Proposed Integrated Project of 10000 TCD Sugar, 41

Proposed Integrated Project of 10000 TCD Sugar, 41 MW Co-Generation Power Plant And 220 KLPD Distillery/Ethanol Plant Along with 8 MW Executive Summary Incineration Boiler Based Power Generation At village Chinamgeri & Choudapur, Tal. Afzalpur, Dist. Kalaburagi, For Draft EIA report Karnataka

By KPR Sugar and Apparels Limited Proposed Integrated Project of 10000 TCD Sugar, 41 MW Co-Generation Power Plant And 220 EIA KLPD Distillery/Ethanol Plant Along with 8 MW Incineration Boiler Based Power Generation Executive Summary CONTENTS 1.0 Introduction ...... 2 2.0 Project Location ...... 2 3.0 Salient features of integrated project ...... 4 4.0 Process description ...... 6 5.0 Description of the Environment ...... 7 6.0 Anticipated Environmental Impacts ...... 7 7.0 Environmental Monitoring Programme...... 7 8.0 Additional Studies ...... 9 9.0 Environmental Management Plan ...... 9 10.0 Environment Management Cost ...... 12 11.0 Project Benefits ...... 12 12.0 Conclusion ...... 12

1.0 Introduction KPRSAL proposes to set up an integrated sugar plant (10,000 TCD), eco-friendly cogeneration power plant (41 MW) for decentralized generation of exportable surplus power, mainly from renewable sources of fuel & 220 KLPD Distillery / Ethanol Plant with 8 MW Incineration boiler based Cogeneration power plant for ZLD, to be located at Chinamgeriand Choudapurvillage, Afzalpur Taluk, Kalaburagi District, Karnataka State Village, Afzalpur Taluk, Kalaburagi District, Karnataka State.

2.0 Project Location The project study area is locatedvillage Chinamgeriand Choudapur village Tal. Afzalpur, Dist. Kalaburagi, Karnataka. Unit is geographically located at 17°13'10.65"N& Long 76°33'48.74"E 442 m MSL.

Figure 1: Map showing general location of the proposed project

Proposed Integrated Project of 10000 TCD Sugar, 41 MW Co-Generation Power Plant And 220 EIA KLPD Distillery/Ethanol Plant Along with 8 MW Incineration Boiler Based Power Generation Executive Summary

F i g ure 2: Google image

Figure 2: Proposed Plant Layout

Proposed Integrated Project of 10000 TCD Sugar, 41 MW Co-Generation Power Plant And 220 EIA KLPD Distillery/Ethanol Plant Along with 8 MW Incineration Boiler Based Power Generation Executive Summary

3.0 Salient features of integrated project Table 1: Brief information of the project and environmental settings Particulate Description Project Proposed integrated project of 10000 TCD Sugar, 41 MW Co- generation power plant & 220 KLPD Distillery/Ethanol Plant along with 8 MW incineration boiler based power generation for ZLD. Location Sy.no. 3/*, 3/*, 4/1, 4/2, 5/1, 5/2, 5/3, 5/5, 5/6, 5/7, 5/8, 5/9, 5/10,6/1, 6/2, 6/3, 6/4, 6/5, 8/3, 13/1, 13/4, 12, 143/2, 144/1, 144/2, 145/1, 145/2, 145/3, 145/4, 145/5, 145/6, 145/7, 146/*, 147/1, 147/2, 148/1, 148/2, 148/3, 148/4 village Chinamgeri, sy. no. 75/pot 2,75/pot 2,75/pot 3, 75/pot/4/1, 75/pot/4/2,75/pot/4/3, 75/pot/5/1,75/pot/5/2, 77,77/2,77/3 Choudapur village Tal. Afzalpur, Dist. Kalaburagi, Karnataka. Product Sugar 10000 TCD Distillery/ Ethanol ENA/RS/AA/Ethanol o220 KLPD(One at a time or in combination) Co-generation 41 MW Incineration boiler 60 TPH with 8 MW TG (Extraction cum condensing) Operation days Sugar 160 days Co-generation 161 days Distillery 330 days Molasses Own Cane Juice 390000 MT requirement Own B-Heavy Molasses 810000 MT C-Molasses-115000 MT. Water requirement Sugar, co-generation and Domestic: 1530 CMD Distillery : 1800 CMD Total: 3330 CMD Source of water Water source will be Bhima River and permission for the same is obtained. Boiler Incineration boiler 60 TPH with 8 MW TG (Extraction cum condensing) Sugar and Cogeneration boiler 210 TPH with 41 MW TG DG Set 1250 kVAx4 and 625 kVA x1 Fuel Sugar & Co-generation Bagasse: 79 TPH Distillery Concentrated spent wash 18.5 TPH Coal-13.5 MT/H for slop fired boiler &38.5 MT/H for sugar boiler. Steam required Sugar steam requirement: 210 TPH Distillery steam consumption 60 TPH Total effluent Sugar, Cogeneration & Domestic : 1156 m3/d generation Distillery (Condensate, spent lees, Blow down and conc. Spent wash)- 2733 m3/d Ash  Bagasse ash generation: 53 TPD  Spent wash ash generation 66.4 TPD 4

