Draft Eia Report (Eid)

DRAFT
ENVIRONMENTAL IMPACT ASSESSMENT

REPORT
Based on: TOR LETTER ISSUED BY THE MINISTRY VIDE NO:

J-11011/336/2012- IA II (I) DATED 29TH APRIL, 2013
FOR
E.I.D PARRY (INDIA) LIMITED

(formerly known as Parrys Sugar Industries Limited)
Village:Hullatti & Alloli, Taluk Haliyal,

District Uttara Kannada, Karnataka.
January, 2014
Prepared by:
ISO 9001: 2008 Certified Accredited by NABET - QCI
6-3-652 | Flat # 7-3 | Dhruvatara Apartments | Amrutha Estates | Erramanjil | Somajiguda |

Hyderabad- 500082
E.I.D. Parry (India) Ltd.
(Expansion of Integrated Sugar Plant)
INDEX
S.NO. CONTENTS PAGE NO.
TOR letter issued by Honourable Ministry
Compliance on TOR
CHAPTER – 1
INTRODUCTION
1.0 PREAMBLE 1-1

1.1 PURPOSE OF THE REPORT 1-2
1.2 IDENTIFICATION OF PROJECT & PROJECT PROPONENT 1-3
1.3 BRIEF DESCRIPTION 1-4
1.3.1 NATURE OF THE PROJECT 1-4
1.3.2 SIZE OF THE PROJECT 1-4
1.3.3 LOCATION OF THE PROJECT 1-5
1.3.4 IMPORTANCE OF PROJECT 1-7
1.4 SCOPE OF THE STUDY 1-12
CHAPTER- 2
PROJECT DESCRIPTION
2.1 TYPE OF PROJECT 2-1

2.2 NEED FOR THE PROJECT 2-1
2.3 LOCATION 2-2
2.4 SIZE / MAGNITUDE OF OPERATION 2-6
2.5 PROPOSED SCHEDULE FOR APPROVAL AND IMPLEMENTATION 2-6
2.6 TECHNOLOGY AND PROCESS DESCRIPTION 2-8
2.6.1 RAW MATERIAL AND ITS SOURCES 2-8
2.6.2 RAW MATERIAL STORAGE AND HANDLING 2-9
2.6.3 TRANSPORT OF RAW MATERIALS 2-9
2.6.4 MANUFACTURING PROCESS 2-10
2.6.4.1 SUGAR MANUFACTURING PROCESS 2-10
2.6.4.2 POWER GENERATION PROCESS 2-14
2.6.4.3 DISTILLERY 2-17
2.7 STEAM BALANCE 2-20
2.7 ENVIRONMENTAL MITIGATION MEASURES 2-20
2.8 ASSESSMENT OF NEW AND UNTESTED TECHNOLOGY FOR THE
RISK OF TECHNOLOGICAL FAILURE 2-22
CHAPTER - 3
DESCRIPTION OF ENVIRONMENT
3.1 AIR ENVIRONMENT 3-1

3.1.1 METEOROLOGY 3-1
3.1.2 METEOROLOGICAL DATA RECORDED AT SITE 3-1
3.1.3 AIR QUALITY 3-3
3.1.3.1 SELECTION OF SAMPLING STATIONS 3-3
3.1.3.2 PARAMETERS MONITORED 3-3
3.1.3.3 SAMPLING & ANALYTICAL TECHNIQUES INSTRUMENTS USED
FOR SAMPLING 3-3
3.2 NOISE ENVIRONMENT 3-6
3.2.1 RECONNAISSANCE 3-7
3.2.1.1 BACKGROUND NOISE 3-7
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3.2.1.2 SOURCES OF NOISE 3-7

3.2.2 COMMUNITY NOISE 3-8
3.2.2.1 OCCUPATIONAL EXPOSURE 3-8
3.2.3 NOISE LEVEL OBSERVATIONS IN THE STUDY AREA 3-9
3.3 WATER QUALITY IMPACTS 3-10
3.3.1 SURFACE WATER QUALITY ASSESSMENT 3-10
3.3.2 GROUND WATER QUALITY ASSESSMENT 3-12
3.3.3 HYDROLOGY OF THE AREA 3-16
3.4 LAND ENVIRONMENT 3-17
3.4.1 LAND USE PATTERN 3-17
3.4.2 MINERAL RESERVES 3-17
3.4.3 SEISMIC EFFECT 3-17
3.4.4 SOIL 3-17
3.5 BIOLOGICAL ENVIRONMENT 3-21
3.6 SOCIO-ECONOMIC ASPECTS 3-21
CHAPTER - 4
ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES
4.0 INTRODUCTION 4 -1
4.1 AIR ENVIRONMENT 4 -1
4.1.1 IMPACT ON TPOPGRAPHY AND CLIMATE 4-2
4.1.1.1 IMPACT ON TOPOGRAPHY 4-2
4.1.1.2 IMPACT ON CLIMATE 4-2
4.1.2 PREDICTIONS OF IMPACT ON AIR ENVIRONMENT 4-2
4.2 PREDICTION OF IMPACTS ON WATER ENVIRONMENT 4-5
4.2.1 WATER REQUIREMENT 4-5
4.2.2 WASTE WATER GENERATION 4-7
4.3 PREDICTION OF IMPACTS DUE TO NOISE 4-9
4.3.1 PREDICTION OF IMPACT DUE TO THE PROPOSED EXPANSION
ACTIVITY 4-9
4.3.2 PREDICTION OF IMPACTS ON COMMUNITY 4-9
4.3.3 PREDICTION OF IMPACT ON OCCUPATIONAL HEALTH 4-9
4.4 PREDICTION OF IMPACTS ON LAND ENVIRONMENT 4-10
4.5 PREDICTION OF IMPACTS ON VEHICULAR MOVEMENT 4-10
4.5 PREDICTION OF IMPACTS ON BIOLOGICAL ENVIRONMENT 4-11
4.6 PREDICTION OF IMPACTS ON SOCIO ECONOMIC ENVIRONMENT 4-11
CHAPTER - 5
ANALYSIS OF ALTERNETIVES
5.1 ALTERNATIVE TECHNOLOGIES 5-1

5.2 ALTERNATIVE SITES EXAMINED FOR SETTING UP OF
SUGAR & DISTILLERY UNIT 5-1
CHAPTER – 6
ENVIRONMENTAL MONITORING PROGRAM
6.1 TECHNICAL ASPECTS 6-1

6.1.1 METHODOLOGIES 6-1
6.1.2 FREQUENCY & LOCATION OF ENVIRONMENTAL MONITORING 6-1
6.1.3 DATA ANALYSIS 6-2
6.1.4 REPORTING SCHEDULE 6-2
6.1.5 EMERGENCY PROCEDURES 6-2
6.1.6 DETAILED BUDGET & PROCUREMENT SCHEDULES 6-2
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CHAPTER - 7
ADDITIONAL STUDIES
7.1 INTRODUCTION 7-1

7.2 SCOPE OF THE STUDY 7-1
7.3 STORAGE TANKS 7-1
7.4 FIRE PROTECTION SYSTEM PROPOSED 7-2
7.5 SAFETY PROVISIONS PROPOSED 7-3
7.6 METHODOLOGY OF MCA ANALYSIS 7-3
7.7 FIRE & EXLOSION AND TOXICITY INDEX 7-3
7.8 ASSESSMENT OF RISK AT M/s. E.I.D PARRY 7-4
7.9 RISK & CONSEQUENCE ANALYSIS OF FIRE 7-5
7.10 RESULT OF CONSEQUENCE ANALYSIS 7-8
7.10.1 IDENTIFICATION OF POTENTIAL HAZARD AREAS 7-8
7.10.2 RELEASE SCENARIOS 7-8
7.10.3 SOURCE STRENGTH ESTIMATION 7-8
7.10.4 CONSEQUENCE ANALYSIS 7-9
7.10.5 HEAT RADIATION EFFECTS DUE TO POOL 7-9
7.11 FREQUENCY / PROBABILITY ESTIMATION 7-11
7.12 RECOMMENDATIONS 7-11
7.13 DISASTER MANAGEMENT PLAN 7-12
7.13.1 DISASTERS 7-12
7.13.2 OBJECTIVES OF DISASTER MANAGEMENT PLAN 7-13
7.13.3 EMERGENCIES 7-13
7.13.3.1 GENERAL, INDUSTRIAL, EMERGENCIES 7-13
7.13.3.2 SPECIFIC EMERGENCIES ANTICIPATED 7-14
7.13.3.3 EMERGENCY ORGANISATION 7-14
7.13.3.4 EMERGENCY COMMUNICATION 7-14
7.13.3.5 EMERGENCY RESPONSIBILITIES 7-14
7.13.3.5.1 SITE CONTROLLER 7-15
7.13.3.5.2 INCIDENT CONTROLLER 7-15
7.13.3.5.3 EMERGENCY COORDINATOR - RESCUE, FIRE FIGHTING 7-16
7.3.3.5.4 EMERGENCY COORDINATOR - MEDICAL, MUTUAL AID,
REHABILITATION, TRANSPORT AND COMMUNICATION 7-16
7.13.3.5.5 EMERGENCY COORDINATOR - ESSENTIAL SERVICES 7-17
7.13.3.5.6 GENERAL RESPONSIBILITIES OF EMPLOYEES DURING AN
EMERGENCY 7-17
7.13.3.6 EMERGENCY FACILITIES 7-18
7.13.3.6.1 EMERGENCY CONTROL CENTRE 7-18
7.13.3.6.2 EMERGENCY POWER SUPPLY 7-18
7.13.3.6.3 FIRE FIGHTING FACILITIES 7-18
7.13.3.6.4 LOCATION OF WIND SOCK 7-18
7.13.3.6.5 EMERGENCY MEDICAL FACILITIES 7-19
7.13.3.7 EMERGENCY ACTIONS 7-19
7.13.3.7.1 EMERGENCY WARNING 7-19
7.13.3.7.2 EMERGENCY SHUTDOWN 7-19
7.13.3.7.3 EVACUATION OF PERSONNEL 7-19
7.13.3.7.4 ALL CLEAR SIGNAL 7-19
7.14 OCCUPATIONAL HEALTH 7-20
7.14.1 CONSTRUCTION & ERECTION 7-20
7.14.2 OPERATION & MAINTENANCE 7-20
7.14.3 OCCUPATIONAL HEALTH & SURVEILLANCE 7-21
7.15 SAFETY PLAN 7-21
7.15.1 SAFETY ORGANISATION 7-22
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7.15.2 OPERATION & MAINTENANCE PHASE 7-22

7.15.3 SAFETY CIRCLE 7-22
7.15.4 SAFETY TRAINING 7-22
7.15.5 HEALTH AND SAFETY MONITORING PLAN 7-23
7.16 SOCIAL IMPACT ASSESSMENT 7-23
7.17 R & R ACTION PLAN 7-24
CHAPTER - 8
PROJECT BENIFITS
8.1 PHYSICAL INFRASTRUCTURE 8-1

8.2 SOCIO INFRASTRUCTURE 8-1
8.3 EMPLOYMENT POTENTIAL 8-1
8.3.1 SKILLED 8-1
8.3.2 SEMI-SKILLED 8-1
8.3.3 UNSKILLED 8-1
8.4 OTHER TANGIBLE BENEFITS 8-1
CHAPTER - 9
ENVIRONMENTAL COST BENEFIT ANALYSIS
CHAPTER - 10
ENVIRONMENTAL MANAGEMENT PLAN
10.0 INTRODUCTION 10-1

10.1 MANAGEMENT DURING CONSTRUCTION PHASE 10-2
10.1.1 SITE PREPARATION 10-2
10.1.2 WATER SUPPLY AND SANITATION 10-2
10.1.3 NOISE 10-2
10.1.4 MAINTENANCE OF VEHICLES 10-2
10.1.5 WASTE 10-2
10.1.6 STORAGE OF HAZARDOUS MATERIAL 10-3
10.1.7 LAND ENVIRONMENT 10-3
10.2 POST CONSTRUCTION PHASE 10-3
10.2.1 AIR EMISSION MANAGEMENT 10-3
10.2.1.1 MONITORING OF SECONDARY FUGITIVE EMISSIONS 10-5
102.1.2 ACTION PLAN TO CONTROL AMBIENT AIR QUALITY AS PER NAAQS
STANDARDS 10-5
10.2.2 WATER POLLUTION MANAGEMENT 10-6
10.2.3 SOLID WASTE 10-14
10.2.4 NOISE LEVEL MANAGEMENT 10-15
10.2.5 LAND ENVIRONMENT 10-15
10.2.6 ODOUR CONTROL MEASURES 10-15
10.2.7 MEASURES FOR IMPROVEMENT OF ECOLOGY 10-16
10.2.7.1 GREEN BELT DEVELOPMENT 10-16
10.2.8 MINIMIZATION MEASURES 10-18
10.3 POST PROJECT MONITORING STRATEGY 10-19
10.4 COMPLIANCE ON CREP RECOMMENDATIONS 10-20
10.5 COST FOR ENVIRONMENTAL PROTECTION 10-23
CHAPTER - 11
SUMMARY 11-1
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CHAPTER - 12
DISCLOSURE OF CONSULTANTS 12-1
TABLES
S. No. CONTENTS PAGE NO.
CHAPTER – 3
3.1.1 AMBIENT AIR QUALITY MONITORING STATIONS 3-5
3.1.2 AMBIENT AIR QUALITY 3-5
3.2.1 NOISE LEVEL MONITORING STATIONS 3-10
3.2.2 EQUIVALENT DAY NIGHT NOISE LEVELS 3-10
3.3.1 SURFACE WATER QUALITY 3-11
3.3.2 GROUND WATER QUALITY MONITORING STATIONS 3-12
3.3.3 GROUND WATER QUALITY ANALYSIS 3-14
3.4.1 SOIL QUALITY MONITORING STATIONS 3-18
3.4.2 SOIL CHARACTERISTICS 3-20
CHAPTER - 4
4.1.1 BOILER STACK DETAILS 4-4

4.1.2 NET RESULTANT MAXIMUM CONCENTRATIONS DUE TO THE
EXPANSION PROJECT 4-5
4.2.1 WATER REQUIREMENT FOR SUGAR & CO-GEN POWER PLANT 4-6
4.2.2 WATER REQUIREMENT FOR DISTILLERY PLANT 4-6
4.2.3 WASTE WATER GENERATION FROM SUGAR & CO-GEN
POWER PLANT 4-7
4.2.4 WASTE WATER GENERATION FROM DISTILLERY PLANT 4-7
4.2.5 CHARACTERISTICS OF SPENT WASH 4-8
4.2.6 CHARACTERISTICS OF SANITARY WASTE WATER 4-8
4.2.7 CHARACTERISTICS OF COOLING TOWER BLOWDOWN 4-8
4.2.8 CHARACTERISTICS OF BOILER BLOWDOWN 4-8
4.2.9 CHARACTERISTICS OF DM PLANT REGENERATION WATER 4-8
CHAPTER - 7
7.1 DETAILS OF TANKFARMS 7-2

7.2 POSSIBLE RISKS FROM EXISTING & EXPANSION PLANT 7-5
7.2 LIST OF PRODUCTS AND NFPA RATINGS 7-5
7.4 EXPLANATION OF NFPA HAZARD CLASSIFICATIONS 7-6
7.5 THERMAL RADIATION EFFECTS DUE TO FIRE 7-10
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E.I.D Parry India Limited
TOR COMPLIANCE
Compliance made on Terms of Reference (TOR) issued by Ministry of Environment and Forest (MoEF) vide letter No. J-11011/336/2012-
IA. II (I) dated 29th April, 2013
TOR No. TOR TOR Compliance Pg. No.

1. A separate chapter on status of compliance of Environmental Kindly refer to Annexure – I
Conditions granted by State/Centre to be provided. As per
circular dated 30th May, 2012 issued by MoEF, a certified
report by RO, MoEF on status of compliance of conditions on
existing unit to be provided in EIA/EMP report.
2. Executive summary of the project. Kindly refer to Annexure - II
3. Detailed breakup of the land area along with latest Kindly refer to Annexure – III for
photograph of the area. Photographs
Kindly refer to CHAPTER – 2 Pg. No. 2.2
4. Present land use based on satellite imagery. Kindly refer to Annexure – IV
Kindly refer to CHAPTER - 3 Pg. No. 3.17
5. Details of site along with photographs and information related Kindly refer to Annexure – III for
to environmental setting within 10 km radius of the project Photographs
site. Kindly refer to CHAPTER – 2 Pg. No.2.3
6. Regulatory framework Kindly refer to CHAPTER – 2 Pg. No.2.7

7. Data for the stack emissions, fugitive emissions; water Kindly refer to CHAPTER – 4 & 10 Pg. No.4.3 to 4.7 &
requirement and water balance chart; wastewater generation, 10.6 to 10.14
treated effluent quality, re-utilization and disposal of
TOR Compliance
1
solid/hazardous waste for the existing unit.

8. Information regarding eco-sensitive area such as national Kindly refer to CHAPTER – 2 Pg. No.2.3
park/wildlife sanctuary / biosphere reserves within 10 km
radius of project area.
9. List of existing distillery units in the area along with their NOT APPLICABLE as there are no
capacity. existing distillery units in the study area.
10. Number of working days of the distillery unit, cogeneration Operation of Sugar plant – 180 days
plant and sugar unit. Operation of Distillery unit – 300 days
Operation of Co-gen plant - 300 days
(Based on Bagasse availability)
11. Total cost of the project along with total capital cost and Kindly refer to CHAPTER – 10 Pg. No.10.23
recurring cost / annum for environmental pollution control
measures.
12. Details of raw material and source of raw material including Kindly refer to CHAPTER – 2 Pg. No.2.8
cereal grains. Availability of molasses and calculation for the
molasses requirement in the proposed manufacturing unit.
13. Manufacturing process details of sugar plant, distillery plant Kindly refer to CHAPTER – 2 Pg. No.2.10 to 2.19
and CPP along with process flow chart.
14. Sources and quantity of fuel for the boiler. Management of Kindly refer to Chapter – 2 Pg. No.2.8 & 2.9
bagasse during the lean season. Details of bagasse storage
facility
15. Action plan to control ambient air quality as per NAAQES Kindly refer to Chapter – 10 Pg. No.10.5 & 10.17
TOR Compliance
2
Standards for PM10, PM2.5, SO2 and NOX as per GSR 826(E)
dated 16th November, 2009.
16. One season site-specific micro-meteorological data using Kindly refer to CHAPTER – 3 Pg. No.3.1 to 3.15
temperature, relative humidity, hourly wind speed and
direction and rainfall and AAQ data (except monsoon) for
PM10, PM2.5, SO2, NOX and HC (methane & non methane)
should 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.
17. Mathematical modeling for calculating the dispersion of air Kindly refer to CHAPTER – 4 Pg. No.4.2 to 4.5
pollutants and ground level concentration along with
emissions from the boiler.
18. An action plan to control and monitor secondary fugitive Kindly refer to CHAPTER – 10 Pg. No.10.3 to 10.5
emissions from all the sources.
19. Details of the use of steam from the boiler. Kindly refer to CHAPTER – 2 Pg. No. 2.20
20. Ground water quality around proposed spent wash storage Kindly refer to Chapter – 3 & 10 Pg. No. 3.11 & 10.13
lagoon and the project area. HDPE-lined lagoon should not
have more than 30 days storage capacity.
TOR Compliance
3
21. Details of water requirement, wastewater generation, and Kindly refer to CHAPTER – 4 & 10 Pg. No.4.5 to 4.7 &
water balance chart for sugar, distillery and co-generation 10.6 to 10.14
plant. Measures for water conservation by recycling and Kindly refer to ANNEXURE - VII
reuse to minimize the fresh water requirement.
22. Source of water supply and ‘Permission’ from concerned Kindly refer to CHAPTER – 4. Pg. No. 4.5
Department/Authority for the drawl of water. Impact of drawl Kindly refer to ANNEXURE – VIII
of water on other user should be assessed and included.
23. Measures for conservation and reuse of water should be Kindly refer to CHAPTER – 4 & 10 Pg. No.4.5 to 4.7 &
maximized so as to keep net water consumption to a 10.5 to 10.14
minimum. Recycle & reuse treated water in cooling tower Kindly refer to ANNEXURE - VII
24. Hydro-geological study of the area for availability of ground Not applicable as no utilization of
water. Ground water is envisaged
25. Proposed effluent treatment system for sugar, distillery and Kindly refer to Chapter – 10 Pg. No. 10.6 to 10.14
co-generation plant. Scheme for achieving ‘zero’ discharge
for distillery effluent and 100 m3/Ton of sugar regarding water
discharge.
26. Details of solid waste management including management Kindly refer to Chapter – 10 Pg. No.10.14
plan of disposal of boiler ash.
27. Sufficient land should be earmarked for bio-composting Not applicable as no bio-composting is
activity and details of bio-composting lining as per CPCB proposed
guidelines.
28. Odour management plan should be prepared to control odour Kindly refer to Chapter – 10 Pg. No.10.15
TOR Compliance
4
from molasses based distillery.

29. Green belt development as per the CPCB guidelines. Layout Kindly refer to Chapter – 10 Pg. No. 10.16 to 10.18
of greenbelt plant to be submitted. Kindly refer to Annexure - IX
30. List of flora and fauna in the study area. Kindly refer to Annexure – V
31. Noise levels monitoring at five locations within the study area. Kindly refer to Chapter – 3 Pg. No. 3.6 to 3.10
32. Traffic study of the area for the proposed projects in respect Kindly refer to CHAPTER – 4. Pg. No.10
of existing traffic, type of vehicles, frequency of vehicles for Kindly refer to Annexure - X
transportation of materials, additional traffic due to proposed
project, parking arrangement etc.
33. Detailed Environment Management Plan (EMP) with specific Kindly refer to Chapter – 10
reference to details of air pollution control system, water &
Pg. No. 10.1 to 10.23
wastewater management, monitoring frequency,
responsibility and time bound implementation plan for
mitigation measure should be provided.
34. Details of TOC analyzer to be installed to monitor TOC in the In the existing plant no TOC analyser is
treated effluent. installed. Will be installed during
implementation of proposed expansion
project
35. Risk assessment for storage and handling of alcohol and Kindly refer to Chapter – 7 Pg. No. 7.1 to 7.12
mitigation measure due to fire and explosion and handling
areas.
36. Alcohol storage and handling area with fire -fighting facility as Kindly refer to Chapter – 7 Pg. No. 7.1 to 7.3
TOR Compliance
5
per norms.
37. Provision of foam system for fire-fighting to control fire from Kindly refer to Chapter – 7 Pg. No.7.2 to 7.3
the alcohol storage tank.
38. Action plan for rainwater harvesting measures at plant site to Kindly refer to Chapter – 10 Pg. No. 10.18
harvest rainwater from the roof tops and storm water drains to
recharge the ground water.
39. Details of occupational health programme. Kindly refer to Chapter – 7 Pg. No. 7.21
i. To which chemicals, workers are exposed directly or
indirectly.
ii. Whether these chemicals are within Threshold Limit
Values (TLV) / Permissible Exposure Levels as per
ACGIH recommendation.
iii. What measures company have taken to keep these
chemicals within PEL / TLV.
iv. How the workers are evaluated concerning their
exposure to chemicals during pre-placement and
periodical medical monitoring.
v. What are onsite and offsite emergency plan during
chemical disaster.
vi. Liver function tests (LFT) during pre-placement and
periodical examination.
vii. Details of occupational health surveillance programme.
TOR Compliance
6
40. Socio-economic development activities should be in place. Kindly refer to Chapter – 8 Pg. No. 8.1 to 8.3
41. Note on compliance to the recommendations mentioned in Kindly refer to Chapter – 10 Pg. No. 10.21 to 10.23
the CREP guidelines.(Corporate Responsibility for
Environment Protection)
42. Detailed Environment management Plan (EMP) with specific Kindly refer to Chapter – 10
reference to details of air pollution control system, water &
Pg. No. 10.1 to 10.23
wastewater management, monitoring frequency,
responsibility and time bound implementation plan for
mitigation measure should be provided.
43. EMP should include the concept of waste-minimization, Kindly refer to Chapter – 10 Pg. No. 10.18
recycle / reuse / recover techniques, Energy conservation,
and natural resource conservation.
44. Corporate Environmental Responsibility Kindly refer to Annexure – XI
a. Does the company have a well laid down Environment
Policy approved 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
TOR Compliance
7
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.
45. Action plan for post-project environmental monitoring. Kindly refer to Chapter – 10 Pg. No. 10.19
46. Any litigation pending against the project and /or any direction Not applicable as no litigation pending
/order passed by any Court of Law against the project, if so, against the project and /or any direction
details thereof. /order passed by any Court of Law
against the proposed expansion project
47. Public hearing issues raised and commitments made by the Will be complied after Public hearing
project proponent on the same should be included separately
in EIA / EMP Report in the form of tabular chart with financial
budget for complying with the commitments made.
48. A tabular chart with index for point-wise compliance of above complied
TORs.
TOR Compliance
8
E.I.D.Parry ( India) Ltd.
CHAPTER – 1
INTRODUCTION
1.0 PREAMBLE
The Indian sugar industry is the country’s second largest agro-processing industry with an annual
production capacity of over 18 Million Tons of sugar. At present, the total turnover of the industry is
about $5000 Million with the total capital employed touching $ 4000 Million. About 45 million farmers
and their families depend directly on sugar industries. Only 2.5 % of the area is under cultivation of
sugar cane of total cultivated area in India. In the year 1999-2000, the sugar produced in India was
a record 19.7 Million Tons.
In India the annual per capita consumption of White Crystal Sugar and that of Non-centrifugal sugar
is 15 Kg per Annum and 20.5 Kg per Annum respectively. The annual overall consumption of the
centrifugal and non-centrifugal sugar in the country comes to more than 25 Million Tones. Thus,
there is vast untapped potential for growth in the area of sugar production.
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 a potential as fuel in the form of power alcohol for blending
with petrol in the ratio of 20:80. Alcohol by fermentation process has a great demand in countries
like Japan, United States, Canada, and Srilanka etc. The synthetic alcohol produced by these
countries from Naphtha or petroleum crude is not useful for beverages. Large quantities of alcohol
have been exported out of country during last few years.
There are about 290 distilleries in the country (as on 2002-03) with a total installed capacity of 3198
million liters per annum. In spite of such abundant licensed and installed capacity and not with-
standing the fact that there is a great demand for alcohol both for chemical industry and potable
purposes, alcohol production in the country is lagging behind and is varying only around 1400-1450
million liters per annum.
Although India is the largest producer of sugarcane and sugar, the sugar factories in India are facing
problems. Sugar factories cannot survive in a healthy condition on a single product i.e. sugar. It is
necessary to develop the factory into an affiliated chemical complex and use the valuable co-
products more profitably. Molasses is a very important by-product of the sugar industry. The profits
earned by the conversion of molasses to alcohol will be much higher than that the value realized by
sale of molasses. There is a good demand for alcohol in the country, as production and
consumption of alcohol are not quite balanced.
The target of alcohol demand as projected in the perspective plan for chemical industry, prepared
EIA report
1.1
by the Govt. of India, Ministry of Industry, Dept. of chemical and petrochemicals is around 2400
million litres per annum. In addition, there is a good demand potential to export alcohol.
In view of the above M/s E.I.D Parry (India) Limited has proposed enhance the production capacity
of Sugar, C-gen and Distillery
M/s.E.I.D.Parry( India) Limited ( Formerly Known as Parrys Sugar Industries Limited) is an

operating Integrated Sugar Complex at Hullatti and Alloli Village, Haliyal Taluk, Uttara Kannada
District, Karnataka.
The Integrated Sugar Complex is being operated with the following capacity
Sugar Plant : 4800 TCD

