Environmental Management Plan for

Obtaining
Environmental Clearance

FOR THE PROPOSED DISTILLERY UNIT

By

M/s. SPAC Starch Products (India) Private Limited

SF. No. 118/2, 118/3, 118/4, 118/7, 118/8, 118/9, 118/10, 118/11,
118/12, 118/13, 118/14, 118/18, 119/13, 188/1A, 189/8, 189/9,
Mugasipudur Village,
Anthiyur Taluk,
Erode District, Tamil Nadu

MoEF&CC Gazette Notification S.O. 2339(E) dated 16.06.2021

[Cat. 5G(a) (Grain based distilleries producing ethanol, solely to be used for Ethanol
Blended Petrol Programme of the Government of India)]

(Accredited by NABET, NABL, BIS, MoEF, MoUD, FSSAI)

(Certified by ISO 9001: 2008 / 14001: 2004 / BS OHSAS 18001)
 TABLE OF CONTENTS

CONTENTS PAGE NO.

BASELINE INFORMATION (FORM 1) 1-15
CHAPTER I 16 - 26
INTRODUCTION 16

1.1 GENERAL 16
1.2 Details of the Project Proponent 17

1.3 Project Need and Importance 17

1.4 Project Categorization 18

1.5 Salient Features of the Project 18
1.6 Preview of the Project 20
1.7 Location (Map Showing General Location, Specific location And
22
Project Boundary & Project Site Layout) With Coordinates
1.8 Nature, Size, Investment Cost, Demand And Category Of The
25
Project

1.8.1 Nature and Size of the Project 25

1.8.2 Demand and Supply Gap 26

1.8.3 Employment Generation (Direct And Indirect) Due To The Project 26

CHAPTER 2 27 - 59

PROJECT AND BACKGROUND INFORMATION 27

2.1 Type of Project 27
2.2 Need for the Project 27
2.3 Process Description 30
2.4 Manufacturing Process 30
2.5 Bulk Storage Facility 40
2.6 Power Requirement 40
2.7 Quantity of Water Requirement, Wastewater Generation and 44
Scheme for Management

2.7.1 Source of Water and Power requirement 44

2.7.2 Wastewater Generation 46
2.7.3Solid waste Generation 46
2.7.4 CPU Treatment System 47
2.8 Environmental Management Plan 56
2.8.1 Air Pollution Control 56
2.8.2 Odour Control Measures 58
2.8.3 Water Environment 58
2.8.4 Water Pollution Control 59
2.8.5 Solid Waste Management 59
2.8.6 Noise Environment 69
2.8.7 Greenbelt Development and Plantation 59
CHAPTER 3 60 - 106

ANTICIPATED ENVIRONMENTAL IMPACTS DUE TO THE

60
PROJECT

3.1 GENERAL 60
3.1.1 Identification, Quantification and Rating of Impacts 60
3.1.2 Rating of Impacts 61
3.2 Project Location 62
3.2.1 Land Use and Land Cover in the Study Area 62
3.3 Objectives of Environmental Management Plan 63
3.4 Environmental Management Cell (EMC) 63
3.5 Environmental Policy 66
3.6 Environmental Training 67
3.7 Other Responsibilities of the Cell Will Include 68
3.8 Anticipated Accidents and Mitigation Measures 68
3.9 Mitigation measures 69
3.10 Safety/Environmental Impact and Mitigation Measure 69
3.11 Environmental Impacts during Construction and Operation Phase 69
3.11.1 Construction Phase 70
3.11.2 Environmental Impact during Operation Phase 70
3.12 Pollution Control Measures and Management Plan 84
3.12.1 Air Pollution Management Plan 84
3.12.2 Action Plan for Control and Monitoring of Fugitive Emissions 84
3.12.3 Noise Pollution Management Plan 85
3.12.4 Water Requirement 85
3.12.5 Solid Waste Generation & Disposal 87
3.12.6 Hazardous waste generation, storage & disposal 88
3.12.7 Waste Minimization, (Reuse, Recycle & Recover Techniques),
88
Energy and Natural Resource Conservation Measures

3.13 Storm Water Management 89

3.13.1 Storm Water and Irrigation Management Plan 89
3.13.2 Storm Water Generated Within Factory Premises 89
3.14 Greenbelt Belt Development 90
3.15 Energy Conservation Measures 91
3.16 Good Housekeeping 92
3.17 Environment, Health and Safety (EHS) 92
3.18 Work Zone Monitoring 93
3.19 Odour Sources and Control Measures 93
3.20 Traffic Management 94
3.20.1 Connectivity 94
3.20.2 Impact of Transportation 95
3.21 Summary of Impacts 95
3.22 Risk Assessment Studies 97
3.22.1 Risk Assessment for Boiler, Turbines and Compressors Boiler 97
3.22.2 Inference 100
3.22.3 Risk Mitigation Measures -Safety Measures for Transportation,
102
Storage & Handling of Chemicals

