WELCOME

Expert Appraisal Committee Members, MoEFCC; New Delhi

Environmental Clearance (EC) Presentation
On
Expansion of 30 KLPD Molasses based Distillery to 300 KLPD C / B- Heavy
Molasses/ Sugarcane Syrup Distillery for Ethanol Production with 6 MW Captive
Power Generation & Enhancement in Sugarcane Crushing from 3,500 to 7,500 TCD
(In Project Complex of 3,500 TCD Sugar Factory, 18 MW Cogeneration Plant & 30 KLPD Distillery)
(Cat. B2 Project as per MoEFCC Notification No. 980 (E) dt.02.03.2021)

By

Nira Bhima Sahakari Sakhar Karkhana Ltd. (NBSSKL)

At: Shahajinagar, Po: Redni, Tal.: Indapur, Dist.: Pune, MS

Prepared By

Equinox Environments (I) Pvt. Ltd.

Environmental; Civil & Chemical Engineers, Consultants and Analysts, Kolhapur (MS)
QCI- NABET & ISO 9001 : 2015 Accredited Organization
Email : eia@[Link], projects@[Link]

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 Nira Bhima Sahakari Sakhar Karkhana Ltd. (NBSSKL), At: Shahajinagar, Po: Redni, Tal.: Indapur,Dist.: Pune, MS
Expansion of Molasses based Distillery (30 to 300 KLPD) using C / B Heavy Molasses/ Cane Syrup for Ethanol
Production with 6 MW Captive Power Generation, Enhancement in Cane crushing (3,500 to 7,500 TCD)
1 New Project / Expansion Project Expansion Project
2 Project Capacity Expansion of Molasses based Distillery (30 to 300 KLPD) using C / B
Heavy Molasses/ Cane Syrup for Ethanol Production with 6 MW
Captive Power Generation, Enhancement in Cane crushing (3,500
to 7,500 TCD)
3 Forest Area/ Wildlife/ ESZ if any Not Applicable
4 Name of EIA Coordinator, Consultant, Ms. Sulakshana Ayarekar, Equinox Environments (I) Pvt. Ltd.,
NABET Registration No. & Validity NABET/EIA/1821/RA 0135, 08.07.2022
5 Monitoring Period Not Applicable. Project to be appraised as B2 as per Notification
6 Date of Public Hearing (P.H.) S.O. 980 (E) 02.03.2021 under EBP program
conducted
7 Status of FC; CRZ & CPA Not Applicable
8 Certified Compliance submitted Yes. For 30 KLPD Molasses based Distillery (EC dt. 17.03.2009) & 18
MW Co-gen Plant (EC dt. 21.01.2014)
9 Ro; MoEFCC, Nagpur Visit & Report Dt. 14.10.2020 & 02.03.2021
10 Any Court Cases against the Project No

Project Proponents
No Name Designation
1 Mr. Lalasaheb Devidas Powar Chairman
2 Mr. Kantilal Shivaji Zagade Vice - Chairman
3 Mr. S. G. Genge - Patil Managing Director 2
 Introduction
1 Project Nira Bhima Sahakari Sakhar Karkhana Ltd. (NBSSKL), At: Shahajinagar, PO: Redni, Tal.: Indapur, Dist.:Pune,
Description MS. Expansion of 30 KLPD Molasses based Distillery to 300 KLPD C / B- Heavy Molasses/ Cane Syrup
based Distillery for Ethanol Production with 6 MW Captive Power Generation & Enhancement in
Sugarcane Crushing from 3,500 to 7,500 TCD, Cat.: B2, Item: 5 (g- i & ii), 5(j).
2 Plot (Ha) 53.40 [Built up : 2.33 (Existing) + 2 (Proposed), Road: 3.79, Open Space : 27.12, Parking: 15.93 (30% of TPA)]
3 GB (Ha) Existing: 12.28 (23% of TPA), Expansion: 5.87 (11% of TPA), Total: 18.15 (34% of TPA)
4 LU change Present Land use is Industrial only
5 Air & Noise Air: Stack Emissions: Proposed Incineration Boiler- 70 TPH (APC: ESP; 100 M Stack); Proposed Sugar
Pollution Factory Boiler- 30 TPH (APC: ESP; 40 M Stack); Existing Sugar & Cogen Boiler- 66 TPH (APC: ESP; 75 M
Sources Stack), & 40 TPH (APC: Wet Scrubber; 60 M Stack), Fugitive Emissions: Mills, Sugar Bagging, Bagasse;
Pressmud & Ash Storage Yards, Bagasse Conveyor. Noise : Mills, Pumps, Compressors, D. G sets, Boiler &
Turbine Section
6 Project Cost Existing: Rs.255.01 Cr., Expansion: Rs. 290 Cr., Total: Rs. 545.01 Cr.
7 EMP Cost Existing: Rs.22.30 Cr., Expansion: Rs. 91.25 Cr., Total: Rs. 113.55 Cr.
8 CER Cost Existing: Rs.4.49 Cr., Expansion: Rs. 2.20 Cr., Total: Rs. 6.49 Cr.
9 EMC Details 9 Members, [Link]. (Env. Sc.), [Link]. (Chem.), PGDISHE. Chairman, MD, Chief Chemist, Distillery Incharge, Environment Engineer

1 Water (CMD) Distillery: 4317 (1103 Fresh+2514 CPU Treated Effluent+354 STP & ETP Treated Effluent+346 RWH); 74% Recycle
Sugar & Co-gen: 3266 (10 Fresh + 3256 Excess Cane Condensate) 100% Recycle
2 Source Bhima River (0.4416 Million Cu.M; Permission granted from Irrigation Dept.; Maharashtra)
3 Energy Existing: 7.3 MW; Proposed: 11.9 MW, Total: 19.2 MW
4 Fuels (TPD) Distillery: Proposed 70 TPH Incineration Boiler (Coal: 278 / Bagasse: 695 + Conc. Sp. wash: 648),
Sugar & Co-gen: Proposed 30 TPH Boiler (Bagasse: 360); Existing: 66 & 40 TPH Boiler (Bagasse: 998 &
Biogas: 12,000 CMD)
5 Effluent (CMD) Spentwash: 2400 (Conc. [Link]: 480); Other Effluents (MEE Cond., Cooling & Boiler B/d, Washing):
2515
6 Treatment & [Link]: MEE- Incineration; CPU Treated Effluent: 100% Recycled in Process- ZLD; Proposed CPU
Disposal (Upgradation): Cap. 2,600 CMD (Operational: 2,515 ), Existing STP : Cap. 30 CMD (Operational : 24)
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 About the Project & Allied Developments

• Year 1999: Industry Registration as - M/s. Nira Bhima Sahakari Sakhar Karkhana Ltd.
• Year 2001-02 : Sugar Factory First Crushing Season (Capacity: 1250 TCD)
• Year 2006 : First Expansion of Sugar Factory (2500 TCD)
• Year 2009 : 30 KLPD Distillery Establishment
• Year 2013 : Second Expansion of Sugar Factory (3500 TCD)
• Year 2014 : 18 MW Cogeneration Plant Establishment 4
• Year 2022 : Expansion of Sugar Factory (3500 - 7500 TCD) & Distillery (30 - 300 KLPD) with 6 MW CPP.
 Salient Features of Integrated Project Complex
A. Distillery -
• 100% Biofuel Ethanol Manufacturing and Participation in National Bio-Fuel Program.
• 100% Fresh Water Saving for Cane Juice Distillery (Requirement: 0 KL/KL, Norm: 10 KL/KL)
• 64% Less Water for Molasses Distillery (Requirement: 3.6 KL/KL, Norm: 10 KL/KL)
• 90% (Cane Juice) Lesser Spentwash to Disposal (Generation : 0.8 KL/KL, Norm : 8 KL/KL)
• 80% (Molasses) Lesser Spentwash to Disposal (Generation: 1.6 KL/KL, Norm: 8 KL/KL)
• Existing Spentwash Bio-composting Discontinuation.
• 70 TPH New Incineration Boiler (APC: ESP, 100 M Stack & OCMS)
• ZLD tho’ Spentwash - MEE Concentration - Incineration
• Spentwash Ash : Good N (1%), P (0.5%) & K (2%) contents. Ash Brick Making Proposed.
• CO2 from Fermenters to be Cleaned, Compressed & Bottled.
• Substantial Investment for EMP; Existing: Rs. 22.30 Cr; Proposed: Rs. 91.25 Cr.
• Handsome Provisions for CER; Existing: Rs. 4.49 Cr; Proposed: Rs. 2 Cr
• O & M of ETP, APC & Other Infrastructure : Rs. 9.50 Cr / Yr.
• 11% More Green Belt to Make up 34% of TPA (Existing GB: 23%)
• 1 MW Solar Photovoltaic Electricity Generation Plant to be provided in the Industry

