PRE-FEASIBILTY REPORT FOR THE

PRE-FEASIBILTY REPORT FOR THE

EXPANSION OF EXISTING CO-GEN SUGAR INDUSTRY

(3500 TCD to 5000 TCD SUGAR PLANT &

24 MW TO 54 MW CO-GEN POWER PLANT)

At

At Survey nos 38/2,40/(1 to 6),

50/2, 51/(1 to 5), 44, 52/1 & 2, 71/P,

Kukkuwada Village,

Davangere Taluk & District, Karnataka state.

Submitted to

Ministry of Environment, Forests and Climate Change,

Indira Paryavarna Bhavan,

Jor Bagh, Jor Bagh Road,

New Delhi – 110 003.

Submitted by

M/s Davangere Sugar Company Ltd.,

Kukkuwada Village,

Davangere Taluk & District, Karnataka State.

- ii -

Contents Sl. No. Description Pg. No

CHAPTER 1

EXECUTIVE SUMMARY

1-20

1.1 Introduction 1

1.1.1 Preamble 1

1.1.2 Project at a glance 2

1.1.3 Water requirement and wastewater treatment and

discharge details

3

1.1.4 Air pollution details 10

1.1.5 Noise pollution details 16

1.1.6 Solid waste details 16

1.2 Environmental Impacts And Management Plan 19

1.2.1 Environmental management plan during operation phase 19

CHAPTER 2

INTRODUCTION OF THE PROJECT/

BACKGROUND INFORMATION

21-25

2.1 Introduction Of Project Proponent 21

2.2 Brief Description About The Nature Of The Project 21

2.3 Need For The Project And Its Importance To The Country

And/Region

22

2.3.1 Need & Importance To The Region 23

2.3.2 Employment Generation Due To The Project 24

2.4 Demand Supply Gap, Imports Vs Indigenous Production 24

2.5 Export Possibility 24

2.6 Employment Generation Due To The Project 25

- iii -

CHAPTER 3

PROJECT DESCRIPTION

26-72

3.1 Type Of Project 26

3.2 Location Of The Proposed Industry 26

3.3 Basis Of Selecting The Proposed Site 27

3.3.1 Proposed Environmental Safeguards 28

3.4 Size/Magnitude Of Operation 29

3.5 Manufacturing Process Description 30

3.5.1 Products Manufactured 30

3.5.1.1 Manufacture Of Sugar 30

3.5.1.2 Co-Generation Of Power 35

3.6 Raw Materials 38

3.6.1 Quantity Requirement 38

3.6.2 Power And Steam Requirement 39

3.6.3 Source Of Supply Of Raw Materials 40

3.7 Resource Optimization/Recycling And Re-Use Envisaged

In The Project

40

3.7.1 Domestic Solid Waste Re-Use 40

3.8 Water, Energy/Power Requirement & Source 41

3.8.1 Water 41

3.8.2 Power 41

3.9 Wastes Generated & Scheme For Their

Management/Disposal

42

3.10 Source Of Pollution And Built-In Mitigation Measures 50

3.10.1 Wastewater Management In Co-Gen Sugar Unit 50

3.11 Air Pollution Sources 62

3.12 Noise Generation And Its Management 68

3.13 Solid Waste Generation And Management 69

3.14 Schematic Representations Of The Feasibility Drawing 71

- iv -

CHAPTER 4

SITE ANALYSIS

73-90

4.1 Connectivity 73

4.2 Land Form, Land Use & Ownership 74

4.3 Topography 74

4.4 Existing Land Use Pattern 76

4.5 Existing Infrastructure 79

4.6 Soil Classification 79

4.7 Meteorological Data 80

4.7.1 Temperature 84

4.7.2 Relative Humidity 84

4.7.3 Rainfall 84

4.7.4 Atmospheric Pressure 84

4.7.5 Inversion Height 85

4.7.6 Cloud Cover 85

4.7.7 Wind 85

4.8 Social Infrastructure Available 90

CHAPTER 5

PLANNING BRIEF

91-92

5.1 Planning Concept 91

5.2 Population Projection 91

5.3 Land-Use Planning 91

5.4 Assessment Of Infrastructure Demand 92

5.4.1 Roadways 92

5.4.2 Water Supply & Sewerage Infrastructure 92

CHAPTER 6

PROPOSED INFRASTRUCTURE

93-96

6.1 Industrial Area (Processing Area) 93

6.2 Green-Belt

93

- v -

6.3 Social Infrastructure 93

6.4 Connectivity 93

6.5 Drinking Water Management 93

6.6 Sewerage System 93

6.7 Industrial Waste Management 94

6.8 Solid Waste Management 94

6.9 Power Requirement & Supply Source 96

CHAPTER 7

REHABILITATION & RESETTLEMENT

PLAN

97

CHAPTER 8

PROJECT SCHEDULE & COST ESTIMATES

98

8.1 Time Schedule 98

8.2 Estimated Project Cost 98

CHAPTER 9

ANALYSIS OF PROPOSAL

99

- vi -

LIST OF TABLES

Table no. Description Pg. No

1.0 Salient Features of the project 2

1.1 Water consumption 3

1.2 Water balance (after expansion) for co-gen sugar unit, m3/d 4

1.3 Characteristics of Wastewater 9

1.4 Characteristics of fuel used 11

1.5 Sources of flue gases and APC 11

1.6 Solid wastes from 5000TCD of Co-gen sugar unit 18

3.0 Cost of the project 34

3.1 Operation Parameters of Co-gen sugar industry 37

3.2 Operating parameters for Power plant 38

3.3 Raw materials and Products for Co-gen sugar plant 42

3.4 Source and quantity of water, m3/d 43

3.5 Utilization of condensate water, m3/d 44

3.6 Quality of water from river Shyagale Halla 44

3.7 Fresh water requirement for the co-gen sugar unit, m3/d 47

3.8 Water balance (after expansion) for co-gen sugar unit, m3/d 49

3.9 Characteristics of Wastewater 54

3.10 Characteristics of fuel used 62

3.11 Sources of flue gases and APC 63


4.1 Connectivity from the project site 74

4.2 Existing land-use pattern 76

4.3 Physico-chemical characteristics of soil 79

4.4 Micro-meteorological data for Davangere district for the

period from January 1st 2013 to December 31st 2013

81

4.5 Meteorological data of Davangere for the year 2013 83

4.6 List of health-care facilities in the surroundings 90

5.1 Land Utilization pattern 91


- vii -

List of Figures

Fig. no. Description Pg. No

3.1 Maps showing project boundary & project site location 26

3.2 Flow chart for manufacture of sugar 32

3.3 Process flow chart with material balance for Co-gen sugar

unit

33

3.4 Schematic representation of Co-generation of power 36

3.5 Schematic flow diagram of water treatment plant 46

3.6 process flow chart with water balance for co-gen sugar unit 48

3.7 Flow diagram of effluent treatment plant – sugar unit 61

3.8 Feasibility & environmental assessment process 72

4.1 Google map showing connectivity 73

4.2 Topo map 75

4.3 Google map showing existing land-use pattern 77

4.4 Google map showing surrounding water bodies 78

4.5 Wind rose diagram obtained from primary data for the

project site during sampling period (October to December

2013)

82

4.6 Wind Rose diagrams 86

List of Annexure

Annexure Description

100 - 101 A Water Withdrawal Agreement

B Project site layout

M/s. Davangere Sugars Company Ltd.,

- 1 - Pre-Feasibility Report

CHAPTER 1

EXECUTIVE SUMMARY

1.1 INTRODUCTION

1.1.1 PREAMBLE

Amendment of the EIA Notification dated 14-09-2006 of Ministry of Environment

and Forests (MoEF), Government of India has made mandatory under Schedule-I of

EIA notification for 30 different activities to obtain NOC (No Objection Certificate)

from the State Pollution Control Board and Environmental Clearance from the

Ministry of Environment & Forests, Govt. of India. This amendment to the EIA

Notification is effective from 14.09.2006. It is in this context that all such activities

need to prepare Rapid Environmental Impact Assessment (REIA) report and also

appear before Public Hearing to ascertain the response of Public for the project

based on the general and specific conditions of amended in said notification.

M/s. Davangere Sugars Company Limited has proposed to expand its existing

Co-gen sugar industry from 3500 TCD to 5000 TCD cane crushing capacity and also

from 24.0 MW to 54.0 MW Co-gen thermal power plant at Kukkawada Village,

Davangere Taluk & District in Karnataka State.

The proposed project will be established in the open area already available in the

existing industry and therefore procurement of additional land is not required. The

location is rain fed agricultural land converted for industrial use.

The industry is listed under EIA Notification dated 14-09-2006 of Ministry of

Environment and Forests (MoEF), Government of India. As per this notification the

industry is categorized under Schedule 1(d) Category-A for expansion of the co-gen

power plant from 24 MW to 54 MW.

In order to asses potential environmental impacts arising due to the proposed

industry, Environmental Impact Assessment (EIA) study covering a radius of 10 km



around the proposed project site incorporating baseline data for various

environmental components, viz. air, water, noise, land and biological environments

along with the parameters of human interest and to prepare Environmental

Management Plan (EMP) for mitigating adverse impacts along with delineation of

post project environmental monitoring program.

1.1.2 PROJECT AT A GLANCE

Table: - 1.0 Salient Features of the project

1

Name & Address of the

Company

M/s Davanagere Sugar Company Ltd.,

Kukkuwada village, Davangere Taluk &

district.(Karnataka state)

2 Chairman Dr. Shamanur Shivashankarappa

MLA & Ex. MP, Davangere

3 Project location Survey Nos. 38/2, 40/(1 to 6), 50/2,

51/(1 to 5), 44, 52/1 & 2, 71/P, Kukkuwada

village, Davangere Taluk & district,

Karnataka state.

4 Constitution Public Limited Company

(Year of in-corporation 1972)

5 Type of the project Expansion of Co-gen sugar capacity from

3500 TCD to 5000 TCD and from 24 MW

to 54MW

6 Products manufactured White sugar and Electric power

Existing Proposed

7 Sugar plant production capacity, TCD 3500 5000

Co-gen power plant capacity,MW 24 54

8 Power export 24 54

9 Capacity of boiler,TPH 90 150

10 Fresh water requirement,KLD 3000 3117

11 Total land 61.94 Hectare No additional land

12 Investment for the project,Lakhs Power & sugar

15729

Power:14625

Sugar:4160

13 Investment for pollution control

Facilities, lakh

600 400

14 Total man power 402 60

15 No. of working days Sugar plant :240

Power plant:330



1.1.3 WATER REQUIREMENT AND WASTEWATER TREATMENT AND DISCHARGE

DETAILS

i) QUANTITY OF WATER REQUIRED AND WASTEWATER GENERATED

The total quantity of water requirement for the industry is about 3117 KLD. The

break-up of the consumption of water is as presented in table 1.1 below.

Table: - 1.1 Water consumption

Sl.

No. Application

Quantity , m3/d

Present expansion After

expansion

1 Domestic 60 06 66

2 Gardening 50 -06 44

3 Washings (Plant, Lab., & WTP) 50 20 70

4 Boiler feed water make up 125 216 341

5 Process 60 36 96

6 Gland cooling/sealing water 120 24 144

7 T.G cooling water make up 740 1466 2206

8 Mill bearing C.W. 120 30 150

Total 1325 1792 3117

LPD = L/day; KLD = kilo liter/day.



Table 1.2: Water balance (after expansion) for co-gen sugar unit, m3/d

Utilization Water input Water output

Fresh Cane

water

Recycle Effluent Recycle Evap.

Loss

Others

Domestic 66 - 56 10 -

Gardening 44 - - 44 -

Washings

(Plant, Lab. &

WTP)

70 - 70 -

Boiler

feed/Steam/

Boiler blow

down

341 - - 185 156 -

Juice process 96 84 - 180 -

Pump gland

sealing/cooling 144 - - 144 -

Turbine

Cooling Water 2206 - 200 2006 -

Sugar Cooling

Water - 1405 559 200 1764 -

Mill bearing

C.W. 150 - 30 120 -

Excess

Condensate - 548 - - 548

Water with

bagasse - 710 - - 710

Water with

press mud &

Molasses

- 200 - - 200

Total 3117 2947 559 326 559 4280 1458



ii) WASTEWATER TREAMENT AND DISPOSAL DETAILS

1. SOURCE OF WASTEWATER

The waste water generated in sugar factory is relatively less toxic and less

hazardous. Further, the sugar processing does not involve any inherent waste water

streams and therefore the waste water generated can be substantially reduced. The

waste water generated is mainly due to washing of floors and equipments in

addition to a small quantity of waste water are due to purge from boiler and cooling

water sumps and also due to domestic source. Further, the large quantity of vapor

condensate is generated as excess water from the factory. It is fairly good quality

and is also discharged as waste water. The details of source and quantity of waste

water from sugar factory are discussed below.

i. SPILLAGE, LEAKAGE AND FLOOR WASHINGS:

In a sugar factory waste water of high contamination is generated mainly due to

leakages and spillages of juice, syrup and molasses in different sections of the

manufacturing plant. Leakages occur at pipe joints and pump glands. Spillage and

splashes occur at different equipments and machinery. The periodical washing of

floor also contributes significant pollution load in the waste water. Waste water is

also produced due to the cleaning of equipments such as evaporators, pans, juice

heaters etc. Though these wastes are small in quantity but contain high BOD and

low pH. Good housekeeping, effective maintenance and efficient plant operation

can considerably reduce the generation of this waste water. Spillage and washings

can be collected in small sumps constructed at such locations and these interns can

be recycled to the process. If planned well the generation of such waste water can

be totally avoided. However, at present the waste water does generate. The effluents

from mill plant contain fibers, grease and oil. The effluent from lime preparation and

clarifier house is alkaline in nature and contains high suspended solids. Quantity of

effluent due to spillage, leakage, floor and equipments is around 70m3/d.

ii. BOILER BLOWDOWN

Boiler feed water contains a small concentration of dissolved solids. Additional

chemicals are also added to the water to prevent scale, corrosion and carry over in

the boiler, as the evaporation continues, concentration of dissolved solids in boiler

increases. Therefore solids continue to build up in the boiler. Boiler blow down is

therefore given from the boiler to control the concentration of dissolved solids in it.