3.22.4 Safety Measures to Prevent Spillage/Leakage of Toxic Chemicals 102

3.22.5 Specific Recommendations Based on Hazard and Severity
103
Mapping

3.22.5.1 Mechanical and Equipment Integrity 103

3.22.5.2 Management Approach 103

3.23 Occupational Health and Safety 103
3.23.1 Occupational Health and Safety Precautions 104
3.23.2 Fire Protection and Fighting System 105
3.24 Occupational Health Centre 106
3.24.1 Frequency & Parameters of Health Check-Up 106
CHAPTER IV 107 - 128

ENVIRONMENT MONITORING PLAN 107

4.1 TECHNICAL ASPECTS OF MONITORING THE EFFECTIVENESS OF
107
MITIGATION MEASURES

4.2 Purpose of Environmental Monitoring 107

4.2 MEASUREMENT METHODOLOGY 109

4.2.1 AIR ENVIRONMENT 109
4.2.1.1 AIR QUALITY 109

4.2.2.2 AMBIENT AIR QUALITY 112

4.2.2 Noise Environment 120
4.2.3 Water Environment 120
4.3 Measurement Location and Frequency 120
4.4 Measurement methodology and Cost of Monitoring 122
4.5 Other Environment Related Monitoring 123
4.6 Online Monitoring 124
4.7 REPORTING & DOCUMENTATION 125
4.8 Activities and Responsibilities of EMC 125
4.9 Budget for Monitoring and Procurement Schedule 126
4.10 Emergency Preparedness and Response Structure 127
CHAPTER V 128

PROJECT BENEFITS 128

5.1 Corporate Environmental Responsibility (CER) 128

5.2 Employment Potential 128

5.3 Other Tangible Benefits 128

CHAPTER VI 129 -131

SUMMARY & CONCLUSION 129

6.1 Overall Justification for Implementation of the Project 129

6.2 Summary of Mitigation Measures 130

CHAPTER VII 132 - 133

DISCLOSURE OF CONSULTANTS ENGAGED 132

7.1 The Name of the Consultant Organization Engaged 132

 LIST OF TABLES

TABLES PAGE NO.

Table 1.1 Salient Features of the Project 18
Table 1.2 List of raw materials 25
Table 1.3 List of Chemicals and Enzymes Used 25
Table 2.1 Air pollution sources fuel requirement and APC measures 44

Table 2.2 Types of fuel & mode of transportation for distillery 44

Table 2.3 Storage of Raw Materials 44

Table 2.5 Water Requirement Details 45

Table 2.6 Wastewater Generation 47

Table 2.7 Details of Solid Waste Generation 47

Table 2.8 Characteristics of Wastewater 48

Table 2.9 Details of the Treatment Units for CPU Treatment 48

Table 2.10 List of Equipments used in CPU 50

Table 2.11 Scope of Supply in CPU 51

Table 2.12 Specification for Electro Static Precipitator 58

Table 2.13 Solid Waste Management 60

Table 2.14 List of Big Trees for Proposed Plantation 62

Table 3.1 Matrix for identification and rating of impacts 64

Table 3.2 Criteria for rating - scale, severity, probability and duration 64

Table 3.3 Environment Management Cell 67

Table 3.4 Responsibilities of Environment Cell personal & others 68

Table 3.5 Environmental impacts & mitigation measures during construction 75

phase
Table 3.5 Environmental Impact and Mitigation Measures during Operation 79
Phase
Table 3.6 Municipal Solid Waste Generation and its Disposal 91

Table 3.7 Rating of Environmental Impacts 99

Table 3.8 Severity, Probability and Duration of Environmental Impacts 100

Table 3.9 Risk Associated with Boiler Operation and Mitigation Measures 101

Table 3.10 Risk Associated with Turbine Operation and Mitigation Measures 102

Table 3.11 Risk Associated with Compressor Operation and Mitigation 103
Measure
Table 3.12 Risk Mitigation Measure for Ethanol Plant 104