B. Sugar Factory -
• 100% Saving in Process Fresh Water (Requirement: 0 Lit/MT; Norm: 100 Lit/MT)
• 73% Reduction in Effluent w.r.t. Norm (Generation: 63 Lit/MT, Norm: 200 Lit/M)
• 40% Increase in ETP Efficiency (Exist. BOD: 100 mg/lit; Prop. BOD: 60 mg/lit)
• ZLD for Sugar Factory tho’ Reduce- Reuse- Recycle
• New 30 TPH Bagasse based Boiler in Sugar Factory (ESP & 40 M stack as APC & OCMS)
• ESP as APC to Cogen Boiler (ESP Efficiency : 99.5%)
• 10% Less Steam Consumption – 46% Steam on Cane to 36%
• 30% of TPA provided for Parking Area 5
 Certification by RO; MoEFCC; Nagpur (Visit dt.: 14.10.2020 & Report dt. 02.03.2021): 30 KLPD Molasses Distillery
• Out of 8 Specific Conditions; 4 were Fully Complied, 1 were Partly Complied & 3 were Not Complied.
• Out of 12 General Conditions; 6 were Fully Complied, 3 were Partly Complied & 3 were Not Complied.
• Action Taken Report (ATR) submitted on 14.07.2021.

No Comments in RO Report Comment / Compliance done by PA Latest Status

A Condition Not Complied
I Specific Conditions
1. Specific Conditions No. IV : Work of 3 Piezometer Installation is under Progress. Hydro- Three piezometer are installed
Adequate numbers of ground geological Survey completed for identification of Piezometer as per hydro-geological Survey
water quality monitoring Locations around Spentwash storage tank & compost yard. Bore around Spent wash storage
stations by providing wells digging completed. After monsoon; Procured Pizometers to be tank & compost yard.
piezometers around the lowered in the wells.
compost plant and project
areas shall be set up. Sampling
and trend analysis monitoring
must be made on monthly a
basis and report submitted to
SPCB and this Ministry.
2. Specific Conditions No. VII : Distillery is setup in complex of sugar Factory (3500 TCD and Co- Industry has Implemented Rain
Company shall adopt rainwater generation 18 MW). For RWH of distillery unit, Industry has prepared water Harvesting system.
harvesting measures to a plan for same. Implementation will be done before Year 2022 Harvested water is used for
recharge the ground water. monsoon season. After completion of work on site, details will be Green Belt, Fire Hydrant, and
submitted to Ministry office in next six monthly report. Flushing.
1. The rainwater harvesting plan is - Surface Harvesting: 83,597.74
M3, Roof Top Harvesting: 10245.74 M3, Total water – 93,843.48M3,
93.84 ML
2. Groundwater recharge through infiltration & percolation shall
have Positive Impact on Water Table in premises. Reuse of Harvested
Water shall save Fresh Water for Domestic and Gardening purposes.

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No Comments in RO Report Comment / Compliance done by PA Latest Status
II General Conditions
3. General Conditions No. IX : The project The details of the funds allocated towards Capital The details of the funds allocated
authorities shall provide all requisite funds (Rs.22.44 Cr) & Recurring (Rs.3.1 Cr) expenditure towards Capital (Rs.22.44 Cr) &
for both recurring and non-recurring provided. Recurring (Rs.3.1 Cr) expenditure
expenditure to implement the conditions provided
stipulated by the non-recurring
expenditure to implement the conditions
stipulated by the Ministry of Environment
and Forest as well as the State
government along with the
implementation schedule for all
conditions stipulated herein. The funds so
provided shall not be diverted for any
other purpose.
A Condition Not Complied
II General Conditions
4. General Conditions No. X : The Latest Six monthly Report for the period October 2020 Industry regularly submitted Six
implementation of the project vis-a-vis to March 2021 is submitted to Regional Office of monthly reports to Ministry. Latest
environmental action plans will be MoEFCC, Nagpur by mail on 02.07.2021. six monthly compliance report for
monitored by ministry’s regional office at Reports shall be submitted regularly to Ministry office. period April to September 2021
Bhopal/State Pollution Control was submitted to ministry on
Board/Central Pollution Control Board. A 08.02.2022 by mail.
six monthly compliance status report
along with the monitored data shall be
submitted to the monitoring agencies..
5. General Condition No. XII The date of financial closure in connection with the The date of financial closure in
The project authorities shall inform the Industrial Project is 31st March. Industry Funds taken connection with the Industrial
Regional Office as well as the Ministry the from NCDC Bank, New Delhi for Cogen Plant. Project is 31st March.
date of financial closure and final approval
of the project by the concerned
authorities and the date of start of land
development work.

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No Comments in RO Report Comment / Compliance done by PA Latest Status
B Conditions Partially Complied
I Specific Conditions
1. Specific Conditions No. IV : Total plot area of 5,34,060 Sq. M. Total open space available Total plot area of 5,34,060 Sq. M. As
Green belt in 33% of the plant in the premises of NBSSKL (including existing sugar factory, per MoEFCC norms, green belt should
area shall be provided to co- gen plant and existing as well as after expansion be developed on 33% of the total plot
mitigate the effects of fugitive distillery) is 27.15 Ha. As per MoEFCC norms, green belt area of industry. Under existing set up,
emissions all around the plant should be developed on 33% of the total plot area of 1, 22,502 Sq. M area is under green
and compost yard as per the industry. Under existing set up, 1, 22,502 Sq. M area is under belt, which is 23 % of total plot area.
CPCB guidelines in consultation green belt, which is 23 % of total plot area. An additional 11 In additional 11 % of total plot area
with the local DFO. % of total plot area i.e., 58,746.60 Sq. M will be developed as i.e., 58,746.60 Sq. M will be before
proposed green belt. monsoon season of 2022.
II General Conditions
2 General Conditions No. V : As per guidelines of MoEFCC and MPCB Industry is Condition is Complied
The overall noise levels in and monitoring Ambient noise levels at 5 location i.e. covering As per the direction, Industry
around the plant area shall be sugar, co-gen, and distillery and work zone which are within monitored Ambient noise levels at
kept well within the standards by limits as per CPCB norms. Workers entering inside plant are location Near Main Gate, Near
providing noise control provided with PPE like earplugs. The overall noise levels in Weighing Bridge, Near Spray Pond,
measures. Including acoustic and around the industry are maintained within the standards Near Sugar Godown, Near Bagasse
hoods, silencers, enclosures etc. prescribed under Environment (Protection) Act, 1986, 1989 Yard during day and night time in
on all sources of noise Rules. month of December 2021 & January
generation. The ambient noise 2022 which are within limits as per
levels should conform to the CPCB norms.
standards prescribed under EPA
rules, 1989 viz. 75 dBA (daytime)
and 70 dBA (night time).
3 General Conditions No. VI : Following measures under implementation: Condition is Complied
Following measures need to be 1. The rain water harvesting will be implemented before next
implemented: monsoon season.
1. Rain water harvesting. 2. The work of 3 piezometer installation is under process.
2. Regular monitoring of ground 3. As per guidelines of MoEFCC & MPCB Industry is
water level and quality monitoring AAQ & noise levels at 5 location (sugar, co-gen,
around compost yard and and distillery and work zone) which are within CPCB limits.
project area.

