly an increase. This small % is not capable to create any impact on the present environment and certainly not any adverse one, by way of secondary pollutants by downstream activities. The impact will be marginal but positive. There will be no effect on land-use pattern, aesthetics, public health, amenities, education or housing by such small activity. The local people will be engaged wherever feasible; VRSL will produce sugar, power, alcohol (Rectified spirit, ENA and absolute alcohol), grape & malt spirit, Cyclodextrin here and dispatch. All sugarcane, grains, grapes as raw materials are not produced here. It will

140 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra be purchased from outside. Some of rectified spirit and extra neutral alcohol product will be used for production of country liquor and Indian Made Foreign Liquor respectively and balance ethanol will be sold from here and not converted to chemicals here (like acetone, acetic acid, VAM etc.) . In other words there will not be any cause for any induced pollution in cascading. VRSL complex will render following services in and around the site.  Medical relief  Education  Drinking water supply  Sports promotion  Cultural events  Religious Activities In addition to above, it is recommended to undertake following activities in order to ensure uninterrupted sugarcane during the crushing season.  Development of Seed Nursery  Seed Distribution- VRSL will have to raise quality seed material of high yielding and high sugar recovery sugarcane varieties and meet the demands so that old seed is replaced after every five years.  Water Management- the VRSL will have to take due care to water management especially in the heavy soil region.  Input Supply to Farming Community- The inputs like pesticide, insecticide, fungicide, micro-nutrient fertilizers, seeds of green manure, organic compost are to be made available. There shall be no difficulty in procuring crop loans.  Capacity Building of Farmers- For implementing above mentioned programme in the command area, training programmers, kisan-mela etc shall be conducted in the various parts of the operational area. Thus the gap between potential yield and actual yield could be reduced.

RISK ASSESSMENT: The environmental risks are inherent in operation of any industry, or any human activity for that matter. Any system failure can lead to disaster. Alcohol manufacturing is a simple three step process. However Risk is posed by (1) Dust in various operational steps and (2) Fuel, which here is in the form of bagasse and coal Dust is generated in many steps from raw material handling, transfer and crushing, grinding, heating, cooling, transporting out and waste treatment. In order to reduce this risk, steps like capturing the same, conveying through ducts, and controlling by Fly dust arrestors are attempted. Conveying by conveyor belts covered, smooth internal roads, watering the roads, regular and quick sweeping and monitoring the efforts, are the minimum actions to be taken. Fuel used here is bagasse & coal. Bagasse can give rise to two types of Risks, namely Fire and Explosion. Although the raw material is not spontaneously flammable, the ethanol product is. VRSL has made complete arrangements that an industry using flammable material will provide. As full fire Protection and extinguishing gadgets are provided; any risk from fuel stands automatically covered. All motors are kept TEFC (totally enclosed fan cooled). Temperature and carbon monoxide control is undertaken by arranging carbon dioxide correct percent. Depending on the convenience of work and situation, bagasse bales are either stored in open or dispatched out

Vehicles bringing in the harvested cane are run at slow speed. It is neatly tied and secured to the vehicles. Guards patrol the entire length, throughout day and night. There is no public traffic here and warning signals are painted on boards.  For other raw materials, it is a policy to bring the same in small doses and in close containers. If sundry raw material comes in bags, hooks and other sharp equipment is not used to be used on bags or unit loads. Cranes, truckles and forklift trucks are used for unloading and loading.  Before storage all units are to be inspected for cleanliness and for damage.

141 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

 All bags are to be stacked on pallets. All damaged bags are to be repaired a second impermeable bag which would be sealed properly and kept separately for use.  Dyke walls, smooth sloping floors provided around storage tanks.  Stocking at work place, loading and maintenance of floor area:  The raw materials are to be placed very near to the feeding point.  Housekeeping is most important of all dust control methods.  Simply cleaning of all possible emission sources as quickly as possible.

5.8 WORK ENVIRONMENT Table 5.19: Dust and free work environment is maintained in view of worker safety, health and hygiene. The efforts taken in this respect are: Sr. No. Source Attenuation 1 Cane Yard Can be avoided by adopting smooth roads and yard. Avoided by adopting good foundation, good 2 Milling plant Alignment well lubricated. 3 Generators Fitted enclosure and tall stack Steam in Heated material. The system is continuous and closed and 4 For sugar , distillery & jacketed by glass wool all around. These systems located in other processes closed building. Only occasional and for a small duration of time. Line is not 5 Release of steam too long. Diffused aeration systems are provided. Free board is adequate 6 Aeration in ETP so that droplets are not spilling out. Spent wash Incinerator This is continuous and closed system and hence arrest any 7 boiler Dust or Heat The aero tiller machine is in open. However , smooth oiling, periodical overhauling , imported gears and level internal service roads are provided to avoid Dust. The material gets 8 Press mud composting heated quickly by microbial activity as soon as culture in inoculated say up to 65 C. but gets quickly utilized in pasteurization and moisture reduction. Proper sturdy foundation provided for all the machines and 9 Vibrations equipments to avoid fugitive escapes. Table- Work Environment Care

5.9 DISASTER MANAGEMENT PLAN: Objectives  To localize the emergency.  To minimize the consequences.  To ensure that following concepts are considered, namely rescue, first aid, evacuation, rehabilitation, spreading the information.

Elements of On-Site Plan:  Assess the size of event.  Plan formulation and liaison.  Action like: Raise alarm, communication within and outside.  Appoint key personnel and deploy. Appoint controller.  Emergency Control Center.  Action on site.  Action off-site.  Alarm and visual signals at strategic points, first alert sent to Incidence Controller.

142 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

Organization Chief Disaster Controller Managing Director 1 2 3 4 5 Area Medical Material Fire-Safety PR & Security Coordinator Co-Ord. Co-ord. Co-ord. Co-ord. Fig. 5.6: Organization Chart

Duty Allocation Chief Disaster Controller (Managing Director)  Take control and declare emergency  Be there.  Contact Authorities

1 Area coordinator  Take steps. Make Emergency shut-down of activities. Put everything in safe condition  Evacuate.  Commence initial fire-fighting, till Fire Department comes to take up.  Identify materials requirements and call Material Manager.

2. Medical Coordinator  Establish Emergency Center. Treat people, Transfer – Remove patients.  Assign Deploy staff  Arrange medical supplies  Summon outside help

3 Material Coordinator:  Dispatch necessary supplies  Arrange purchases

4 Fire – Safety Coordinator :  Be Overall in-charge for Fire and Safety.  Coordinate with Area Coordinator and Direct the Operations.  Coordinate with City and Other Fire – tenderness.

5 PR & Security Coordinator  Remove Crowd  Arrange gate security  Contact Police  Arrange evacuation  Control outside Agencies if asked.  Handle news media  Mobilize vehicles  Arrange food, clothing’s to Officers inside.

6 Emergency Control Center  Adequate Internal phones  Adequate external phones  Workers Tally  Map showing hazardous storages, Fire sirens, Safety equipments, Gates and side gates, Assembly points, List of persons.

143 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

7 Action on Site  Evacuate Non-essential people first at Assembly point  Persons Accounting  Record of next-of-kins  Public Relations

8 Post Disaster Analysis  Why happened  How to avoid in future  Whether on-site operations failed? In what respect?  How to avoid such failure in future  Report to be submitted in detail to Authorities  Compensation arrangements if any, commenced?  Call suggestions on shortfalls observed  Give rewards openly, pull defaulters individually.

Integration: Technique: For siting of an activity, “Delphi Technique” is advised by MoEF. The government of India has recommended this technique in the book on “Siting of Hazardous Waste Disposal Areas” prepared by NEERI, Nagpur and published by the Ministry of Environment and Forest (MoEF) in 1991. The same is proposed to be used with due improvisation, mutatis mutandis, covering other media of environment.

1. (a) The Delphi Technique considers the following 34 attributes and four weight – ages i.e. 7 attributes, receptor related 10 attributes, pathway related 8 attributes, pollutant related 9 attributes, waste management related. (b)The modified Technique used here considers 23 attributes and four weight–ages i.e. 7 attributes, receptor related 5 attributes, pathway related 5 attributes, water pollution & waste management related 4 attributes, air pollution and waste management related 2 attributes, solid waste management related. 2. Four types of marks for each attribute like 0 to 0.25, 0.25 to 0.5, 0.5 to 0.75 and 0.75 to 1.0 depending on facts of situations, chemical properties of pollutants and quantification are considered. These marks are known as Sensitivity Index (SI). 3. combined consideration of (1) and (2) together gives attribute-wise weight-ages. These are the negative marks out of 1000 and ranking of candidate sites is based on comparison of these marks. Finding the Sensitive index (SI) shall be first task and is done in the table below 5.19 The attribute measurements or values or description are known as the team has traversed the area. The sensitivity index is awarded based on attribute properties in above table. The attribute wise score is arrived at by multiplying the sensitivity index and the weight-age of each attribute and is given in following Table No.5.20. The total score is also worked out. Table 5.20: Attributes & Sensitive Index Attribute Sensitivity Index Receptor related 0.0-0.25 0.25-0.50 0.50-0.75 0.75 -1.00 Population within 500 0 to 100 100 to 250 250 to 1000 > 1000 meters Distance to nearest >5000m 2500 to 5000 m 1000 to 2500 m <1000 m

144 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

drinking water well Use of site by nearby No used Occasional Moderate Regular residents Distance to nearest >3000 m 1500 to 3000 m 500 to 1500 m < 500 m off site building Presence of major Airport Internal road Highway Rail transportation routes Land use/zoning Completely Agricultural Commercial or Residential Remote (zoning industrial N/A) Critical environments Not a critical Pristine natural Wetlands, flood Major habitat or environmental areas plains, & endangered or element preserved areas threatened species Attribute Sensitivity Index Pathway related 0.0- 0.25 0.25 -0.50 0.50 – 0.75 0.75 – 1.00 Distance to nearest > 8000 m 1500 to 8000m 500 to 1500 m < 500 m surface water Ground water depth >30 m 15 to 30 m 5 to 15 m < 5 m Type of No Soil Biota Air , water or food contamination Contamination contamination contamination contamination only Precipitation Semi arid Semi humid Humid Wet effectiveness index Susceptibility to 0- 0.25 not 0.25 – 0.50 0.50 – 0.75 0.75 – 1 erosion & run-off susceptible potential Moderate Severe problem Waste related Attribute Sensitivity Index Water 0.0- 0.25 0.25- 0.50 0.50 –0.75 0.75 – 1.00 BOD generation level < 250 mg/l 250- 500 mg/l 500 – 1000 mg/l Above 1000 mg / 1 Treatability < 2.5 2.5- 3.5 3.5 – 5 Above 5 COD-BOD Treatment Tertiary Secondary Primary No Disposal Land assured and Land seasonal Stream up to 5 Riparian crop perennial km PH 6 -8 5- 6 or 8- 9 3 -5 or 9 - 11 Below 3 or above 11 Air 0.0 -0.25 0.25- 0.50 0.50 – 0.75 0.75 -1.00 Industrial mix fuel Electricity Oil Bagasse Coal Control equipment All including Bag filter Cyclone , fly ash None though ESP or wet arrestor Required scrubber Stacks heights As per Act 30 < 30 None though required Noise at boundary Up to 55 dB(A) 55 to 70 dB(A) 70 to 85 dB(A) Above 85 dB(A)

SOLID WASTE 0.0 – 0.25 0.25- 0.50 0.50- 0.75 0.75 – 1.00 Industrial mix(waste None Non-hazardous Hazardous & Hazardous type) Non-hazardous Treatment- Non Recycle / sale Secured landfill Low landfill None though hazardous required Hazardous Recycle / Secured landfill Sanitary landfill None though Incinerator required

145 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

Table 5.21: Attribute wise score is arrived at by multiplying the sensitivity index and the weight-age of each attribute Attribute Sensitivity Attribute Weight age Attribute score Measurement Index Receptor related Population within 500 meters zero zero 80 0 Distance to nearest drinking water 2000 0.57 60 34.2 well Use of site by nearby residents No Zero 50 0 Distance to nearest off site 2000 M 0.675 40 27.0 building Presence of major transportation Agriculture 0.25 30 7.5 routes Land use/zoning Village road 0.25 30 7.5 Critical environments No Zero 30 0 Sub Total 320 76.2 Attribute Sensitivity Attribute Weightage Attribute Score measurement Index Pathway related Distance to nearest surface water 5000 0.385 55 21.18 Ground water depth 35 0.12 45 5.4 Type of contamination No Zero 45 0 Precipitation effectiveness index Semi Arid / Arid 0.12 25 3 Susceptibility to erosion & run-off Not susceptible 0.25 25 6.25 problem to potential Sub Total 195 35.83

Waste related Attribute Attribute Sensitivity Weightage Attribute Score Measurement Index Water BOD generation level , mg/l>1000 1 40 40 PH 6 – 8 0.05 20 2.5 Treatability COD-BOD 3.5 0.5 40 20 Treatment Secondary 0.25 50 12.5 Disposal Secured Land 0.05 50 2.5 Air Industrial mix fuel Bagasse & coal 0.75 70 49 Control equipment ESP 0.05 50 2.5 Stacks heights As per Act 0.05 50 2.5 Noise at boundary 55-70 0.25 30 7.5 Solid waste Mix Non –Hazardous 0.25 45 11.25 Facilities Compost & Sale 0.12 40 4.8 Sub total 485 155.05 Total 267.08

146 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

Table- DELPHI TECHNIQUE From the above considerations we have to place our present proposed units at appropriate level as per following slab Score 750 to 1000 = Pollution Potential Very High Score 600 to 750 = Pollution Potential High Score 450 to 600 =Pollution Potential Moderate Score 300 to 450 = Pollution Potential Low Score Below 300 = Pollution Potential Very Low Yard stick for Ranking Since with the methodical working of sensitivity index and weight-ages, the total scope of pollution potential has come to 267.08, the site fits into “LOW” Pollution Potential. Greening Drive: Objective: To provide a measure of air pollution mitigation, fugitive dust control, shed for men and bullocks, cooler atmosphere, camouflage the land-use, aesthetics of the region, absorption of green-house gas, utilization of NPK of the wastewater after treatment.

