APPLICATION FOR GRANT OF TORenvironmentclearance.nic.in/writereaddata/Online/TOR/25... ·...

OCTOBER 2017

APPLICATION FOR GRANT OF TOR

OF

EXPANSION OF SUGAR PLANT (7,000 TCD TO 12,000 TCD)

AND CO-GENARTION POWER PLANT OF 37 MW

AT

Village-Randhawa, Tehsil-Dasuya, District-Hoshiarpur, Punjab

BY

M/s A. B. SUGARS LIMITED

SCHEDULE AS PER EIA NOTIFICATION: 5(J) Cat. A

PLOT AREA: 103722.04 m2 or 10.3722Ha or 170 Acres

M/s PERFACT ENVIRO SOLUTIONS PVT. LTD.

(NABET Accredited consultant; 16th October,2017/ Rev. 58/ Sr. No. 107)

5th Floor, NN Mall, Mangalam Palace

Sector 3, Rohini, New Delhi

Email: [email protected]

Phone No.: 011-49281360

mailto:[email protected]

Expansion of Sugar Mill from 7,000 TCD to 12,000 TCD by M/s A.B Sugars Ltd

Prepared By: M/s Perfact Envirosolutions Pvt Ltd, New Delhi 2

ENCLOSURE: 1- FORM-1 ................................................................................................................................... 3

ENCLOSURE: 2- PRE-FEASIBILITY REPORT ....................................................................................................... 23

2.1 INTRODUCTION OF THE PROJECT ......................................................................................................................... 24

2.2 PROFILE OF PROMOTER .................................................................................................................................... 24

2.3 REQUIREMENT AND NEED OF THE PROJECT AND THE BENEFITS ................................................................................. 24

2.4 PROJECT DESCRIPTION ............................................................................................................................... 25

2.4.1 Project Details ..................................................................................................................................... 25

2.4.2 Details of Products and Production ..................................................................................................... 26

2.4.3 Details of Raw Material Requirement ................................................................................................. 26

2.4.4 Land Area Details ................................................................................................................................ 27

2.4.5 The Google Image of Project Site ........................................................................................................ 28

2.4.6 10 Km Buffer Zone Map on SOI OSM Sheet......................................................................................... 29

2.4.7 Connectivity......................................................................................................................................... 29

2.4.8 Layout Plan ......................................................................................................................................... 30

2.4.9 Process Description ............................................................................................................................. 30

2.4.10 Process flow Diagram ....................................................................................................................... 36

2.4.11 Material Balance ............................................................................................................................... 36

2.5 SITE PHOTOS .................................................................................................................................................. 37

2.6 ENVIRONMENT MANAGEMENT .......................................................................................................................... 39

2.6.1 Manpower ........................................................................................................................................... 39

2.6.2 Water Management ........................................................................................................................... 39

2.6.3 Rain water harvesting scheme ............................................................................................................ 49

2.6.4 Waste Generation and Management ................................................................................................. 52

2.6.5 Details of Air Emissions and Control ................................................................................................... 54

2.6.6 Noise Pollution Management ............................................................................................................. 55

2.6.7 Plantation Details ................................................................................................................................ 55

2.6.8 Safety .................................................................................................................................................. 56

ANNEXURE I: DISCLOSURE OF ENVIRONMENTAL CONSULTANT ..................................................................... 58

ANNEXURE II: TOPOGRAPHICAL MAP ............................................................................................................ 59

ANNEXURE III: LAYOUT PLAN ......................................................................................................................... 60

ANNEXURE IV: COPY OF LATEST/ VALID CTO GRANTED ................................................................................. 61

ANNEXURE V: COPY OF EARLIER ENVIRONMENT CLEARANCE ........................................................................ 62

ANNEXURE VI: LAND PAPERS ......................................................................................................................... 63



ENCLOSURE: 1- FORM-1



FORM 1 (I) Basic Information

Sl. No.

Item Details

1. Name of the project/s Expansion of Sugar Mill

2. S.No. in the schedule 5 (j)

3. Proposed capacity/area/length/ tonnage to be handled/command area/lease area/ number of wells to be drilled

Proposed capacity: 5000 TCD Total Capacity after expansion: 12000 TCD and cogeneration power plant of (37 MW)

4. New/Expansion/Modernization Expansion

5. Existing capacity/area etc., 7000 TCD and cogeneration power plant of (33 MW).

6. Category of Project i.e ‘A’ or ‘B’ ‘A’

7. Does it attract the general condition? If yes, please specify

No

8. Does it attract the specific condition? If yes, please specify

No

9. Location

Plot/Survey/Khasra No. Village-Randhawa, Tehsil-Dasuya, District-Hoshiarpur

Village Randhawa

Tehsil Dasuya

District Hoshiarpur

State Punjab

10. Nearest railway station/airport along with distance in Kms

Nearest Railway Station: Dasuya Railway Station- 5.33 Km NW Nearest Airport: Pathankot Airport- 49.69 Km N Nearest Highway: SH-24– Adjacent to project area

11. Nearest Town, city, District Headquarters along with distance in Kms

Dasuya- 4.1 Km

12 Village Panchayats, Zilla Parishad, Municipal Corporation, Local body (complete postal addresses with telephone nos. to be given)

Municipal Corporation of Hoshiarpur

13 Name of the applicant M/s A.B. Sugars Limited

14 Registered Address C-1, Sector-3, Noida, Uttar Pradesh- 201301



15 Address for correspondence: Village-Randhawa, Tehsil- Dasuya, District – Hoshirpur, Punjab

Name Ramandeep Singh

Designation (Owner/Partner/CEO) President

Address Village-Randhawa, Tehsil- Dasuya, District – Hoshirpur, Punjab

Pin Code 144205

E-Mail [email protected]

Telephone No. 01883-503503

Fax No. 01883-503510

16 Details of Alternative Sites examined, if any. Location of these sites should be shown on a topo sheet

No

17 Interlinked Projects No

18 Whether separate application of interlinked projects has been submitted?

No

19 If yes, date of submission Not Applicable

20. If no, reason Not Applicable

21 Whether the proposal involves approval/clearance under: If yes, details of the same and their status to be given. (a) The Forest (Conservation) Act, 1980 ? (b) The Wildlife (Protection) Act, 1972 ? (c) The C.R.Z Notification, 1991 ?

No

22 Whether there is any Government Order/Policy relevant/relating to the site ?

No

23 Forest land involved (hectares) No

24 Whether there is any litigation pending against the project and/or land in which the project is propose to be set up?

(a) Name of the Court (b) Case No. (c) Orders/directions of the Court, if any and its

relevance with the proposed project.

No

mailto:[email protected]



(II) Activity 1. Construction, operation or decommissioning of the Project involving actions, which will cause physical changes in the locality (topography, land use, changes in water bodies, etc.)

S. No. Information/Checklist confirmation Yes/No Details thereof (with approximate quantities /rates, wherever possible) with source of information data

1.1 Permanent or temporary change in land use, land cover or topography including increase in intensity of land use (with respect to local land use plan)

No This is expansion of existing Sugar Manufacturing unit on the same land. Change of Land use has already been done earlier.

Environment clearance had been granted vide letter no. J-11011/764/2007-IA II (I) dated 3rd June, 2010 for 7000 TCD and cogeneration power plant of 33 MW on plot area 170 acre.

1.2 Clearance of existing land, vegetation and buildings?

No It is expansion of already existing unit, so no clearance required.

1.3 Creation of new land uses? No This is expansion of existing unit on same plot.

1.4 Pre-construction investigations e.g. bore houses, soil testing?

No Preconstruction soil investigation has already been carried out.

1.5

Construction works? No For expansion part, only additional plant / machineries are required; hence, no construction will be done related to process.

1.6 Demolition works? No Not applicable

1.7 Temporary sites used for construction works or housing of construction workers?

No During expansion of proposed plant, 50 Nos. of contractor’s labour will be engaged.

As it is an expansion project of already existing unit, 217 No. of employees are working at present and after expansion employee’s population will increase to 250 No. Residential building already provided for staff/labour in the premises.