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No Comments in RO Report Comment / Compliance done by PA Latest Status
3. General Conditions No. VI : 4. As per MoEFCC norms, green belt should be
3. Monitoring of work zone noise levels. developed on 33% of the total plot area of
4. Increasing green belt from 23% to 33% industry. Under existing set up, 1,22,502 Sq.M
of the total project area. area is allocated for green belt, which is 23% of
5. Regular submission of six monthly total plot area. Additional 11 % of total plot area
compliance reports (58,746.60 Sq.M) will be developed as proposed
green belt.
5. Industry to regularly submit six monthly
compliance report to regulatory authority.
4. General Conditions No. XI : Condition is complied. The Environmental Industry have published advertisement of
The project Proponent shall inform the Clearance was granted on date 17.03.2009 accord of EC to our 30 KLPD Molasses
public that the project has been accorded Thereafter, an advertisement of accord of EC to Distillery unit in two local newspapers
environmental clearance by the Ministry our 30 KLPD Molasses Distillery unit was one is local language and English
and copies of the clearance letter are published on 09.03.2020 in two local newspapers newspaper.
available with the State Pollution Control one is local language and English newspaper.
Board /Committee and may also be seen at
Website of the Ministry of Environment
and Forest at http:/[Link]. this shall
be advertised within seven days from the
date of issue of the clearance letter, at
least in to local newspapers that are widely
circulated in the region of which one shall
be in the vernacular language of the
locality concerned and a copy of the same
shall be forwarded to the Regional office.

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 Certification by RO; MoEFCC; Nagpur (Visit dt.: 14.10.2020 & Report dt. 02.03.2021): 18 MW Cogeneration Plant
• Out of 27 Conditions; 20 were Fully Complied, 2 were Partly Complied & 5 were Not Complied.
• Action taken Report submitted on 19.11.2021.
No Comments in RO Report Comment / Compliance done by PA Latest Status
A Conditions Not Complied
1 Conditions No. XIX : Mock Drills & Training sessions conducted 6 Mock drill sessions are conducted half yearly.
Regular mock drill for the on –site emergency Monthly. Workshops on Safety & Health are Also, health check-up of all workers is being
management plan shall be carried out. organized once a Year. Periodical medical done once in a year. Latest mock drill was
Implement of changes/ improvement required, if examination for employees is arranged on conducted in month of December 2021 &
any, in the on-site management plan shall be regular basis. Fire extinguisher installed in latest health check-up was on done on
ensured. strategic locations January 2021.
2 Conditions No. XXIV : Inadvertently, there was delay in publishing Inadvertently, there was delay in publishing
The project management shall advertise at least newspaper advertisement. EC was granted on newspaper advertisement. The
in two local newspapers widely circulated in the 21.01.2014. the ad w.r.t. accord of EC was advertisement w.r.t. accord of EC was
region around the project, one of which shall be published in 2 newspapers on 09.03.2020. published in two newspapers on 09.03.2020.
in the Marathi language of the concerned within
seven days of issue of this letter, informing that
the project has been accorded environment
clearance and copies of clearance letter are
available with the Maharashtra Pollution Control
Board and may also be seen at Website at
http;//ec. [Link].
3 Conditions No. XXV & XXVIII: Latest Six monthly report for period October Industry regularly submitted Six monthly
Six monthly monitoring reports should be 2020 to March 2021 is submitted to RO; reports to Ministry. Latest six monthly
submitted to the Regional office MoEF, Bhopal MoEFCC Nagpur on 02.07.2021. Henceforth, compliance report for period April to
with copy to this department and MPCB. reports shall be submitted regularly. September 2021 was submitted to ministry
on 08.02.2022 by mail.
4 Conditions No. XXVI : Condition is compiled. Industry submitted granted EC to local body
A copy of the clearance letter shall be sent by (Grampanchyat - Bodani) on 09.04.2009. Also
proponent to the concerned Municipal EC is uploaded on industrial website.
Corporation and the local NGO, if any, from
whom suggestions/representations, if any, were
received while processing the proposal. The
clearance letter shall also be put on the website
of the Company by the proponent.

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No Comments in RO Report Comment / Compliance done by PA Latest Status

5 Conditions No. XXVI : Compliance is being done. The ES for each financial year ending Complied
The environmental statement for each 31st March in Form-V is submitted to SPCB under the EPA 1986. Industry regularly submits
financial year ending 31st March in Copy of ES is uploaded on Company website. Environment Statement.
Form-V as in mandated to be submitted Environment statement for FY
by the project proponent to the 2019-20 vide no. –
concerned State Pollution Control Board [Link] Distillery
as prescribed under the Environment (molasses/grain/yeast based) -
(Protection) Rules, 1986, as amended MPCB-ENVIRONMENT_STATEMENT
subsequently, shall also be put on the 0000016400 dated 17.06.2019
website of the company along with the [Link] Sugar (Excluding Khandsari –
status of compliance of EC conditions MPCB –
and shall also be sent to the Regional ENVIRONMENT_STATEMENT-
Offices of MoEF by e-mail. 0000016414) dated – 18.06.2019
Submitted .
B Conditions Partially Complied
1 Condition No. III: Ambient Air Quality (AAQ), we have already monitored Particulate Matter Condition is Complied
Regular monitoring of the air (PM10 and SO2). SPM is measured for stack emissions. As per NAAQS standards Latest Ambient Air Quality (AAQ)
quality, including SPM & SO2 level for ambient air quality vide No. B29016/20/90 PCI-I dated 18th November monitoring, has carried out in
both in work zone and ambient air 2009, we have to measure PM10 & PM2.5 instead of SPM for ambient air. December 2021 & January 2022 at
shall be carried out in and around Hence, we have monitored PM10 & PM2.5. As far as installation of air quality Bagasse Yard, Ash Storage, Near Main
station is concerned, we would like to inform you that ours is a seasonal Gate, Near Weigh Bridge, at Sugar
the power plan and records shall Industry which operates for 270 days in a year. Presently, we are monitoring House, Centrifuge Section, near Sugar-
be maintained. The location of AAQ in upwind and down wind direction during distillery operation period Co Gen boilers, Back Side of Distillery,
monitoring stations and frequency through MoEFCC and NABL approved laboratory. As per your directions, we will near Fermentation Section, near office
of monitoring shall be decided in increase the number of locations of AAQ presently from Two to Six to be and in Village Bodani & Redani on
consultation with Maharashtra additionally taken at cane yard, bagasse yard. Moreover, the frequency of monthly basis. All parameters are well
Pollution Control Board (MPCB) & monitoring is being done on monthly basis only. Ash storage location for within the limits at all locations
Submit report accordingly to fugitive emissions will be monitored.
MPCB.
2 Condition No. XXVII: Condition has been complied. Industry has developed website and
The proponent shall upload the The compliance of EC conditions has been uploaded on the Industry’s uploaded all documents i.e.
status of compliance of the website and is updated from time to time. A display board is erected on Granted EC, Environment
stipulated EC conditions, including site near main gate of the industry to show the air quality levels, effluent Statement, Six Monthly Compliance
results of monitored data on their quality etc. report etc
website and shall update the same
periodically.

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No Comments in RO Report Comment / Compliance done by PA Latest Status

2 Condition No. XXVII:

It shall simultaneously be sent to the
Regional Office of MoEF, the respective
Zonal Office of CPCB and the SPCB. The
criteria pollutant levels namely; SPM,
RSPM, SO2, NOx (ambient levels as well
as stack emissions) or critical sectorai
parameters, indicated for the project
shall be monitored and displayed at a
convenient location near the main gate
of the company in the public domain.

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Web Site

13
 Location of Project & its Connectivity

15 Km

10 Km

5 Km

Accessibility Connectivity Latitude 17°59'26.87"N

Highway / Road NH- 65: 14 Km; NE & SH-71: 5 Km; E Longitude 74°56'48.83"E
Railway Station Baramati Railway Station, 49 Km; NW Elevation 524 M above MSL
Airport Baramati , 49 Km; NW
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 Topographical Map

Particulars Distance & Directions

Water Bodies Nira River (6 Km; SW) & Bhima River (8.38 Km; SE)
Forest Not applicable
Populated Area Satara (105 Km; SW), Pune (129 Km; NW)
15
 Project Site
Location - Industrial Site is at 129 Km South East of Pune & at 248 Km South East of Mumbai.