Methodology: CPCB Documentation: CPCB has considered this area in their book titled as “guidelines for developing green belts”. They have summarized this area as follows:  This is zone: Trans Gangetic plains  Subzone Plains  Normal rainfall: 561 mm  Climate: Semi-arid to dry sub humid  Soil: Alluvial (Recent Calcareous)  Species Recommended 149

Design of Plantation will be such as  Not to get disturbed in future expansions  Be nearer to source of water and supervision  Be where the need is  Capability of securing maximum survival rate with an aim of 100%

Selection of species will be done by detailed considerations:  A large variety of species selected to have bio-diversity  Indigenous local species have a more chance of survival. So will be surveyed.  Species of origin outside of India, but subsequently found established too shall be encouraged.  Species that will grow rapidly under local dominant stress of soil salinity, high wind, water needs, sustainability in dry months.  Species that have more foliage area, absorbing gasses

Sections will be at least four for greening drive:  Three row curtain on periphery  Block of trees near approach road and internal roads  Ornamental trees in the garden  Bushes on slopes of roads  Fruit trees in the colony

147 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

Logistics Provision is made in advance for:  Securing plants from nearby nursery  Water distribution arrangement  Staff earmarked for the purpose having trained in the respect  Agricultural implements, pesticide and manures necessary  Fire protection

5.10 CHAPTER CONCLUSION: The earlier chapter showed the present status of environment both natural and manmade. The status however, is never static. It changes with the activities of man and with the vagaries of nature. The impact created by the new activity is to be assessed and quantified. This has since been done. Control plans and mitigation measures are designed and enlisted so as to be inside the laws of the land. The gap in between the present level of pollution and the one permitted by statutes is found out. Prevention and abatement measures especially for fugitive emissions are considered. Wastewater and soil part too are considered and found to be surmountable. The operation phase as also the pre-operation (or construction phase) and post operation phases are considered. A final integration by considering various attributes (receptor related, pathway related and waste related) is attempted by using Delphi Technique with slight homogenization. The final acceptability appeared to be 267.08 out of 1000. The location, production activity and pollution control effects thus makes this project safe.

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CHAPTER – 6

ANALYSIS OF ALTERNATIVES FOR TECHNOLOGY AND PROJECT SITE

6.1 ALTERNATIVES Any proposed human activity is never a simple straightforward matter. A number of decisions are required to be taken and for each step a number of alternatives are available. Selection is thus all the more critical in an industrial development where time, money and natural resources are in stake.

Although the present case is not a production of such chemicals, pharmaceuticals, pesticides etc. which will threaten by mammalian toxicity and toxicity to fish, VRSL decided to undertake an Alternative Analysis (AA) for this project. The various alternatives were:  Raw Materials  Technology  Engineering & hardware  Site  No Project This will be discussed and may be finally seen that the environmentally preferable and best-preferred alternative is the same.

6.2 RAW MATERIAL ALTERNATIVE The product will involve certain raw material. There was debate internally and finally the following was selected.

6.2.1 Sugar Production Unit The Sugar cane is the raw material - Available plenty in local area

6.2.2 Co-generation Unit The bagasse is the raw material available from sugar Unit as Co-product.

6.2.3 Molasses/Cane Juice based distillery The basic raw material is available from the same sugar unit. If there is deficit, it can be procured from the sugar factories not having distillery.

6.2.4 Grain Based Distillery Basic raw material is grains (jawar and maize) which is available plenty in the operation area of sugar unit

6.2.5 CO2 Recovery Plant The raw material from distillery units will be available

6.2.6 Malt Spirit The barley as raw material will be available from north India

6.2.7 Grape Spirit The raw material is grape and available in the operational area

6.2.8 Cyclo dextrin The raw material will be grains.

6.2.9 Country Liquor The raw material will be available from the distillery unit as potable grade rectified spirit.

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6.2.10 Indian Made Foreign liquor The raw material will be available from the distillery unit as potable grade Extra- neutral Alcohol. It may be seen that basic raw material is sugar cane which will be used for production of sugar and its co-products bagasse, molasses are used for generation of power and alcohol (potable RS/ENA/fuel alcohol) purposes. The Grains, grapes available from adjoining area are being used for spirit production. In short, the alternatives of raw materials selected which is agro-based and more environmental friendly. Even the transport, packing and transfer of raw material is taken in to consideration. These are brought in such a manner that will not give way to fugitive emissions during the planned careful loading, transfer and unloading. If some sundry material comes, it is brought in bags impervious. No problem of any empty containers or bags is encountered.

6.3 TECHNOLOGY ALTERNATIVES:

The technology of manufacturing of sugar, power, alcohol, CO2 recovery, CL/IMFL, spirit from grape & barley etc. is very simple and straightforward. Each one is described in detail in Chapter,” Project Description”

However, for a careful production without pollution, coupled with waste minimization and energy conservation, a Scientist has to think of a number of alternatives at each step, such as-

 Whether the raw material is brought /procured from vicinity or brought from long distances too  Whether the raw material transfer is manual, mechanical, pneumatic, and whether dry or wet.  Whether the weighing of raw material is automatic/semi automatic/ manual  Whether the raw material selection be in our hand or on market supply  Whether combustion efficiency can be increased from engineering means from the available fuels.  Whether production processes be controlled by automation  Whether production processes be on batch, continuous or semi continuous basis  Whether can we use by-products/co-products to its maximum efficiencies?  In case of all units, are we adopting latest modern technology to conserve energy, increase efficiencies of extraction thereby minimizing the requirement of basic raw material, conserving water resources by way of 3 R principle VIZ., reduce/ reuse/recycle

The technologies for production of sugar/ power/ alcohol/ grape & malt spirit, CL & IMFL, recovery of

CO2 etc. have been developed over the years and refined indigenously by various research Institutions, Indian Companies in which devoted Scientists, Engineers, Skilled and Experienced staff is working to find the best alternatives , addressing above enquiries.

6.4 ENGINEERING & HARDWARE OPTIONS The process development and engineering designing of this project has been done in such a way that the whole operation of manufacturing can be carried out in a controlled system with no or low gaseous emissions, effluents and minimum liquid/solid wastes generation. The material handling and transfer of raw materials are also carried out in controlled and supervised system. Thus the technology is not only cost- effective but also environment friendly.

6.5 SITE ALTERNATIVES The criteria kept for candidate sites included –  Nearness of raw materials  Purity of raw materials  Ease of conveyance of raw materials

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 Desire of Government for industrialization in that area  Nearness of market  Dispatch facilities  Fuel, Power and water supply without encroaching on needs of others.  Remoteness of target  Not destroying prime agricultural lands  Public acceptability

It was our Endeavour to strike such a balance that the environmentally best should also have acceptability commercially. Study of many existing local sugar units brought out an interesting point that they have good quality sealable molasses to offer as well as bagasse.

The site should be well connected by road so that both the raw materials and finished goods can be conveniently handled. The road is neither too busy so as to have a fear of accident, nor is too away from network. Many parts of Solapur in general and Karmala tehsil particular is economically backward and the Government has a desire to improve its status. The pollution generation from this industry is finally made insignificant having taken all the precautions right from the raw materials selected up to low or no waste generation and conversion. This site has connecting road nearby and has approachability. When various sites seen, this site appeared to be environmentally friendly and best as also from the business angle and therefore this option was finally adopted. There is no sensitive establishment in the vicinity such as sanctuaries, hospital, and health resort. There are 30 villages in the influential zone of this project. The list of villages around the project site comes under influential zone of 10 km radius are given in following table No. 6.1.

Table 6.1: List of Villages around the Project Site (influential zone of 10 KM Radius) Distance in Km Direction w.r.t. Sr. no. Name of villages w.r.t. Project Site Project Site 1 Dhaykhindi 2.0 NE 2 Khambewadi 4.2 NE 3 Karanje 5.0 NE 4 Nilaj 6.3 NE 5 Borgaon 6.5 NE 6 Dilmeshwar 7.0 NE 7 Bhalewadi 7.0 NE 8 Potegaon 8.5 NE 9 Bitargaon 9.6 NE 10 Wadachiwadi 9.1 NE 11 Balewadi 9.7 NE 12 Mirghavan 10 NE 13 Pande 2.4 SE 14 Shelgaon 6.4 SE 15 Arjunnagar 6.8 SE 16 Phisare 8.6 SE 17 Sounde 9.7 SE 18 Gulsadi 6.6 S 19 Deolali 5.6 SW 20 Khadakewadi 8.2 SW 21 Karmala city 2.5 W 22 Roshewadi 6.0 W 23 Karmala rural 3.5 NW

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24 Hiwarwadi 5.3 NW 25 Pimpalwadi 5.9 NW 26 Bhose 7.5 NW 27 Mangi 8.4 NW 28 Wadgaon Khurd 8.6 NW 29 Pothare 5.3 N 30 Khadaki 9.0 N  Most of the villages grow sugarcane.  All these villages have road network connected.  None of these villages have fully satisfactory amenities like medical facilities, education, employment etc. They would like to have this through media of industry.

With all this considerations, this site was ranked first and hence adopted.

6.6 “NO- PROJECT” OPTION In this option, it is necessary to consider as to whether it is more advantageous to the Nation, not to commence at all the production proposed.

India has 17.5 percent of the world population only to be supported on only 2.4 Percent of the global landmass. The population is growing, it is becoming all the more essential to provide Food, shelter/roof on their head and communication. The District Statistical Census report and Gazetteer of the District in general and Karmala tehsil in particular, states that the socio-economic conditions in this area are very low. They will therefore need a reasonable industrialization.

On this background in order to support the National requirement, VRSL has proposed this activity to have a integrated Sugar Complex thereby to produce sugar, power, alcohol, spirits etc. The substantial value additions will be done by way of utilizing various by-products/co-products of sugarcane such as bagasse, molasses and press mud. Availability of power is major problem in rural area and hence power will be supplied to Grid. Similarly, molasses with potential property of auto-combustion, and a high BOD of about nine lakh Mg/lit, is an environmental risk if not consumed and spilling out occurs. On the other hand, the resultant product Fuel Alcohol is a partial substitute to the petrol and thus a foreign exchange saver to the nation. In other word, if a “No –Project” option is selected, the repercussions will be widely felt around. Therefore, No-Project Option is overruled.

It is noteworthy that the activity now proposed in backward area of Solapur region will support this cause of National Productivity, of providing employment, of saving of the foreign exchange and in an environmental friendly manner. It will make use of co-products which may turn as wastes if not used judiciously.

The project as it is, keeps an aim of sustainable development. No-Project option is adopted only in an extreme as step of negative listing and is not warranted at all in the present case.

6.7 CONCLUSION In any human activity, there are always possibilities of finding various options. VRSL decided to examine and adopt one such option that will be both environmentally friendly and best suited for production. Various alternatives in terms of raw material selection, technology, engineering and equipments are considered. A final selection of the proposed site is thus arrived.

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CHAPTER – 7

ENVIRONMENTAL MONITORING PROGRAM 7.1 INTRODUCTION The objective of this study is to minimize or off-set the adverse impacts that due to expansion of project. Various mitigation measures are designed and described in chapter 4. After expansion in operation phase we shall have to check continuously as to – (1) Whether our measures are being operated as per design and (2) Whether the resultant impacts are within the tolerance limits. For this we have a specialized cell, higher management support for the cell, adequate funding, support of library-laboratory, open dialogue corridor with all the stake-holders and authorities, and also success indicators are in agreement with our findings. Documentation is necessary along with periodic Reporting to factory management and statutory authorities such as MoEF, MPCB, factory inspectorate etc. Environmental Monitoring program is frame for both in Construction and Operational stages to monitor the effectiveness of the mitigation measures by judging the impact on environment. A separate budget is proposed for the same as also a dedicated Cell is proposed. A transparent approach will be kept with documentation and reporting with statistical treatment to the data. Checklist of Statutory Obligations will be maintained and compliance with it will be monitored. A sugar or process industry in general produces solid, liquid and gaseous wastes, which are discharged to the environment. These discharges pollute receiving media such as air, water and land which in turn harm living beings and property. The waste product may contain one or more chemical constituents. It is the responsibility of the industries to prevent or minimize the discharges of waste products by adopting suitable control measures in the factory to avoid harm to the environment. The effectiveness of such measures is ascertained by systematic monitoring of discharges at factory level and at receiving level. Systematic monitoring of various environmental parameters is carried out on regular basis to ascertain the following  Pollution status within the plant and in its vicinity.  Generate data for predictive or corrective purpose in respect of pollution.  Effectiveness of pollution control measures and control facilities.  To assess environmental impacts.  To follow the trend of parameters which have been identified as critical;

7.2 MONITORING PLAN The routine monitoring program is indicated below. Also monitoring facilities provided for stack emissions from boilers. Regular monitoring of important and crucial environmental parameters is of immense importance to assess the status of environment during plant operation. The knowledge of baseline status and monitored data is an indicator to ascertain for any deterioration in environmental conditions due to operation of the plant. Based on these data, suitable mitigation steps could be taken in time to safeguard the environment. Monitoring is as important as that of pollution control since the efficiency of control measures can only be determined by monitoring. A comprehensive monitoring system in the industry is discussed in detailed. Details of post project monitoring schedule given in Table No. 7.1.

7.2.1 Air Pollution and Metrological Aspects Both ambient air quality and stack emissions are monitored. The parameters monitored are SPM, NOx and

SO2. The ambient air is monitored as per the guidelines of Maharashtra Pollution Control Board.

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7.2.2 Water and Wastewater Quality All the effluents emanating from the plant are monitored for their physicochemical characteristics and heavy metals. In addition ground water samples surrounding the hazardous waste storage area are monitored.

7.2.3 Noise Levels Noise levels in the work zone environment are monitored once a month.

7.3 SAMPLING SCHEDULE AND LOCATIONS The solid, liquid or gases discharges from the factory are analyzed at the sampling points indicated below by the factory as self monitoring system. Post Project Monitoring Plan with environmental attributes and schedule of monitoring is given in Table 6.1. Table 7.1: Post project monitoring schedule Sr. No. Particulars Location Frequency Ambient air quality for PM , PM , SO 2 no’s downwind direction and one 10 2.5 2 24 hrs sample, half 1 and NOx each in upward and crosswind yearly direction. Flue gases from stack for PM , PM , 2 10 2.5 Sampling port of chimney Monthly SO2 and NOx Down flow direction: 2 nos. Near lagoon: 1 no., Agri land Quarterly 3 Ground water drinking water standards utilizing treated effluent: 1 no. Near quarters: 1 no. 4 Soil - organic & inorganic matter At site Pre & post monsoon 5 Effluent water Final discharge point Daily 6 Noise level, work zone (hourly) 6 locations Monthly For process, domestic, cooling and Daily 7 Water utilization, m3/d boiler For air pollution control facility 8 Power utilization Daily (ESP) and for ETP

7.4 LABORATORY FACILITIES Environment Laboratory is proposed with manpower and facilities for self monitoring of pollutants generated in the industry and also its effects on the receiving soil, water body and atmosphere. The list of laboratory facilities to be provided in the industry is given below. The laboratory is equipped with instruments and chemicals required for monitoring following pollution parameters 1. pH 2. TH 3. BOD 4. COD 5. TDS 6. TSS 7. Oil & Grease

List of laboratory equipments proposed 1. pH Meter 2. Conductivity meter 3. TH analysis kit. 4. BOD and COD incubator 5. TDS meter 6. Oil & Grease separator 7. Reflux apparatus for BOD /COD Analysis

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8. Flame Photometer

Environment lab is working in three shifts. Each shift is of 8 hrs in crushing season. In off season other work of maintenance of ETP, APC is done along with paper work related to Maharashtra pollution control board.

