FINAL ENVIRONMENT IMPACT ASSESSMENT REPORT NEW MOLASSES BASED DISTILLERY (100 KLPD) For KARAN SUGARS PVT. LTD. GAT No: 487/488 A/2 & 488A/3, HARWAD, TAL: SHIROL, DIST: KOLHAPUR. (M.S) Prepared By Mantras Green Resources Ltd. (Engineers & Environmental Consultant) NABET/QCI Accredited Consultant Sr. No 96th (List 5 September, 2014) An ISO 9001:2008 Certified. B-5,B-7, Flushing Meadows, Plot No. 63, Mahatma nagar Nashik-422007 Ph- +253 2355665/2355086 E-Mail: [email protected] [email protected] September 2014 TOR Index TOR Description Page No/ point Annexure no 1 Layout maps indicating existing unit as well as proposed unit indicating Refer annexure storage area, plant area, greenbelt area, utilities etc XLVII, VIII 2 Details of proposed products along with manufacturing capacity Chapter-2 page No. 4 3 Number of working days of the distillery unit. 330 days Chapter-2 page No. 14 4 Details of raw materials, its source with availability of molasses Chapter-2 page No. 13 5 Manufacturing process details of distillery along with process flow chart Chapter-2 Page No. 5 - 10 6 Sources and quantity of fuel (rice husk/bagasse/ coal etc.) for the boiler. Chapter-2 page No. 11 Measures to take care of SO2 emission. A copy of Memorandum of Understanding (MoU) signed with the coal suppliers should be submitted. 7 Storage facilities for raw materials, prepared alcohol, fuels and fly ash. Annexure XL VIII 8 One season site-specific micro-meteorological data using temperature, Chapter 3 relative humidity, hourly wind speed and direction and rainfall and AAQ data (except monsoon) for PM10, PM2.5, SO2, NOX , CO and HC (methane & non methane) shall be collected. The monitoring stations should take into account the pre-dominant wind direction, population zone and sensitive receptors including reserved forests. Data for water and noise monitoring should also be included. 9 Mathematical modeling for calculating the dispersion of air pollutants and Annexure 5 ground level concentration along with emissions from the boiler’s stack. 10 Details of boiler and its capacity. Details of the use of steam from the boiler. Chapter-2 Page No. 10 11 Ground water quality around proposed spent wash storage lagoon and the Chapter 3 project area 12 Details of water requirement, water balance chart for proposed project. Chapter-4 Measures for conservation water by recycling and reuse to minimize the Page No. 5 fresh water requirement. 13 Source of water supply and permission of withdrawal of water from Annexure Competent Authority 14 Proposed effluent treatment system for grain/molasses based distillery (spent Chapter 2 wash and spent lees) along with utility wastewater including CPP/Co-gen Page No. 16 Unit (wherever applicable) as well as domestic sewage and scheme for achieving zero discharge. Details of treatment of effluent generation from sugar unit 15 Spent wash generation should not exceed 8 KL/KL of alcohol production. Chapter-4 Details of the spent wash treatment for molasses based distillery based page No.7 distillery. 16 Capacity for spent wash holding tank and action plan to control ground 30 days water pollution Chapter 4 Page 7 to 9 17 Layout for storage of bagasse/biomass/coal. Annexure XLVIII 18 Capacity for spent wash holding tank and action plan to control ground 30 days water pollution. Chapter 4 Page 7 to 9 19 Dryer shall be installed to dry DWGS Not applicable 20 Layout for storage of rice husk/biomass/coal. Not applicable 21 Details of solid waste management including management of boiler ash. Chapter-6 page No.4 22 Risk assessment for storage and handling of alcohol and mitigation measure Chapter-8 due to fire and explosion and handling areas page No.10 23 Alcohol storage and handling area fire fighting facility as per norms. Chapter-8 Provision of Foam System for fire fighting to control fire from the alcohol page No.5 storage tank. 24 Action plan for development of green belt over 33 % of the total project area Chapter-6 within plant premises with at least 10 meter wide green belt on all sides page No.5 along the periphery of the project area, in downward direction, and along road sides etc 25 Detailed Environment management Plan (EMP) with specific reference to Chapter-6 details of air pollution control system, water & wastewater management, page No.1-8 monitoring frequency, responsibility and time bound implementation plan for mitigation measure should be provided. 26 EMP should also include the concept of waste-minimization, recycle/reuse/ Chapter-6 recover techniques, Energy conservation, and natural resource conservation. page No.1-8 27 Action plan for rainwater harvesting measures at plant site should be Chapter-4 included to harvest rainwater from the roof tops and storm water drains to page No.11 recharge the ground water. 