The quality of blow down is relatively better and therefore advantageously added to

circulating cooling water. The boiler blow down allowed in the boiler is about

156 m3/d.



iii. Domestic wastewater

Domestic wastewater is generated from factory and from residential quarters. A total

of 450 persons are working in the industry. A total of 400 persons are expected to

be residing in quarter. Fresh water is utilized for domestic needs in the factory at a

rate of 130L/d per head. Fresh water consumed and wastewater generated due to

domestic usage of water in m3/d is given below:

Domestic water usage in the factory : 13.5

(at 30L/d per head for 450 persons), m3/d

Domestic water usage in quarters : 52

(at 130 L/d per head for 400 persons), m3/d

Total domestic water usage : 65.5 or say 66 m3/d

Domestic wastewater from factory : 12.15

(at 90 % of the water utilized), m3/d

Domestic wastewater from residential quarters : 46.8


Total domestic wastewater : 58.95 or say 60 m3/d

v. Purge from barometric condenser

The vapours from last effect evaporator and pan boiling are passed through steam

ejector and then sent to barometric condenser, wherein circulating cooling water at

the rate of about 3000 m3/day is used to scrub, condense and cool the vapours. The

total quantity of vapour condensate added into the circulation water is 1214m3/d.

1324 m3/d of the circulation water is lost as vapour and drift losses in cooling tower.

In case of overloading of pan and evaporators the vapours may become

contaminated due to entrainment. This circulation water is relatively more

contaminated as compared to that of boiler blow down and turbine cooling water

purge. The quality of circulation water is improved by its dilution with 66m3/d

boiler blow down and 200 m3/d turbine cooling water purge. Excess water of about

156 m3/d from cooling tower channel is drained out as purge.

Circulation cooling water : 3000

Vapour condensate added : 1214

Boiler blow down added : 66

Turbine cooling water purge added : 200

Drift & evaporation loss : 1324

Purge water drained out : 156



vi. HOT CONDENSATES

Large quantities of steam condensates are obtained as hot water from the evaporators and

pan jacket bodies. The condensate is of good quality and therefore it is used in the process

for boiler feed, mill imbibition, lime preparation, juice dilution etc. Excess condensate is let

out as effluent. Though the condensate has high temperature it is cooled during the passage

in the gutter and mixing with other effluent.

vii. Purge from mill tower cooling water

Large quantity of water is circulated for cooling of mill and turbine bearings. It is necessary

to purge some of the cooling water to maintain its quality. Evaporation and drift loss in this

case is small. Fresh water of about 150 m3/day is used as make up water to compensate the

purge and also the vapour and drift losses.

viii. Purge from turbine cooling water

Large quantity of water is circulated through turbine surface condenser for

condensation of exhaust steam. Cooling water purge of this system is of relatively

good quality, it is sent to sugar plant cooling water system. Fresh water is used as

make up water to compensate the purge and also the vapour and drift losses.

Evaporation and drift losses, m3/d : 2006

Make up cooling water, m3/d : 2206

Purge water from cooling tower, m3/d : 200

ix. Cooling water from glands

Cooling water is circulated through pump glands, centrifuge glands and sulphur

burners etc. This water can also be totally re-circulated. However, in practice this

water is drained out due to its likely contamination with juice.

x. Cleaning day washings

Evaporators, juice heaters, pans etc are cleaned once in 50-60 days time for removal

of scale. Chemicals such as caustic soda, sodium carbonate and hydrochloric acid

are used for scale removal. Spent wash and washings generated during cleaning

operations is about 70m3/d. It is highly alkaline and contains heavy BOD load. If

added directly to effluent treatment plant the waste water gives a shock load, and

disturbs its process. Cleaning day waste water is therefore collected and stored

separately in a cleaning day effluent storage tank. 70m3/d of this waste water is

drawn from the storage tank and then mixed with other factory effluent in the

neutralizer cum hold up tank.



2. ISOLATION AND SEGREGATION OF WASTEWATER

The effluent from sugar industry is relatively non-toxic and less-hazardous in nature.

Effluent from domestic source is received in septic tanks. It has low dissolved solids

and moderate BOD. The wastewaters generated at various sources in the sugar

factory are segregated into three streams based on their pollution load for the

convenience off their subsequent treatment and disposal. The details of waste water

generated (after expansion) Co-gen sugar industry is summarized below:

Sl.

No.

Source Quantity

m3/day

1 Stream A : Process effluent, (High BOD effluent) 270

2 Stream B : Excess condensate water 548

3 Stream C : Domestic effluent 56

3. CHARACTERISTICS OF WASTEWATER

The wastewater from sugar industry is relatively non-toxic and non-hazardous in

nature. In-plant measures are adopted in the factory as enumerated elsewhere to

reduce the quantity and contamination of wastewater. Oil taps are provided in the

mill house to minimise the contamination of oil & grease in the wastewater. Small

sumps are provided at suitable location in the factory to receive the leakages, juice

and syrup, which may be present at pumps and near some process equipment. The

leakage of juice and syrup thus collected is recycled to process. Floor cleaning is

done by dry baggage to minimise the quantity of wastewater. Further hot

condensates obtained from evaporators are recycled to the process to meet the

requirement of imbibition etc. in the process, and also to meet the makeup water

requirement for cooling tower.

Waste from domestic source is received in septic tanks. It has low dissolved solids

and moderate BOD. The overflow from septic tank is sent to effluent treatment

plant. The wastewater generated at various sources in the sugar factory are

segregated into three streams based on their pollution load and the convenience of

their subsequent treatment and disposal. The characteristics of wastewater of

different streams are given in Table 1.3



Table 1.3: Characteristics of Wastewater

Sl.

No.

Parameters Stream

A

Stream B Stream

C

Total(A+B+C)

1 Flow rate (m3/day) 270 56 548 874

2 Temperature (0C) 38 32 42 39

3 pH 5.5 7.2 6.6-7.0 6.0

4 Dissolved solids(ppm) 1800 840 360 835

5 Suspended solids(ppm) 320 180 60 148

6 BOD(ppm) 1800 240 260 772

7 COD(ppm) 2800 360 416 1148

The existing co-gen sugar industry is already having a full pledged effluent treatment

plant. This was originally designed for the effluent capacity of 1310 m3/d. The plant

is working satisfactorily. The quantity of effluent generated in the industry has

subsequently reduced by incorporating various measures to control the quality and

quantity of effluent. After proposed expansion, the quantity of combined effluent

from the industry will be 874m3/d. Hence, the capacity of the existing ETP is

adequate to treat the effluent generated from the expanded plant. The operational

parameters of the effluent treatment plant will be reviewed to suit the influent

characteristics. The effluent treatment plant is designed for about 30% higher

quantity of effluent to take care of shock loads & any eventualities

i. Influent qualities of combined wastewater

Sugar factory crushing capacity : 5000 TCD

Effluent flow rate, hourly maximum : 60 m3/h

Daily maximum : 1100 m3/d

Temperature : 32-40 OC

pH : 5.5

T.D.S : 1650 ppm

S.S : 300 ppm

B.O.D : 1500 ppm

C.O.D : 2600 ppm

Oil : 20 ppm



ii. Quality of treated wastewater

The treated effluent shall be discharged to agricultural land for irrigation. Prescribed

standards to be achieved for treated effluent is given below.

pH : 7.0 - 7.8

T.D.S : less than 2000 ppm

S.S : less than 100 ppm

B.O.D : less than 100 ppm

C.O.D : less than 250 ppm

Oil : less than 5 ppm

1.1.4 AIR POLLUTION DETAILS

Gaseous emissions in the industry will be mainly flue gases from boilers and diesel

generators. Diesel generators will be used to meet only during emergency

requirement of power. Other emissions include fugitive emissions due to bagasse,

ash and movement of vehicles.

1. Flue gases from boilers and diesel generators

2. Fugitive emissions due to bagasse, ash and movement of vehicles.

1. FLUE GASES FROM BOILERS AND DIESEL GENERATORS

The sources of flue gases for existing and proposed project are:

i. Existing: Boiler of 90TPH, D.G sets of capacity 500KVA and 160KVA

ii. Proposed: Boiler of 150TPH

During crushing season Bagasse is used as fuel and during off season coal is used.

The Characteristics of the fuel are given in the table 1.4



Table 1.4: Characteristics of fuel used

Sl.No. Parameters Fuel type

Bagasse Agro waste Coal Diesel

1 Heat value, GCV,

kcal/kg

2272 3600 6000 10700

2 S content, kg/T 0.1 0.1 1.2 1

3 Ash, kg/T 10 10 100 -

4 Steam / fuel ratio, kg/kg 2.4 3.6 6.0 -

The information on stack, sources of emissions and APC facilities adopted are given

in Table 1.5

Table 1.5: Sources of flue gases and APC

Stack

No.

Source

of

emission

Type of

Fuel

Sulphur,

%

Fuel consumption Chimney

Ht, m

APC

Measures

Season Off-

season

EXISTING

1 90 TPH

Boiler

Bagasse/

Bio mass

Coal

0.04

0.6

(T/hr)

40

-

(T/hr)

-

15

80 m

AGL

ESP

2 D.G. Set

500KVA

Diesel - 118 L/hr 118 L/hr 7 m ARL Acoustic

enclosure

3

D.G. Set

160KVA

Diesel

-

37.6 L/hr

37.6 L/hr

5 m ARL

Acoustic

enclosure

PROPOSED

1 150 TPH

Boiler

Bagasse/

Bio mass

Coal

0.04

0.6

65.21

-

25

-

80m

AGL

ESP



Stack height calculation

Existing

90 TPH boiler

During season:

Fuel used – Bagasse/agro-biomass = 39.13 or say 40 TPH

Relation for stack height

H = 74 (Q)0.27

Where, H = Height of Stack in m &

Q = Ash produced in TPH

As per KSPCB norms, for agro based fuels ash produced per ton of fuel burnt = 6kg

However assuming ash produced per ton of fuel burnt = 10 kg

Ash produced = 40 TPH x 10 = 400 kg/hr

Therefore Q = 0.4 TPH

Hence, H = 74 (0.4)0.27 = 57.72 m

Or say 58m AGL

During off-season:

Fuel used – Coal: 15 TPH


H = 14(Q) 0.3

Where, H = Height of stack in m

Q = SO2 emissions in kg/h

Sulfur content in coal = 0.6 %

1Kg of sulphur=2Kg of sulphur-di-oxide

Q= [15000 X 2 X (0.6/100)] = 180 kg/hr

Q=180kg/hr



Hence, H = 14 (180) 0.3

= 66.48 m or 67 m AGL

PROPOSED HEIGHT OF STACK

Height of stack to be provided: 80 m AGL

500 KVA D.G set

Fuel used – Diesel = 117.5 LPH = 66.76kg/hr


H = 14(Q) 0.3



Sulfur content in coal = 1.2%

Specific gravity of sulfur = 2.046

Therefore, Q = 66.76x 1.2/100 x 2.046 = 0.3915 kg/hr

Hence, H = 14 (0.3915)0.3

= 10.57 or say 10.6 m

PROPOSED HEIGHT OF STACK TO BE PROVIDED: 7 m AGL

160 KVA D.G set

Fuel used – Diesel = 37.6 LPH=21.36 kg/hr


H = 14(Q) 0.3






Hence, H = 14 (0.1252)0.3

= 7.5 m or say 8 m



Proposed

150 TPH boiler

During season:

Fuel used – Bagasse/agro-biomass = 65.2 TPH


H = 74 (Q)0.27

Where, H = Height of Stack in m & Q = Ash produced in TPH



Ash produced = 65.2 TPH x 10 = 0.652 kg/hr

Therefore, Q = 0.652 kg/hr

Hence, H = 74 (0.652)0.27 = 74 X 0.89= 65.92m

Or say 66 m AGL

During off-season:

Fuel used – Coal: 25TPH


H = 14(Q) 0.3




Therefore, Q = 25 x (2x0.6/100) = 0.3 TPH =300 Kg/hr

Hence, H = 14 (300)0.3

= 77.56 m

Or say 78 m AGL




Technical specifications of air pollution control equipments

ELECTROSTATIC PRECIPITATOR

MAKE: M/s. BHARAT HEAVY ELECTRICALS LTD.

SUPPLIER: M/s. FIVES CAIL KCP LTD.

Design details

Sl.No Description Details

1 No of Field 3 Field

2 Gas flow rate 52 m3 / s

3 Dust load at exit 50 mg/ nm3

4 Inlet dust concentration 6 mgs / nm3

5 Flue gas moisture percentage 23% & 28%

6 Un-burnt carbon in fly ash 35%

7 Gas velocity through ESP less than 1M/s

Material details

Sl.No Description Qty

1 Collecting Electrode 315 No's

2 Emitting Electrode 600 No's

3 Outlet GD screen plate 13 No's

4 Inlet GD screen plate 32 No's

5 Collecting Rapping Sys 3 No's

6 Collecting Rapping Hammer 63 No's

7 Emitting Rapping Sys 3 No's

8 Emitting Rapping Hammer 72 No's

9 GD Rapping Sys 1 No

10 GD Rapping hammer 16 No's

11 Shaft Insulator 3 No's

12 Support Insulator 12 No's

13 Inspection Door (723x523) 5 No's

14 Hopper Door(460x410) 3 No's

15 Collecting & GD Rapping Motor 0.33 HP, 1.1 RPM 4 No's

16 Emitting Rapping Motor 0.33 HP, 2.5RPM 3 No's

17 Knife edge gate valve 3 No's

18 Expansion Joint Size: 2310x2810 2 No's

19 Heating Elements S.S 51 No's

20 Thermostat for hopper 4 No's



2. PROCESS EMISSIONS

Carbon dioxide generated in the fermenters carries traces of alcohol vapors. The

vapors are scrubbed with water and then vented to atmosphere through a stack of

3 m height above roof level. The scrubbed solution is returned to the fermenter.

1.1.5 NOISE POLLUTION DETAILS

Noise is described as an unwanted sound. Exposure to noise affects the human

beings in many ways depending upon the intensity of noise, its frequency and

exposure duration. Exposure to excessive noise produces varying degree of damage

to human hearing system, which is initially reversible.

WHO has recommended 75 dB as exposure limit to industrial noise. The BIS

recommended the acceptable noise level in an industrial area between 45 and

60 dB. The threshold limit value (TLV) under occupational safety and health is 85

dB for 8 hours, 90 dB for 4 hours, 95 dB for 2 hours and 100 dB for 1 hour and 110

dB for 15 minutes per day. Sound beyond 80 dB harms hearing system and it can be

regarded as pollution. The largest noise a man hears without discomfort is thus 80

dB.