7.5 COMPLIANCES TO ENVIRONMENTAL STATUTES 1) This industry is law-abiding and the Environmental Statutes are proposed to be complied with letter and spirit. 2) Carrying out “Environmental Audit Statement” of various environmental 3) Aspects review the environmental policies with the help of experts and make the up gradation /changes accordingly. 4) Submission of the “Environmental Statement” to the State Pollution Control 5) Board in Form V under Rule 14 of the Environment (Protection) Second Amendment Rules 1992 of the Environment (Protection) Act, 1986. 6) Renewal of Consent to Operate under the Water and Air Acts. 7) Filing the Cess returns to the State PCB under the Water (Prevention and Control of Pollution) Cess Act, 1977. 8) Renewal of the Hazardous Waste Authorization under sub-rule 3 of the Hazardous Waste (Management and Handling) Rules, 1989.

7.6 MONITORING OF COMPLIANCES TO STATUTORY CONDITIONS Environmental clearance from MoEF is always accompanied by the specified terms and conditions. Necessary measures are taken to comply with these conditions. Environmental Cell and the associated staff monitor the compliances regularly. Financial allocation for Environmental Monitoring is given in following Table No. 7.2. Table 7.2: Financial Allocation for Environmental Aspects Cost, Recurring Cost, Sr. No. Description of Item Rs Lakh Rs Lakh/ annum 1 Electrostatic precipitators 500 15.00 2 Stacks 170 3.00 Effluent treatment plants (ETP), Sewage 3 450 12.50 collection, treatment & disposal (STP) 4 Fire fighting system 75 2.25 5 Noise Abatement 0.25 0.10 6 Env. Lab equipment & on line monitoring system 50 5.00 7 Rain water harvesting 15 4.50 8 Green belt 35 5.00 Total 1295.25 47.35

7.7 SUCCESS INDICATORS The success of the sincere and honest efforts put in, will be judged by various indicators, such as 1. No complaint from the villagers regarding transfer of lands. 2. No complaint from the customers regarding quality of product and delivery schedule. 3. No complaints from Government or Non Government Authorities and Public. 4. Statistics of Health, Safety and Environment maintained. 5. Other Promoters come to seek our advice. 6. Demonstration to others for rainwater harvesting, environmental status report, environmental statements (annually), Water cess returns (monthly), groundwater recharging, sand-substitute ash, plastic-free packing, care for disabled etc.

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CHAPTER – 8 ADDITIONAL STUDIES 8.1 PUBLIC HEARING AND CONSULTATION The project is establishment of the integrated sugar industry consisting of Sugar cane crushing -5000 TCD, Co-generation power plant and power from incineration boiler- 29.5 MW, Molasses/cane juice based distillery -60 KLPD, Grain based distillery - 45 KLPD, Malt spirit - 5 KLPD, Grape spirit - 5 KLPD,

Distillery CO2 recovery plant - 50 TPD, Cyclodextrane plant - 2.5 TPD, IMFL bottling - one lac cases / Month, Country liquor bottling- two lac cases / Month; at A/P Pande, Karmala Taluka, Solapur District in Maharashtra State.

Public hearing was conducted on 17.06.2017 at Karkhana Site

8.2 RISK ASSESSMENT FOR THE STORAGE & HANDLING OF ALCOHOL & MITIGATION MEASURES DUE TO FIRE & EXPLOSION & HANDLING AREAS The Environmental risks are inherent in operation of any industry, or any human activity for that matter. Any system failure can lead to disaster.

These Organic Chemicals manufacturing is a simple three step process, as seen earlier. However Risk is posed by (1) Dust in various operational steps and (2) Fuel, which here is in the form of power and coal/bagasse.

Dust is generated in many steps from raw material handling, transfer, heating, cooling, transporting out and waste treatment. In order to reduce this risk, steps like capturing the same, conveying through ducts, and controlling by ESP are attempted. Conveying by smooth internal roads, watering the roads, regular and quick sweeping and monitoring the efforts, are the minimum actions to be taken.

Fuel used here is coal/ bagasse. Fuel can give rise to one Risk, namely Fire. As full fire protection and extinguishing gadgets are provided, any risk from fuel stands automatically covered. All motors are kept TEFC (totally enclosed fan cooled). Temperature and Carbon Monoxide control is undertaken by arranging carbon dioxide correct percent. This minimizes the Risk to a very great extent.  Vehicles bringing in the materials are run at slow speed. It is neatly tied and secured to the vehicles.  Guards patrol the entire length, throughout day and night. There is no public traffic here and warning signals are painted on boards.  For other raw materials, it is a policy to bring the same in small doses and in closed containers. If sundry raw material comes in bags, hooks and other sharp equipment is not to be used on bags or unit loads. Cranes, tackles and forklift trucks are used for unloading and loading.  Before storage all units are to be inspected for cleanliness and for damage.  All bags are to be stacked on pallets. All damaged bags are to be repaired. a second impermeable bag which would be sealed properly and kept separately for use.  Dyke walls, smooth sloping floors provided around storage tanks.  Emergency Management Training  The key personnel would undergo special courses on Emergency, Disaster management & Occupational Health. This may preferably be in-plant training. The Managers, Senior Officers & involved staff would undergo a course on the use of personal protective equipment also. In addition, special courses will be designed team-wise. In such training, outside government agencies also will be invited to be familiar with the plant layout.

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 Stocking at work place, loading and maintenance of floor area:  The raw materials are to be placed very near to the feeding point.  Housekeeping is most important of all dust control methods.  Simply cleaning of all possible emission sources as quickly as possible.

 Work Environment: Dust and Heat free work environment is maintained in view of workers’ safety, Health and Hygiene. The efforts taken in this respect are:

Sr. No. Source Attenuation by 1. Scrap Yard Avoided by adopting smooth roads and yard. 2. Plant Avoided by adopting good foundation, good alignment, well lubricated 3. Generators Fitted enclosure and tall stack 4. Vibrations Proper sturdy foundation provided for all the machines and equipments to avoid fugitive escapes. 5. Fumes Closed, covered and carried through ducts

8.3 DISASTER MANAGEMENT PLAN:  Objectives  To localise the emergency  To minimize the consequences  To ensure that following concepts are considered, namely rescue, first aid, evacuation, rehabilitation, spreading the information

 Elements of On-Site Plan:  Assess the size of event  Plan formulation and liaisons  Action like: Raise alarm, communication within and outside  Appoint key personnel and deploy. Appoint Controller.  Emergency Control Center  Action on site  Action off-site  Alarm and visual signals at strategic point, first alert sent to Incidence Controller.

8.4 HAZARD ANALYSIS Preliminary Hazard analysis is used to identify typical and often relatively apparent risk sources and damage events in a system. A characteristic of Alcohol is a clear, colorless and flammable liquid. It has the boiling point of 780 C, ignition point of 363 0C and explosive limits of 3.3 % - 19.0 % by volume. It is listed as hazardous substance by NFPA, MSIHC Rules. It is important to control or eliminate all potential ignition sources in areas that might lead to ignition of vapor. The potential sources of ignition are: Open flames, Electrical wiring / devices, Smoking, Heat sources / hot surfaces, Welding and cutting, Friction, Sparks and Arcs, Static sparks, Gas Compression. Following are the precautions that will be taken to minimize the probability of ignition:  Electrical equipment and wiring should be suitable for the hazard.  If a heating operation is necessary, use only indirect heating methods.  Do not allow any open flames.  Provide grounding and bonding for all equipment handling using these liquids.  Maintenance program will be established to assure that all equipment and safety controls are functioning satisfactorily.

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8.4.1 Characteristics of Ethanol Rectified spirit (RS), Absolute Alcohol and Extra Neutral Alcohol (ENA) are basically ethanol of different grades and have the same hazard characteristics. Hence, all these products are considered as ethanol in hazard analysis. Ethanol is a clear, colorless and flammable liquid. It has the boiling point of 780 C, ignition point of 363oC and explosive limits of 3.3% - 19.0% by volume. It is listed as hazardous substance by ACGIH, DOT, NFPA and NIOSH and is regulated by OSHA. The characteristics of ethanol are given in following Table No. 8.1. Table 8.1: Properties of Ethanol Physical State Liquid Appearance Clear Color Colorless Physical Form Volatile Liquid Odour Alcohol Odour Taste Burning taste Molecular Weight 46.07 Molecular Formula C-H3-H2-O-H Boiling Point 1720F (780C) Freezing point -1790F (-1170C) Vapor Pressure 40 mm Hg @ 190C Vapor Density 1.59 Specific Gravity 0.789 Water Solubility Soluble Volatility 100 % Odour Threshold 5 – 10 ppm Viscosity 1.22 – 1.41 cp @ 200C Solvent Solubility Benzene, ether, acetone, chloroform, methanol, organic solvents

Table 8.2: Hazard Rating of Alcohol is based on flammability, reactivity and toxicity as given in National Fire Protection Association codes 49 and 345 M as Chemical NH (Health Factor) NF (Fire Factor) NR (Reactivity) Ethanol 2 3 0 (Least-0, Slight-1, Moderate-2, High-3, Extreme-4)

Based on Manufacture, Storage and Import of Hazardous Chemical Rules, 1989 framed under Environment Protection rule 1986 We find applicability of GOI Rules 1989 to the notified threshold quantities, analysis of products and quantities of storage in the plant has been carried out & are given in following Table No. 8.3. Table 8.3: Threshold Quantity Product Listed in Total Threshold Quantity Applicable Rule Schedule Quantity Rules 5,7-9 & 13-15 Rule 10-12 Ethanol 1 (2) 6300 KL 1000 t 50000 t Rule 5, 7-9 and 13-15

Based on the above, it is noted that alcohol produced and stored in the plant attract the rules of GOI 1989.

Table 8.4: Degree of Hazard based on Fire explosion and Toxicity indices for the storages Section Fire Explosion Toxicity Ethanol Intermediate Light

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Table 8.5: Minimum preventive and protective measures are recommended Features FE & I Rating Light Intermediate Fire Proofing 2 3 Water Spray Directional 2 3 Curtain special instr. 1 2 Flow Control 2 4 Blow down-spill 1 3 Internal Explosion 2 3 Combustible gas Monitors 1 3 Remote Operation 1 2 Dyking 4 4 Blast and Barrier wall 1 3 separation (1= optional, 2= suggested, 3= recommended, and 4= required)

Maximum Credible Accident Analysis (MCA Analysis) is one of methodologies evolved to identify worst credible accident with maximum damage distance which is still believed to be probable. The probable fire hazard in the plant is in the area of ethanol and is due to storage and handling. It is proposed to store about 60 day’s production of both the products within a common dyke of 40 m x 50 m. As a worst case it is assumed that the entire contents are leaked out. In the event of spilling its contents through a small leakage or due to rupture of the pipeline connecting the tank and on ignition fire will eventually forming pool of fire. In order to assess the radiation levels, Heat Radiation model has been used the algorithm of the models is based on the formulae published in the yellow book by the TNO, Netherlands.

Alcohol Storage is as Day receiver, IS Receiver, Fusel alcohol, Bulk receiver, IS Bulk Storage and DN Spirit, as totally 13 tanks with capacity of 6000 KL

With a dyke area as 40 x 50 m., the results are computed for Pool Fire Scenarios and Distances and accordingly fire protection is designed.

8.4.2 Site Specific Consequences: In order to assess the site-specific consequences, information pertaining to the site such as nearest habitation, nearest industry etc was collected. The nearest village to the plant site is Dhaykhindi village with a population of about a 764 located at distance of 2.0 km from the plant site in the NE direction. Consequences of Heat Radiation is also seen. As the project is located for away from any human habitation and surrounded by dry lands & hillocks with scrubs the offsite damage to the general public and property is negligible.

8.4.3 Fire Fighting Facilities in Ethanol Plant 1. Possible Fire Hazards i. Fire in fuel/bio-mass storage yard ii. Fire in Alcohol storage tanks Electric static electricity and consequent fire accident.

2. Fire Fighting Facilities Elaborate firefighting system will be made available in any corner of the plant. Fire detection is also envisaged.  Fire water storage tanks  Fire water pump house containing combination of diesel & electrically driven pumps  Hydrant system with piping, valves, instrumentation, hoses, nozzles etc

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 Foam injection system for fuel oil tanks of foam concentrate tanks, foam pumps, in- line inductors, valves, piping & instrumentation  Automatic high velocity water spraying system consisting of detectors. Deluge valve projectors, valves, piping & instrumentation  Automatic medium velocity water spraying system consisting of QB (Quartzoid Bulb).  Water curtain arrangement will be commissioned between each storage tank to avoid dissipation of heat to nearby tank.  Linear heat sensing cable detectors, deluge valves, isolation valves, nozzles, piping & instrumentation  Early warning fire detection & alarm system

 Portable & mobile extinguishers of type –Pressurized water, CO2, foam, DCP (Dry Chemical Powder) at strategic locations throughout the plant

a. Water Hydrant System  Fire hydrant system with hose pipe of 7 kg/cm2 pressure with hydrants are located at in bio-mass yard, distillery house, ethanol storage area  A jockey pump and accessories 50 m3/ hr at 90 m head Corrosion protected M.S. underground piping 150 mm dia. and 100 mm and around the plant as closed loop  Nos. single headed hydrants distributed around the plant at about 30 m spacing to supply pressurized water for fire fighting.  10nos. m. s. hydrant nose cabinet adjacent to each cabinet.

b. Fire Extinguishers Type No. At Foam water 2 each Main office and store.

CO2 type 6 each Departmental office and electrical installations. DCP type 8 each Distillery plant and power plant. Sand buckets various Different locations Note- The above requirement will be separately each for 60 KLPD Molasses based distillery unit and 45 KLPD Grain based distillery unit c. Fire Protective Appliances Two sets of fire safety appliances each consisting of following units are located at store and alcohol storage, respectively, such as Self Content Breathing apparatus (SCBA), Air line respirator arrangement, Face masks & gas masks (2), Face shield (2), Helmet (6), Safety belts (2) and Safety ladder (1) d. Fire Brigade Fire brigade facilities available at Karmala and Solapur shall be utilized whenever need arises. Contacts are already established.

