EXECUTIVE SUMMARY OF ENVIRONMENTAL IMPACT ASSESSMENT REPORT (Including Environmental Management Plan) ON ESTABLISHMENT OF 70 KLPD ETHANOL PLANT AT Kenganur Village, Bailhongal Taluk, Belgaum District, Karnataka Project Proponents M/S LORVIN INDUSTRIES LIMITED Kenganur Village, Bailhongal Taluk, Belgaum District, Karnataka State Consultants SEAMAK HI-TECH PRODUCTS 12 TH Main HAL 2 nd Stage
CHAPTER-1 PROJECT DESCRIPTION 1.1.0 PROJECT BACKGROUND M/s Lorvin Industries Limited (KAIPL) is an agro based Company focused on the manufacture of ethanol, power and allied products. The company proposes to establish a distillery project for the production of 70KLPD ethanol and 2.5 MW co-gen power at Kenganur village, Bailhongal taluk, Belgaum District in Karnataka state. The use and importance of alcohol is well known as an ingredient in beverages and industrial raw material for manufacture of a variety of organic chemicals including pharmaceuticals, cosmetics, potable alcohol etc., also as a potential fuel in the form of power alcohol when blended with petrol. Further the project is based on agricultural raw material and rural location. 1.2.0 LOCATION The proposed site is located at Kenganur Village, Bailhongal Taluk, Belgaum District. It is about 14 km from Bailhongal. National High Way, NH-4 (-Pune) is about 24 km from the site. The project site is rain fed uncultivated covered with minor shrubs and free from trees or other vegetation of any worth. The area experiences a dry climate. Summer temperature is high touching 42 0 C. There are no eco- sensitive locations such as bio-sphere, mangrove, protected forest, national parks, protected monuments, historical places with in 25 km from the site. However, a perennial river Malaprabha is about 3 km N from the site. 1.3.0 MANUFACTURING PROCESS Alcohol with a chemical formula of CH 3 CH 2 OH, as per international nomenclature (IUPAC) is known as Ethanol. It is commonly referred as Ethyl alcohol. In practice, ethanol is simply referred as alcohol or spirit. Alcohol is manufactured by fermentation of diluted molasses in the presence of bioculture (yeast) and nutrients (phosphate and urea). The fermented solution (wash) is clarified to separate spent yeast from the product. The wash contains about 10 % alcohol. It is purified in series
of distillation columns to produce different grades of ethanol. Alcohol is collected in storage tanks. Alcohol is dispatched through specified lorry tankers. The fermented solution after separation of alcohol is referred as spent wash. This is contaminated with organic and inorganic matter. Hence, the spent wash will be treated and utilized as fuel in the plant itself. CO-GEN POWER PLANT Co-gen power plant consists of 24 T/h boiler and 2.5 MW steam turbine. High pressure steam from the boiler will run the back pressure turbine to produce electric power. Exhaust steam (14 T/h at 2.5.0 kg/cm 2 ) from turbine will be utilized in the process. Power requirement of 1.5 MW to the project will be met from captive source and surplus of about 1.0 MW power will be exported public grid. LIQUEFIED CARBON DIOXIDE Raw carbon dioxide gas generated from fermenters is passed through moisture separator to free it from water particles. The gas is then compressed from 0.0 to 0.8 kg/cm 2 in root blower, from 0.8 to 5.0 kg/cm 2 in compressor Stage I and from 5.0 to 20.0 kg/cm 2 in compressor Stage II. At each stage the compressed gas is cooled in heat exchanger and the condensed water is removed in moisture separator. The gas is then passed through activated carbon filter and potassium permanganate solution to free it from odor. The gas is further washed in water and freed from moisture. The resultant gas is then condensed into liquid at 20 kg/cm 2 and -20 0 C. The finished liquefied carbon dioxide is stored in special storage tanks and dispatched in specified lorry tankers. 1.4.0 LAND UTILIZATION A total of 17.5 hectares land will be utilized for establishment of industry. It includes 7.0 he. Built up area and 4.5 he. open area for future use and the balance of 6.0 he. is meant for greenery development. 33 % of the total area will be covered with greenery and green belt. 1.5.0 MAN POWER REQUIREMENT Man power requirement to the industry is 125 including skilled and unskilled. Qualified and experienced personnel in the field are available in the region and shall be recruited.