Co-generation Power plant : 24 MW
Distillery : 45 KLPD
Now the company has proposed to enhance the capacity of

 Sugar plant from 4800 TCD to 6000 TCD
 Cogeneration Power plant from 24 MW to 37 MW including 3 MW incidental
power generation from Distillery Spent wash incineration boiler
 Distillery from 45 KLD to 90 KLD
The proposed expansion will be taken up in the existing plant premises only. The total cost of the
proposed expansion project will be Rs. 125 Crores.
1.1 PURPOSE OF THE REPORT
As per the stipulations of EIA Notification, 2006 and its amendments, the projects listed under
Category A and B need to obtain Environmental clearance from Ministry of Environment & Forests,
New Delhi.
The following are the details of the units of Integrated sugar complex and proposed enhancement of
capacities and Categorization as per EIA Notification, 2006
S. No Unit Capacity Categorization as

Existing Expansion Total per EIA
Notification, 2006
1. Sugar 4800 TCD 1200TCD 6000 TCD 5(j)
2. Co-gen Power 24 MW 10 MW 34 MW 1(d)
plant
3. Distillery 45 KLPD 45 KLPD 90 KLPD 5 (g)
4. Power from -- 3 MW 3 MW 1(d)
incineration
boiler
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1.2
Hence, we have submitted Form – I along with proposed TOR for EIA study & Project report to
MoEF as per the stipulations of EIA Notification, 2003. A presentation was made before the Expert
Appraisal Committee of MoEF on 5 th March, 2013 for the approval of Terms of Reference (TOR) for
EIA study. The Draft EIA report has been prepared in accordance with the TOR issued by the
Hon’ble Ministry vide letter F.No. J-11011 / 336 / 2012- IA II (I) dated 29th April, 2013.
This report furnishes the details of location of Site, Description of the project, prevailing baseline
status w.r.t Air Environment, Water Environment, Noise Environment, Land Environment, Flora &
Fauna and Socio-economic environment. This report also helps in identification of environmental
impacts and suggesting mitigation measures to be followed during Construction and Operation of
the project as part of Environmental Management Plan. This report also acts as guidance manual
for the proponent for following the Environmental Management Plan (EMP) and for adopting post
project Environmental Monitoring Program as per statutory norms.
1.2 IDENTIFICATION OF PROJECT & PROJECT PROPONENT
M/s.E.I.D.Parry( India) Limited is a distinguished and rapidly expanding sugar producer in India.
EID Parry (India) Ltd, a Murugappa Group company one of the fastest growing organizations In
India. Our sugar manufacturing facility is under the process of obtaining ISO 9000:2001 and the
distillery is certified "zero-effluent discharge ”
We are deeply committed to a larger vision of our social responsibility, of looking after the needs
and quality of life of the farmers and local communities. Through our effective farmer partnership
model we provide assistance in farming practices and undertake various economic initiatives for the
benefit of the local communities.
The Promoters
The following is the list of promoters of the group
S.No Name Designation

1. Mr. S. Sandilya Chairman
2. Mr. D. Kumaraswamy Managing Director
3. Mr. V. Ravichandran Director
4. Mr. N. Srinivasan Director
5. Mr. K. Ramadoss Director
6. Mr. K. Balasubramanian Director
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1.3
1.3 BRIEF DESCRIPTION
1.3.1 NATURE OF THE PROJECT
The proposed project involves:

 Manufacturing of Sugar with sugar cane.
 10 MW power generation by using Bagasse / coal
 Manufacturing of Rectified Spirit / ENA / Ethanol by using Molasses as raw materials.
 3 MW captive Power using Concentrated spent wash / Bagasse as raw materials.
1.3.3 SIZE OF THE PROJECT
M/s. E.I.D.Parry( India) Limited is an existing Integrated Sugar Complex operating at Hullati
Village, Haliyal Taluk, Uttara Kannada District.
The following is the capacity of the existing Integrated Sugar Complex
Sr. No Unit Capacity
1. Sugar 4800 TCD
2. Co-gen Power plant 24 MW
3. Distillery 45 KLPD
Total area already in possession of the management is 226 acres.
Now the company has proposed to enhance the capacity of the Integrated Sugar Complex. The
proposed expansion will be taken up in the existing plant premises only.
The following will be the capacities after proposed expansion
Existing Expansion Total
1. Sugar 4800 TCD 1200TCD 6000 TCD
2. Co-gen Power plant 24 MW 10 MW 34 MW
3. Distillery 45 KLPD 45 KLPD 90 KLPD
4. Power from -- 3 MW 3 MW
incineration boiler
The total capital investment of the proposed expansion project will be Rs. 125 Crores.
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1.4
1.3.3 LOCATION OF THE PROJECT
The existing Integrated Sugar Complex is located at Hullati & Alloli Villages, Haliyal Taluk, Uttara
Kannada District, and Karnataka state. Now the company has proposed to take up expansion
activities in the existing plant premises only.
The following factors have been considered for taking up this proposed expansion project
a. Availability of suitable land (226 Acres).
b. Availability of water.
c. Availability of raw materials.
d. Availability of man power.
e. Availability of infrastructural facilities
f. Suitability of land from geological and topographical aspects.
g. The following are the Environmental aspects of the Plant site
 The Plant area does not fall under the industrial areas / cluster, which are listed in
MoEF office memorandum dated 13th January 2010.
 Nearest Habitation is Haliyal village at a distance of 0.6 Kms. from the plant.
 There are no National Parks / Wild life Sanctuaries within 10 Km radius of the plant.
 A few Unnamed Reserve forests are present within 10 Km. of the plant.
 Tattihala River is flowing at a distance of 2.2 Kms. from the plant.
 No Historical places and Places of Tourist importance within 10km. radius of the site.
The existing plant in Hullati & Alloli Villages, Haliyal Taluk, Uttara Kannada District, Karnataka is
complying with sitting guidelines as MoEF. Hence, no other sites were examined for proposed
expansion.
The topographical map showing the location of the plant site is shown in Fig. 1.1.
EIA report
1.5
E.I.D.Parry (India) Ltd.
PLANT SITE
Fig 1.1
EIA report
1.6
E.I.D.Parry ( India) Ltd
Integrated Sugar Complex
1.3.4 IMPORTANCE OF PROJECT
Snapshot of Indian sugar industry
 Operational sugar mills – 526 operational (695 installed)

 Total sugarcane crushing capacity – 2.3 mln tcd
 Total sugar production capacity – over 30 mln tons per annum
 Average crushing capacity - 4000 tons per day per unit
 Out of total operational 526 units:- - 30%
 Mix of Private/Public/Cooperative:- –309 units(Cane crushing Capacity –
19.1 mln tons/annum)
 Cooperative – 217 units (Cane crushing Capacity – 12.7 mln tons/annum)
Average Milling capacity at different countries
Capacity profile of Indian sugar industry
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1.7
Integrated Sugar Mills

Integrated sugar mills having Co-gen & Distillery – 160 units
India Distilleries (attached with Sugar Mills) Co-generation
No. of units Capacity No. of units Exportable
(million litres per Energy
annum) (MW)
160 2281 210 3200
(147 units (capacity of 147 units is
make fuel 2 billion lit/year)
ethanol)
Note :- in addition to the above, another 168 standalone distilleries in India
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1.8
Consideration of by-products in cane pricing
 Government of India’s Fair & Remunerative Price

 Considers realisation from by-products while fixing the FRP
 Rangarajan Committee on linking cane & sugar price
 Cane price be determined at either 70% of revenue realised from
sugar and first stage by-products or
 75% of revenue realised from sugar only (5% weightage to byproducts)
Distillation capacity in India
 Total about 328 distilleries having installed capacity of 6 billion litres of alcohol
production
 Out of it, 2 billion litres of fuel ethanol capacity
 1.8 billion litres with sugar mills
 0.2 billion litres with standalone distilleries
 A total of 160 sugar mills have 2.3 billion litres distillation Capacities
Ethanol blending programme

• Oct 2007:
 CCEA decision for mandatory 5% blending,
 With fixed procurement price of INR 21.50 per litre
EIA report
1.9
• Nov 2009:
 Mandatory 5% blending reiterated by CCEA and
 Procurement price re-fixed at INR 27 per litre
• 2009 National Bio-fuel Policy:
 20% ethanol blending by 2017
• Aug, 2010:
 • Mandatory 5% blending again reiterated by CCEA
 • INR 27 per litre fixed as provisional price ex-factory
 • Expert Committee formed for final ethanol pricing policy
• Nov, 2013:
 • Mandatory 5% blending reiterated
 • OMCs floated requirement for 2 seasons
Ethanol: tool to balance sugar production
 5% blending programme requires 1 billion litres of ethanol

 All ethanol currently produced only from molasses
 Approval and standards fixed in 2009 for 10% blending
 Increase from 5% to 10% will require another 1 billion litres
 Can divert cane juice or B-heavy molasses into ethanol
 Can reduce 1.7 million tons of sugar production
 Flexible blending programme can control sugar surplus
Several uses of Bagasse
 Burn in boilers to generate power

 Sell to paper manufacturers
 Use to make press board
 Research on use of bagasse to make ethanol
 But, in India, largest use is for generation of power
Bagasse based cogeneration of power
 At current installed crushing capacity, potential to generate power is said to be 7500

MW
 Only 210 mills generating exportable power
 Currently, 3200 MW of power is exported by sugar mills to the grid
 Rates offered by State Government agencies in the range of
 INR 3.12 - INR 6 per unit
 Some units are trading power at INR 4.5 per unit too
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1.10
The technology
 High pressure boilers of 108 ata being used for last 5 years
 Higher pressure boilers of 130 ata under commissioning in few mills
 Use back pressure and condensing type turbo-generators
 A few multi fuel boilers to allow use of coal, grain husks etc. also getting installed
in last few years, for sale of power in off-season
 Concept of better utilisation of idle capacity in off-season too
Government support for by-products
 Government of India provides concessional loans

 From Sugar Development Fund (SDF)
 To meet shortfall in promoter’s contribution
 For both cogen and ethanol projects
 Capital subsidies are also provided
 For cogen projects
Conclusion
 Integrated units give better realization and tool to balance the sugar surplus to the
sugar mills
 Huge untapped potential
 7500 MW of power and unlimited potential for ethanol
 Almost all new mills in India coming up in integrated form
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1.11
 Government support should help improve

 Finance availability and rationalisation of tariff rates
 Challenges to smaller units with 2500 TCD or lower, mostly in the cooperative sector
In view of the above, M/s.E.I.D.Parry( India) Limited has proposed to enhance the production
capacity of Integrated sugar complex
 Sugar plant from 4800 TCD to 6000 TCD
 Cogeneration Power plant from 24 MW to 37 MW including 3 MW incidental power
generation from distillery spent wash fired incineration boiler
 Distillery from 45 KLD to 90 KLD
in the existing sugar plant premises of Hullati & Alloli Villages, Haliyal Taluk, Uttara Kannada
District, Karnataka
1.4 SCOPE OF THE STUDY
The scope of work includes a detailed characterization of the environment in an area of 10 km.
radius of the proposed expansion project site for various environmental parameters like air, water,
noise, land, biological and social-economic aspects. The present Final REIA report is prepared
incorporating all the TORs accorded by the Hon’ble Ministry of Environment & Forests, New Delhi
vide letter F.No. J-11011/336/2012- IA II (I) dated 29th April, 2013.
EIA report
1.12
E.I.D. Parry ( India) Limited
CHAPTER – 2
PROJECT DESCRIPTION
2.1 TYPE OF PROJECT
E.I.D.Parry ( India) Limited is an operating Integrated Sugar Complex at Hullatti and Alloli Village,
Haliyal Taluk, Uttara Kannada District, Karnataka.
The Integrated Sugar Complex is being operated with the following capacity
Sugar Plant : 4800 TCD
Co-generation Power plant : 24 MW
Distillery : 45 KLPD
Now the company has proposed to enhance the capacity of

 Sugar plant from 4800 TCD to 6000 TCD
 Cogeneration Power plant from 24 MW to 34 MW including 3 MW incidental
power from distillery spent wash incineration boiler
 Distillery from 45 KLD to 90 KLD
The proposed expansion will be taken up in the existing plant premises only. The total cost of the
proposed expansion project will be Rs. 125 Crores.
2.2 NEED FOR THE PROJECT
The international sugar market remains one of the most volatile of all commodity markets due to
uncertainty in supply among some Asian countries, particularly India. The sugar production in
India is characterized by the cyclical nature of production, where 2-3 years of surplus are followed
by 2-3 years of deficit. In recent years, the cycle has been more pronounced, with larger swings in
production and trade. Trade generally follows a similar trend, with imports during the deficit
phase of the cycle, replaced by large exports during the surplus phase. The cyclical production is
due to uncertain weather conditions, lower productivity and use of traditional method of
production. The government policies also amplify the cycle through their effect on incentives
along the sugar value chain, including for farmers and sugar factories.
The world sugar market has undergone significant structural changes over the past decade still it
remains heavily distorted due to protectionism policy by various governments. Changes in domestic
support policies and border measures, such as the imposition of export restrictions, have a major
impact on trade volumes and international prices. Other uncertainties like saturated demand from
developed countries also affecting the market. Changes in oil and energy prices and their
EIA report
2.1
implications on the share of sugarcane for ethanol production, particularly in Brazil, will also
influence the market.
India is the fourth largest exporter of sugar; exporting to UAE, Sri Lanka, Yemen, Saudi Arabia,
Maldives, Pakistan and Malaysia. India has the potential to export sugar to sugar deficit
countries in the Middle East and East Africa. India enjoys freight advantage in exporting
sugar to these countries but the only disadvantage is that price fetched in these countries is much
lower than the price fetched in Europe and North America. The Indian sugar sector needs to focus
on European and North American markets on a long term basis to fetch higher prices for Indian
sugar.
India is net exporter of sugar despite constant government interventions in external trade of sugar is
to curb the rise in prices of sugar in the domestic market. But higher domestic sugar prices than
international sugar prices suggest the significant policy changes are needed. Also, the potential for
expanding sugar production in India exists and can be fully exploited if adjustments were introduced
to ensure a market driven relationship between sugar and sugarcane prices. The use and
valorization of sugarcane byproducts, such as ethanol, electric power, and other derivatives, can
cushion against low sugar prices and other market risks. Clearly, the liberalization of the sugar
industry can only be undertaken within the context of broader domestic reforms, because of the
linkages on both demand and supply sides that prevail in agricultural commodity markets .
In view of the above, the company has proposed to enhance the capacity of Integrated Sugar
Complex
2.3 LOCATION
The existing Integrated Sugar Complex is located at Hullati & Alloli Villages, Haliyal Taluk, Uttara
Kannada District, Karnataka state. Now the company has proposed to take up expansion activities in
the existing plant premises only. The topographical map showing the location of the project is shown
in fig 2.2
LAND USE-STATEMENT [TOR # 3]

ITEM EXTENT OF LAND (ACRES)
Existing Expansion After expansion
Built up area of Sugar plant 5.23 1.00 6.23
Built up area of Co-Gen Power plant 19.54 1.20 20.74
Built up area of Distillery plant 3.00 3.00 6.00
Internal roads 3.60 0.4 4.00
Green belt area 85.00 85.00
Vacant area 104.03 104.03
Total 226.00 226.00
EIA report
2.2
Environmental Setting within 10 Km. radius of the Project site [TOR # 5]

The site is in accordance with the guidelines issued by MoEF. The following are the salient features
of the site proposed.
 The Plant area does not fall under the industrial areas / cluster, which are listed in MoEF
office memorandum dated 13th January 2010.
 Nearest Habitation is Haliyal village at a distance of 0.6 Kms. from the plant.
 There are no National Parks / Wild life Sanctuaries / biosphere reserves within 10 Km
radius of the plant. [TOR # 8]

 A few Unnamed Reserve forests are present within 10 Km. of the plant.
 Tattihala River is flowing at a distance of 2.2 Kms. from the plant.
 No Historical places and Places of Tourist importance within 10km. radius of the site.
 No R & R is involved.
 No litigation pending against the project and / or any direction / order passed by any
Court of Law.
The general location of the proposed site is shown in fig. 2.1 and topographical map showing the
location of the project is shown in fig 2.2.
EIA report
2.3
E.I.D Parry (India) Limited
General Location of The

Proposed Site
Fig. 2.1
EIA report
2.4
PLANT SITE
Fig 2.2
FIGURE 2.1
EIA report
2.5
2.4 SIZE / MAGNITUDE OF OPERATION
M/s.E.I.D.Parry( India) Limited is an existing Integrated Sugar Complex operating at Hullati

Village, Haliyal Taluk, Uttara Kannada District.
The following is the capacity of the existing Integrated Sugar Complex
1. Sugar 4800 TCD
2. Co-gen Power plant 24 MW
3. Distillery 45 KLPD
Total area already in possession of the management is 226 acres.
Now the company has proposed to enhance the capacity of the Integrated Sugar Complex. The
proposed expansion will be taken up in the existing plant premises only.
The following will be the capacities after proposed expansion
1. Sugar 4800 TCD 1200TCD 6000 TCD
2. Co-gen Power plant 24 MW 10 MW 34 MW
3. Distillery 45 KLPD 45 KLPD 90 KLPD
4. Power from -- 3 MW 3 MW
incineration boiler
The total capital investment of the proposed expansion project will be Rs. 125 Crores.
BREAK UP OF PROJECT COST

S.No. Particulars Cost in Crores
1. Land Development & Civil Works : 1.50
2. Plant & Machinery : 123.50
Total : 125.00
2.5 PROPOSED SCHEDULE FOR APPROVAL AND IMPLEMENTATION
The project will be implemented within 12 months from the date of issue of Environmental
Clearance by the Hon`ble Ministry of Environment & Forests & Consent for Establishment by
KSPCB.
EIA report
2.6
Regulatory Framework [TOR #6]

The following are the permissions and clearances required for the proposed expansion
Project.
S.NO. PERMISSION REQUIRED CONCERNED DEPARTMENT
1 Registration of Project Company (Certificate of Already Existing
Incorporation)
2 Memorandum of Articles & Association Already Existing
3 Registration under Central Sales Tax Already Existing
4 Registration for TAN Already Existing
5 Registration for PAN Already Existing
6 Registration under Local Sales Tax Already Existing
7 Registration under Central Service Tax Already Existing
8 License from labour Commissioner for Labour commissioner
construction labor
9 Industrial Entrepreneurs' Memorandum Ministry of Commerce & Industry,
New Delhi
10 Registration for Employee Provident Fund Already Existing
under EPF Act
11 Registration & grant of License under the Factory Inspector
Factories Act, 1948 (Required before
Operation)
12 Land related clearances Not applicable as the expansion is in
the existing premises only
13 Environment & Forest related clearances
a TOR for Preparation of EIA & EMP Already issued by MoEF, New Delhi
b Environmental Clearance Awaited from MoEF, New Delhi
14 Consent to Establish KSPCB, Hyderabad
Forest Clearance / NOC from Forest
15 Not applicable.
Department
N.O.C from Irrigation Department for Water with
16 Already Obtained
drawl
17 Financial Closure Financial Institutions
EIA report
2.7
E.I.D.Parry( India) Limited
2.6 TECHNOLOGY AND PROCESS DESCRIPTION
2.6.1 RAW MATERIALS AND ITS SOURCES [TOR # 12 & 14]
S.NO RAW MATERIAL SOURCE QUANTITY ( TPD) METHOD OF TRANSPORT

Sugar plant :
1 Sugar Cane Local area 4800 1200 6000 By trucks, tractors& bullock carts
2 Lime Local area 9.60 2.4 12.0 Through covered trucks by Road
3 Sulphur Local area 3.84 0.96 4.8 Through covered trucks by Road
4 Phosphoric Acid Local area 0.96 0.24 1.20 Through covered trucks by Road
Co-gen power plant :
1 Fuel
Bagasse From Sugar plant 1108 528 1636 Conveyor
Distillery :
1 Molasses From Sugar plant 165 165 330 Through Pipeline/Tanker
2. Fuel for Incineration Boiler
Concentrated Spent wash From Distillery Unit 72 108
(10 TPH (15 TPH 180 Through Pipeline
Boiler) Boiler)
Coal 60 Conveyor
24 36
EIA report
2.8
MOLASSES REQUIREMENT [TOR # 14]

Molasses generation from 6000 TCD sugar plant @ 4.5% on cane : 270 TPD
Nos. of days of operation of Sugar plant : 180 days
Total Molasses available per annum : 48,600 T
Nos. of day’s operation of Distillery unit : 300 days
Molasses Requirement to Distillery plant per day : 330 TPD
Molasses Requirement to Distillery per annum (330 x 300 days) : 99,000 T
Additional molasses requirement per annum : 50,400 T
Additional Molasses required will be sourced from the sister concern unit, Ram Durg, Karnataka
and other sugar plants
BAGASSE REQUIREMENT [TOR # 14]

Bagasse generation from 6000 TCD sugar plant @ 30% on cane : 1800 TPD
Nos. of Sugar crushing days : 180 days
Total Bagasse available per annum : 3,78,000 T
Bagasse consumption (120 TPH (existing) & 45 TPH (expansion) : 1636 T
Hence the bagasse generated will be adequate for operating Co-gen power plant for 231 days.
During off-season power generation will be through imported coal if power tariff is encouraging.
2.6.2 RAW MATERIAL STORAGE & HANDLING
Bagasse generated will be stored in the yard and will be transferred to the Boiler through closed
conveyors.
Coal for Distillery will be stored in the closed shed
Molasses generated will be stored in closed MS tanks
2.6.3 TRANSPORT OF RAW MATERIALS
Sugarcane required for the Plant will be transported through trucks, tractors and bullock carts. Raw
materials required for power plant will be mainly Bagasse which is generated from crushing of sugar
cane in the plant premises itself. Coal required for Distillery alone will be imported from other
countries to near by Port and from there it will transported by road. The existing roads are capable
of absorbing the additional traffic. Hence there will not be any adverse impact on environment due
to additional vehicular movement due to the proposed expansion project.
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2.9
2.6.4 MANUFACTURING PROCESS [TOR # 13]

2.6.4.1 SUGAR MANUFACTURING PROCESS
Cane Procurement
Matured cane is harvested and transported by trucks & tractors to the factory site, taking care that
the time gap between harvesting & milling should be less than 22 hours, cane is harvested on the
basis of (1) Age of the crop (2) Hand refractometer brix (3) Lab crusher test.
Preparation - cane is cut up into pieces with cane knives, resulting in a fiberized mass. The more
finely prepared the cane the better will be the extraction.
Diffusion - i.e. Extraction of juice from the prepared cane by the process of leaching by circulating
hot water at about 85-90 deg C in a counter current flow. A typical diffuser would have 12 extraction
stages with a total length of about 68 m between drive and non- drive end shaft centres and 6.5 m
wide.
De watering Mill- i.e. "Squeezing" the water from the magasse using large grooved rollers. Due to
the leaching process with an imbibition of about 300% on fiber, the output of diffuser, termed as
Magasse will have a moisture of about 80% that has to be brought down to 50% to be able to use in
boiler for steam generation.These de-watering mills are used for reducing the moisture to the
desired level of 50%.
Juice screening - to remove the fibre from the extracted juice. The fibrous residue Bagasse is
used mainly as fuel. Weighing - of the "mixed juice" in the mass flow meter.
Juice Clarification
Before clarifying the sugar cane juice it is weighed for the material balance purpose. Weighed juice
is pumped to continuous liming & sulphitation tank, termed as Juice Sulphitor through a direct
contact heater to get temperature of juice 70 deg C to 75 deg C. Heated juice is treated with milk of
lime & SO2 gas, to precipitate out the non-sugar content of the juice. To avoid fluctuations film type
continuous suphur furnace is installed. This unit has installed a Short retention time clarifier for
removing the mud from the juice and take out clear juice for processing further.
In the clarifier, precipitated non sugars settle in the bottom compartment and decanted juice comes
out from the upper portion, under flow of the clarifier is sent to diffuser.
To add milk of lime to juice reaction tank, it is made in a slacker, where quick lime is mixed with hot
condensate. To maintain quality of lime, fresh quick lime is procured from lime kilns. To prepare
sulphur dioxide gas, superior quality rolled sulphur is burnt in a furnace, supplied with atmospheric
air.
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2.10
Evaporation
Clear juice coming out from the clarifier is fed to multiple effect evaporator set, to concentrate the
juice to 58 deg to 60 deg brix. Condensate collected from evaporator later bodies is used for mill
imbibition purpose.
Syrup clarification
Concentrated syrup from evaporator outlet is sent to, syrup reaction tank & syrup clarifier. Syrup is
treated with phosphoric acid, to separate out non sugars to the possible extent. Clarified syrup is
suphited for bleaching action purpose. Clarified & syphited syrup is sent to pan house to crystallize
sugar.
Crystallization process
To extract the sugar from cane syrup it is boiled 3 times in pans. After extracting the maximum
quantity of sugar, the left over liquor is called as waste molasses or final molasses.
Cane syrup (mother liquor) is boiled in bagging massecuite called as 1 st massecuite of “A”
massecuite. From this massecuite, commercial sugar and mother liquor are separated out. This
mother liquor after 1st extraction is called “A” heavy molasses. To get required number of sugar
crystals and to maintain uniformity. “A” massecuite is boiled on seed sugar collected from sugar
hopper.
A-Heavy molasses is again boiled as “B” massecuite. It is centrifuged & the sugar is melted in pan
condensate water. This melt is used in “A” massecuite boiling. Molasses coming out from “B”
massecuite centrifugation is called as “B” molasses.
This “B” molasses is again boiled as “C” massecuite, Sugar coming out by the centrifuging of “C”
massecuite is melted and used in “A” massecuite boiling. Molasses coming out from C-Centrifugal
is called as final molasses.
Conveying and Grading of Sugar
“A” massecuite (Bagging Massecuite) is centrifuged in fully automatic batch type centrifugal to get
commercial grade sugar. This sugar is discharged on a hopper cum conveyor. While conveying the
sugar to grader, it is treated with hot air and cold air to remove moisture & to bring down the
temperature of sugar 38 deg C before packing.
Magnets are provided just above the sugar hopper and at the bottom of sugar elevators to separate
out pieces if any.
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2.11
Sugar packing, weighment & storage
Graded sugar is sent to sugar silos. These sugar silos are attached with auto weighers. Sugar is
bagged according to market requirement in 50 kg. Pack using H.D.P.E bags with polythene lining.
In the godown bags are stacked in lots and are covered with L.D.P.E black sheets.
EIA report
2.12
Parrys Sugar Industries Ltd. PROCESS FLOW DIAGRAM
(Expansion of Integrated Sugar Plant) (SUGAR)
EIA report
2.13
2.6.4.2 POWER GENERATION PROCESS

CO-GENERATION POWER PLANT
The power plant consists of the following.

