Introduction
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Chapter 1 Introduction 1.1 INTRODUCTION 'Environmental Impact Assessment (EIA)' is the process of evaluating likely environmental impacts, both positive and negative, of a new or expansion project by taking into account natural, social and economic aspects. It also comprises of suggesting possible mitigation measures, for the negative impacts, before implementation of the project. The main objectives of an EIA report are - • To describe a pre-project baseline condition with respect to Environmental Indicators. • To identify possible sources of pollution and their environmental impacts including identifying risks associated with setting up of a new / expansion project and suggesting appropriate mitigation measures for alleviating adverse impacts to the extent possible. • To suggest environmental / risk management plans for implementing the mitigation measures. India is the largest producer of sugarcane and sugar, still sugar factories in India are facing problems. Sugar factories cannot survive in healthy condition on a single product i.e. sugar. Thus, it is essential to develop sugar factory into an affiliated complex so as to utilize the valuable by-products more profitably.Bio-mass is the most promising alternative fuel. Agro- waste and agro industrial products have today been recognized as ‘modern’ bio-mass material which can be converted directly into useful forms of energy. Bio-mass has the crucial advantage of being environment friendly. Bagasse is a captive bio-mass. In India, there are large numbers of sugar mills of varying crushing capacity ranging from a critical period because of over-production, low sugar price, low international market, etc., can enhance revenue by co-generation. So co-generation would benefit both the nation and the industry. It is estimated that Indian sugar industry can export 3600 MW power by adopting bagasse based co-generation units. In the co-generation sugar mills, power generation and consumption per ton cane is about 108 and 36 units. So power revenue of co-generation sugar mills is around Rs. 210 per ton of cane.Molasses is a very important by-product of the sugar industry. The profits earned by conversion of molasses into alcohol are much higher than that of sale of molasses alone. Moreover, there is a good demand for alcohol in the country as production and consumption of alcohol in India are quite balanced. Also, there is a good export potential out of the country for the alcohol. With a due consideration to all the above facts, the management of Shree Chhatrapati Shahu Sahakari Sakhar Karkhana Ltd. (SCSSSKL), Kagal, Tal.: Kagal, Dist.: Kolhapur has decided to go for an expansion of its existing sugar factory, co-gen plant and distillery projects. 1.2 THE PROJECT & PROPONENTS The project site of SCSSSKL is located on survey no. 144/1/B, 144/2, 148-151, 153-157, 159-161, 164-172, 186, 244/B, 247/2/3, 61/32. Tal.: Kagal, Dist.: Kolhapur, Maharashtra. The expansion of SCSSSKL sugar factory would be undertaken from7,000 TCD to 10,000 TCD (increase by 3,000 TCD) co-gen plant from 28 MW to 38 MW (increase by 10 MW) and distillery from 60 KLPD to 90 KLPD (increase by 30 KLPD). This report is made in the overall context of Environmental Impact Assessment (EIA) Notification No. S. O. 1533 (E) dated 14.09.2006 and amendments thereto issued by the 1 Ministry of Environment, Forest and Climate Change (MoEFCC); New Delhi. SCSSSKL Industry comes under Project types namely 5 (j), 1(d) & 5(g) i.e. Sugar Factory, Thermal Power (Co-gen) Plant and Distillery respectively. As per the schedule, Sugar Factory & Co-gen Plant are categorized as 'B' and the Distillery as 'A'. But as expansion of Sugar Factory, Co-gen plant and distillery shall take place in an integrated project complex, entire complex activities would be appraised as Category ‘A’. Present EIA report has been prepared by incorporating required information and details required as per the Terms of Reference (ToRs) issued by MoEFCC vide letter No.J-11011/225/2015-IA II (I) dated 06.09.2018 to SCSSSKL The sugar factory is registered with Govt. of Maharashtra vide certificate No. KPR/PRG (A)/7 dated 21.02.1977.In addition, it has been registered as Multi-State Cooperative Society vide registration no. MSCS/CR/238/2006 dated 05.05.2006. The first crushing season of sugar factory was undertaken in the year 1980-81. Table 1.1 Project Investment Details No. Industrial unit Capital Investment Existing Expansion Total 1 Sugar Factory, Co-gen Plant & Distillery Rs. 350.86 Cr. Rs. 110 Cr. Rs. 460.86 Cr. Table 1.2 Promoters of SCSSSKL No. Name Designation 1 Late Shri Vikramsinh Jaysingrao Ghatge Founder-Chairman 2 Shri Samarjeetsinh V. Ghatge Chairman 3 Shri AmarsinhGopalraoGhorpade Vice - Chairman 4 Shri. Jitendra Anandrao Chavan Managing Director 1.2.1 Achievements by SCSSSKL SCSSSKL have been honoured by various awards since 1986 till date - • Best Sugar Factory in India. • Best Sugar Factory in