On site emergency plan is in place. Emergency Organization is constituted below Table No. 8.6 Table 8.6: Emergency Organization Sr. No. Designation Person Alternate person 1 Declarer of Emergency General Manager( Prod) General Manager (Adm.) 2 Incidence Controller Manager Engineering Manager (Prod) 3 Evacuation and Rescue Team Production Manager Production 4 Repair Team Boiler Supervisor Plant Supervisor 5 Essential Service Team Lab. Chemist Electrical Supervisor 6 Emergency coordinator Boiler Supervisor Power plant Supervisor

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7 Transportation Vehicle Team Personal Officer Office Clerk 8 Medical Services Team Environmental Manager Digester Supervisor 9 Security Security Officer Security Supervisor 10 Communication Gen. Manager (Adm.) Gen. Manager (Prod.)

Safety Equipments And Appliances will be kept at administrative building/stores building and are under the control of emergency Co-ordinator, namely First AID medical units, 4 units at store and 4 units at ECR, Safety belts, Ear muffs, Noise muffs, against dusts, Aprons against chemical spillage, Shock proof gloves and mats, Leather Aprons, and Leather gloves, Safety items against chemicals like gum shoes, hand gloves, helmets, goggles, Safety ladder, Breathing apparatus, Stretchers and oxygen cylinder, Emergency lighting facilities and Air life line for working in vessels and tanks.

As Emergency Transport Vehicle, One vehicle along with driver is always made available at the factory premise for emergency needs. Ambulance facilities available at general hospitals of Daund will be made use whenever necessary.

Assistance of District Fire Brigade and Central Labour Institution shall be utilized for conducting training programmes arranged every year. Once the emergency is controlled the Declarer of Emergency assesses the situation along with other team heads. If he is satisfied that normalcy is regained and no further hazards involved, he shall arrange all clear signal by giving one minute continuous siren at high pitch. All Authorities will be informed about this episode including Police Station, Revenue Department, Factory Inspectorate, SPCB and others. The incidence will be reviewed. After emergency situation is over, the Declarer of Emergency should appoint an expert committee of two to three members to, i. Identify the causes lead to the emergency situation. ii. Preventive measures to avoid recurrence of such situations in future iii. Identifying the areas of lapses in implementation emergency plan so that the same can be improved in future iv. Recommendation for further strengthening of EMP

8.5 OCCUPATIONAL HEALTH & SAFETY During operation stage, dust, gas cutting, welding may cause hazards, micro-ambient conditions near border, platforms etc. Periodical examination of workers’ occupational health is necessary. Health evaluation should do: Table 8.7: Health Evaluation Frequency Pre-placement & Thereafter Sr.No. Occupation Type of Evaluation For Age <30 For Age 30-40 For Age 41-50 every (years) every (Years) every (years) Chest X-ray, Spirometry 1. Cane crushing area 5 4 2 & vision testing Sugar Process area Chest X-ray, Spirometry 2. 5 4 2 & Co-generation Area & vision testing Far & Near Vision, 3. Main Control Room colour vision and hearing 5 4 2 test Ash & Bagasse Chest X-ray, Spirometry, 4. 5 4 2 handling area vision & Hearing testing 5. Noise prone area Audiometry Annually

Note: All workers engaged in material handling system will be regularly examined for lung diseases such as PFT (Pulmonary Function Test).

161 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

8.6 HEAT RADIATION As a worst case, it is assumed that the entire contents are leaked out & on ignition; fire will eventually form a pool of fire. The resultant radiation has to be assessed of the pool fire. The heat load on objects outside the burning pool of liquid can be calculated with the heat radiation model. This model uses an average radiation intensity which is dependent on the liquid. Account is also taken of the diameter to height ratio of the fire, which depends on the burning liquid. In addition, the heat load is also influences by the following factors:

8.6.1 Distance from the fire The relative humidity of the air (water vapor has a relatively high heat absorbing capacity). Visualization and Simulation of Maximum Accidental Scenarios The worst case scenario which is considered for MCA analysis is Pool fire due to failure of storage of ethanol storage tanks in the farm area. The proposed industry will provide 15 days storage of the final product within the plant premises. The following table provides the storage details of ethanol and Rectified spirit. Ethanol Storage Details (For both Molasses based distillery & Grain based Distillery) Sr.No. No. of Tank Capacity ,m3 1. 13 6000 As a worst case it is assumed that the entire contents are leaked out. In the event of spilling its contents through a small leakage or due to rupture of the pipeline connecting the tank and on ignition fire will eventuate forming pool fire as the tanks are provided within the dyke the fire will be confined within the dyke wall? Fires affect surroundings primarily through radiated heat, which is emitted. If the level of heat radiation is sufficiently high, other objects, which are inflammable, can be ignited. In addition, any living organism may be burned by heat radiation. The damage caused by heat radiation can be calculated from the dose of radiation received, a measure of dose is the energy per unit area of surface exposed to radiation over the duration of exposure.

8.6.2 Effects of Pool Fire Pool fire may result when bulk storage tanks will leak/burst, and the material released is ignited. As these tanks are provided with dyke walls to contain the leak and avoid spreading of flammable material, the pool fire will be confined to the dyke area only. However, the effects of radiation may be felt to larger area depending upon the size of the plant and quantity of material involved. Thermal radiation due to pool fire may cause various degrees of burns of human bodies. More ever, their effects on objects like piping, equipment are severe depending upon the intensity. The heat radiation intensities due to the pool fire of the above tank farms are computed using the pool fire model. The results obtained are presented in the following Table. Table 8.8: Pool Fire Scenarios and Radiation Distances Ethanol Storage Tanks Farm Quantity of Storage : 6300 m3 Dyke area : 40 m x 50 m Damage Criteria Damage Distance (m) 100 % Lethality (35.5 kW/m2) 5.0 50% Lethality (25.0 kW/m2) 25.0 1 % Lethality (12.5 kW/m2) 65.0 First Degree burns ( 4.5 kW/m2) 140 Normal Intensity with no discomfort 170 (1.6 kW/m2)

162 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

8.7 RISK ASSESSMENT FOR 60 KLPD MOLASSES BASED DISTILLERY UNIT

Sr. No. Ethanol Storage Tank Nos. Capacity, m3 1 RS Receiver tank 3 60 2 ENA Receiver tank 3 60 3 AA Receiver tank 3 60 4 Intermediate RS tank for AA 1 60 5 Day Receiver tank IS 2 20 6 Day receiver tank TA 2 20 7 DS tank 1 10 8 FO Storage tank 1 10

Bulk Storage Sr. No. Bulk Storage Tank Nos. Capacity, m3 1 Bulk Storage Tank – RS 2 500 2 Bulk Storage Tank – ENA 2 500 3 Bulk Storage Tank – AA 2 500 4 Bulk Storage Tank – IS 1 200 5 Bulk Storage Tank – TA 1 200

8.7.1 RS/ENA LEAKAGE THROUGH CATASTROPHIC FAILURE (2 x 500 MT = 1000 MT): PARAMETERS: Tank diameter : 6.11 m Tank height : 6 m Storage temperature : 30oC Pool area : 200 m3 OUTCOME: Flammable Vapor cloud

Weather Condition Stability Class D Stability Class F Wind speed 3 m/sec Wind speed 2 m/sec Down wind distance for 12 15 LEL – 3.3%, m Max. approximate evacuation 14 18 Zone width, m Containment arrival time at downwind distance 2.1 6.5 for LEL, min. Containment departure time at downwind 4.1 10.3 distance for LEL, min

163 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

8.7.2 RS/ENA LEAK (1000 MT): RS/ENA leakage through failure LEL : 3.3% Atmospheric Stability Class : D Wind velocity : 3 m/sec

Downwind distance Ground level Initial evacuation (m) Concentration (ppm) Zone width (m) 05 1254440 12 08 560982 14 10 200424 16

Downwind distance Containment Arrival Time Containment Departure (m) (minutes) Time (minutes) 05 0.2 4.3 08 0.3 5.4 10 0.5 6.6

RS/ENA LEAK (1000 MT): RS/ENA leakage through catastrophic failure LEL : 3.3% Atmospheric Stability Class : F Wind velocity : 2 m/sec

Downwind Distance Ground level Initial Evacuation (m) Concentration (ppm) Zone width (m) 04 1150000 08 06 959554 10 08 480850 12 10 180580 14

Downwind distance Containment Arrival Time Containment Departure Time (m) (minutes) (minutes) 04 0.3 4.5 06 0.8 5.1 08 1.1 5.8 10 1.5 7.4

FIRE: For LEL 3.3 % hazardous distance Flash point : 13C Vapor density : 1.59 Vapor pressure : 40mmHg@19C Downwind : 12 m Zone width : 16 m BLEVE: Fireball diameter : 12.5m Fireball height : 20.5m Fireball duration : 15.0 seconds Fatality zone : 15 m Injury zone radius : 18.5 m

164 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

8.7.3 Unconfined Vapor Cloud Explosion: Range of injuries from flying glass / object (0.1 bars) : 10-15 m Nearly complete destruction of houses : 10 – 15 m 1 – 99 % fatality among exposed population (1.0 bar) : 10 – 15 m

8.7.4 Domino Effect: In case of BLEVE and Unconfined Vapor Cloud Explosion (UVCE), it is observed that the structural damage distance is about 10 m. The inter distance of tanks is more than 3.5m (0.5d) which is adequate for preventing any domino effect. This may result into failure of neighboring tanks and subsequent release of larger quantity of RS, further cascading the severity of damage.

8.7.5 RS/ENA Leakage Through 50mm Pipeline Failure (2 x 500 = 1000 MT): PARAMETERS: Tank diameter : 6.11 m Tank height : 6 m Storage temperature : 30oC Pool area : 50 m3 Note: Line leakages are depending upon the tank head i.e. static pressure of material. OUTCOME: FLAMMABLE VAPOR CLOUD Weather Condition Stability Class D Stability Class F Wind speed 3m/sec Wind speed 2m/sec Downwind distance for 05 08 LEL – 3.5% Max. approximate evacuation zone width, (m) 07 10 Containment arrival time at downwind distance 0.7 2.8 for LEL, minutes Containment departure time at downwind distance 4.2 6.4 for LEL, minutes

Table 8.9: SCENARIO DESCRIPTIONS AND DATA FOR EMERGENCY PLANNING: (For 60 KLPD Molasses Based Distillery)

Chemical RS/ENA(Denatured Spirit) Catastrophic 2”Leakage Road Tanker Quantity, MT 1000 50mm line 20 Storage temperature, oC 30 30 30 Max. Ambient temperature, oC 40 40 40 Pool area, m3 100 100 50 VAPOR DISPERSION – D-3 LEL, % Downwind distance, (m) 12.0 12 10 Max. evacuation zone width, (m) 14 14 12 Containment arrival time, min 0.4 6.4 8.0 Containment departure time, min 1.5 1.57 1.5 VAPOR DISPERSION – F-2 2.1 5.2 10.0 LEL, % Downwind distance, m Max. evacuation zone width, (m) 2.2 2.2 2.2 Containment arrival time, min 10 12 16 Containment departure time, min 3 2 2 VAPOR CLOUD FIRE HAZARDS Downwind hazardous distance, m(LFL) 12.0 14.0 16.0 Max. downwind hazardous distance, (m) 14.0 15.0 18.0 VAPOR CLOUD EXPLOSION

165 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

3.4 bar overpressure radius, m 10 10 15 FIREBALL (BLEVE) Diameter of fireball, (m) 10 10 10 Height of fireball, (m) 14 14 14 Duration of fireball, seconds 15 10 10 Thermal load radius, (m) - injury 5 kW/m2 12 12 12 - fatality 10 kW/m2 15 15 15

8.8 RISK ASSESSMENT FOR 45 KLPD GRAIN BASED DISTILLERY UNIT Sr. No. Ethanol Storage Tank Nos. Capacity, m3 1 RS Receiver tank 3 45 2 ENA Receiver tank 3 45 3 IS Receiver tank 2 15 4 DS tank 1 50 5 FO Storage tank 1 10

Bulk Storage Sr. No. Bulk Storage Tank Nos. Capacity, m3 1 RS Storage Tank 2 600 2 ENA Storage Tank 2 600 3 IS Bulk Storage Tank 1 200

8.8.1 RS/ENA LEAKAGE THROUGH CATASTROPHIC FAILURE (2 x 600 MT = 1200 MT): PARAMETERS: Tank diameter : 8.5 m Tank height : 8.5 m Storage temperature : 30oC Pool area : 200 m3 OUTCOME: Flammable Vapor cloud Weather Condition Stability Class D Stability Class F Wind speed 3 m/sec Wind speed 2 m/sec Downwind distance for LEL – 3.3%, m 12 15 Max. approximate evacuation Zone width, m 14 18 Containment arrival time at downwind distance for 2.1 6.5 LEL, min. Containment departure time at downwind distance for 4.1 10.3 LEL, min

8.8.2 RS/ENA LEAK (1200MT): RS/ENA leakage through failure LEL : 3.3% Atmospheric Stability Class : D Wind velocity : 3 m/sec Downwind distance Ground level Initial evacuation (m) Concentration (ppm) Zone width (m) 05 1254440 12 08 560982 14 10 200424 16

166 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

Downwind distance Containment Arrival Time Containment Departure (m) (minutes) Time (minutes) 05 0.2 4.3 08 0.3 5.4 10 0.5 6.6

RS/ENA LEAK (1200 MT): RS/ENA leakage through catastrophic failure LEL : 3.3% Atmospheric Stability Class : F Wind velocity : 2 m/sec

Downwind Distance Ground level Initial Evacuation (m) Concentration (ppm) Zone width (m) 04 1150000 08 06 959554 10 08 480850 12 10 180580 14

Downwind distance Containment Arrival Time Containment Departure Time (m) (minutes) (minutes) 04 0.3 4.5 06 0.8 5.1 08 1.1 5.8 10 1.5 7.4

FIRE: For LEL 3.3 % hazardous distance Flash point : 13C Vapor density : 1.59 Vapor pressure : 40mmHg @19C Downwind : 12 m Zone width : 16 m

BLEVE: Fireball diameter : 12.5m Fireball height : 20.5m Fireball duration : 15.0 seconds Fatality zone : 15 m Injury zone radius : 18.5 m

8.8.3 UNCONFINED VAPOR CLOUD EXPLOSION: Range of injuries from flying glass / object (0.1 bars) : 10 – 15 m Nearly complete destruction of houses : 10 – 15 m 1 – 99 % fatality among exposed population (1.0 bar) : 10 – 15 m

8.8.4 DOMINO EFFECT: In case of BLEVE and Unconfined Vapor Cloud Explosion (UVCE), it is observed that the structural damage distance is about 10 m. The inter distance of tanks is more than 3.5m (0.5d) which is adequate for preventing any domino effect. This may result into failure of neighboring tanks and subsequent release of larger quantity of RS, further cascading the severity of damage.