Proposed Integrated Project of 10000 TCD Sugar, 41 MW Co-Generation Power Plant And 220 EIA KLPD Distillery/Ethanol Plant Along with 8 MW Incineration Boiler Based Power Generation Executive Summary

 Coal ash generation: 127 TPD ETP sludge The sludge from primary clarifies, settling tank and secondary clarifier will be sent to sludge drying beds. Sludge will be dried in natural heat of sunlight. The dried cakes will be can be utilized for as manure. Air pollution control Sugar boiler 210 TPH : Electrostatic precipitator with 80 m stack measures Distillery boiler 60 TPH withstack height: 80 m stack with BAG FILTER. Man-power Total 375 Skilled 275 and unskilled 100 Total project cost Rs741.68 Cr. EMP capital cost Total Rs.7.11 Cr CER Cost Rs. 5.0 Cr Nearest Village Chinmmgeri 400 m in west Nearest Town / City Gulbarga (Kalaburagi) – 31 km Nearest SH 34 is 3 km SE Nation/state Highway Nearest Railway Gulbarga 30 km in NE station Nearest Airport Gulbarga (Kalaburagi Airport) 43.8 km in NE National Parks, No any in within 10 km of project area Reserved Forests (RF) / Protected Forests (PF), Wildlife Sanctuaries, Biosphere Reserves, Tiger/ Elephant Reserves, Wildlife Corridors etc. within 10 km radius River / Water Body Bhima River is flowing at a distance of 3.4 km in S. (within 10 km radius)

Proposed Integrated Project of 10000 TCD Sugar, 41 MW Co-Generation Power Plant And 220 EIA KLPD Distillery/Ethanol Plant Along with 8 MW Incineration Boiler Based Power Generation Executive Summary

4.0 Process description Alcohol manufacturing mainly involved below given steps  Feed preparation and weighing  Dilution: Preparation of molasses for fermentation by appropriate dilution with water  Fermentation: Production of alcohol from fermentable sugars in molasses solution with the help of yeast

 Distillation: Product recovery through distillation processes

MolassesDilution Spent lees will Activated be recycled Yeast Fermentation Ethanol & CO2 Emission

Multi-Pressure Steam Spent wash Distillation and Spent lees

Molecular Sieve

Spent wash treatment through MEE & Incineration boiler RS/ENA/FO/AA/Ethanol

Storage

Figure 4: Distillery process flow chart

Proposed Integrated Project of 10000 TCD Sugar, 41 MW Co-Generation Power Plant And 220 EIA KLPD Distillery/Ethanol Plant Along with 8 MW Incineration Boiler Based Power Generation Executive Summary

5.0 Description of the Environment The study area as per awarded model TOR, 2015 is earmarked to be 10 km from the project site. The baseline survey was conducted from Oct2020 to Dec2020. The guiding factors for the present baseline study are the requirements prescribed by the guidelines given in the EIA Manual of the MoEFCC and methodologies mentioned in Technical EIA Guidelines Manual for Distilleries by IL&FS Ecosmart Ltd., approved by MoEFCC.

6.0 Anticipated Environmental Impacts Table 4: Anticipated Impacts Environmental Facets Anticipated Impacts Air Environment Probable increase in concentration of air pollutants due to process, fugitive and utility emissions. Water Environment Generation of industrial & domestic wastewater. Land Environment Impacts on land due to improper disposal of hazardous/ solid waste. Ecological Environment Positive as greenbelt of appropriate width will be developed and maintained by the company in the area. No impacts are envisaged on aquatic flora & fauna as there will be zero effluent discharge outside the plant premises. Social Environment Overall development of the area in respect of the infrastructure development, educational growth, health facilities etc. Economic Environment Positive impacts on economy of the region and the country as the Alcohol will be exported and revenue generation. Noise Environment Minor increase in noise level within the project area. Occupational Health & Major health hazards are identified in worst case scenario. Safety