1.6.0 RAW MATERIALS AND PRODUCT The products from the distillery will be 70 KLPD ethanol of industrial, potable and fuel grade. Molasses is the main raw material for manufacture of ethanol which is available as by-product from sugar industries. Requirement of molasses will be 280 T/d. Other chemicals such as urea, DAP, antifoaming agents etc. are used in small quantities. 1.7.0 WATER REQUIREMENT Requirement of fresh water to the industry will be 770 m 3 /d and this will be met from river/bore-well source. A water reservoir of about 2 months hold up capacity will be constructed at the factory premise to collect and store water for use in scarcity days. The reservoir will be filled up during rainy season. During lean period, water will not be drawn from river. 1.8.0 STEAM & POWER The distillery will be associated with the co-gen power plant consisting of 24 T/h boiler and 2.5 MW steam turbine. High pressure steam (36 kg/cm 2 pr.) from boiler will run condensing cum back pressure turbines to produce electric power. Exhaust steam, 14 T/h at 2.5 kg/cm 2 from turbine will be utilized in distillation and evaporation plants. The balance 11 T/h of steam will be condensed in the turbine. Power requirement to the project (1.5 MW) will be met from captive source and surplus of about 1.0 MW power will be exported to public grid. Diesel generators, 2 Nos. each of 500 KVA & 250 KVA will be installed for use in the eventualities of power supply failure to run the essential services.
CHAPTER-2 DESCRIPTION OF ENVIRONMENT Base line environmental data were collected primary and secondary sources for the study area of 10 km region from the site. The environmental parameters studied were weather, air, water, soil, ecology and socio-economical status. 2.1 CLIMATE The region experiences dry climate with hot summer and moderate winter. Monthly maximum temperature during summer and minimum temperature during winter reach to 37 0 C and 17.5 0 C, respectively. Relative humidity is in the range of 27% to 56% during summer and 56 % to 84% during monsoon. Average annual rain fall is 664 mm and most of the precipitation occurs during July to September. Light to moderate winds with monthly mean velocities of 1.6 km/hr to 2.8 km/hr blow through the year. Predominant directions of wind are W-E or E-W, 2.2 AIR ENVIRONMENT Ambient air quality of the study area was monitored at 6 different locations. The concentration of pollutants such as SPM 10, SO 2 and NO X were measured. Maximum concentration (µg/m 3 ) of these pollutants is SPM 10 is 69.4, SO 2 18.2 and NO X 20.6 respectively. Permissible limits of these parameters for rural area are SPM 10 100, SO2 80 and NO X 80, respectively. The quality of air in the region is good and with in the permissible limits for the rural area. 2.3 WATER ENVIRONMENT The quality of ground water samples from 5 bore wells around the site and surface water samples from Malaprabha River were monitored. The river water is suitable for drinking after conventional treatment and disinfection. The hardness and dissolved solids of some of the bore well waters is above the desirable limits and with in the permissible limits for drinking water. In the absence of alternative source this water can be used for drinking purpose.
2.4 SOIL QUALITY The quality of soil samples collected from 7 different locations in the study area was analyzed. The soil in the region is sandy loam to medium black cotton soil. The soils are slightly alkaline with moderate organic carbon and other nutrients. The soil is fertile and suitable for agriculture. 2.5 SOCIO ECONOMICAL The region is basically agrarian and crops cultivated are ground nut, maize, sun flower, cotton and sugar cane. No protected forests or thick plantations in the region. There is no endangered flora or fauna species in the region. The region is rural and economically backward. Infrastructure facilities including education, medical, road, transportation and job opportunity are limited.