167 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

8.8.5 RS/ENA LEAKAGE THROUGH 50mm PIPELINE FAILURE (2 x 600 = 1200MT): PARAMETERS: Tank diameter: 8.5 m Tank height: 8.5 m Storage temperature: 30oC Pool area: 50 m3 Note: Line leakages are depending upon the tank head i.e. static pressure of material. OUTCOME: FLAMMABLE VAPOR CLOUD Weather Condition Stability Class D Stability Class F Wind speed 3m/sec Wind speed 2m/sec Downwind distance for LEL – 3.5% 05 08 Max. approximate evacuation zone width, (m) 07 10 Containment arrival time at downwind distance for 0.7 2.8 LEL, minutes Containment departure time at downwind distance 4.2 6.4 for LEL, minutes

Table 8.10: SCENARIO DESCRIPTIONS AND DATA FOR EMERGENCY PLANNING: (For 45 KLPD Grain Based Distillery) Chemical RS/ENA(Denatured Spirit) Catastrophic 2”Leakage Road Tanker Quantity, MT 1000 50mm line 20 Storage temperature, oC 30 30 30 Max. Ambient temperature, oC 40 40 40 Pool area, m3 100 100 50 VAPOR DISPERSION – D-3 LEL, % Downwind distance, (m) 12.0 12 10 Max. evacuation zone width, (m) 14 14 12 Containment arrival time, min 0.4 6.4 8.0 Containment departure time, min 1.5 1.57 1.5 VAPOR DISPERSION – F-2 2.1 5.2 10.0 LEL, % Downwind distance, m 2.2 2.2 2.2 Max. evacuation zone width, (m) 10 12 16 Containment arrival time, min 3 2 2 Containment departure time, min

VAPOR CLOUD FIRE HAZARDS

Downwind hazardous distance, m(LFL) 12.0 14.0 16.0 Max. downwind hazardous distance, (m) 14.0 15.0 18.0

VAPOR CLOUD EXPLOSION

3.5 bar overpressure radius, m

168 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

10 10 15 FIREBALL (BLEVE) 10 10 10 Diameter of fireball, (m) 14 14 14 Height of fireball, (m) 15 10 10 Duration of fireball, seconds Thermal load radius, (m) 12 12 12 - injury 5 kW/m2 15 15 15 - fatality 10 kW/m2

8.9 ESTIMATION OF PLANT RISK ASSESSMENT From the above consequences analysis of the plant risk assessment and followed by the preventive measures along with credible losses are exercised as below:- 1. Manufacturing plants are installed at open and well-ventilated location. The total plant is observed as “No Smoking” zone. 2. The present plant is capable to produce 45 KL of RS from grain based and in addition to the plant capacity for EN molasses based is having 60 KL per day. 3. Even though the leakage through any leaky pipe line or total failure of process plant which spill total reaction mass in to plant nearby atmosphere and immediately such reaction mass will be converted in to flammable vapor cloud. Then plant risk due to Vapor cloud should be manageable. Vapor cloud generation due to flammable material and as a result it will be travelled to 10 to 12 meters with respect to wind velocity to attend the lower explosive limit (LEL). These generated vapor cloud should be needed source of ignition to explode or initiate the fire. 4. The source of ignition in the event of vapor cloud as boiler house and utility plant are situated at a distance of 90 meters from the existing plant activity. 5. Risk of the plant will minimized by curbing the vapor cloud by generating water mist by installed sprinkler system. RS/ENA is highly soluble in the running water. 6. Flammable vapor detection system will be commissioned at manufacturing plant and storage tank yards to alert to discontinue the boiler operation and take appropriate action to break electrical energy. 7. The electrical distribution system around the manufacturing plant will be installed as per the guide lines prescribed under Petroleum rules 2002 i.e. observing zone “1” area. 8. Ear thing and bonding will be provided to each pipeline of flammable material. Ear thing are also installed to all non current carrying metallic parts of structures. 9. Cathodic protection will be provided to eliminate the danger of sparking in a hazardous area. 10. Electrical installation, cable insulation and ear thing grids will be certified periodically to avoid the source of ignition at hazardous operation area. Cable insulation of cables are checked periodically, in- house maintenance crew. 11. Finish material tanks and raw material tanks, both flammable chemicals, will be installed nearly 55 meter away from the existing boiler house. The distance between each tank is kept nearly 2 to 3 meters. Tank farm is provided with water sprinkler system to cool the adjacent tank in the event of any emergency. 12. Fire Hydrant system as per the norms prescribed under the Maharashtra factory rules and stipulated code of practices is under commissioning. The required static water storage capacity is already created. 13. In the event of any emergency the thermal radiation to nearest flammable material tank will be minimized by localized water mist generating sprinkler system. The fire hydrant monitor will be utilized additionally to avoid heat radiation and dissolve the vapor cloud formation. This will monitor the Boiling Liquid Expanding Vapor Explosion criteria in the event of emergency.

169 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

8.10 RISK ASSESSMENT FOR PRODUCT – BAGASSE 8.10.1 FIRST AID MEASURES  Eye - If in eyes, hold eyelids apart and flush continuously with running water. Continue flushing until advised to stop by a Poisons Information Centre, a doctor, or for at least 15 minutes.  Inhalation - If inhaled, remove from contaminated area. Apply artificial respiration if not breathing.  Skin - Exposure is considered unlikely. Skin irritation is not anticipated.  Ingestion - For advice, contact a Poison Information Centre on 13 11 26 (Australia Wide) or a doctor (at once). Due to product form and application, ingestion is considered unlikely.  Advice to doctor - Treat symptomatically  Product Name: BAGASSE

8.10.2 FIRE FIGHTING MEASURES  Flammability – Combustible, May evolve toxic gases (carbon oxides, hydrocarbons) when heated to decomposition. Finely divided dust may form explosive mixtures with air.  Fire and explosion  Evacuate area and contact emergency services. Toxic gases may be evolved in a fire situation. Remain upwind and notify those downwind of hazard. Wear full protective equipment including Self Contained Breathing Apparatus (SCBA) when combating fire. Use water fog to cool intact containers and nearby storage areas.  Extinguishing - Dry agent, carbon dioxide, foam or water fog. Prevent contamination of drains or waterways.  Hazchem code - None Allocated

8.10.3 ACCIDENTAL RELEASE MEASURES  Personal precautions - Wear Personal Protective Equipment (PPE) as detailed in Section 8 of this SDS.  Environmental precautions - Prevent product from entering drains and waterways.  Methods of cleaning up - Moisten with water to prevent a dust hazard and place in sealable containers for disposal.

8.10.4 STORAGE AND HANDLING  Storage - Store in a cool, dry, well ventilated area, removed from incompatible substances, heat or ignition sources and foodstuffs. Ensure containers are adequately labeled, protected from physical damage and sealed when not in use. Check regularly for damage to containers.  Handling - Before use carefully read the product label. Use of safe work practices are recommended to avoid eye or skin contact and inhalation. Observe good personal hygiene, including washing hands before eating. Prohibit eating, drinking and smoking in contaminated areas.

8.10.5 EXPOSURE CONTROLS / PERSONAL PROTECTION  Exposure standards - No exposure standard(s) allocated.  Biological limits - No biological limit allocated.  Engineering controls PPE - Avoid inhalation. Use in well ventilated areas. Maintain dust levels below the recommended exposure standard.  Eye / Face - When using large quantities or where heavy contamination is likely, wear dust-proof goggles.  Hands - Wear PVC or rubber gloves.

170 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

 Body - When using large quantities or where heavy contamination is likely, wear coveralls.  Respiratory - Where an inhalation risk exists, wear a Class P1 (Particulate) respirator.

PHYSICAL AND CHEMICAL PROPERTIES Appearance - STRAW LIKE SOLID Odour - ODOURLESS WHEN FRESH Flammability - COMBUSTIBLE

STABILITY AND REACTIVITY  Chemical stability - Stable under recommended conditions of storage.  Conditions to avoid - Avoid heat, sparks, open flames and other ignition sources.  Material to avoid - Incompatible with oxidizing agents (e.g. hypochlorite)  Hazardous Decomposition Products - May evolve carbon oxides and hydrocarbons when heated to decomposition.  Hazardous Reactions - Polymerization is not expected to occur.

8.10.6 TOXICOLOGICAL INFORMATION  Health Hazard Summary - Low toxicity. Under normal conditions of use, adverse health effects are not anticipated. However, if dust is generated, over exposure may result in irritation of the eyes, nose, throat and skin.  Eye - Low irritant. Contact with dust may result in slight eye irritation.  Inhalation - Low irritant. Over exposure to dust may result in irritation of the nose and throat, with coughing.  Skin - Low irritant. Prolonged or repeated exposure to dust may result in irritation and dermatitis.  Ingestion - Ingestion is considered unlikely due to product form.  Toxicity data - No LD50 data available for this product.

8.10.7 ECOLOGICAL INFORMATION  Toxicity - No information provided.  Persistence and degradability - No information provided.  Bioaccumulative potential - No information provided.  Mobility in soil - No information provided.  Other adverse effects - No information provided.

8.10.8 DISPOSAL CONSIDERATIONS  Waste disposal - Reuse where possible. No special precautions are required for this product.  Legislation - Dispose of in accordance with relevant local legislation.

8.10.9 REGULATORY INFORMATION Poison schedule - A poison schedule number has not been allocated to this product using the criteria in the Standard for the Uniform Scheduling of Medicines and Poisons (SUSMP). Inventory Listing(s) AUSTRALIA: AICS (Australian Inventory of Chemical Substances). All components are listed on AICS, or are exempt.

8.10.10 NECESSARY CAUTIONS TO BE TAKEN WHILE STORING BAGASSE IN YARD  Avoid storage of bagasse below & near high voltage (H.T.) transmission lines  Avoid route of electric supply cables &cable trenches far away from stored bagasse or bagasse heaps.

171 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

 Always kept raw & useful material far away from storage of bagasse area  Installation of Fire Hydrant (self auto-mode fire fighting) system around the area of bagasse yard  Posting of proper supervision staff with necessary communication facility  Daily record of bagasse storage data, proper review taken by higher authority  Training of all the involved staff in normal & emergency operating system  Thus in this way doing proper planning & taking some necessary steps, also creating awareness among workers about sudden bagasse fire and emergency action plan will definitely avoid risks of heavy fire. In this way we can save a valuable fuel & life of human being working near bagasse. Also it is quite suitable &self-dependent thing of installing self auto-mode fire fighting system which is having less cost than cost paid by fire incidents say upto Crores of rupees loss. Since, definitely erection cost of self auto-mode fire fighting system is less than to pay much more after happening of fire accident.

8.10.11 HOW SYSTEM WORKS In this fire water pump house there are two pumps present out of this one pump is called as Johnny pump & other as fire pump (such details given in Table 8.11).Johnny pump is having low capacity used for minor requirement and other is used major requirement which is working on the base of sensing line pressure & operates on auto mode due to falling of line pressure. In emergency case, working of Diesel engine started by operator. The necessary communication required for this is carried out by using Walkie Talkie set. This is done by bagasse yard supervisor to pump house operator. The distance between two fire hydrants will be not exceeding 30 meters.

TABLE 8.11: PUMP HOUSE DETAILS

Name Pump Motor Johnny pump 100 m3/hr 20 HP Fire pump 273 m3/hr 150HP/1485RPM Diesel engine 273 m3/hr Engine Rating 133HP

172 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

CHAPTER – 9

PROJECT BENEFITS

Proposed integrated sugar complex will result in considerable growth of stimulating the industrial and commercial activities in the Karmala tehsil of Solapur district. VRSL will be beneficial in reducing the existing and ever escalating demand of electricity to some extent.

9.1 AVAILABILITY OF QUALITY POWER AND ALCOHOL

The co-generation plant is having installed power capacity as 29.5 MW of energy, out of which about more than 20 MW will be exported to the grid. Thus the project will be beneficial in Government’s target of providing power access to all people.

Government of India has announced 10 percent mixing of fuel alcohol in the petrol thereby saving of petrol and in turn saving of foreign exchange.

9.2 IMPROVEMENT IN THE PHYSICAL INFRASTRUCTURE

The beneficial impact of proposed VRSL plant on the civic amenities will be substantial after the commencement of the project activities. The basic requirement of the community needs will be strengthened by extending educational facilities, health care, building and strengthening of existing roads. The living standards of the nearby villages will be improved.

The construction of new roads and improvement in existing roads in the influential area will enhance the transportation facilities. With improved transportation facilities, there is always scope for development.

9.3 IMPROVING THE ECONOMY OF FARMING COMMUNITY

The farmers will be provided with good quality seeds, improved farm implements, credit facilities for adoption of micro-irrigation system, the advanced training to improve yield and recovery etc. The capacity building of farmers will help them to achieve the targeted potential yields of various crops including sugarcane which in turn minimizes the cost of production with more emphasis on maintaining fertility of soil too.

9.4 IMPROVEMENT IN THE SOCIAL INFRASTRUCTURE

 Generation of employment both direct & indirect.  Improvement in living standard of the area.  Further development of small scale industries may be developed.  Increase revenue both to the State and Central Govt. by way of taxes  Overall growth of agriculture & allied businesses based on agriculture  Improvement in Water conservation/ water shed management and overall water management system.  Improvement in health and family welfare.  In addition to above, due to increase in purchasing power of local habitats:  There will be significant change in the socio-economic scenario of the area.  The proposed project will enhance the prospects of the employment.  Recruitment for unskilled and skilled workers for the proposed project will be from the nearby villages.

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 The development of basic amenities such as roads, transportation, electricity, proper sanitation, educational facilities, medical facilities etc. will be developed.  Overall, the proposed project will change living standards of the people and improve the socio- economic conditions of the area.

9.5 EMPLOYMENT POTENTIAL

The impact of the project on the economic aspects can be clearly observed. The VRSL project activities will provide employment to persons of different skills and trade. The local population will be given preference to the employment. The employment potential will ameliorate economic conditions of these families directly and provide employment to many other families indirectly who are involved in business and service oriented activities.

The employment of local people shall upgrade the prosperity of the area. This in turn will improve the socio-economic conditions of the area.

 During construction phase of the project, this project will provide temporary employment to both skilled and unskilled labours in nearby villages.  During operational phase, considerable people will be benefitted by provision of services to the residents. Thus, the direct and indirect generation of employment by this project.  The trend of out migration for employment will be reduced due to better economic opportunities available in the area.

About 150 people will be deployed temporarily during construction of the project and about 460 people will be employed during operational phase of the project.