Table 3.13 Preventive Action and Corrective Action for Impacts 107

Tale 3.14 Budget Allocation for Occupational Health and Safety 109

Table 3.15 Health check-up parameters 110

Table 4.1 Site Specific Micro Meteorology Data (March 2022 to May 2022) 114

Table 4.2 Air Quality Results 122

Table 4.3 Environmental Attributes, Frequency and Parameters 124

Table 4.4 Cost of Monitoring for Environmental Parameters 126

Table 4.5 Other environment related monitoring activities required 127

Table 4.6 Locations where online monitoring is proposed to be provided 128

Table 4.7 Investments on Environmental Protection Measures (Rs. in Lakhs) 130

Table 5.1: Budget allocation during proposed expansion for CERs 132

Table 6.1. Mitigation Measures for Proposed Project 124

 APPENDIX I
(See paragraph – 6)
FORM 1
Basic Information
S. No. Item Details
1. Name of the Project : M/s. SPAC Starch Products (India) Private
Limited (BIOETHANOL DIVISION)
2. S. No. of the Schedule : 5 g (a)
3. Proposed : Fuel grade Bio Ethanol -160 KLPD
capacity/area/length/tonnage to be DDGS (for Broken rice) -10320 TPA
handled/command area/lease DDGS (for Maize) – 17844 TPA
area/number of wells to be drilled. CO2 – 14549.54 TPA
Technical Alcohol – 5.24 KLPD
Fusel Oil – 0.16 KLPD
Co- gen Power – 4.6 MW
4. New/Expansion/Modernization : New
5. Existing Capacity/Area etc. : -
6. Category of Project i.e. „A‟ or „B‟ : Category „B2‟ 5 G(a)
Grain based distilleries producing ethanol,
solely to be used for Ethanol Blending
Petrol Programme of the Government of
India.
7. Does it attract the general condition? :
No
If yes, please specify.
8. Does it attract the specific condition? : No.
If yes, please specify. The proposed project site is located in
Unclassified Area. (Now Applied for
conversion of Industrial Land Use).
9. Location
Latitude: 11°35'52.64"N
Longitude: 77°40'27.92"E
Plot/Survey/Kharse No : SF. No. 118/2, 118/3, 118/4, 118/7, 118/8,
118/9, 118/10, 118/11, 118/12, 118/13,
118/14, 118/18, 119/13, 188/1A, 189/8,
189/9,
Village : Mugasipudur
Tehsil : Anthiyur
District : Erode
State : Tamilnadu
10. Nearest railway station/airport : Railway Station:
along with distance in kms Erode Railway Junction – 37 km

1
 Airport: Coimbatore – 95.2 Km

11. Nearest Town, city, District : Nearest Town: Anthiyur – 10.5 km

Headquarters along with distance in Nearest City: Erode – 28.9 Km
kms District Head Quarters: Erode – 28.9
km.
12. Village Panchayats, Zilla Parishad, Anthiyur Town Panchayat,
Municipal corporation, Local Body Anthiyur Taluk,
(complete postal addresses Erode - District,
telephone no. to be given) Tamil Nadu. 638314
13. Name of the applicant : M/s. SPAC Starch Products (India)
Private Limited
14. Registered Address : D4/2, Vijayaraghava Manor
Vijaya Raghava Road
Teynampet
Chennai
Tamilnadu – 600 018
15. Address for Correspondence : : SPAC Starch Products (India) Private
Limited,
S.F.No : 65,66,67, Poonachi Village
Anthiyur Taluk, Erode - 638314
Name : S. Balamurugan
Designation (Owner /Partner/CEO) : Associate Vice President (Operation &
Maintenance)
Address : D4/2, Vijayaraghava Manor
Vijaya Raghava Road
Teynampet,
Chennai
Tamilnadu
Pin Code : 600 018
E-mail : [email protected]
Telephone/Mobile No. : 04256 257901 Mob: 9842911175
Fax No. : --
16. Details of Alternative Sites :
examined, if any. Location of these Not Applicable
sites should be shown on a topo
sheet.
17. Interlined Projects : Not Applicable
18. Whether separate application of :
Not Applicable
interlined project has been submitted
19. If yes, date of submission : --
20. If no, reason : This is a Proposed Distillery unit.

2
21. Whether the proposal involves :
approval/clearance under:
(a) The Forest (Conservation) Not Applicable
Act, 1980
(b) The Wildlife (Protection) Act,
1972
(c) The C.R.Z. Notification, 1991
22. Whether there is any Government :
Not Applicable
Order/Policy relevant relating to the
site?
23. Forest land involved (hectares ) : Not Applicable
24. Whether there is any litigation : Not Applicable
pending against the project and/or
land in which the project is propose
to be set up
(a) Name of the Court
(b) Case No.
(c) Orders/directions of the Court, if
any and its relevance with the
proposed project.
 Capacity corresponding to sectoral activity (such as production capacity for
manufacturing, mining lease area and production capacity for mineral production, area
for mineral exploration, length for linear transport infrastructure, generation capacity for
power generation etc.,)

Activity

1. Construction, operation or decommissioning of the Project involving

actions, which will cause physical changes in the locality (topography,
land use, changes in water bodies, etc.)

Details thereof (with

approximate quantities
S.
Information/Checklist confirmation Yes/No /rates, wherever possible)
No.
with source of information
data
Permanent or temporary change in land
use, land cover or topography including No No permanent or temporary
1.1
increase in intensity of land use (with change in land use.
respect to local land use plan)
Clearance of existing land,
Clearance of existing land, vegetation
1.2 No building and vegetation
and buildings?
will not be undertaken.

3
1.3 Creation of new land uses? No Not applicable
Pre-construction investigations e.g. bore Soil testing through bore
1.4 Yes
houses, soil testing? hole drilling will be done.
1.5 Construction works? Yes Proposed distillery unit.

