Executive Summary New 65 KLPD

For Draft EIA report Molasses/Sugarcane Juice

Based Distillery/ Ethanol
Plant
At survey no. 51/4,51/5 Kukkuwada village, Tal & Dist. Davangere,
Karnataka

By
 EIA
New 65 KLPD Molasses/Sugarcane Juice Based Distillery/ Ethanol Plant
Executive Summary

CONTENTS
1.0 Introduction...................................................................................................................... 2
2.0 Project Location................................................................................................................ 2
3.0 Salient features of integrated project .............................................................................. 5
4.0 Process description .......................................................................................................... 7
5.0 Description of the Environment ....................................................................................... 8
6.0 Anticipated Environmental Impacts ................................................................................. 9
7.0 Environmental Monitoring Programme ......................................................................... 10
8.0 Additional Studies .......................................................................................................... 11
9.0 Environmental Management Plan ................................................................................. 11
10.0 Environment Management Cost .................................................................................. 14
11.0 Project Benefits ............................................................................................................ 14
12.0 Conclusion .................................................................................................................... 14

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 EIA
New 65 KLPD Molasses/Sugarcane Juice Based Distillery/ Ethanol Plant
Executive Summary

Executive Summary
1.0 Introduction
The Davangere Sugar Company Ltd. (DSCL) is presently operating 4750 TCD sugar factory &
24.0 MW installed capacity Cogeneration Power Plant. DSCL now proposes to set up a 65 KLPD
capacity distillery / ethanol plant, along with incineration boiler/TG & auxiliaries for achieving
Zero Liquid Discharge (ZLD) to produce ethanol, in the existing sugar premises. The proposed
distillery/ethanol plant envisages to utilize Cane Juice & B-Molasses own sugar plant &
procured C- molasses from factories in the surrounding area to set up a 65 KLPD capacity
distillery / ethanol plant, along with incineration boiler / TG & auxiliaries for achieving Zero
Liquid Discharge (ZLD) to produce ethanol.

2.0 Project Location

The proposed distillery location will be at Sr. No. 51/4, 51/5, village Kukkuwada, Tal. & Dist.
Davangere, Karnataka. For the present study, an area covered in 10 Km radius from the
project location has been considered. Proposed distillery will be geographically located at
14°19'37.56"N N & 75°52'43.22"E. Project site and the 10 km radius study area falls in the
survey of India Toposheet no. 48 N /15 & 48 N/16. Project area is connected to SH-65 Anaji-
Hadadi－Udipi－Umblibail adjacent to the factory, railway station Tholahhunase 12 km and
Davangere railway station 16.0 km, Airport Vijaynagar airport 124.0 km and Hubballi Airport
139.0 km. Nearest densely populated city Davangere is 15.0 km away from the project site.
Land for proposed project is a vacant plot and it is under for industrial purpose. There is no
forest land, wild life sanctuary and an eco-sensitive area comes in 10 km radius of the
proposed project location.

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 EIA
New 65 KLPD Molasses/Sugarcane Juice Based Distillery/ Ethanol Plant
Executive Summary

Figure 1: General Location Map

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 EIA
New 65 KLPD Molasses/Sugarcane Juice Based Distillery/ Ethanol Plant
Executive Summary

Figure 2: Proposed Distillery Plant Layout

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 EIA
New 65 KLPD Molasses/Sugarcane Juice Based Distillery/ Ethanol Plant
Executive Summary

