proposed integrated project of 10000 tcd sugar, 41 mw co

Executive Summary

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

By

KPR Sugar and Apparels Limited

For Draft EIA report

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

1

EIA 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


2


Executive Summary

1.0 Introduction

KPRSAL proposes to set up an integrated sugar plant (10,000 TCD), eco-friendly co-

generation 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


3


F

i

g

ure 2: Google image

Figure 2: Proposed Plant Layout


4


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 requirement

Own Cane Juice 390000 MT 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 generation

Sugar, Cogeneration & Domestic : 1156 m3/d 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


5


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 measures

Sugar boiler 210 TPH : Electrostatic precipitator with 80 m stack 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 Nation/state Highway

SH 34 is 3 km SE

Nearest Railway station

Gulbarga 30 km in NE

Nearest Airport Gulbarga (Kalaburagi Airport) 43.8 km in NE

National Parks, Reserved Forests (RF) / Protected Forests (PF), Wildlife Sanctuaries, Biosphere Reserves, Tiger/ Elephant Reserves, Wildlife Corridors etc. within 10 km radius

No any in within 10 km of project area

River / Water Body (within 10 km radius)

Bhima River is flowing at a distance of 3.4 km in S.


6


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

Figure 4: Distillery process flow chart

Spent lees will be recycled

Steam

RS/ENA/FO/AA/Ethanol

Ethanol & CO2 Emission

Storage

Spent wash treatment through MEE & Incineration boiler

MolassesDilution

Fermentation

Spent wash and Spent lees

Multi-Pressure Distillation

Molecular Sieve

Activated Yeast


7


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 &

Safety

Major health hazards are identified in worst case scenario.

7.0 Environmental Monitoring Programme

Table 5: Environmental monitoring schedule

Particulate Parameters Number of location Frequency

Ambient air quality

PM10, PM2.5, SO2, NOx etc. Ambient air quality at minimum 3 locations. Two samples downwind direction at 500m and 1000m respectively. One sample upwind direction at 500m.

Monthly

Stack emission

PM, SO2 and NOx All stacks Monthly

Online stack monitoring will be -


8



installed

Work place PM2.5, SO2, NOx, CO, O3 Process emission in workplace area/plants (for each area/plant minimum 2 locations and 1 location outside plant area near vent)

Monthly

Waste water pH, EC, SS, TDS, O&G, Ammonical Nitrogen, COD, BOD, Chloride, Sulphides etc.

Wastewater from all sources. Inlet & outlet of ETP, spent wash, Condensate treatment plant

Monthly

Online Monitoring machine is already installed at existing ETP. Camera at spent wash tank will be installed.

Surface water and ground water

pH, Salinity, Conductivity, TDS, Turbidity, DO, BOD, Phosphate, Nitrates, Sulphates, Chlorides, Total Coliforms (TC) &E.Coli

3-5 location Ground as well as Surface water. 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

Half yearly

Solid waste Ash Process dust generated sludge and ash.

Before used as manure if used manure

Monthly

Soil Organic and Inorganic matter

N, P, K, moisture, EC, heavy metals etc.

At lands utilizing compost manure and treated effluent, 3 locations

Pre –monsoon and Post monsoon

Noise Equivalent noise level - dB (A) at min. Noise Levels measurement at high noise generating places as well as sensitive receptors in the vicinity

5 location At all source and outside the Plant area.

Monthly

Green belt Number of plantation (units), number of survived plants/ trees, number of poor plant/ trees.

In and around the plant site Monthly

Soil Texture,pH,electrical conductivity,cation

2-3 near Solid/ hazardous waste storage.

Quarterly


9



exchange capacity,alkali metals,Sodium Absorption Ratio (SAR),permeability,porosity.

At least five locations from Greenbelt and area where manure of biological waste is applied. Near spent wash storage lagoon

Occupational health

Health and fitness check-up of employees getting exposed to various hazards and all other staff

All worker Yearly/ twice a year

Emergency preparedness, such as fire fighting

Fire protection and safety measures to take care of fire and explosion hazards, to be assessed and steps taken for their prevention.

Mock drill records, on site emergency plan, evacuation plan

Monthly during operation phase

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.


10


Table 6: EMP for various environmental attributes

Environmental Attributes

Mitigation Measures

Air Quality Management

Process Emission

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 & Wastewater Management

The distillery would be based on ‘Zero Liquid Discharge’ technology.

Total spent wash generation will be 531 CMD. For existing unit spent 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 Management

Closed room shall be provided for all the utilities so as to attenuate the 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 Management

Odour shall be primarily controlled at source by good operational 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.


11


Environmental Attributes

Mitigation Measures

Solid & Hazardous Waste Management

The hazardous waste i.e. spent oil generated shall be very minor and shall be burnt in boiler along with fuel.

Boiler coal ash shall be sold to brick manufacturer.

spent wash ash will be used as

ETP & yeast sludge can be used in greenbelt development

Traffic Management

Culverts shall be maintained.

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 Development / Plantation

Plantation shall been done as per Central Pollution Control Board (CPCB) Norms.

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 Social Responsibility

An amount of INR 5.0 Crwill be allocated for CSR activities in the coming 3 years which will be utilized on the basis of requirement for weaker sections of the society for next 3 years.

Occupational Health & Safety

Factory shall monitor the health of its worker before placement and periodically examine during the employment

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


12


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, waste water, Soil, Solid waste, Noise)

- 3

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.


13


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.

proposed integrated project of 10000 tcd sugar, 41 mw co

Documents