1.6 Demolition works? No Not applicable

The local labors will be
Temporary sites used for construction utilized for the construction
1.7 works or Housing of construction No purpose; hence no housing
workers? facility is proposed for the
construction workers.
Above ground buildings, structures or
Will be carried out after
1.8 earthworks including linear structures, Yes
getting clearance.
cut and fill or excavations
Underground works including mining
1.9 No Not Applicable
or tunneling?
1.10 Reclamation works? No Not Applicable

1.11 Dredging? No Not Applicable

1.12 Offshore structures? No Not Applicable

Production and manufacturing Enclosed in the Pre-
1.13 Yes
processes? Feasibility Report
Suitable storage facilities
Facilities for storage of goods or
1.14 Yes are available for goods or
materials?
materials.
Facilities for treatment or disposal of Enclosed in the Pre-
1.15 Yes
solid waste or liquid effluents? Feasibility Report
Operations key personnel
will be engaged in existing
Facilities for long term housing of quarter‟s facility. Workers
1.16 Yes
operational workers? will be engaged on daily
basis (8Hrs). Toilet facilities
along with STP.
Existing Anthiyur-
New road, rail or sea traffic during Ammapettai road (NH 28)
1.17 No
construction or operation? will be used. No new roads
envisaged in this project
New road, rail, air waterborne or other
transport infrastructure including new Existing transport facilities
1.18 No
or altered routes and stations, ports, will be utilized.
airports etc?

4
 Closure or diversion of existing
transport routes or infrastructure No Closure or diversion of
1.19 No
leading to changes in traffic existing transports routes.
movements?
New or diverted transmission lines or No transmission/pipelines
1.20 No
pipelines? are in the project site.
Impoundment, damming, culverting,
1.21 realignment or other changes to the No Not applicable.
hydrology of watercourses or aquifers?
1.22 Stream crossings? No Not applicable.
Kaveri River will be the
source of water. The order
obtained from Public
Abstraction or transfers of water from
1.23 Yes Works Department, Erode.
ground or surface waters?
G.O No: 282 dated 26-10-
2018 (Public Works
Department).
Changes in water bodies or the land Not applicable
1.24 No
surface affecting drainage or run-off?

The existing roadways/

Transport of personnel or materials for facilities will be used for the
1.25 construction, operation or Yes transport of materials and
decommissioning? personnel through public
transports only.
Long-term dismantling or
1.26 No Not envisaged in the project.
decommissioning or restoration works?
Ongoing activity during
1.27 decommissioning which could have an No Not Applicable
impact on the environment?
Influx of people to an area in either
1.28 No Not Applicable
temporarily or permanently?
1.29 Introduction of alien species? No Not Applicable
Loss of native species or genetic Not Applicable
1.30 No
diversity?
1.31 Any other actions? No Not Applicable

5
 2. Use of Natural resources for construction or operation of the Project (such as land,
water, materials or energy, especially any resources which are non-renewable or in
short supply):
Details thereof (with
S.
Information/checklist Yes/ approximate quantities /rates,
No
confirmation No wherever possible) with
.
source of information data
No Unclassified Area (Now
2.1 Land especially undeveloped or Applied for conversion of
agricultural land (ha)
Industrial Land Use).
Kaveri River will be the
source of water. The order
Yes obtained from Public Works
Department, Erode.
Water (expected source &
2.2
competing users) unit: KLD Fresh Water consumption
during start-up is 2899 KLD.
Fresh Water consumption at
Steady State Operations with
recycle streams is 1036 KLD
2.3 Minerals (MT) No Not Applicable

All construction material –

Construction material - stone,
stone, aggregates, and
2.4 aggregates, sand / soil (expected Yes
sand/soil will be bought from
source - MT)
the authorized Seller.

2.5 Forests and timber (source - MT) No Not applicable

Total Power requirement of

the Plant will maximum of
Yes 3380 KWH for Broken Rice &
3550 KWH for Dry Maize 5.3
Energy including electricity and
TPH (70%) Rice Husk and 1.8
2.6 fuels (source, competing users)
TPH (30%) Imported coal
Unit: fuel (MT), energy (MW)
(For Broken Rice) 5.6 TPH
(70%) Rice Husk and 1.9 TPH
(30%) Imported Coal (For
Dry Maize)
Any other natural resources (use
2.7 No Not applicable
appropriate standard units)

6
3. Use, storage, transport, handling or production of substances or materials, which
could be harmful to human health or the environment or raise concerns about
actual or perceived risks to human health.

Details thereof (with

approximate quantities /
S. No. Information/Checklist confirmation Yes/No rates, wherever
possible) with source of
information data
Use of substances or materials, which are
hazardous (as per MSIHC rules) to human
3.1 No Not applicable
health or the environment (flora, fauna, and
water supplies).
Changes in occurrence of disease or affect
3.2 disease vectors (e.g. insect or water borne No Not applicable
diseases).

This project will

No improve the welfare of
Affect the welfare of people e.g. by changing nearby village people
3.3 by raising the living
living conditions?
standards and
employment
opportunities.