CHAPTER-3 ANTICIPATED ENVIRONMENTAL IMPACTS AND MITIGATION MEASURES Waste water, gaseous emissions and solid wastes will be generated from the ethanol plant as listed below. These wastes will be effectively treated to avoid their adverse impact on environment. 3.1.0 WASTE WATER Source, treatment & disposal of waste water is given below. Sl. Source Quantity Treatment & Disposal No. m 3 /d 1. Spent wash 560 The spent wash bio-methanated to generate bio-gas and then concentrated in evaporator. The concentrated spent wash is admixed with bio-mass and then burnt as fuel in the boiler. The bio-gas will also be used as fuel in the boiler. 2. Effluent from boiler, 260 Treated to irrigation standards by neutralization, cooling tower, plant activated sludge process and then utilized in washings. development of greenery at site. 3. Domestic 06 Septic tank and soak pit As the spent wash is concentrated and completely utilized as fuel in the boiler. With measure as above the environment will not be affected by the waste water. 3.2.0 GASEOUS EMISSIONS The sources, air pollution control measures and disposal of gaseous emissions are given below. Source of gaseous emissions Flue gases from 24 T/hr boiler Air pollutants SPM, SO 2 and NO x Air Pollution Disposal Control Measures ESP Through a chimney of 50 m ht. Fermenter gases Ethanol vapor Water scrubber Through a stack of 3 m ht. 500 KVA & 250 KVA diesel generators SO 2 and NO x Muffler, Acoustic room Through a stack of and 6 m ht. 8 m ht. SPM and SO 2 are the major gaseous pollutants from the industry. Presently, the maximum concentration of SPM and SO 2 in ambient air is 110.6 µg / m 3 and 15.3 µg /m 3, respectively. After
establishment of the project the maximum values of SPM and SO 2 in ambient air under worst condition is expected to be 112.83 and 31.18 µg/m 3, respectively. This will be well within the permissible limits. In view of air pollution control measures adopted in the industry the impact of proposed project activities is not likely to cause significant impact on the existing ambient air quality in the region. ii. FUGITIVE EMISSIONS Handling boiler fuel (bio-mass) and boiler ash and the movement vehicles is the source of fugitive emission in the plant premises. The impact of fugitive emissions in the industry are controlled by following measures Green belt and greenery development around storage yards, around plants, either side of roads and around the periphery of the industry. Water spray and sprinkling is practiced at roads and near loading unloading locations. The roads will be sprayed with water through tractor tankers. The conveyors of fuel are suitably covered with hood or enclosures to control fugitive emissions. All internal roads in the premise will be paved / tarred. 3.3.0 SOLID WASTES AND ITS DISPOSAL Fermenter sludge of 4 T/d and boiler ash of 16 T/d is produced from the industry. Fermenter sludge contains plant nutrients such as nitrogen, potash, phosphate and organic carbon. This will be dried and then disposed to farmers for its use as bio-manure or cattle feed. Boiler ash contains soil nutrients such as phosphate and potash. This is also disposed to farmers for its use as soil nutrient. 3.4.0 SOCIO-ECONOMIC IMPACT Establishment of project will enhance the transportation activity. This will create apportunities to the localites to start vehical garages. With development of the industry the roads and communicatiun facilities will be enhanced. The distillery will also create job aportunities to the local mass. Presently the educational facilities in the study area are limited to primary and high school. With establishment of this industry the transportation, public mobility and job opportunity along with
associated activities in the region may increase.service infrastructure like transportation, health care, education, communication facilities are expected to be improved. CHAPTER-4 ENVIRONMENTAL MONITORING PROGRAMME An Environmental Cell will be established in the industry to implement and monitor environmental policy and programme. 4.1.0 Environmental Cell Environmental cell consisting Managing director and departmental heads will be created to effectively manage the environmental activities in the distillery. 4.2.0 Environmental Department Environmental department will be formed with environmental scientist, laboratory chemists and operators to implement and operate pollution control and environmental protection measures. 4.3.0 Environmental Monitoring Plan Self monitoring system consisting of well equipped laboratory and manpower will be established in the industry with man power and facilities to analyze waste water, soil, stack emission, ambient air etc. to ascertain the compliances of environmental norms and standards.. 4.4.0 Environmental Records Environmental department will maintain log sheets and records for operation and maintenance of pollution control and related facilities. 4.5.0 Budget for Environmental Management The estimated investment on monitoring facility will be Rs. 15.00 Lakhs and the recurring cost of monitoring will be Rs. 18 Lakhs.