1.8 Above ground buildings, structures or earthworks including linear structures, cut and fill or excavations

No For expansion part, only additional plant / machineries are required; hence, no further above ground



building or excavation will be done related to process.

1.9 Underground works including mining or tunnelling?

No Not applicable

1.10 Reclamation works? No Not applicable

1.11 Dredging? No Not applicable

1.12 Offshore structures? No Not applicable

1.13 Production and manufacturing processes?

Yes Manufacturing process details for sugar production & co-generation are given in Pre-feasibility Report.

1.14 Facilities for storage of goods or materials?

Yes Separate Godown has been provided for the storage for Sugarcane.

Separate Raw materials storage yards is being provided with exhaust system. Proper care is being taken and storage of all chemicals shall not exceed their threshold limit.

This shall be done with compliance to MSIHC Rules, 1989.

1.15 Facilities for treatment or disposal of solid waste or liquid effluents?

Yes Installation phase:

Approx. 8 kg/day of municipal solid waste will be generated and shall be disposed off at MSW site & Approx. 2 KLD of waste water generated through labors which will be channelized to existing sewerage system.

Operation Phase:

Municipal waste: 40 kg/day Municipal Solid Waste (Existing 19 kg/day & Proposed 19 kg/day) will be generated out of which 28 kg/day biodegradable waste will be disposed at MSW site and recyclable waste of 12 kg/day shall be given to Authorized Recycler. Process waste: Process waste includes Bagasse, Ash content, Molasses & Press Mud/Filter Cake.



3360 tonnes/day (Existing: 1960 tonnes/day & Proposed: 1400 tonnes/day) of bagasse is being generated which is used as fuel in Boiler for the production of steam. Ash content of 50 tonnes/day (Existing: 29 tonnes/day & Proposed: 21 tonnes/day) is being generated which is being disposed off to allocated site within the premises. Molasses of 540 tonnes/day (existing: 315 tonnes/day & Proposed: 225 tonnes/day) which is used in the existing distillery unit in the premises. 504 tonnes/day (existing: 294 tonnes/day & proposed: 210 tonnes/day) of pressed mud/filter cake shall be sold out to the farmers and brick manufactures. It shall not be kept in the premises. STP sludge is being used as manure. After Expansion Approximately 2000 Kg/day of ETP sludge shall be generated from ETP Plant. It shall be Stored in separated room and sent to authorized TSDF.

Liquid effluents: In existing unit, the total waste water generation from unit is 1870 KLD including 120 KLD of domestic waste water. Process waste water is being treated in ETP of 3500 KLD & domestic waste waters in STP of 250 KLD.

After expansion, total waste water generation will be 3236 KLD including 120 KLD of domestic waste water which shall be treated in the existing ETP & STP. The capacity of STP & ETP will remain the same is will suffice for the treatment of increased waste water.



Detail of solid waste and liquid effluent management is given in EIA report.

1.16 Facilities for long term housing of operational workers?

No Residential building has been provided for the staff.

1.17 New road, rail or sea traffic during construction or operation?

No Not applicable

1.18 New road, rail, air waterborne or other transport infrastructure including new or altered routes and stations, ports, airports etc?

No Not applicable

1.19 Closure or diversion of existing transport routes or infrastructure leading to changes in traffic movements?

No No such closure or diversion of existing transport is required.

1.20 New or diverted transmission lines or pipelines?

No No new or diversion of transmission lines or pipelines will be done.

1.21 Impoundment, damming, culverting, realignment or other changes to the hydrology of watercourses or aquifers?

No No impoundment, damming, culverting, realignment or other changes to the hydrology of surface watercourse is required.

1.22 Stream crossings?

No No stream crossing the site.

1.23 Abstraction or transfers of water from ground or surface waters?

No Extraction of water from ground is being done. Application for NOC from CGWA for the same has been applied.

1.24 Changes in water bodies or the land surface affecting drainage or run-off?

No There will be no changes in water bodies or the land surface effective drainage or run-off.

1.25 Transport of personnel or materials for construction, operation or decommissioning?

Yes In existing unit, all raw materials are transported using road trucks from various parts of India. All the finished products are transported using road trucks to various parts of India. Same shall be done after expansion.

1.26 Long-term dismantling or decommissioning or restoration works?

No Not Applicable



1.27 Ongoing activity during decommissioning which could have an impact on the environment?

No Not Applicable.

1.28 Influx of people to an area in either temporarily or permanently?

Yes There will be temporary influx of 50 nos. of labour for installing the unit.

During operational phase there is already temporary influx of approx. 217 people in existing unit, after expansion approx. 33 people more people will influx. So, there will be increase in influx of people to the area.

1.29 Introduction of alien species?

No There is no alien species at the proposed site.

1.30 Loss of native species or genetic diversity?

No No loss of native species or genetic diversity.

1.31 Any other actions? No None

2. Use of Natural resources for construction or operation of the Project (such as land, water, materials or energy, especially any resources which are non-renewable or in short supply):

S. No Information/checklist confirmation Yes/No

Details thereof (with approximate quantities /rates, wherever possible) with source of information data

2.1 Land especially undeveloped or agricultural land (ha)

No Change of land use has already been done. It is an expansion of existing unit. No further change in land use shall be there.

2.2 Water (expected source & competing users) unit: KLD

Yes Uses: Process/Boiler/Cogeneration, Cooling Tower, domestic purposes & Gardening.

Water requirement: The present total water consumption is around 6275 KLD and the total quantity of water required after the proposed expansion is estimated as 10571 KLD.

Water Management is given in pre-feasibility Report.

2.3 Minerals (MT) No Not applicable



2.4 Construction material – stone, aggregates, sand / soil (expected source – MT)

No Only Additional plant / machineries are required for expansion, but no further construction will be done related to process.

2.5 Forests and timber (source – MT) No Not Applicable

2.6 Energy including electricity and fuels (source, competing users) Unit: fuel (MT), energy (MW)

Yes DETAILS EXISTING AFTER

Expansion

DG Sets 1 x 500 KVA and 1 x 725 KVA

(Fuel-Diesel)

No Change

Boiler 80 TPH and 120

TPH (Fuel-

Bagasse)

80 TPH, 120 TPH & 2 x 32 TPH

(Fuel-Bagasse)

Power Requirement

10,000 KW/hr

13,500 Kw/hr

2.7 Any other natural resources (use appropriate standard units)

No None.

3. Use, storage, transport, handling or production of substances or materials, which could be harmful to human health or the environment or raise concerns about actual or perceived risks to human health.

S.No. Information/Checklist confirmation Yes/No Details thereof (with approximate quantities/rates, wherever possible) with source of information data

3.1 Use of substances or materials, which are hazardous (as per MSIHC rules) to human health or the environment (flora, fauna, and water supplies)

No There is no Raw Material which are hazardous (as per MSIHC rules).

3.2 Changes in occurrence of disease or affect disease vectors (e.g. insect or water borne diseases)

Yes Suitable drainage and waste management measures has already been adopted. This restrict stagnation of water or accumulation of water. This will effectively restrict the



reproduction and growth of disease vectors.

3.3 Affect the welfare of people e.g. by changing living conditions?

Yes The expansion of project will provide increased employment and there will be increase in per capita income.

3.4 Vulnerable groups of people who could be affected by the project e.g. hospital patients, children, the elderly etc.,

No No, vulnerable group of people will be affected by the project.

3.5 Any other causes No None

4. Production of solid wastes during construction or operation or decommissioning (MT/month)

S. No.

Information/Checklist confirmation

Yes/No

Details thereof (with approximate quantities/rates, wherever possible) with source of information data

4.1 Spoil, overburden or mine wastes

No Not applicable

4.2 Municipal waste (domestic and or commercial wastes)

Yes Municipal waste:

Installation phase: Approx. 8 kg/day of municipal solid waste will be generated and shall be disposed off at MSW Site.