Vulnerable groups of people who could be

3.4 affected by the project e.g. hospital patients, No Not applicable
children, the elderly etc.,

3.5 Any other causes No Not applicable

4. Production of solid wastes during construction or operation or decommissioning

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

4.1 Spoil, overburden or mine wastes No Not Applicable

7
 Domestic wastes will be
Municipal waste (domestic and or
4.2 Yes disposed to local
commercial wastes)
panchayat.
The hazardous waste
(Used Oil) generated
from the proposed unit
will be 80 L/year, and
stored in HDPE Barrel.
Hazardous wastes (as per Hazardous Waste This will be send to send
4.3 Yes
Management Rules) to TNPCB authorized
recycler.
DM plant used resins
below 60 kg/year will
be sent to TNPCB
authorized recycler.
Boiler Ash, 25.78 TPD
Yes of Fly Ash will be
generated (Broken
4.4 Other industrial process wastes
Rice) 27.34 TPD of Fly
Ash will be generated
(Dry Maize)
No Not Applicable
4.5 Surplus product

Boiler ash will be used

Sewage sludge or other sludge from effluent Yes for making fly ash
4.6
treatment bricks.
Yes Construction waste
4.7 Construction or demolition wastes will be used for
leveling.
No Not Applicable
4.8 Redundant machinery or equipment

Soil contaminated with

cement is used at land
Yes fill. Construction
4.9 Contaminated soils or other materials
waste and cement
contaminated soil will
be used for land filling.
No Not Applicable
4.10 Agricultural wastes

No Not Applicable
4.11 Other solid wastes

8
5. Release of pollutants or any hazardous, toxic or noxious substances to air (Kg/hr)

Details thereof (with

approximate quantities /
S. No. Information/Checklist confirmation Yes/No rates, wherever possible)
with source of
information data
For the emission from
5.1 Emissions from combustion of fossil fuels Yes Boiler (40 TPH) ESP with
from stationary or mobile sources stack of 68 Mtr. height
will be provided.
Fermenter - wet scrubber
followed by stack with
the height of 15 Mtrs will
5.2 Emissions from production processes Yes
be provided. Alternately
CO2 plant installation
shall be Considered.
Emission will be arrested
Emissions from materials handling including by an adequate
5.3 Yes
storage or transport mitigation measure
during storage and
transport.
Maximum construction
Emissions from construction activities works will be done
5.4 Yes
including plant and equipment manually and with well-
maintained equipment‟s.
Dust collectors system will
be provided at various
material transfer points
Yes during the operation
phase and proper
Dust or odors from handling of materials
maintenance will be done
5.5 including construction materials, sewage and
for arresting odour.
waste
Extensive greenbelt
development will also
reduce the odour in
greater extent. Hence,
odour is not envisaged.
There will no
5.6 Emissions from incineration of waste No incineration of waste in
this project.

9
 Emissions from burning of waste in open air No such activities will be
5.7 No permitted.
(e.g. slash materials, construction debris)
No emission from any
5.8 Emissions from any other sources No other source.

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

Details thereof (with
approximate quantities /
rates, wherever possible)
S. No. Information/Checklist confirmation Yes/No
with source of information
data with source of
information data
All the equipments utilized
are properly enclosed to
From operation of equipment e.g. engines, avoid noise and heat. The
6.1 Yes
ventilation plant, crushers levels will be monitored
continuously using in-house
infrastructure facility.

All process will be in closed

6.2 From industrial or similar processes No condition.

6.3 From construction or demolition No Not Applicable.

6.4 From blasting or piling No Not Applicable.

Will be controlled through

proper maintenance of
No
6.5 From construction or operational traffic construction equipment‟s/
vehicles.

No Not Applicable.
6.6 From lighting or cooling systems

No Not Applicable.
6.7 From any other sources

10
7. Risks of contamination of land or water from releases of pollutants into the
ground or into sewers, surface waters, groundwater, coastal waters or the sea:

Details thereof (with

approximate quantities /
S. No. Information/Checklist confirmation Yes/No rates, wherever possible)
with source of
information data
From handling, storage, use or spillage of
7.1
hazardous materials No Not Applicable.
From discharge of sewage or other effluents
Sewage will be disposed
7.2 to water or the land (expected mode and
Yes through proposed STP
place of discharge)
(Capacity - 10 KLD).
Emission will be well
By deposition of pollutants emitted to air into
7.3 Yes below the SPCB/CPCB
the land or into water
limit.
7.4 From any other sources No Not Applicable.
Is there a risk of long term build-up of
7.5 pollutants in the environment from these No Not Applicable.
sources?

8. Risk of accidents during construction or operation of the Project, which could

affect human health or the environment

Details thereof (with

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

No Minimal quantity of Hazardous

material will
be used. Precautionary measures
From explosions, spillages, fires etc will be provided as per the
8.1 from storage, handling, use or norms. Fully automated fire
production of hazardous substances hydrant system will be provided
in the entire
campus.
Fire proof motors, lightings and
fire detector will be provided.
8.2 From any other causes No -

11
 The project site falls under
seismic zone – II according to
No the Indian Standard Seismic
Zoning Map. Further it is not
Could the project be affected by
flood prone or landslide prone
natural disasters causing
area.
8.3 environmental damage (e.g. Floods,
Hence, no risk due to natural
earthquakes, landslides, cloudburst
hazards is envisaged. However
etc)?
suitable seismic coefficients in
horizontal and vertical
directions will be adopted while
designing the structures.