7.0 Environmental Monitoring Programme Table 5: Environmental monitoring schedule Particulate Parameters Number of location Frequency Ambient air PM10, PM2.5, SO2, NOx etc. Ambient air quality at minimum Monthly quality 3 locations. Two samples downwind direction at 500m and 1000m respectively. One sample upwind direction at 500m. Stack PM, SO2 and NOx All stacks Monthly emission Online stack monitoring will be -

Proposed Integrated Project of 10000 TCD Sugar, 41 MW Co-Generation Power Plant And 220 EIA KLPD Distillery/Ethanol Plant Along with 8 MW Incineration Boiler Based Power Generation Executive Summary

Particulate Parameters Number of location Frequency installed Work place PM2.5, SO2, NOx, CO, O3 Process emission in workplace Monthly area/plants (for each area/plant minimum 2 locations and 1 location outside plant area near vent) Waste water pH, EC, SS, TDS, O&G, Wastewater from all sources. Monthly Ammonical Nitrogen, COD, Inlet & outlet of ETP, spent BOD, Chloride, Sulphides wash, Condensate treatment etc. plant Online Monitoring machine is already installed at existing ETP. Camera at spent wash tank will be installed. Surface water pH, Salinity, Conductivity, 3-5 location Half yearly and ground TDS, Turbidity, DO, BOD, Ground as well as Surface water Phosphate, Nitrates, water. Sulphates, Chlorides, Total Coliforms (TC) &E.Coli Within 1 km radius from spent wash tank. 2 locations downward, 1 location upward additional three locations within 10 km radius from the site. River sample One each at upstream and downstream Solid waste Ash  Process dust generated Monthly sludge and ash.  Before used as manure if used manure Soil Organic N, P, K, moisture, EC, heavy At lands utilizing compost Pre –monsoon and Inorganic metals etc. manure and treated effluent, 3 and Post matter locations monsoon Noise Equivalent noise level - dB 5 location Monthly (A) at min. Noise Levels At all source and outside the measurement at high noise Plant area. generating places as well as sensitive receptors in the vicinity Green belt Number of plantation In and around the plant site Monthly (units), number of survived plants/ trees, number of poor plant/ trees. Soil Texture,pH,electrical 2-3 near Solid/ hazardous waste Quarterly conductivity,cation storage.

Proposed Integrated Project of 10000 TCD Sugar, 41 MW Co-Generation Power Plant And 220 EIA KLPD Distillery/Ethanol Plant Along with 8 MW Incineration Boiler Based Power Generation Executive Summary

Particulate Parameters Number of location Frequency exchange capacity,alkali At least five locations from metals,Sodium Absorption Greenbelt and area where Ratio manure of biological waste is (SAR),permeability,porosity. applied. Near spent wash storage lagoon Occupational Health and fitness check-up All worker Yearly/ twice a health of employees getting year exposed to various hazards and all other staff Emergency Fire protection and safety Mock drill records, on site Monthly preparedness, measures to take care of emergency plan, evacuation during such as fire fire and explosion hazards, plan operation fighting to be assessed and steps phase taken for their prevention.

8.0 Additional Studies

The following additional such as risk assessment for storage and handling of alcohol and mitigation measure due to fire and explosion and handling area has been carried out.

9.0 Environmental Management Plan Following mitigation measures shall be adopted by factory to minimize the impact of project on the surrounding environment.

Proposed Integrated Project of 10000 TCD Sugar, 41 MW Co-Generation Power Plant And 220 EIA KLPD Distillery/Ethanol Plant Along with 8 MW Incineration Boiler Based Power Generation Executive Summary Table 6: EMP for various environmental attributes Environmental Mitigation Measures Attributes Air Quality Process Emission Management  The whole process will be carried out in closed condition so as to avoid any chances of VOC emissions. Utility Emission  All the D.G. sets shall be standby arrangement and will only be used during power failure.  Adequate stack height shall be provided to Boiler and D.G. sets.  Electrostatic Precipitator and BAG filtersshall be provided as an air pollution control device to the boiler with approximately 99.99 % efficiency to capture maximum boiler fly ash. Fugitive Emission  The main raw material and product shall be brought in and dispatched by road in covered enclosures.  Dust suppression on haul roads shall be done at regular intervals. Water &  The distillery would be based on ‘Zero Liquid Discharge’ technology. Wastewater  Total spent wash generation will be 531 CMD. For existing unit spent Management wash will be concentrated in MEE and then burn in spent wash fired boiler.  The Process condensate, spent lees will be cooled and will be treated in Condensate Polishing Unit, after treatment of which it will be recycled back to the process again.  The treated water will be used for gardening.  Proper storm water drainage will be provided during rainy season to avoid mixing of storm water with effluent.  Rain water harvesting Noise  Closed room shall be provided for all the utilities so as to attenuate the Management noise pollution.  Acoustic enclosure shall be provided to D.G sets.  Free flow of traffic movement shall be maintained. Earmuffs shall be used while running equipment’s of the plant.  Proper maintenance, oiling and greasing of machines at regular intervals shall be done to reduce generation of noise.  Greenbelt shall be developed around the periphery of the plant to reduce noise levels. Odour  Odour shall be primarily controlled at source by good operational Management practices, including physical and management control measures.  Better housekeeping will maintain good hygiene condition by regular steaming of all fermentation equipment.  Use of efficient biocides to control bacterial contamination.  Control of temperature during fermentation to avoid in-activation/ killing of yeast.  Avoid staling of fermented wash.