3.0 Salient features of integrated project

Table 1: Brief information of the project and environmental settings

# Particulate Description
1. Project New 65 KLPD molasses based sugarcane juice distillery/ ethanol
plant at 51/4, 51/5 village Kukkuwada, Tal. & Dist. Davangere,
Karnataka.
2. Available land Total distillery plot area:13 acres
Green belt area: 4.3 acres
3. Product Molasses based distillery / Ethanol Plant (65 KLPD)
- R S & IS / Fuel Ethanol/ENA :65 KLPD
- Fusel oil: 0.195 KLPD
(One at a time)
4. Operation days Sugar factory season: 160 day
Cogeneration : 193 (Seasonal operational days 160 and off season
operational days 33)
Distillery plant will operate for 330 days
(330 days season or 150 days on own Cane Juice, 144 days on own
B-molasses generated & 36 days on procured molasses)
5. Molasses Own Cane juice on at 100 % utilization: 150000 (150 days) MT
requirement Own B-Molasses at 100 % utilization:29250 (144days) MT
Procured Final molasses: 9070 (36 days) MT.
6. Water requirement Total fresh water requirement for proposed distillery will be 498
CMD.
7. Source of water Water permission from Shygala halla is available with sugar
factory
8. Boiler Incineration Boiler – 30 TPH
9. TG Proposed distillery incineration boiler 4 MW TG ( double
extraction cum condensing turbine)
10. DG 250 kVA
11. Electricity Particulates Proposed
requirement Electricity generation 4.0 MW
Electricity consumption 1.5 MW
12. Fuel Concentrated spent wash: 8.45 MT/hr (202.8 MTD)
Coal: 3.48 MT/hr. (83.52 MTD)
13. Steam Steam generation 30 TPH
Steam consumption 18.50
14. Total effluent Proposed Distillery effluent generation: Spent wash 650-685
generation CMD, spent lees 150 CMD (100% lees shall be reuse in process),
process condensate 520 CMD
Existing effluent generation from sugar unit: 472 CMD
15. Effluent treatment Total Spent wash generation will be 650-685 CMD, it will be
system concentrated in MEE and then burn in proposed 30 TPH spent
wash fired boiler. Condensate water will be recycled back in the
process
Existing 1310 CMD ETP from sugar unit
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 EIA
New 65 KLPD Molasses/Sugarcane Juice Based Distillery/ Ethanol Plant
Executive Summary

Treated water is recycled/reused in green belt development and

ferti-irrigation.
16. Ash Distillery
Coal ash from proposed distillery: 29.23 TPD (max 35% for Indian
coal)
Spent wash ash from proposed distillery: 26.36 TPD
Spent wash ash collected from the furnace bottom hoppers shall
be used as manure.
Coal ash will be sold to the brick manufacturer.
Sugar
Existing bagasse ash generation: 15.3TPD
17. ETP sludge Maximum sludge is recirculated back in the aeration tank. Excess
of sludge from clarifiers is dewatered and partially dried in sludge
drying beds.
18. Air pollution control Proposed: Electrostatic precipitator
measures Existing: Electrostatic precipitator
Existing sugar Stack: 80 m
Proposed distillery stack height: 74 m
19. Man-power Proposed distillery skilled 50 & unskilled 30
20. Total project cost Project cost of the distillery: Rs. 98.00 Cr.
21. Total EMP capital Total 4.0 Cr.
cost
Environment Sensitivity
22. Nearest Village Kukkuvada at 300 m
23. Nearest Town / City Davangere is 15 km away
24. Nearest National SH-65 Anaji- Hadadi－Udipi－Umblibail adjacent to the factory
Highway
25. Nearest Railway Tholahhunase 12 km and Davangere railway station 16.0 km
station
26. Nearest Airport Airport Vijaynagar airport 124.0 km and Hubballi Airport 139.0
km
27. National Parks, No any in within 15 km of project area
Reserved Forests
(RF) / Protected
Forests (PF),
Wildlife
Sanctuaries,
Biosphere Reserves,
Tiger/ Elephant
Reserves, Wildlife
Corridors etc.
within 10 km radius

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 EIA
New 65 KLPD Molasses/Sugarcane Juice Based Distillery/ Ethanol Plant
Executive Summary

4.0 Process description

Alcohol manufacturing mainly involved below given steps
 Feed preparation and weighing
 Dilution: Preparation of molasses for fermentation by appropriate dilution with water
 Fermentation: Production of alcohol from fermentable sugars in molasses solution
with the help of yeast

 Distillation: Product recovery through distillation processes

Molasses Dilution
Spent lees will
Activated be recycled
Yeast Fermentation Ethanol & CO2
Emission

Multi-Pressure Spent wash

Steam Distillation and Spent lees

Molecular Sieve
Spent wash treatment through
MEE & Incineration boiler
RS/ENA/FO/AA/Ethanol

Storage

Figure 4: Distillery process flow chart

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 EIA
New 65 KLPD Molasses/Sugarcane Juice Based Distillery/ Ethanol Plant
Executive Summary

5.0 Description of the Environment

The study area as per awarded model TOR, 2015 is earmarked to be 10 km from the project site.
The baseline survey was conducted from Oct 2018 to Dec 2018. The guiding factors for the
present baseline study are the requirements prescribed by the guidelines given in the EIA Manual
of the MoEFCC and methodologies mentioned in Technical EIA Guidelines Manual for Distilleries
by IL&FS Ecosmart Ltd., approved by MoEFCC.