Sugar Factory

Distillery

The Maps are purely graphical & not to scale. 16

Latitude: 17°59'27.25"N, Longitude: 74°56'41.97"E
 Sugar Factory, Co-generation Plant & Distillery Unit
Sugar Factory

Distillery Unit

17
 Achievements by NBSSKL
NBSSKL have been honored by various awards since 2001 till date

S.N. Season Award Prize Institute

1 2002–03 Best Technical Efficiency 2nd Prize VSI, Pune

2 2003–04 Best Technical Efficiency 1st Prize VSI, Pune

3 2004–05 Best Technical Efficiency 2nd Prize VSI, Pune

4 2006–07 Best Technical Efficiency 3rd Prize VSI, Pune

5 2007–08 Best Technical Efficiency 1st Prize National Federation, New

Delhi
6 2008–09 Best Technical Efficiency 1st Prize National Federation, New
Delhi
7 2009–10 Best Financial Management 1st Prize VSI, Pune

8 2012–13 Best Technical Efficiency 2nd Prize National Federation, New

Delhi
9 2014–15 Best Technical Efficiency 2nd Prize VSI, Pune

10 2014–15 Best Distillery in State 1st Prize VSI, Pune

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 Integrated Project Complex Process Flow Diagram

Sugar Factory

Weighment & Cane

Preparation To Grid
Cogeneration Plant

Bagasse Boiler Turbines

Cane Milling/ Crushing
30% Steam Power

Ash Used as Manure To Factory

Press Mud
Juice Extraction & 4% Sold as a Manure
Clarification
Distillery Unit
Juice Sulphitation Coal /
Incineration Brick Making
Bagasse
Conc. Spent Wash
Syrup Boiling
MEE Recycle
Condensate
Molasses (4%) Raw Spent wash
Centrifuging Alcohol
Fermentation Distillation
Storage
Alcohol

Storage of Sugar

19
 Products, By-products & Value Addition

Sugarcane in Farm

Sugar Factory
7,500 TCD Sugar
(10-12% on Cane Crushed)

Ma
nur
e Bagasses
Ash Pressmud Molasses (28.5%)

Lo
Brick Making (4%) (4%)

w
Pr
es
Cogen Boiler

su
re
Steam
Incineration

S
tea
High Pressure

m
Boiler Coal / Bagasse Steam

Conc. Spentwash Distillery Turbine

Spentwash 300 KLPD

Multiple Effect CO2

Evaporator (MEE)
Alcohol CO2 Bottling Plant Electricity
20
 Products & Raw Materials
A. Products: Distillery (30 to 300 KLPD) & Sugar Factory (3500 to 7500 TCD)
Unit Quantity
Industrial Unit Product
Existing Expansion Total
RS / ENA (C Heavy Molasses) KLPD 30 - 30
Ethanol (B Heavy Molasses/ Sugarcane Syrup) KLPD - 300 300
Distillery Ethanol (C Heavy Molasses) KLPD 30 270 300
(30 to 300 KLPD)
By-products
CO2 Gas MT/D 23 226 249
Fusel Oil MT/D 1.7 15 16.7
Electric Power from Incineration Boiler MT/D 0 6 6
Sugar Factory Sugar (12 %)* MT/M 12,600 -- 12,600
(3500 to 7500 TCD) By-products MT/M
Molasses (4 %)* MT/M 4,200 -- 4,200
Bagasse (28.5%)* MT/M 29,925 34,200 64,125
Pressmud (4%)* MT/M 4,200 4,800 9,000
Co-gen Plant (18 MW) Electricity MW 18 -- 18
B. Raw Materials: Distillery (30 to 300 KLPD) & Sugar Factory (3500 to 7500 TCD)
Quantity (MT/M)
Industrial unit Name of Raw Material Source
Existing Expansion Total
Sugarcane for Juice 0 1,28,700 1,28,700 Own Sugar Factory &
Molasses 3,330 30,000 33,330 Open Market
Distillery Yeast 2.4 22 24.4 Local Vendors
(30 to 300 KLPD)
Urea 36 324 360
De-foaming Oil 102 918 1,020
Sugarcane 1,05,000 1,20,000 2,25,000 Near By Farms
Sugar Factory Lime 240 274 514
(3,500 to 7,500 TCD) Sulphur 60 69 129 Nearby Market
Lubricants 3.90 4.45 8.35
Co-gen Plant (18 MW) Bagasse 30,840 - 30,840 Own Sugar Factory 21
 Seasonal Cane Availability for Sugar Factory
No. Description Remarks
1 Cane available from Command Area 5.70 Lakh MT / Season
2 Avg. distance from Sugar Factory 40 Km
Sugarcane Transportation Details (Traffic Density- After Expansion)
No Type of Vehicle Wt. (MT) / Vehicle (LF) Daily No. of Vehicles Raw Material (MT) %
A Sugarcane
1 Tractor Trolley 10.00 242 2,420 32%
2 Mini Tractor 8.00 117 936 13%
3 Trucks 16.00 128 2,044 27%
4 Bullock Carts 13.00 162 2,100 28%
Sugarcane Harvesting 3,500 MT 100%
Product & By-product Transportation Details (After Expansion)
No Product Type of Vehicles Daily No. of Vehicles Avg. wt. (MT)/ Vehicle Avg. Quantity
1 Alcohol Tanker 14 22 300 KL
2 Sugar Truck 26 35 900 MT
3 Bagasse Tractor 535 4 2138 MT
Seasonal Bagasse Availability for Co-gen Plant
No Description Quantity
1 Sugarcane Crushing & Total Working Days 7,500 TCD & 160 Days
2 Total Crushing 12,00,000 MT/Season
3 Bagasse Quantity (30-32% on cane) generated during Season 3,42,000 MT /Season
4 Bagasse Consumption in Co-gen Boiler (@ 210 / Day) 3,73,728 MT/Season
5 Procured Bagasse - 31,728 MT 22
 Availability of C Heavy Molasses for Proposed Distillery
Quantity
No Description
B Heavy C Heavy
1 Sugarcane Crushing Capacity 7500 TCD & 160 Days 7500 TCD & 160 Days
2 Total Cane Crushing 12,00,000 MT/Season 12,00,000 MT/Season
3 Molasses generated (6%- C heavy & 4%- B-heavy) 450 MT/D 300 MT/D
4 Molasses generated during season (160 days) 72,000 MT/Season 48,000 MT/Season
5 Total molasses required for distillery (330 Days) 3,09,375 MT/Season 3,66,630 MT/Season
6 Molasses to be purchased from outside parties 2,37,375 MT/Season 3,18,630 MT /Season
7 Distillery working pattern on
Own molasses 77 Days 48 Days
Purchased molasses 253 Days 287 Days
Availability of Sugarcane Syrup for Proposed Distillery
No Description Quantity
1 Sugar cane crushing capacity 7500 TCD
2 Sugar factory operating days 160 Days
3 Total Cane Crushing 12,00,000 MT/Season
4 Cane Juice / Syrup based Operations (Crushing Season); 160 Days 12,00,000 MT Cane
Product and By-product Storage Details
No. Products & By- Mode of Storage Details of Storage
products
1 Molasses Molasses Storage Tanks (In Existing Sugar Factory) Qty.: 1 Nos., Cap.: 5500MT
2 Sugar Sugar bags are stored in Godowns
3 Bagasse Bagasse is bailed & stored in dedicated. Separate yard in own
premises.
4 Pressmud Immediate disposal through
Alcohol [Link]
Storage Sold to farmers as a manure
No Storage Details Capacity
1 R.S. Cap.: 427 Cu. M; 2 Nos.; H-8.15 M, Dia. – 8.40 M
2 ENA Cap.: 427 Cu. M; 2 Nos.; H-8.15 M, Dia. – 8.40 M
3 Impure spirit Cap.: 200 Cu. M; 2 Nos.; H-6.79 M, Dia. – 6.09 M
4 Ethanol Tank 1 - Cap.: 600 Cu. M; H-10.39 M, Dia. – 6.09 M Tank 2 - Cap.: 772 Cu. M; H-13.35 M, Dia. – 8.85 M 23
 Imbibition – 1725 MT
Process Flow Chart- Sugar Factory 7500 TCD