Proposed Integrated Project of 10000 TCD Sugar, 41 MW Co-Generation Power Plant And 220 EIA KLPD Distillery/Ethanol Plant Along with 8 MW Incineration Boiler Based Power Generation Executive Summary

Environmental Mitigation Measures Attributes Solid &  The hazardous waste i.e. spent oil generated shall be very minor and shall Hazardous be burnt in boiler along with fuel. Waste  Boiler coal ash shall be sold to brick manufacturer. Management  spent wash ash will be used as  ETP & yeast sludge can be used in greenbelt development Traffic  Culverts shall be maintained. Management  The trucks carrying raw material & fuel shall be covered to reduce any fugitive dust generation.  Good traffic management system shall be developed and implemented for the incoming and outgoing vehicles so as to avoid congestion on the public road. Green Belt  Plantation shall been done as per Central Pollution Control Board (CPCB) Development Norms. / Plantation  The plantation in and around the plant site helps/will help to attenuate the pollution level.  Native species shall be given priority for Avenue plantation. Corporate  An amount of INR 5.0 Crwill be allocated for CSR activities in the coming 3 Social years which will be utilized on the basis of requirement for weaker Responsibility sections of the society for next 3 years. Occupational  Factory shall monitor the health of its worker before placement and Health & periodically examine during the employment Safety  Health effects of various activities and health hazard if any observed shall be recorded and discussed with the health experts for corrective and preventive actions need to be taken by the industry  All safety gear shall be provided to workers and care shall be taken by EMC that these are used properly by them. All safety norms shall be followed

Proposed Integrated Project of 10000 TCD Sugar, 41 MW Co-Generation Power Plant And 220 EIA KLPD Distillery/Ethanol Plant Along with 8 MW Incineration Boiler Based Power Generation Executive Summary

10.0 Environment Management Cost Table 7: Environment Management Cost Sr. No Construction phase (with Break-up) Capital Cost (lakhs) O & M (lakhs) 1. Environmental monitoring _ 1.5 2. Air Environment _ 0.5 3. Health Check Up _ 1.5 4. Occupational Health _ 2.5 Total - 6 Sr. No Operation Phase (with Break-up) Capital Cost (lakhs) O & M (lakhs) 1. Air pollution - Electrostatic precipitator 250.0 2.5 2. CPU 200.0 1.5 3. Sugar ETP 150.0 1.5 4. Environmental Monitoring (Air, water, - 3 waste water, Soil, Solid waste, Noise) 5. Occupation health 5.0 3.0 6. Green belt 50.0 10.0 7. Solid waste 6.0 3.0 8. Rain water 50.0 2.5 Total 711 25.5

11.0 Project Benefits  Proposed project will help to increase the socio-economic status of the local people as well as provide the stability to the existing sugar factory.  Further it helps to uplift the rural mass.  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.  Sugarcane potential available in the area. Sugarcane cultivated in the region is presently transported through 30 to 50 km.  Favourable policy regime for Fuel ethanol at the Central Govt. and State, with defined policies regarding sale of fuel ethanol  As compared to other crops sugarcane cultivation gives higher economical returns to the farmers. 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 economic power and food through sustainable development.  A large demand is anticipated for alcohol as a fuel. Alcohol is an eco-friendly product and is a substitute to the imported petroleum.  Factory proposes zero liquid discharge method for waste water treatment. Maximum waste water will be recycled back into the system.

Proposed Integrated Project of 10000 TCD Sugar, 41 MW Co-Generation Power Plant And 220 EIA KLPD Distillery/Ethanol Plant Along with 8 MW Incineration Boiler Based Power Generation Executive Summary

12. Conclusion  Zero liquid discharged is proposed with efficient mitigation measures implemented.  Air emissions through stack will be controlled by ESP& Bag filters.  Loss of vegetation and habitat will not be attributed.  Personal protective equipment’s, safety precautions, emergency plan & disaster management plan shall be in place to avoid the environment hazards.