Table 3: Observation of Environmental monitoring

Environmental Frequency of Parameters Observed Results
Attributes monitoring
Meteorology Microprocessor based Wind direction North East and East
Weather Monitoring Max. Temp. 41.7 0C
Station Mini. Temp. 8.30C
Continuous hourly Relative Humidity 25-86%
recording Precipitation Monthly total annual avg. 607.57
mm
Ambient Air 10 Locations PM10 All parameters are within limit
Quality 24 hourly samples PM2.5 of NAAQ 2009
Twice a week for 3 SO2
months NOx
(in µg/m3)
Water Quality Once in season at 10 Parameter Ground water Surface water
(Ground & locations pH 7.13 to 7.50 7.27-7.45
Surface) (Physical, chemical and TDS 450 to 760 319-532
biological parameters) COD - <1
Total Coliforms <2 300
Soil Quality Once in season at 10 Soil type and Red sandy soil and followed by
locations texture, Physico- black soil. Soil is medium in
chemical fertility, good water holding
properties, NPK capacity, heavy metal
contamination signs not seen.
Noise Level Once in season at 9 Day 40.2- 58.2
Locations (Noise levels Night 31.4 – 40.1
in dB(A))
Land use One time visit of the Identification & Most of the land is Agricultural
Pattern study area classification of land followed by Barren land
land use
Geology and Based on secondary Geology and Basaltic lava flows, the ground
hydrogeology data hydrogeology of water in Deccan trap basalt
the study area occurs mostly in the upper
weathered and fractured parts

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 EIA
New 65 KLPD Molasses/Sugarcane Juice Based Distillery/ Ethanol Plant
Executive Summary

Environmental Frequency of Parameters Observed Results

Attributes monitoring
down to 20-25 m depth, alluvium
occurs in small areas.
Ecology General in 10 km radial Flora The most abundant species in
study area and data the study areas are, Bauhinia
collected around the spc., Taalegari, Acasia Sp.
project site through field Azadirachta indica Linn.,
visits Euphorbia Species, Albizia,
Jatropha curcas, Melia spc.,
Lantanta camara etc.
Fauna Plain tiger, Common Mormon,
Lemon pansy, Green Bee-eater,
Drongo etc.
Socioeconomic General in 10 km radial Socio-economic Sanitation facilities are
Data study area and data characteristics of satisfactory, Power supply
collected around the the affected area facility is available in almost
project site through field villages and town, Drinking water
visits sources is mostly from PWD
water supply, Medical facilities in
terms of primary health centre
and primary health sub centres
in the rural areas are good.

6.0 Anticipated Environmental Impacts

Table 4: Anticipated Impacts
Environmental Facets
Air Environment
Water Environment
Land Environment
Ecological Environment
Social Environment
Economic Environment
Noise Environment
Anticipated Impacts
Probable increase in concentration of air pollutants due to
process, fugitive and utility emissions.
Generation of industrial & domestic wastewater.
Impacts on land due to improper disposal of hazardous/ solid
waste.
Positive as greenbelt of appropriate width will be developed
and maintained by the company in the area. No impacts are
envisaged on aquatic flora & fauna as there will be zero
effluent discharge outside the plant premises.
Overall development of the area in respect of the
infrastructure development, educational growth, health
facilities etc.
Positive impacts on economy of the region and the country as
the Alcohol will be exported and revenue generation.
Minor increase in noise level within the project area.