 45 TPH Traveling Grate Boiler with ESP
 1 x 10 MW Triple Extraction cum condensing type Steam turbine
 Mechanical auxiliaries like Fuel handling system.
 Water cooled condenser system.
 Electrical auxiliaries
The boiler will be designed to operate with bagasse only.
The whole process comprises of generating heat energy in the boiler and then converting heat
energy generated in the Traveling Grate Boiler into Mechanical energy in the turbine and further
converting this mechanical energy generated in the turbine into electrical energy in the alternator.
The fuel will be fed into the boiler and will be burnt in the boiler. The combustion generates the
heat energy in the boiler. This heat energy is transferred to heat transfer area provided in different
areas like (water wall, steam drum/mud drum, Bank tubes, Economizer, Super heater, Air-pre
heater). This heat is transferred to the Air, which is passing through and steam is generated and
this steam is further superheated in the Super heater so that dry super heated steam is generated.
Boiler outlet steam parameters are 110ata, 540 0C.
The quantity of steam generated in the boiler is 120 TPH (MCR). This steam is fed into the turbine
and this steam expands in the turbine and generates mechanical energy i.e. it starts rotating the
rotor at high speed and further this mechanical energy is converted into electrical energy in the
alternator. The power generated at the alternator terminal is 24 MW.
The feed water from the deaerator is pumped to the steam drum through HP heater and
economizer by means of feed water pump (three no's out of which normally two are working and
one is standby). The feed water gets preheated in the HP heater by recovery of heat from MP
steam extraction from turbine initially and in economizer by way of recovery of heat from flue gases
before it enters the steam drum, where it mixes with boiler water. A minimum re-circulation flow line
is provided in the feed water line to pump the water back to deaerator and safeguard the pump from
overheating in very low or no flow (to boiler) condition.
EIA report
2.14
BOILER WATER CIRCULATION SYSTEM
The boiler water circulation system consists of two sections in boiler bank tubes and water wall
tubes. The boiler bank tubes have a self adjusting circulation pattern, with a few tubes connected to
the water space, serving as down comer tubes and the remaining serving as riser tubes. A portion
of the water circulated is evaporated and the steam water mixture rises up into the steam drum
where steam is separated from water. Dry steam leaves the steam drum, while the separated water
mixes with the incoming feed water for further circulation. The water wall tubes receive water from
water drum through down comer/connecting pipes. The steam water mixture, rising through water
wall tubes, enters the steam drum and the dry saturated steam leaves the drum.
SUPER HEATER SYSTEM
The saturated steam from the steam drum enters the super heater. This is located at the outlet of
the furnace and is of pendant type, arranged for counter flow configuration. The heat from the flu e
gases is transferred to the steam and the super heater is suitably sized to achieve the rated steam
temperature. The inter stage attemperator provided enables to maintain the super heat steam
temperature within allowable limits. The superheated steam flows through the main steam piping to
the end use equipment. The main steam stop valve isolates the boiler form the process/turbine, as
the case may be. Boiler starts up vent and super heater safety valve are located in this line.
FIRING SYSTEM
The spreader stoker with traveling grate is most widely used combustion process for burning fuels
for generation of steam. The primary purpose of this grate is to provide a platform for the fuel to be
distributed over and for the forced draft air to pass through, providing oxygen for combustion. The
travelling grate moves forward and towards the fuel feed end. The design is such that it releases
equal amounts of energy over each square meter of the grate.
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2.15
The process flow diagram is shown in Fig 2.2 B
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2.16
2.6.4.3 DISTILLERY
The proposed distillery will be operated with Molasses raw materials.
A) WITH MOLASSES
YEAST PROPAGATION
Yeast seed material is prepared in water-cooled yeast vessels by inoculating molasses with yeast.
The contents of the yeast vessel are then transferred to the Yeast activation vessel. The purpose
of aerated yeast activation in the yeast activation vessel is to allow time for the yeast cell
multiplication.
FERMENTATION
The fermentation technology adopted in the industry is of Semi continuous fermentation with yeast
recycles with this technology the total spent wash generation will be restricted to a max. Of 10 kl/kl
of R.S. (As per latest CPCB recommendation).
The purpose of fermentation is to convert the fermentable sugars into alcohol. During fermentation,
sugars are broken down into alcohol and carbon-di-oxide. Significant heat release takes place
during fermentation.
However the fermentation temperature is maintained at 32 – 35 0C by forced recirculation heat
exchangers.
At the end of fermentation, the wash is fed through a yeast separator where the yeast cream is
separated, acidified in the yeast treatment tank and returned to the yeast activation vessel for
activation. Sludge is separated in a sludge decanter. The clear wash from both the yeast separator
and sludge separator flows to the clarified wash tank. The wash is then pumped to distillation.
ECOFINE - P : PRIMARY DISTILLATION
Fermented Wash about 8% v/v alcohol is preheated in two stages i.e. in the beer heater using the
Rectifier vapours and then in the Fermented wash PHE using the effluent. The preheated wash is
then fed the Degasifying Column to remove residual CO 2 and volatiles.
The wash then flows down to Analyser Column, which acts as a total stripper. The alcohol water
vapour mixture which rises upward in this column is fed to the Rectifier Column. The spent wash,
after separation of alcohol, flows down the Analyser Column bottom and pumped for suitable
treatment.
The lower boiling impurities are concentrated in the Aldehyde Column where about 5% spirit is
drawn off as impure spirit with strength of 94.0%v/v.
The alcohol vapours are concentrated in the Rectifier Column to produce Rectified Spirit of 95% v/v
strength. Higher boiling impurities, which are formed during fermentation, are removed by taking
side draw purges to a decanter from the Rectifier Column. A trace stream of spirit is drawn off as
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2.17
impure spirit (about 0.2% of plant capacity) to remove the concentrated volatile compounds. The
high grade Rectified Spirit is taken as a draw from the upper trays of the Rectifier Column.
ECOFINE – R5: REDISTILLATION (5% TECHNICAL ALCOHOL CUT)
High proof alcohol (95% v/v) is fed to the purification column. Dilution water is fed on the top most
tray of the column with a dilution ratio of 1: 9. This column serves to remove the impurities based
on the principle of HYDRO SELECTION/ HYDRO EXTRACTION. The water is fed to the column in
such a way that it selects the higher alcohols and other impurities to move upwards and extracts
alcohol down. The purifier bottom alcohol composition is maintained at 12 % v/v. At this
composition there is an inversion in relative volatiles of higher alcohols as compared to alcohol and
these alcohols get separated in the top distillate. Top draw for volatiles is fed to the Fusel oil
concentration column.
The purified dilute alcohol is removed from the bottom of the purification column and fed to the
rectification column, which concentrates the ethanol to 96% v/v. The high grade spirit is drawn from
one of the upper trays of the rectification column. A small heads cut is removed from the overhead
stream as technical alcohol (T.A.) cut to with draw impurities and is fed to the heads concentration
column. The lees from the exhaust column are recycled as dilution water after a part of it is purged.
The purged spent lees is used to preheat the make-up dilution water.
Lower side draw streams are taken from rectification column to avoid fusel oil build up in the
column. These streams are then taken to the fusel oil column. This column concentrates the dilute
streams of alcohol containing esters and fusel oils to approximately 95% v/v of alcohol. The
concentrated alcohol is removed as T.A. cut from the top of the column. T.A. cut is removed out of
the system in order to remove propanol and remaining is fed to the heads concentration column
where the heads from the purification column and rectification are fed to the static mixer. Soft
water, which has been preheated, is used for diluting the high proof ethanol. An impure spirit cut of
about 5% of the rectified spirit feed is drawn from the top of the column. The dilute ethanol solution
at the bottom of this column is pumped back to the purification column for repurification.
CARBON DIOXIDE RECOVERY SYSTEM (BY PRODUCT)
CO2 gas will pass through scrubbing tower, where the gas is scrubbed with water. From the
scrubber after washing the gas is passed through air compressor and than the gas will pass
through a tower containing sodium dichromate to eliminate the impurities, if any and then to drying
arrangement with sulphuric acid. Subsequently it passes through a tower containing coke coated
with washing soda to eliminate odour. . The scrubber blowdown will be recycled into the fermenters.
After the scrubber, the pressurized CO2 will be liquefied and stored in the storage container which
will be disposed through tankers to the soft drink units
Total CO2 that can be produced : 34.2 T/day
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2.18
MOLECULAR SIEVE TECHNOLOGY FOR ETHANOL
Molecular sieve technology works on the principle of pressure swing adsorption. Here water is
removed by adsorbing on surface of `molecular sieves' and then cyclically removing it under
different conditions (steaming).
Molecular sieves are nothing but synthetic zeolites typically 3A zeolite. Zeolites are synthetic
crystalline Alumino Silicates. This material has strong affinity for water. They adsorb water in cold
condition and desorb water when heated. This principle is used to dehydrate ethanol. The
crystalline structure of zeolites is complex and gives this material the ability to adsorb or reject
material based on molecular sizes. Water molecule can enter the sieve and be adsorbed, but larger
alcohol molecule will not be retained and will go through the bed. There can be two to three beds in
parallel. Once a particular bed is saturated with water, it is heated with steam so that adsorbed
water is desorbed from the bed. Till that time, other bed is used for dehydration.
This type of system is characterized by high capital investment. Low steam consumption and low
power consumption as compared to distillation. The only disadvantage of molecular sieves is the
high attrition rates of sieves in case of small plants. Hence, typically, some amount of sieve material
needs replacement periodically, thereby resulting in higher cost of production in case of small
capacity plants. in case of large capacity plants, the molecular sieve is the most optimum both in
terms of initial investment and operating cost.
The process flow diagram is shown in fig 2.2 C
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2.19
2.7 STEAM BALANCE [TOR # 19]

The following is the steam balance for the Sugar and Co-gen power plant during season and during
off season
Season FOR 4800 Season for Off-season
TCD additional 1200
TCD
Boiler steam generation 120 TPH 45 TPH 103 TPH
Turbine inlet flow 118.2 TPH 45TPH 102.8 TPH
Ejector/seals steam flow 0.5 TPH 0 0.5 TPH
HP Heater – I 8.97 TPH 0 7.81TPH
HP Heater – II 10.01 TPH 0 7.8TPH
HP steam to process 2.0 TPH 0 -
HP steam to Distillery 5.71 TPH 0 7.06 TPH
LP steam to Process 78 TPH 42 -
Deaerator steam 8.01TPH 3 9.5TPH
Condenser steam 33.38 TPH 0 70.13 TPH
Steam required for the Distillery plant (existing and expansion) will be met from the 10 TPH and
new 15 TPH Boiler. The following is the steam balance for the Distillery plant for existing and
expansion together.
Boiler steam generation 25 TPH
Turbine inlet flow 25 TPH
Ejector/seals steam flow 0 TPH
HP Heater – I 0 TPH
HP Heater – II 0 TPH
HP steam to process 0 TPH
HP steam to Distillery 0 TPH
LP steam to Process 25 TPH
De-aerator steam 0 TPH
Condenser steam 0 TPH
2.7 ENVIRONMENTAL MITIGATION MEASURES
1. Air Emission Control
 A stack height of 44 m will be provided for 45 TPH boiler for effective dispersion of
emissions into the atmosphere. High efficiency Electro Static Precipitator will be
provided for bringing down PM emission to less than 50 mg/Nm3 to comply with
CREP recommendations.
 A stack height of 50 m will be provided for the new boiler of 15 TPH capacity as per
CPCB norms for effective dispersion of pollutants into the atmosphere. High
efficiency Bag filter will be provided for bringing down PM emission to less than 50
mg/Nm3.
 All conveyor transfer points will be closed.
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2.20
2. Wastewater :
Sugar Plant
The effluent from sugar plant will be treated in Effluent treatment plant and after ensuring
compliance with KSPCB norms, the treated effluent will be utilized on land for irrigation.
Co-generation Power Plant

Cooling tower blowdown and DM plant regeneration water will be recycled into process.
Boiler blowdown and service water effluent will be treated in neutralization tank and treated
effluent is will be utilized for greenbelt development / ash conditioning / dust suppression in
the plant premises after ensuring quality of treated effluent with standards stipulated for
onland for irrigation by CPCB / KSPCB
Distillery
The spent wash generated from the distillery will be concentrated in Multiple Effect
Evaporators (MEE) to 60% solids and then will be sent to two boilers of total 25 TPH steam
generating capacity for incineration. This will be a zero discharge based technology
approved by the Central pollution Control Board.
3. Noise Emissions
 Acoustic enclosure will be provided to STG. All the machinery will comply with noise
levels stipulated by MOEF vide notification dated 14-02-2000. The major noise levels
will be confined to the working zones of the proposed ethanol plant.
 Ear mufflers will be provided to all employees who will enter into the noise prone areas.
4. Solid waste
 Baggase from sugar plant will be used as fuel in co-gen boiler.

 Molasses from sugar plant will used in Distillery plant.
 Yeast Sludge will be mixed with concentrated spent wash and incinerated in the
boiler.
 Ash from the boilers will be given to brick manufactures/Cement plants/ used as
manure
 Ash generated from concentrated spent wash incineration boiler will be bagged as
KASH and given to group company fertilizer units
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2.21
2.8 ASSESSMENT OF NEW & UNTESTED TECHNOLOGY FOR THE RISK OF

TECHNOLOGICAL FAILURE
Sugar manufacturing and power generation technologies are well proven all over the world.
Fermentation technology for production of ethanol with Molasses as raw materials is well proven
technology all over the world. Hence there will not be any risk of technological failure from this
plant.
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2.22
E.I.D Parry (India) Limited.
CHAPTER – 3
DESCRIPTION OF ENVIRONMENT
(BASELINE ENVIRONMENTAL STATUS)
This chapter gives an idea and description of environmental status of the study area with reference
to the prominent environmental attributes. The general study area covers 10 Km. radius of the
proposed project site. The impact identification always commences with the collection of baseline
data such as ambient air quality, ground water quality, noise levels, land environment, land use
pattern, flora & fauna and socio economic aspects with in the study zone of 10 Km. radius during
October, 2013 to December, 2013.
3.1 AIR ENVIRONMENT [TOR # 16]

3.1.1 METEOROLOGY
Meteorology of the study area plays an important role in the air pollution studies. The prevailing
micro meteorological conditions at the site will regulate the dispersion and dilution of air pollutants in
the atmosphere. The predominant wind directions and the wind speed will decide the direction and
distance of the most affected zone from the proposed expansion activity. The meteorological data
collected during the monitoring period is very useful in interpretation of baseline data as input for
dispersion models for predicting the Ground Level Concentrations (GLC).
3.1.2 METEOROLOGICAL DATA RECORDED AT SITE
A Temporary Weather Monitoring Station was installed at the site and temperature, relative
humidity, wind direction, wind speed, and rainfall were recorded for one season from October, 2013
to December, 2013.
Temperature
The maximum temperature recorded was 35.5 0C and the minimum temperature was 14.30C at the
weather monitoring station at the Plant site.
Wind Pattern at Project Site during the study period
Wind speed and direction are recorded at site every hour. The predominant winds during this
season are mostly from E direction. The wind rose diagram at site is shown in fig. 3.1.
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3.1
EIA report
3.2
3.1.3 AIR QUALITY

The ambient air quality with respect to the study zone of 10 Km. radius around the plant site forms
the baseline information. The study area represents mostly rural environment. The various sources
of air pollution in the region are vehicular traffic, dust arising from unpaved village roads. The Prime
objective of baseline air quality survey is to assess the existing air quality of the area. This will also
be useful is assessing the conformity to standards of the ambient air quality during the plant
operation.
3.1.3.1 SELECTION OF SAMPLING STATIONS

The base line status of the ambient air quality can be assessed through scientifically designed
Ambient Air Quality Monitoring Network.
The selection of sampling locations in the air quality surveillance programme is based on the
following as per CPCB guidelines
(a) Representation of Plant site.
(b) Representation of down wind direction.
(c) Representation of cross sectional distribution in the down wind direction.
(d) Representation of residential areas.
3.1.3.2 PARAMETERS MONITORED
At each Monitoring Station PM2.5, PM10, SO2, NOX & HC (methane & non-methane) are monitored.
The sampling was carried out for 2 days in a week for three months (from October, 2013 to
November, 2013) to assess the existing status of air pollution and pollution dispersion pattern over
the whole air basin of proposed project site. PM2.5, PM10, SO2, and NOX are sampled as per MOEF
guidelines.
3.1.3.3 SAMPLING & ANALYTICAL TECHNIQUES INSTRUMENTS USED FOR SAMPLING
APM 550 dust sampler is used for monitoring PM2.5, PM10, SO2 and NOx. PM10 & PM2.5 are
estimated by gravimetric method West & Gaeke method (IS –5182, part III 1969) has been adopted
for estimation of SO2, Jacob – Hochheiser method (IS –5182, part IV, 1975) has been adopted for
estimation of NOx.
Calibration
Calibration charts have been prepared for all gaseous pollutants. The Calibration is carried out
when new absorbing solutions are prepared.
6 nos. of Ambient Air Quality Monitoring Stations were established with in the study zone of the
proposed site in accordance with CPCB guidelines. The sampling locations and their distances are
shown in Table 3.1.1 and in fig 3.2 The Max., Min. and 98th percentile values for all the sampling
locations for PM10, PM2.5, SO2, NOX and HC (methane & non-methane) are shown in Table
3.1.2 to 3.1.7.
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3.3
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3.4
TABLE 3.1.1
AMBIENT AIR QUALITY MONITORING STATIONS
S.No. STATION DIRECTION DISTANCE IN KMS.
1. Existing Plant Core ---
2. Haliyal 0.6 N
3. Teganhalli 2.6 SE
4. Niralga 4.1 NW
5. Kesroli 3.1 SW
6. Khamdoli 2.6 S
TABLE 3.1.2
Sampling Location: Existing plant Sampling Period: 1st Oct, 2013 to 31st Dec,2013
Unit : g/m3
Parameter Maximum Minimum 98th percentile NAAQ Standard
PM2.5 32.5 21.6 32.4 60
PM10 49.6 38.6 49.5 100
SO2 13.9 11.5 13.9 80
NOx 18.7 15.9 18.7 80
The concentration levels of HC (Methane & Non methane) in ambient air is BDL
TABLE 3.1.3
Sampling Location: Haliyal Sampling Period: 1st Oct, 2013 to 31st Dec,2013
Unit : g/m3
PM2.5 28.9 19.5 28.9 60
PM10 46.5 36.4 46.5 100
SO2 12.5 9.6 12.4 80
NOx 14.9 10.2 14.8 80
TABLE 3.1.4
Sampling Location: Teganhalli Sampling Period: 1st Oct, 2013 to 31st Dec,2013
Unit : g/m3
PM2.5 25.6 18.5 25.6 60
PM10 41.5 31.2 41.4 100
SO2 10.5 8.9 10.4 80
NOx 13.2 9.4 13.2 80
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3.5
TABLE 3.1.5
Sampling Location: Niralga Sampling Period: 1st Oct, 2013 to 31st Dec,2013
Unit : g/m3
PM2.5 23.5 17.8 23.5 60
PM10 40.5 31.2 40.4 100
SO2 10.5 8.6 10.5 80
NOx 12.8 10.1 12.7 80
TABLE 3.1.6
Sampling Location: Kesroli Sampling Period: 1st Oct, 2013 to 31st Dec,2013
Unit : g/m3
PM2.5 24.5 18.2 24.4 60
PM10 41.2 31.8 41.1 100
SO2 12.9 9.8 12.9 80
NOx 13.2 10.3 13.2 80
TABLE 3.1.7
Sampling Location: Khamdoli Sampling Period: 1st Oct, 2013 to 31st Dec,2013
Unit : g/m3
PM2.5 23.8 16.5 23.8 60
PM10 39.8 24.1 39.7 100
SO2 10.5 8.8 10.4 80
NOx 12.2 10.3 12.2 80
The 98th percentile PM2.5 concentration recorded at the Plant site is 32.4 g /m3. The 98th
percentile PM10 concentration recorded at the Plant site is 49.5 g /m3. The 98th percentile SO2 &
NOx concentration recorded at the Plant site are 13.9 & 18.7 respectively. The concentration levels
of HC (Methane & Non methane) in ambient air are found to be below detectable level.
3.2 NOISE ENVIRONMENT [TOR # 31]

The physical description of sound concerns its loudness as a function of frequency. Noise in
general is sound, which is composed of many frequency components of various loudness
distributed over the audible frequency range. Various noise scales have been introduced to
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3.6
describe, in a single number, the response of an average human being to a complex sound made
up of various frequencies at different loudness levels. The most common and heavily favored of
those scales is the weighted decibel (dBA). This is more suitable for audible range of 20 to 20,000
Hertz. The scale has been designed to weigh various components of noise according to the
response of a human ear.
The impact of noise sources on surrounding community depends on

 Characteristics of noise sources (instantaneous, intermittent or continuous in nature). It is well
known that steady noise is not as annoying as one that is continuously varying in loudness.
 The time at which noise occurs, for example loud noise levels at night in residential areas are
not acceptable because of sleep disturbance.
 The location of the noise source, with respect to noise sensitive area, which determines the
loudness and period of noise exposure.
The environmental impact of noise can have several effects varying from Noise Induced Hearing
Loss (NIHL) to annoyance depending on loudness of Noise levels.
The environmental impact assessment of noise from the plant can be carried out by taking into
consideration of various factors: potential damage to hearing, potential physiological responses,
annoyance and general community responses.
The main objective of noise level monitoring is to assess the background noise levels in different
zones viz., industrial, commercial, residential and silence zones within the study area.
The basic studies conducted were

a. Assessment of background noise levels.
b. Identification and monitoring the major noise generating sources in the study area.
c. Impact of noise on general population in the study zone of 10 Km. radius.
3.2.1 RECONNAISSANCE
Noise levels were measured at different locations within 10 Km. radius of the plant site such as
villages, bus stands etc.
3.2.1.1 BACKGROUND NOISE
Baseline noise data has been measured at different locations using A-weighted sound pressure
level meter. The equivalent day-night noise levels in the study zone are ranging from 42.35 dBA to
57.40 dBA.
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3.7
3.2.1.2 SOURCES OF NOISE
Typical considerations in environmental noise assessment can be divided into two categories; one
is related to noise sources and the other related to potential receiver.
Two quantities are needed to describe completely the strength of the source. They are sound
power level and directivity. Sound power levels measures the total sound power radiated by the
source in all directions where as directivity is a measure of difference in radiation with direction.
This concept of sound power level and directivity index makes it possible to calculate the sound
pressure level created by the source.
3.2.2 COMMUNITY NOISE
The ambient noise level is characterized by significant variations above a base or a residual noise
level. The residual noise level is that level below which the ambient noise does not seem to drop
during a given time interval and is generally caused by the unidentified distant sources. It differs in
rural and urban areas. At night, its level is low due to lesser elements of noise. The annoyance that
people experience depends upon the number of noise elements that produce noise concurrently at
a given time that occur during a time interval.
The noise rating developed by EPA for specification of community noise from all sources is the day
night sound level, Ldn. It is similar to a 24 hour equivalent sound level except that during the night
period, which extends from 10.00 p.m. to 7.00 a.m. A 10 dBA weighing penalty is added to the
account for the fact that noise at night when people are trying to sleep is judged more annoying
than the same noise during the day time.
The Ldn for a given location in a community is calculated from an hourly equivalent sound level
given be the following equation.
Ldn =10 log (1/24 [15 (10 (Ld/10) + 9 (10(Ln+10)/10)])
Where Ld is the equivalent noise level during day time (7A .M. to 10 P.M.)
Ln is the equivalent noise level during night time (10 P.M. to 7 A.M.)
3.2.2.1 OCCUPATIONAL EXPOSURE
To assess the magnitude of impact due to noise sources, it is essential to know the following.
a. The duration of sound.
b. Distribution through the working day.
c. Overall noise levels.
d. It’s composition including frequency and intensity at various intervals of time.
Other factors regarding receiver include
a. The age of the individual.
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3.8
b. The sensitivity of the individual.