Operation Phase: 40 kg/day Municipal Solid Waste (Existing 34 kg/day & Proposed 6 kg/day) will be generated out of which 28 kg/day biodegradable waste will be disposed off at MSW site & 12 Kg/day recyclable waste will be given to authorized recycler.

4.3 Hazardous wastes (as per Hazardous Waste Management Rules)

Yes Hazardous waste generated includes Used oil which is being given to authorised vendor for recycle/disposal. ETP sludge is being disposed to TSDF site.

4.4 Other industrial process wastes

Yes Process Waste

Existing

Proposed

Total Disposal Method



Bagasse 1960 1700 3360 Tonnes/ day

Used as fuel in Boiler

Ash Content

29 21 50 tonnes/day

Ash shall be disposed off within the site and is used for levelling the area.

Molasses

315 225 540 tonnes/day

Used in Distillery for Alcohol Production

Press Mud/Filter Cake

294 210 504 tonnes/day

It shall be sold to Farmers and Brick manufactures.

4.5 Surplus product No Not applicable

4.6 Sewage sludge or other sludge from effluent treatment

Yes STP sludge is non-hazardous and is being used as manure. Same shall be followed after expansion also. ETP sludge is hazardous & will be temporarily stored in site in closed containers. Approximately 2000 Kg/day of ETP sludge shall be generated from the ETP after expansion. It shall be Stored in secured manner and sent to authorized TSDF.

4.7 Construction or demolition wastes

No No construction will be done related to process; hence, No Construction or demolition wastes shall be generated during construction phase.

4.8 Redundant machinery or equipment

No Not applicable

4.9 Contaminated soils or other materials

No Not applicable

4.10

Agricultural wastes

No Not applicable

4.11

Other solid wastes

No Not applicable



5. Release of pollutants or any hazardous, toxic or noxious substances to air (Kg/hr)

S.No.


Yes/No


5.1 Emissions from combustion of fossil fuels from stationary or mobile sources

Yes In existing unit, the major air pollutants sources are DG sets, Boiler (80 TPH, 120 TPH) & chimneys. For mitigation, ESP is installed on 120 TPH boiler with stack height of 65 m and wet scrubber on 80 TPH boiler with 50m stack height. Adequate stack height has been provided for the DG set. After Expansion, wet scrubber shall be provided with proposed 2 x 32 TPH boiler having 50m stack height.

5.2 Emissions from production processes

No No major emissions are envisaged; The Process emissions are controlled by providing closed circuit for production.

5.3 Emissions from materials handling including storage or transport

Yes Dust will be generated from the handling of sugar cane and bagasse.

5.4 Emissions from construction activities including plant and equipment

Yes There will be dust generation during construction/Installation phase. Water sprinklers will be used for dust suppression.

5.5 Dust or odours from handling of materials including construction materials, sewage and waste

Yes Dust is likely to be generated during construction/installation phase. Water will be sprinkled and tarpaulin cover will be provided over stored raw material to reduce dust emission. In existing unit, Odour is being generated from Press mud waste which is being used for manufacturing of Bio-compost from distillery spent wash after primary treatment. This bio-compost is being sold to the fertilisers. Now and after expansion, Press mud shall directly send to the brick



manufacturers and farmers without storage in the premises. Also, Dust is being generated during handling of Ash. It shall be transported to disposal site after sprinkling of ash with water in order to suppress the ash and to avoid air emission. Process waste water will be treated in Effluent treatment plant. There is no odour problem occurs through process of production. Processing area has been properly ventilated to avoid the odour.

5.6 Emissions from incineration of waste No Not Applicable as there is no incinerator

5.7 Emissions from burning of waste in open air (e.g. slash materials, construction debris)

No Not applicable

5.8 Emissions from any other sources

No Not applicable

6. Generation of Noise and Vibration, and Emissions of Light and Heat:

S.N o.


Yes/No

Details thereof (with approximate quantities/rates, wherever possible) with source of information data with source of information data

6.1 From operation of equipment e.g. engines, ventilation plant, crushers

Yes Noise shall be generated from the process. All the machinery has in built control for noise and vibration. The DG sets have been kept in acoustically treated room. Ear plugs & ear mufflers is being provided to the workers. The same shall be followed for achiness & equipment for expansion also.

6.2 From industrial or similar processes

No Heat is being dissipated from Boiler during fuel burning. Cooling tower has been installed. Same shall be followed in the expansion.

6.3 From construction or demolition No No further construction or demolition shall be done.



6.4 From blasting or piling No Not applicable.

6.5 From construction or operational traffic

Yes Some amount of noise will be generated from vehicular movement in the construction and operational phase & will be within permissible limit. Green belt has been developed at the periphery of the project site.

6.6 From lighting or cooling systems

Yes From cooling tower some noise is being generated. Proper management measures has been taken.

6.7 From any other sources No None

7. Risks of contamination of land or water from releases of pollutants into the ground or into sewers, surface waters, groundwater, coastal waters or the sea:

S.No.


Yes/No


7.1 From handling, storage, use or spillage of hazardous materials

No Raw material is being stored in separate room. Used oil from machineries/D.G. Set will be stored in Steel drums and kept in proper rooms. It will be sold to authorize vendors only. Special care will be taken to prevent leakages and spills.

7.2 From discharge of sewage or other effluents to water or the land (expected mode and place of discharge)

No In existing 3500 KLD ETP & 200 KLD STP has already been provided to treat process and domestic waste respectively. Treated waste is being reused in the premises for gardening. After expansion, same shall be maintained to remain a zero-liquid discharge unit.

7.3 By deposition of pollutants emitted to air into the land or into water

Yes All spillage control measures have been taken. All effluent is channelized to ETP. In existing it is a Zero Liquid Discharge Unit and the same shall be maintained after expansion also.



All the emission from the boiler is being passed through ESP and Wet scrubber for the treatment. All emissions and discharges will conform to the discharge standards stipulated by the regulatory authorities Ash generated from the boiler is being disposed on the allocated land. Same shall be followed after expansion.

7.4 From any other sources No Not applicable

7.5 Is there a risk of long term buildup of pollutants in the environment from these sources?

No Not applicable

8. Risk of accidents during construction or operation of the Project, which could affect human health or the environment

S.No.


Yes/No


8.1 From explosions, spillages, fires etc from storage, handling, use or production of hazardous substances

Yes Bagasse and Molasses are more prone to fire, which will be store in separate room and adequate measures shall be taken to avoid fire explosion. Fire may result into loss of machines and the damage by fire may high economic losses. To prevent and control this damage all the raw material & chemicals have been stored in leak & fire proof underground MS tanks and proper fire-fighting system has already been installed.

8.2 From any other causes No Not applicable

8.3 Could the project be affected by natural disasters causing environmental damage (e.g. floods, earthquakes, landslides, cloudburst etc)?

No The project site falls under seismic zone-IV according to the Indian Standard Seismic Zoning Map. Further it is not flood prone or landslide prone areas. Hence, no risk



due to natural hazards is Envisaged. However suitable seismic coefficients in horizontal and vertical directions will be adopted while designing the structures.

9. Factors which should be considered (such as consequential development) which could lead to environmental effects or the potential for cumulative impacts with other existing or planned activities in the locality

S. No.


Yes/No


9.1 Lead to development of supporting. cities, ancillary development or development stimulated by the project which could have impact on the environment e.g.: • Supporting infrastructure (roads, power supply, waste or waste water treatment, etc.) • housing development • extractive industries • supply industries • other

Yes

Roads, power network exists in the area. For waste water treatment ETP of 3500 KLD & STP of 250 KLD has already been installed.

9.2 Lead to after-use of the site, which could have an impact on the environment

No Proper care shall be taken to avoid any adverse impact on the environment.

9.3 Set a precedent for later developments Yes

It will be an Environmentally sustainable project. It will attract people to develop more organized type of industries.