Sugar Cane 7500 MT Milling Section Bagasse; 2138 MT

Lime 14 MT
Juice 7552 MT Condensate 750 MT
Heat Exchanger

Clarification Filtrate
Sediment 750 MT
450 MT
6802 MT
Steam 3150 MT
Condensate Vacuum
1st Effect 1275 MT

2nd effect

3rd effect

4th effect
1st effect
Vapours 750 MT Filter
Steam
2077 MT condensate; Pressmud 300 MT
Vapours 3150 MT
to Pan
Evaporation Loss
Vacuum Pan; 2700 MT
2077 MT
Pan Condensate 1725 MT
Condensate;
Crystallizer; 975 MT
225 MT

Molasses ; 300 MT Centrifuge; 1200 MT

Condensate
Sugar 900 MT 1275 MT

Condensate for Recycling

2025 Cu.M

Washing Vacuum Pump Brushing Boiler Make-up Mill Bearing Ash Quenching Turbine Cooling Mill Turbine DM Backwash Excess Condensate
8 CMD Sealing 120 CMD 326 CMD 40 CMD 3 MD 324 CMD 300 CMD 65 CMD to Distillery 494
120 CMD CMD
 Proposed Distillery Process Flow Chart - 300 KLPD (Molasses)
Sugar Factory
Molasses
Weighing of Molasses
Molasses (794 KL; 1111 MT)
Water 2382 KL (From CPU Recycle)
Molasses Dilution
Ash (138 MT/D)
To Brick Making / Diluted Wash 3176 KL (794 + 2382)
Cement Industry
Pre-Fermentation Yeast Culture

Yeast Sludge Fermentation CO2 (249 MT) Bottling

Incineration Boiler (64 KL) Plant
Fermented Wash (3112 KL)
Conc. Spentwash (480 KL; 648 MT)

Coal/Bagasse Distillation Alcohol (300 KL) Storage

(55-60 % Solids) 20 %

278 MT/D; 695 MT/D Section

Spent Lees
10-12% Solids (412 KL)

Spentwash CPU Other Effluents (233 KL);

Raw Spent wash (2400 KL)
Tank (2565 KL) (Lab .,Washings, Cool B/d)

MEE Condensate (1920 KL) 80%

2514 KL; Recycle in Process (100%)
(2382 KL for Process + 132 KL for Cooling) 25
 Proposed Distillery Process Flow Chart - 300 KLPD (Sugarcane)

Sugar Crushing : 4290 TCD Bagasse; 30% (1287 MT)

Cane Juice; 70% (3003 KL)
Sugar Factory
Juice Boiling; Concentration & Syrup
Condensate (1201 KL)
Cane Juice Syrup (1802 KL)

Weighing of Syrup

Juice Syrup (1802 KL)

Ash (69 MT/D)
(95% solids) Pre-Fermentation Yeast Culture

Incineration Boiler Yeast Sludge CO2 Bottling

Fermentation
(36 KL) (249 MT) Section
Fermented Wash (1766 KL)
Conc. Spentwash
(240 KL; 324
55-60 % Solids

Coal 139 MT/ Alcohol (300 KL) Storage

Distillation
Bagasse 348 MT Section
MT)

6-8% Solids Spent Leese (266 KL)

Raw Spentwash Spentwash CPU Other Effluents (233 KL);

MEE (1200 KL) Tank (1459 KL) (Lab .,Washings, Cool & Boiler B/d)

Condensate (960 KL) 80% Treated CPU Effluent

for Reuse 1430 KL
 Environmental Aspects
A. Water Consumption: Sugar Factory (3,500 to 7,500 TCD) & Co-gen Plant: (M3/Day)
No Description Existing After Expansion Remark
1 Domestic #
8 #
10 Fresh Water Norm : 100
2 Industrial Lit / MT of Cane
Process *968 *2230 • Existing: 83 Lit./MT
• After Expansion: 0
Cooling Makeup *461 *624 Lit./MT
Boiler Makeup #
254 *326
DM Plant #
50 *65 Note : # - Fresh water, *-
Excess Cane Condensate
Lab & Washing *5 *8
Ash Quenching *2 *3
Industrial Use 1740 (*1436 + #304) *3256
(83 % Recycle) (100% Recycle)
Grand Total (1+2) 1,748 ( 312+*1436)
# 3266 (#10+*3256)

B. Effluent Generation: Sugar Factory & Co-gen Plant (M3/Day)

No Description Existing After Expansion Treatment

1 Domestic 6 8 Existing STP

2 Industrial Treated in Existing ETP. Treated effluent
a. Process 116 268 recycled in Process & Green Belt to
Achieve ZLD.
b. Cooling Makeup 46 63
c. Boiler Makeup 51 65 Effluent Generation Norm: 200 Lit/ MT of
d. DM Backwash 50 65 Cane
e. Lab & Washing 5 8 • Existing: 77 Lit./MT 27

• After Expansion: 63 Lit./MT

 Environmental Aspects
C. Water Consumption in Distillery Unit: (M3/Day)
After Expansion (300 KLPD)
Existing Molasses Based Syrup Based
No Description
(30 KLPD) Crushing Season Non-Crushing Season

1 Domestic #
4 #
15 #
15 #
15
2 Industrial
Process #
240 2382
♠
2382
♠
--
Cooling Makeup #
35 1000 (*274+♠132 +#594) 1000 (♠132 + #868) Ø
1000
Boiler Makeup #
45 168( *99 + #69) #
168 Ø
168
DM Backwash #
5 *34 #
34 Ø
34
Lab & Washing #
2 *15 #
15 Ø
15
Ash Quenching *3 #
3 Ø
3
Industrial Use 327
#
3602 ( 2514+*425+ #663)
♠
3602 ( 2514 + #1088)
♠ Ø
1220
(No Recycle) (82 % Recycle) (70% Recycle) (100 % Recycle)
3 Green Belt #
85 700 ($354 + Ω277 + *69) 700 ($354 + Ω277 + *69) 700 (Ø210+$354+Ω136)
4317 4317 1935
Grand Total (1+2+3) #
416
(♠2514 + *494 + #678+ $354 + Ω277) (♠2514 + #1103 + $354 + Ω277+*69) (Ø1430+$354+Ω136+#15)
Norm: 10 KL/KL of
Alcohol 10.9 KL/KL 2 KL/KL 3.6 KL/KL 0 KL/KL
Note:- #: Fresh Water from Bhima river, ♠ : Treated Effluent from Distillery CPU, $: Treated Effluent from existing ETP & proposed STP , @: Harvested Rain Water
D. Effluent Generation from Proposed Distillery Unit: (M3/Day)
No Description Existing After Expansion Treatment
Molasses Based Molasses Based Sugarcane Syrup based
1 Domestic 3 16 16 Existing STP
2 Industrial Raw Spentwash : Raw Spentwash: 2400; Raw Spentwash: 1200; • After Expansion 300 KLPD : [Link] -
Fermentation 240; Conc. Spentwash: 480 Conc. Spentwash: 240 MEE – Conc. [Link] - Incineration
Spent Leese: 45 MEE Condensate:1920; MEE Condensate: 960; • Other Effluents :
Spent Leese: 412 Spent Leese: 266 - Molasses based : 2565 CMD
Cooling B/D 3 150 150 - Treatment : In Proposed CPU
Boiler B/D 4 34 34 • Treated Effluent: 100% Recycle.
• Total ZLD Project
Lab & Wash 2 15 16 • Spentwash Storage Tank Capacity : 5
DM Backwash 5 34 34 Days
8 KL / KL of Conc. Sp wash: 240 Conc. Sp wash: 480 Conc. Sp wash: 240
Alcohol Other Effluent: 59 Other Effluent: 2565 Other Effluent: 1460
[Link] : @ 8 KL/ KL [Link]: @ 1.6 KL/ KL [Link] : @ 0.8 KL/ KL 28
 Sugar Factory, Co-gen Plant & Distillery Integrated Project ZLD Plan
1 Daily Sugarcane Crushing 7,500 TCD
2 Water Content of Cane Crop @ 68% by weight 5,100 MT
3 Actual Cane Condensate for reuse is to the tune of 50 % on Cane Wt. after losses as - (1) Moisture in Pressmud 3,750 CMD
(70%) (2) Bagasse (50%), (3) Sugar (5%), (4) Molasses (60%) as well as (5) Losses during juice heating,
concentration in pans etc.
4 Sugar & Cogen ETP Treated Effluent for Recycle 476 CMD after Primary & Sec. Treatment shall yield 466 CMD
5 Treated STP Effluent for Recycle; Sewage @ 24 CMD 23 CMD
Total Recycle Availability (3+4+5) 489 CMD
• Water Consumption in Sugar Factory (7,500 TCD) & Cogen Plant (18 MW) (M3/Day):
No Sugar Factory Water Quantity Effluent Generation Remarks
A Domestic #
10 8 Proposed STP
B Industrial Treated in existing ETP
Process *2230 # - Fresh water taken from Bhima
268 river,
Cooling Makeup *624 63 * - Sugar Cane Condensate
Boiler Makeup *326 65
DM Backwash *65 65
Lab & Washing *8 8
Ash Quenching *3 3
Industrial Total
*3256 469
(100% Recycle)
D Total (A+B) 3266 (#10+*3256) • 494 CMD Excess Cane
Condensate will be recycled in
E Cane Condensate Utilization in Sugar 3256 Distillery Operation.
Factory • 489 CMD treated ETP & STP
F Total Cane Condensate Availability 3750 effluent will be used for Green
Belt purpose.