c. The efficiency of the protective devices used.
After characterizing the noise sources noise at receiver’s location, the impact must be assessed.
The environmental impact of noise can lead to the following effects.
a. Damages the hearing capacity.
b. Interference in communication.
c. Interference with work.
d. Interference with sleep.
e. Causes annoyance
METHODOLOGY ADOPTED FOR NOISE LEVEL OBSERVATION
For measurement of Ambient Noise level in the Study area, a Digital Sound Level Meter (Make &
Model: Lutron SL-4001) was used. The instrument was calibrated with a Standard Acoustic
calibrator before using in the field. The measurements were carried out continuously for the 24-
hour period to obtain hourly equivalent sound pressure level, 1 hour Leq. From these values, day
and night time as well as 24-hour Leq values were also calculated. The Leq is the equivalent
continuous sound level, which is equivalent to the same sound energy as the fluctuating sound
measured in the same period.
Guidance for assessment of representativeness and reliability of baseline environmental
attributes
Attributes Sampling Measurement Remarks
Noise Network Frequency Method
Hourly equivalent Identified study Once in each Instrument : IS:4954-1968 as
noise levels area season Noise level adopted by CPCB
meter
Hourly equivalent In plant Once Instrument : CPCB/OSHA
noise levels (1.5 metre from Noise level
machinery) meter
Hourly equivalent Highways Once in each Instrument : CPCB/IS:4954-
noise levels season Noise level 1968
meter
Peak particle 150 - 200m from Once PPV meter ---
velocity blast site
3.2.3 NOISE LEVEL OBSERVATIONS IN THE STUDY AREA
Baseline noise levels have been monitored at different locations within the study zone of the plant
site. 6 nos. of stations have been selected for measurement of noise levels and their distances
with respect to site are shown in table 3. 2.1.
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3.9
TABLE 3.2.1
S.No. STATION DISTANCE IN KMS. DIRECTION
1. Existing Plant Core ---
2. Haliyal 0.6 N
3. Teganhalli 2.6 SE
4. Niralga 4.1 NW
5. Kesroli 3.1 SW
6. Khamdoli 2.6 S
TABLE 3. 2 .2
EQUIVALENT DAY NIGHT NOISE LEVEL
S.No. LOCATION EQUIVALENT NOISE LEVELS (dBA)
DAY NIGHT DAY-NIGHT
1. Existing Plant 51 44 52.37
2. Haliyal 57 48 57.40
3. Teganhalli 43 31 42.35
4. Niralga 45 33 44.35
5. Kesroli 44 36 44.86
6 Khamdoli 46 35 45.65
3.3 WATER QUALITY IMPACTS
The water samples have to be collected and analyzed for various parameters like pH, Suspended
Solids, Total Dissolved Solids, Temperature, Total Hardness, Calcium Hardness, Magnesium
hardness, Alkalinity, Fluoride, Chloride, Sulphates, Nitrates, Chemical Oxygen Demand (COD) and
for various heavy metals and is compared with the standards to know the water quality. Selection
of sampling locations will be generally done based on the following factors:
i) Proximity of the industries to the site.
ii) Residential areas.
iii) Representation of project site.
3.3.1 SURFACE WATER QUALITY ASSESSMENT
Tattihala River is situated at a distance of 2.2 Kms. from the Plant site. Two nos. of surface water
samples were collected from upstream & downstream to assess surface water quality. These
water samples are analysed for various parameters as per IS: 2296. The surface water
characteristics were shown in table No. 3.3.1.
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3.10
TABLE 3.3.1
SURFACE WATER QUALITY December, 2013
S. NO. PARAMETER UNIT Tattihala River Tattihala River
60 m upstream 60 m downstream
PHYSICAL CHARACTERISTICS
1. Colour ----- -----
2. pH 7.1 7.4
3. Turbidity NTU 3 4
4. Electrical Conductivity ms/cm 289 275
5. Total Dissolved Solids mg/l 141 138
CHEMICAL CHARACTERISTICS
6. Total Hardness mg/l 114 108
7. Calcium Hardness mg/l 63 52
8. Magnesium Hardness mg/l 86 71
9. Alkalinity mg/l 151 167
10. Sulphates mg/l 56 66
11. Chlorides mg/l 44 36
12. Nitrates as NO3 mg/l 3.5 3.1
13. Fluoride as F mg/l 0.45 0.43
14. Sodium as Na mg/l 28 21
15. COD mg/l 3 4
16. Residual chlorine mg/l <0.01 <0.01
17. Cyanides as CN- mg/l <0.01 <0.01
18. Phenols as C6H5OH mg/l Absent Absent
19. Hexavalent chromium as Cr mg/l <0.01 <0.01
20. Iron as Fe mg/l 0.21 0.25
21. Copper as Cu mg/l <0.01 <0.01
22. Arsenic as As mg/l <0.01 <0.01
23. Selenium mg/l <0.01 <0.01
24. Cadmium as cd mg/l <0.01 <0.01
25. Boron as B mg/l <0.01 <0.01
26. Mercury as Mg mg/l <0.001 <0.001
27. Lead as Pb mg/l <0.01 <0.01
28. Silica as SiO2 mg/l 2 2.5
29. Mineral oil mg/l <0.01 <0.01
30. Total coliforms (MPN/100 ml) 31 24
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3.11
3.3.2 GROUND WATER QUALITY ASSESSMENT
6 numbers of ground water samples from open wells / bore wells were collected from the nearby
villages to assess ground water quality impacts. The ground water sampling locations and their
distances from the proposed project site were shown in table 3.3.2. The Map showing water quality
sampling stations are shown in fig. 3.3. The ground water characteristics were shown in table Nos.
3.3.3.
All the water samples collected shows that they are suitable for potable purpose.
TABLE 3. 3. 2
GROUND WATER QUALITY MONITORING STATIONS [TOR # 20]

S.No. STATION DISTANCE IN KMS. DIRECTION
G1. Existing Plant (at proposed Core ---
Spent Wash storage lagoon)
G2. Haliyal 0.6 N
G3. Teganhalli 2.6 SE
G4. Niralga 4.1 NW
G5. Kesroli 3.1 SW
G6. Khamdoli 2.6 S
EIA report
3.12
EIA report
3.13
TABLE 3.3.3
GROUND WATER QUALITY ANALYSIS
Month: December, 2013

Standard as Sampling Locations
S.No Parameter per BIS:
G1 G2 G3 G4 G5 G6
10500
1. Colour (Hazen) 5 / 25* <5 <5 <5 <5 <5 <5
2. Odour U/O U/O U/O U/O U/O U/O U/O
3. Taste Agreeable AG AG AG AG AG AG
4. Turbidity (NTU) 5/10* 2 3 2 3 2 3
5. pH Value 6.5-8.5 7.8 7.2 7.4 7.0 7.8 8.0
6. Total Hardness (as CaCO3), mg/l 300/600* 178 201 166 176 196 224
7. Iron (as Fe), mg/l 0.3/1.0* 0.2 0.1 0.1 0.2 0.1 0.1
8. Chloride (as Cl), mg/l 250/1000* 106 122 141 115 135 126
9. Residual, free Chlorine, mg/l 0.2 ND ND ND ND ND ND
10. Dissolved Solids, mg/l 500/2000* 311 355 406 295 334 206
11. Calcium (as CaCO3), mg/l 75/200* 54 43 72 66 49 56
12. Magnesium (as CaCO3), mg/l 30/100* 16 24 33 21 30 18
13. Copper (as Cu), mg/l 0.05/1.5* BDL BDL BDL BDL BDL BDL
14. Manganese (as Mn), mg/l 0.1/0.3* BDL BDL BDL BDL BDL BDL
15. Sulphates (as SO4), mg/l 200 65 88 94 75 103 59
16. Nitrate (as NO3), mg/l 45 5.0 6.5 5.8 4.5 3.5 6.0
17. Fluoride (as F), mg/l 1.0/1.5* 0.45 0.58 0.51 0.49 0.62 0.55
Phenolic Compounds
18. 0.001/0.002* BDL BDL BDL BDL BDL BDL
(as C6H5OH), mg/l
19. Mercury (as Hg), mg/l 0.001 BDL BDL BDL BDL BDL BDL
20. Cadmium (as Cd), mg/l 0.01 BDL BDL BDL BDL BDL BDL
21. Selenium (as Se), mg/l 0.01 BDL BDL BDL BDL BDL BDL
22. Arsenic (as As), mg/l 0.05 BDL BDL BDL BDL BDL BDL
EIA report
3.14
23. Cyanide (as CN), mg/l 0.05 BDL BDL BDL BDL BDL BDL
24. Lead (as Pb), mg/l 0.05 BDL BDL BDL BDL BDL BDL
25. Zinc (as Zn), mg/l 5/15* BDL BDL BDL BDL BDL BDL
26. Chromium (as Cr+6), mg/l 0.05 BDL BDL BDL BDL BDL BDL
27. Mineral Oil, mg/l 0.01/0.03* ND ND ND ND ND ND
28. Alkalinity , mg/l 200/600* 155 184 209 156 177 196
29. Aluminium as Al, mg/l 0.03/0.2* BDL BDL BDL BDL BDL BDL
30. Boron mg/l 1/5* BDL BDL BDL BDL BDL BDL
31. E. Coli , MPN/100ml Absent Absent Absent Absent Absent Absent Absent
32. Total Coliform, MPN/100ml 10 Absent Absent Absent Absent Absent Absent
* Permissible limits in the absence of alternate source.
CL – Colorless, U/O – Unobjectionable, AG – Agreeable, ND – Not detectable

BDL Values: Cadmium- 0.001 mg/l, Mercury- 0.0001 mg/l, Arsenic- 0.001 mg/l, Zinc- 0.005 mg/l, Copper – 0.01 mg/l , Cyanide- 0.001 mg/l,
Cr+6- 0.001 mg/l, , Selenium- 0.001 mg/l. Al-0.001 mg/l.
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3.15
3.3.3 HYDROLOGY GEOLOGY OF THE AREA
Major Water Bearing Formations

Shallow aquifers of alluvium along the stream courses, sea coast, creeks, weathered zones
of schists, metasedimentaries and metavolcanics occurring between the depths of 3 to 20
mbgl
Deeper aquifers of fractured and jointed Schists, gneisses and metavolacanics and meta
sedimentaries up to 200 mbgl.
DRAINAGE
The important rivers in the district are Sharavathi, Kali, Aghanashini, and Gangavali. All these
rivers flowing in westerly direction to Join Arabian sea. All the rivers in the district together
with their tributaries exhibit dendritic drainage pattern.
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3.16
3.4 LAND ENVIRONMENT

3.4.1 LAND USE PATTERN [TOR # 4]
The following is the land use pattern within 10 Km radius of the project:
Sl. No. LAND USE AREA (Sq. km) %
1. BUILT- UP LAND
A. Settlements 9.734 3.1
B. Industrial area 2.512 0.8
2. WATERBODIES
A. Tank, River etc. 21.038 6.7
3. FOREST
A. Scrub forest 74.104 23.6
4. CROP LAND
A. Single crop 157.628 50.2
5. WASTELANDS
A. Land with scrub 22.294 7.1
B. Land without scrub 13.816 4.4
C. Stony waste area 12.874 4.1
TOTAL 314 100
Please refer to ANNEXURE – IV for Land use & Land Cover map & satellite Imagery of the
Study area.
3.4.2 MINERAL RESERVES
There are no mineral reserves in the study area.
3.4.3 SEISMIC EFFECT
The project site falls in zone-II of seismic zone classification of India.
3.4.4 SOIL
6 nos. of soil samples were collected and for analyzed for various parameters like texture,
infiltration rate, bulk density, pH, Ca, Mg, Na, K, Zn, Mn etc. The soil sampling locations and
their distances from the plant were shown in table 3.4.1. The soil quality sampling stations are
shown in fig. 3.4. The soil characteristics were shown in table Nos. 3.4.2.
EIA report
3.17
TABLE 3.4.1
SOIL QUALITY SAMPLING STATIONS
GROUND WATER QUALITY MONITORING STATIONS
S.NO STATION DISTANCE IN DIRECTION
KMS.
S1 Existing Plant (at proposed Core ---
Spent Wash storage lagoon)
S2 Haliyal 0.6 N
S3 Teganhalli 2.6 SE
S4 Niralga 4.1 NW
S5 Kesroli 3.1 SW
S6 Khamdoli 2.6 S
EIA report
3.18
EIA report
3.19
TABLE 3.4.2
SOIL CHARACTERISTICS
Sampling locations Month: December, 2013
S.No. Parameter Unit
S1 S2 S3 S4 S5 S6
1 Bulk Density g/cc 1.8 1.6 1.5 1.6 1.8 1.7
2 Infiltration rate cm/sec 1.5 1.4 1.1 1.2 1.6 1.5
3 pH 7.0 7.8 7.5 7.3 7.2 7.4
Soil type Clay Loamy Loamy Black cotton Clay Loamy
4
Loamy soil Loamy
5 Calcium mg/Kg 804 864 913 755 1025 675
6 Electrical Conductivity µS/cm 95 88 115 121 92 78
7 Nitrogen Kg/Ha 231 215 244 214 235 205
8 Potash Kg/Ha 44 54 47 61 55 68
9 Available Phosphorous as P2 O5 Kg/Ha 18 24 20 34 28 24
10 Mn mg/100 gm BDL BDL BDL BDL BDL BDL
11 Zn mg/100 gm BDL BDL BDL BDL BDL BDL
12 Pb mg/100 gm BDL BDL BDL BDL BDL BDL
EIA report
3.20
3.5 BIOLOGICAL ENVIRONMENT
Kindly refer to Annexure - V for list of Flora and Fauna in the study area
3.6 SOCIO – ECONOMIC ASPECTS
A detailed survey was conducted to assess socio – economic aspects of the region. The data
collected from the census book include demographic details, infrastructural facilities, agricultural
status etc.
The study area covers within a radius of 10 km from the proposed Plant site. The 10 km radius
study area around the project site comprises of 50 villages. The socio-economic profile of the
study area is presented based on site visits; discussions with the villagers and the secondary
data available from various agencies such as Hand Books for Census 2011.
Socio economic details of the study area are enclosed in Annexure - VI
EIA report
3.21
CHAPTER – 4
ANTICIPATED ENVIRONMENTAL IMPACTS
&
MITIGATION MEASURES
4.0 INTRODUCTION
Impact prediction is a very important phenomenon in evaluating the environmentally potential
adverse impacts for any proposed industrial activities. The impact prediction is always carried out
under worst possible conditions so as to mitigate or to eliminate the environmental hazards. These
predictions thus calculated are superimposed over the baseline data to know the quality of
environment in the vicinity of the project site so as to calculate the net impact on the environment
after the project comes into production.
4.1 AIR ENVIRONMENT

Prediction of impacts is the most important component in the Environmental Impact Assessment
studies. Several scientific techniques and methodologies are available to predict impacts of
developmental activities on physico, ecological and socioeconomic environments. Such predictions
are superimposed over the baseline (pre project) status of environmental quality to derive the
ultimate (post project) scenario of environmental conditions. The prediction of impacts helps to
identify the environmental management plan required to be executed during and after commissioning
the proposed plant to minimize the adverse impacts on environmental quality.
The mathematical models are the best tools to quantitatively describe cause-effect relationships
between sources of pollution and different components of environment. In case, mathematical
models are not available or it is not possible to identify / validate through models for particular
situation, prediction could be arrived at through available scientific knowledge and judgments.
The mathematical model used for predictions in the present study include, steady state Gaussian
Plume dispersion model designed for multiple point sources for air quality, Wave divergence and
Federal Highway Administration (FHWA) models for noise levels. In case of water, land, biological
and socio-economic environments the prediction have been made based on available scientific
knowledge and judgments.
EIA report
4.1
4.1.1 IMPACT ON TOPOGRAPHY AND CLIMATE

4.1.1.1 IMPACT ON TOPOGRAPHY
The major envisaged topographical changes would be limited to the immediate vicinity of the plant.
The change in topography will be only due to man made structures like Industrial complex and
Administrative building. Similarly, it will invite positive benefits in the form of land leveling and green
belt development in the plant vicinity.
4.1.1.2 IMPACTS ON CLIMATE

As the temperature of the effluent gases will not be high, generally this will not cause any thermal
imbalance as extensive greenbelt will be developed within the plant premises. However, there will be
natural dispersion of heat due to unstable conditions during day and as such there would be no
significant micro / macro climatological changes of any consequence.
4.1.2 PREDICTION OF IMPACTS ON AIR ENVIRONMENT [TOR # 17]

It is absolutely essential to study the impacts of air pollution on its environs due to the proposed
Plant. These impacts are assessed with the help of Mathematical model based on steady state
Gaussian Plume Dispersion Model designed for multiple point sources for short term. In the present
case, Industrial Source Complex Short Term (ISCST-3), 1993 dispersion model based on steady
state Gaussian plume dispersion, designed for multiple point sources for short term developed by
United States Environment Protection Agency (USEPA) has been used for simulations from point
sources.
Model Input
Emissions
Emissions from co-gen boilers (existing & expansion) and Spent wash fired Distillery have also been
considered. The emission data from the stacks is shown in Table 4.1.1
Receptor Locations
The software is capable of generating a polar receptor grid at every 10 radial angles at specified
distances (in Kms).
Meteorological data
For the prediction of rise in Ground Level concentrations of pollutants, the actual hourly
meteorological data recorded at the site during the study period (October, 2013 –December, 2013) is
converted to mean meteorological hourly data as specified by CPCB and the same is used in the
model. In the absence of site specific mixing heights, mixing heights published in ‘Spatial distribution
of hourly mixing depths over Indian region’ by Dr. R.N.Gupta have been used.
EIA report
4.2
Presentation of results
In the present case model simulations have been carried out for the pre summer season. For the
short term simulations, the concentrations have been estimated around 1600 receptors to obtain
optimum description of variations in concentrations over the site in 10 Km. radius covering 16
directions.
Model Output
The output contains the first through sixth highest concentration values at each receptor, Maximum
concentration tables and daily concentration tables for each averaging period.
The calculations for stack height, ash generation quantity have been done considering the above
scenarios to represent the worst scenarios. The expected emissions from the proposed boilers are
PM, SO2, NOX. [TOR # 7]

The stacks height is calculated as per CPCB guidelines with the following formulae:
I. STACK HEIGHT CALCULATION FOR 45 TPH BOILER

(A) 100% Bagasse
a. STACK HEIGHT BASED ON SO2 EMISSION

There will not be any sulphur content in bagasse. Hence there will not be any SO 2 emission. Hence a
minimum stack height of 30 m is required. Coal use is not envisaged in this boiler. Hence, stack
height based on coal as fuel is not calculated.
b. STACK HEIGHT BASED ON PARTICULATE EMISSION

Stack height will also be calculated based on the following equation.
Stack height H = 74 (Q)0.27
Where H = Stack height in meters
Q = Quantity of particulate matter in Tonnes / Hour
Q = 22 TPH x 6.5 = 0.143 TPH
Stack height based on particulate matter
Stack height H= 74 (0.143) 0.27 = 43.76 m
Hence a stack height of 44 m will be provided for effective dispersion of particulate matter.
II. STACK HEIGHT CALCULATION FOR 15 TPH BOILER:

Concentrated Spent wash:
Concentrated Spent wash consumption : 4,500 Kg/Hr
Sulphur content in Concentrated spent wash : 0.56%
SO2 emission (Q) : 50.4 Kg/hr
EIA report
4.3
Stack height : 14(Q)0.3

: 14(50.4)0.3
: 45.4 m
b. STACK HEIGHT BASED ON PARTICULATE EMISSION
Stack height will also be calculated based on the following equation.

Stack height H = 74 (Q)0.27
Where H = Stack height in meters
Q = Quantity of particulate matter in Tonnes/Hour.
Q = 2.5 TPH x 5% = 0.125 TPH
Stack height based on particulate matter

Stack height H = 74 (0.13) 0.27 = 42.7 m
Hence a stack of 46 m is adequate for effective dispersion of emissions into the atmosphere.
However a stack of 50 m height will be provided.
High efficiency Electro static precipitators (ESP) will be provided to 45 TPH Boiler & Bag filter for the
15 TPH spent wash fired incineration boiler for effectively bringing down the Particulate Matter
concentration to less than 50 mg/nm3 to comply with MoEF / KSPCB Norms. The boiler and the ESP
will be interlocked in such a way that in case the ESP fails, the raw material feed to the boiler will stop
and consequently there will be no power generation in the plant. The following are the boiler stacks
details of the proposed expansion project.
TABLE 4.1.1
BOILER STACK DETAILS [TOR # 7]
Units 120 TPH Boiler 45 TPH Boiler 10 TPH Boiler 15 TPH
Item Existing Proposed Existing boiler
proposed
Number of stacks 1 1 1 1
Height of the stack m 72 44 50 50
Internal stack dia at top m 2.8 1.8 1.2 1.3
3
Volumetric flow rate m /sec 92.4 38.2 12.5 16.67
Exit velocity of flue gas m/sec 15 15 11 12.57
Temperature of flue o 95 150 95 95
C
gas
PM emission g/s 3.9 1.4 0.5 0.7
SO2 emission g/s 48.6 9.8 9.4 14.0
NOx emission g/s 39.0 14.0 5.0 7.0
The emissions of concern are Particulate Matter (PM), Sulphurdioxide (SO2) and Nitrogen oxides
(NOx). A stack height of 50 m is proposed for the new 15 TPH boiler in Distillery and stack height of
44 m will be provided to the 45 TPH boiler as per CPCB guidelines for effective dispersion of sulphur
dioxide emissions into the atmosphere. High efficiency Electro static precipitators (ESP) will be
EIA report
4.4
provided to 45 TPH Boiler and Bag filter for 15 TPH Spent wash incineration Boiler for effectively
bringing down the Particulate Matter concentration to less than 50 mg/Nm3 to comply with CREP
recommendations. The boiler and the ESP will be interlocked in such a way that in case the ESP
fails, the raw material feed to the boiler will stop and consequently there will be no power generation
in the plant.
INCREMENTAL GLC`s DUE TO THE PROPOSED EXPANSION PROJECT
The max predicted incremental rise in SO 2 concentrations (24 hourly) will be 12 g/m3 at a distance of
900 m from the origin stack in the down wind direction over the baseline concentrations.
The max predicted incremental rise in PM10 concentrations (24 hourly) will be 0.8 g/m3 at a distance
of 900 m from the origin stack in the down wind direction over the baseline concentrations.
The max predicted incremental rise in NO X concentrations (24 hourly) will be 7.9 g/m3 at a distance
of 900 m from the origin stack in the down wind direction over the baseline concentrations.
The net resultant concentrations (Maximum baseline conc. + predicted incremental rise in conc.) of
PM10, SO2 and NOX are shown in Table No. 4.1.2. The net resultant concentrations of PM10, SO2 and
NOX during the operation of the existing and expansion project are well within the revised National
Ambient Air Quality Standards (NAAQS) stipulated by MOEF vide notification dated 16-11-2009.
Hence there will not be any adverse impact on air environment due to the proposed expansion
project.
TABLE 4.1.2
NET RESULTANT MAXIMUM CONCENTRATIONS DUE TO THE EXPANSION PROJECT
Item PM10 SO2 NOX

(µg/m3) (µg/m3) (µg/m3)
Maximum baseline concentration in the study area 49.6 13.9 18.7
Maximum predicted incremental rise in concentration
0.8 12.0 7.9
due to existing and proposed expansion project
Net Resultant concentration 50.4 25.9 26.6
Revised National Ambient Air Quality Standards 100 80 80
4.2 PREDICTION OF IMPACTS ON WATER ENVIRONMENT
4.2.1 WATER REQUIREMENT [TOR # 21, 22 & 23]

The total water requirement for existing integrated complex will be 3157 cum/day. After proposed
expansion water requirement will be 4316. This includes Process water, CT make up, DM Water for
Boiler & ENA plant, DM Plant regeneration waste water and for Domestic requirement. The water
required is being drawn from Kali river which is situated at 23 Kms. from the plant through dedicated
EIA report
4.5
pipeline. For the proposed expansion water required will be met from Kali river. Water permission for
drawing water Kali River has already been obtained from Irrigation department, Govt. of Karnataka
and copy of the same is enclosed as ANNEXURE - VI. The break of water requirement shown in
Table 4.2.1 and 4.2.2
TABLE 4.2.1
WATER REQUIREMENT FOR SUGAR & CO-GEN POWER PLANT [TOR # 7]

WATER CONSUMPTION (in KLD)
Sugar Co-gen
Section Total after
Existing Expansion Existing Expansion expansion
(4800 TCD) (1200 TCD) (24 MW) (10 MW)
a)Domestic 10 -- 10 5 25
b)Industrial purpose
1.Process water 72 -- -- -- 72
2.Boiler feed 288 140 428
3.DM plant
172 84 256
regeneration
4.Cooling water make
1700 0 1700
up
5.Service water 10 5 15
Total 82 -- 2180 234 2496
TABLE 4.2.2
WATER REQUIREMENT FOR DISTILLERY PLANT [TOR # 7]
Water requirement
SECTION Expansion Total
Existing ( 45 KLPD Distillery
( 45 KLPD Distillery)
with 3 MW Power)
Process water 420 420 840
Make up water for Boiler 15 40 55
DM water for R.S dilution 145 145 290
Cooling tower make up 210 210 420
DM plant regeneration 95 110 205
Domestic 10 -- 10
Total 895 925 1820
Water requirement for Sugar (Existing) : 82 KLD
Water requirement for Sugar (Expansion) : 0 KLD
Water requirement for Co-gen power (existing) : 2180 KLD
Water requirement for Co-gen power (expansion) : 234 KLD
Water requirement for Distillery (existing) : 895 KLD
Water requirement for Distillery (expansion) : 925 KLD
Total water requirement after proposed expansion will be : 4316 cum/day
Total water recycled : 1155 cum/day
Net water requirement : 3161 cum/day
EIA report
4.6
4.2.2 WASTE WATER GENERATION
Waste water generation from the existing Integrated Sugar Plant 1363 KLD. Waste water generation
from the proposed expansion of Integrated Sugar Plant will be 806 KLD. Hence total waste water
generation after proposed expansion will be 2169 KLD. Waste water generation mainly includes,
effluent from Sugar plant, Boiler blowdown, cooling tower blowdown, DM plant regeneration, Spent
wash from Distillery. The waste water generation breakup is shown in Table 4.2.3 and 4.2.4. The
characteristics of different effluent streams are presented in Tables 4.2.5 to 4.2.9.
TABLE 4.2.3
WASTE WATER GENERATION FROM SUGAR & CO-GEN POWER PLANT [TOR # 7]
SECTION SUGAR CO-GEN Total after
Existing Expansion Existing Expansion proposed
(4800 TCD) (1200 TCD) (24 MW) (10 MW) expansion
a)Domestic 8 8 4 20
b)Industrial purpose
1.
Process &
472 112 -- -- 584
Washings
2.
Boiler Blow down -- -- 15 9 24
3.
DM plant
-- -- 172 84 256
regeneration
4.
Cooling tower
-- -- 100 0 100
blow down
5.
Service water -- -- 10 5 15
Total 480 112 305 102 999
TABLE 4.2.4
WASTE WATER GENERATION FROM DISTILLERY PLANT [TOR # 7]
Waste Water generation
SECTION Expansion
Existing
( 45 KLPD Distillery)
( 45 KLPD Distillery with 3 Total
MW Power)
Spent wash generation 450 450 900
Boiler blow down 5 12 17
Cooling tower blowdown 20 20 40
DM plant regeneration 95 110 205
Domestic 8 0 8
Total 578 592 1170
Waste water generation from Sugar (Existing) : 480

Waste water generation from Sugar (Expansion) : 112
Waste water generation from Co-gen power (existing) : 305
Waste water generation from Co-gen power (expansion) : 102
Waste water generation from Distillery (existing) : 578
Waste water generation from Distillery (expansion) : 592
EIA report
4.7
TABLE 4.2.5
CHARACTERISTICS OF SPENT WASH
S.No. PARAMETER CHARACTERISTICS OF
SPENT WASH
1. pH 4.2 – 4.8
2. Total Dissolved Solids(mg/l) 80,000-1,00,000
3. COD(mg/l) 70,000–1,20,000
4. BOD(mg/l) 45,000 – 55,000
TABLE 4.2.6
CHARACTERISTICS OF SANITARY WASTE WATER(UNTREATED)
PARAMETER CONCENTRATION
pH 7.0 – 8.5
BOD 200 – 250 mg/l
COD 300 – 400 mg/l
TDS 800 – 900 mg/l
TABLE 4.2.7
CHARACTERISTICS OF COOLING TOWER BLOWDOWN
pH 7.0 – 8.5
TDS 2000 mg/l
TABLE 4.2.8
CHARACTERISTICS OF BOILER BLOWDOWN
pH 9.5 – 10.0
TDS 100 mg/l
TABLE 4.2.9
CHARACTERISTICS OF DM REGENERATION
pH 6–9
TDS 2000 – 2500 mg/l
EIA report
4.8
4.3 PREDICTION OF IMPACTS DUE TO NOISE