9.4 Have cumulative effects due to proximity to other existing or planned projects with similar effects

No Not applicable

(III) Environmental Sensitivity

S. No.

Areas Name/ Identity

Aerial distance (within 15 km.) from Proposed project location boundary



1 Areas protected under international conventions, national or local legislation for their ecological, landscape, cultural or other related value

Dasuya Forest Division 11.1 Km E

2 Areas which are important or sensitive for ecological reasons - Wetlands, watercourses or other water bodies, coastal zone, biospheres, mountains, forests

Water Bodies Drain Dasua Distributary Drain Drain Machhian Cho Forest PF PF PF PF PF PF

7.37 Km N 5.08 Km N 1.02 Km N 0.77 Km S 8.33 Km SSE 0.82 Km NNW 1.11 Km NW 3.02 Km NW 8.02 Km NW 8.2 Km N 8.44 Km N

3 Areas used by protected, important or sensitive species of flora or fauna for breeding, nesting, foraging, resting, over wintering, migration

N/A

4 Inland, coastal, marine or underground waters.

None None

5 State, National boundaries

Himachal Pradesh Boundary 21.16 Km NEE

6

Routes or facilities used by the public for accessto recreation or other tourist, pilgrim areas

Dasuya-sansarpur Rd Dasuya-sansarpur Rd SH-24 Railway Station Dasuya Railway Station Airport Pathankot Airport Kangra Airport

4.17 Km N 4.58 Km W Adjacent to project area 5.33 Km NW 49.69 Km N 68.08 Km NE

7 Defense installations None none



8

Densely populated or built-up area

Bersha 20.42 Km W

9 Areas occupied by sensitive man-made land uses (hospitals, school, places of worship, community facilities)

Hospital Civil Hospital Dasuya Deep Hospital Chopra hospital Post Office Post Office in Berchha Post Office in Badal Post Office in Bhana Post office in Dafar Place of Worship Temple in Kular Temple in Kular School Govt High School Berchha SVJC DAV public School Darshan Academy Cambridge Academy school Banks Airtel Payment Bank Yes Bank Dasuya Branch Bank Of india

4.65 Km NW 4.98 Km NW 5.26 Km NW 2.54 Km W 3.17 Km W 1.46 Km SE 3.09 Km E 1.98 Km E 2.00 Km E 2.57 Km W 4.65 Km NW 3.04 Km NW 5.99 Km NW 2.85 Km W 5.41 Km NW 6.06 Km NW

10

Areas containing important, high quality or scarce resources (Ground water resources, surface resources, forestry, agriculture, fisheries, tourism, minerals)

None

None

11 Areas already subjected to pollution or environmental damage. (Those where existing legal environmental standards are exceeded)

None None



12 Areas susceptible to natural hazard which could cause the project to present environmental problems (Earthquakes, subsidence, landslides, erosion, flooding or extreme or adverse climatic conditions)

The project area falls in seismic zone –IV.



ENCLOSURE: 2- PRE-FEASIBILITY REPORT



2.1 Introduction of the project

The existing industry mainly produce Sugar from Sugarcane. The project has already got

environmental clearance vide letter no J-11011/764/2007-IA. II (I) dated 03.06.2010 for the

capacity of 7000 TCD and cogeneration power plant of 10 MW and 23 MW. The CTO has been

granted vide letter dated 5.08.2014 for the capacity of 7000 TCD for product-sugar 700 MT

per day and electricity 33 MW. The CTO is valid up to 31.03.2019.

Now, the unit wishes to expand the capacity of the plant as per the local requirement from

7,000 TCD to 12,000 TCD and co-generation power plant from 33MW to 37MW. As the project

have co-generation of 37 MW power plant, therefore as per EIA Notification the project falls

under Scheduled 5(j) and Category A.

2.2 Profile of Promoter

A B. Sugars Limited (ABSL) is a private sector company with varied businesses. ABSL, formerly

known as Guru Teg Bahadur Sugars Ltd., was taken over by Chadda group in the year 1997,

having its plant at Village: Randhawa Tehsil Dasuya, Hoshiarpur District in Punjab.

The Chadha group is a highly reputed with diverse interests that include sugar, distillery,

Paper, Liquor Retailing, Construction, Operation of Multiplex and screening of film. The

groups rapid growth on Indian corporate scenario rest on its strong foundations of

professional management and astute collective enterprise.

2.3 Requirement and Need of the Project and the Benefits

The world's largest consumers of sugar are India, China, Brazil, USA, Russia, Mexico, Pakistan,

Indonesia, Germany and Egypt.

India is predominantly an agro based economy. Sugarcane plays a very vital role in this agro

based economy by providing sugar, the main sweetener used in India. With the growing

demand for sugar, the emphasis has been on increasing sugar production.

The Indian sugar industry is the country’s second largest agro-processing industry with an

annual production capacity of over 18 million tonnes of sugar. 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 India, the annual per capita consumption of white crystal sugar and that of non-centrifugal

sugar is 15 Kgs per annum and 23 Kgs per annum respectively. The annual overall

consumption of the centrifugal and non-centrifugal sugar in the country comes to more than

25 million tonnes. Thus, there is vast untapped potential for growth in the area of sugar

production. Hence to cater the market demand we are increasing capacity of plant.

2.4 PROJECT DESCRIPTION

2.4.1 Project Details

DETAILS EXISTING PROPOSED AFTER EXPANSION

Activity Sugar Manufacturing Unit and Co-generation power plant

Location Village-Randhawa, Tehsil-Dasuya, District-Hoshiarpur, Punjab

Plot Area (sqm) 6,87,966 sqm (170 Acres)

Sugar Plant Area- 59 acre

- 6,87,966 sqm (170 Acres)

Sugar Plant Area- 59 acre

Production Capacity Sugar - 7000 TCD

Co-generation power

plant - 33 MW

- Sugar - 12,000 TCD

Co-generation power

plant - 37 MW

Estimated Cost 208 Crore 17 Crore 225 Crore

Employment 217 33 250

Power Requirement - - 13,500 Kw/hr

DG Sets 1 x 500 KVA and 1 x 725

KVA

- 1 x 500 KVA and 1 x 725

KVA

Boiler 80 TPH and 120 TPH 2 X 32 TPH 80 TPH, 120 TPH & 2 x 32

TPH

Air Pollution Control

Devices

Stack, Wet Scrubber,

Electrostatic Precipitator

(ESP)

- Stack, Wet Scrubber,

Electrostatic Precipitator

(ESP)

Total Water

Requirement

6275 KLD 4296 KLD 10571 KLD

Fresh Water

Requirement

1363 KLD 864 KLD 2227 KLD

Waste Water

Generation

1870 KLD 1366 KLD 3236 KLD

Water Source Bore Well - Bore Well



Water Pollution

Control Devices

STP - 250 KLD

ETP - 3500 KLD

STP - 250 KLD

ETP - 3500 KLD

Rain Water

Harvesting Pit

3 5 8

2.4.2 Details of Products and Production

A. SUGAR

S. No PRODUCT EXISTING Qty. (Tonnes/day)

PROPOSED Qty. (Tonnes/day)

TOTAL Qty. (Tonnes/day)

1 L Quality Sugar (31) 77 55 132

2 M Quality Sugar (31) 616 440 1056

3 S Quality Sugar (31) 77 55 132

Total 770 550 1320

B. CO- GENERATION POWER PLANT

S. No PRODUCT EXISTING PROPOSED TOTAL

1. Sailing Power 23 MW - 23 MW

Captive Power 10 MW 4 MW 14 MW

Total Power Generation

33 MW 4 MW 37 MW

2.4.3 Details of Raw Material Requirement

S.NO RAW MATERIAL DAILY CONSUMPTION (Existing)

DAILY CONSUMPTION (Proposed)

DAILY CONSUMPTION (Expansion)