1.1.6 SOLID WASTE DETAILS

The solid wastes or by-products produced in sugar industry such as bagasse, press

mud and molasses are made use as valuable resources as discussed below. Other

solid wastes in the industry are boiler ash, lime sludge and ETP sludge. Spent

lubricating and cooling oils produced in the industry are specified as hazardous

wastes and these are disposed as per the prescribed guidelines.

Bagasse

Bagasse is the fibre material left out after extraction of the treated sugarcane juice.

The average bagasse content in sugarcane is 30%. Major quantity of the bagasse

produced will be utilized in the plant itself as a boiler fuel. A small quantity of

bagasse will also be used as filter aid in the plant. The saved bagasse will be stored

on the storage yard for use in off season.



Molasses

Molasses is produced in the industry at average of 4% on sugarcane crushed. It

contains large percentage of non crystallisable sugar and is a valuable source of raw

material for manufacture of ethyl alcohol or other products such as oxalic acid,

lactic acid etc. Molasses is also used as nutritive additive in manufacture of cattle

feed.

Press mud

Press mud is produced in the industry at an average of 4% on cane crushed in the

sugar plant. It contains fibrous material and crop nutrients such as phosphorous and

potassium and therefore it is disposed to farmers for use in agricultural land. The

press mud will be composted along with spent wash generated from the distillery.

The composted press mud is a bio-manure containing, fortified plant nutrient such

as potassium, phosphorous and nitrogen.

Boiler ash

Boiler ash is un-burnt matter left out in the furnace after complete burning of fuel in

the boiler. Ash produced from bagasse/agro waste will be 1.0%. The ash contains

plant nutrients. It is a non-toxic material. It can be used as soil conditioner in

agriculture land or in brick making. It can also be composted along with press mud

to produce bio-manure.

ETP & lime sludge

Small quantity of sludge is produced from primary and secondary clarifiers in the

industry. Major quantity of the sludge from secondary clarifiers is re-circulated to

the aeration tank. Excess of sludge from clarifiers is dewatered and partially dried in

sludge drying beds. The sludge with an average moisture content of 50% produced

from ETP will be 100 kg/d.

Hydrated lime is used in the plant for purification of juice and therefore, the

quantity of lime sludge produced from the plant is small. The sludge with an

average moisture content of 50% will be produced from lime plant. A maximum of

about 0.1 T /d of sludge will be produced from lime plant. The quantities of various

solid wastes produced from the proposed sugar industry of 5000 TCD are

summarized in table 1.5



Table 1.6: Solid wastes from 5000TCD of Co-gen sugar unit

Solid waste % on

cane

Existing Expansion

Quantity, T/d Quantity, T/d

Bagasse

(50% moisture) 30 1050 1500

Molasses 4 100 180

Press Mud 4 140 180

Boiler Ash

Season

Off season

-

-

13.05

10.50

-

13.5

19.2

ETP Sludge - 0.15 0.2

Lime Sludge - 1.5 2.1



1.2. ENVIRONMENTAL IMPACTS AND MANAGEMENT PLAN

Sl.

no.

Environmental

components

Predicted

impacts

Probable source of

impact

Mitigation measures Remarks

1 Ambient air

quality

Minor negative

impact.

1. Flue gases

from boilers and diesel

generators

2. Fugitive

emissions due to

bagasse, ash and

movement of vehicles

Gaseous emissions in the industry will be

mainly flue gases from boilers and diesel

generators. Diesel generators will be used

only during emergency requirement of

power. Other emissions include fugitive

emissions due to bagasse, ash and movement

of vehicles.

Electrostatic Precipitators are proposed

to neutralize and control dust and

fumes from the process section.

The emissions from DG & boiler will

be let out through stacks of heights 7 m

ARL and 80 m AGL respectively.

DG sets shall be

used only during

power failure.

2 Noise Minor negative

impact near

noise

generation

sources inside

the premises.

Handling and

conveying of raw

materials and

semi-finished

components to

different

operations.

The conveying system shall be

maintained by following routine and

periodic maintenance to reduce noise

generation in material handling.

DG set will be provided with acoustic

enclosure. They will be installed in

dedicated utility area, where the access

-

1.2.1 Environmental management plan during operation phase



Operation of DG

set.

will be restricted. Also the use of PPE

(ear plugs) will be mandatory in this

area.

Green belt at the project boundary will

further act as noise barrier and help in

attenuation of noise.

3 Water quality No significant

adverse impact.

Discharge of domestic

sewage and industrial

effluent.

The domestic sewage will be stabilized in

septic tank & the overflow from septic

tank will be treated in sugar plant ETP.

Effluent generated from the proposed

sugar plant will be treated in ETP.

Water conservation

measures shall be

encouraged.

4 Land No negative

impact

Discharge of

wastewater.

Storage and

disposal of solid

wastes.

The domestic sewage will be stabilized in

septic tank & the overflow from septic tank

will be treated in sugar plant ETP.

Effluent generated from the proposed sugar

plant will be treated in ETP.

The solid wastes or by-products produced

in sugar industry such as bagasse, press mud

and molasses are made use as valuable

resources.

-

5 Socio-

economic

Overall positive

impact

Employment

opportunities

Locally available man power will be utilized

to the maximum possible extent.

-

M/s Davangere Sugars Company Ltd.,


CHAPTER 2

INTRODUCTION OF THE PROJECT/

BACKGROUND INFORMATION

2.1 INTRODUCTION OF PROJECT PROPONENT

M/s. Davangere Sugar Company Ltd (DSCL) is an existing manufacturing company

focused on sugar and power.

The industry is located in Kukkuwada Village, Davangere Taluk & district, Karnataka

State.

The industry was established way back in 1974 with cane crushing capacity of 1250

TCD and subsequently enhanced to 3500 TCD with 24 MW co-generation power

plant during 2003.

Considering the scope for additional sugar cane availability, the management of

DSCL has proposed to enhance its sugar cane crushing capacity from 3500 to 5000

TCD and also Co-gen power plant capacity from 24 MW to 54 MW.

EC has already been obtained from Ecology and Environment from Govt. Of

Karnataka (No. AaPaJEE 209 ECO2001 Dated:5/7/2002)

2.2 BRIEF DESCRIPTION ABOUT THE NATURE OF THE PROJECT

M/s DAVANGERE SUGAR COMPANY LTD (DSCL) is located At Sy.nos 38/2, 40/ (1to6),

50/2, 51/(1to5), 44, 52/1&2, 71/p (total 153A 20G), Kukkuwada village, Davangere Taluk

& district- 577 004, Karnataka.

The area is in dry tropical climate with hot summer and moderate winter. The surrounding

area of the project site is rural agrarian. Annual rainfall is low with an average of about

562 mm. Shyagale halla carrying water almost throughout the year is 0.5 km north to the

site. Rain water streams are present in the region and they carry water only during rainy

days.

The site is nearly a plain land with gentle slope towards NE & SW. The region in the

vicinity is basically agrarian and extensively cultivated. The lands are irrigated through

Bhadra and Tunga dam canals and through bore wells, rain fed and also cultivated rain fed



and poorly cultivated. Small patches of agriculture land rain fed crops such as jawar, maize

and ground nut are seen in the region. Few patches of agricultural lands cultivating sugar

cane through lift irrigation also exist in the region. Sugar cane and paddy are the main

crops in irrigated lands. Ground nut, maize are the crops in rain fed lands. There are no

eco-sensitive locations such as national park, wild life sanctuary, protected forests, and bio-

sphere reserve in the vicinity of the project site.

2.3 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY

AND/REGION

The Indian sugar industry is passing through a difficult period. The sugar price in the Indian

market is low, and even the world market price is low. The release of sugar for sales from

the mills is controlled and hence, the Indian manufacturers are saddled with higher

Inventories. On the other hand, the cost of the raw material, the sugar cane, keeps

increasing every year and so is the production cost. With high inventories and the prices

low and with the raw material and production costs increasing every year, survival has

become a major problem for the Indian sugar industry. The sugar industry can hope to

come out of this situation only by cutting down the cost of production, and by adopting

energy efficient processing and this justifies going in for higher and more efficient systems.

With liberalized industrial policy, economy and globalization, Indian industries including

sugar industries are facing tough competition from the global players. Unless improved

technologies and all by-products are converted into value added products, survival of the

sugar industries is at stake. However, with the advent of co-generation technology in sugar

industry, bagasse being used as the main source of fuel for generating power and steam

together. Since, the generation of co-gen power is more than its captive requirement in the

industry the surplus power will be sold to the public power grid. This helps in distributed

generation of power reducing the transmission loss and improved voltage at the rural

arrears.

Under the above scenario, where there is a need to augment the steam and power

generation within the plant to improve the energy efficiency of the sugar plant to go in for

high pressure and high efficiency boilers and matching turbo generators. Such system, in

addition to generating surplus power for export which improves the bottom line of the

sugar mill operations, improves the energy efficiency of the sugar mill process itself.



Considering the business opportunity in carbon trading it is essential to go into the business

of renewable energy based power generation and Cogeneration projects. The above

justifies the need for the proposed project of co-generation system in DSCL.

India has a large potential for generating power through co-generation of electricity and

thermal energy. The largest contribution to the total potential is from Bagasse based

cogeneration. Exploiting the potential the maximum will not only make additional power

available to reduce perennial shortage of power, but will provide quality power at much

lower cost than price charged by the power utilities.

The power situation in the Karnataka State displays an appreciable shortfall in the power

availability even after taking into account the entire sanctioned projects including the

State’s share from the Central Sector projects. Another notable feature with regard to the

utility of power generation in the state is that hydro-power, which is subjected to the

uncertainties of the rainfall, contributes to the extent of 75% of the total power generation.

Under the circumstances, alternate power generation and conservation constitute the only

rationale option in the sphere of power planning, so that the gap between the demand and

supply of power can be bridged through generation of power from renewable sources of

power like co-generation using bagasse.

The National Productivity Council, (NPC) in its report revealed that currently, the country

is facing 20% shortage at peak electricity generation capacity and the position is likely to

worsen as the capacity addition programmes are not keeping pace with the increase in

demand. The study has suggested bio-mass based energy efficient co-generation as a prime

alternative for supplementing power production as it involves low capital requirement and

short gestation period.

2.3.1 NEED & IMPORTANCE TO THE REGION

The industry is located in the rural backward region of the state and has a good scope for

development of sugarcane with suitable climatic conditions and assured source of

underground and surface water. Hence, with the proposed industry more agricultural land

would be brought under sugarcane cultivation and it benefits the farmers in the local

region. The establishment of the integrated sugar industry will thus meet the national

interest of economical power and food through sustainable development. Further it helps to

uplift the rural mass.



2.3.2 EMPLOYMENT GENERATION DUE TO THE PROJECT

The existing co-gen sugar industry is having a total of 400 direct employees including

Manager, office staff, skilled & unskilled workers and indirect employment of 800 indirect

employees towards transportation, vehicle maintenance, petty shops etc., Further, about

10,000 farming families are engaged in sugar cane cultivation and supply of the sugar cane

to the present industry. The project will require additional man power of 60 direct and 200

indirect persons.

2.4 DEMAND SUPPLY GAP, IMPORTS vs INDIGENOUS PRODUCTION

The power situation in the Karnataka State displays an appreciable shortfall in the power

availability even after taking into account the entire sanctioned projects including the

State’s share from the Central Sector projects. Another notable feature with regard to the

utility of power generation in the state is that hydro-power, which is subjected to the

uncertainties of the rainfall, contributes to the extent of 75% of the total power generation.

Under the circumstances, alternate power generation and conservation constitute the only

rationale option in the sphere of power planning, so that the gap between the demand and

supply of power can be bridged through generation of power from renewable sources of

power like co-generation using bagasse.

The National Productivity Council, (NPC) in its report revealed that currently, the country is

facing 20% shortage at peak electricity generation capacity and the position is likely to

worsen as the capacity addition programmes are not keeping pace with the increase in

demand. The study has suggested bio-mass based energy efficient co-generation as a prime

alternative for supplementing power production as it involves low capital requirement and

short gestation period.

2.5 EXPORT POSSIBILITY

Bagasse is used as fuel in the associated co-gen power plant. It is fired in the boiler for

production of high-pressure steam. The steam in turn is used in generation of captive

electric power. The surplus power from the co-gen plant after meeting its captive needs in

the industry will be exported to public power distribution system. The co-gen power helps

to overcome power shortage in the state. The bagasse is obtained from renewable source

and is a substitute to fossil fuels such as coal or petroleum. Since the location of sugar mills

are decentralized, the co-gen power plants become decentralized bio-mass based power

station. Power export to the grid is provided below.



Power Particulars Operation

period

Existing

Addition

After

Expansion

Power Export

Season

10.0 MW

27.9 MW

37.9 MW Off-season

22.0 MW 27.9 MW 49.9 MW

2.6 EMPLOYMENT GENERATION DUE TO THE PROJECT

Existing manpower in the industry has employees about 400 people. Additional manpower

needed to operate the proposed expansion power and sugar plants will be 60 employees.

More than 85 % of the manpower requirement will be met from the local source. Man

power requirement for construction work will be about 160 Construction workers are from

nearby villages and residential facility will not be required for the construction personnel.



CHAPTER 3

PROJECT DESCRIPTION

3.1 TYPE OF PROJECT

M/s. Davangere Sugars Company Limited has proposed to expand its existing Co-gen sugar

industry from 3500 TCD to 5000TCD cane crushing capacity and also from 24.0 MW to

54.0 MW Co-gen thermal power plant.

3.2 LOCATION OF THE PROPOSED INDUSTRY

M/s. Davangere Sugars Company Limited is located at Kukkawada Village, Davangere

Taluk & District in Karnataka State. The Google map is appended as fig 3.1.

Fig 3.1: Maps showing project boundary & project site location

Note:

Latitude: 14019’48’’N ; Longitude: 75052’51’’E ; 567m above MSL



3.3 BASIS OF SELECTING THE PROPOSED SITE

1. The sugar and co-gen power plants will be associated with activities of the existing co-gen

sugar unit. The plant will utilize bagasse available in the sugar plant. The land, water and

other infrastructural facility is available in the existing sugar industry. Hence, the project is

essentially to be located in the premise of the existing sugar industry.



2. The selection of site location for the industry depends mainly on the availability of

resources such as raw materials, fuel, power, water, manpower, connectivity for

transportation of men and material, market for the product and more important is

environmental compatibility and sustainability. The existing sugar industry is located at

Kukkuwada village, Davangere Taluk & District in Karnataka state. The choice of the land

confers several advantages, which are summarized below.

1) The site is well connected by roadways.

2) Water requirement is met from Shyagale halla for which permission has been obtained.