4.3.1 PREDICTION OF IMPACT DUE TO THE PROPOSED EXPANSION ACTIVITY
The sound pressure level generated by noise source decreases with increasing distance from the
source due to wave divergence. An additional decrease in sound pressure level with distance from
the source is expected, due to atmospheric effect or its interaction with objects in the path of
transmission. For hemispherical sound wave propagation through homogeneous loss free medium,
one can estimate noise levels at various locations, due to different sources using model based on
first principle, as per the following equation:
Lp2 = Lp1 – 20 Log (r2/r1) - Ael.2
Where Lp1 and Lp2 are sound pressure levels at points located at distance r1 and r2 from the source
and Ae1.2 is the excess attenuation due to environmental conditions. Combined effect of all the
sources then can be determined at various locations by logarithmic addition.
It is first approximation one can assume that for all general population in the villages, every noise
source in the plane is a point source. The average equivalent sound power level of such a point
source can be estimated for different distances and directions from hypothetical source by applying
following equation:
Lp = Lw - 20 Log r – Ae – 8
Where Lw is the sound power level of the source, Lp is sound pressure level at a distance r and Ae is
environmental attenuation factor. A combined noise level Lp (total) of all the sources at a particular
place is given by:
Lp (total) = 10 Log (10Lp1/10) + 10 (Lp2/10) + ---------)
Major noise generating sources were identified from the proposed activity for prediction purposes.
The major noise generating sources are STGs, Boiler, compressors. Predictions have been made to
represent the worst case. The noise levels at various distances were calculated using wave
divergence model.
The Ambient Noise levels will be within the standards prescribed by MOE&F, GOI vide Notification
dated 14-02-2000 under the Noise pollution (regulation & control) Rules, 2000. The ambient noise
levels will be less than 75dBA during day time & less than 70dBA during night time.
4.3.2 PREDICTION OF IMPACTS ON COMMUNITY
Day and Night sound pressure levels, Ldn are often used to describe the community noise exposure,
which include 10 dBA night time penalty. As the nearest habitation is at a distance of 0.6 Km. from
the Plant site, the impact of noise on general population would be insignificant.
EIA report
4.9
As per the WHO recommendation, there is no identified risk and damage of hearing due to the noise
levels (Leq = 8 hours) less than 75 dBA. Most of the international damage risk criteria for hearing loss
permit (Leq = 12 hours) upto 87 dBA. Further, WHO recommendation on community noise
annoyance, permits day time out door noise levels of 55 dBA. Leq and night time outdoor noise level
of 45 dBA leq to meet sleep criteria i.e. Leq (24 hours) = 52.2. dBA and Ldn = 5.5 dBA.
4.3.3 PREDICTION OF IMPACT ON OCCUPATIONAL HEALTH
The damage risk criteria as enforced by OSHA (Occupation Safety and Health Administration) to
reduce hearing loss, stipulates that noise level upto 85 dBA are acceptable for 8 hour working shift
per day. Plant authorities will provide ear plugs to the employees and will be enforced to be used by
the employees.
4.4 PREDICTION OF IMPACTS ON LAND ENVIRONMENT
Total 226 acres of land is in the possession of the management. The treated effluent from the sugar
and Co-generation power plant is being utilized for on land for irrigation within the premises after
ensuring compliance with CPCB / KSPCB norms. Similar practice will be followed after proposed
expansion. Spent wash generated from the distillery is being treated in Multiple Effect Evaporators
(MEE) to concentrate the solid to 60% and being used as fuel for incineration boiler. Similar practice
will be followed after proposed expansion. Hence zero discharge will be implemented for Sugar , Co-
gen and Distillery units as per CPCB norms.
The treated non process effluent from the distillery and Co-generation power plants is being utilized
for dust suppression, ash conditioning and for Dust suppression, Ash Conditioning, Bagasse wetting
Greenbelt development / R&D sugar plantation etc, after ensuring compliance with CPCB/KSPCB
norms.
As there are no rare and endangered species in the vicinity of the proposed activity, there will not be
any concern for the loss of important germ plasm that needs conservation.
Greenbelt already developed in the plant premises will aid in mitigating the air emissions and noise
generation. Hence there will not be any adverse impact on land environment due to proposed
expansion Integrated Sugar Complex
4.5 PREDICTION OF IMPACTS DUE TO VEHICULAR MOVEMENT [TOR # 32]

Total no. of trucks required for transportation of raw materials and products after proposed expansion
will be 370 per day. The trucks carrying coal and sugar will be covered, molasses and ethanol will be
transported in tankers hence there will not be any fugitive dust generation during transportation of
raw materials and trucks. Pucca road exist upto the site. The existing road (Haliyal to Yallapur) is
EIA report
4.10
capable of absorbing this additional truck movement. Hence there will not be any adverse impact on
vehicular traffic due to the proposed expansion project.
In the plant premises total 5 acres land has been earmarked for parking trucks.
4.5 PREDCTION OF IMPACTS ON BIOLOGICAL ENVIRONMENT
The effluent from sugar plant will treated in Effluent treatment plant and after ensuring compliance
with KSPCB norms, the treated effluent will be utilized for on land for irrigation. Cooling tower
blowdown and DM plant regeneration water will be recycled into process. Boiler blowdown and
service water effluent will be treated in neutralization tank and treated effluent is will be utilized
for greenbelt development / ash conditioning / dust suppression in the plant premises after ensuring
quality of treated effluent with standards stipulated for onland for irrigation by CPCB / KSPCB. The
spent wash generated from the distillery will be treated in Multiple Effect Evaporators (MEE) to
concentrate the solids to 60% and then will be sent to a boiler for incineration. Hence zero discharge
will be implemented in the plant as per CPCB norms. The treated non process effluent will be utilized
for dust suppression, ash conditioning and for on land for after ensuring compliance with CPCB /
KSPCB norms. The proposed spent wash treatment technology is approved by CPCB.
The flue gases from the 45 TPH and 10 and 15 TPH Boilers will be treated in ESP and Bag filter
respectively and discharged through a stack height of 44 m and 50m respectively as per CPCB
guidelines for effective dispersion of sulphur dioxide emissions into the atmosphere. The particulate
matter in the exhaust gas will be less than 50 mg/Nm3. There are no rare & endangered species in
the study area. All the required emission control systems will be installed and operated to comply
with MoEF / CPCB / KSPCB norms. Hence there will not be any adverse impact on flora & fauna due
to the proposed expansion project.
4.6 PREDCTION OF IMPACTS ON SOCIO ECONOMIC ENVIRONMENT
The project creates employment to about 50 persons once the plant is commissioned and for 250
persons during construction stage. Priority will be given to local people for employment of Unskilled
and semi skilled workers.
E.I.D Parry is very much committed in taking up socio economic developmental activities in the profits
earned. Already many developmental activities have been initiated in the surrounding villages and
are being implemented in true spirit. Similarly after proposed expansion also, developmental activities
will be taken up as per the need based and in consultation with village heads.
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4.11
E.I.D PARRY (INDIA) LIMITED.
CHAPTER – 5
ANALYSIS OF ALTERNATIVES
(TECHNOLOGY & SITE)
5.1 ALTERNATIVE TECHNOLOGIES
Technology for producing Sugar, Combustion technology for Electricity, Fermentation technology for
production of Alcohol is well proven technology over a few decades all over the world. Hence no
alternative technologies are considered.
5.2 ALTERNATIVE SITES EXAMINED FOR SETTING UP PROPOSED EXPANSION

PROJECT
The proposed expansion plant will be taken up in the existing plant premises. Hence no alternative
sites are considered.
E.I.D Parry (India) Limited is an operating Integrated Sugar Complex at Hullatti and Alloli Village,
Haliyal Taluk, Uttara Kannada District, Karnataka. 226 Acres of land is in the possession of the
management. Now it has been proposed to expand the existing sugar plant by increasing sugar
plant capacity from 4800 TCD to 6000 TCD, Cogeneration Power plant from 24 MW to 34 MW and
an Ethanol plant from 45 KLD to 90 KLD along with 3 MW Power which will be established in the
existing sugar plant premises. The following are the salient features of the plant site.
 The Plant area does not fall under the industrial areas / cluster, which are listed in MoEF
office memorandum dated 13th January 2010.
 Nearest Habitation is Haliyal village at a distance of 0.6 Kms. from the plant.
 There are no National Parks / Wild life Sanctuaries within 10 Km radius of the plant.
 A few Unnamed Reserve forests are present within 10 Km. of the plant.
 Tattihala River is flowing at a distance of 2.2 Kms. from the plant.
 No Historical places and Places of Tourist importance within 10km. radius of the site.
Based on the above the existing plant has been selected for proposed expansion project. The site is
in accordance with the MoEF guidelines.
EIA report
5.1
CHAPTER – 6
ENVIRONMENTAL MONITORING PROGRAM
6.1 TECHNICAL ASPECTS

6.1.1 METHODOLOGIES
To know the effectiveness of environmental mitigation measures post project environmental

monitoring program will be strictly followed as per statutory requirement.
 Always particulate matter in the exhaust gas of 10 (existing) + 15 TPH (proposed)
Incineration boiler will be maintained below 50 mg/Nm3.
 Always particulate matter in the exhaust gas of 45 TPH Co-gen boiler will be maintained
below 50 mg/Nm3.
 Energy meters will be provided to all air pollution control systems to ensure effective
operation of the control systems.
 Zero effluent discharge will always be maintained to comply with CREP recommendations.
 All pollution control systems will be taken-up for maintenance as per prescribed dates and
always ensure compliance with norms.
 KSPCB will also carry out stack monitoring, ambient air quality & Effluent analysis at
regular intervals. This will also help in cross checking the performance of Pollution control
systems implemented in the plant.
6.1.2 FREQUENCY & LOCATIONS OF ENVIRONMENTAL MONITORING
A comprehensive monitoring program is given under. This environmental monitoring will be

entrusted to a third party.
MONITORING SCHEDULE FOR ENVIRONMENTAL PARAMETERS

S.NO PARTICULERS FREQUENCY OF DURATION OF PARAMETERS
MONITORING SAMPLING REQUIRED TO BE
MONITORED
1.WATER QUALITY
Water and waste water
Quality Once in a month Composite pH, EC,TDS, BOD, COD,
a. Sanitary Effluents sampling Cl, SS, Sulphates
/Industrial Effluents.
b. Ground water
Quality (Peizometric wells As per BIS: 10500
will be located around spent Once in a month Grab sampling
wash storage area, ETP )
2. AIR QUALITY
A. Stack Monitoring
15 TPH Incineration Boiler Once in a month PM
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6.1
45 TPH Co-gen boiler Online monitors PM
Once in a month SO2 & NOx.

B. Ambient Air quality Twice a week 24 hours PM10, PM2.5, SO2 & NOx
continuously
C. Fugitive emissions Once in a Month 8 hours SPM
3. METEOROLOGICAL DATA
Meteorological data to be Daily Continuous Temperature, Relative
monitored at the plant. monitoring Humidity, rainfall, wind
direction & wind speed.
4. NOISE LEVEL MONITORING
Ambient Noise levels Twice in a year Continuous for Noise Levels
24 hours with 1
hr. interval
6.1.3 DATA ANALYSIS
All the parameters will be analysed as per IS procedures specified for those parameters. All water
samples will be analysed for various parameters as per IS: 10500 with the specified procedures.
The methodology adopted for monitoring & analysis of PM10 & PM2.5 is as per IS: 5182 Part IV SO2
& NOx as per IS: 5182 Part II & Part VI respectively. Samples were analysed for SO 2 using
improved West-Geake method for air samples using a spectrophotometer at a wavelength of 560
nm.
Samples were analysed for NO x using Jacob and Hocheiser modified (Na-As) method, for Air
samples using a spectrophotometer at wavelength of 540 nm.
PM10 & PM2.5 in ambient air are found by using Respirable Dust Sampler (RDS) & APM-550.
6.1.4 REPORTING SCHEDULE
After completion of analysis, a copy of all the analysis reports will be sent to the Ministry of
Environment & KSPCB on regular basis. Copy of the reports will be maintained in the plant and will
be made available to the concerned inspecting authorities.
6.1.5 EMERGENCY PROCEDURES
The plant along with Boiler, turbine will be shut down as per the procedure to have least
environmental impact.
6.1.6 DETAILED BUDGET & PROCUREMENT SCHEDULES
A third party will be engaged to monitor all the environmental parameters as per CPCB / KSPCB
norms.
The annual budgetary allocation for environmental monitoring : Rs. 10 Lakhs.
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6.2
EID PARRY (INDIA) LIMITED.
CHAPTER – 7
ADDITIONAL STUDIES
RISK ASSESSMENT AND DISASTER MANAGEMENT PLAN
7.1 INTRODUCTION [TOR # 35]

Risk analysis deals with the identification and quantification of risks, the plant equivalent and
personnel are exposed to, due to accidents resulting from the hazards present in the factory. Hazard
analysis involves the identification and quantification of the various hazards (unsafe conditions)
Involved in the factory.
Both hazard and risk analysis very extensive studies, and require a very detailed design and
engineering information.
The various hazard analysis techniques that may be applied are Hazard and Operability (HAZOP)
studies, Fault – Tree Analysis (FTA), event –tree analysis and failure and effects mode analysis.
Risk analysis follows an extensive hazard analysis. It involves the identification and assessment of
risks the neighbouring populations are exposed to as result of hazard present. This requires a
through knowledge of failure probability, credible accident scenario, vulnerability of populations etc.,
much of this information is difficult to get or generate. Consequently, the risk analysis is often
confined to maximum creditable accident studies.
7.2 SCOPE OF THE STUDY
The scope of study includes the study of proposed operations, storage and handling of raw materials
with respect to Hazard Identification. Risk Assessment and preparation of Disaster Management
plan. Based on the Hazard Identification and analysis, the major disaster scenarios would be worked
out to estimate the consequence of failure. A Disaster Management Plan (DMP) would also be
evolved to meet the emergency situation including the occupational health and safety.
7. 3 STORAGE TANKS [TOR # 36]

Details of tank farms are shown in Table 7.1
EIA report
7.1
TABLE - 7.1
Details of the Tank farms (after expansion)
Description of the Tank Tank Capacity No. of Tanks Total capacity
(m3) (m3)
ENA Daily Receivers 50 4 200
RS daily receiver 50 4 200
Ethanol Receiver 50 4 200
ENA Bulk Storage 400 10 4000
RS Bulk Storage 400 2 800
Ethanol Bulk Storage 400 4 1600
Impure Spirit Daily Receivers 9 2 18
Impure Spirit Bulk Storage 100& 200 100-2; 200-2 600
Fusel Oil Storage 20 1 20
Denatured Spirit - - -
Total 35 7638
7.4 FIRE PROTECTION SYSTEMS [TOR # 36 & 37]

The following Fire Protection system has already been provided in the plant
 Hydrant system covering the entire plant including all important auxiliaries and buildings. The
system is complete with piping, valves instrumentation, hoses, nozzles and hydrants, valves
etc.
 Portable extinguisher such as pressurized water type, carbon dioxide type and foam type are
located at strategic locations throughout the plant.
 Modular type carbon dioxide panel injection fire extinguishing system has been provided in
control equipment room, cable space below control room and at other unmanned electrical
and electronic equipment room.
 Automatic Medium Velocity water Sprinkler system for cable galleries / vaults / spreader
room, coal conveyors, crusher house, Transfer points.
 Foam injection system for fuel oil storage tanks consisting of foam concentration tanks, foam
pumps, piping, instrumentation, valves etc.
 Automatic high velocity water spray system has been provided for all the transformers
located in transformer yard, turbine generator lube oil equipment rooms, sets of Boiler
burners, boiler feed pump, lube oil systems, diesel engine driven fire pump, etc.
 Fire water reservoir is part of the water storage tank.
The following pumps are provided in the fire protection system.

Fire water pumps.
a) AC motor driven fire water pumps for hydrant, medium velocity water spray system and foam
system.
b) AC motor driven fire water pumps for high velocity water spray system.
EIA report
7.2
c) Diesel engine driven pump as stand by for the above.

d) Jackey pump 1 no. (AC motor driven) for maintaining pressure.
Suitable number of electric motor driven and diesel engine operated hydrant and spray pumps with
automatic starting are provided for the above systems. The fire water pumps will take suction from
the fire water reservoir to be created in the plant area.
 High velocity water spray system near storage tanks.

 Portable extinguisher such as pressurized water type, carbon dioxide type and foam type will be
located at strategic locations through out the plant.
7.5 SAFETY PROVISIONS PROPOSED [TOR # 37]

The following safety provisions are made in the plant
 Flame arrestors on the top of all the storage tanks.
 Flame proof fitting to all the systems which handles the alcohol.
 Transfer of alcohol by pipes only.
 All the lightings are of flame proof.
 Water sump with a holding capacity of minimum 400 m 3.
 Foam Extinguishers inside the warehouse.
7.6 METHODOLOGY OF MCA ANALYSIS
The MCA Analysis involved ordering and ranking of various sections in terms of potential
vulnerability. The following steps were involved in MCA Analysis.
 Preparation of an inventory of major storages and rank them on the basis of their hazard
properties.
 Identification of potentially hazardous storage sections and representative failure cases from the
vessels and the pipelines.
 Visualisation of chemical release scenarios.
 Effect and damage calculation from the release cases through mathematical modeling.
 Inventory Analysis and Fire & Explosion and Toxicity Index (FETI) are the two techniques
employed for hazard identification process.
7.7 FIRE & EXPLOSION AND TOXICITY INDEX
The role of Fire & Explosion toxicity Index (FET) aids in quantitative hazard identification. The FEI is
calculated by evaluating the loss potential of all the units in the storage area and the hazardous
areas were classified accordingly. The role of FET is
EIA report
7.3
 Identification of the equipment/areas that could likely contribute to the creation or escalation of
incident and relatively rank the incidents.
 Quantification of the expected damage of potential fire and explosion incidents.
 Preparation of guidelines for mitigating fire hazards.
The loss potential which could actually be experienced under the most adverse operating conditions
is quantitatively evaluated. The FEI is used for any operation in which a flammable, combustible or
reactive material is stored, handled or processed.
FEI = MF * GPH * SPH
Where MF: Material factor
GPH: General Process Hazard
SPH: Special Process Hazard
TOXICITY INDEX
The Toxicity Index is calculated using the Nh, GPH and SPH. TI is calculated by the following
formula.
(Nh + Ts) * (1 + GPH + SPH)
TI = -------------------------------------------
100
The degree of hazard is identified based on FEI & TI range as per the criteria given below.
FEI RANGE DEGREE OF HAZARD
0 – 60 LIGHT
61 - 96 MODERATE
97 - 127 INTERMEDIATE
128 - 158 HEAVY
159 & Above SEVERE
TI RANGE DEGREE OF HAZARD

0–5 LIGHT
5 - 10 MODERATE
> 10 SEVERE
Depending on the category of hazard preventive and protective system will be recommended.
7.8 ASSESSMENT OF RISK AT M/s. E.I.D PARRY

Based on the storage inventory the following areas are identified as potential safety risk areas are
shown below.
EIA report
7.4
TABLE 7.2
POSSIBLE RISKS FROM THE EXISTING & EXPANSION PLANT
S.No. Block / Areas Quantity Hazard Identified
1. Boilers 120 TPH, 45 TPH & Fire (mainly near oil burners
10 & 15 TPH (4 Nos.) steam explosion, fire explosion
2. Transformer - Explosion & fire
3. Coal handling plant - Fire and or dust explosion
4. Chlorine Storage 2 Tonners Vapor Release
5. Coal storage 540 tons (15 days) Fire, spontaneous combustion
CHLORINATION PLANT
To prevent the growth of algae in cooling water system, Chlorine dosing in the CW forebay is
proposed. The system will be designed for 1ppm continuous dosing and 5ppm shock dosing. 2 x 100
% capacity vacuum type chlorinators (with evaporator) will be provided along with the 2 nos. of
chlorine tonne containers As the chlorine storage at site is less than 10 tonnes, risk assessment for
chlorine is not required. However to tackle any chlorine leakage, chlorine absorption system will be
provided.
Chlorination Plant
Chlorine Storage System:
1. 2 nos. of Chlorine tonners each of 840 Kg capacity will be provided in the site.
2. The chlorination system is located in a detached building near the circulating water pump
house.
3. Safety masks, showers and eyewash shall be provided.
4. Leak detection and hooter alarm shall be provided for quick evacuation of personnel.
5. The leaked chlorine will be absorbed automatically by the chlorine Absorption System.
6. Facilities in the form of water curtain will be provided for absorption of chlorine released
during an emergency as chlorine is highly soluble in water.
7.9 RISK & CONSEQUENCE ANALYSIS OF FIRE
List of products and NFPA Ratings is given in Table 7.3

TABLE 7.3
List of products and NFPA Ratings
S.No. Chemical NFPA Ratings
Nh NF Nr
1. Ethanol 0 3 0
Explanation of NFPA ratings is given in Table 7.4
EIA report
7.5
TABLE 7.4
Explanation of NFPA Hazard Classifications
Health Hazard Definition
4 Materials which on very short exposure could cause death or major
residual injury even though prompt medical treatments were given.
3 Materials which on short exposure could cause serious temporary or
residual injury even though prompt medical treatments were given.
2 Materials which on intense or continued exposure could cause temporary
incapacitation or possible residual injury unless prompt medical treatment
is given.
1 Materials which on exposure would cause irritation but only minor residual
injury even if no treatment is given.
0 Materials which on exposure under fire conditions would offer no hazard
beyond that of ordinary combustible material.
Flammability Definition
4 Materials which will rapidly or completely vaporize at atmospheric
pressure and normal ambient temperature, or which are readily dispersed
in air and which will burn readily
3 Liquids and solids that can be ignited under almost all ambient
temperature conditions.
2 Materials that must be moderately heated or exposed to relatively high
ambient temperatures before ignition can occur.
1 Materials that must be preheated before ignition can occur.
0 Materials that will not burn.
Reactivity Definition
4 Materials which in themselves are readily capable of detonation or of
explosive decomposition or reaction at normal temperatures and
pressures.
3 Materials which in themselves are capable of detonation or explosive
reaction bur require a strong initiating source or which must be heated
under confinement before initiation or which must be heated under
confinement before initiation or which react explosively with water.
2 Materials which in themselves are normally unstable and readily undergo
violent chemical change but do not detonate. Also materials which may
react violently with water or which may form potentially explosive mixtures
with water.
1 Materials which in themselves are normally stable, but which can become
unstable at elevated temperatures and pressures or which may react with
water with some release of energy but not violently.
0 Materials which in themselves are normally stable, even under fire
exposure conditions, and which are not reactive with water.
METEOROLOGICAL DATA
The atmosphere acts like a large non-homogeneous reactor with several accompanying
complimentary phenomena. Meteorological information plays an important role in the risk analysis.
The atmospheric stability conditions, wind speed, wind directions, humidity etc. are necessary to find
the damage potential due to any chemical release.
Atmospheric stability is important with regard to the extent to which it suppresses or enhances the
vertical movement in the air’s turbulent motion. This is most strongly a function of vertical
temperature profile in the atmosphere. If a volume of air rises, it would normally be expected to coal
EIA report
7.6
as it expands. If the rate of cooling with height by this process equals the vertical temperature profile
then turbulence is neither suppressed nor enhanced. Such conditions are termed neutral. If the
vertical temperature profile is more marked then turbulence is enhanced and if the profile is less
marked then turbulence is suppressed. Neutral conditions correspond to a rate of decrease in
temperature with height of about 1 0 C per 100 meters.
Atmospheric stability is a very important factor for predicting the dispersion characteristics of
gases/vapors of the surrounding environment. Change in atmospheric stability is due to the direct
consequence of its vertical temperature structure.
For a given location, this tends to vary from season to season. Wind speed and stability conditions/
should be obtained from local meteorological records whenever possible. Where these stability data
are not available, the stability effects are mathematically represented through pasquill parameters.
In Pasquill stability categorisation, class A is the one having most unstable and class F is the most
stable weather condition. An unstable weather condition promotes better dispersion, a high wind
speed and high incoming solar radiation favour the formation of unstable weather condition.
Turbulence induced by buoyancy forces in the atmosphere is closely related to the vertical
temperature structure. The magnitude of atmospheric temperature gradient is compared against the
Adiabatic Lapse Rate (ALR=0.98 0C/100m), which is the rate of temperature change with height for a
parcel of dry air rising adiabatically. In neutral stability the gradient is equal to the ALR. Stable
conditions refer to a gradient less than the ALR (ultimately to a temperature inversion) and unstable
conditions to greater than the ALR.
Stability Class Atmospheric Condition
A Very Unstable
B Unstable
C Slightly Unstable
D Neutral
E Stable
F Very Stable
Condition of atmospheric stability is estimated by a suitable method that uses dispersion parameters
viz., vertical temperature gradient, and wind profile and roughness factor. The roughness factor for
the area is small since it mainly comprises of plain land. In general, very stable and stable
conditions are highly favourable for evaporation and dispersion of gases and hence for maximum
credible accident calculations, only these stability conditions will be assumed.
EIA report
7.7
7.10 RESULTS OF CONSEQUENCE ANALYSIS
Maximum Credible Accident and Consequence (MCAC) Analysis aims at identifying the unwanted
hazardous events which can cause damage to human beings and the environment in and around
EID PARRY (INDIA) LIMITED alcohol storage facilities at Hullatti and Alloli Village. For this purpose
a host of probable or potential accident scenarios have been visualized, examined, screened and the
credibility of the most probable events established.
The following steps have been followed for the analysis:
 A detailed study of the storage and handling information
 Identification of representative failure cases of the tanks.
 Consequence analysis of the release cases and shortlisting of the most hazardous
events.
The release scenarios are selected based on hazard identification, past accident data and
engineering judgement. Chemicals handled in this transfer operation are basically non-boiling in
nature. Spillage of these chemicals may lead to heat radiation effects.
7.10.1 IDENTIFICATION OF POTENTIAL HAZARD AREAS
The facilities are examined along with the terminal layout. An inventory of the amount of various
chemicals to be stored is made. The consequence in terms of heat radiation due to release of
chemicals are broadly analysed.
7.10.2 RELEASE SCENARIOS
The release of chemical from the pipe line over the ground from the land point to the storage
terminal, storage tank failure are all the possible scenarios. Failure of underground pipe line has not
been considered credible. Even in case of such a failure, the released material will be confined
underground and is unlikely to find an ignition source.
7.10.3 SOURCE STRENGTH ESTIMATION
Mathematical models are employed to estimate the outflow the liquids. In general, liquid release can
be expected from pipe failures as the pipe line extends over a long distance. The released liquid will
form the pool which can spread. The most vulnerable section of the piping network will be near
flanges, valves and other fittings. It may be worthwhile for E.I.D Parry India Limited to provide
some sort of collecting mechanism to hold any unexpected release near the loading area and
isolation valves. Major failures of pipe line will lead to pool formation which on ignition can lead to
pool fire.
EIA report
7.8
7.10.4 CONSEQUENCE ANALYSIS
Consequence Analysis is a tool to estimate the potential damage due to accidental release of a
hazardous chemical. A large number of failure cases can lead to the same type of consequences
hence representative failure cases are selected for this analysis.
The release scenarios are selected based on hazard identification, past accident data and
engineering judgment. Alcohol, which is proposed to be handled in this storage and transfer
operation, is basically non-boiling in nature. Spillage of the alcohol, if it finds any ignition source,
may lead to heat radiation effects.
7.10.5 HEAT RADIATION EFFECTS DUE TO POOL FIRE
E.I.D Parry India Limited handles alcohol which is basically non-boiling liquid; it can cause heat
radiation effects due to pool fires. The release of combustible liquid can take place due to
catastrophic rupture of the tank itself or rupture of a transfer line. In case of a transfer line, the
spillage can be stopped through isolation valves. However, in case of rupture of tanks or the line
close to the tank (before isolation valve), the release can be large enough to fill the bund. This may
likely to result in a pool fire in case of immediate ignition. This could be the worst possible scenario
in the storage area as far as the heat radiation effects are concerned.
It is found that pool fires generally tend to have localized effects and are mainly of concern in
establishing the potential for cascade effects and employee safety zones rather than for any off -site
problem. The estimation of damage distance can help in solving issues connected with inter tank
spacing, thermal insulation, fire/wall barrier specification etc.
The estimation of heat radiation depends on the bund size (which is same as pool volume in the
case of catastrophic rupture of the tank leading to spillage of large quantity of the chemical), burning
rate (a property which depends on the heat of combustion and latent heat of vaporization), surface
emitted power (which takes into consideration the radiated fraction of total combustion power),
besides the atmospheric transmissivity and geometric view factor. However, the following points are
to be noted:
 Duration of burning varies with the quantity spilled. However, it does not have any
direct of effect on the radiation levels.
 Burning rate is independent of the meteorological conditions so long as sufficient oxygen
is available in the atmosphere. We assume complete combustion in our calculation.
 The pool fire doesn’t depend on the material of construction of bund and bund floor.
However, the surface emitted power by the chemical is included in the mathematical
calculation.
EIA report
7.9
It should be noted that the damage distances due to heat radiation is independent of the quantity
spilled. It depends on the area exposed. However, the quantity will determine the duration of the
fire.
Release of flammable liquid followed by ignition may lead to pool fire. The transfer lines of EID
PARRY (INDIA) LIMITED mostly will go over the ground all over the storage terminal. Release and
spreading of chemicals at the storage tank area is quite possible.
In case of leak / rupture of transfer line at the storage terminal may spill and spread the chemical.
On immediate ignition the scenario will be spreading of burning pool. Delayed ignition may also
lead to spreading of burning pool or confined pool fire if there are bunds. Spreading burning pools
cause less damage than the pool fire resulting after spreading as the spreading area is less due to
loss of chemicals in the burning. In case of leak of underground lines, released chemicals will
diffuse from the ground and form a pool on the ground but quantity in the pool will be low as the
ground itself acts as an obstruction. On ignition, this will damage pipeline due to heating which
leads to catastrophic failure of transfer line. Nevertheless, this situation has remote probability.
The thermal radiation effects due to pool fires at the storage terminal are calculated and the results
are presented in Table 7.5.
TABLE 7.5
THERMAL RADIATION EFFECTES DUE TO FIRE
S.No. Thermal radiation intensity Hazard distance
(KW/m2) (m)
1 37.5 4
2 12.5 10
3 4.0 21
4 KW/m2 thermal radiation intensity occurs at a distance of 21m and will be within the premises.
Hence no outside population would be affected due to the pool fire scenario. There will be no effect
on any structure related to the plant.
A heat radiation effect of 37.5 KW/m2 can cause sufficient damage to adjacent units and fatality rates
will be 100%. 12.5 KW/m2 level can cause ignition of wood, melt plastic tubing etc., while 4.0 KW/m2
can cause pain to personnel if unable to reach cover within 20s. However, blistering of the skin
(second degree burns) is likely but the lethality level will be zero. The firemen with protective clothing
can handle the fire without discomfort under this heat radiation level.
If a tank ruptures and results in a pool fire, this will spread to other tanks in the same enclosure. If
the other tanks/bunds also catch fire because of the cascade effects, the difference will mainly be
that the total heat flux will remain the same but the fire will last for a longer duration. This is because
the scenario chosen covers the chemical with maximum radiation intensity and maximum quantity.
EIA report
7.10
7.11 FREQUENCY / PROBABILITY ESTIMATION
The reliability data of pipelines and atmospheric storage tanks are presented here from the
international database. These cannot be taken as absolute values as there is no information
available for Indian conditions. Therefore, these can be taken indicative values
The probability of tank failures, pipe ruptures and ignition are presented below:
Atmospheric storage tank failure rate 1 x 10-5/yr
Pipe line failure (pipe lengths between connections)
25 mm $ or less 30 x 10-6/yr
50 mm $ 7.5 x 10-6/yr
100 mm $ 4 x 10-6/yr
150 mm $ or greater 3 x 10-6/yr
7.12 RECOMMENDATIONS
I. General Recommendations to Combat Liquid Pool Fires