Maharashtra. • Best Distillery of Maharashtra. • Best Co-operative Sugar Factory Award in High Recovery Area. • Cane Development in High Recovery Area. • Best Overall Performance Sugar Mill from Co-operative unit. • Maximum Export of Sugar. These awards were given by various institutes and organisations like - • National Federation of Co-operative Sugar Factories, New Delhi. • Vasant dada Sugar Institute, Pune. • Vasantrao Naik Agri & Rural Development Foundation, Mumbai. • Maharashtra Rajya Sahakari Sakhar Karkhana Sangh Ltd .Mumbai etc. Moreover, in August 2016, SCSSSKL have been privileged by ‘Vanashri’ award for plantation in non-forest area by Social Forestry Department, Maharashtra by the hands of Cabinet Minister –Shri Nitin Gadkari. Refer Appendix–U for more details regarding awards. 2 1.3 THE PLACE The proposed expansion of sugar factory, co-gen plant and distillery shall be carried out at existing set up of SCSSSKL.The total land acquired by the industry is 14,00,000Sq.M. (140 Ha.) .The total built up area of sugar factory, distillery & co-gen projects is 1,74,013 Sq.M. (17.4 Ha).A no objection certificate forthe proposed expansion projects activities has been obtained from the Kagal Municipal Council, Kagal. Following aspects have been taken into consideration while planning expansion project activities in the SCSSSKL complex - 1. Availability of excess cane for crushing in sugar factory from the operational area. 2. Availability of adequate equipments and allied infrastructure in sugar factory, co-gen and distillery unit. 3. Availability of adequate quantity of water and electricity for the proposed project. 4. The nearest city Kolhapur is 13 km and town Kagal is 1.20 Km away from the project site which is very well connected with other parts of the country by roads, rail. 5. No rehabilitation and resettlement are required to be done. 3 Figure 1.1 Location of the Project Site e Maps are purely graphical and not to scale, Latitude: 16°35'24.36"N, Longitude: 74°17'54.21"E 4 1.4 IMPORTANCE TO COUNTRY & REGION The sugar industries in India is well maintained and is growing at a steady pace, boasting of a consumer base of over billions of people. The bulk of rural population in India depends on this industry. One of the agro-based enterprises in India, sugar manufacturing is the second largest agricultural industry, after the textile sector. Sugar manufacturing in Maharashtra is one of the most notable sectors in the country. The pace of growth of this industry has been massive over the past few years. Most of the sugar units have by-product utilization plants, based on bagasse and molasses. Ethanol, power and paper projects have tremendous scope for development in India. In near future, about 10-15% ethanol may be allowed to be blended with petrol. Thus, alcohol production from molasses has the most promising prospects. Bagasse based power generation projects, installed in the premises of sugar factory, not only fulfil captive need of the industry but also make available surplus power which could be exported in the grid thereby providing value addition. Bagasse based co-generation of steam and electricity is not new to India and has been practised for long in sugar mills. The primary objective in the past had been to produce steam required for processing and incidentally generating electricity. Since process steam was required at pressures that were not high, low pressure boilers were used to produce steam. Steam turbines driving the mills and generators were therefore, designed to operate with low pressure steam. As the low-pressure steam has a large quantum of heat, which is lost in the process of condensing, the efficiency of conventional power plants is only around 35%. In a cogeneration plant, very high efficiency levels, in the range of 75% – 90%, can be reached. This is so, because the low-pressure exhaust steam coming out of the turbine is not condensed, but used for heating purposes in factories or houses. In certain mills, electricity generated was not enough to meet captive requirements and the short fall was met by drawing electricity from the utility grid. In the mid-eighties it was realized that by making maximum use of potential for co-generating steam and electricity from baggase, generation of electricity could be increased not only to fully meet the captive requirements but also to have exportable surplus that could bring in additional profit. Since co-generation can meet both power and heat needs, it has other advantages as well in the form of significant cost savings for the plant and reduction in emissions of pollutants due to reduced fuel consumption. Where there is a need to augment the steam and power generation within the plant on account of capacity up- gradation, where there is a potential to improve the energy efficiency of the sugar plant by retiring inefficient boilers and turbo generators, it is prudent for the sugar factory to go in for new high pressure and high efficiency boilers and matching turbo generators.