3) The main raw material to the industry is sugarcane which is available from agriculture

source. The location has good scope for development of sugarcane with suitable climatic

conditions and assured source of underground and surface water. Sugar cane is grown in

large quantities in the vicinity of project site.

4) 66 KV KPTCL sub-station to draw exportable power is present at 0.6 km from the site.

5) No incidences of cyclones, earthquake, floods or landslides in the region have been

reported.

6) There are no eco-sensitive locations such as national park, wild life sanctuary, protected

forests, and bio-sphere reserve within 25 km radius around the proposed project site.

3.3.1 PROPOSED ENVIRONMENTAL SAFEGUARDS

1. What type of mitigative measures has been incorporated for control &

prevention of water pollution due to effluent discharge?

The domestic sewage will be stabilized in septic tank & the overflow from septic tank


Effluent generated from the proposed sugar plant will be treated in ETP.

Adequate measures are adopted for collection and storage of effluents

generated in the Industry and also to prevent spillages and overflows.

Therefore pollution in the surrounding areas is not anticipated.

2. Measures incorporated for control & prevention of air pollution due to boiler

stack, DG exhaust and process exhaust?

1) Well-designed stacks of adequate heights are proposed for the boiler and

generator for dispersion of gaseous emissions as per the guidelines.

2) Gaseous emissions in the industry will be mainly flue gases from boilers and diesel

generators. Diesel generators will be used to meet power requirement only during

emergency. Other emissions include fugitive emissions due to bagasse, ash and

movement of vehicles.



3. Measures proposed for prevention of adverse effect on fragile ecosystem?

M/s. Davangere Sugars Company Limited has proposed to expand its existing Co-gen sugar

industry & and it is not an ecologically sensitive area. Therefore no adverse effects

on the fragile ecosystem are anticipated.

3.4 SIZE / MAGNITUDE OF OPERATION

The industry M/s. Davangere Sugar Company Limited has proposed to enhance its cane

crushing capacity from 3500 to 5000 TCD and Co-generation plant from 24.0 MW to

54.0 MW. The total capital investment for the expansion of Co-gen project is Rs. 187.85

Crores (Sugar plant= 41.6 Crores & Power plant=146.25 Crores).

The estimated cost for the Existing and proposed project and for pollution Control facilities

are given below.

Table: - 3.0 Cost of the project

Sl. No. Particulars

Amount, Rs Lakhs

Existing Proposed

1 Capital Investment on proposed

project

Power plant

15,729

14,625

Sugar plant 4,160

2 Capital Investment On Pollution

Control Facilities & environmental

protection 600

400

Total 16,329 19,185



3.5 MANUFACTURING PROCESS DESCRIPTION

3.5.1 PRODUCTS MANUFACTURED

The industry has proposed to expand its capacity of Sugar plant from 3500 TCD to 5000

TCD and Power generation from 24.00 MW to 54.00 MW.

3.5.1.1 MANUFACTURE OF SUGAR

Sugar cane is the raw material for manufacture of sugar. Juice is extracted from sugar cane,

which is then processed to recover sugar. Bagasse, which is the left out fiber material after

extraction of juice from sugarcane, is used as fuel in boiler to produce steam. Steam is used

in sugar plant for evaporation of juice to recover sugar and in power plant for generation of

captive electric power. The operational parameters of Co-gen sugar industry during Season

and Off-season is given in table 3.1. The flow chart for manufacture of sugar is depicted in

the figure 3.2. A brief description of the process is given below:

The manufacture of sugar involves 5 stages:

1. Crushing of sugar cane.

2. Juice clarification (Double sulphitation of clarification).

3. Crystallization.

4. Curing and Drying.

5. Grading and bagging.

1. Crushing of Sugarcane:

Sugar cane is harvested in the fields, dressed and bundled in small bundles, stacked in

Lorries, tractor trailers, or bullock carts, supplied to factories, weighed and crushed in the

set of milling tandems. Cane crushing takes place mainly in two stages, first preparation

and then milling. Milling takes place after preparing the cane in leveler, cutter and fibrizer.

The prepared cane is then crushed by passing through 4 sets of mills. Weighed water is

added in the course of crushing as imbibition water for better extraction of juice. After

crushing, the bagasse is sent to boiler as fuel and juice is sent for purification and recovery

of sugar.



2. Juice Clarification:

The weighed juice is primarily heated in juice heaters at 65 to 70°C. It undergoes a

process of clarification i.e., addition of lime and sulphur-dioxide simultaneously. The juice

thus sulphited is again heated in another set of juice heaters at 100 to 105°C. The hot juice

is decanted out from the clarifier and sent for evaporation in a set of multiple effect

evaporator bodies. These multiple effect evaporators are designed for steam economy

(quintuple effect of evaporation). The juice thus evaporated gets concentrated to form thick

syrup of about 58 to 60%. The syrup thus obtained is again mixed with SO2 gas to pH of

5.0 to 5.2 for the purpose of bleaching.

3. Crystallization:

The sulphited syrup is sent to pan floor for further crystallization in vacuum pans. The

syrup collected in supply tanks is taken to pans for boiling where the syrup attains super

saturation stage. In such a condition sugar grains are formed in the syrup form a mass

called massecuite. The massecuite is dropped in crystallizers and cooled to complete the

crystallization.

4. Curing and Drying:

Massecuite is taken into the centrifugal machine. Sugar crystals are separated from mother

liquor in high speed centrifugal machines. Sugar is separated and sent to drier. Non

crystalisable matter from the syrup called molasses drained out from the centrifuge. It is

then weighed and sent to storage tanks. Sugar is dried in the vibrating hopper.

6. Grading and bagging:

The dried sugar is graded by passing through standard sieves. The graded sugar is bagged,

weighed for 100 kg net, stitched, numbered and stacked in sugar godwons.



Figure 3.2: Flow chart for manufacture of sugar



Figure 3.3: Process flow chart with material balance for Co-gen sugar unit



Table 3.1: Operation Parameters of Co-gen sugar industry

DURING CRUSHING SEASON

Sl.

No.

Parameter Existing Proposed

1 Plant Capacity

a. Sugar plant, TCD 3500 1500

b. Co-gen power plant, MW 24 30

c. Boiler, TPH 90 150

2 No. of crushing days, d/yr 240 240

3 Annual cane crushing, MT/yr 840 360

4 Sugar production (at 10% on cane), T/d 350 150

5 Bagasse production (at 30% on cane), T/d 1050 450

6 Bagasse use as filter aid, T/d 56 24

7 Bagasse available as fuel, T/d 994 426.40

8 Boiler steam capacity

90TPH

@87ata

and 5200C

150TPH

@110 ata

and 5400C

9 Steam generation, T/h 90 140

10 Fuel utilization in boiler, T/d

a.Bagasse 765 655

b.Coal (@15%) 54 84

c.Biomass -- 423.3

11 Steam to fuel ratio, kg/kg

Steam to bagasse 2.4 2.4

Steam to coal 6.0 6.0

Steam to biomass 3.6 3.6

12 Steam utilization

30 ata steam to HP heater 4.0 18.0

5.8 ata steam to Deaerator - 12.5

2.5 ata steam to LP Heater 72.0 4.5

2.5 ata steam to Sugar process 14.0 70.0

0.35 ata steam to condensing 14.0 44.0

13 Power generation, MW 17 30

14 Power consumption, MW

a. Sugar plant 5.0 --

b. Power plant auxillaries & lighting 2.0 2.1

15 Power export 10.0 27.9



POWER PLANT DURING OFF-SEASON

Sl.

No. Parameter

Existing

Proposed

1 Boiler Steaming capacity, T/h

90, at

87 ata and

520 oC

140, at

110 ata and

540 oC

2 Off-season working days, d/yr 90 90

3 Boiler steam generation, T/h 90 150

4

Utilization of Boiler fuel, T/d (T/yr)

Bagasse,

Coal, (at 15 %)

Biomass

Nil

54 (4860)

510 (45900)

Nil

69.6 (6294)

657(59157)

Steam utilization

30 ata Steam to HP Heater

5.8 ata steam to Deaerator

2.5 ata steam to LP Hater

2.5 ata steam to Sugar process

0.35 ata steam to Condensing

Total

- 4.0

-

-

86.0

90.0

14.9

9.8

8.9

Nil

82.4

116.0

5 Power generation, MW 24.0 30.0

6 Power consumption towards power plant

auxiliaries & lighting, MW

2.0 2.1

Power to sugar plant - -

7 Power export 22.0 27.9

3.5.1.2 CO-GENERATION OF POWER

The cane crushing capacity of the factory at present is 3500 TCD and will be expanded to

5000 TCD. The plant will be installed with high pressure boiler for generating power and

process steam for the sugar plant. Co-generation is broadly defined as the coincidental

generation of useful thermal energy and Electrical power from the same input fuel. Thus

Cogeneration can allow the energy consumers to lower their energy costs, through use of

the energy normally wasted in conventional systems. The useful thermal energy could be

in the form of hot gases, hot liquids or steam, generally used for meeting the process

requirements.



Power generation Process: The high pressure steam generated in the boiler is passed

through double extraction condensing turbine. Steam required for processing the cane

juice to sugar is drawn through the turbine at required pressure and temperature. In the

process, part of the thermal energy from the steam is used for power generation. Balance

steam is condensed in the turbine producing power. Low pressure steam requirement is

more in the cane crushing season and during off season entire steam goes for condensing.

When high pressure steam is passed through the turbine, the turbine will rotate at high

speed which in turn runs the alternator to produce the power. The schematic

representation of power generation process is shown in the figure 3.4. The operation

parameter for Co-generation plant are given in the table 3.2

Figure 3.4: Schematic representation of Co-generation of power

Boiler Turbine with

alternator

Makeup

Water LP/HP Steam for

Sugar

In-House consumption for

Sugar, Co-gen

DM Plant

Raw Water

Fuel Steam

Exhaust



Table 3.2: Operating parameters for Power plant

Sl.No. Particulars Description

1 TURBINE (30MW)

1.1 Type Double Extraction cum Condensing

1.2 Main stream pressure at turbine

stop valve

105 kg/cm2

1.3 Main stream temperature at

turbine stop valve

530 deg C

1.4 Turbine speed 5000 rpm

1.5 Extraction I 12.0 kg/cm2 to HP heater

1.6 Extraction II 2.5 kg/cm2 to process and Deaerator

1.7 Exhaust 0.12 kg/cm2 to condenser

2 GEAR BOX & COUPLINGS

2.1 Type Parallel Shaft with flexible couplings

2.2 Input speed 5000 rpm

2.3 Output speed 1500 rpm

2.4 Service Factor 1.5

3 GENERATOR

3.1 Rating 37500 KVA / 11,000 KV

3.2 Max cont rating at generator

terminals 30000 kw

3.3 Rated terminal voltage 11 kv

3.4 Phase / Frequency Three / 50 Hz

3.5 Rated speed 1500 rpm

4 CONDENSER

4.1 Type Shell and tube

4.2 Number of passes Two

4.3 Tube material SS 304

5 CONDENSATE EXTRACTION PUMPS

5.1 Type Vertical Turbine type

5.2 No of pumps 50% x 3

5.3 Air extraction system Steam jet ejector

6 FEED CYCLE EQUIPMENT

6.1 High pressure feed water heater One

6.2 Deaerator Variable pressure, spray cum tray type

7 BOILER FEED PUMPS

7.1 Type Multistage

7.2 Number of pumps 2 x 50 % (2 W + 1 SB)

7.3 Design capacity 80 cum / hr each

7.4 Design Head 1350 meters (tentative)



3.6 RAW MATERIALS

3.6.1 Quantity requirement

The main raw material required for manufacture of sugar is sugarcane. Sugar cane is

available from agricultural operations in the vicinity of the factory. Chemicals such as lime

and sulphur are used in the process for purification of sugar cane juice. Lubricating oil and

grease are also required in significant quantities as consumables in the industry. The raw

materials, chemicals and consumables are readily available in the country. The factory has

the capacity to crush on an average of 5000 MT of sugar cane per day. However, the co-

gen power plant runs throughout the year.

White sugar is the only main product in the industry. However, bagasse, molasses and

press mud are also produced as by products in the process. Bagasse is advantageously used

as fuel in factory boilers for production of high pressure steam. The later in turn is used in

generation of captive electric and motive power. Major part of the bagasse produced in the

industry is thus internally consumed as boiler feed. Other products viz., press mud and

molasses, which once thought to be waste products, are now advantageously sold to

profitable application as enumerated elsewhere. The quantitative details of raw material,

products, consumables and other are given in table 3.3.

Table 3.3: Raw materials and Products for Co-gen sugar plant

Sl.

No.

Item % of

cane

After expansion Storage

facility

Transportation

T/D T/m

1 RAWMATERIAL

sugar cane 100 5000 1500000 Cane yard Lorry, & Tractors

2 Consumables

Lime 0.22 11.00 210 60 T, Godown Lorry

Sulphur 0.06 3.00 45.0 20 T, Godown Lorry

Caustic soda (50

%)

0.30 9.0 15 T, M.S. tank Lorry tanker

Hydrochloric

acid (30%)

0.20 6.0 15 T,

Lined tank

Lorry tanker

Sodium chloride

(100%)

0.20 6.0 100 kg bags Lorry

Phosphoric acid 0.1 3.0 5 T,

35 kg carboys

Lorry



3 Oil, grease and

oil coolant

- 3.0 6 T,

200 kg drums

Lorry

4 Product,

Sugar

500 15000 Go down, 100

kg bags

Lorry

5 By product

a.Bagasse ( 50 %

moisture)

30 1500 45000 Yard Belt conveyor

b.Press mud, 75

% moisture

4 200 6000 Yard Tractors

c.Molasses, 25

% moisture

4 200 6000 M.S. tank Lorry tanker

3.6.2 POWER AND STEAM REQUIREMENT

The existing co-gen sugar industry includes 24 MW power plant. The present project is for

expansion of the power plant capacity from 24 MW to 54 MW. The generation and

utilization of power is given below. During expansion additional power unit consisting of

150 T/h boiler and 30 M.W T.G. set will be installed. The proposed power plant needs 2.1

M.W. power for its operation. The power generation in season and off season with captive

power use and power export to the grid is provided below.


period

Existing

Addition

After

Expansion

Power generation

Season

17.0 MW

30.0 MW

47.0 MW

Off-season

24.0 MW 30.0 MW 54.0 MW

Captive use of power Season

7.0 MW

2.1 MW

9.1 MW

Off-season 2.0 MW 2.1 MW 4.1 MW

Power Export

Season

10.0 MW

27.9 MW

37.9 MW

Off-season

22.0 MW 27.9 MW 49.9 MW



3.6.3 SOURCE OF SUPPLY OF RAW MATERIALS

The main raw material required for manufacture of sugar is sugarcane. Sugar cane is

available from agricultural operations in the vicinity of the factory. Chemicals such as lime

and sulphur are used in the process for purification of sugar cane juice. Lubricating oil and

grease are also required in significant quantities as consumables in the industry. The raw

materials, chemicals and consumables are readily available in the country.