The major hazard in a flammable storage may arise from pool fire of combustible liquid. Removal of
all ignition sources and maintaining sterile conditions in and all around the plant area.
II. Measures for Containing Liquid Pool Fires
Pool fire in one part of the installation may spread to another unless it is adequately contained. It is
essential to provide spill-impounding areas popularly known as bunds to prevent
Spread of liquid from the immediate spill area to other sections and if the liquid from the immediate
spill is ignited despite safety precautions, impounding areas will serve to control the fire hazard by
 Minimizing the fire size thus reducing radiant heat exposure to the surroundings
 Localizing the need for fire protection.
III. General Recommendations
 Joints in piping should be kept to a minimum. Piping more than 50 mm outside diameter
should have welded or welded flanged joints except when connecting to equipment fitted with
screwed connections. Piping 50 mm diameter and less may have screwed joints. Where
piping has screwed joints, which may be subjected to vibration, consideration should be
given to tack welding them to prevent them from coming loose.
 To prevent the accumulation of static electricity metal piping should be electrically continuous
so that the resistance to earth of the installation does not exceed 10 6 ohms. Reference
should be made to BIS 5958: Part 1:1980 for further information.
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7.11
IV. Specific Recommendations
i. Hydrocarbon sensors may be provided at the vulnerable areas and in case of any alcohol
vapor release, immediate action to be taken to dilute the alcohol vapor concentration by
suitable vapor dispersal mechanism.
ii. The entire area has to be kept free from the sources of ignition and made sterile during
the storage, handling and transfer operation of all flammable chemicals.
iii. The piping design should conform to the codes and regulations.
iv. In case of a spill, mobile foam dispending system can be effective in reducing vapor
generation by minimizing surface area exposed to atmosphere in addition to providing
containment.
v. Other protective gadgets like gloves, DCP, CO 2 Extinguishers should be made available.
The thick green belt already developed will help to mitigate the radiation intensity level outside plant
boundary.
7. 13 DISASTER MANAGEMENT PLAN

7.13.1 DISASTERS
A disaster is catastrophic situation in which suddenly, people are plunged into helplessness and
suffering and as a result, need protection, clothing, shelter, medical and social care and other
necessities of life.
Disasters can be divided into two main groups. In the first, are Disasters resulting from natural
phenomena like earthquakes, volcanic eruptions, cyclones, tropical storms, floods, avalanches,
landslides etc. The second group includes disastrous events occasioned by man, or by man’s impact
upon the environment. Examples are industrial accidents, radiation accidents, factory fires,
explosions and escape of toxic gases or chemical substances, river pollution, mining or other
structural collapses, air, sea, rail and road transport accidents and can reach catastrophic
dimensions in terms of human loss.
There can be no set criteria for assessing the gravity of a disaster in the abstract since depends to a
large extent on the physical, economic and social environment in which it occurs. What would be
considered a major disaster in developing country, will be equipped to cope with the problems
involved, may not mean more than temporary emergency elsewhere. However all disasters bring in
their wake similar consequences that call for immediate action, whether at the local, national or
international level, for the rescue and relief of the victims. This includes the search for the dead and
injured, medical and social care, removal of the debris, the provision of temporary shelter for the
homeless food, clothing and medical supplies, and the rapid reestablishment of essential services.
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7.12
7.13.2 OBJECTIVES OF DISASTER MANAGEMENT OF PLAN

The disaster Management Plan is aimed to ensure safety of life, protection of environment,
protection of installation, restoration of production and salvage operations in this same order of
priorities. For effective implementation of Disaster Management Plan, it will be widely circulated and
personnel training through rehearsals.
The Disaster Management Plan would reflect the probable consequential severity of undesired event
due to deteriorating conditions or through knock on effects. Further the management should be able
to demonstrate that their assessment of the consequences uses good supporting evidence and
based on currently available and reliable information, incident data from internal and external
sources and if necessary the reports of out side agencies.
To tackle the consequences of a major emergency inside the factory or immediate vicinity of the
factory, a Disaster Management Plan has to be formulated and this planned emergency is called
Disaster Management Plan.
The objective of the Industrial Disaster Management Plan is to make use of the combined resources
of the plant and the outside services to achieve the following.
 Minimise damage to property and the environment.

 Effect the rescue and medical treatment of causalities.
 Provide for the needs of relatives.
 Provide authoritative information to news media.
 Secure the safe rehabilitation of affected areas.
 Safeguard other people.
Initially contain and then ultimately bring the situation under the control.
Preserve subsequent records and equipment for subsequent enquiry the cause and circumstances
leading to emergency.
7.13.3 EMERGENCIES
7.13.3.1 GENERAL, INDUSTRIAL, EMERGENCIES
The emergencies that could be envisaged in the plant are as follows:
 Pool fire scenario due to storage of R.S / ENA / Ethanol.
 Contamination of food / water.
 Sabotage / social disorder.
 Structural failures.
 Slow isolated fires
 Earthquakes.
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7.13
7.13.3.2. SPECIFIC EMERGENCIES ANTICIPATED

Fire consequences can be disastrous as they involve in huge quantities of fuel. During the study of
risk assessment, the probabilities of occurrence of hazards are worked out along with the nature of
damage. This is the reason why one should study risk assessment in conjunction with DMP.
7.13.3.3 EMERGENCY ORGANISATIONS
It is recommended to setup an Emergency Organisation. A senior executive who has control over
the affairs of the plant would be heading the Emergency Organisation. He would be designated as
Site Controller. In case of stores, utilities, open areas which are the not under the control of
production heads, executive responsible for maintenance of utilities would be designated as Incident
Controller. All the Incident Controller would be reporting to the site controller. Each Incident
Controller, for himself, organises a team responsible for controlling the incidence with the personnel
under his control. Shift Incharge would be the reporting Officer, who would bring the incidence to the
notice of the Incidence Controller and Site Controller.
Emergency Coordinators would be appointed who would be undertake the responsibilities like fire
fighting, rescue, rehabilitation, transport and support services. For this purposes, Security Incharge,
Personal Department, Essential services personnel would be engaged. All these personnel would be
designated as key personnel.
In each shift, electrical supervisor, electrical filters, pump house Incharge and other maintenance
staff would be drafted for emergency operations. In the event of power communication system
failure, some of staff members in the office/ plant offices would be drafted and their services would
be utilised as messengers for quick passing of communications. All these personnel would be
declared as essential personnel.
7.13.3.4 EMERGENCY COMMUNICATION
Whoever notices an emergency situation such as fire, growth of fire, leakage etc. would inform his
immediate superior and Emergency Control Center. The person on duty in the Emergency Control
Centre would appraise the site controller. Site controller verifies the situation from the Incident
Controller of that area or the shift Incharge and takes a decision about an implementing on Site
Emergency. This would be communicated to all the Incident Controllers, Emergency Coordinators.
Simultaneously, the emergency warning system would be activated on the instructions of the Site
Controller.
7.13.3.5. EMERGENCY RESPONSIBILITIES

The responsibilities of the key personnel are appended below:
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7.14
7.13.3.5.1 SITE CONTROLLER

On receiving information about emergency he would rush to Emergency Control Centre and take
charge of ECC and the situation and assesses the magnitude of the situation on the advice of
incident controller and decides.
 Whether affected area needs to be evacuated.
 Whether personnel who are at assembly points need to be evacuated.
 Declares Emergency and orders for operation of emergency siren.
 Organises announcement by public address system about location of emergency.
 Assesses which areas are likely to be affected, or need to be evacuated or are to be
altered.
 Maintains a continuous review of possible development and assesses the situation in
consultation with Incident Controller and other key personnel whether shutting down the
plant or any section of the plant required and if evacuation of persons is required.
 Directs personnel of rescue, rehabilitation, transport, fire brigade, medical and other
designated mutual support systems locally available, for meeting emergencies.
 Controls evacuation of affected areas, if the situation is likely to go out of control or
effects are likely to go beyond the premises of the factory, informs to District Emergency
Authority, Police, Hospital and seeks their intervention and help.
 Informs Inspector of factories, Deputy Chief Inspector of factories, KSPCB and other
statutory authorities.
 Gives public statement if necessary.
 Keeps record of chronological events and prepares an investigation report and preserves
evidence.
On completion of on site Emergency and restoration of normalcy, declares all clear and orders for all
clear warning.
7 .13.3.5.2 INCIDENT CONTROLLER

 Assembles the incident control team.
 Directs operations within the affected areas with the priorities for safety to personnel
minimise damage to the plant, property and environment and minimise the loss of
materials.
 Directs the shutting down and evacuation of plant and areas likely to be adversely
affected by the emergency.
 Ensures that all-key personnel help is sought.
 Provides advice and information to the Fire and Security officer and the local Fire
Services as and when they arrive.
EIA report
7.15
 Ensures that all non-essential workers / staff of the effected areas evacuated to the
appropriate assembly points and the areas are searched for causalities.
 Has regard to the need for preservation of evidence so as to facilitate any enquiry into the
cause and circumstances, which caused or escalated the emergency.
 Coordination on with emergency services at the site.
 Provides tools and safety equipments to the team members.
 Keeps in touch with the team and advice them regarding the method of control to be
used.
 Keep the site Controller of Emergency informed of the progress being made.
7.13.3.5.3 EMERGENCY COORDINATOR - RESCUE, FIRE FIGHTING

 On knowing about emergency, rushes to Emergency Control Centre.
 Helps the incident controller in containment of the emergency.
 Ensure fire pumps in operating conditions and instructions pump house operator to be
ready for any emergency, which stand arrangement.
 Guides the fire fighting crew i.e. Firemen trained plant personnel and security staff.
 Organises shifting the fire fighting facilities to the emergency site, if required.
 Takes guidance of the Incident Controller for fire fighting as well as assesses the
requirements of outside help.
 Arranges to control the traffic at the gate and the incident area / Directs the security staff
to the incident site to take part in the emergency operations under his guidance and
supervision.
 Evacuates the people in the plant or in the near by areas as advised by site controller
 Searches for casualties and arranges proper aid for them.
 Assembles search and evacuation team.
 Arranges for safety equipments for the members of this team.
 Decides which paths the evacuated workers should follow.
 Maintains law and order in the area, and if necessary seeks the help of police.
7.13.3.5.4 EMERGENCY COORDINATOR - MEDICAL, MUTUAL AID, REHABILITATION,

TRANSPORT AND COMMUNICATION.
 In the event of failure of electric supply and there by internal telephone, sets up
communication point and establishes contact with the Emergency Control Center (ECC).
 Organises medical treatment to the injured and if necessary will shift the injured to near
by hospitals.
 Mobilises extra medical help from outside, if necessary
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7.16
 Keeps a list of qualified persons first aiding workers of the factory and seek their
assistance.
 Maintains first aid and medical emergency requirements.
 Makes sure that all safety equipment are made available to the emergency team.
 Assists Site Controller with necessary data and to coordinate the emergency activities.
 Assists Site Controller in updating emergency plan.
 Maintains liaison with Civil Administration.
 Ensure availability of canteen facilities and maintenance of rehabilitation centre.
 He will be in liaison with Site Controller / Incident Controller.
 Ensures availability of necessary cash for rescue / rehabilitation and emergency
expenditure.
 Controls rehabilitation of affected areas on discontinuation of emergency.
 Makes available diesel, petrol for transport vehicles engaged in emergency operation.
7 .13.3.5.5 EMERGENCY COORDINATOR – ESSENTIAL SERVICES

He would assist Site Controller and Incident Controller
 Maintains essential services like Diesel Generator, Water, Firewater, Compressed Air /
Instrument Air, Power Supply for lighting.
 He would plan alternate facilities in the event of power failure, to maintain essential
services such as lighting, etc.
 He would organize separate electrical connections for all utilities and during emergency
or fires, essential services and utilities are not affected.
 Gives necessary instructions regarding emergency electrical supply, isolation of certain
sections etc. to shift Incharge and electricians.
 Ensure availability of adequate quantities of protective equipment and other emergency
materials, spares etc.
7.13.3.5.6 GENERAL RESPONSIBILITIES OF EMPLOYEES DURING AN EMERGENCY

During an emergency, it becomes more enhanced and pronounced when an emergency warning is
raised, the workers if they are incharge of process equipment should adopt safe and emergency shut
down and attend any prescribed duty as essential employee. If no such responsibility is assigned, he
should adopt a safe course to assembly point and await instructions. He should not resort to spread
panic. On the other hand, he must assist emergency personnel towards objectives of DMP.
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7.17
7.13. 3.6 EMERGENCY FACILITIES

7.13.3.6.1 EMERGENCY CONTROL CENTRE
For the time being office block is provided as Emergency control centre. It would have external
Telephone and Fax facility. All the Incident controller officers, senior personnel would be located
here.
The following information and equipment are provided at the Emergency control centre (ECC).
 Intercom, telephone
 P&T telephone
 Fire suit / gas tight goggles / gloves / helmets
 Factory layout, site plan
 Emergency lamp / torchlight
 Plan indicating locations of hazard inventories, plant control room, locations of safety
equipment, road plan, assembly points, rescue location vulnerable zones, escape routes.
 Hazard chart
 Breathing apparatus
 Wind direction, wind velocity indications
 Public Address Megaphone, Hand bell, Telephone directories (Internal, P&T).
 Address with telephone numbers and key personnel, Emergency coordinator.
 Important addresses, telephone numbers such as experts from outside,
 Government agencies neighboring industries etc
 Emergency shutdown procedures
 Nominal roll of employees
7.13.3.6.2 EMERGENCY POWER SUPPLY
Plant facilities would be connected to Diesel Generator and would be placed in auto mode.
7.13.3.6.3 FIRE FIGHTING FACILITIES
First Aid Fire fighting equipment suitable for emergency should be maintained as per stationary
requirements as well as per TAC Regulations. Fire hydrant line converting major areas would be
laid. It would be maintained as 6 kg / sq. cm. Pressure.
7.13.3.6.4 LOCATION OF WINDSOCK

On the top of each main block and on the top of administrative block wind sock would be installed to
indicate direction of wind during emergency period.
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7.18
7.13.3.6.5 EMERGENCY MEDICAL FACILITIES
Gas masks and general first aid materials for dealing with chemical burns, fire burns etc. would be
maintained in the medical centre as well as in the emergency control room. Private medical
practitioners help would be sought. Government hospital would be approached for emergency help.
Apart from plant first aid facilities, external facilities would be augmented. Names of Medical
Personnel, Medical facilities in Haliyal town would be prepared and updated. Necessary specific
medicines for emergency treatment of Burns patients, and for those affected by toxicity would be
maintained.
Breathing apparatus and other emergency medical equipment would be provided and maintained.
The help of near by industrial managements in this regard would be taken on mutual support basis.
7.13.3.7 EMERGENCY ACTIONS

7.13.3.7.1 EMERGENCY WARNING
Communication of emergency would be made familiar to the personnel inside the plant and people
outside. An emergency warning system would be established.
7.13.3.7.2 EMERGENCY SHUTDOWN

There are number of facilities which can be provided to the help deal with hazard conditions. The
suggested arrangements are
# Stop feed
# Deluge contents
# Remove heat
# Transfer contents
7.13.3.7.3 EVACUATION OF PERSONNEL
The area would have adequate number of exits, staircase. In the event of an emergency
unconnected personnel have to escape to assembly point. Operators have to take emergency
shutdown procedure and escape. Time office maintains a copy of deployment of employees in each
shift at Emergency Communication Centre. If necessary, persons can be evacuated by rescue
teams.
7.13.3.7.4 ALL CLEAR SIGNAL
At the end of emergency, after discussing with Incident Controllers and Emergency Coordinators, the
site controller orders an all clear signal.
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7.19
7.14 OCCUPATIONAL HEALTH
In large scale industries where multifarious activities are involved during construction, erection,
testing, commissioning, operation and maintenance, the men, materials and machines are the basic
inputs. Along with the booms, the industrialization generally brings several problems like
occupational health and safety. Occupational health needs attention both during construction and
operation phases. However the problem varies both in magnitude and variety in the above phases.
7.14.1 CONSTRUCTION & ERECTION
The occupational health problems envisaged at this stage can be mainly due to constructional
accident and noise.
To overcome these hazards, in addition to arrangements to reduce it within TLV’S, personnel
protective equipments should also be supplied to workers.
7.14.2 OPERATION & MAINTENANCE
The working personnel should be given the following appropriate personnel protective equipments.
 Industrial Safety helmets
 Crash helmets
 Face shield with replacement acrylic vision
 Zero power plain goggles with cut type filters on both ends
 Zero power goggles with cut type filters on both sides and blue colour glasses
 Welders equipment for eye and face protection
 Cylindrical type earplug
 Ear plugs
 Canister gas masks
 Self contained breathing apparatus
 Leather apron
 Boiler suit
 Safety belt / line man's safety belt
 Leather hand gloves
 Asbestos hand gloves
 Canvas cum leather hand gloves with leather palm
 Industrial safety shoes with steel toe
 Electrical safety shoes without steel toe and gum boots
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7.20
7.14.3 OCCUPATIONAL HEALTH SURVEILLANCE [TOR # 39]

In this Integrated Sugar Plant, there will be utilization of chemicals like Sulphur, DAP, Lime, Alum
and polymers. The usage of this above chemicals will be in low quantities and exposure of these
chemicals to the employees will be also very low. However all the precautionary measures are being
taken while handling these chemicals.
The following are the details of the Occupational Health Surveillance
 Occupational Health Surveillance (OHS) is being under taken as regular exercise for all the
employees specifically for those engaged in handling hazardous substances.
 All the first aid facilities are provided in the Occupational Health Centre.
 The medical records of each employee are being maintained separately.
 Occupational health center for medical examination of employees with all the basic facilities
have been established with in the plant.
 The noise levels in critical area are being monitored regularly and the workers at high noise
level generating areas will undergo audiometric tests once in six months.
 Liver function test is also being planned for the workers as a part of surveillance.
7.15 SAFETY PLAN
Safety of both men and materials during construction and operation phases is of concern. The
preparedness of an industry for the occurrence of possible disasters is known as emergency plan.
The disaster in any plant is possible due to collapse of structures and fire / explosion etc .
Keeping in view the safety requirement during construction, operation and maintenance EID PARRY
( INDIA) LIMITED has formulated safety policy with the following regulations.
 To take steps to ensure that all known safety factors are taken into account in the design,
construction, operation and maintenance of plants, machinery and equipment.
 To allocate sufficient resources to maintain safe and healthy conditions to work.
 To ensure that adequate safety to instructions are given to all employees.
 To provide protective equipment, safety appliances and clothing and to ensure their
proper use.
 To inform employees about materials, equipments or processes used in the work, which
are known to be potentially hazardous to health or safety?
 To promote the established machinery, joint consultation in health and safety to ensure
effective participation by all employees.
 To keep all operations and methods of work under regular review for making necessary
changes from the point of view safety in the light of experience and upto date knowledge.
 To provide appropriate facilities for first aid and prompt treatment of injuries and illness at
work.
EIA report
7.21
 To provide appropriate instructions, training and supervision to employees’ health and

safety, first aid and to ensure that adequate publicity is given to these matters.
 To ensure proper implementation of fire preventive methods and an appropriate fire
fighting service together training facilities for personnel involved in this service.
 To publish / notify regulations, instructions and notices in the common language of
employees.
 To prepare separate safety rules for each type of process involved.
 To ensure regular safety inspection by a competent person at suitable intervals of all
buildings, equipments, work places and operations.
7.15.1 SAFETY ORGANISATION

7.15.1.1 CONSTRUCTION AND ERECTION PHASE:
A qualified and experienced safety officer will be appointed. The responsibilities of the safety officers
include identification of the hazardous conditions and unsafe acts of workers and advice on
corrective actions, conduct safety audit, organize training programmes and provide professional
expert advice on various issues related to Occupational Safety and Health.
7.15.1.2 OPERATION & MAINTENANCE PHASE

When the construction is completed the posting of safety officers should be in accordance with the
requirement of factories act and their duties and responsibilities should be as defined there off.
7.15.1.3 SAFETY CIRCLE

In order to fully develop the capabilities of the employees in identification of hazardous processes
and improving safety and health, safety circles would be constituted in each area of work. The circle
would consist of 5-6 employees from that area. The circle normally should meet for about an hour
every week.
7.15.1.4 SAFETY TRAINING

Safety training will be provided by the safety officers to all the employees with the assistance of
faculty members called from professional safety institutions and universities. In addition to regular
employees, limited contractor labours are also provided with safety training.
To create safety awareness safety films will be shown to workers and leaflets etc. will be distributed.
 Compartmentalization of the cable galleries, use of proper sealing techniques of cable
passages and crevices in all directions would help in localising and identifying the area of
occurrence of fire as well as ensure effective automatic and manual fire fighting
operations.
 Spread of fire in horizontal direction would be checked by providing fire stops for cable
shafts.
EIA report
7.22
 Reliable and dependable type of fire detection system with proper zoning and interlocks
for alarms
 Housekeeping of high standard helps in eliminating the causes of fire and strengthens fire
prevention and fire fighting.
7.15.1.5 HEALTH AND SAFETY MONITORING PLAN