G Condensate Remaining (F-E) 3750­– 3256 = 494

29
 Proposed Distillery CPU (Cap.: 2600 M3/Day)
Condensate &
Other Effluents
2565 CMD Primary Clarifier
(6Ø X 8 M SWD)
UASBR
Treated Effluent Neutralization Aeration Tank
Equalization Tank (15 Ø x 6 M
Tank Tank
(22 x 20 x 5.5 M)
( 20 x 19 x 6 M)
Ht.) ( 18 x 15 x 6 M)
( 23 x 20 x 5.5 M)

Sludge

To SDB
Treated Effluent Tank SST SST
(8 Ø x 9 M)
Reject

(16 X 15 X 4 M) (8 Ø x 9 M)

Aeration Tank
( 18 x 15 x 6M)
ACF (2 Nos.) PSF (2 Nos.)
50 Cu.M / Hr 50 Cu.M / Hr
Intermediate Tank RAS
(10 X 10 X 3 M) RAS

UF Sludge Dewatering
Plant Unit
Sludge to Excess Sludge
Disposal

Permeate for Reuse

Filtrate to Equalization
in Process Tank No Param. Unit Inlet Outlet
1 pH -- 5-6 7–8
Note:
2 COD mg/lit 3500-4000 < 100
RAS: Return Activated Sludge
3 BOD mg/lit 2000-2500 < 50
ACF : Activated Carbon filter
PSF : Pressure Sand Filter 4 TDS mg/lit 2000-3000 < 100 30
 Existing Sugar Factory ETP (Capacity : 500 M3/Day)
Primary Clarifier Bio Tower Sump Settling Tank
(6Ø X 2.8 M SWD) (9 X 9 X 1.8 M) (4 X 4 X 2M)

Inlet Equalization Tank

469 CMD (12 X 11 X 1.7 M)
O & G Chamber
Sludge
(1 X 1 X 1.3M)
Sludge
To SDB
To SDB
Secondary Clarifier
(7 M Ø X 3 M SWD)

Aeration Tank
To Reuse (20 X10 X 4M)
ACF DMF
Treated Water Tank
RAS

Excess
Sludge

1 2 3
Sludge Cake
No Parameters Unit Inlet Outlet
to Disposal
4 5 6
1. pH --- 5–6 7-8
2. COD mg/lit 2,000 – 2,500 < 250
Sludge Drying Bed (6 Nos.)
3. BOD mg/lit 1,000 – 1,500 < 100 (4 X 6 X2 M)
4. TDS mg/lit 1,800 – 2,200 < 2,100
Filtrate to
5. SS mg/lit 250 – 300 <100 Equalization Tank
 Proposed Sugar Factory CPU (Capacity : 2500 M3/Day)
Filtrate from SDB
Cane
Condensate
2025 M3/ Day Flash Mixer
(1.5 x 1.5 x 2)
M)
Equalization Tank PST MBBR Reactor
(16 X 16 X 4 M) (6 Ø X 3 M) (25 X 22 x 4.5 M)

Flocculator
(2 x 2 x 2.5 M)
Sludge
RAS
To SDB
Sludge
to SDB

Treated
Pump Treated Effluent SST
Condensate for
Tank (8 Ø X 3 M)
Reuse in Process
(18 X 18 X 4 M)
ACF; 2 Nos. PSF; 2 Nos.
(60 Cu.M / Hr) (60 Cu.M / Hr)

Sludge
Excess
No Para. Inlet Outlet
Sludge to SDB
1 pH 5-6 7–8 Disposal
Note:
2 COD 700-800 < 200 PSF: Pressure Sand Filter
RAS : Return Activated sludge
3 BOD 300-400 < 30 ACF : Activated carbon Filter Filtrate to
4 TSS 200-300 < 10 SST: Secondary Settling Tank Equalization Tank
SDB: Sludge Drying Beds 32
 Existing STP (Capacity: 30 M3/Day)

Inlet
30 M3/Day Sedimentation &
Bar Screen O&G Equalization Pump Anaerobic Contact
Separation
Chamber Chamber Tank Media Chamber
Chamber
(2 X 1.5 X 1 M) (2 X 1.5 X 1 M) (4.5 X 4 X 2 M) (3.798 M3)
(3.440 M3)

Recirculation Line

Disinfection Sedimentation Moving Bed

Treated Water Tank
To Reuse (3 X 3 X 2 M3) Chamber Chamber Chamber
(0.115 M3) (2.006 M3) (4.452 M3)

No Parameter Unit Inlet Outlet

1 pH --- 6.0 – 8.5 6.0 – 8.5
2 COD mg/lit 400 – 500 < 50
3 BOD mg/lit 250 – 300 < 20
4 TSS mg/lit 150 - 250 < 30
5 O&G mg/lit 20 - 30 < 10

 High Treatment Efficiencies (BOD Removal >90%)

 AAA Technology (Ministry of Jal Shakti; GOI & CII Approved)
 Low Energy (80% Lesser Power than Conventional Technologies)
 Design & Manufacturing Complying International Standards
 Low O & M Cost (80% lesser than Conventional STPs)
 No Operator Required (Fully Automated System)
 Non-corrosive, Stable High-Quality FRP Body (30 + Years’ Durable)
 Blower Noise (< 45 dBA)
 Portable & Scalable Modules (1-50 KL Models for Various Capacity Combinations)
 Quick Installation & Remote Monitoring Possible
 Johkasou STP Treatment Process

Unit MOC Process Description

Technological Frame Work
Separation & Sedimentation Chamber FRP Suspended Solids (SS) are separated.
Organic matters are anaerobically • Technology approved by
Anaerobic Chamber FRP
decomposed. National Jal Jeevan
Moving Bed Chamber FRP BOD content reduced by continuous aeration. Mission.
SS are settled and clear treated water is
Sedimentation Chamber FRP • Technology Approved by
obtained.
Treated Water is disinfected by Disinfection CII (Confederation of
Disinfection Chamber FRP Indian Industry)
agent.
Sludge from 2nd Sedimentation Chamber is • No COVID-19 Trace
Sludge Re-circulation Arrangement - recirculated to the 1st Sedimentation observed in outlet water
Chamber.
34
Existing ETP