CHAPTER-5 ADDITIONAL STUDIES 5.1 PUBLIC CONSULTATION The Public hearing and Public consultation as per the guidelines will be conducted in co-operation with KSPCB. 5.2 RISK ASSESSMENT An industry with its complex nature of activities involving man, material and machineries of various nature and has a number of associated hazards. Risk assessment studies are being conducted to ensure safety and reliability of plant through a systematic and scientific methods to identify possible failures and prevent their occurrences before they actually cause disasters and production loss. Ethanol is a clear, colorless and flammable liquid. It has the boiling point of 78 0 C, ignition point of 363 0 C and explosive limits of 3.3 % - 19.0 % by volume. Storage and handling of bio-gas is another source of fire and explosion. Ethanol and bio-gas are listed as hazardous substance. Based on the preliminary hazard identification, the storage and handling facilities of ethanol and bio-gas have been recognized as distinctive and relatively evidential risk source. Such situation can cause fire or explosions depending upon the situation. 5.3 SAFETY MANAGEMENT AND PERSONNEL HEALTH CARE PROGRAMME Environmental cum Safety officer will be appointed in the industry to manage safety and occupational health care programme. i. Safety training will be given to the employees. ii. Safety appliances, first aid medical kits and Personnel protective will be maintained. iii. Health and safety related displays will be provided in the work place and premise. iv. Fire fighting facility including Fire hydrants, fire extinguishers and fire protective appliances will be provided. v. Medical Check ups and health records of employees will be maintained.
5.4 EMERGENCY MANAGEMENT PLAN Even though all safety measures are adopted, the hazards leading to emergency situations are likely occur in the industries under unforeseen circumstances. The project proponents are therefore prepared an Emergency Management Plan (EMP) for the proposed industry with the main objective to keep the organization in a state of readiness to contain the emergency and its cascading effect and to bring the incident under control with priority to saving of life, preventing injury and loss of property and also to bring back the plant to normality and working condition. EMP is the systematic information along with a set of instructions and preparatory details to meet such eventualities with a view to contain it to be minimal in terms of damage or loss to health, life, property with in the industry or outside the industry. In the distillery, the eventualities are likely to cause emergency situation confined to the industry itself, and therefore, on-site emergency management plan is prepared for the proposed industry. In the distillery, the eventualities are likely to cause emergency situation confined to the industry itself, and therefore, on-site emergency management plan is prepared for the proposed industry.
CHAPTER-6 PROJECT BENEFITS 1. The use and importance of alcohol is well known as an as an ingredient in beverages and industrial raw material for manufacture of a variety of organic chemicals including pharmaceuticals, cosmetics, potable alcohol etc. also as a potential fuel in the form of power alcohol when blended with petrol. Further the project is based on agricultural raw material and rural location. 2. Alcohol is produced from molasses which is a renewable source and a by-product of the sugar industry. Alcohol is an eco-friendly product. 3. With enhancement in sugar cane cultivation in the country, the production of molasses from the sugar industry has greatly increased. The sugar industries are facing the problem for storage and disposal of molasses. It is necessary to create additional capacity for utilization of molasses. This will enable sugar factories to give better prices to the farmers supplying sugar cane. 4. The plant nutrients present in spent wash are recovered in compost or boiler ash. These products are rich in micro and other nutrients and therefore useful to the formers to enhance the nutrient values of the soil. 5. The industry is established in the rural region of the state. The presence of the industry helps to develop road, transportation, communication and related facility in the region. The industry will provide direct and indirect employment to more than 500 local rural persons. 6. Greenery development in the premise will give a green look to the region and it encourages the locals to develop greenery in their premises. 7. The distillery is agro based and has a national priority to overcome the shortage of energy and to save foreign exchange.
CHAPTER-7 ENVIRONMENTAL MANAGEMENTAL PLAN A comprehensive environmental management plan is adopted consisting of environmental protection measures as indicated below. i. Establishment of pollution control facilities to manage gaseous emissions, waste water and solid wastes. ii. Operation and Maintenance of pollution control facilities. iii. Green belt and greenery development in and around the factory site iv. Storm water management & Rain water harvesting v. Paving and lining of roads, fuel and solid storage yards. vi. The solid storage yard and spent wash storage tanks will be suitably lined to prevent percolation. vii. Personal health care programme, emergency management plan and safety management systems will be implemented in the distillery. viii. Establishment of Environmental Cell, Environmental department and self monitoring systems in the industry.