1 Lime 10.5 MT 7.5 MT 18 MT

2 Sulphur 4.2 MT 5 MT 7.2 MT

3 Biocide 70 kg/day 50 kg/day 120 kg/day

4 Magnafloc 21 kg/day 15 kg/day 36 kg/day

5 Phosphoric Acid 35 kg/day 25 kg/day 60 kg/day

6 Colour Precipitation

100 kg/day 70 kg/day 170 kg/day

7 Sugarcane 7,000 TCD 5,000 TCD 12,000 TCD



2.4.4 Land Area Details

PARTICULAR TOTAL AREA % AREA

Sugar Division 59 Acre 34.7%

Cogeneration 3 Acre 1.8%

Distillery Unit 24 Acre 14.1%

Residential Area 12 Acre 7.1%

Green Belt Area 55 Acre 32.3%

Ash Disposal area 7 Acre 4.1%

Agricultural Land 10 Acre 5.9%

Total Area 170 Acre 100%

Sugar Division35%

Cogeneration2%

Distillery Unit14%

Residential Area7%

Green Belt Area32%

Ash Disposal area4%

Agricultural Land6%

LAND USE



2.4.5 The Google Image of Project Site

Figure 1; Aerial View of the Unit



2.4.6 10 Km Buffer Zone Map on SOI OSM Sheet

2.4.7 Connectivity

Roads & Highway Dasuya-sansarpur Rd Dasuya-sansarpur Rd SH-24 Railway Station Dasuya Railway Station Airport Pathankot Airport Kangra Airport

4.17 Km N 4.58 Km W Adjacent to project area 5.33 Km NW 49.69 Km N 68.08 Km NE



2.4.8 Layout Plan

Figure 2; Master Layout Plan

2.4.9 Process Description

A) SUGAR

(i) Washing, Cutting of Canes, Shredding:

• Washing the sugarcane before processing i.e. removing dirty

• Cutting operation is the first operation in industry.

• Cutters are mechanical equipment which is used to cut the canes into

desired size

• Shredder is used to remove leaves and undesired solid particles from cane.

(ii) Milling

• Milling is process of crushing the sticks of sugar cane to extract the juice.

• The shredded cane id fad through a series of crushing mills to extract the

sugar rich juice.

• Consists of three roller mills connected in series:

NO.2

G.M

. RESID

EN

CE

MOLASSES

TANK

GU

EST H

OU

SE

TEMPLE

TH

REE R

OO

M

7 ACRES.

ASH DISPOSAL AREA

BO

ILE

R N

O.1

BO

ILE

R N

O.2

AGRICLUTRE LAND

PROPOSED

SUGAR

GODOWN

STAFF Q

TR

S.

STAFF Q

TR

S.

DO

OR M

ATRY

PROPOSED

TURBINE

DO

OR M

ATRY

PROPOSED

DO

OR M

ATRY

NO.6

DO

OR M

ATRY

NEW

MOLASSES

TANK

DO

OR M

ATRY

SIN

GLE Q

UTRS.

SIN

GLE Q

UTRS.

LAND AREA DETAILS

DO

OR M

ATRY

WORK

SHOP

LAWN

STAFF QTRS.

PZ METER NO.3PZ METER NO.2

PZ METER NO.1

PARK

25 ACRES

OFFICE

RO

AD

C.U

. N

O.2

CANTEN

TG-3

A-FIL

TER

AUX. PANEL OF

P.S.E.B.

GRO

UP

PRESID

EN

T

RESID

EN

CE

TO

DASU

A

D.M. PLANT

U.G.R.

HE

AD

SH

AST

C/L

OF

3rd

MIL

L

C/L

OF

FIB

RIZ

ER

C/L

OF

M.C

.C.

CH

OPPE

R

C/L

OF

LE

VL

LE

R

A.C.

BO

ILE

R N

O.3

SHED

ELEC

. LIN

E (1

1KV.)

OF

TW

O R

OO

M S

ET

STAFF Q

TRS.

B OI LE R NO.1

R.B.C.45°

STAFF Q

TRS.

RO

AD

SECU

RIT

Y R

OO

M

GATE N

O 1

WORK SHOP

SULPHUR STORE

STORE

FU

TU

RE S

TAFF Q

TRS.

DO

OR M

ATRY

C/L

OF

AU

X.

CH

OPP

ER

BORE

WELL

CAR P

ARCKIN

G

BORE

WELL

TH

REE R

OO

M

TH

REE R

OO

M

HALL

NEW

STAFF Q

TR

S.

C.U

. N

O.1

RO

AD

GUST HOUSE

APROX. 100 MTRS. FROM

C/L

OF

B.E

.

C/L

OF

4th

MIL

L

TIME

C/L

OF

1st

MIL

L

C/L

OF

2nd

MIL

L

GATE NO 2

A.D

.M. B

LO

CK

O .T ANK

I . D. FAN

ELEC

. LIN

E (1

1KV.)

TW

O R

OO

M S

ET

TH

REE R

OO

M

TH

REE R

OO

M

TW

O R

OO

M S

ET

TBM ON PILLAR

101.12M. (TOP)

GU

RD

WARA

RO

AD

STAFF Q

TR

S.

WS

.1

DO

OR M

ATRY

I . D. FAN

TRANSF. 1000 KVA

TRASF. SHED P.S.E.B.

C OL LI NG T OWER

5 X1 7 Mt r.

O .W.

C OL LI NG T OWER

ELECTRIC

SPRAY PUMP

WS

.1

B OI LE R NO.3C HI MMNEY

M I L L H O U S E

WS

.2

DISTRIBUTION PANEL OF TURBINE

10

x6

M

tr.

PIT

NO

. 1

VC

.3V

C.2

PU

MP

HO

US

E

HO

T W

AT

ER

CH

AN

NE

L

CO

LD

WA

TE

R C

HA

NN

EL

IN

JEC

TIO

N P

UM

P

FILTER STATION

C HI MMNEYB OI LE R NO.1&2

CL

AR

IFIER

PIT

NO

. 1

10

x6

M

tr.

LIME STATION

CL

AR

IFIER

C OL LI NG T OWER

ETP

PLAN

T

WATER

TAN

K

ETP PLANT

EUCALYPTUS

PLANTATION

PAN

NEL

WA

TE

R T

AN

K

WATER T

ANK

5 X1 7 Mtr.

BODAL TO RANDHAWA

N EW CO LLING TOWER

P A

N S

T A

T I O

N

C.U

. N

O.3

BO

ILIN

G H

OU

SE

C.U

. N

O.4

NE

W C

OL

LIN

G T

OW

ER

RO

AD

ID

F

AN

NO

.1

AS

H

HA

ND

LI

NG

SY

ST

EM

ID

F

AN

NO

.2

3 MW TU RVINE

POWER HOUSE

C/L

B.C.

C OL LI NG T OWER

5 X1 7 Mt r.

OFC/L

BOILER HOUSE

BORE

WELL

GATE NO 3

DIR

EC

TO

R

RESID

ENCE

TH

REE R

OO

M

M.D.HOUSE

WATER

TANK

SH

ED

TOTAL PLOT AREA = 170 ACRES

TEL. L

INE

RO

AD

KACHA AREA

SHOPS

TO

HO

SHIA

RPUR

DRG. NO. COM

IN M.M. DATEAPRD.

DATECHD.

MOLASSES

TANK

NO.3

SUGAR GODOWN

NEW

NO.1

DRIER HOUSE

NO.1

SUGAR

GODOWN

MOLASSES MOLASSES

MOLASSES

GATE

O

FF

ICE

PWD ROAD

A.B. SUGARS LTD. RANDHAWA HSP. (PB.)

ALL DIMS

SCALE

BRICK WALL

DESCRIPTION DATEREV.

TANK

NO.5

TANK

NO.3 NO.4

TANK

STAFF Q

TR

S.

STAFF Q

TR

S.

SH

ED

NO.2

SUGAR GODOWN

B O

U

N

D

A

R

Y

W

A

L L O

F

S

U

G

A

R

P

L

A

N

T

TUBEWELL / BATHROOM



Top roller

Feed roller

Discharge roller

• These used to extract the juice from crushing sticks.

• To make the mill process more efficient, the poor juices of the subsequent

milling are reprocessed (mashing process) and hot water is applied in the

last milling to increase the extraction.

• Bagasse is produce as a byproduct.

(iii) Clarification

• In clarification process sludge, mud, suspended & colloidal particles are

remove by some chemical compounds.