35
Existing STP

3
 Spentwash Handling System

Spentwash Tank

Bio-methanation Tank MEE

37
 Spentwash Bio-Composting

RCC Yard

Windrows

38
 Environmental Aspects
 Air Pollution Control
No. Description Sugar Factory & Cogeneration Plant
Distillery
Stack attached to Existing Expansion
Boiler 1 Boiler 2 DG Set (2 Nos.) Boiler Incineration Boiler
1 Capacity 66 TPH 40 TPH 500 KVA each 30 TPH 70 TPH
2 Fuel type Bagasse Bagasse/ Biogas HSD Bagasse Bagasse/ Coal + [Link]
3 Fuel Qty. (MT/D) 566 432/ 12000 M3/D 20 Lit/Hr - Each 360 695/278 + 648
4 Stack Ht. (M) 75 M 60 M 14 M ARL 40 M 100 M
5 MOC RCC RCC MS RCC RCC
6 Shape Round Round Round Round Round
7 Diameter (M) 3.6 M 3.5 M 150 mm 3.6 M 4.6 M
8 APC ESP Wet Scrubber - ESP ESP
 Hazardous Waste

Quantity (Kg/M)
No. Industrial Unit Category Disposal
Existing Expansion
1 Sugar Factory Spent Oil – Cat.5.1 200 428 Burnt in boiler
 Solid Waste
Quantity (MT/M)
No. Industrial Unit Type Disposal
Existing After Expansion
1 Distillery Yeast Sludge 150 1920 Burnt in Incineration Boiler
CPU Sludge -- 74
Boiler Ash ([Link]+ Coal) 360 455 Brick Making
2 Sugar & Co-gen Boiler Ash (Bagasse) 451 636
ETP Sludge 8 15 Used as Manure 39
 Photograph of ESP & Stack

Stack

Boiler
ESP

Conveyer

40
Existing Stack & OCMS

41
 Environmental Aspects
 Noise
Unit Source Control Measures
Distillery Fermentation & Distillation Section • Isolation, Separation and Insulation techniques adopted
Sugar Factory Mills, Pumps Compressors & D. G • PPE as Earmuffs, Earplugs provided to staff & workers.
Boiler Section & Turbine

 Dust

Unit Source Control Measures

Sugar Factory Mills, Sugar Bagging, Bagasse & Efficient Exhaust & Ventilation Systems, Efficiency
Pressmud Storage Areas Monitoring of APC & Dust Control Equipments, Regular
Self Monitoring of Work Zone Dust Levels, PPE,
Adequate Density & Type Green Belt Development,
Proper Surfacing of Internal Roads, Yards, Water Sprays
& Mist Arrangements.

 Odour
Unit Source Control Measures
Distillery Molasses Tanks, Fermentation Section,
Yeast Sludge & Spentwash Storage Tanks
• Proper House Keeping, Prompt Sludge
Management in Biological Treatment units, GMPs
Sugar Factory ETP, Molasses Tanks, Pressmud Yard,
• Efficient handling, prompt & proper disposal of
Pressmud, Yeast Sludge & Spentwash.
Bagasse Conveyor; Feeding Section, Ash • Close Fermentation & Molasses Handling.
Storage
42
 Risk Analysis & Disaster Management
Project Risk Area Hazard Mitigation Measures
Distillery Molasses Rupture & • Dyke walls is constructed around the tank.
Storage Toxic Liquid • In case of temp. beyond 300C; external cooling system
Tanks Leakage • Mechanical Seals to Pump Gland to avoid leakages
• Hot work permit for maintenance to avoid direct contact with pressurized gases in tank.

Alcohol Fire (Worst • All tanks in Dyke Walls (Std. design & construction norms).
Storage case • Guidelines in OISD 117 Std. is followed for fire fighting around alcohol storage area.
scenario) • Pump Motors & Electrical Fittings to be Flame Proof.
• On Site Emergency Control Plan : RA & DMP is implemented.

Sugar Bagasse Fire • Self & Auto-mode Fire Fighting System around Bagasse Yard.
Factory Storage • Hot Work, Welding, Gas Cutting avoided near Bagasse Storage
• Training of all Staff in Normal & Emergency Conditions.
• High Voltage Transmission Lines above Bagasse Yard Avoided.
• Firefighting Plan & Lightning Arrestors Provided

Sulphur Dust • Shed with Min. Horizontal Surfaces to avoid Dust Accumulation, All Ignition sources excluded.
Storage Explosion & • Formation & Suspensions of Sulphur Dust in air avoided, Chemical Foam Fire Extinguishers
Fire • Bag Opening Device, PPE (mask, hand gloves) provided.

SO2 Prod. Toxic Gas • Installation of SO2 Leak Detectors & Alarm Systems.
Leakage
• Pressure & Thickness Tests of equipment & piping carrying SO2 to avoid leakage.

Occupational Health & Safety Measures

 Occupational Health Center., 24 X 7 Ambulance Facility available, Regular Medical Checkup of Employees & Records Keeping followed .
SO2 Production procedure has been prepared.
 Workmen Compensation Policy, Mediclaim Health Policy (Temporary & Permanent), GMPs being followed.
 Well Managed Process Operations, Automation of Production, Interlocking with Pollution Control Equipment done.
 Health & Safety Awareness camps arranged. Posters & Boards displayed in Industry.
 PPEs such as Shoes, Helmets, Goggles, Earmuffs, Ear Plugs are provided.
 Housekeeping & Waste Handling : Training & Education to Workers, Good O & M Practices 43
 Sanitary Facilities & Other Measures – Adequate Toilets, Changing Rooms, Rest Rooms Provided. Good Aesthetics maintained.
Arrangement of Fire Fighting System

44
 Aloha – Ethanol

Scenario: BLEVE of flammable liquid in vertical cylindrical tank Threat Zone :

• Tank Dia.: 8.85 M; Tank Length: 13.35 M; Red: 744 M—(10.0 KW/Sqm)=potentially lethal within 60 sec)
• Tank Volume: 821 Cubic Meter, Fireball Dia.: 482 M Orange: 1.1 Km – (5.0 KW/sq m)=2nd degree burns within 60 sec)
• Burn duration: 25 Sec. Yellow: 1.7 Km (2 kW/sq m) = Pain within 60 sec.
Mitigation Measures:
1. It is recommended to have Alcohol storage tanks with dyke walls & must have spill collection and control (recycle)
arrangement to pump into another tank.
2. Clear distance between tanks will be provided as per the requirement of Petroleum Rules
3. Location of pumps, location of tank farm in the Industry will be as per the requirements of PESO Petroleum rules.
4. Necessary approval /License from Chief Controller of Explosives will be obtained for proposed alcohol storage. 45
 Green Belt Development Plan
 Total Land acquired for NBSSKL Complex : 53.40 Ha
 Existing Green Belt (23% of Total Plot Area) : 12.28 Ha; No. of Trees : 3,500
 Proposed GB (11 % of Total Plot Area) : 5.87 Ha; No. of Trees : 41,900
 Total Green Belt after Expansion (35% of TPA) : 18.15 Ha; No of Trees : 45,400 (2500 Nos. / Ha)
 Distance between two Rows = 2 M; Distance between two Trees = 2 M
 Important Features of the Green Belt Development Program:
• Avenue Plantation : Internal Roads to various Units, Bagasse; Pressmud; Ash Yards
• Shelter Belt Plantation: A thick barrier of trees to be created along periphery / fence.
• Mass Plantation : Vicinity of Ash & Bagasse Storage, Trees controlling dust planted.
• Plantation of Peculiar Tree Species - Noise Attenuation, Dust Suppression, Indigenous, Ever Green.
Rain Water Harvesting Details
Runoff Factors Average Annual
No Description Area (Sq.M.) RWH Quantity (M3)
considered Rain Fall (M)
A Roof Top Harvesting
1 Rooftop Area 23,716.98 0.8 0.54 10,245.7
Total Rooftop Harvesting 10,245.7
B Surface Water Harvesting
1 Green Belt Area 1,81,248.60 0.3 0.54 M 29,362.27
2 Area under Roads 37,938.65 0.5 0.54 M 10,243.4
3 Open Space 1,11,924.14 0.3 0.54 M 18,132
Total Surface Water Harvesting 57,737.67
Total (A + B) 67,983.37