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 EIA
New 65 KLPD Molasses/Sugarcane Juice Based Distillery/ Ethanol Plant
Executive Summary

Occupational Health & Major health hazards are identified in worst case scenario.
Safety
7.0 Environmental Monitoring Programme

Table 5: Environmental monitoring schedule

Particulate Parameters Number of location Frequency
Ambient air PM10, PM2.5, SO2, NOx Ambient air quality at minimum Monthly
quality etc. 3 locations. Two samples
downwind direction at 500 m
and 1000 m respectively.
One sample upwind direction at
500m.
Stack PM, SO2 and NOx All stacks Monthly
emission
Online stack monitoring will be -
installed
Work place PM2.5, SO2, NOx, CO, O3 Process emission in workplace Monthly
area/plants (for each area/plant
minimum 2 locations and 1
location outside plant area near
vent)
Waste water pH, EC, SS, TDS, O&G, Wastewater from all sources. Monthly
Ammonical Nitrogen, Inlet & outlet of ETP, spent
COD, BOD, Chloride, wash, Condensate treatment
Sulphides etc. plant
Online Monitoring machine is
already installed at existing ETP.
Camera at spent wash tank will
be installed.
Surface water pH, Salinity, 3-5 location Half yearly
and ground Conductivity, TDS, Ground as well as Surface water.
water Turbidity, DO, BOD,
Phosphate, Nitrates, Within 1 km radius from spent
Sulphates, Chlorides, wash tank and compost yard. 2
Total Coliforms (TC) & locations downward 1 location
E.Coli upward additional three
locations within 10 km radius
from the site.
River sample One each at
upstream and downstream
Solid waste Ash  Process dust generated Monthly
sludge and ash.
 Before used as manure if used
manure
Soil Organic N, P, K, moisture, EC, At lands utilizing compost Pre –
and Inorganic heavy metals etc. manure and treated effluent, 3 monsoon
matter locations
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 EIA
New 65 KLPD Molasses/Sugarcane Juice Based Distillery/ Ethanol Plant
Executive Summary

Particulate Parameters Number of location Frequency

and Post
monsoon
Noise Equivalent noise level - 5 location Monthly
dB (A) at min. Noise At all source and outside the
Levels measurement at Plant area.
high noise generating
places as well as
sensitive receptors in
the vicinity
Green belt Number of plantation In and around the plant site Monthly
(units), number of
survived plants/ trees,
number of poor plant/
trees.
Soil Texture, pH, electrical
2-3 near Solid/ hazardous waste Quarterly
conductivity, cation
storage.
exchange capacity, alkali
At least five locations from
metals, Sodium
Greenbelt and area where
Absorption Ratio (SAR),
manure of biological waste is
permeability, porosity.
applied.
Near spent wash storage lagoon
Occupational Health and fitness check- All worker Yearly/
health up of employees getting twice a year
exposed to various
hazards and all other
staff
Emergency Fire protection and Mock drill records, on site Monthly
preparedness, safety measures to take emergency plan, evacuation during
such as fire care of fire and plan operation
fighting explosion hazards, to be phase
assessed and steps taken
for their prevention.

8.0 Additional Studies

The following additional such as risk assessment for storage and handling of alcohol and
mitigation measure due to fire and explosion and handling area has been carried out.

9.0 Environmental Management Plan

Following mitigation measures shall be adopted by factory to minimize the impact of project
on the surrounding environment.

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 EIA
New 65 KLPD Molasses/Sugarcane Juice Based Distillery/ Ethanol Plant
Executive Summary