3.7 RESOURCE OPTIMIZATION/RECYCLING AND RE-USE ENVISAGED IN THE

PROJECT

The main objective of mitigation measures is to conserve the resources, minimise the waste

generation, treatment of wastes, recovery of by products and recycling of material. It also

incorporates greenery development and landscape of open area and also the post project

monitoring of environmental quality. The measures under mitigation plan are classified as,

Measures built in the process

Measures during construction phase

Measures during operation phase.

Built in measures for resource conservation and pollution control in the industry are

discussed along with project details in Chapter-2. The measures adopted are mainly the

ESP, Bag-filter or wet scrubber and chimney for control of air pollution. The main objective

is to follow environment friendly process, with efficient utilisation of resources, minimum

waste generation and built in waste treatment and operation safety.

Ash is being used for composting as manure.

3.7.1 DOMESTIC SOLID WASTE RE-USE

The total quantity of domestic wastes generated which will be segregated at source,

collected in bins and composted. The composted waste will be used as manure for

landscape development.



3.8 WATER, ENERGY/POWER REQUIREMENT & SOURCE

3.8.1 WATER

Fresh water requirement to the industry will be met from the Shyagalle Halla located at

about 0.6 km North to the site. The industry has obtained permission for drawal of water

from the Shyagalle Halla. Sugarcane utilized as raw material in the sugar unit contains 70%

of its weight as water. Details are appended in section 3.9 later in the report.

3.8.2 POWER

The existing co-gen sugar industry includes 24 MW power plant. The present project is for


utilization of power is given below. During expansion additional power unit consisting of

150 T/h boiler and 30 M.W T.G. set will be installed. The proposed power plant needs 2.1

M.W. power for its operation. The power generation in season and off season with captive

power use and power export to the grid is provided below.


period

Existing

Addition

After

Expansion

Power generation

Season

17.0 MW

30.0 MW

47.0 MW

Off-season

24.0 MW 30.0 MW 54.0 MW

Captive use of power

Season

7.0 MW

2.1 MW

9.1 MW


Power Export

Season

10.0 MW

27.9 MW

37.9 MW

Off-season

22.0 MW 27.9 MW 49.9 MW



3.9 WATER REQUIREMNET AND WASTES GENERATION DETAILS & SCHEME FOR

THEIR MANAGEMENT/DISPOSAL

1. Source of water for the Co-gen industry


about 0.6km North to the site. The industry has obtained permission for drawal of water

from the Shyagalle Halla. Sugarcane utilized as raw material in the sugar unit contains 70%

of its weight as water. The water will be recovered by evaporation of juice and reused in

the process. The quantity of fresh and water obtained from sugarcane is given in table 3.4

Table 3.4 :- Source and quantity of water, m3/d

Sl.

No. Sources

Quantity of water required

in m3/d

1 Fresh water from river Shyagale halla 3117

2 Water from Sugarcane (70% of 5000 cane) 3500

Total 6617

2. Utilization of water in Co-gen sugar unit

I.WATER RECOVERED FROM SUGARCANE:

Sugar cane contains about 70% by weight of water. Sugar cane is crushed in mills to

separate the juice from the sugar cane. Juice is boiled in evaporators and pans where the

above water gets evaporated. These vapors are condensed and collected in the process. A

large quantity of water is thus generated in the plant itself. The condensed water is used as

a source of water during normal factory working. The quantitative details of water present

in cane and its distribution in the system is given below table 3.4 A.



Table 3.4 A :- quantitative details of water present in cane and its distribution in the

system

Sl. No. Parameters Quantity of water in m3/day

1 Water in cane 3500

2 Water loss with bagasse 730

3 Imbibition water added 1500

4 Water vapour loss at mill 50

5 Water in raw juice 4200

6 Filter wash water added 300

7 Lime water added 73

8 Water added with filter aid 20

9 Water vapour loss at clarifier 50

10 Water in clear juice 4500

11 Water loss with press mud 150

12 Medium pressure steam in to syrup 112

13 Water loss with molasses 50

14 Water vapour loss at crystallizer & centrifuge 132

15 Excess condensate water 548

The water present in cane juice is vaporized in evaporators and pans. For the sugar unit of

5000 TCD the water evaporated in the process amounts to 4455 m3/d. The vapours

generated from evaporators and pans are condensed in evaporator jackets, pan jackets and

juice heaters. The condensate water thus generated is collected and utilized to meet the

process water requirement in the plant such as imbibitions in mill, washing in vacuum

filter, pump gland cooling etc. Excess condensate will be let out on land for irrigation.

Low pressure steam in the plant is used as heating media to heat the juice/syrup in

evaporators, juice heaters and pans. Large quantity of vapour condensate is obtained as hot

water from these equipments. The pH is in the range of 6.2 to 7.5. The condensate water is

of relatively good quality and therefore it is used in the process for mill imbibitions, lime

preparation, juice dilution etc. If necessary, the hot water is cooled and treated in water

treatment plant and then used in the process. The excess condensate thus generated is

about 548 m3/d for the co-gen sugar industries of 5000 TCD capacities. The utilization of

condensate water in the plant is given in Table-3.5. The quantity of vapour condensate is

more than its utilization in the industry.



Table 3.5: Utilization of condensate water, m3/d

Sl. No. Particulars After expansion

1 Imbibition (30 % on cane) 1500

2 Lime preparation (1.46 % on cane) 73

3 Vacuum filter wash (6 % on cane) 300

5 Sugar plant cooling water make up 2034

6 Excess condensate water 548

Total 4455

II FRESH WATER REQUIREMENT FOR THE CO-GEN SUGAR UNIT

A large quantity of fresh water is required from raw water reservoir for industrial purpose

during start up for filling up spray pond, service water storage tank, cooling water tank and

boiler feed water tank etc. Fresh water is obtained from nearby Shyagale Halla located at

about 0.6 km from the industry. The industry has obtained permission from the authorities

to draw 3800 m3/d from Shyagale halla for use in the co-gen sugar industry. The quality of

water drawn from Shyagale Halla River is given in table 3.6

Table 3.6:- Quality of water from river Shyagale Halla

Sl. No. Parameter Units Results

Maximum

Acceptable

Limits As per

IS:10500-

1991 (amd-3)

Maximum Permissible

Limits in the Absence

of Alternate Source As

Per IS:10500-1991

(amd-3)

1 pH No 7.8 6.5-8.5 No relaxation

2 Conductivity µS/Cm 348 - -

3 TDS ppm 217 500 2000

4 Turbidity NTU 8.2 5 10

5 P- alkalinity as CaCO3 ppm 0.0 200 600

6 Total Hardness as CaCO3 ppm 115 300 600

7 Calcium Hardness as CaCO3 ppm 65 75 200

8 Magnesium Hardness as CaCO3 ppm 50 30 100

9 Sulphate as SO42- ppm 32 200 400

10 Nitrate ppm 7.6 45 No relaxation

11 Fluoride ppm 0.25 1.0 1.5

12 Iron as Fe ppm 0.32 0.30 1.0

13 Sodium as Na ppm 72.0 - -

14 Potassium as K ppm 2.8 - -

15 Phosphate as PO43- ppm 1.1 - -

16 Chloride as Cl- ppm 45.0 250 1000



III. WATER TREATMENT

The water has to be treated in suitable water treatment plant. The extent of water treatment

required for different applications is given below.

Boiler feed : De-mineralized water

Cooling water : Soft water

Domestic use : Clarified, filtered and

Chlorinated

Gardening : Raw water

Process in sugar plant & distillery : Soft water

Raw water from the source is pumped to the main water reservoir of 5000 m3 capacity. The

reservoir is a rectangular tank constructed of stone masonry/RCC. The water from reservoirs

is pumped to chemical mixer and then to mechanical clariflocculator. The clarified water is

collected in a clarified water treatment plant for further treatment.

The clarified water is passed through pressure filter and then water softening plant. The soft

water is collected in soft water storage tank for use in cooling water make up, sugar plant

and distillery applications. Part of the filter plant outlet water is directly taken to

demineralised plant for use in boiler feed water makeup.

Water requirement for domestic use is drawn from filter plant outlet and collected in an

overhead water storage tank. Chemicals such as lime, sodium carbonate, caustic soda,

bleaching powder, flocculants and hydrochloric acid are used in water treatment plant.



Fig 3.5: Schematic flow diagram of water treatment plant

Pressure

filter

Water reservoir

Shyagale Halla

Chemical mixer

Mechanical

clariflocculator

Clarified water tank

Water softening plant

Soft water storage tank

To cooling tower,

sugar plant & distillery

De-mineralization plant

To boiler feed

make-up

Overhead storage tank

To domestic use

IV. WATER BALANCE

The major demand of process water in sugar plant is met by recovered vapour condensate.

The requirement of fresh water for different applications in the sugar industry is given in

Table 3.7. The flow chart of manufacturing process with water balance is given in Figure

3.6. The water balance statement for sugar industry is given in Table 3.8.



Table 3.7: Fresh water requirement for the co-gen sugar unit, m3/d

Sl.

No.

Application Quantity , m3/d

Present expansion After

expansion

1 Domestic 60 06 66

2 Gardening 50 -06 44

3 Washings (Plant, Lab., & WTP) 50 20 70

4 Boiler feed water make up 125 216 341

5 Process 60 36 96

6 Gland cooling/sealing water 120 24 144

7 T.G cooling water make up 740 1466 2206

8 Mill bearing C.W. 120 30 150

Total 1325 1792 3117



3.6



Table 3.8: Water balance (after expansion) for co-gen sugar unit, m3/d

Utilization Water input Water output

Fresh Cane

water

Recycle Effluent Recycle Evap.

Loss

Others

Domestic 66 - 56 10 -

Gardening 44 - - 44 -

Washings (Plant,

Lab. & WTP) 70 - 70 -

Boiler

feed/Steam/

Boiler blow

down

341 - - 185 156 -

Juice process 96 84 - 180 -

Pump gland

sealing/cooling 144 - - 144 -

Turbine Cooling

Water 2206 - 200 2006 -

Sugar Cooling

Water - 1405 559 200 1764 -

Mill bearing

C.W. 150 - 30 120 -

Excess

Condensate - 548 - - 548

Water with

bagasse - 710 - - 710

Water with press

mud & Molasses - 200 - - 200

Total 3117 2947 559 326 559 4280 1458



3.10 SOURCE OF POLLUTION AND BUILT-IN MITIGATION MEASURES

Wastewater, gaseous emissions and solid wastes generated in the industry are likely to

cause pollution to the environment. Reduce, recycle and reuse principles will be adopted

to control the generation of wastes in the industry. Further they have to be handled, treated

and disposed scientifically to avoid adverse impact on the environment. Source wastes

and their management are presented below.

3.10.1 WASTEWATER MANAGEMENT IN CO-GEN SUGAR UNIT

1. SOURCE OF WASTEWATER

The wastewater generated in sugar factory is relatively less toxic and less hazardous.

Further, the sugar processing does not involve any inherent wastewater streams and

therefore the wastewater generated can be substantially reduced. The wastewater

generated is mainly due to washing of floors and equipments in addition to a small

quantity of wastewater are due to purge from boiler and cooling water sumps and also due

to domestic source. Further, the large quantity of vapor condensate is generated as excess

water from the factory. It is fairly good quality and is also discharged as waste water. The

details of source and quantity of waste water from sugar factory are discussed below.

I .SPILLAGE, LEAKAGE AND FLOOR WASHINGS:

In a sugar factory waste water of high contamination is generated mainly due to leakages

and spillages of juice, syrup and molasses in different sections of the manufacturing plant.

Leakages occur at pipe joints and pump glands. Spillage and splashes occur at different

equipments and machinery. The periodical washing of floor also contributes significant

pollution load in the waste water. Waste water is also produced due to the cleaning of

equipments such as evaporators, pans, juice heaters etc. Though these wastes are small in

quantity but contain high BOD and low pH. Good housekeeping, effective maintenance

and efficient plant operation can considerably reduce the generation of this waste water.

Spillage and washings can be collected in small sumps constructed at such locations and

these interns can be recycled to the process. If planned well the generation of such waste

water can be totally avoided. However, at present the waste water does generate. The

effluents from mill plant contain fibers, grease and oil. The effluent from lime preparation

and clarifier house is alkaline in nature and contains high suspended solids. Quantity of

effluent due to spillage, leakage, floor and equipments is around 70m3/d.



ii. BOILER BLOWDOWN

Boiler feed water contains a small concentration of dissolved solids. Additional chemicals

are also added to the water to prevent scale, corrosion and carry over in the boiler, as the

evaporation continues, concentration of dissolved solids in boiler increases. Therefore

solids continue to build up in the boiler. Boiler blow down is therefore given from the

boiler to control the concentration of dissolved solids in it. The quality of blow down is

relatively better and therefore advantageously added to circulating cooling water. The

boiler blow down allowed in the boiler is about 156 m3/d.

iii. Domestic wastewater

Domestic wastewater is generated from factory and from residential quarters. A total of 450

persons are working in the industry. A total of 400 persons are expected to be residing in

quarters. Fresh water is utilized for domestic needs in the factory at a rate of 130 L/d per

head. Fresh water consumed and wastewater generated due to domestic usage of water in

m3/d is given below:

Domestic water usage in the factory : 13.5

(at 30L/d per head for 450 persons), m3/d

Domestic water usage in quarters : 52

(at 130 L/d per head for 400 persons), m3/d

Total domestic water usage : 65.5 or say 66 m3/d

Domestic wastewater from factory : 12.15


Domestic wastewater from residential quarters : 46.8


Total domestic wastewater : 58.95 or say 60 m3/d

v. Purge from barometric condenser

The vapours from last effect evaporator and pan boiling are passed through steam ejector

and then sent to barometric condenser, wherein circulating cooling water at the rate of

about 3000 m3/day is used to scrub, condense and cool the vapours. The total quantity of

vapour condensate added into the circulation water is 1214 m3/d. 1324 m3/d of the

circulation water is lost as vapour and drift losses in cooling tower. In case of overloading

of pan and evaporators the vapours may become contaminated due to entrainment. This



circulation water is relatively more contaminated as compared to that of boiler blow down

and turbine cooling water purge. The quality of circulation water is improved by its

dilution with 66m3/d boiler blow down and 200 m3/d turbine cooling water purge. Excess

water of about 156 m3/d from cooling tower channel is drained out as purge.