174 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

CHAPTER – 10

ENVIRONMENTAL COST BENEFIT ANALYSIS

In proposed integrated sugar complex, water conservation techniques will be adopted. Principle of reduce, reuse, followed strictly. Modernization of the existing sugar plant to reduce captive steam and power consumption and to improve the technical performance of the sugar plant and to Achieve zero discharge in inland surface water bodies

Bagasse based co-gen power plant is environmental friendly as compared to fossil fuel based power generation station as bagasse being a bio-mass renewable fuel does not add any net carbon-di-oxide (CO2) to the atmosphere.

175 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

CHAPTER – 11 ENVIRONMENT MANAGEMENT PLAN 11.1 CORPORATE ENVIRONMENTAL POLICY (CEP) We at M/s. Vitthal Refined Sugars Ltd., A/P Pande Tal - Karmala Dist: Solapur commit to improve our Environmental Management System and minimize the impact of our manufacturing activity on the environment, on continual basis, by: • complying with applicable environmental laws and regulations, • Establishing systems and processes which minimize /prevent pollution and foster conservation of resources. • Improving efficiency of all the operations through our proactive efforts in environmental management and incorporating cleaner technologies in the projects. • Establishing objectives and targets and the review of policy. • Enhancing the skills and competence of our employees to ensure sound environmental management.

 NEED Environmental management is a crucial segment of Industrial Management, in view of the global concept of sustainable development. Apart from the social obligation, the industries are liable to suffer a series of drastic actions by statutory authorities, if the former ignore the above said aspect. At its worst; the running factories may be brought to a grinding halt by the pollution control authorities that possess the requisite powers. Therefore, preparation of environmental management plan is a must to fulfill bifocal aspect of the statutory compliance as well as that of social concern. Water needs of Vitthal Refined Sugars Ltd (VRSL) may be reasonably low due to recycle/reuse principle, but generally this resource is dwindling. Thus, on one hand one should use it less and on the other the source should not be left polluted for others. Air environment needs to be continuously managed, because man needs inhalation every moment, so also is Flora and Fauna dependent on it. The biological aspects, soil and ground water are all interdependent. Thus, a need of proper environmental management and a conscious plan for it To draw a rigid EMP is especially important for us because India has to support 16.1% of the world’s population only 2.3% of the global area with 0.4% only of energy reserve. This point of Low Energy Reserve is especially taken note by the PP Project Proponents. In this respect here efforts are oriented towards: Waste bagasse is used for energy as carbon source Waste press mud is sold to farmers as soil conditioner as filler material which is carbon source for crop Effluent is used as carbon source and concentrated distillery effluent is used in boilers The product itself serves as additive in petrol for energy  Objectives a) To define the components of environmental management b) To prepare an environmental hierarchy c) To prepare a checklist for statutory compliance d) To prepare environmental organization e) To prepare a schedule for monitoring and compliance f) To establish a watchdog committee voluntarily with an ultimate aim to get ISO 14000 certification

11.2 ENVIRONMENT COMPONENTS 11.2.1 Air environment a) Monitor the consented parameters at ambient stations b) Monitor the work zone at various stations to satisfy the corporate requirements for health and environment

176 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra c) Maintain a record of running of DG (diesel generating) sets d) Monitor the stacks or vents fitted to sections of raw material, manufacture, thermal and DG power plants)

11.2.2 Water environment a) Keep record of input water every day for quantity and periodically of quality b) Measures are taken to segregate the sub-streams of effluent as per their characterization. c) Water conservation is accorded high priority in every section of the factory. d) Keep record of wastewater returned back to process, to spray pond and to gardening, both the quantity and quality details. e) Keep record of molasses based wastewater/ spentwash converted into concentrated form and used in boiler as fuel and the grain based slop converted in to DDGS as cattle feed.

11.2.3 Aesthetic (Noise and Odour) environment: Monitor the ambient noise level and work zone noise level to conform the stipulated norms a) Creation of awareness for noise attenuation and mitigation program b) Monitor the ambient odour attenuation and mitigation program

11.2.4 Biological environment: a) Special attention is planned to maintain green belt in and around the factory premises b) Adequate provisions are made to facilitate daily watering of all plants and lawns. Special attention provided during summer to ensure that the green belt does not suffer from water shortage c) Development and maintenance of green belt to be considered as a priority issue d) No outside soil is brought for any building developments

11.2.5 Work-zone comfort environment: a) Monitor the work zone temperature levels b) Monitor the work zone humidity c) Examine the health of workers and keep record d) Keep record where nutritional assistance is given to workers case wise

11.2.6 Socio-economic environment: a) The operators and workers are trained in various aspects of ESH (Environment, Safety and health) b) The managers and officers involved in environment management cell shall undergo refresher workshop and up gradation of information on various environmental issues c) The industry shall help in promoting the activities related to environmental awareness in nearby villages d) The industry shall help in promoting local people for livelihood commensurate with their will, skill and abilities

11.3 ENVIRONMENT MANAGEMENT HIERARCHY: VRSL is aware that environmental management is not a job, which can be handled without a careful planning. The success lies if three components are simultaneously present viz. (1) management support, (2) efficiency of the environment management cell and (3) acceptability of resulting environmental quality, both by SPCB and by public. A structure of this plan and hierarchy of process flow for environmental management is prepared and enclosed as logics, which is self-explanatory. VRSL will adopt this structure and hierarchy, which is akin to principles and practice.

177 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

Draft VRSL Policy on Environment

Legal requirements of Expectation of nearby SPCB, MoEF people Final Policy and Design

Schedule of Technological Schedule of Funds input Input Preparation of Implementation Schedule Implementation

Part a Fully Part B Difficulties

Implemented Encountered

Monitoring Additional inputs of Funds /Technology

Unsatisfactory results Satisfactory results

Review Continue

Fig. 11.1: EMP Hierarchy

Prevention Top Management In –plant Abatement Control

Waste Minimization Internal Lab Operation SPCB

Treatment Environmental Documentation Management Plan

Operation Public Disposal

Monitoring III-Party Lab

Awareness Training Attenuation

Feedback Fig. 11.2: Table- Structure

178 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

11.4 CHECKLIST OF STATUTORY OBLIGATIONS: There are a number of environmental statues required to be attended to by the industries. VRSL has prepared a checklist of these obligations, which facilitates the obedience of the laws of land. These are advised to VRSL as follows: 1. The Consents, whether under the Water Act or under the Air Act, are normally issued for a fixed validity period. Please check whether the Consent is valid. If the same is expiring, it is better to apply for a fresh renewal at least thirty days prior to the expiry date. 2. The Consent normally describes the items of manufactured products with quantity. One should see that, the described framework is not overstepped. In case, there is any likely hood of such increase, it will be worthwhile to obtain permission for the same. At least a letter to that effect be posted to the relevant board officer. 3. The Consent lays down a condition as to the volume and rate of discharge of effluents both for domestic as well as the industrial activity. By daily and hourly checks at the measuring devices, this is ascertained. Please do not forget to immediately make a record in the daily log-book. 4. A condition laid down for the treatment and disposal is of extreme importance. For this purpose, ETP or ECE is provided by the industry. There should be a continuous performance evaluation of these gadgets, so as to always remain inside tolerance limits. In case, you are exceeding the limits in certain parameters it is better to bring it on your internal record. The exceedance is discussed with the consultant, your production group and well-meaning Board authorities to seek guidance. Perhaps solution may be found in any or all of the following steps:  Characterization of raw effluents/ emissions  Attempting in-plant controls  Operation, maintenance, repairs and replacement of the ETP, ECE  Retrofit equipment to the existing plant 5. Disposal is the last ditch battle. Disposal, dispersion, dilution, diversion, therefore, has to be planned very methodically and operated efficiently. This is a place where more reliable staff is required to be deployed. Any untoward incidence be reported. 6. Please check that the storm water and effluents do not get mixed. Keep the terminal manhole clean and always hospitable to facilitate taking of sample by the Board officials. Also check that no effluent is admitted in the channel down-stream of the terminal manhole, which means all the effluent, finally should pass via the terminal manhole only. 7. Monitoring aspects are always very crucial. For operating the plant, certain parameters be constantly checked. However, it will be a good practice to check monthly all the parameters through standard and approved laboratories. The result so obtained is routinely informed to the board offices. In case there is a water body in the vicinity, it is advised to take periodically samples from it. This applies both to the surface water as well as ground water. The findings will either give you a confident satisfaction or may give you a timely warning for improvement in the treatment or more so in the disposal system. 8. Although the environmental audit statement is required to be submitted on annual basis, it is better to keep the board progressively informed every quarter about efforts of pollution control and environment protection. 9. The industry should device their own format for a daily logbook recording of the running of their ETP or ECE. If the format is found to be satisfactory by trial and error it is better to finalize it and get printed. A printed format shows your conscious efforts towards the goal of pollution control, whenever any inspection takes place. 10. Please open an inspection book and make it a point that the visiting inspector, irrespective of their grades, gives some remark in the inspection book. If the remarks are favorable it shows your diligence and gives you an encouragement. If some of the remarks are unsatisfactory, it at least gives you an early opportunity to improve. The remark, in any case, gives a framework for improvement. Do not take

179 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

inspection visit as a burden and indeed take it an opportunity for improvement. The compliance of the unsatisfactory remarks is shown during next inspection. This is better way to brighten your image. This diligence becomes helpful to you even in the court case. 11. In case, there is an unfortunate accident, unforeseen act or event by which pollutants are excessively released into the environment, the same is brought immediately to the notice of the board and other concerned agencies. This will enable you to get experienced timely help form them. Your burden gets shared. Synergistic effects can be predicted by an overview. 12. In case, you feel aggrieved by any conditions imposed in the consent approach the board immediately for discussion, or thereafter prefer an appeal timely. Therefore, read the Consent carefully as soon as you receive the same. 13. The Water Cess Act, 1977, is applicable to certain specified industries. In case your industry is covered, the regular returns be submitted. Water meters be installed, whether the industry is covered or not under the Cess Act. Also check from time to time whether the class of your industry which may not be presently specified, has since got covered under the Cess Act. 14. The Cess amount be paid as per assessment orders and record maintained. 15. In case you feel aggrieved by excessive Cess assessment or non-sanction of rebate, the appeal be preferred in time, that is within 30 days. And in case, you are late in doing this, at least submit with reasons for the delay. 16. The Government or Board while giving site clearance or Consent, normally puts a condition of plantation of trees. Otherwise also, planting trees within the compound gives a good demonstration of your plant performance. A better practice is to select about three varieties and density is about 1000 trees per acre of the 33% of the available open land. The species selected is tough and tolerant for your type of environment. 17. An unsafe working and the environmental pollution generally goes hand-in –hand. Therefore, the obligations under the Factories Act be scrupulously followed and record maintained. 18. There are certain responsibilities regarding the hazardous waste. These can be summarized as follows: a) Identification of quantity, constituents and compatibility of hazardous waste, being generated during the activity. b) Proper labeling and marking of containers, which are used for store, transport, or disposal of hazardous waste? c) Use of appropriate containers for storage and transport d) Furnishing of information regarding the waste, its nature, its hazards, antidotes, and non-compatibility etc. to the persons who either transport, treat, store or dispose -off the waste e) Use of authorized operator agency system to ensure the proper disposal of hazardous wastes and to streamline the treatment and disposal f) Training of personnel for handling and proper storage of such categorized waste g) Identify a transporter specialized in such wastes, and the practice of hex plicate manifest be followed h) Submission of reports to MOEF and SPCB i) To provide safety measures for handling of hazardous waste j) In case of an unforeseen act or event in transit occurs, the transporter should immediately report to the nearest police station about  The accident, and the clean-up measures k) He should also report to SPCB on the Form prescribed by the Hazardous Waste (Management and Handling) Rules, 1989 and the Annexure-XI of the Guidelines issued by the Central Government l) A container be opened for a short duration while receiving the hazardous material in it a while removing out from it, or otherwise it must always be kept closed in storage yard.  A container be opened or handled so carefully and slowly as not to rupture/ damage the container  Always keep in spare some empty, clean and sturdy containers handy and immediately available

180 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

 Inspect the filled and stored containers every day and if any found in bad condition transfer the contents to a good container immediately but carefully  Keep a daily record of your custody m) Documentation is always a matter of evidential value. No job is complete unless paper work is complete. Occupier/ generator should carefully note this, and following be developed.  Gate-pass when waste leaves the factory by a transport towards the treatment facility. Keep the receipts.  A receipt of material as signed by the facility Operator as a manifested color coded copy be preserved for three years  Analyze the out-going waste and keep the results for three years from the date of dispatch  Daily record of waste generation be maintained 1. Quantity and points of generation 2. Physical state and chemical constituents 3. Hazardous waste category as per E.P Rules of 1989 4. Hazardous waste class, as per Motor Vehicle Rules of 1989 5. Certify internally, the limit of 90 days and storage of ten tons 6. Quarterly returns to State PCB , on prescribed format 7. Annual returns to State PCB, on Form 4 8. Annual returns to State PCB, on Form 5 n) Under the Manufacture, Storage and Import of Hazardous Chemicals Rules, 1989, the immediate duties can be summarized as:  To forecast the possible situations of major accidents  To design steps in advance to avoid accidents and its consequences including cascading effect  To educate the related workers to stand to such occurrence 19. The occupier should not merely do the above job, but also make a show of his work. Occupier is best advised to inform the concerned authorities and agencies, as to his preparing documents like risk analysis, emergency plan, safety training, avoidance of major accidents, health plan, etc. 20. Under the Motor Vehicle Act, as amended in 1989, certain responsibilities are required to be fulfilled. The intending consignor is duty bound by Rule 131, to supply the transport owner full information about the dangerous and hazardous chemicals being transported to enable the owner and driver to: a) Comply the requirements on classification, labeling, preventive, precautions, updating emergency information panel, and proper reporting to the police b) Be aware of the risks created to health and safety of persons and environment by the dangerous and hazardous goods being transported. 21. Under the Public Liability Insurance Act, 1991 the industrial manager is advised to check some important activities, such as: a) Owner should take out one or more insurance policies b) He should take out such policies before he starts handling any hazardous substances. If he has existing activities involving hazardous substances, he should take the cover early as the rule had become applicable from 1st April, 1992 c) The policies should always be kept renewed and alive d) The amount insured shall not be less than the paid capital. Check this from time to time by taking a review of your position (but shall not exceed Rs. 50 Crores) e) General Insurance Corporation or similar agencies may be able to throw light, if approached

11.5 ENVIRONMENTAL ORGANIZATION: Environmental organization will have an environmental cell responsible for pollution control and also for self-examination through monitoring

181 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

11.5.1 Environment Management cell (EMC) – In any industry, production group is developed over the years but not so in case of the environment group. Special efforts, therefore, are required to be undertaken to select good officers and deploy them in a well- designed environment organization cell.