Table 6: EMP for various environmental attributes

Environmental Mitigation Measures
Attributes
Air Quality Process Emission
Management  ESPs shall be provided for PM emissions.
 The whole process will be carried out in closed condition so as to avoid
any chances of VOC emissions.
Utility Emission
 All the D.G. sets shall be standby arrangement and will only be used
during power failure.
 Adequate stack height shall be provided to Boiler and D.G. sets.
 Electrostatic Precipitator shall be provided as an air pollution control
device to the boiler with approximately 99.99 % efficiency to capture
maximum boiler fly ash.
Fugitive Emission
 The main raw material and product shall be brought in and dispatched
by road in covered enclosures.
 Dust suppression on haul roads shall be done at regular intervals.
Water &  The distillery would be based on ‘Zero Liquid Discharge’ technology.
Wastewater  Total spent wash generation will be 650-685 CMD. For existing unit spent
Management wash will be concentrated in MEE and then burn in proposed 30 TPH
spent wash fired boiler.
 The Process condensate, spent lees will be cooled and will be treated in
Condensate Polishing Unit, after treatment of which it will be recycled
back to the process again.
 The treated water will be used for gardening.
 Proper storm water drainage will be provided during rainy season to
avoid mixing of storm water with effluent.
 Rain water harvesting
Noise  Closed room shall be provided for all the utilities so as to attenuate the
Management noise pollution.
 Acoustic enclosure shall be provided to D.G sets.
 Free flow of traffic movement shall be maintained. Earmuffs shall be
used while running equipment’s of the plant.
 Proper maintenance, oiling and greasing of machines at regular intervals
shall be done to reduce generation of noise.
 Greenbelt shall be developed around the periphery of the plant to reduce
noise levels.
Odour  Odour shall be primarily controlled at source by good operational
Management practices, including physical and management control measures.
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 EIA
New 65 KLPD Molasses/Sugarcane Juice Based Distillery/ Ethanol Plant
Executive Summary

Environmental Mitigation Measures

Attributes
 Better housekeeping will maintain good hygiene condition by regular
steaming of all fermentation equipment.
 Use of efficient biocides to control bacterial contamination.
 Control of temperature during fermentation to avoid in-activation/
killing of yeast.
 Avoid staling of fermented wash.
Solid &  The hazardous waste i.e. spent oil generated shall be very minor and shall
Hazardous be burnt in boiler along with fuel.
Waste  Boiler coal ash shall be sold to brick manufacturer.
Management  spent wash ash will be used as
 ETP & yeast sludge can be used in greenbelt development
Traffic  Culverts shall be maintained.
Management  The trucks carrying raw material & fuel shall be covered to reduce any
fugitive dust generation.
 Good traffic management system shall be developed and implemented
for the incoming and outgoing vehicles so as to avoid congestion on the
public road.
Green Belt  Plantation shall been done as per Central Pollution Control Board (CPCB)
Development Norms.
/ Plantation  The plantation in and around the plant site helps/will help to attenuate
the pollution level.
 Native species shall be given priority for Avenue plantation.
Corporate  An amount of INR 1.96 Cr. (As CER OM dated 1.05.2018 Greenfield
Social project. 2% of total project cost) will be allocated for CSR activities in the
Responsibility coming 3 years which will be utilized on the basis of requirement for
weaker sections of the society for next 3 years.
Occupational  Factory shall monitor the health of its worker before placement and
Health & periodically examine during the employment
Safety  Health effects of various activities and health hazard if any observed shall
be recorded and discussed with the health experts for corrective and
preventive actions need to be taken by the industry
 All safety gear shall be provided to workers and care shall be taken by
EMC that these are used properly by them. All safety norms shall be
followed

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 EIA
New 65 KLPD Molasses/Sugarcane Juice Based Distillery/ Ethanol Plant
Executive Summary

10.0 Environment Management Cost

Table 7: Environment Management Cost
Sr. No Description Capital Cost Recurring Cost
(Rs. in lakhs) (Rs. in lakhs)
1. Air Pollution Control 150 10
2. Water Pollution Control 150 5
3. Solid waste Management _ 7
4. Environmental Monitoring and
Management 40 3
5. Rainwater Harvesting 25 4
6. Occupational Health 20 4.8
7. Green belt development 15 3.5
Total 400 37.3

11.0 Project Benefits

1. Readily available infrastructure, fuel, & water for renewable energy power generation
project.
2. Provides an initiative to sugar mill to concentrate more on conservation of energy &
reduction of operating cost, thereby improving their profitability of operation.
3. Saves the expenditure on safe storage and disposal of bagasse.
4. Benefits of quick return on biomass power capital investment and generation of
additional revenue.
5. The economic benefits available to the sugar factories from sale of exportable surplus
and improvement in the operations
6. Entire integrated project is proposed to be set up based on the stand-alone commercial
viability of each component of the project.

12. Conclusion
 Zero liquid discharged is proposed with efficient mitigation measures implemented.
 Air emissions through stack will be controlled by ESP.
 Loss of vegetation and habitat will not be attributed.
 Personal protective equipment’s, safety precautions, emergency plan & disaster
management plan shall be in place to avoid the environment hazards.

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