9. Factors which should be considered (such as consequential development) which

could lead to environmental effects or the potential for cumulative impacts with
other existing or planned activities in the locality
Details thereof (with
approximate quantities/rates,
S. No. Information/Checklist confirmation Yes/No
wherever possible) with source
of information data
Lead to development of supporting No The proposed project site
utilities, ancillary development or located in unclassified area.
development stimulated by the project
which could have impact on the The site consists of all
environment e.g.: supporting infrastructure
Yes facilities like well laid roads,
• Supporting infrastructure (roads, water, Electricity and water
power supply, waste or waste water treatment facilities.
treatment, etc.)
No housing development is
proposed.
9.1 No
Not applicable (for Extractive
• Housing development industries, Supply industries &
others)

No N/A
• Extractive industries
N/A

• Supply industries No

• Other No

12
 Lead to after-use of the site, which This will not have an impact on
9.2 could have an impact on the No the environment.
environment
This project will enhance the
Social Welfare of the
surrounding villages through
9.3 Set a precedent for later developments No opportunities and Corporate
Social/Environment
Responsibility of the project
proponent.
The mitigation measures and
Have cumulative effects due to regular monitoring will be
9.4 proximity to other existing or planned No done in and around the project
projects with similar effects site as per PCB norms.

10. Environmental Sensitivity

Aerial distance (within 15 kms)

Name/
S. No. Areas Proposed project location
Identity
boundary
The proposed project site does
not fall under international
conventions, national or local
legislations. No ecological
sensitive ecosystem, notified
reserve forests/wildlife area
Areas protected under located around the industry.
international conventions, Yes
1 national or local legislation for The proposed grain-based
their ecological, landscape, distillery will be designed as a
cultural or other related value Zero Effluent discharge plant
which comes under Category B
project. This project is proposed
under Ethanol Blending
Programme of India. The
proposed site project site is
located in unclassified.

13
 Areas which are important or Kaveri River – 6.34 Km (SE)
sensitive for ecological reasons - Channel – 1.3 Km (W) (Un-
2 Wetlands, watercourses or other Yes notified watercourse)
water bodies, coastal zone, Anthiyur Periya Yeri – 9.2 Km
biospheres, mountains, forests (NW)
Areas used by protected,
important or sensitive species of
No Nil
3 flora or fauna for breeding,
nesting, foraging, resting, over
wintering, migration
Inland, coastal, marine or No Nil
4
underground waters

5 State, National boundaries No Nil

Routes or facilities used by the
6 public for access to recreation or No Nil
other tourist, pilgrim areas

7 Defense installations No Nil

Patlur Village – 1.30 km, W
Nagireddipalayam – 2.2 km, W
8 Densely populated or built-up area Yes Podapadi Village - 3.30 Km, E
Podiipatti Village– 4.09 Km, E
Anthiyur Town – 10.5 km, W
Schools & Colleges:
1. SET Higher Secondary School –
1.1 km (E)
PUM School, Sembadapalayam –
2.15 Km (S)
3. Vidhayalam Tuition Tutorial
College – 6.11 Km (NW)
Religious Places:
Areas occupied by sensitive man- 1. Nandeeshwarar Temple –
made land uses (hospitals, schools, 1.75 km(W)
9 Yes
places of worship, community 2. Shri. Semmunisvarar Temple–
facilities) 2.61 Km (NW)
3. Ayyanarappan Kovil – 2.72
Km (N)
4. Varakoor Kaani Ayyanar -
2.92 km (NW)
5. Selampooramman Kovil –
5.47 km (SW)
6. Periyandhichi Amman
Temple – 8 km(SE)

14
 Areas containing important, high
quality or scarce resources
10 (ground water resources, surface No Nil
resources, forestry, agriculture,
fisheries, tourism, minerals)
Areas already subjected to
pollution or environmental Nil
11 damage. (those where existing legal No
environmental standards are
exceeded)
This area is generally plain not
prone to any natural disasters.
Areas susceptible to natural hazard The area under study falls in
which could cause the project to Zone-II, according to the Indian
present environmental problems Standard Seismic Zoning Map.
12 No
(earthquakes, subsidence, landslides, Suitable seismic Co- efficient in
erosion, flooding or extreme or adverse horizontal and vertical
climatic conditions) directions respectively, has to
be adopted while designing the
structures.

‘’I hereby given undertaking that the data and information given in the application and
enclosures are true to the best of my knowledge and belief and I am aware that if any part of
the data and information submitted is found to be false or misleading at any stage, the project
will be rejected and clearance give, if any to the project will be revoked at our risk and cost.