Executive Vice President/ Managing Director

Manager Factory Manager Environment Medical Surveillance Services Officer

Env Audit Safety Officer Ecologist Laboratory I/C Engineer

Support Staff Technicians Lab Attendants

Fig. 11.3: Environment Management Cell

11.5.2 Monitoring System- Monitoring and feedback becomes essential to ensure that the mitigation measures planned by way of environmental protection function efficiently during the entire period of VRSL operation. Hence an environmental management cell involving top Management may be considered. Organizational set up of Environment Management Cell (EMC) has been indicated in Fig. No. 11.3 Environment Management Cell will perform the following functions.  Monthly review of environmental problems and monitoring of installation /performance /maintenance of pollution control measures.  Enforcement of latest rules and regulations under relevant Environmental Protection Acts.  Preparation of budgetary estimates to seek sanctions for new pollution control measures if required and/or for up-gradation of existing ones based on new technologies.  Emergency planning

EMC shall meet at least once a month and take stock of progress of work relating to decisions taken and targets set in the previous meeting. In VRSL following is decided as a policy. A judgment can become truncated if it is scientifically supported. This work is done by an appropriate monitoring which is a technique of drawing a sample and understanding from it the universe. The sampling station, the parameters and frequency is of extreme importance as also the careful analysis, reporting and interpretation. The schedule decided for a small activity like that of Vitthal refined Sugars Ltd. is as follows –

182 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

Sr. Storm Media Water Waste water Air Noise Solids Aesthetic No. water Stations/ Ambie Hazardo Odor, WDC, 1 frequency/Nu Incoming, M/2 Raw, M/2 Run-off DG vent, M/3 nt, M/1 us Q/1 Q/1 mbers x3 Sugar & distillery Effluent M/1, M= monthly, Ground water 2 Purified, M/4 Stack, M/1 Q= Quarterly down and I up spentwash lagoon Q/1 WDC= watch Conc. spentwash Trees, dog Ambient, M/1x 3 & DDGS, M/4 WDC, Q/1 committee Qualitative PM , PM , Schedul pH, turbidity, pH, BOD, 10 2.5 (severe, All consented, TPM, SO , NO , e 2 of Parameters hardness, TDS, COD, Oil, 2 X dB (A) tolerable, TDS, Color CO , CH , wind rules MPN pesticides 2 3 average, speed, direction 2000 excellent) Table 11.1: Schedule for small activity 11.5.2.1 Schedules: There will be three facets to design and follow the schedules VIZ: A) for compliance of responsibilities, B) for day- to- day operation and management of ETP and ECE, and C) for routine environmental monitoring, to assess the impact and take timely warning. The schedule: 11.5.2.2 Daily Compliance: 1. Take the meter reading- initial and final, for checking the water consumption. 2. Maintain the electricity consumption record for pollution control equipments. 3. Monitor ambient air twice per week as per notification of April 1996. 11.5.2.3 Monthly Compliance: 1. Monitor the influent & effluent of sugar & distillery & other units 2. Monitor the emission sources through the competent authority and submit the analysis reports to the board. 3. Monitor ambient/ work zone noise levels & ensure conformance to standards. 11.5.2.4 Quarterly Compliance: 1. Monitor the leachate around periphery of spent wash lagoon 2. Monitor the ambient air quality at upwind and downwind locations of the factory. 3. Review the water reuse performance. 11.5.2.5 Yearly Compliance: 1. Carry out the “Environmental Audit Statement” of various environmental aspects, review the environmental policies with the help of experts and make the up gradation/changes accordingly. 2. Submit the “Environmental Statement” to the State Pollution Control Board in Form V under Rule 14 of the Environment (Protection) Act, 1986. 3. Review of Green belt development, Adoption of latest techniques & on line monitoring techniques may be done 4. Renew the Consent to Operate under the Water and Air Acts. 5. File the Cess Returns to the State PCB under the Water (Prevention and Control of Pollution) Cess Act, 1977. 6. Renew the Hazardous Waste Authorization under sub-rule 3 of the Hazardous Waste (Management & Handling) Rules, 1989.

183 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

Table 11.2: Consent Compliance: Vitthal Refined Sugars undertakes to comply the conditions prescribed by the Consent. In this direction, the following discipline will be followed

S.N. Condition regarding Mode of Compliance Action by Keeping a watch, Application for renewal will MD, FM, ENV-M 1 Validity Period be submitted in advance Not to exceed the permitted quantity. Feed will MD, FM, CC & DI 2 Production Quantity be adjusted to recovery To be measured daily and in-plant control. Not CC & DI, Env. Eng 3 Quantity of effluent to exceed any time 4 Quantity of sewage To me measured periodically. Not to exceed Env-M To be measured daily. Not to exceed. Repair Env-M, FM 5 Total water input meters. Make break-up as per usages. Fill monthly Cess returns. Pay as per assessment. By running ETP in correct fashion, Monitor, FM, CC, Env-M, 6 Quality of Effluents correct. Env. Eng, MD Disposal of treated Not over application. No Percolation, No Env-M, 7 effluent spillages. Monitor 8 Fuel Quantity Not to exceed permitted quantity FM, Control boiler dampers, ID/FD fans, Co2 % FM, Env- M, MD 9 Emission System monitor 10 Ambient air quality Keep monitoring Env-M, Env. Eng, Check foundations for vibrations, Tree FM, Env. Eng., MD 11 Noise Levels plantation Quantity to be measured & record kept, Ago, FM, Env.-M, 12 Solid wastes bagasse to be baled, molasses not in open pits, MD press mud to be carted out every day 13 Environ. Audit To be complied every year before 30th Sept. Env. Eng., MD Inspection book to be opened. Instruction MD, EC 14 Inspections given by State PCB visiting Officer to be complied & reported. Legends: MD- Managing Director, FM- Factory Manager, ENV-M- Manager- Env., CC- Chief Chemist, DI- Distillery In-charge, Env. Eng.- Environmental Engineer/ Environmental Cell In Charge, AgO-Agricultural Officer,

11.5.3 Watch-dog committee A high power watch dog committee will be set up which will have a power of sudden spot inspection, checking of documents and listening of complaints if any. This committee will supervise over the monitoring and environmental management cell as may be necessary, generally over the following facets of works: 1. Permit management 2. Construction management 3. Treatment and emission management 4. Transport management 5. Disposal management 6. Monitoring 7. Documentation 8. Law enforcement

11.5.4 Monitoring and reporting mechanism The Watch- Dog Committee will supervise and monitor the working of Environmental Management Cell and give its report to Board of Directors (BOD) every three months. Any Deviation/violation / adoption of latest techniques in respect of Environmental management will be brought to the notice of BOD. The

184 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra remedial measures/actions will be proposed with justifications for thereof. The BOD will discuss the subject and approve the appropriate action. The Executive Vice president/Managing Director will implement the decision of BOD.

11.5.4.1 Construction Phase Management:  Site Preparation: The clearance of site may involve the movement of soil. No major leveling operations are envisaged. During dry weather conditions it is necessary to control dust nuisance created by excavation and transportation activities. However, because the proposed built-up area is of considerable low requirement, this problem should not be insurmountable, or else some water sprinkling will be resorted to.  Sanitation: The construction site shall be provided with sufficient and suitable toilet facilities for construction workers to allow proper standards of personal hygiene. These facilities shall be connected to a septic tank and maintained to ensure minimum or no environmental impact.  Noise: Though the noise effect on the nearest inhabitants due to construction activity will be negligible (being away) it is advisable that on site workers using high noise equipment adopt noise protection devices like earmuffs.  Construction Equipment and Waste: It shall be ensured that both gasoline and diesel powered construction vehicles are properly maintained to minimize smoke in the exhaust emissions. The vehicle maintenance area shall be located in such a manner to avoid sources by accidental spillage of oil. Unauthorized dumping of waste oil should be prohibited. Wastes shall be disposed off at an approved site.  Storage of Hazardous Material: The following hazardous materials if used for site preparation and construction activity shall be stored as per international standards. 1. Explosives for rock blasting (This will not be permitted) 2. Petrol and diesel 3. LPG 4. Painting materials 5. Asbestos products  Site Security: Construction site is a potential hazardous environment. To ensure that the local inhabitants and stray cattle are not exposed to these hazards, the site shall be secured by fencing and manned entry points. It will be fully illuminated.  Land Environment: An inventory shall be prepared of standing trees and bushes of significance. To prevent unauthorized felling of trees by construction workers for their fuel needs it will be ensured that the contractor provides fuel to them.

11.6 GREENBELT DEVELOPMENT With rapid industrialization and consequent deleterious impact of pollutants on environment, values of environmental protection offered by tress are becoming clear. Trees are very suitable for detecting, recognizing and monitoring air pollution effects. Monitoring of biological effects of air pollutant by the use of plants as indicators has been applied on local, regional and national scale. Trees function as sinks of air pollutants, besides their bio-esthetical values, owing to its large surface area. The greenbelt development not only functions as foreground and background landscape features resulting in harmonizing and amalgamating the physical structures of the plant with surrounding environment, but also acts as pollution sink.

185 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

Thus, implementation of afforestation program is of paramount importance. It will also check soil erosion, make the ecosystem more complex and functionally more stable and make the climate more conductive. The total greenbelt area is around 14.52 Ha. The Layout plan of the green belt and tree cover in plant area is shown in Fig. 3.3 Species for Plantation Tress will be selected based on the type of pollutants, their intensity, location, easy availability and suitability to the local climate. They have different morphological, physiological, bio-chemical mechanism/ characters like branching habits, leaf arrangement, size, shape, surface, presence or absence of trichomes, stomatal conductivity proline content, ascorbic acid content, cationic peroxide and sulphite oxidize activities etc to trap or reduce the pollutants Species to be selected will fulfill the following specific requirements of the area.  Tolerance to specific conditions or alternatively wide adaptability to eco- physiological conditions;  Rapid growth  Capacity to endure water stress and climate extremes after initial establishment  Pleasing appearances  Providing shade Table 11.3 List of proposed trees Common Name Botanical Names Specification Height in (m) Neem Azadirachta indica Fast growing 15 – 20 Mango Mangifera indica Deep route, Evergreen 35 – 40 Yellow Gulmohar Peltophorum pterocarpum Quick growing 10-12 Bahava Cassia fistula Fast growth 15-20 Jambhul Syzigium cumini Evergreen, Tropical 30 Moh Madhuca longifolia Fast growing 20 Sita Ashok Saraca asoka Evergreen 10-15 Apta Bauhinia racemosa Small crooked tree 3-5 Palas / Flame of the forest Butea monosperma Dry season, deciduous 15 Kadamb Anthocephallus cadamba Large, quick growing 45 Ber Ziziphus mauritiana Evergreen shrub 15 Shivan Gmelina arborea Fast growing, deciduous 30 Shirish Albizia lebbeck Flowering tree 25 Maharukh Ailanthus excelsa Large deciduous tree 25 Karanj Pongamia pinnata Legume Tree 15-25 Katesavar Bombax ceiba Tall flowering tree 20 Fish tail palm Caryota urens Flowering plant 12 Nandruk Ficus retusa Rapidly growing, evergreen shrub 15 Son chafa Michelia champaca Tall, Flowering Tree 30 Safed Khair Acacia ferruginia Draught resistant 12 Babul Acacia nilotica Slow growing, long lived 5 -20 Bakul Mismusops elangi Evergreen tree 16 Kaner Nerium indicum Evergreen Shrub 4

186 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

11.7 RAINWATER HARVESTING SYSTEM Rain water harvesting structures are proposed to recharge the ground water resources in the region. The run – off water from the roof of the structures and paved areas will be collected through storm water drainage system and led to rain water harvesting structure. The rainwater harvesting structure will be decided during detailed engineering of the project. The typical rainwater harvesting structure is shown in Figure Peak Runoff for Design Purpose Assumptions 1. Average Annual Rainfall – 522.74 mm (based on Yearly (2000-2014) Average Rainfall data of Solapur District) 2. Runoff coefficient assumed = a. Roof Terrace = 0.85 b. Paved and other area = 0.50 c. Green Area = 0.15 3. Coefficient for Evaporation, spillage and first flush etc. 0.80 4. Intensity of rainfall considered on the basis of rainfall occurred in August 2014 i.e. 201.6 mm Based on this, the peak intensity of rainfall will be 6.5 mm/day. We have assumed that 6.5 mm (0.0065 m/hr) rainfall will occur in one hour for calculation purpose A. Runoff calculations for Terrace Area Peak Runoff (Q) = 0.85 x 0.0065 m/hr x 52770 (m2) = 291.55m3/hr B. Runoff calculations for Paved and other Area Peak Runoff (Q) = 0.50 x 0.0065 m/hr x 242387 (m2) = 787.75m3/hr C. Runoff calculations for Green Area Peak Runoff (Q) = 0.15 x 0.0065 m/hr x 149800 (m2) = 146.05m3/hr

Area in Peak intensity of Particular Coefficient Runoff in m3/hr Sq. m. Rain fall (m) Terrace Area 52770 0.0065 0.85 291.55 Paved & Other area 242387 0.0065 0.5 787.75 Green Area 149800 0.0065 0.15 146.05 Total 444957 1225.35

11.8 STORM WATER MANAGEMENT The Integrated sugar complex water management system will be designed to minimize the potential for storm water contamination occurring at the site. This will be achieved by incorporating the following features into the storm water management system:  Run-off from upstream areas will be diverted around the plant site.  The quantity of contaminated run off generated will be minimized by diverting run-off from areas external to the plant to storm water discharge points.  Hazardous material and fuel storage areas will be bunded and drains will be provided around these facilities to prevent entering of runoff water.  Run-off from area external to process areas of the plant will be contained within a storage system.

187 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

FIG. 11.4 TYPICAL PLAN AND SECTION OF DEEP WELL RECHARGE PITS

11.9 COST PROVISION FOR ENVIRONMENTAL MEASURES It is proposed to invest about Rs 1295.25 Lacs on pollution control, treatment & monitoring system for proposed integrated sugar complex. In addition to these Rs. 5.00 Lakh per annum will be spent on green belt development in and around the proposed sugar complex. The breakup of the investment is given in the following Table 11.4

188 SGM Corporate Consultants Pvt. Ltd Environment Assessment Report For M/s Vitthal Refined Sugars Ltd. A/P- Pande, Tal- Karmala, Dist- Solapur, Maharashtra

Table 11.4 Cost Provision for Environmental Measures Recurring Cost, Rs Sr. No. Description of Item Cost, Rs Lac Lac/ annum 1 Electrostatic precipitators 500 15.00 2 Stacks 170 3.00 Effluent treatment plants (ETP), Sewage 450 12.50 3 collection, treatment & disposal (STP) 4 Fire fighting system 75 2.25 5 Noise Abatement 0.25 0.10 Env. Lab equipment & on line 50 5.00 6 monitoring system 7 Rain water harvesting 15 4.50 8 Green belt 35 5.00 Total 1295.25 47.35

11.10 CHAPTER CONCLUSION: Unless an EMP is prepared in advance, as like production campaign the environmental protection will not automatically happen. For such EMP, fixing of objectives is the first step and ensures its implementation is the last step. This is designed in this Chapter and we have a commitment from the higher management to strict to this design. This will meet the objectives of fulfilling the legal requirements and not causing any hardships to people, whether it is only formulation extension or a technical grade manufacture.