The potential occupational hazardous work places will be monitored regularly. The health of
employees working in these areas will be monitored once in a year.
7.10 SOCIAL IMPACT ASSESSMENT
The local areas will be benefited by way of generation of employment opportunities, increased
demand for local products and services. There will be an overall improvement in the income level of
the local people.
The project creates employment to about 50 persons once the plant is commissioned and for 250
persons during construction stage. Priority will be given to locals for Semi-Skilled and Unskilled
workers. With the development of this Plant there will be lot of scope for more industrial investments
which in turn will benefit the nation.
EID PARRY INDIA LIMITED , being a constituent of "The Murugappa Group" has upheld its ancient
family tradition of earmarking and spending a portion of its income for social service in its business
enterprise as well. E.I.D Parry firmly believes that social responsibility is not just a ritual, but it is
fulfilling one's dharma. Therefore, in all its philanthropic endeavors, the Murugappa Group reflects its
spiritual conscience and not just corporate obligation.
EID PARRY believes not only in value-added business, but also in discharging its responsibilities to
various sections of society and in providing opportunities to learn, contribute, advance, recognize
and reward initiative, innovativeness and creativity. It believes in not only making customers
delighted, but the community around also, by establishing service-oriented philanthropic institutions
in the field of Education and Medicare.
EID PARRY , through Murugappa Group invests a portion of its wealth - one percent of profit after
tax (PAT), for the welfare of society since it went into business. In addition to this, it also conducts a
lot of welfare measures for the needy residing in and around its various units.
EIDP, Haliyal has been involved with community and social services in factory related villages. EIDP
has commenced a series of social development programs in villages. We believe that a social
interface with the community is a continuous process and is essential for a long term relationship
where we contribute to each other’s growth and well-being.
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7.23
Similarly after proposed expansion, many developmental programmes will be taken up as per the
need based and in consultation with village heads.
7.17 R & R ACTION PLAN

There is no habitation in the proposed expansion project site. The proposed expansion will be taken
up in the existing plant premises only. Hence no Rehabilitation & Resettlement Action Plan has been
envisaged in the proposed expansion project.
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7.24
CHAPTER – 8
PROJECT BENEFITS
The proposed expansion project will benefit the local area in the following ways.
8.1 PHYSICAL INFRASTRUCTURE
Once the expansion project is commissioned the socio-economic status of the local people will
improve and there by infrastructure facilities like communication systems and others will improve.
8.2 SOCIAL INFRASTRUCTURE [TOR # 40]

With the implementation of the expansion project, the socio-economic status of the local people will
improve substantially. The land rates in the area will improve in the nearby areas due to the
proposed plant. This will help in upliftment of the social status of the people in the area. Educational
institutions will also come-up and will lead to improvement of educational status of the people in the
area. Medical facilities will certainly improve due to the proposed expansion project.
8.3 EMPLOYMENT POTENTIAL
The proposed project creates employment to 250 people during construction and 50 people during
operation of the expansion plant.
8.3.1 SKILLED
Total skilled employment in the proposed expansion plant will be 10
8.3.2 SEMI-SKILLED
Total Semi-skilled employment in the proposed expansion plant will be 20. Priority will be given to
local people for semi-skilled jobs.
8.3.3 UNSKILLED
Total Unskilled employment in the proposed plant will be 20. Top priority will be given to local people
for unskilled jobs.
8.4 OTHER TANGIBLE BENEFITS
EID Parry ( India) Limited , being a constituent of "The Murugappa Group" has upheld its ancient
family tradition of earmarking and spending a portion of its income for social service in its business
enterprise as well. EID Parry firmly believes that social responsibility is not just a ritual, but it is
EIA report
8.1
fulfilling one's dharma. Therefore, in all its philanthropic endeavors, the Murugappa Group reflects its
spiritual conscience and not just corporate obligation.
EID Parry believes not only in value-added business, but also in discharging its responsibilities to
various sections of society and in providing opportunities to learn, contribute, advance, recognize and
reward initiative, innovativeness and creativity. It believes in not only making customers delighted,
but the community around also, by establishing service-oriented philanthropic institutions in the field
of Education and Medicare.
EID Parry , through Murugappa Group invests a portion of its wealth - one percent of profit after tax
(PAT), for the welfare of society since it went into business. In addition to this, it also conducts a lot of
welfare measures for the needy residing in and around its various units.
EID Parry, Haliyal has been involved with community and social services in factory related villages.
EID Parry has commenced a series of social development programs in villages. We believe that a
social interface with the community is a continuous process and is essential for a long term
relationship where we contribute to each other’s growth and well-being.
The company has initiated the following activities as a part of its socio-economic responsibility.
1. Education to poor (Running of Balwadi)
Company has contributing in running of Balwadi (Education for kids) for the benefits of kids near our
factory premises. Company has provided books to all poor children, and assisted in conducting
annual sports, festival in the village schools, Further company has planed to provide amenities like
lavatories, maintain playground etc.
2. Water for the villagers near factory premises:
The company is providing water for the villagers near factory for cultivation of cane, as there is
scarcity of water. Further the management is also having plan for making arrangement to villagers for
drinking water.
3. Training to unskilled manpower:
The company is having plan to train the villagers in various technical trades enabling to get the
employment. The company is having tie-up with I.T.I College for providing apprenticeship to newly
pass out candidates.
4. Village Roads:
The company is paying tax on cane purchase and following-up with the Government to make the
roads pertaining to our villages of our cane growers.
EIA report
8.2
5. Health and Hygiene
The company started Mobile Health Van in coordination with Wockhardt hospital, Bangalore. We are
organizing the same in 12 villages which is benefiting the villagers for their better health and
wellbeing. By introducing the Mobile health van the medical facilities are at the doorsteps of the
villagers. Further the company is conducting awareness programmers about health, maintaining
cleanliness near their surroundings. The company is planning to extend the facility to more no. of
villages.
6. Agriculture development
The company is supplying cane seeds and fertilizers to farmers for quality production resulting in
vertical growth. The company is also giving training to villagers for getting high quantity and quality of
yield. Our cane circle offices will support for any grievances of farmers.
Collecting soil samples from different villages through mobile soil testing lab centers which will help
the farmers to know and analyze nutrient status of soil.
Company is supplying fly ash to farmers which will enhance the water holding capacity of soil and
also contains potash which is a good fertilizer.
Company is providing seed nursery to farmers for ratoon gap filling and drip irrigated fields by which
farmers will get good quality seeds (i.e. disease free) and also maintains population.
7. Irrigation
The company is providing drip irrigation system, lift irrigation schemes to cane cultivators. And also
giving training to farmers regarding latest technologies on irrigation methods for water conservation
and to avoid consequences due to over irrigation.
Similarly, as a part of proposed expansion project, we will plan and implement more schemes and
developmental progarmmes in consultation with village heads in the surrounding villages.
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8.3
CHAPTER – 9
ENVIRONMENTAL COST BENEFIT ANALYSIS
 No specific TOR has been stipulated in TOR letter issued by MoEF for carrying out
environmental cost benefit analysis. Hence it has not been carried out.
 However all required Environmental protection measures will be taken in the proposed
expansion project to ensure compliance with the norms.
 The total project cost is Rs.125 Crores, out of which Rs. 10 Crores have been earmarked for
Environmental protection.
EIA report
9.1
CHAPTER – 10
ENVIRONMENTAL MANAGEMENT PLAN
[TOR # 33 & 42]
10.0 INTRODUCTION
The major objective and benefit of utilising Environmental Impact Assessment in project planning
stage itself is to prevent avoidable losses of environmental resources and values as a result of
Environmental Management. Environmental Management includes protection / mitigation /
enhancement measures as well as suggesting post project monitoring programme. Environmental
management may suggest revision of project site or operation to avoid adverse impacts or more
often additional project operations may have to be incorporated in the conventional operation.
The industrial development in the study area needs to be intertwined with judicious utilization of
non-renewable resources of the study area and with in the limits of permissible assimilative
capacity. The assimilative capacity of the study area is the maximum amount of pollution load that
can be discharged in the environment without affecting the designated use and is governed by
dilution, dispersion, and removal due to physico-chemical and biological processes. Detailed
Environment Management Plan (EMP) is required to ensure sustainable development in the study
area of the plant. Hence it needs to be an all encompassive plan for which the proposed industry,
Government, Regulating agencies likes Pollution Control Board working in the region and more
importantly the affected population of the study area need to extend their cooperation and
contribution.
It has been evaluated that the study area is likely to get new economical fillip. The affected
environmental attributes in the region are air quality, water quality, soil, land use, ecology and public
health.
The Management Action Plan aims at controlling pollution at the source level to the possible extent
with the available and affordable technology followed by treatment measures before they are
discharged. Environmental Management aims at the preservation of ecosystem by considering the
pollution abatement facilities at the plant inception. In the upcoming modern integrated sugar plants,
pollution abatement has become an integral part of planning and design along with Techno
economic factors.
EIA report
10.1
10.1 MANAGEMENT DURING CONSTRUCTION PHASE
Environmental pollution is inevitable during the construction phase. The project proponent should
take appropriate steps to control pollution during construction phase. The following are the factors
requiring control during construction phase.
10.1.1 SITE PREPARATION
At the time of construction there will be a substantial quantity of soil and debris and produce large
quantities of unstable material. The disturbed slopes shall be well stabilized before the on set of the
monsoon. The leveling operation would also involve piling up of backfill materials. Use of dust
suppressant spraying to minimize fugitive dust during construction activities is recommended. Dust
masks will be provided to all workers working in the dust prone areas. Good house keeping and
proper maintenance will be practiced which will help in further controlling the dust emissions during
construction phase.
10.1.2 WATER SUPPLY AND SANITATION
The employees at the proposed expansion project site shall be provided with water for their
requirement and for the construction activities. The construction site shall be provided with sufficient
and suitable toilet facilities to allow proper standards of hygiene. These facilities would preferably
be connected to a septic tank and shall be maintained properly to have least environmental impact.
The existing facilities will be used during construction phase.
10.1.3 NOISE
Noise levels may increase during the construction phase due to the usage of various construction
equipment such as mechanical vibrator, mixers etc. The noise effect on the nearest habitations due
to construction activity will be negligible. However, it is advisable that onsite workers working near
the noise generating equipment shall be provided with noise protection devices like ear plugs.
10.1.4 MAINTENANCE OF VEHICLES
One should be very careful in selecting the site for vehicle maintenance, so as to prevent the ground
water contamination due to the spillage of oil. Both diesel and petrol engine vehicles shall be
maintained properly. Unauthorised dumping of waste oil should be prohibited. Wastes should be
disposed off at an approved dump.
10.1.5 WASTE
The solid waste shall be collected, segregated and will be disposed off as per norms.
EIA report
10.2
10.1.6 STORAGE OF HAZARDOUS MATERIAL
The following hazardous materials need to be stored at the site during construction.
a. Gas for welding purpose
b. LDO
c. Painting materials
All these materials would be stored as per international safety standards.
10.1.7 LAND ENVIRONMENT
The proposed expansion activities will not create any major impact on land environment. As soon as
the construction activity is over the surplus earth will be utilized to fill up low lying areas, the rubbish
will be cleared and all inbuilt surfaces will be reinstated. Appropriate vegetation will then be planned
and all such areas shall be landscaped. Extensive green belt is proposed to be developed in the
plant site in addition to the existing greenbelt.
10.2 POST CONSTRUCTION PHASE
10.2.1 AIR EMISSION MANAGEMENT [TOR # 18]

A) Sugar & Co-gen Power Plant:
The steam requirement for the proposed expansion of sugar plant from 4800 TCD to 6000 TCD will
be met from the proposed 45 TPH Co-generation boiler. High efficiency Electro Static Precipitator
will be provided to proposed cogeneration Boiler of 45 TPH boiler to bring down the particulate
matter in the exhaust gas to less than 50 mg/Nm3 to comply with CREP recommendations. A stack
height of 44 m will be provided for effective dispersion of sulphur dioxide emissions into the
atmosphere. An interlocking system will be provided to the Boiler in such a way that whenever the
ESP fails, the raw material feed to the boiler will stop and the boiler will trip down. Consequently
there will be no power generation till ESP is rectified. The following are the Technical specifications
of Electrostatic precipitator.
TECHNICAL SPECIFICATIONS FOR ESP (45 TPH BOILER)

S.No Description Unit 100% Bagasse
(on any given day)
1 Gas Flow rate at ESP inlet m3/s 45
o
2 Gas temperature at ESP inlet C 160
3 Dust concentration at inlet g/Nm3 15
4 Outlet emission (Max.) mg/Nm3 < 50
5 ESP collection efficiency % 99.16
6 Draft loss across ESP mmWc < 25
7. No. of fields Nos 2
EIA report
10.3
B) Distillery Plant:
The steam requirement for the proposed existing and expansion of distillery plant will be met from
the existing 10 TPH and proposed 15 TPH boiler. In this Boiler concentrated spent wash and coal to
the tune of 1.5 MT/hr (max.) will be used as fuels. Bag filters will be provided to the proposed 15
TPH boiler to bring down the particulate matter in the exhaust gas to less than 50 mg/Nm3. Stack of
50 m height will be provided to 15 TPH boiler for effective dispersion of sulphur dioxide emissions
into the atmosphere.
TECHNICAL SPECIFICATIONS FOR BAG FILTERS (15 TPH BOILER)

Boiler capacity TPH 15
1. System Parameters
Gas Volume m3 / hr. 62,000
o
Gas Temperature C 150
Inlet dust loading gm/Nm3 15
Flange to flange pr. Drop mm Wg 150
2. Bag Filter
Total filter area m2 862
Air to Cloth ratio m min. m2
3
1.2
Outlet Emission mg/N m3 < 50
3. Bags
Diameter mm 6000
Length mm 150
Material RYTON
o
Max. Operating temp. C 180
Weight gm/m2 550
Permeability m3/min.m2 15 to 18
4. Bag Cleaning
Compressed air required m3/min. 1.2
No. pulse cum solenoid valve 25
Size of pulse valve Inch 2
The following measures will be taken up to prevent the fugitive dust emissions from the proposed
expansion.
 Raw material unloading areas will be provided with dust suppression system.
 All material transfer points will be provided with dust extraction system with bag filters.
 All the conveyers will be covered to prevent the fly-off of fugitive dust.
 All internal roads will be made pucca to prevent the fugitive dust to vehicular movement.
EIA report
10.4
The emission level will always be maintained below the stipulated standards. In the event of failure
of any pollution control system adopted by the unit, the respective unit will not be restarted until the
control system is rectified.
10.2.1.1 MONITORING OF SECONDARY FUGITIVE EMISSIONS [TOR # 18]

Fugitive emissions will be monitored as per CPCB guidelines and the norms of the Ministry of
Environment & Forests.
Secondary fugitive emissions will be generated at Raw Material feeding points. These emissions will
be monitored regularly as per CPCB guidelines & the reports will be submitted to MOEF, Regional
office & KSPCB.
The following measures will be taken up to prevent the fugitive dust emissions
 Raw material unloading areas will be provided with dust suppression system.
 All material transfer points will be provided with dust extraction system with bag filters.
 All the conveyers will be covered to prevent the fly-off of fugitive dust.
 All internal roads will be made pucca to prevent the fugitive dust to vehicular movement.
 There will not be any open storage of ash and the ash will be stored in silo only.
The emission level will always be maintained below the stipulated standards. In the event of failure
of any pollution control system adopted by the unit, the respective unit will not be restarted until the
control measures are rectified to achieve the desired efficiency.
10.2.1.2 ACTION PLAN TO CONTROL AMBIENT AIR QUALITY AS PER NAAQS STANDARDS
[TOR # 15]
 The particulate matter from the proposed expansion project will be < 50 mg/ Nm3.
 All the internal roads will be asphalted in the plant.
 Water sprinklers will be installed at the raw material loading and unloading areas
 Fly ash will be stored in silos only
 Dust extraction system with bag filters will be provided at the dust emanating areas.
By following above control measures, we will comply with the National Ambient Air Quality
Standards issued by the Ministry vide G.S.R. No. 826(E) dated 16 th November, 2009.
Recommendations
a) The proposed air pollution control equipment should be installed prior to commissioning the
plant.
b) Stack emissions for PM, SO2 and NOx shall be monitored regularly to meet the statutory
requirements.
c) All the internal roads shall be asphalted to reduce the fugitive dust due to truck movement.
EIA report
10.5
10.2.2. WASTEWATER MANAGEMENT [TOR # 7, 21 & 25]

Sugar Plant
Total wastewater generation will be 600 KLD. Effluent generation per ton of cane crushed will be as
per CREP recommendations. The following is the ETP description.
Design Data & Performance Projections
This Wastewater Treatment plant (sugar + distillery) is designed for following parameters & shall
perform as under upon reaching steady state of its operation:
PARAMETER RAW WASTE WATER TREATED WASTEWATER

3
Flow (m /Day) 1600 1600
pH 5.0 – 6.5 6.5 – 8.0
BOD (mg/l) 3000 < 30
COD (mg/l) 6000 < 250
TDS mg/L 2000 < 2100
TSS mg/L 500 < 100
Oil & Grease mg/L 100 < 10
Note: The existing ETP is designed for 1000 KLD. Now we proposed to upgrade the ETP to 1600
KLD, to treat 1300 KLD of trade effluent with a cushion of 25% in order to treat the condensate
generated during the evaporation of Spent wash.
PROCESS DESCRIPTION
The proposed wastewater treatment plant shall consist of following treatment units.
PRIMARY TREATMENT
 Screen
 Oil & Grease trap
 pH adjustment
 Equalization Tank
SECONDARY TREATMENT
 UASB Anaerobic reactor
 Aeration Tank
 Secondary Clarifier
 Sludge Drying Beds
EIA report
10.6
Screen Chamber:
Screen chamber constructed in RCC shall be provided with SS 304 fabricated bar screen for
removal of free and floating material. The screen shall be inclined at 45 Deg with horizontal.
Oil & Grease Trap:

Oil and grease trap constructed in RCC shall be provided for removal of free and floating oil from
the Wastewater. The oil trap shall of gravity type and shall be provided with Belt type oil Skimmer.
Lime Preparation Tank:

A lime preparation tank constructed in RCC. In this tank is used for lime solution preparation and
continuous mixing of lime. Lime solution is then feed to equalization tank for pH correction in a
required proportion. 1 HP agitator shall be provided for mixing in the tank content.
Equalization:
Wastewater emanating from sugar has fluctuations in wastewater quality and quantity. Equalization
tank shall be provided for dampening these fluctuations. In equalization tank the raw effluent is
collected and equalized for adequate time. An equalization tank shall be provided with an agitator to
mix the tank content thoroughly. The equalized effluent from equalization tank shall then be pumped
to buffer tank. A stand by floating mixer shall also be provided for equalization tank
Buffer Tank:
Buffer tank constructed in RCC shall be provided for preconditioning / pre-acidification of the raw
effluent. In buffer tank the Raw Effluent is mixed with treated effluent form UASB Reactor. The
nutrient required for the process will also be added to the effluent in Buffer tank. The content of
buffer tank shall be mixed hydraulically using UASB Reactor feed pumps. The tank content will then
be pumped to UASB Reactor for first stage biological treatment.
UASB Reactor:
Upflow Anaerobic Sludge Blanket reactor is provided for anaerobic treatment of dairy effluent. The
UASB reactor shall be constructed in RCC M-25. The reactor consists of three zones viz. Influent
distribution zone, Reaction zone, Gas solid liquid separation zone.
Influent Distribution zone: The raw wastewater enters into the at the bottom through influent
distribution zone. A sophisticatedly designed piping net work is provided for uniform distribution of
the effluent in the tank. The effluent then travels upward in the reactor.
Reaction Zone: In the reaction zone the anaerobic bacteria are maintained in the form of sludge
blanket. The organic matter in the wastewater comes in contact with the bacterial population and is
EIA report
10.7
degraded anaerobically to methane rich biogas, the end product of anaerobic digestion. The
process of conversion of organic matter in to the biogas is a two-stage process. In the first stage the
organic matter in the raw effluent is converted in to the volatile acids by acid forming bacteria. In the
second stage the acid produced in the first stage are converted in to methane by another group of
bacteria i.e. methane formers. In UASB process both the stages are completed in single reactor.
The biogas so produced is bubbled through the effluent and is separated out in the third section i.e.
Gas-Solid-Liquid separation zone. The suspended solids are also separated to prevent escape of
solids from the reactor.
Gas-Solid – Liquid Separation: In gas solid liquid separation a hood fabricated in M S and duly
painted with corrosion resistant paint is provided. The hood separates the solid from the overflowing
reactor content. Gas collectors are provided for collection and conveyance of gas. The treated
effluent overflows through a launder and will take to a secondary treatment.
Aeration tank:
The partially treated effluent from UASB shall then be subject to activated sludge process for further
reduction of organic matter. Aeration tanks are provided for degradation of organic matter through
biological process. Microorganism in the controlled environment carries out the biodegradation
process. The container i.e aeration tank of requisite capacity is provided for this purpose. The tank
shall be provided with an aeration mechanism to transfer the oxygen from air to tank content for
survival for microorganisms. Slow speed fixed type surface aerators shall be provided for this
purpose. The content in the aeration tank is kept under constant aeration and mixing. The aeration
thank shall be constructed in RCC.
Secondary Clarifier:
A secondary Clarifier in the form of circular tank shall be provided for settlement of fully aerated
Effluent from the aeration tank. The tank shall be provided with centrally driven fixed bridge type
clarifier mechanism. Part of the settled sludge at the bottom of the settling tank will be pumped to
the aeration tank and part of it will be discharged on sludge drying beds as per operational
requirement. This sludge being fully mineralized is suitable for sun drying on sand drying beds.
Sludge Drying Beds: In aeration system the sludge is sufficiently mineralized and does not need
any further treatment before dewatering and disposal. Sand filtration drying beds will be provided,
where sludge will be dewatered by filtration through sand bed and sun drying of the dewatered
sludge is scraped & may be used as manure after composting.
EIA report
10.8
DETAILS OF TREATMENT UNITS:

ETP SPECIFICATION DETAILS
Sl.No Tank Name Details Cap/ M3 PUMP & MOTOR

01 Bar screen chamber 1400 x 3000 x 4.2
1000swd+300FB
02 Oil removal tank 2000 x 8500 x1200swd 20.4
+400FB
03 Oil collection pit 1000 x 1000 x 1.00
1000SWD+500FB
04 Equalization tank 10000 x 20000 x 500 KGEC 14-8, 3.7 KW,
2500SWD +500FB 2900 rpm
05 Lime dosing tank 1500 x 1500 x 3.375 510 LPH 0.75 KW,
1500SWD +300FB 1410 rpm
06 Flash mixer tank 2300 x 2300 x 10.58 10.58
2000SWD +300FB
07 Tube settler tank 4500 x 4000 x 2500 45 KGEC 12-5 2.2 KW,
SWD + 300 FB 2850 rpm
08 Feed tank 4000 x 4500 x 48.6 KGEC 14-8 5.5
2700SWD + 300FB KW, 2905 rpm
09 Anaerobic reactor 10400Dia x 8900SWD 755.65
+1000 FB
10 Bio-Tower 8000 x 8000 x 6000 384 KGEC 14-8 5.5
KW, 2905 rpm
11 Settling tank 4600 Dia x 2500SWD 41.5 41.5
+500FB
12 Aeration tank-I 5000 x 10000 225 1150 M3/Hr, pr- 0.4
x4500SWD+500FB kg/cm2,22KW,30HP, 1475
rpm
13 New Aeration Tank-II 39000 x18000 x3000 2106 Make: Premium, O.No:
(Fixed Aerators) 160811, Type: U8004DS,
Ratio:20:1,18.5KW,25HP,
1455 rpm
14 Primary clarifier 9000 Dia x 2500 SWD 158.96 KGEC 12-5 2.2 KW,
+ 500 FB 2850 rpm
15 New Secondary 11000Dia x4500Hig 450 KGEC 12-5 2.2 KW,
clarifier 2850 rpm
16 Primary Clarifier Gear Box:- 40:1, Type:- 1.5 KW, 1450 rpm
Stirrer NU
17 Secondary clarifier O.No: 160611, Type: 1.5KW,706rpm
Stirrer U400, Ratio:70:1, Sl
No: 213F133273
18 Treated Effluent 3000 x 6000 x 41.4
Collection tank 2300SWD + 500FB
19 New Sludge drain 4980x4930x1450 350 2.2KW,2900rpm
bed
20 Sludge drying bed 5000 x 5000 x 1400 350
21 Filter chamber 1500 x 1500 x 2000 9 9
22 Control panel room 6000 x 5000
and lab
EIA report
10.9
PUMP AND MOTOR DETAILS
SN. DESCRIPTION PUMP MOTOR NOS

.
1 Equalization tank outlet pumps KGEC 14-8 3.7 KW, 2900 rpm 02
2 Lime Dosing tank stirrer 0.75 KW, 90 rpm 01
3 Lime dosing pump 510 LPH 0.75 KW, 1410 rpm 02
4 Tube settler tank sludge pumps KGEC 12-5 2.2 KW, 2850 rpm 02
5 Feed tank outlet pumps KGEC 14-8 5.5 KW, 2905 rpm 02
6 Bio Tower outlet pumps KGEC 14-8 5.5 KW, 2905 rpm 02
7 Aeration tank air blowers 1150M3/Hr, pr- 0.4 22KW 1475 rpm 02
kg/cm2,
8 Aeration tanks I Make: Premium, O.No: 18.5KW 1455rpm 03
160811, Type:
U8004DS, Ratio:20:1,
9 Primary clarifier Sludge KGEC 12-5 2.2 KW, 2850 rpm 02
Recirculation Pumps
10 Primary clarifier Stirrer Gear Box:- 40:1, Type:- 1.5 KW, 1450 rpm 01
NU
11 Secondary clarifier Stirrer O.No: 160611, Type: 2.2KW,2900 rpm 01
U400, Ratio:70:1, Sl No:
213F133273
12 Secondary clarifier Sludge KGEC 14-8 2.2KW,2900 rpm 02
Recirculation pumps
13 Treated Tank Pumps
14 Sludge Drain Bed KGEC 14-8 2.2KW,2900 rpm 02
Note: All the civil structures in the ETP except sludge drying beds have been constructed
with RCC M20 grade to make them impervious. Sludge drying beds will be constructed with
brick masonry. Sugar ETP diagram shown below.
EIA report
10.10
EIA report
10.11
B) Cogeneration Power Plant
Total wastewater generation from power plant will be 407 Cum/day (including expansion). The
effluent generated from the power plant will be treated and utilized as following.
Cooling tower blow down and DM plant regeneration will be recycled back into process. Boiler blow
down and Service water will be neutralized and after treatment it will be utilized for ash quenching,
dust suppression and greenbelt development.
Sanitary waste water will be treated in septic tank followed by soak pit. Hence there will not be any
adverse impact on environment due to the proposed activities.
C) Distillery Plant:
As per CPCB recommendations the spent wash quantity will be restricted to a maximum of 10 kl/kl
of R.S. for Molasses by adopting continuous fermentation technology. The Maximum Spent wash
generation from the Ethanol plant with Molasses as raw material will be 900 KL/day after proposed
expansion
The spent wash will be concentrated to 60 – 65 % solids in Multiple Effect Evaporators and then will
be incinerated in exclusive 10 TPH Boiler (existing) and 15 TPH Boiler (expansion). This is a ZERO
discharge system already approved by Central Pollution Control Board.
EVAPORATION SYSTEM
The objective of Evaporation is to concentrate a solution consisting of a volatile solute and a volatile
solvent. Evaporation is conducted by vaporizing a portion of the solvent to produce a concentrated
solution of thick liquor with 60% solids and 40 % moisture content.
The evaporation system consists of 5 evaporators, which are connected, in series. The spent wash
will be pumped from distillation section, which will be fed to the evaporator by using feed pump. Gas
Liquid separator (5 Nos.) will be used to separate the vapor and liquid. Both Vapor & Spent wash
will be fed to the next evaporation effect so it is called as feed forward effect evaporation. The vapor
from last evaporator will be condensed in condenser and transferred to the dryer while the
condensate from the evaporators is first utilized for heat recovery. While vacuum pump maintains
vacuum in the entire system. Product final thick spent wash with 60% solids will be used in boiler for
incineration.
INCINERATION OF CONCENTRATED SPENT WASH
The final concentrate from the Evaporators (60% solids w/w) will be incinerated in the Boiler by
mixing with coal. The condensate from the Evaporation system will be reused in the plant operation.
Zero discharge will be implemented as per CREP recommendations. ETP diagram shown below
EIA report
10.12
ETP FLOW CHART