• Raw cane juice is filled in clarifier (conical shape vessel), where phosphoric

acid, lime & Sulphur dioxide are mixed with the help of agitator.

• When these chemicals are mixed, suspended and colloidal particles are

collect in flock and resulting settled down.

• Neat and clean juice comes out from the upper section of clarifier, sludge

and mud are collect in bottom and drainage to rotary filter.

a. Calcium phosphate: as flocculent

b. Lime & SO2: acts as bleaching agent

c. CO2: acts as acidifying agent



(iv) Filtration

• Clarified mud from the clarifier further filtered in rotary filter. Mud &

sludge are stick on the periphery of rotating drum by the action of section.

Solid cake removes from the drum by doctor blade.

(v) Evaporation

• Evaporators are used in process industry to concentrate liquids.

• The operation is performed normally by use of low pressure, dry &

saturated steam.



• The evaporator consists a heat exchanger in inner section.

• In the evaporator feed interred at upper section and concentrated thick

liquor exit at bottom section.

• Multiple effect evaporator increase quality.

(vi) Pan Boiling

• The syrup is again treated with sulphur dioxide before being sent to the

pan station for crystallization of sugar. Crystallization takes place in single-

effect vacuum pans, where the syrup is evaporated until saturated with

sugar. At this point “seed grain” is added to serve as a nucleus for the sugar

crystals, and more syrup is added as water evaporates.

(vii) Centrifugation

• The massecuite from crystallizer is drawn into revolving machines called

centrifuges. The perforated lining retains the sugar crystals, which may be

washed with water, if desired. The mother liquor “molasses” passes

through the lining because of the centrifugal force exerted and after the

sugar is “purged” it is cut down leaving the centrifuge ready for another

charge of massecuite.

• Centrifuge operated at 100-1800 rpm.

• Sugar crystals are washed with 85C

• Raw Sugar and molasses produced



(viii) Gradation & Packing

• The final product in the form of sugar crystal is dropped through pan

section and this sugar is graded and picked in 50 kg bags. The grade of the

sugar depends on the size of the crystal viz. Small (S), Medium (M) and

Large (L)

Process Flow



B) Co-Generation

AB Sugar proposes to expand the current 33 MW co-generation bagasse plant to 37 MW, the

peculiarities of manufacturing process are as follows: This is a simple three step process

namely Water preparation, Steam Generation and Power Generation. The steam turbine

operates on basic principles of thermodynamics. After leaving the boiler, superheated vapour

enters the turbine at high temperature and high pressure. The high heat/pressure steam is

converted into kinetic energy using a nozzle (a fixed nozzle in an impulse type turbine or the

fixed blades in a reaction type turbine). Once the steam has left the nozzle it is moving at high

velocity and is sent to the blades of the turbine. A force is created on the blades due to the

pressure of the vapour on the blades causing them to move. A generator or other such device

can be placed on the shaft, and the energy that was in the vapour can now be stored and

used. The gas exits the turbine as a saturated vapour at a lower temperature and pressure

than it entered with and is sent to the condenser to be cooled (During off season) . During

Crushing season after de-superheating, the exit steam from Power Turbine is sent to

evaporator to evaporate juice and its condensate return to boiler.



2.4.10 Process flow Diagram

2.4.11 Material Balance



2.5 Site Photos

Utilities

Electro Static Precipitator (ESP)

Wet Scrubber Chimney

Acoustically enclosed DG Sets



Plant Area



2.6 Environment Management

2.6.1 Manpower

Total Population after Expansion 280

Total employees 250 (Existing 217, Proposed-33)

Visitors (Average) 30

2.6.2 Water Management

The present total water consumption is around 6275 KLD and the total quantity of water

required after the implementation of the proposed expansion activity is estimated as 10571

KLD. Extraction of water from ground is being done. In existing unit, the present total waste

water generation from Unit is 1870 KLD including 120 KLD of domestic waste water. Process

water is being treated ETP of 3500 KLD & domestic waste water in STP of 250 KLD. After

expansion, total waste water generation will be 3236 KLD including 120 KLD of domestic waste

water. The capacity of STP & ETP will remain the same is will suffice for the treatment of

increased waste water.

2.6.2.1 Water consumption

S. No Description Existing (KLD)

Proposed (KLD)

Total (KLD)

1 For process/Boiler/Cogeneration 2798 2418 5216

2 Cooling Tower 1834 878 2712

3 Domestic Usage 135 - 135

4 Gardening 1508 1000 2508

Total 6275 KLD 4296 KLD 10571 KLD

2.6.2.2 Wastewater generation

S. No Description Quantum of effluent (KLD)

Existing Proposed Total

1 Process/Boiler/Cogeneration 1660 (process) +90 (Boiler)

1302 (process) + 64 (Boiler)

2962 (process) +154 (Boiler)

2 Cooling Tower NIL NIL NIL

3 Domestic 120 0 120

4 Gardening NIL NIL NIL

TOTAL TRADE EFFLUENT 1750 1366 3116

Total Quantity of Sewage 120 - 120

Total Quantity of Waste Water 1870 KLD 1366 KLD 3236 KLD



2.6.2.3 EXISTING WATER BALANCE



2.6.2.4 WATER BALANCE AFTER EXPANSION



2.6.2.5 Scheme of ETP & Technical Specifications

The upgraded treatment scheme consists of treating the combined waste water comprising

of Sugar Mills effluents, cooling overflow and domestic waste waters in two stages-Anaerobic

followed by Aerobic biological treatment.

The process flow diagram of the proposed upgraded treatment scheme is presented: -

The unit proposed are: - 1. Bar Screen 2. Oil & Grease Traps 3. Equalisation Tank 4. Anaerobic Filter 5. Aerobic Reactor 6. Secondary Sedimentation Tank 7. Sludge Drying bed.

The preliminary treatment shall comprise of arresting of floating matters such as plastics, jute-

bags, cane wood, etc in bar screens and removal of O & G in gravity traps. V-notch plates shall

be provided at the inlet as well as outlet of the effluent treatment plant for measurement of

flow. An equalisation tank of four hours capacity exists to take care of varying pollution load

discharged by the mills. The effluents shall then be lifted with pump(s) from the equalisation

tank into the anaerobic filter to enable gravitational flow through all the other units of the

plant. The pH of the influent to the treatment plant is likely to be acidic most of the time. Lime

shall be added downstream of the equalisation tank for neutralization as per requirement.

The anaerobic filter shall consist of a reactor filled with coarse inert graded packing media.

The waste water shall enter at the base of the reactor through the under-drainage system

and flow upwards through the filter bed. Anaerobic organisms shall accumulate in the voids

of the media as well as become attached to the media surfaces. The waste shall, thus, come

into intimate contact with a large active biomass as it passes through the reactor. The BOD

removal shall be 77%.

The effluent from the filter shall be further treated in a complete mix activated sludge reactor,

the process has the capacity to hold a high MLSS level in the aeration tank imparting increased

operational stability at shock organic loading. The deficiency of nitrogen and phosphorous

estimated for the biological degradation shall be made good by addition of urea and di-



ammonium phosphate (DAP). The aerobic process shall remove more than 92% of the BOD

from the effluents. Diffused aeration shall be employed to maintain the desired DO level and

adequate mixing of liquor in the reactor.

The aerated effluent shall then be sedimented. The settled sludge from the sedimentation

tank bottom shall be lifted with the help of sludge pump and re-circulated back into the

aeration tank for seeding. The surplus from aerobic stage shall be partly anaerobically

digested in the filter and the balance sun dried on sludge drying beds.

The treated waste waters shall be used for irrigating the green areas within the complex.