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CHAPTER – 12

EPILOGUE

About war, it was said that planning is that by which harm is avoided and advantage gained. So is true for environment. Prediction of impact through ENVIRONMENTAL IMPACT ASSESSMENT (EIA) is a good tool for the planning. VRSL has prepared this report to serve as a vehicle to provide the proponent & related decision makers with complete information about the proposal. VRSL after full analysis finds that for the people in the region the future with this project is better than the future without it.

Proponents of VRSL have an excellent track record in the past being associated with number of co- operative units and especially the one of the Co-operative sugar unit. VRSL premises will be open for concerned pollution control authorities at any time in the future with transparency. The policy and practice will synchronize here.

India has been transformed tremendously over the past few years with the advent of open global market and competitive economy. To VRSL, that competition is the driving force for the improvement, entailing sustainable latest technologies followed the world over, adoption of the best global practices and to further inculcate the same into the large number of small and marginal farmers who will start a new era of adopting latest farming techniques to increase the agricultural production and thereby self- reliance.

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CHAPTER – 13 DISCLOSURE OF CONSULTANTS ENGAGED This EIA report is prepared on behalf of the proponents, taking inputs from proponent’s office staff, their R & D wing, Architects, Project Management Professionals etc. by Environmental Consultants M/s. S G M Corporate Consultants Pvt. Ltd, Address 206,207, Sai Chambers, Pune-Mumbai Road, Wakdewadi, Pune- 411 003 who have been accredited by QCI-NABET S. No., 138 of list of Consultants with Accreditation (Rev.29) of dated 07th April 2015.

 INTRODUCTION SGM Corporate Consultant Pvt. Ltd. Pune which is an ISO 9001:2008 certified company with QCI- NABET Accreditation of category ‘A’ for the various project sectors for obtaining Environmental Clearances from authorities like Ministry of Environment and Forests (MoEF), State level Environment Impact Assessment Authority [SEIAA] etc.

SGM is a core group of professionals, dedicated & committed to a singular goal – Various Services under One Roof. The innovative idea of SGM is to provide the professional expertise at all levels to all the customers of SGM. We at SGM believe in delivering quality work within the stipulated time frame, with perfect professional care. Our team contributes Technical, Managerial & Financial Experts in the respective fields. SGM has well qualified & professional persons; who are looking after their departments in successful manner & have experience in respective fields for last 20 years. Client Satisfaction is our main motto. Team Work gives sure success and this is what we aim for and achieves Client Satisfaction. Well defined working philosophy, is the backbone of SGM’s growth.  WORKING PHILOSOPHY: • Services Identification of industrial pollution problems in air, water and solid disposal, the environmental concerns and providing precise solutions, forms the core of our activities. • Quality Results oriented services intended to suit customer requirement. Getting clear documents that require no corrections and impose minimum conditions to be on right side of law • Integrity Not letting down customer in the hour of crisis, clarifications and repeated explanations called upon authorities. Provide answers with patience. • Customer satisfaction Strive consciously to exceed customer expectations. • Self Reliance Practice self reliance in all the aspects of management skills, technical competence, and application of sophisticated tools in project execution and report presentation, to provide one stop

FIRM'S EXPERIENCE Since inception, S G M Corporate Consultants Pvt. Ltd have successfully completed several diverse projects for different type of industries and are regarded as a leading environmental management firm. S G M Corporate Consultants Pvt. Ltd has served as consultants to industries, institutions and government for projects executed in India. S G M Corporate Consultants Pvt. Ltd have acquired firsthand experience for the environmental problems of diverse industrial units such as Distilleries, Sugar industry, Building & Construction projects, Thermal Power Plants, Synthetic Organic Chemical Industry, Metallurgical industries, Townships and Area development projects etc, for Government, Private and Co-operative organizations. An important aspect of S G M Corporate Consultants Pvt. Ltd. capabilities is the multi- disciplinary expertise and approach.

S G M Corporate Consultants Pvt. Ltd. employs about fifty qualified technical personnel from various disciplines and offers services that integrate different dimensions of environmental engineering & technology. Capabilities and services provided by S G M Corporate Consultants Pvt. Ltd. Resources include;

 OUR SERVICES IN ENVIRONMENT MANAGEMENT  Preparing Environment Impact Assessment (EIA)reports

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 Obtaining compliance certification to EC, preparing EC compliance and six monthly compliance.  Selecting, Designing and executing Pollution Control Systems.  Obtaining Consent from State Pollution Control Board  Obtaining compliance to consent conditions  Preparation of Detailed Project Report (DPR)  Groundwater and Surface Water Investigations  Soil Analysis & Testing  Solid waste management (Industry and construction projects)  Operation and maintenance of Effluent Treatment Systems (Industry)  Social Impact Assessment (SIA)  Conducting Energy Audit  Conducting Environmental Audit  Preparing Environmental Statement reports  INFRASTRUCTURE Over the years S G M Corporate Consultants Pvt. Ltd has acquired an operational infrastructure which provides a strong base to the services rendered by the organization Outline of the infrastructure which is specifically developed to meet services oriented work is summarized below:  TECHNICAL EXPERTISE S G M Corporate Consultants Pvt. Ltd. considers their employees as human resources as they are obviously at the heart of any successful organization. The organization has result-oriented, experienced people with adequate qualification. S G M Corporate Consultants Pvt. Ltd employs and has associated technical people to suit services provided, apart from the administration, accounts and other support staff.  OFFICE S G M Corporate Consultants Pvt. Ltd has a comfortable, centrally located office in Pune. The office is equipped with all modern amenities and gadgets to complete any design, drafting, and publishing work in- house. In addition the state-of-art communication system facilitates immediate contact, interactions and data communication either from field to office or with any client around the globe.  COMPUTER CENTER: S G M Corporate Consultants Pvt. Ltd. Computer center attached with various gadgets cans rapidly process and store data. Computer is equipped with latest and custom-built software for designing and detailing equipments, Process flow diagram, Layout, drawings etc. Word processors and printing devices ensure quality production of any document or report. Internet facility is provided to all of employees in order to let them upgrade their knowledge and self search answer to their queries.  REFERENCE LIBRARY: S G M Corporate Consultants Pvt. Ltd. maintains a library consisting of reference books, journals, papers, articles, publishers, reports and other such comprehensive study material. Continuous up-gradation of knowledge in the chosen area of business is a regular activity and every employee is trained and encouraged to do so. Latest edition of Handbooks on environmental, chemical, civil, mechanical, electrical engineering have been made available. Additional reference books on legal, management, communication and computers are also available here. Copies of environment protection act, notifications issued by MoEF are carefully preserved and referred. In addition books on specialized knowledge of functional areas as specified by QCI / NABET for example Air pollution, water pollution, land use, ecology and biodiversity, solid waste management etc are provided.  COLLABORATION WITH LABORATORY: S G M Corporate Consultants Pvt. Ltd. is engaged with Environmental services as well as doing work of Environmental Clearance under various Environmental Laws, thereby requiring the laboratory for the purpose of EIA monitoring and analysis . S G M Corporate Consultants Pvt. Ltd. getting done all the lab work through M/s. Insta Pollutech Labs, Pune, which is the MoEF, Govt. of India approved laboratory. The lab provides laboratory facilities to M/s. S G M Corporate Consultants Pvt. Ltd. when and as required. The copy of MOU between M/s S G M Corporate Consultants Pvt. Ltd. and M/s. Insta Pollutech Labs, Pune is attached below.

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NABET Surveillance Certificate of M/s. SGM Corporate Consultants Pvt. Ltd

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Functional area experts and assistance to FAE involved in the EIA study for “M/s Vitthal Refined Sugars Ltd. A/p – Pande, Taluka – Karmala, District – Solapur, Maharashtra, India” is as follows: Table 13.1 List of Experts

Signature Sr. Name of Technical Educational Sectors Approved/ Functional Experience Remarks No. Staff Member(s) Qualification Area Expert i)1977-1987 yrs. as a Teaching/Professor Sectors Approved ii) 1987- 1992yrs. as a Process Engineer 1)Sugar Industry (25) iii) 1992-2007yrs. as a head Env.Sci.& Prof. Baban B. M.Tech (Dairy & Food 1. 2) Distilleries (22) 37 Years Alcohol Technology Gunjal Engg.) 3) Thermal Power Plant (Co-gen) In SGM (4) i)2008-Till date as a EIA Co-Ordinator in sectors (25), (22), (4) i) 1969 to 2006 yrs. Sectors Approved In NEERI Scientist M.Sc. Botany 1) Mining of Mineral Including In SGM Dr. Mrs. Rekha Opencast/Underground mining (1) 2. 41 Years ii) 2010 to to till date as a EIA Coordinator Thakre Ph.D. (Botany) 2)Thermal Power Plant (4) in Sctors (1), (4), (9), (8) 3)Cements Plants (9) iii) FAE in 1)Ecology & Biodiversity (EB) 4) Metallurgical Industries (8) 2) Soil conservation (SC) i) 1971-2000 yrs. Safety officer in a E.H.S Sectors Approved - Dept. Synthetic Organic Chemicals (21) ii) 2000-2010 yrs. HAZOP, EIA Proprietor in Functional Area Expert in – a E.H.S Dept. PG Diploma 1)Risk assessment & hazard Mr. Somnath V. In SGM 3. Industrial Safety management (RH) 47 Years Deshpande i) 2007-Till date as a EIA Co- ordinator in PG Diploma( Fire 2. Solid Waste and Hazardous sector (21) Safety) Waste Management (SWM) ii) Functional Area Expert in RH, SWM, 3. Air Pollution Monitoring, AP. Prevention & Control (AP)

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i) 1979 to 2007 yrs. as assistant/ Deputy Functional Area Expert in M. Tech. Engineer 1. Water Pollution Monitoring, (Environmental ii) 2007- 2012 as a Teaching in Engg. College Prevention and Control (WP) 4. Mr. R. C. Katdare Engineering 36 Years In SGM 2. Land Use (LU) Persuing Ph.D in Soil i) Dec 2012- till date as an FAE in WP, LU, 3. Hydrology & Ground Water Erosion HG (HG)

i) 1977 to 2010 yrs as a Professor in Economics Dept. Dr. Adam M. M. Phil (Economics) Functional Area Expert in 5. 38 Years In SGM Shikalgar Ph. D (Economics) Socio-Economics (SE) “Cat- B” i) 2010- Till date as an Functional Area Expert in SE “Cat- B” Sectors Approved i) 2006 – 2011 as a Env. Engineer & Sr. 1.Building & Large Construction Manager in EIA & projects Mr. Sourabh Singh Projects (38) M. Tech. In SGM Jaiswar Functional Area Expert in 6. (Environmental 8 Years i) 2012-Till date in SGM as a EIA (Empanelled 1. Water Pollution Control (WP) Engineering) Coordinator in Sector (38) Expert) 2. Noise (N) ii) FAE in WP, N, SWM 3. Solid & Hazardous Waste Management (SWM) i) 2 yrs, as a Project Assistant Functional Area Expert in ii). 1 yr. Analytical lab incharge Ms. Archana N. M.Sc. (Environmental 7. 1. Water Pollution Control (WP) 6.0 Years In SGM Mohite Science) i) Feb 2012- till date as a Environmental Officer and as a FAE in WP

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INSTA POLLUTECH LABS, PUNE

 LABORATORY INTRODUCTION Insta Pollutech Labs, Pune (IPL) has well equipped ‘Sampling & Testing Laboratory’ located in Pune, to fulfill requirements of various Industries in the field of Testing. IPL has an Experienced and Qualified team of technicians, with all relevant Testing with all sophisticated Instruments. The detailed scope of our services in the field of Testing is enclosed for your perusal. IPL has been associated with many reputed Organizations like Bajaj Auto Ltd, Coca -Cola (I) Ltd, Cotton Group, Thermax Group, Finolex Group, Honeywell, Sudarshan Chemicals, KPIT & many more. The Laboratory is Certified from ISO 9001:2008, ISO 14001:2004 & OHSAS 18001:2007 & Gazetted from Ministry of Environment & Forest (MOEF) in the field of Pollution Control. THE SCOPE OF IPL’s SERVICES IS MENTIONED BELOW A) TESTING I) Pollution Control Monitoring 1) Effluent Testing. (Treated / Untreated) 2) Ambient Air Testing, Stack Emission Testing of D.G. Sets, Furnaces, Boilers etc. 3) Work Area Monitoring. 4) Solid & Hazardous Waste Testing. 5) Noise & Lux Monitoring. 6) Soil Testing II) Testing of Water Samples. (Chemical, Physical & Bacteriological Analysis) 1) Drinking Water Testing for ‘Potability Test’/ Process Water / Well / Bore well. 2) Swimming Tank Water Testing. III) Testing of Food Products 1) Fruit & fruit products. 2) Vegetable products. 3) Cereals & their products. 4) Milk & milk products. 5) Alcoholic & Non-alcoholic beverages. 6) Instant mixes & Vegetable oils. 7) Cooked food products. 8) Spices condiments & other food products. IV) Petroleum Oil Testing 1) Testing of Fuels like LDO, SK 2) Engine Oil, Lubricating / Hydraulic Oil, Thermic Fluid, Quenching Oil, Transformer Oil, etc. 3) Grease Testing. 4) Solid Fuels such as Coal, Bagasse, Briquettes. V) Analysis of Metals 1) Chemical analysis of Ferrous & Non 2) Microstructure & density of Metals. VI) PVC Testing 1) Testing of PVC Pipes, Cables, Sheets, Grade raw materials, etc. 2) Testing of PVC Finished Products for tests like Effect on water, density. VII) Rubber Testing VIII) Pesticide Residue testing of all samples B) MISCELLANEOUS SERVICES. 1) Legal Services in the field of Environmental & Pollution Control such as Getting Consent from MPCB, Preparation Environmental Statement, Operation of Effluent Treatment Plants etc.

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2) Any Chemical Testing as per specific requirements. 3) Foundry Chemicals. 4) Testing of Soaps, Waxes, Inks, Gums, Plastic goods, etc. 5) Soil & Fertilizers Testing. 6) Solvents & other analysis on GC

The name of M/s. Insta Pollutech Labs, Pune has been appeared in “The Gazette of India” Sr. No. 102. The copy is attached below.

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