(DISTILLERY)
EIA report
10.13
Non-Process Effluent Treatment & Disposal:

Cooling tower blowdown and DM plant regeneration water will be recycled into process. Boiler
blowdown and service water effluent will be treated in neutralization tank and treated effluent will be
utilized for greenbelt development / ash conditioning / dust suppression in the plant premises after
ensuring quality of treated effluent with standards stipulated for onland for irrigation by CPCB /
KSPCB.
Storage Lagoon: [TOR # 20]

A Spent wash storage lagoon of storage capacity of 3 days which is less than 30 days will be
provided as per CPCB protocol. Closed storage tank will be provided.
Recommendations
a) Minimize the quantity of effluent through reuse to the maximum possible extent.
b) The ETP shall be constructed before commissioning of the main plant.
c) The ETP units shall be taken up for maintenance; whenever for main plant is taken for
maintenance.
d) Inlet and outlet effluent samples shall be collected monthly and shall be analyzed to
ascertain the efficiency of ETP and meet the statutory requirements.
10.2.3. SOLID WASTE & DISPOSAL METHOD [TOR # 7 & 26]

The following are the solid waste generation & disposal.
Quantity (TPD)
S.No Solid waste Disposal
Sugar Plant
Will be used as fuel in Co-gen
1. 1Bagasse 1440 360 1800 Boiler (120 TPH (existing) & 45
TPH (proposed) Boilers
Will be used in the proposed
2. Molasses 216 54 270
Distillery
3. ETP Sludge 0.14 0.1 0.24 Will be used as manure
Cogeneration Power plant
When Bagasse Will be disposed to farmers to
4. used as fuel in 23 8.5 31.5 use as manure in Agricultural
Boiler lands
Distillery
Yeast Sludge Mixed with spent wash and
6. 6.0 6.0 12.0
incinerated in the boiler.
When concentrated Ash generated will be given to
7. spent wash used as 7.2 10.8 18 Group fertilizer unit
fuel in Boiler
EIA report
10.14
10.2.4 NOISE LEVEL MANAGEMENT
The major sources of noise generation are STGs, Boiler & compressors. STG will be of
internationally reputed make which will be manufactured as per MOEF/OSHA/other international
guidelines on noise levels. Noise enclosures will be provided to Steam turbines. The major noise
levels will be confined to the working zones of the proposed activities. The Leq of eight hours will
be within the prescribed standards. Community noise levels are not likely to be effected due to the
proposed thick green belt which will act as physical barrier and further attenuate the noise levels.
Recommendations
a) Noise enclosures will be provided to STGs.
b) By adopting shock-absorbing techniques noise impact can be reduced.
c) Earplugs shall be provided to the workers and this shall be enforced strictly.
d) Increase the distance between source and receiver, by altering the relative orientation of
receiver and the source.
e) Rotation of workers working in the noise prone areas.
f) Thick greenbelt shall be developed to further mitigate the noise levels.
10.2.5 LAND ENVIRONMENT
The effluent from Sugar and co-gen power plant will be treated and utilized for Dust suppression,
Ash Conditioning, Bagasse wetting Greenbelt development / R&D sugar plantation etc. The spent
wash (thin slop) will be treated to achieve zero discharge as per CPCB stipulation. Hence there will
not be any impact on land environment due to the proposed expansion project. The solid waste will
be disposed off to the satisfaction of CPCB / KSPCB. Due to the extensive greenbelt development
proposed the aesthetics of the land will improve. The land prices in the area will increase due to the
proposed expansion project.
Recommendations
Land scaping can be done around the Administrative building, E.T.P etc. This will help in preserving
the ecological conditions.
10.2.6 ODOUR CONTROL MEASURES [TOR # 28]

The following measures will help in minimizing the odor.
 The spent wash storage will be restricted to 3 days capacity.

 Spent wash generated will be concentrated and will be incinerated in exclusive 10 TPH
(existing) and 15 TPH ( proposed) Boilers.
 Spent wash treatment takes place in closed condition.
 Greenbelt developed all around the plant will aid in controlling odour.
EIA report
10.15
10.2.7 MEASURES FOR IMPROVEMENT OF ECOLOGY
There are no National Parks/Sanctuaries within 10 Km. radius of the plant. In the existing and
proposed expansion plant zero discharge method will be followed as per CPCB norms. There are
no rare and endangered species in the area. Hence there will not be any adverse impact on flora &
fauna due to the proposed expansion.
Recommendations
Plantation programme should be undertaken at vacant areas available in the plant premises.
Plantation programme should include species which are dust tolerant and gas absorbing. People
should be educated and trained in social forestry activities by local governmental and non-
governmental organizations.
Plantation for Aesthetics

Plantation in industrial areas should be done along the narrow and broad internal road. This will not
only improve the flora in the region but also will add to the aesthetics of the region.
10.2.7.1 GREEN BELT DEVELOPMENT [TOR # 29]

Extensive greenbelt has already been developed in the plant premises. In addition to the existing,
efforts will be made to develop more greenbelt in the existing plant. This will further mitigate the
pollution impacts. Greenbelt has been developed all around the plant. A detailed greenbelt plan will
be developed as per CPCB guidelines in consultation with local DFO.
Greenbelt plantation
Greenbelt has already been developed in a set of rows of trees in such a way that they form an
effective barrier between the plant and the surroundings. The main purpose of greenbelt
development is to contribute to the following factors.
 To maintain the ecological homeostatus.
 To attenuate the air emissions from the boiler and the fugitive dust emissions.
 To prevent the soil erosion.
 To attenuate the noise levels.
 To utilise the treated effluents.
Plantation of grass, flowers, bushes and trees will be developed in future taken up to reduce the
generation of dust from the bare earth and to enhance the aesthetic value.
Plantation species
Plantation species will be considered based on the following.
 Suitable to the Geo-climatic conditions of the area.
EIA report
10.16
 Mix of round, spreading, oblong and conical canopies.

 Ever green trees.
 Different heights ranging from 4m to 20m.
Plantation for arresting dust

Trees particularly having compact branching closely arranged leaves of simple elliptical and hairy
structure, shiny or waxy leaves and hairy twigs are efficient filters of dust. The following species are
suggested to arrest the dust
Alstonia Scholaris
Bauhinia purpurea
Cassia siamea
Peltoferrum ferrugineum
Butea monosperma
Tamarindus indica
Azadirachta indica
Plantation to absorb SO2 emissions
The following plants are suggested for plantation to absorb SO2 in the air.
Azadirachta indica
Albizia lebbeck
Alstonia scholaris
Lagerstroemia flosregineae
Melia azedarach
Minusops elangi
Polyalthia longifloia
Plantation to reduce noise pollution
Trees having thick and flushy leaves with petioles are suitable. Heavier branches and trunks of trees
also deflect the sound waves. The following plant species are suggested to reduce noise pollution.
Alstonia scholaris
Azadirachta indica
Melia monosperma
Grevillea peridifolia
Tamarindus indica
Plantation along the roads

Alstonia scholaris
Cassia fistula
EIA report
10.17
Bauhinia purpurea
Mimusops elangi
Pongamia pinnata
Polyalthia longifolia
Poluferrum ferrugineum
Lagerstroemia flosreginea
Cassia siamea.
Greenbelt development plan

 Local DFO will be consulted in developing the green belt further.
 Greenbelt of 85 acres (Including existing greenbelt) will be developed in the proposed
expansion project.
 15 m wide greenbelt will be developed all around the plant.
 The tree species to be selected for the plantation are pollutant tolerant, fast growing, wind
firm, deep rooted. A three tier plantation is proposed comprising of an outer most belt of
taller trees which will act as barrier, middle core acting as air cleaner and the innermost core
which may be termed as absorptive layer consisting of trees which are known to be
particularly tolerant to pollutants.
 1500 nos. of plants will be planted per hectare i.e 600 per Acre.
 Greenbelt will be developed as per CPCB Norms.
10.2.8 MINIMIZATION MEASURES [TOR # 38 & 43]

RAIN WATER HARVESTING
Rainwater harvesting pits will be constructed to harvest the run-off water from roof top by laying a
separate storm water drainage system for recharging of ground water in consultation with the State
Ground Water Board.
RECYCLE / REUSE / RECOVER MEASURES
 Cooling tower blowdown & DM plant regeneration waste water is being recycled into the
process
 Condensate generated from Spent wash treatment is being utilized as cooling tower make
up and boiler make up
 Waste water generated from the Sugar plant is being treated in ETP and treated waste water
is being used for Greenbelt development, ash conditioning and dust suppression after
ensuring the quality of treated waste water with standards laid down by MoEF/KSPCB
standards
EIA report
10.18
10.3 POST PROJECT MONITORING STRATEGY [TOR # 15 & 45]

The monitoring of various environmental parameters is necessary, which is one of a part of
environmental protection measures. Monitoring is an important feature because the efficiency of
control measures can only be determined by monitoring. A comprehensive monitoring programme is
given under.
PM2.5, PM10, SO2 and NOX & Asbestos Fibre count are monitored as per Ministry notification vide
G.S.R. No. 826(E) dated 16th November, 2009.
Locations and frequency of monitoring as per the guidelines of KSPCB and MoEF are tabulated
below.
MONITORING SCHEDULE FOR ENVIRONMENTAL PARAMETERS

S.NO PARTICULERS FREQUENCY OF DURATION OF PARAMETERS
MONITORING SAMPLING REQUIRED TO BE
MONITORED
1.WATER QUALITY
A. Water and waste
water Quality
A.Sanitary Effluents
/Industrial Effluents. Once in a month Composite sampling pH, EC,TDS, BOD,
COD, Cl, SS,
b. Ground water Sulphates
Quality (Peizometric
wells will be located Once in a month Grab sampling As per BIS: 10500
around spent wash
storage area, ETP )
2. AIR QUALITY
A. Stack Monitoring
Once in a month PM,SO2 & NOx
45 TPH Boiler
Online monitors PM
15 TPH boiler
Once in a month SO2 & NOx.
B. Ambient Air quality Twice a week 24 hours PM10, PM2.5, SO2 &
continuously NOx
C. Fugitive emissions Once in a Month 8 hours PM
3. METEOROLOGICAL DATA
Meteorological data Daily Continuous Temperature,
to be monitored at the monitoring Relative Humidity,
plant. rainfall, wind direction
& wind speed.
4. NOISE LEVEL MONITORING
Ambient Noise levels Twice in a year Continuous for 24 Noise Levels
hours with 1 hour
interval
EIA report
10.19
Infrastructure for Environmental Protection

Man Power
In the existing plant, equipped laboratory has been provided to carry out the analysis of waste water
and treated waste water. An external testing laboratory also has been appointed for carrying out
monitoring of air, water and noise. The following manpower are already appointed to look after
environmental protection
Environmental Engineer / Safety Officer

An Environmental Officer with adequate experience has been appointed. He is responsible for
implementing and monitoring the environmental impacts and all the safety aspects. He is also a
laisioning officer between the industry and the regulatory agencies like KSPCB, CPCB etc.
Chemist
A qualified chemist has been appointed to carry out the analysis of various samples.
10.4 COMPLIANCE ON CREP RECOMMENDATIONS [TOR # 41]

In the existing plant we are complying with the CREP recommendations and similar practice will be
followed in the proposed expansion project also.
The following is the compliance on CREP recommendations for Sugar, Power & Distillery
Sugar Plant
S.No. CREP recommendation Compliance

Waste Water Management
1. Operation of ETP shall be started at least Every year we are starting the ETP operation
one month before starting of cane on month prior to the starting of the crushing
crushing to achieve desired MLSS so season. And the desired MLSS level is being
as to meet the prescribed standards from maintained and the standard prescribed
day one of the operation of mill. norms are maintained from the day one of the
operation of mill.
2. Reduce wastewater generation to 100 Waste water generation is being maintained
liters per ton of cane by April 2004. below 100 liters per ton of cane crushed.
Similar practice will be followed after proposed
expansion also
3. To achieve zero discharge in inland Treated waste water is being utilized for
surface water bodies by December 2004. Greenbelt development, ash conditioning and
dust suppression
4. To provide 15 days storage capacity for We have provided 15 days storage capacity
treated effluent to take care of no for treated effluent to take care of no demand
EIA report
10.20
demand for irrigation by April 2004. for treated effluent for irrigation.
Emission Control
To install ESP/bag filter /high efficiency We have already installed ESP for 120 TPH
scrubber to comply with standards for Boiler of Co-Generation plant and we have
particulate matter emission to< 150 achieved particulate matter emission to <150
mg/Nm3 by April 2004. mg/Nm3. In the proposed expansion Bag filters
will be provided to the 45 TPH Boiler to bring
down the particulate emissions to less than
<150 mg/Nm3
Power Plant

1. New / expansion power projects to be Particulate emission from the proposed new
accorded environmental clearance on or 45 TPH Boiler will be below 50 mg/Nm3
after 1.4.1.2003 shall meet the limit of
100 mg/Nm3 for particulate matter.
2. New plants shall adopt dry fly ash In the proposed expansion, fuel for the Boiler
extraction or dry disposal system or (45 TPH) will be only bagasse and for
Medium (35-40%) ash concentration Incineration boiler will be Concentrated spent
slurry disposal system or Lean phase wash. Hence ash generation from Co-gen
with hundred percent ash water re- boiler will be very low and will be utilized as
circulation system depending upon site manure or disposed to brick manufacturers.
specific environmental situation. The ash from the Incineration boiler will be
given to group company fertilizer units
3. Install opacity meters / continuous Online stack monitor will be provided to the
monitoring system. stack to monitor PM continuously
4. New plants shall promote adoption of Only Bagasse will be used as fuel in the Boiler
clean coal and clean power generation which has low ash and sulphur content.
technologies Concentrated spent wash will be used as fuel
for incineration boiler
EIA report
10.21
Distillery Plant

1. Existing molasses Based Distilleries will Not applicable
furnish bank guarantee and Action Plan
to concerned State Board to ensure
compliance with any combination of the
following measures;
2. Compost making with press Not applicable as we are following 100%
mud/agricultural residue/ Municipal incineration technology in the existing and
Waste: proposed expansion project
3. Concentration and drying/ Incineration. Spent wash generated is being evaporated in
Multiple Effect Evaporators. The concentrated
spent wash is being be used as fuel for 10
TPH capacity incineration boiler. The entire
quantity of concentrated spent wash is burnt in
to incineration boiler. Similar system will be
followed in the proposed expansion project
also
4. Treatment of spent wash through bio- Not applicable as we are following
machination following by secondary concentration followed by incineration
treatment (BOD < 2500 mg/I) for technology in the existing and proposed
controlled discharge into sea through a expansion project
proper submerged marine outfall at a
point permitted by SPCB/CPCB in
consultation with National Institute of
Oceanography (NIO), so that Dissolved
Oxygen in the mixing zone does not
deplete, less than 4.0 mg/I.
For taking decision on feasibility of one Not applicable as we are following
time controlled land application of treated concentration followed by incineration
effluent, a study will be under taken technology in the existing and proposed
within three months. expansion project
The road map for utilization of spentwash
by the distilleries to achieve zero
discharge of spent wash in inland surface
water courses will be as below:-
EIA report
10.22
50% utilization of spentwash - By March,

2004
75% utilization of spentwash - By March,
2005
100% utilization of spentwash - By
December, 2005
The 100% utilization of spentwash is
achieved, controlled and restricted
discharge of treated effluent form lined
lagoons during rainy season will be
allowed by SPCB/CPCB in such a way
that the perceptible coloring of river water
bodies does not occur.
Monitoring Task Force consisting of Noted the condition.
CPCB, SPCB, Experts and industry shall
be constituted for monitoring the
implementation of action points.
New Distilleries & Expansion of Existing Spent wash generated is being evaporated in
Distilleries Multiple Effect Evaporators. The concentrated
(Molasses based) Proposal for spent wash is being be used as fuel for 10
Standalone new distilleries and TPH capacity incineration boiler. The entire
expansion of existing distilleries will out quantity of concentrated spent wash is burnt in
achieving zero discharge in surface to incineration boiler to achieve zero
water/ groundwater will not be discharge. Similar system will be followed in
considered MoEF/ SPCB. the proposed expansion project also
* to be decided by SPCB/ CPCB/ MoEF.
10.5 COST FOR ENVIRONMENTAL PROTECTION [TOR # 11]

The capital investment of the proposed expansion project is Rs. 125.0 Crores.
Capital Cost for Environment Protection for proposed project: Rs.10 Crores.
Recurring Cost per annum for Environmental protection: Rs. 0.5 Crores.
EIA report
10.23
CHAPTER – 11
SUMMARY
Existing capacities : Sugar – 4800 TCD

Co-gen power – 24 MW
Distillery plant – 45 KLD
1. Proposed expansion : Expansion of sugar plant from 4800 TCD to 6000 TCD
Expansion of Co-gen power plant – 24 MW to 34 MW
Expansion of Ethanol Plant – 45 KLPD to 90 KLPD
Electricity from the Incineration Boiler – 3 MW
2. Main Products (after proposed : Sugar – 600 TPD
expansion) Power – 34 MW
Rectified Spirit /ENA/ Ethanol - 90 KLPD
Power from incineration boiler – 3 MW
Sugar Plant :
3. Raw materials requirement for Sugar cane -1200 TPD
expansion Lime – 2.4 TPD
Sulphur – 0.96 TPD
Phosphoric acid – 0.24 TPD
Co-generation power Plant (45 TPH Boiler) :

Bagasse -528 TPD
Distillery Plant :
Molasses – 165 TPD
Fuel for Incineration Boiler(15 TPH Boiler):

Concentrated spent wash - 108 TPD
Coal - 36 TPD
4. Water requirement for expansion 1159 KLD
5. Boiler details Capacity of proposed Cogen Boiler - 45 TPH
Capacity of proposed Incineration Boiler - 15 TPH
Co-genBoiler:
6. Air Emission Control equipments Air emission Control system : ESP
PM : < 50 mg/Nm3
Stack Height : 44 m
EIA report
11.1
Distillery Boiler:
Air emission Control system : Bag filter
PM : < 50 mg/Nm3
Stack Height : 50 m
7. Source of water Water requirement for the existing Plant is being met
form the Kali River. For the proposed expansion also,
water required will be met from the Kali River.
8. Wastewater management Sugar plant
 Effluent generation per ton of cane crushed will
be below 100 lit /ton of cane crushed as per
CREP recommendations.
 Effluent generated from the Sugar plant will be
treated in specially designed ETP and treated
effluent will be utilized for greenbelt
development after ensuring quality of treated
effluent with standards stipulated for onland for
irrigation by CPCB / KSPCB.
Co-generation Power Plant
 Cooling tower blowdown and DM plant
regeneration water will be recycled into process.
Boiler blowdown and service water effluent will
be treated in neutralization tank and treated
effluent is will be utilized for greenbelt
development / ash conditioning / dust
suppression in the plant premises after ensuring
quality of treated effluent with standards
stipulated for onland for irrigation by CPCB /
KSPCB Sanitary waste water will be treated in
septic tank followed by soak pit. Hence there will
not be any adverse impact on environment due
to the proposed activities.
Distillery Plant :
 The spent wash generated from the distillery will
be concentrated in Multiple Effect Evaporators
(MEE) to 60% solids and then the concentrated
EIA report
11.2
spent wash will be incinerated along with coal in

10 & 15 TPH incineration boilers.
 This is totally a zero discharge based
technology.
 This technology is approved by CPCB.
9. Solid waste disposal Sugar plant:

Bagasse - Used as fuel in co-gen power plant
Molasses - Used as raw material in Distillery plant
Filter cake- As mud is recycled to diffusor, Filter cake
no generation.
ETP Sludge - Will be used as manure
Co-generation Power Plant:

When Bagasse is used as fuel
Boiler ash - Will be given to nearby farmers to use in
Agriculture as manure.
Distillery Plant:
Yeast Sludge - Mixed with spent wash and incinerated
in the boiler.
When concentrated spent wash is used as fuel
Boiler ash - Ash generated will be given to Group
fertilizer unit
10. Green belt development Greenbelt of 85 acres will be developed (Including
existing greenbelt) in the plant premises as per CPCB
guidelines.
EIA report
11.3
CHAPTER – 12
DISCLOSURE OF CONSULTANTS
12.0 DISCLOSURE OF CONSULTANTS
PIONEER ENVIRO LABORATORIES & CONSULTANTS PVT. LTD. (PELCPL) is an ISO

9001-2008 certified organization. It is an QCI – NABET accredited EIA consultant (Sl. No. 109
in the List of Consultants with Provisional Accreditation as on 5th December 2013) for
Category – A projects.
The Experts involved for the Study are:
Name of EIA coordinator: Shri. Y.Maheshwara Reddy
Name of Team member: Shri. K. Santhosh Kumar
It is one of the leading Environmental Consultancy organizations in South India and

Chhattisgarh. Established in 1996 PIONEER ENVIRO has an excellent track record of
serving several well established Group companies across the Country.
PIONEER ENVIRO is a team of professionals in various disciplines such as Environmental

Engineering & Environmental Management. The team is slated to double in next two years.
Our goals are to provide all of our clients with quality services at a fair, competitive price. By
offering a turnkey service (excepting some specific areas), we can maximize the efficiency of
data collection so that our clients pay one time for similar services. The technologies deployed
at PIONEER ENVIRO are current and leading edge, duly validated.
PIONEER ENVIRO has an exceptional team of Environment professionals. PIONEER

ENVIRO has the expertise to assess the impact of various industrial activities such Power
Plants, Steel Plants, Distilleries, Cement Plants etc., on the environment. These assessments
will help the industry to install the best Environmental Management Systems and to maintain
the plant in accordance with the norms stipulated for ISO-14001 & ISO-18000. PIONEER
ENVIRO services range from site assessments, environmental audits, environmental impact
statements and risk assessments to waste management.
Following are some of the services which are PIONEER ENVIRO core competency:
 Helping the client to select the suitable site as per the norms of Ministry of
Environment and Forest, Govt. of India and State Pollution Control Boards in India.
EIA report
12.1
 Environmental Impact assessment studies carried out as per the guidelines issued by
Ministry of Environment and Forest, Govt. of India and State Pollution Control Boards
in India.
 Environment Audits.
 Risk Assessment and Disaster Management Studies.
 Occupational health & industrial hygiene.
 Solid waste management.
 Environmental baseline studies covering the fields of ambient Air, Surface water,
Ground water, Soil, Noise and Biological Environment (Flora & Fauna).
 Stack Emission Monitoring, Effluent Analysis, Ground water analysis.
EIA report
12.2

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DRAFT

ENVIRONMENTAL IMPACT ASSESSMENT

Based on: TOR LETTER ISSUED BY THE MINISTRY VIDE NO:

E.I.D PARRY (INDIA) LIMITED

Village:Hullatti & Alloli, Taluk Haliyal,

ISO 9001: 2008 Certified Accredited by NABET - QCI

6-3-652 | Flat # 7-3 | Dhruvatara Apartments | Amrutha Estates | Erramanjil | Somajiguda |

1.0 PREAMBLE 1-1

2.1 TYPE OF PROJECT 2-1

3.1 AIR ENVIRONMENT 3-1

EIA report - Index

3.2.1.2 SOURCES OF NOISE 3-7

5.1 ALTERNATIVE TECHNOLOGIES 5-1

6.1 TECHNICAL ASPECTS 6-1

EIA report - Index

7.1 INTRODUCTION 7-1

EIA report - Index

7.15.2 OPERATION & MAINTENANCE PHASE 7-22

8.1 PHYSICAL INFRASTRUCTURE 8-1

10.0 INTRODUCTION 10-1

EIA report - Index

S. No. CONTENTS PAGE NO.

4.1.1 BOILER STACK DETAILS 4-4

7.1 DETAILS OF TANKFARMS 7-2

EIA report - Index

TOR No. TOR TOR Compliance Pg. No.

6. Regulatory framework Kindly refer to CHAPTER – 2 Pg. No.2.7

treated effluent quality, re-utilization and disposal of

solid/hazardous waste for the existing unit.

from molasses based distillery.

of the company to deal with the environmental issues

M/s.E.I.D.Parry( India) Limited ( Formerly Known as Parrys Sugar Industries Limited) is an

Sugar Plant : 4800 TCD

Now the company has proposed to enhance the capacity of

1.1 PURPOSE OF THE REPORT

S. No Unit Capacity Categorization as

1.2 IDENTIFICATION OF PROJECT & PROJECT PROPONENT

S.No Name Designation

1.3 BRIEF DESCRIPTION

1.3.1 NATURE OF THE PROJECT

The proposed project involves:

1.3.3 SIZE OF THE PROJECT

1.3.3 LOCATION OF THE PROJECT

1.3.4 IMPORTANCE OF PROJECT

Snapshot of Indian sugar industry

 Operational sugar mills – 526 operational (695 installed)

Average Milling capacity at different countries

Capacity profile of Indian sugar industry

Integrated Sugar Mills

Note :- in addition to the above, another 168 standalone distilleries in India

Consideration of by-products in cane pricing

 Government of India’s Fair & Remunerative Price

Distillation capacity in India

Ethanol blending programme

Ethanol: tool to balance sugar production

 5% blending programme requires 1 billion litres of ethanol

Several uses of Bagasse

 Burn in boilers to generate power

Bagasse based cogeneration of power

 At current installed crushing capacity, potential to generate power is said to be 7500

Government support for by-products

 Government of India provides concessional loans

 Government support should help improve