Circulation cooling water : 3000

Vapour condensate added : 1214

Boiler blow down added : 66

Turbine cooling water purge added : 200

Drift & evaporation loss : 1324

Purge water drained out : 156

vi. HOT CONDENSATES

Large quantities of steam condensates are obtained as hot water from the evaporators and pan

jacket bodies. The condensate is of good quality and therefore it is used in the process for boiler

feed, mill imbibitions, lime preparation, juice dilution etc. Excess condensate is let out as effluent.

Though the condensate has high temperature it is cooled during the passage in the gutter and

mixing with other effluent.

vii. Purge from mill tower cooling water

Large quantity of water is circulated for cooling of mill and turbine bearings. It is necessary to

purge some of the cooling water to maintain its quality. Evaporation and drift loss in this case is

small. Fresh water of about 150 m3/day is used as make up water to compensate the purge and

also the vapour and drift losses.

viii. Purge from turbine cooling water

Large quantity of water is circulated through turbine surface condenser for condensation of

exhaust steam. Cooling water purge of this system is of relatively good quality, it is sent to

sugar plant cooling water system. Fresh water is used as make up water to compensate the

purge and also the vapour and drift losses.

Evaporation and drift losses, m3/d : 2006

Make up cooling water, m3/d : 2206

Purge water from cooling tower, m3/d : 200



ix. Cooling water from glands

Cooling water is circulated through pump glands, centrifuge glands and sulphur burners

etc. This water can also be totally re-circulated. However, in practice this water is drained

out due to its likely contamination with juice.

x. Cleaning day washings

Evaporators, juice heaters, pans etc are cleaned once in 50-60 days time for removal of

scale. Chemicals such as caustic soda, sodium carbonate and hydrochloric acid are used

for scale removal. Spent wash and washings generated during cleaning operations is about

70m3/d. It is highly alkaline and contains heavy BOD load. If added directly to effluent

treatment plant the waste water gives a shock load, and disturbs its process. Cleaning day

waste water is therefore collected and stored separately in a cleaning day effluent storage

tank. 70m3/d of this waste water is drawn from the storage tank and then mixed with other

factory effluent in the neutralizer cum hold up tank.

2. ISOLATION AND SEGREGATION OF WASTEWATER

The effluent from sugar industry is relatively non-toxic and less-hazardous in nature.

Effluent from domestic source is received in septic tanks. It has low dissolved solids and

moderate BOD. The wastewaters generated at various sources in the sugar factory are

segregated into three streams based on their pollution load for the convenience off their

subsequent treatment and disposal. The details of waste water generated (after expansion)

Co-gen sugar industry is summarized below:

Sl.

No.

Source Quantity

m3/day

1 Stream A : Process effluent, (High BOD effluent) 270

2 Stream B : Excess condensate water 548

3 Stream C : Domestic effluent 56



3. CHARACTERISTICS OF WASTEWATER

The wastewater from sugar industry is relatively non-toxic and non-hazardous in nature. In-

plant measures are adopted in the factory as enumerated elsewhere to reduce the quantity

and contamination of wastewater. Oil taps are provided in the mill house to minimise the

contamination of oil & grease in the wastewater. Small sumps are provided at suitable

location in the factory to receive the leakages, juice and syrup, which may be present at

pumps and near some process equipment. The leakage of juice and syrup thus collected is

recycled to process. Floor cleaning is done by dry baggage to minimise the quantity of

wastewater. Further hot condensates obtained from evaporators are recycled to the process

to meet the requirement of imbibition etc. in the process, and also to meet the makeup

water requirement for cooling tower.

Waste from domestic source is received in septic tanks. It has low dissolved solids and

moderate BOD. The overflow from septic tank is sent to effluent treatment plant. The

wastewater generated at various sources in the sugar factory are segregated into three

streams based on their pollution load and the convenience of their subsequent treatment

and disposal. The characteristics of wastewater of different streams are given in table 3.9

Table 3.9: Characteristics of Wastewater

Sl.

No.

Parameters Stream

A

Stream B Stream

C

Total(A+B+C)

1 Flow rate (m3/day) 270 56 548 874

2 Temperature (0C) 38 32 42 39

3 pH 5.5 7.2 6.6-7.0 6.0

4 Dissolved solids(ppm) 1800 840 360 835

5 Suspended solids(ppm) 320 180 60 148

6 BOD(ppm) 1800 240 260 772

7 COD(ppm) 2800 360 416 1148

The existing co-gen sugar industry is already having a full pledged effluent treatment plant.

This was originally designed for the effluent capacity of 1310 m3/d. The plant is working

satisfactorily. The quantity of effluent generated in the industry has subsequently reduced

by incorporating various measures to control the quality and quantity of effluent. After

proposed expansion, the quantity of combined effluent from the industry will be 874m3/d.

Hence, the capacity of the existing ETP is adequate to treat the effluent generated from the

expanded plant. The operational parameters of the effluent treatment plant will be

reviewed to suit the influent characteristics. The effluent treatment plant is designed for

about 30% higher quantity of effluent to take care of shock loads & any eventualities. The

influent data of combined wastewater assumed for design is given below.



i. Influent qualities of combined wastewater

Sugar factory crushing capacity : 5000 TCD

Effluent flow rate, hourly maximum : 60 m3/h

Daily maximum : 1100 m3/d

Temperature : 32-40 OC

pH : 5.5

T.D.S : 1650 ppm

S.S : 300 ppm

B.O.D : 1500 ppm

C.O.D : 2600 ppm

Oil : 20 ppm

ii. Quality of treated wastewater

The treated effluent shall be discharged to agricultural land for irrigation. Prescribed

standards to be achieved for treated effluent is given below.

pH : 7.0 - 7.8

T.D.S : less than 2000 ppm

S.S : less than 100 ppm

B.O.D : less than 100 ppm

C.O.D : less than 250 ppm

Oil : less than 5 ppm

4. EFFLUENT TREATMENT PROCEDURE

The wastewater treatment is designed based on the following considerations

Characteristics of waste water

Quantity of effluent

Prescribed standards for discharge of wastewater.

The mill plant effluent contains oil and fiber in large concentration. This effluent is

therefore subjected to de-skimming operation in mill plant itself to free it from oil and fiber,

and then mixed with other factory effluents. The combined effluents are treated in



preliminary and secondary treatment as described below. The flow chart of effluent

treatment plant is given in Figure-3.7

i. Preliminary treatment:

Combined effluent in a common drainage is led to the effluent treatment premise. It is

passed through bar screens, oil separator and then received in equalization tank. Excess

condensate from sugar plant is also sent to equalization talk. Effluent from equalization

tank is then neutralized with lime solution in flash mixer, flocculated with alum and

electrolytic polymer agents in coagulation tank and then clarified in settling tank. Settled

sludge from clarifier is sent to sludge dewatering beds. The neutralised and clarified

effluent is sent to secondary treatment unit. Domestic effluent collected as overflow from

septic tanks is also sent to secondary treatment unit.

ii. Secondary treatment:

Secondary treatment plant consists of sequential batch reactor (SBR), pressure sand filter

and activated carbon filter. Effluent from primary clarifier is treated in sequential batch

reactor consisting of pre-aeration, final aeration and decanter. Clarified effluent from

decanter is further treated in pressure sand filter and activated carbon filter. The treated

effluent is received in treated effluent collection sump and from there it is tested for quality

and sent to agriculture land for irrigation.

5. SPECIFICATIONS OF EFFLUENT TREATMENT UNITS:

The specification of the upgraded ETP is presented below.

01. Screen

i. Fine Screen

Quantity : 02

Width of screen : 6 mm

Inclination to horizontal : 45 0.

ii. Coarse Screen

Quantity : 01

Width of screen : 6 mm

Inclination to horizontal : 45 0.



02. Oil & Grease trap

This tank is provided for process effluent. The floating scum consisting of oil, grease & fiber

matter is periodically skimmed off manually.

Quantity : 02

Tank size : 3.5 m ×1.2 m × 1.5 m SWD

03. Colony & other Sewage Collection Tank

This material will be sent to Pre-aeration part of SBR Tank.

04. Equalization Tank

As the name indicates flow equalization achieved in this tank, it is achieved by using

aeration grids through which coarse bubble air has been passed.

Mixing arrangement : Coarse bubble air diffusers.

MOC : HDPE.

Size of the tank : 12 m ×12 m ×2 SWD.

05. Flash Mixing Tank

The effluent pumped at a constant rate from equalization tank has been mixed with lime

solution for pH correction; the agitation at this tank

Size : 1.0 m × 1.0 m ×2.7 m SWD.

MOC : RCC m-20.

06. Flocculation Tank

The pH corrected effluent passes through flocculator tank where flocculation of primary

sludge takes place by adding polymer solution.

Size : 2.0 m× 2.0 m × 2.7 m SWD.

MOC : RCC m-20.

07. Primary Settling Tank

Over flow effluent from the flocculator passes through primary settling tank. The settled

primary sludge is transferred to sludge drying bed. The over flow of clarified effluent after

primary treatment is taken to aeration tank for further aeration where balance BOD shall

be removed.

Size : 4.5 m× 4.5 m ×3.0 m HOS with hopper bottom

MOC : RCC M-20.



8 & 9. Sequential Batch Reactor Tank (SBR) & Decant Tank.

Clarified effluent, overflow from primary settling tank flows into SBR tank by gravity to the

pre-aeration part and then to final aeration part. This has been designed to take the load of

continuous inflow and to control the batch outflow.

Size : 23.5 m ×23.5 m × 3.0 m SWD with partition walls.

MOC : RCC M-20 (modification).

The outlet batch goes to the “Decant” part of the whole tank.

10. Pressure Sand Filter (PSF)

Water from the decant tank is sent to pressure sand filter through filter feed pumps to

remove suspended solids. This vessel is equipped with a distribution pipes, filled with filter

media comprises of graded sand.

Quantity : 2

Size : 1.85 m ×2 m HOS.

Type : Down Flow.

Media : Graded Sand.

11. Activated Carbon Filter (ACF)

Water from PSF passes through ACF. This is to remove color & odor if any. This is a

pressure vessel equipped with a distribution pipes fitted with valves having an inside

construction of perforation of headers, filled media comprises of activated carbon.

Quantity : 2

Size : 1.85 m × 2 m HOS.

Type : Down Flow.

Media : Activated Carbon.

12. Sludge drying beds

These tanks are constructed of stone masonry and they are filled with graded sand and

pebbles.

Quantity : Total 11 nos.

Size : 3 m ×3 m ×1.5 SWD

13. Treated Effluent Collection Tank

Size : 10.0 m × 10.0 m × 3.0 SWD

MOC : RCC M-20



14. Lime Dosing Tank

Size : 1000 L.

MOC : LDPE

15. Lime Dosing Tank Agitator

Quantity : 1

Motor Rating : 1.5 HP.

Speed : 100 rpm.

MOC : SS 304 wetted parts.

16. Poly Electrolyte Dosing Tank

Size : 500 L.

MOC : LDPE.

17. Poly Electrolyte Dosing Pump

Quantity : 1

Capacity : 0 – 50 LPH.

MOC : SS 304 wetted parts

18. Poly Dosing Tank Agitator

Speed : 50 rpm.

MOC : SS 304 wetted parts

19. Air Blower

No of air blowers : 4

Service : Continuous.

Capacity : 540 m3 ×3 = 1620 m3/hr.

Discharge Pressure : 4000 mm WC.

Type of blowers : Rotary twin lobe

20. Sludge Transfer Pump

These pumps provided to transfer sludge from SBR tank to sludge drying beds

Quantity : 2

Capacity : 2 HP.

21. Sewage Transfer Pump

This pump is provided to pump sewage from collection tank to SBR tank.

Quantity : 1

Capacity : 1 HP.



22. Sodium hypochlorite (NaOCl) dosing system

This system provided to dose NaOCl for final treated effluent.

Quantity : 1

Type : Automatic.

Capacity : 100 L.

MOC : LDPE

23. Decanter Mechanism

This system is provided for decantation of treated effluent from SBR Tank to decant

tank.

Quantity : 2

Size : 300 NB.



Figure 3.7: Flow diagram of effluent treatment plant – sugar unit

To Irrigation

Nutr

ient

Neutralize

Excess Condensate Water

Lab Operator House

Scre

en a

nd

V

-Notc

h Sludge

Slu

dg

e

L.T

. P

ow

er

Supply

Pota

ble

Wa

ter

Cleaning Day Wash Tank

Oil Separator Sludge Drying Bed

Treated Effluent

Aeration Tank

(2 stages) Secondary

Clarifier

Secondary Sludge Pit

Sludge

Sludge

Primary Sludge Pit

* *

Oil and fibrous separator in Mill House

Hot water-cooling plant adjacent to sugar plant

Sump

Effluent from Sugar Plant

Lime

Primary clarifier



Gaseous emissions in the industry will be mainly flue gases from boilers and diesel

generators. Diesel generators will be used to meet only during emergency requirement

of power. Other emissions include fugitive emissions due to bagasse, ash and

movement of vehicles.

1. Flue gases from boilers and diesel generators

2. Fugitive emissions due to bagasse, ash and movement of vehicles

FLUE GASES FROM BOILERS AND DIESEL GENERATORS

The sources of flue gases for existing and proposed project are:

i. Existing: Boiler of 90TPH, D.G sets of capacity 500KVA and 160KVA

ii. Proposed: Boiler of 150TPH

During crushing season Bagasse is used as fuel and during off season coal is used. The

Characteristics of the fuel are given in the table 3.10

Table 3.10: Characteristics of fuel used

Sl. No. Parameters Fuel type

Bagasse Agro waste Coal Diesel

1 Heat value, GCV,

kcal/kg

2272 3600 6000 10700

2 S content, kg/T 0.1 0.1 1.2 1

3 Ash, kg/T 10 10 100 -

4 Steam / fuel ratio,

kg/kg

2.4 3.6 6.0 -

The information on stack, sources of emissions and APC facilities adopted are given in

table 3.11

3.11 AIR POLLUTION SOURCES



Table 3.11: Sources of flue gases and APC

Stack

No.