Date: 02/08/2022

Place: ERODE

Signature of the Applicant

With Name and Full Address
(Project Proponent / Authorized Signatory)

15
 CHAPTER I
INTRODUCTION
1.1 GENERAL
 The Government of India launched Ethanol Blended Petrol (EBP) Programme
in January, 2003 for supply of 5% ethanol blended Petrol. Subsequent to this,
Ethanol Blended Petrol programme was launched in January, 2003 in 9 States
i.e. Maharashtra, Gujarat, Goa, Uttar Pradesh, Haryana, Punjab, Karnataka,
Andhra Pradesh, Tamil Nadu and 4 Union Territories.

 Government of India has issued a National Policy on bio fuel in 2018 vide
Notification No. F. No. P 13032(16) 18/2017 dated 04.06.2018. Under this
policy, the Ethanol Blending with Petrol Programme is one of the measures to
reduce the emission from the vehicles and also to reduce the import burden of
petroleum crude. It is planned to achieve 10% blending of ethanol with petrol
by 2022 and achieved. In this direction, the Government of India is
encouraging the distilleries to produce more quantity of ethanol to achieve
the target. This intervention also seeks to reduce import dependence of crude
oil for energy requirements and give boost to agriculture sector.

 The Cabinet Committee on Economic Affairs (CCEA) chaired by the Prime

Minister Shri Narendra Modi had approved fixing higher ethanol price
derived from different sugarcane-based raw materials also Grain based
ethanol under the Ethanol Blended Petrol (EBP) Programme for the
forthcoming sugar sea-son 2020-21 during Ethanol Supply Year (ESY) 2020-21
from December 1, 2020 to November 30, 2021 also for forth coming ethanol
supply years.

 All distilleries will be able to take benefit of the scheme and large
numbers of them have planned to increase the capacity of the plant to
produce ethanol to supply under the EBP programme. Remunerative price to
ethanol suppliers will help in reduction of cane farmer’s arrears, in the
process contributing to minimizing difficulty of sugarcane farmers.

16
 M/s. SPAC Starch Products (India) Private Limited., is also taking part in this
National Programme.

 The Government has 10% blending target for mixing ethanol with petrol by
2022 & 25% blending target by 2025.

 An amendment is brought in the EIA Notification No. S.O. 980(E) dated

02.03.2021 and Notification no S.O. 2339 (E) dated 16.06.2021, wherein, in the
Schedule of notification 2006 5G(a) in column (5) inserted indicating;

 The present proposal is for establishment of distillery to produce Ethanol

under EBP programme. Therefore, EMP report is prepared.

1.2 DETAILS OF THE PROJECT PROPONENT

M/s. SPAC Starch Products (India) Private Limited has proposed to establish
a Distillery Unit with the capacity of 160 KLPD (Fuel grade Bio Ethanol) and 4.6 MW
S. No. 118/2-4,118/7-14,118/18,119/13, 188/1A, 189/8, 9, Mugasipudhur Village, in
Erode District, Tamil Nadu. The nearest major human settlement is Anthiyur. The
nearest railway station is Erode Railway Junction (37 km). The nearest airport is
Coimbatore Airport which is 95.2 km from the project site.
1.3 PROJECT NEED AND IMPORTANCE
Besides the technical and environmental benefits fuel ethanol offers, it makes
tremendous economic sense in India as India's Import bill of crude petroleum is
increasing every year.
The introduction of ethanol fuel will give big boost to Indian economy by following
Ways:
 Agriculture will get boost because of additional production of Maize, Jowar
and rice.
 Less dependence on imports of crude oil and more production of ethanol with
lower price will keep the petrol price well in control and saves foreign
exchange.
 Overall, it is "Eco friendly Project". In view of the above positive results, it is
recommended without any reservation that the establishment of this factory
be granted.

17
1.4 PROJECT CATEGORIZATION
The project activity is listed at item 5g (a) [Ethanol based distilleries, solely to be
used for Ethanol Blended Petrol Programme of the Government of India] in the
Schedule of EIA Notification, 2006 and subsequent amendments vide gazette
notification
S.O. 2339(E) dated 16.06.2021 & categorized as Category “B” project (to be appraised
under category B2) as per condition listed in column 5 of the project /activity 5 to
the schedule of the notification) and there-fore requires prior Environmental
Clearance from MoEF CC.
1.5 SALIENT FEATURES OF THE PROJECT
The salient features of the project are summarized as under:
Table 1.1 Salient Features of the Project
Sl. No. Item Details
SPAC Starch Products (India) Private
1. Name of the Project :
Limited
2. S. No. of the Schedule : 5g (a)
Fuel grade Bio Ethanol -160 KLPD
Proposed DDGS (for Broken rice) -10320 TPA
capacity/area/length/tonnage to DDGS (for Maize) – 17844 TPA
3. : CO2 – 14549.54 TPA
be handled/command area/lease
Technical Alcohol – 5.24 KLPD
area/number of wells to be drilled. Fusel Oil – 0.16 KLPD
Co- gen Power – 4.6 MW
4. New/Expansion/Modernization : New