Figure 3; Schematic representation of treatment of effluent in ETP

2.6.2.6 Specifications of ETP

1) PRELIMINARY TREATMENT

a) Bar Screens Bar Spacing : 15 mm c/c

b) Oil & Grease Detention Time : 20 min c) Equalization Tank d) Peak Factor : 1.15 e) Detention Time : 3 hrs



2) SECONDARY TREATMENT

STAGE-I ANAEROBIC

a) Anaerobic Filter

Loading Rate : 6 kg COD/m3/d Detention Time : 14 hrs Media : Graded Gravel Removal Efficiency : 77 % COD

STAGE-II AEROBIC

b) Aeration

Loading Rate : 0.18 kg BOD/kg MLVSS/d MLSS : 5000 mg/l MLVSS : 4000 mg/l SRT : 12 d Volumetric Loading : 0.77 kg BOD/m3/d Detention Time : 9 hrs Oxygen Required : 1.4 kg the or O2/Kg BOD rem c) Secondary Sedimentation

Overflow Rate : 12 m3/m2/h Solids loading : 2.5 kg/m2/h Detention time : 7 hrs Sludge Recirculation : 100 % Efficiency : 92 %

3) Sludge Drying

Bed Loading Rate : 200 kg/m2/year Application Depth : 0.3 m

UNITS AND EQUIPMENT PROPOSED

A) Units:

S.No Units

1 1 No. Bar Screens, O & G Trap

2 1 No. 25.50 x 16.00 x 2.50 m SWD Equalisation Tank

3 1 No. 40.00 x 20.00 x 4.50 m SWD Anaerobic Filter



4 1 No. 33.00 x 11.00 x 5.00 m SWD Aeration Tank

5 1 No. 23.00 diameter, 3.75 m SWD Secondary Sedimentation Tank

6 16 No. 40.00 x 20.00 x 4.50 m SWD Sludge Drying Bed

Top Dimension of trapezoidal shaped tank

B) Equipments

S.No Units

1 1 No. Bar Screens

2 1 No. Lime Dosing System

3 4 No 22.5 lps, 10-12m head Waste Water Lift Pump

4 3 No.- 920 m3/h, 0.6m head Air blower

5 1 lot Air Diffusers

6 1 No.- 23.00 m diameter Secondary Sedimentation Tank,

Scrapper Mechanism

7 4 No.- 20 lps, 6-8 m head Sludge Recirculation Pump

8 1 Lot Pipes, Valves & Specials

9 1 Lot Electricals

SPECIFICATION

CIVIL WORKS

S.No. Unit Construction Material

1. Anaerobic Filter, Secondary

Sedimentation Tank

R.C.C [M-20], L.C.C [1]

2. Sludge Drying Beds, Miscellaneous work,

Foundations, Drains and Sumps etc

R.C.C. [M-15], L.C.C. [2],

P.C.C., B.B.M.

2.6.2.7 Process & Operation of STP

The existing unit already has the STP which shall not be modified or upgraded as it will be able

to meet the needs of the expansion in its current capacity.

The waste water generated from the complex shall be collected in the equalization tank

through the pipe from bar screen chamber and oil and grease trap. The bar screens will be

cleaned as and when required. From the bar screen chamber the waste water shall be taken

in the oil and grease trap where oil and grease shall be skimmed off from the top being lighter

in weight. From the oil and grease trap the waste water shall be passed into the equalisation



tank. In the equalisation tank air will be purged to avoid the septic conditions. The waste

water from the equalisation tank the waste water shall be lifted with the help of submersible

pump to the grit chamber.

In grit chamber the grit will settle down and will be removed from the bottom periodically.

The waste water from the grit chamber will then flow into the Aerobic Bed Bio-Reactors. In

this reactor, synthetic media shall be introduced enabling the attachment of micro-organisms.

In these bio-reactors air shall be diffused from bottom through diffusers/nozzles by the twin

lobe air blower. The organic load will be reduced with the help of attached growth on

synthetic media and dissolved oxygen. The BOD/COD load will reduce considerably in Bio-

Reactor-I. From here the waste water will go to the Bio-Reactor-II where further reduction of

BOD/COD will take place.

From the bio-reactor the waste water will flow into the secondary clarisettler. In the

secondary clarisettler provision of Tube deck is made to make the design compact. The waste

water will be fed in the secondary clarisettler with upward flow. The sludge will settle down

and the clear supernatant be collected at the top through launders. The over flow from

secondary clarisettler shall be discharged into the chlorine contract tank where chlorine shall

be dosed for proper disinfections of the treated waste water before passing through the

pressure sand filter. The chlorine (sodium hypochlorite solution) will be dosed @4-5 mg/lit

(max).

From this tank, the waste water will be passed through the pressure sand filter with the help

of filter feed pumps to remove the colloidal particles present in the standard form. Further

the treated waste water shall be passed through the Activated Carbon Filter for final polishing

& to make it free from any toxicity. The treated waste water shall be stored in a treated waste

water collection sump from where it shall be pumped with the help of treated waste water

pumps for final disposal/non-potable applications like cooling towers make up water,

gardening, horticulture etc. The treated waste water shall confirm to the PPCB norms.

The sludge from bottom of secondary clarisettler shall be dewatered in the filter press. The

dried sludge shall be used as organic manure for lawn/garden/horticulture and the filtrate

will be taken back to equalization tank. The treated water is used for gardening.



Figure 4; Schematic representation of treatment of sewage in STP

2.6.2.8 Photos of STP & ETP

STP



Oil and grease Trap of ETP Aeration Tank

Clarifier Online Waste water meter



2.6.2.9 Characteristics of waste water & treated water

Raw Effluent Characteristics:

pH - 5.5 – 6

BOD mg / l 1250

COD mg / l 1800

TSS mg / l 800

Oil & Grease mg / l 150

Treated Effluent Characteristics

pH - 7-8.0

BOD mg / l < 25

COD mg / l < 150

TSS mg / l < 80

Oil & Grease mg / l < 8

Raw Sewage Characteristics:

pH - 6-8.5

BOD mg / l 300

COD mg / l 700-900

TSS mg / l 200-300

Treated Sewage Characteristics

pH - 7-8.0

BOD mg / l < 10

COD mg / l < 150

TSS mg / l < 80

2.6.3 Rain water harvesting scheme

The scheme of recharge of rainwater Is implemented successfully in the unit and shall be

maintained after expansion. The rainwater from surface runoff and part of rooftops is

diverted using rain water pipes to the surface and via storm water drain network and then

recharge pits. 5 RWH pits has already been installed in the unit.



Scheme for Ground Water Recharging

The rainwater will be diverted from the rooftop using rain water pipes to the surface /

underground drainage network. The entire campus will be sub divided for recharging

structures. The rainwater will be diverted into the de-silting tank to remove inorganic

impurities and the outflow of the de-silting tank is taken into the recharge well.

De-silting Tank

The de-silting tanks will be used to remove silt and other floating impurities from rainwater.

De-silting tank is like an ordinary container having provision for the inflow, outflow and

overflow. Apart from removing silt it holds the excess amount of water till it is soaked up by

the recharge structure. The bottom of tank will have unpaved surface (layers of coarse sand)

to allow standing water to percolate into the soil. The rainwater collected in these de-silting

chambers shall be utilized for horticulture.

Recharge well

The Recharge Well consist the pit with 150 mm UPVC perforated pipe will be lowered in the

middle of the boreholes and the pit will be filled with gravel and pebbles consisting of

boulders, gravel and coarse sand. The mouth of the PVC pipe shall be protected to avoid silt

getting into it. The

RAIN WATER HARVESTING PLAN

The pit sizes depend on the max. peak intensity of the rainfall for 15 minutes. Maximum peak

intensity of the region is 40 mm for one hour. Considering 15 mins of continuous rainfall at

peak intensity the runoff generated is as follows:

Description Area Rain fall in

Meter Run off

Coefficient Total in m3

Roof top area of building/sheds

38,148 0.01 0.9 343.33

Road and Paved area 16,820 0.01 0.7 117.74

Open Area – Plantation / Landscaping/Plantation

Area 2,22,577 0.01 0.2 445.154

Total 2,77,545 sqm 906.224 Cum



Details of existing Pits:

Sr. No.