Source

of

emission

Type of

Fuel

Sulphur,

%

Fuel

consumption Chimney

Ht, m

APC

Measures Season

Off-

season

EXISTING

1 90 TPH

Boiler

Bagasse/

Bio mass

Coal

0.04

0.6

(T/hr)

40

-

(T/hr)

-

15

80 m

AGL

ESP

2 D.G. Set

500KVA

Diesel - 118L/hr 118L/hr 7 m ARL Acoustic

enclosure

3

D.G. Set

160KVA

Diesel

-

37.6L/hr

37.6L/hr

5 m ARL

Acoustic

enclosure

PROPOSED

1 150 TPH

Boiler

Bagasse/

Bio mass

Coal

0.04

0.6

65.21

-

25

-

80m

AGL

ESP

Stack height calculation

Existing

90 TPH boiler

During season:

Fuel used – Bagasse/agro-biomass = 39.13 or say 40 TPH


H = 74 (Q)0.27

Where, H = Height of Stack in m &

Q = Ash produced in TPH



Ash produced = 40 TPH x 10 = 400 kg/hr

Therefore Q = 0.4 TPH



Hence, H = 74 (0.4)0.27 = 57.72 m

Or say 58m AGL

During off-season:



H = 14(Q) 0.3



Sulfur content in coal = 0.6 %

1Kg of sulphur=2Kg of sulphur-di-oxide

Q= [15000 X 2 X (0.6/100)] = 180 kg/hr

Q=180kg/hr

Hence, H = 14 (180) 0.3

= 66.48 m or 67 m AGL

PROPOSED HEIGHT OF STACK

Height of stack to be provided: 80 m AGL

500KVA D.G set

Fuel used – Diesel = 117.5 LPH = 66.76kg/hr


H = 14(Q) 0.3








Hence, H = 14 (0.3915)0.3

= 10.57 or say 10.6 m


160KVA D.G set

Fuel used – Diesel = 37.6 LPH=21.36 kg/hr


H = 14(Q) 0.3






Hence, H = 14 (0.1252)0.3

= 7.5 m or say 8 m

Proposed

150 TPH boiler

During season:

Fuel used – Bagasse/agro-biomass = 65.2 TPH


H = 74 (Q)0.27

Where, H = Height of Stack in m & Q = Ash produced in TPH



Ash produced = 65.2 TPH x 10 = 0.652 kg/hr

Therefore, Q = 0.652 kg/hr

Hence, H = 74 (0.652)0.27 = 74 X 0.89= 65.92m

Or say 66 m AGL



During off-season:



H = 14(Q) 0.3




Therefore, Q = 25 x (2x0.6/100) = 0.3 TPH =300 Kg/hr

Hence, H = 14 (300)0.3

= 77.56 m

Or say 78 m AGL


Technical specifications of air pollution control equipments

ELECTROSTATIC PRECIPITATOR



MAKE : M/s. BHARAT HEAVY ELECTRICALS LTD.

SUPPLIER : M/s. FIVES CAIL KCP LTD.

Design details

Sl.No Description Details

1 No of Field 3 Field

2 Gas flow rate 52 m3 / s

3 Dust load at exit 50 mg/ nm3

4 Inlet dust concentration 6 mgs / nm3

5 Flue gas moisture percentage 23% & 28%

6 Un-burnt carbon in fly ash 35%

7 Gas velocity through ESP less than 1M/s

Material details

Sl.No Description Qty

1 Collecting Electrode 315 No's

2 Emitting Electrode 600 No's

3 Outlet GD screen plate 13 No's

4 Inlet GD screen plate 32 No's

5 Collecting Rapping Sys 3 No's

6 Collecting Rapping Hammer 63 No's

7 Emitting Rapping Sys 3 No's

8 Emitting Rapping Hammer 72 No's

9 GD Rapping Sys 1 No

10 GD Rapping hammer 16 No's

11 Shaft Insulator 3 No's

12 Support Insulator 12 No's

13 Inspection Door (723x523) 5 No's

14 Hopper Door(460x410) 3 No's

15 Collecting & GD Rapping Motor 0.33 HP, 1.1

RPM

4 No's

16 Emitting Rapping Motor 0.33 HP, 2.5RPM 3 No's

17 Knif edge gate valve 3 No's

18 Expnsion Joint Size: 2310x2810 2 No's

19 Heating Elements S.S 51 No's

20 Thermostat for hopper 4 No's



Noise is described as an unwanted sound. Exposure to noise affects the human beings

in many ways depending upon the intensity of noise, its frequency and exposure

duration. Exposure to excessive noise produces varying degree of damage to human

hearing system, which is initially reversible.

WHO has recommended 75 dB as exposure limit to industrial noise. The BIS

recommended the acceptable noise level in an industrial area between 45 and 60 dB.

The threshold limit value (TLV) under occupational safety and health is 85 dB for 8

hours, 90 dB for 4 hours, 95 dB for 2 hours and 100 dB for 1 hour and 110 dB for 15

minutes per day. Sound beyond 80 dB harms hearing system and it can be regarded as

pollution. The largest noise a man hears without discomfort is thus 80 dB.

The sound intensity appears to be at higher level especially in the locations of following

machineries.

i. Steam turbines : 95 – 100 dB

ii. Diesel generator : 70 - 75 dB

iii. Fans, blowers and compressors : 80 – 85 dB

iv. Sugar graders : 75 – 80 dB

v. Centrifuges : 80 – 85 dB

Necessary measures as indicated below are taken to reduce the sound intensity below

the allowable limits at the source itself in the present sugar industry. In general at the

location of turbines, compressors, fans etc., the sound intensity generally exceeds the

limit. The workers engaged in such locations are provided with ear muffs to have an

additional safety against noise nuisance.

SAFETY MEASURES AGAINST NOISE:

i. Adoption of noise reduction measures in the construction of the industry as per the IS

3408-1965.

ii. Specifying the noise standards to the manufacturing of machineries.

iii. Acoustic barriers or shields to the machineries.

3.12 NOISE GENERATION AND ITS MANAGEMENT



iv. Heavy foundations and vibration absorption two things to steam turbines,

Centrifuges etc.

v. Acoustical walls, roofs to buildings where such machinery are installed.

vi. Segregation of machineries having high noise level in separate buildings.

vii. Incorporation of silencers and sound absorbers to gas inlet and outlet of fans,

blowers and compressors.

viii. Sound control measures to steam vents.

ix. Proper maintenance of machineries especially oiling and greasing of bearings, gears

etc.

x. Avoiding vibration of machineries with proper design of machineries such as speed,

balancing etc.

xi. Use of personal protective aids to ear for the persons working in such locations.

xii. Plantation of green trees around the factory buildings to control the intensity of

noise to the surrounding premises.

The solid wastes or by-products produced in sugar industry such as bagasse, press mud

and molasses are made use as valuable resources as below. Other solid wastes in the

industry are boiler ash, lime sludge and ETP sludge. Spent lubricating and cooling oils

produced in the industry are specified as hazardous wastes and these are disposed as

per the prescribed guidelines.

Bagasse

Bagasse is the fibre material left out after extraction of the treated sugarcane juice. The

average bagasse content in sugarcane is 30%. Major quantity of the bagasse produced

will be utilized in the plant itself as a boiler fuel. A small quantity of bagasse will also

be used as filter aid in the plant. The saved bagasse will be stored on the storage yard

for use in off season.

3.13 SOLID WASTE GENERATION AND MANAGEMENT



Molasses

Molasses is produced in the industry at average of 4% on sugarcane crushed. It contains

large percentage of non crystallisable sugar and is a valuable source of raw material for

manufacture of ethyl alcohol or other products such as oxalic acid, lactic acid etc.

Molasses is also used as nutritive additive in manufacture of cattle feed.

Press mud

Press mud is produced in the industry at an average of 4% on cane crushed in the sugar

plant. It contains fibrous material and crop nutrients such as phosphorous and

potassium and therefore it is disposed to farmers for use in agricultural land. The press

mud will be composted along with spent wash generated from the distillery. The

composted press mud is a bio-manure containing, fortified plant nutrient such as

potassium, phosphorous and nitrogen.

Boiler ash

Boiler ash is un-burnt matter left out in the furnace after complete burning of fuel in the

boiler. Ash produced from bagasse/agro waste will be 1.0%. The ash contains plant

nutrients. It is a non-toxic material. It can be used as soil conditioner in agriculture land

or in brick making. It can also be composted along with press mud to produce bio-

manure.

ETP & lime sludge


industry. Major quantity of the sludge from secondary clarifiers is re-circulated to the

aeration tank. Excess of sludge from clarifiers is dewatered and partially dried in sludge

drying beds. The sludge with an average moisture content of 50% produced from ETP

will be 100 kg/d.

Hydrated lime is used in the plant for purification of juice and therefore, the quantity of

lime sludge produced from the plant is small. The sludge with an average moisture

content of 50% will be produced from lime plant. A maximum of about 0.1 T /d of

sludge will be produced from lime plant. The quantities of various solid wastes

produced from the proposed sugar industry of 5000 TCD are summarized in table 3.12




Solid waste % on

cane

Existing Expansion


Bagasse

(50% moisture)

30 1050 1500

Molasses 4 100 180

Press Mud 4 140 180

Boiler Ash

Season

Off season

- -

13.05

10.50

-

13.5

19.2



A schematic representation of the overall feasibility and environmental assessment

process is shown in Figure 3.8.

3.14 SCHEMATIC REPRESENTATIONS OF THE FEASIBILITY DRAWING



Fig 3.8: Feasibility & environmental assessment process

Significant

Not Economic

Feasibility study conducted for newly proposed industry

Statement of intent by proponent

Guidelines for EIA by SEAC/MoEF

Abandon project

Determine the coverage of the EIA - scoping

Describe the environment – baseline study

Describe the project

Identify the impacts

Evaluate the impacts

Mitigation

Preventive measures

Prepare draft EIS

FINAL EIS REPORT

CONSIDER ALL PHASES OF PROJECT –

CONSTRUCTION, DEVELOPMENT, INSTALLATION &

FINAL OPERATION/ PRODUCTION

SO

CIO

-ECO

NO

MIC

ISSU

ES

MO

NIT

OR R

EVIE

W



CHAPTER 4

SITE ANALYSIS

4.1 CONNECTIVITY

Fig 4.1: Google map showing connectivity

SH-65

SH-76



Table 4.1: Connectivity from the project site

Sl.

No.

Road Distance from the

project site (km)

Direction w.r.t.

project site

1 NH- 4 12.26 North

2 SH-25 14.22 West

3 SH-76 11.69 East

4 Davangere city railway station 15.73 North

5 Davangere KSRTC Bus Stand 15.28 North

Note: All distances mentioned are aerial.

4.2 LAND FORM, LAND USE & OWNERSHIP

M/s. Davangere Sugars Company Limited has proposed to expand its existing Co-gen

sugar industry from 3500 TCD to 5000TCD cane crushing capacity and also from

24.0 MW to 54.0 MW Co-gen thermal power plant at Kukkawada Village, Davangere

Taluk & District in Karnataka State. The proposed project will be established in the

open area already available in the existing industry and therefore procurement of

additional land is not required. The location is rain fed agricultural land converted for

industrial use.

4.3 TOPOGRAPHY

M/s Davangere Sugars Company Limited. is located at latitude of 14019’48’’N &

longitude 75052’51’’E at an elevation of 567 m above MSL. The topo map showing

the location of the project site is appended as fig 4.2.



Fig 4.2: Topo map

Source: Survey of India; Scale 1:50000

PROJECT SITE



4.4 EXISTING LAND USE PATTERN

Table 4.2: Existing land-use pattern

Sl.

No.

Particulars Details Distance

From the

Project site

(km)

Direction

w.r.t

project

site

1 Agriculture Scattered - -

2 National park, Forest None - -

3 Water bodies Shyagale Halla 0.5 North

Shanthi sagara 22.6 South

Devara belakere 9 North West

Hadadi reservoir 3 North

Kogalur lake 17.6 South East

Lokikere 6 South East

Tungabhadra river 27 North

4 Archaeological

Monuments

- - -

Note:

a) All distances mentioned are aerial.



Fig 4.3: Google map showing existing land-use pattern



Fig4.4: Google map showing surrounding water bodies



4.5 EXISTING INFRASTRUCTURE

The list of available infrastructure to the project is

1. Water supply from Shyagale halla.

2. 66 KV KPTCL sub-station to draw exportable power is present at 0.6 km from the

site.

3. Storm water drainage system is existing

4. Domestic sewage & domestic garbage treatment is proposed in-house

5. Industrial wastewater generated from the industry is proposed to be treated in

Effluent Treatment Plant.

4.6 SOIL CLASSIFICATION

Soil characteristics, erosion aspects, soil fertility etc., have direct bearing on the

environment. Knowledge of soil parameters is essential for the planning and

implementation of green-belt. Hence it becomes important to study the soil

characteristics. Baseline data for land environment was collected at two locations in

order to assess the soil quality of the study area. Soil samples at a depth of one and half

feet were collected using sampling augers, spades and field capacity apparatus. The list

of locations and the orientation with reference to the project site are listed in table 4.3

Table: - 4.3 Physico-chemical characteristics of soil

Sl.No Characteristics Unit Results

1 pH No 7.4

2 Conductivity µS/Cm 375

3 Alkalinity as CaCO3 % 0.069

4 Chloride % 0.0055

5 Sulphate % 0.0004

6 Nitrate % 0.38

7 Nitrogen % 0.034

8 Total Phosphorous % 0.025

9 Phosphorous % 0.055

10 Calcium % 0.005

11 Sodium % 0.018

12 Potassium % 0.85

13 Iron % 0.0035

14 Organic matter % 2.3



15 Percolation &

Infiltration (cm/sec) % -Nil-

16 Water holding capacity % 11.0

17

Particulate distribution

a. Gravel

b. Sand

c. Silt

d. Clay

%

%

%

%

3.85

10.3

60.12

10.00

4.7 METEOROLOGICAL DATA

Assessment of the micro and macro meteorology is important from the standpoint of

understanding the nature and extent of air pollution in the study area. Climate has an

important role in the build-up of pollution levels. The climatic condition of the area

may be classified as moderately or seasonally dry, tropical or temperate savanna

climate with four seasons in a year. Winter is critical for air pollution build-up because

of frequent calm conditions with temperature inversions resulting in poor atmospheric

mixing, natural ventilation and high emission loads.

The classification of months according to the seasons is given in the following table.