 Runoff from Rooftop & Surface to be harvested & stored in Tanks (Farm Pond Type).
 Rooftop Yield is 10,245.7 M3 while Surface Runoff Yield is 57,737.67 M3 ; Total Runoff Yield of 67,983.37 M3
 Two existing RWH Tanks (30,000 M3 & 18,000 M3) & Three proposed (15,000 M3 22,000 M3 & 30,000 M3)
 Utilization for Green Belt, Fire Hydrant, Washing & Flushing
 Excess RWH Qty. diverted out through Storage Tank out lets on Site 46
 Green Belt (GB) Design Details
Type of Location GB GB GB Area No. of Tree Trees / Total Trees Characteristics
Plantation on Plot Length Width (Sq. M) Rows Row Trees
(M) (M)

D = B/2 E = A/2
(2= Dist. (2= Dist.
A B C = A*B F = D*E
Bet. 2 Bet. 2
Rows) trees)
North 1287 10 12870 5 644 3218 Neem, Shisav, Trees with round &
East 1500 10 15000 5 750 3750 Karanj, Umbar, oblong canopy,
Wilayati Chinch, native, evergreen,
South 1326 10 13260 5 663 3315 Saptaparni, Apta, pollution resistant,
Shelter Belt
along 915 10 9150 5 458 2288 Mahogani, Bel, fast growing, high
Compound Ran Bibba, dust settling index
Wall West Nandruk,
Kadamb, Limbara

Khair, Saag, Bel, Tree with round &

Bahava, Shivan, oblong canopy,
Mass Open Areas with 4 Sq. M. for Each Tree Nandruk, Umbar, native, evergreen,
122900 30730
Plantation Areas Uneven Shapes Species Limbara, Kadamb pollution resistance

Bakul, Bahava, Tree species with

Tamhan, Ashoka, conical, columnar
Saptaparni canopy, ornamental,
Avenue Along fast growing,
2100 4 8400 2 1050 2100 pollution resistance
Plantation Roadside
will be planted as
avenue plantation

Total 1,81,580 45,400

47
 Names; Numbers & Types of Trees in Green Belt
Proposed Tree List

Sr. No. Name of the plant Common Name Quantity Characteristics & Ecological Importance
1 Azadirachta indica Neem 4500 Native, evergreen, fast growing, tolerant
2 Dalbergia sissoo Shisav, Shisham 1500 Native, evergreen, tolerant
420 Native, ornamental, host plant for bees and
3 Mimusops elengi Bakul butterflies.
4 Pongamia pinnata Karanj 3000 Pollution tolerant
5 Acacia Catechu Khair 3500 Native and pollution resistant
6 Tectona grandis Saag 3000 Native and pollution resistant
5500 Native, evergreen, fast growing, pollution
7 Neolamarckia cadamba Kadamb tolerant
420 Native, ornamental, host plant for bees and
8 Cassia fistula Bahava butterflies.
9 Gmelina arborea Shivan 3650 Native and pollution resistant
1000 Native, ornamental, host plant for bees and
10 Pithecellobium dulce Wilayati Chinch butterflies.
11 Alstonia scholaris Saptaparni 420 Native, evergreen, higher dust settling index
2500
12 Swietenia mahogani Mahogani Native, evergreen, higher dust settling index
13 Aegle marmelos Bel 1070 Native and pollution resistant
1000
14 Holigarna grahamii Ran Bibba Native and pollution resistant
15 Ficus macrocarpa Nandruk 2000 Native and pollution resistant
16 Melia azedarach Limbara 3500 Native and pollution resistant
1000
17 Bauhinia racemosa Apta Native and pollution resistant
1500
18 Butea monosperma Palas Native, Evergreen tree,
2030
19 Lagerstroemia speciosa Tamhan Native, State flower of Maharashtra
390
20 Polyalthia longifolia Ashoka Air pollution absorbing species
Total 41,900 48
Green Belt

49
Existing Green Belt

50
Existing Green Belt

51
Existing Green Belt

52
Existing Green Belt

53
Existing Green Belt

54
Photographs of Storage Tanks

55
 Proposed CER

Amount (Rs.
No. CER Activity Lakhs)
1 Non- Conventional Energy Promotions (10 Villages): Provision of Solar Street Lights with Gadget – Rs. 90 Lakhs
1 MS Pole, 18-20 W LED Lamp, Battery, Solar Panel, Wiring etc. 10 Villages X 30 Nos./Village = Total
300 Solar Street Lights X Rs.30,000/- per No. = Rs.90 Lakhs
2 Solar Photovoltaic Energy (10 Villages): 35 KW @ Rs. 0.5 Lakh per KW to be installed at
grampanchayat / school building in 10 villages. Cost= 10 x 35 KW x Rs. 50,000/- = Rs. 175 Lakh Rs. 175 Lakhs
3 Drinking Water Supply Infrastructure (10 Villages): Safe Drinking Water Units with Filtration, RO
Module & Storage Tank (1 Unit/ Village @ 500 Lit/Hr) - 10 Units X Rs.2.5 Lakhs = Rs.25 Lakhs Rs. 25 Lakhs
(1% of Capital Investment 290.00 Cr.) Total Amount Rs. 290 Lakhs

Existing CER
No. Name of Social Work Amount (Rs. In Lakhs)
1 Drip Irrigation 300.00
2 Distribution of Sugar cane culture 50.0
3 Distribution of compost, Green Manure & Chemical fertilizer 80.0
4 Agriculture Trading Programme 5.0
5 Field Staff training 7.50
6 Tree Plantation 5.0
7 Distribution of notebook for students 0.50
8 Distribution safe drinking water 1.0
Total 449

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 Environment Management Plan (EMP)
 EMC of 9 Members, Qualification : M.E. (Env.), [Link]. (Env. Sc.), [Link]. (Chem.), PGDISHE.
 Chief Chemist, Chief Engineer, Chief Accountant, Distillery Incharge, Dy. Co-gen. Manager, Civil Engineer, Chief
Agree Officer, Labor Welfare Officer, Environmental Officer.
The Capital as well as O & M Costs towards Environmental Management -
Cost Component (Rs. Lakh)
No. Description
Capital Annual O & M
A Existing Project
1 APC Equipment’s: ESP (66 TPH), Wet scrubber (40 TPH), Stack heights 75 M & 60 M. 725 70
2 Water Pollution Control: ETP, OCMS, Bio-compost Yard, Machine, Sp. wash Tank & OCMS
etc. 1250 20
3 Noise Pollution : Insulation, Isolation, Attenuation Infrastructure of Plant & Machinery,
PPEs 100 10
4 Occupational Health & Safety (Medical Check-up of employees, PPEs) 50 10
5 Environmental Monitoring & Management 25 5
6 Green Belt Development 80 15
(9% of Capital Investment of Rs. 254.04 Cr) Total Rs. 2230 Rs. 310
B Sugar Factory & Distillery Expansion
1 Air Pollution Control: 70 TPH incineration boiler (ESP- 1 No.), ESP – Sugar Boiler, Stacks (2
Nos.) 100 M & 65 M, OCMS, CO2 Bottling Plant 6950 700
2 Water Pollution Control – Proposed Distillery CPU, MEE, Sugar Factory CPU, Spent wash
Storage Tank and OCMS. 2000 200
3 Noise Pollution Control 25 10
4 Environmental Monitoring & Management 25 10
5 Occupational Health & Safety 50 10
6 Green Belt Development 50 10
7 Rainwater Harvesting Infrastructure 25 10
(31% of Rs. 290 Cr; Expansion Investment) Total Rs. 9,125 Rs. 950
(21 % of Capital Investment of Rs. 545.01 Cr) Grand Total Rs.11,355 Rs. 1260
THANK YOU
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