28 Details of occupational health surveillance programme Chapter-6 page No.6 29 Transportation of raw materials and finished products for the project Chapter 4 (proposed/expansion) in respect of existing traffic, type of vehicles, Page 13 frequency of vehicles for transportation of materials, additional traffic due to proposed project, parking arrangement etc 30 Action plan for post-project environmental monitoring. Chapter-7 31 Corporate Environmental Responsibility 32 (a) Does the company have a well laid down Environment Policy approved Chapter 7 by its Board of Directors? If so, it may be detailed in the EIA report. (b) Does the Environmental Policy prescribe for standard operating process/procedures to bring into focus any infringement / deviation / violation of the environmental or forest norms / conditions? If so, it may be detailed in the EIA report. (c) What is the hierarchical system or Administrative order of the company to deal with the environmental issues and for ensuring compliance with the EC conditions. Details of this system may be given. (d) Does the company have a system of reporting of non compliance / violations of environmental norms to the Board of Directors of the company and / or shareholders or stakeholders at large? This reporting mechanism should be detailed in the EIA report. 33 At least 5 % of the total cost of the project should be earmarked towards the Confirmed Enterprise Social Commitment based on Public Hearing issues and item- wise details along with time bound action plan should be prepared and incorporated EXECUTIVE SUMMARY 1.0 INTRODUCTION Karan Sugars Pvt. Ltd hereafter being referred as project proponent or KSPL or project proponent (PP) in this text belongs to Kalani Group of companies. The group has diverse interests in packaging, distillery and bottling, dairy and dairy products etc. KSPL is owned by Mr Dharmpal Kalani and his associates. KSPL purchased an existing distillery of 30 KLPD owned by Shetmal Sahakari Prakriaya Sansthan Ltd located at village Herwad in taluka Shirol in district Kolhapur.. The unit was producing alcohol from cane juice. The company was not able to operate and suffered losses due to several reasons major one being non availability of cane for juice extraction. Cane was being picked up by sugar mills in the vicinity and severe price fluctuations in cane price affected profitability. Unit was non operational much before the present project proponent took over. There are several sugar mills in area who do not have own distillery. Hence sufficient molasses and bagasse are available from within 50 km area of location. A detailed list of surrounding sugar mills, their installed capacity and capacity of distillery installed if any is reproduced below: Name of factory Distance Capacity last year Distillery TCD Crushing KLPD Shree Datta sahakari sakhar karkhana Ltd 18 Km 7000 91800 60 Sirod, Dist- Kolhapur Shree Gurudutta Sucrose Ltd Takrewadi 8 KM 2500 670000 Nil Sirod Dist- Kolhapur Shree Jawahar Shetkari Sahakari Sakhar 23 KM 9000 1428000 Nil Karkhana Ltd, Hupari,Tal- Hatkanangale Dist- Kolhapur Shri Sharad Sahakari Sakhar Karkhana Ltd 45 KM 2500 589000 Nil Narande Tal- Tal- Hatkanangale Dist- Environment Impact Assessment Executive summary New 100 KLPD Molasses based distillery Kolhapur Shree Panchganga Sahakari Sakhar Karkhana 23 KM 5000 740000 Nil Ltd Ganganagar Ichalkaranji Tal- Hatkanangale Dist- kolhapur Shri Chhatrapati Rajaram Sahakari Sakhar 49 Km 2200 410000 Nil Karkhana Ltd, kasba bawda, Dist Kolhapur Shree Chattrapati Shahu SSKL Kagal Tal- 36 Km 3500 731000 45 kagal Dist- Kolhapur Vasantdado SSKL Madhavnagar Sangali 34 Km 5000 530000 Nil Tal Miraj Dist - Sangli Shree Guppy Sugar Works Ltd, Kagwad, Tal 30 Km 5000 46600 Nil – chikkodi Dist – Belgaon Karnataka Shree Shiv Shakti Sugar ltd Yadrav Ankali 41 Km 2500 390000 Nil tal- Chikodi, Dist Belgaum Karnataka Dudhganga- Krushna SSK Ltd, Nanandi, tal- 32 Km 60000 836000 Nil Chikkodi Dist Belgaon, Karnataka Venkateshwara Power Project Bedkihal Tal- 18 Km 3500 707000 Nil Chikodi dist- Belgaum Karnataka Uugar Sugar Ltd, Ugar khurd Tal-Chikodi 48 Km 10,000 1156000 Old dist- Belgaum Karnataka 30 KLPD New 45 KLPD Total 117700 180 KLPD Molasses generated / required 4708 MT 720 KLPD Molasses required for 100 KLPD distillery proposed 400 KLPD All above units are operational as shown in column showing total cane crushed last year. If cane crushed by Karnataka factories 81,000 MTD is excluded still 1468 KLPD molasses is available for alcohol production from nearby factories in Maharashtra.. Karan Sugars Pvt Ltd 2 Herwad Taluka Shirol,Dist Kolahapur Environment Impact Assessment Executive summary New 100 KLPD Molasses based distillery Hence it was clear to new management that a molasses based distillery is feasible at this site and it will present an opportunity for surrounding sugar mills to dispose molasses generated in their factory for profit at a site not involving much transportation. Karan Sugars Pvt. Ltd. proposes to dismantle existing sugar cane based distillery of 30 KLPD and install a new molasses based distillery of capacity 100 KLPD.