Location Length

(m) Width

(m) Free

Board Filter

Media No. of

Borewell

Water Handling Capacity

1 Godown 1 34.2 2 1.5 1 10 258.12

2 Godown 2 26.3 2 1.5 1 8 202.68

3 Godown 3 13.2 2 1.5 1 6 128.52

TOTAL 589.32 KL

We need to provide rainwater harvesting pits to collect 906.224 KL of rainwater in one hour

of rainfall at peak intensity. As the industry has already practicing rainwater harvesting system

and already constructed three recharge pits and has the water handling capacity is 589.32 KL

as shown in above table. For the remaining capacity, the industry has proposed 5 recharge

pits within the industry premises. The proposed Rainwater harvesting pits details are as

follows:

Sr. No. Location Length (m)

Width (m)

Free Board

Filter Media

No. of Borewell

Water Handling Capacity

1 RWHP 1 15 3.5 2 1.5 6 209.625

2 RWHP 2 15 3.5 2 1.5 6 209.625

3 RWHP 3 13 3.5 2 1.5 4 165.475

4 RWHP 4 13 3.5 2 1.5 4 165.475

5 RWHP 5 13 3.5 2 1.5 4 165.475

Total

915.67 KL

Each Injection well is of 150 mm dia. and at the depth of 24m from ground with recharge rate

of 15 L/sec.



Rain Water Harvesting Pit Diagram:

2.6.4 Waste Generation and Management

Municipal solid waste:

Category Type of Waste Color of

Bins

Disposal Method

(Existing) Total Waste

(Kg/day)

(After Expansion) Total Waste

(Kg/day)

Bio Degradable Organic Waste (Includes Food & Kitchen Waste,

Leaves etc.)

Green MSW Site 24 28

Non-Biodegradable

Recyclable Waste (Includes Poly-bags, Plastic, wood, paper,

glass, containers etc.)

Blue Approved Recycler

10 12

Total 34 Kg/day 40 Kg/day



Process waste:

Process Waste Existing (Tonnes/day)

Proposed (Tonnes/day)

Total (Tonnes/day)

Disposal Method

Bagasse 1960 1400 3360 Used as fuel in Boiler for producing Steam

Ash Content 29 21 50 Ash is being disposed off within the site. 7-acre area has been allocated for disposal of ash in the premises.

Molasses 315 225 540 Used in existing Distillery for Alcohol Production present in the premises.

Press Mud/Filter Cake

294 210 504 It shall be sold out to the farmers and brick manufactures. It shall not be kept in the premises.

Hazardous Waste

Used Oil

Approximately 15 lt/month of used oil shall be generated from the DG Sets. It Shall be

disposed in leak proof containers & disposed only to authorized re-processors/ authorized

common collection center provided the oil meets the standards as per schedule -5 Part A rules

Sludge from Plant Effluent Treatment Plant

Approximately 2000 Kg/day of ETP sludge shall be generated from waste water of ETP. It shall

be Stored in secured manner and sent to authorized TSDF.



2.6.5 Details of Air Emissions and Control

SL

No.

Existing

Air pollution sources

Type of

fuel Fuel Qty.

Pollution control

measures

Chimney

height AGL

MOC

Proposed change

after expansion

1.

80 TPH boiler

Bagasse

37 tph

Stack, Wet Scrubber

& ESP

Height - 50 Mts stack

AGL Dia – 2.0 m

MS

No change

3.

120 TPH

Boiler

Bagasse 47 tph

Stack, Wet Scrubber

& ESP

Height - 65 Mts stack

AGL Dia – 2.5 m

MS

No

change

4.

500 KVA DG SET

HSD 100 l/hr

Stack,

acoustic enclosures

6 Mts stack AGL

MS

No

change

5.

725 KVA DG SET

HSD

150 l/hr Stack,

acoustic enclosures

6 Mts stack

AGL MS

No

change

Proposed:

SL

No.

Addition of

Air pollution sources

after expansion

Type of

fuel Fuel Qty.

Pollution control

measures

Chimney

height AGL

MOC

1.

2 x 32 TPH boiler

Bagasse

30 tph

Stack, Wet Scrubber

Height - 50

Mts stack AGL Dia – 2.0 m

MS



Following measures shall be adopted to mitigate the air emissions:

1. Ash generated from the Boiler shall be transported to disposal site after sprinkling of

ash with water in order to supress the ash and avoid air emission.

2. To avoid odour of Press mud, shall directly send to the brick manufactures & farmers

without storing in the premises.

3. Green development will be developed within the plant premises. The plantation work

for green belt development shall be carried out as per CPCB guidelines.

4. Ambient air quality would be regularly monitored to ensure that ambient air quality

standards and suggested limits will be met at all the time.

2.6.6 Noise Pollution Management

To reduce Ambient Noise level the following measures will be adopted --

➢ Existing DG set has been bought acoustically enclosed & placed inside a acoustically

treated room as per CPCB guidelines.

➢ Noise generating units like machinery area, canteen etc. are well insulated with

enclosed doors. Earmuffs are being used while in high noise areas.

➢ Maintenance of vehicles and machinery will be done in a sustainable manner to

ensure best performance and less loss.

➢ Vehicle and people flow during shift changes shall be regulated by allowing exits in a

phased manner.

➢ The green belt will help in reducing noise levels in the complex as a result of

attenuation of noise generated due to plant operations and transportation.

2.6.7 Plantation Details

Shelter belt planning has been done with ecological perspectives for the project taking into

consideration availability of space and other aspects. Green belt/greenery has been

developed along most of the periphery of the project area as well as along roads. The trees

planted are of adequate height. Any trees that do not survive shall be replaced. The Total

Green area developed within the unit is 55 acres of area. The trees maintain the regional

ecological balance and conform to soil and hydrological conditions. Indigenous species has

been preferred. 37800 trees has already been planted. Species the trees are given below:



• Eucalyptus

• Globulus

• Tabernaemontana divaricate

• Eucalyptus poplar

• Hibiscus rosa-sinensis

2.6.8 Safety

Safety in design and operations are therefore of paramount importance. M/s AB Sugar have

taken initiative to implement an integrated process safety management system:

2.6.8.1 Safety in Design

Following are the strategies to improve the safety of the people and plant:

• Use of proven technologies and equipment

• Use of latest safety process know-how

• Modern risk assessment techniques to design effective safeguarding system for all

critical locations in the process

• Design plant in accordance with applicable codes and standards and maintain

standard engineering practices during detailed engineering

• Carryout extensive studies during the process design stage to ensure safety,

occupational health and environmental aspects are addressed in P& IDs, PFDs and

other engineering deliverables.

• Locate storage tanks in off-site area

• Pressure relief valves in all pressure vessels.

• Occupational Health

• Fixed detection system with alarms and data logging

• Trained personnel made fully aware of the hazards of process and operations.

Personnel must also be informed of the health hazards

• Periodic refresher training

• Minimize unnecessary exposure to airborne contaminants and direct exposure to

chemical hazards



• Good housekeeping

• Emergency showers and eye wash facilities at appropriate locations

• Health surveillance programs

2.6.8.2 Safety in Operations

A suitable organization shall be implemented to manage the safety of people and plant. The

organization shall be responsible for building and maintaining “a culture of safety” and shall

thrive to elevate safety to near religious levels. Suitable systems shall be designed and

implemented for safety training and awareness.

A suitable fire protection system with dedicated fire hydrant network for the whole complex

has been designed and installed. Besides, facilities such as dedicated fire station equipped

with fire-fighting equipment such as foam monitors has been put up. A dedicated fire alarm

system and special arrangements to protect manufacturing areas in case of fire has also been

commissioned as part of the project. Existing unit is operating at highest safety standards with

the principle that safety of a person overrides all production targets.



ANNEXURE I: DISCLOSURE OF ENVIRONMENTAL CONSULTANT



ANNEXURE II: TOPOGRAPHICAL MAP



ANNEXURE III: LAYOUT PLAN



ANNEXURE IV: COPY OF LATEST/ VALID CTO GRANTED



ANNEXURE V: COPY OF EARLIER ENVIRONMENT CLEARANCE



ANNEXURE VI: LAND PAPERS

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