Season Period Summer March to May

Monsoon June to September

Post monsoon October to November

Winter December to February

The meteorological data for various parameters from both primary & secondary sources

are detailed subsequently.

Sources of meteorological data

The meteorological data for Davangere District was obtained from two sources namely:

1. Project site (Primary data)



Primary Meteorological data of Project site (Kukkuwada), Davangere district.

Table 4.4 : Micro-meteorological data for Davangere district from January 1st 2013 to

December 31st 2013

Month Temperature

0C

Mean

Relative

Humidity

%

Monthly

average

Wind

speed, m/s

Monthly

average

rainfall

(mm)

Min Max

Jan 20.3 31.2 72 5.1 -Nil-

Feb 23.0 33.8 73 5.3 -Nil-

Mar 26.4 35.5 77 6.8 22.606

Apr 28.4 36.9 82 6.3 -Nil-

May 27.6 35.8 85 7.7 124.968

June 26.5 33.2 86 7.5 67.310

July 23.9 29.8 86 8.1 143.002

Aug 24.2 30.1 83 7.0 139.446

Sept 24.4 31.3 80 6.2 214.526

Oct 23.5 32.0 80 4.9 44.958

Nov 22.4 30.9 82 6.6 43.434

Dec 22.8 30.4 81 6.5 70.104



2 – 5 6 – 11 12 – 19 >19

C = calm condition in percent

The wind is blowing from North-East to South West

Figure 4.5: Wind rose diagram obtained from primary data for the project site during

sampling period (October to December 2013)

C

2.0

C



Table 4.5: Meteorological data of Davangere for the year 2013

Month Temperature

0C

Relative

Humidity,

%

Atmospheric

pressure (mb)

Wind

speed, m/s

Wind

direction

Inversion/

mixing

Height (m)

Cloud cover

(tenths)

Min Max Min Max Min Max Min Max Day Night Min Max

Jan 14 26.9 33 55 943 952 0 5.7 SW & NW 1675 756 2 10

Feb 16.2 27.8 32 63 941 951 0 5.7 W 2244 764 2 10

Mar 17.2 31.8 20 67 942 951 0 6.7 S 2701 956 2 10

Apr 17.8 35 27 71 939 949 0 5.7 E 2465 781 2 7

May 20.2 35.2 18 83 940 949 0 6.2 E 2621 870 2 8

June 20.2 32.8 33 84 938 945 0 10.8 NE 1693 1659 2 10

July 19.2 30.8 49 88 937 947 2.1 10.3 NE 1739 1606 3 10

Aug 19.5 30.1 47 85 938 946 0.5 10.3 E 1777 1626 3 10

Sept 16.2 30.9 26 79 938 948 0 10.8 NE 1834 1710 2 10

Oct 18.4 32.2 29 70 942 950 0 5.7 SW 2280 764 2 5

Nov 16.8 29.6 32 66 944 952 0 7.7 W 2187 1077 2 10

Dec 14.2 29.2 32 58 944 951 0 7.7 NW 1835 1033 2 10



4.7.1 TEMPERATURE

The mean maximum temperature is observed at (35.2°C) in the month of May and the

mean minimum temperature at (14°C) is observed in the month of January. In the

summer season the mean minimum temperature is observed during the month of

March (17.2°C). During the monsoon the mean maximum temperature is observed to

be 32.8°C in the month of June with the mean minimum temperature at 16.2°C during

September. By the end of September with the onset of post monsoon season (October -

November), day temperatures drop slightly with the mean maximum temperature at

32.2°C in October and mean minimum temperature is observed at 16.8°C in

November. The values are presented in table 4.5.

4.7.2 RELATIVE HUMIDITY

Minimum and maximum values of relative humidity have been recorded. The

minimum humidity is observed to be at 18% in the month of May and the maximum is

88% in the month of July. The mean minimum values of humidity during summer,

monsoon, post-monsoon and rainy seasons are 18%, 26%, 29% & 33% during the

months of May, September, October and January respectively. Similarly the maximum

values are 83%, 88%, 70%, and 63% in the months of May, July, October & February

during the summer, monsoon and post monsoon & winter seasons. The values are

presented in table 4.5.

4.7.3 RAINFALL

The monsoon in this region usually occurs twice in a year i.e., from June to September

and from October to November. The maximum annual rate of precipitation over this

region ranges between 0 to 4.57 mm/hr.

4.7.4 ATMOSPHERIC PRESSURE

The maximum and the minimum atmospheric pressures are recorded during all

seasons. In the summer season, the mean maximum and minimum pressure values are

observed to be 951 mb in the month of March and 939 mb in the month of April &

May. During monsoon season, the maximum pressure is 948 mb and minimum 937

mb. The maximum pressure during the post-monsoon season is observed to be 952 mb



in November and minimum pressure is 942 mb in the month of October. During the

winter season the minimum atmospheric pressure is 941 mb in February and the

maximum is 952 mb in the month of January. The values are presented in table 4.5.

4.7.5 INVERSION HEIGHT

The maximum inversion heights at the project site during the day time & night time for

all the months of the year is as given in the table 4.5. The maximum mixing height of

2701 m is observed during the month of March during the day time and 1710 m during

the month of September during the night time. The minimum inversion heights are

1675 m in the month of January during the day and 756 m during the night also in the

month of January.

4.7.6 CLOUD COVER

The minimum cover measured in the unit of tenths is 2 and the maximum observed

cloud cover is 10.

4.7.7 WIND

The data on wind patterns are pictorially represented by means of wind rose diagrams

for the entire year in figure 4.6 (for different seasons).

Predominant wind direction

Season Period Wind direction

Summer March to May East & South East

Monsoon June to September North East

Post monsoon October to November South West

Winter December to February West, North West & South West



Fig 4.6: Wind Rose diagrams

1. March to May (summer season)



2. June to September (monsoon season)



3. October to November (post monsoon season)



4. December to February (winter season)



4.8 SOCIAL INFRASTRUCTURE AVAILABLE

Primary health centers are located in some villages. For higher health care, people have

to depend on nearby towns. Co-operative, nationalized banks service is available in

some villages of the area. Rural post offices are available at most of the locations. There

are no good roads except the approach roads and very few private buses are operating.

No harbors, air ports and railway station are located in the study area. There are no

mining or other developmental activities. Government electric supply is provided to

meet the domestic lighting and irrigation requirements.

The rural mass is calm, peace loving and hard working. There are no reported epidemic

diseases in the region. General health status of the people is satisfactory. The literacy

rate in the region is about 60%.

The list of hospitals & other infrastructural facilities available in the vicinity of the

proposed industry is tabulated below.

Table 4.6: List of health-care facilities in the surroundings

Sl.

No.

Hospital Distance from the

industry

Direction

w.r.t. the

industry

1 Prathamika Arogya Kendra 9.30 South West

2 Thyavanige primary health

centre

8.83 South

3 Davanagere Heart Hospital 13.71 North

4 Kadli Hospital 14.23 North

5 Davangere city railway

station

15.73 North

6 Davangere KSRTC Bus Stand 15.28 North

Note: All distances mentioned are aerial.



CHAPTER 5

PLANNING BRIEF

5.1 PLANNING CONCEPT

M/s. Davangere Sugars Company Ltd. has planned to expand its cane crushing capacity

from 3500 to 5000 TCD and power plant from 24.0 MW to 54.0 MW.

5.2 POPULATION PROJECTION

The existing co-gen sugar industry is having a total of 400 direct employees including

Manager, office staff, skilled & unskilled workers.

Indirect employment of 800 employees towards transportation, vehicle maintenance,

petty shops etc.

5.3 LAND-USE PLANNING

The industry is designed envisaging adequate area for landscape, process section and

utilities, storage areas for raw materials, finished products and internal movement of

vehicles as shown in the table below.

Table 5.1: Land Utilization pattern

Land Utilization Existing

(hectares)

Proposed

(hectares)

After expansion

(hectares)

Built up Area 28.45 1.5 29.95

Pollution Control

facilities

4.06 --- 4.06

Greenbelt area 21.86 --- 21.86

Open area for future

expansion

7.57 -1.5 6.07

Total 61.94 Nil 61.94

The site area details are shown in the plot area drawing appended.



5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND



The infrastructure demand for the project is detailed in the following sections

5.4.1 ROADWAYS

Roadways are required for

Transportation of materials & workers during construction phase &

Transportation of employees to & from the industry during the operation phase.

The major roadways in the vicinity of the project site are shown in section 4.1,

Chapter 4

5.4.2 WATER SUPPLY & SEWERAGE INFRASTRUCTURE

Fresh water requirement to the industry will be met from the Shyagalle Halla

located at about 0.6 km North to the site. The industry has obtained permission

for drawal of water from the Shyagalle Halla is appened as annexure - A.

The domestic sewage will be stabilized in septic tank & the overflow from septic

tank will be treated in sugar plant ETP.




CHAPTER 6

PROPOSED INFRASTRUCTURE

6.1 INDUSTRIAL AREA (PROCESSING AREA)



6.2 GREEN-BELT

The industry is designed with utmost consideration to the environment. A total area of

21.86 hectare i.e. 35.29% of the total plot area is reserved exclusively for green-

belt/landscape development.

6.3 SOCIAL INFRASTRUCTURE

Detailed in Chapter 4, Section 4.8.

6.4 CONNECTIVITY

Detailed in Chapter 4, Section 4.1.

6.5 DRINKING WATER MANAGEMENT


about 0.6km North to the site. The industry has obtained permission for drawal of water

from the Shyagalle Halla.

6.6 SEWERAGE SYSTEM

The domestic sewage will be stabilized in septic tank & the overflow from septic tank





6.7 INDUSTRIAL WASTE MANAGEMENT

The industrial wastewater is proposed to be treated in Effluent Treatment Plant.

6.8 SOLID WASTE MANAGEMENT

The solid wastes or by-products produced in sugar industry such as bagasse, press mud

and molasses are made use as valuable resources as discussed below. Other solid

wastes in the industry are boiler ash, lime sludge and ETP sludge. Spent lubricating and

cooling oils produced in the industry are specified as hazardous wastes and these are

disposed as per the prescribed guidelines.

Bagasse

Bagasse is the fibre material left out after extraction of the treated sugarcane juice. The

average bagasse content in sugarcane is 30%. Major quantity of the bagasse produced

will be utilized in the plant itself as a boiler fuel. A small quantity of bagasse will also

be used as filter aid in the plant. The saved bagasse will be stored in the storage yard for

use in off season.

Molasses

Molasses is produced in the industry at average of 4% on sugarcane crushed. It contains

large percentage of non crystallisable sugar and is a valuable source of raw material for

manufacture of ethyl alcohol or other products such as oxalic acid, lactic acid etc.,

Molasses is also used as nutritive additive in manufacture of cattle feed.

Press mud

Press mud is produced in the industry at an average of 4% on cane crushed in the sugar

plant. It contains fibrous material and crop nutrients such as phosphorous and

potassium and therefore it is disposed to farmers for use in agricultural land. The press

mud will be composted along with spent wash generated from the distillery. The

composted press mud is a bio-manure containing, fortified plant nutrient such as

potassium, phosphorous and nitrogen.



Boiler ash

Boiler ash is un-burnt matter left out in the furnace after complete burning of fuel in the

boiler. Ash produced from bagasse/agro waste will be 1.0%. The ash contains plant

nutrients. It is a non-toxic material. It can be used as soil conditioner in agriculture land

or in brick making. It can also be composted along with press mud to produce bio-

manure.

ETP & lime sludge


industry. Major quantity of the sludge from secondary clarifiers is re-circulated to the

aeration tank. Excess of sludge from clarifiers is dewatered and partially dried in sludge

drying beds. The sludge with an average moisture content of 50% produced from ETP

will be 100 kg/d.

Hydrated lime is used in the plant for purification of juice and therefore, the quantity of

lime sludge produced from the plant is small. The sludge with an average moisture

content of 50% will be produced from lime plant. A maximum of about 0.1 T /d of

sludge will be produced from lime plant. The quantities of various solid wastes

produced from the proposed sugar industry of 5000 TCD are summarized in table 6.1


Solid waste % on

cane

Existing Expansion


Bagasse

(50% moisture) 30 1050 1500

Molasses 4 100 180

Press Mud 4 140 180

Boiler Ash

Season

Off season

-

-

13.05

10.50

- 13.5

19.2





6.9 POWER REQUIREMENT & SUPPLY SOURCE

The existing co-gen sugar industry is 24 MW power plant and the present project is for


utilization of power is given below. During expansion additional power unit consisting

of 150 T/h boiler and 30 M.W T.G. set will be installed. The proposed power plant

needs 2.1 M.W. power for its operation. The power generation in season and off season

with captive power use and power export to the grid is provided below.


period

Existing

Addition

After

Expansion

Power generation

Season

17.0 MW

30.0 MW

47.0 MW

Off-season

24.0 MW 30.0 MW 54.0 MW

Captive use of power Season

7.0 MW

2.1 MW

9.1 MW


Power Export

Season

10.0 MW

27.9 MW

37.9 MW

Off-season

22.0 MW 27.9 MW 49.9 MW



CHAPTER 7

REHABILITATION & RESETTLEMENT PLAN


from 3500 to 5000 TCD and power plant from 24.0 MW to 54.0 MW. No home

outstees/land outstees are expected & hence no rehabilitation plan is envisaged.



CHAPTER 8

PROJECT SCHEDULE & COST ESTIMATES

8.1 TIME SCHEDULE

The time schedule for completion of the proposed project is given in the following

table

Particulars Time schedule

Construction and implementation December 2014

Completion and commissioning January 2015

8.2 ESTIMATED PROJECT COST

The estimated cost for the Existing and proposed project and for pollution Control

facilities are given below.

Sl. No. Particulars

Amount, Rs Lakhs

Existing Proposed

1 Capital Investment on proposed

project

Power plant

15,729

14,625

Sugar plant 4,160

2 Capital Investment On Pollution

Control Facilities & environmental

protection 600

400

Total 16,329 19,185



CHAPTER – 9

ANALYSIS OF PROPOSAL

Observing the demographic pattern of the study area it can be inferred that

occupational pattern is a mixture of industrial and agricultural. The proposed project

will increase the employment potential by creating direct and in-direct employment

opportunities and thus be beneficial for the local populace (about 2,581 people are

non-workers in Kukkawada according to the census data).

The management of the industry proposes to give preference to local people

with both direct and indirect employment.



Annexure – A

WATER WITHDRAWL AGREEMENT



Annexure – B

Project site layout

EXPANSION

AREA

Documents

PRE-FEASIBILTY REPORT FOR THE