5. Existing Capacity/Area etc. : -

6. Category of Project i.e. „A‟ or „B‟ : Category „B2‟

Does it attract the general
7. : No
condition? If yes, please specify.
Does it attract the specific
8. : No
condition? If yes, please specify.
Latitude : 11°35'52.64"N
Location
Longitude:77°40'27.92"E
SF. No. 118/2, 118/3, 118/4, 118/7,
9.
118/8, 118/9, 118/10, 118/11, 118/12,
Plot/Survey/Kharse No :
118/13, 118/14, 118/18, 119/13, 188/1A,
189/8, 189/9,

18
 Village : Mugasipudur
Tehsil : Anthiyur
District : Erode
State : Tamil Nadu

Nearest railway station/airport Railway Station:

10. : Erode Railway Junction – 37 km
along with distance in kms
Airport: Coimbatore – 95.2 Km
Nearest Town, city, District Nearest Town: Anthiyur – 10.5 km
11. Headquarters along with distance : Nearest City: Erode – 28.9 Km
District Head Quarters: Erode – 28.9
in kms
km.
Village Panchayats, Zilla Parishad, Anthiyur Town Panchayat,
Municipal corporation, Local Body Anthiyur Taluk,
12. Erode - District,
(complete postal addresses
Tamil Nadu. 638314
telephone no. to be given)
M/S.SPAC Starch Products(India)
13. Name of the applicant :
Private Limited
D4/2, Vijayaraghava Manor
VijayaRaghava Road
14. Registered Address : Teynampet
Chennai
Tamilnadu – 600 018
SPAC Starch Products (India) Private
Limited,
Address for Correspondence : :
S.F.No : 65,66,67, Poonachi Village
Anthiyur Taluk, Erode - 638314
Name : S. Balamurugan
Designation (Owner Associate Vice President (Operation &
:
/Partner/CEO) Maintenance)
D4/2, Vijayaraghava Manor
15. Vijaya Raghava Road
Address : Teynampet,
Chennai
Tamilnadu
Pin Code : 600 018

E-mail : [email protected]
Telephone No. : 04256 257901
Fax No. : --

19
1.6 PREVIEW OF THE PROJECT

Project Overview
Sl. Description Broken Rice Maize
No. Operation Operation
1 Capacity of Ethanol plant in terms of AA Production 160 160
(KLPD)
2 Capacity of Ethanol plant in terms of Total Spirits 174.74 174.74
Production (KLPD)
3 Feed Stock Broken Rice Maize
4 No. Of days of operation 165 165
5 Starch content in Broken Rice (%) 68 60
6 Total Spirit production per MT of feed stock (Yield) 466 411
(Lites/MT)
7 Feed Stock requirement per day (MT / Day) 375 425
8 Annual requirement of Feed Stock (MT) 58,778 66,644
9 Distillery Products Absolute Alcohol (AA)
10 AA Production/Annum, Lakh Lites 250.80 250.80
11 Distillery by products DDGS, Carbon-di-oxide,
Technical Alcohol, Fusel oil
12 DDGS produced per day (MT) 65.84 113.84
13 DDGS produced per annum (MT) 10320 17844
14 CO2 produced per day (TPD) 132.6
15 CO2 recoverable per day (TPD) 92.82
16 CO2 recoverable per Annum (MT) 14,549.54
17 Technical Alcohol (RS2) Produced per day (LPD) 5240.00
18 Technical Alcohol (RS2) Produced per annum (Lakh Litres) 8.21
19 Fusel Oil produced per day (LPD) 160
20 Fusel Oil produced per annum, (Lakh Litres) 0.25
21 Process steam requirement for Distillery plant (TPH) 25.48 27.67
22 Boiler design MCR capacity 40
23 Boiler steam outlet parameters 45 kg/Sq.cm & 440 Deg. C
24 TG capacity (KW) 4600
25 Type of TG Selected Back Pressure with exhaust pressure of Back Back
4.5 Pressure with Pressure
exhaust with exhaust
pressure of pressure of

20
 4.5 kg/Sq. 4.5 kg/Sq.
cm (g) cm (g)
26 Steam generation from New Boiler (TPH) 31.36 33
27 Power Generation from TG (kW) 3380 3550
28 Power consumed for Distillery plant & Power plant 3380 3550
29 Fuel Envisaged in the Boiler Rice Husk or Imported Coal/
Combination of Rice Husk
and Coal
30 Rice Husk / Imported coal Consumption in the 5.3 & 1.8 5.6 & 1.9
Boiler (TPH)
31 No. of days of operation with Rice Husk in an Year 165 165
32 No. of days of operation with Coal in an year 165 165
33 Total water requirement (Cu.M / day) 2899
34 Actual Fresh water requirement considering 1036
recyling of water (Cu.M / day)
35 Project Commissioning Schedule 31st January 2024
36 Total Works cost Including GST (in Rs. Lakhs) 20475
37 Installed project cost considering IDC, Contingency, Pre- 23109.02
operative expenses etc., (Rs. In Lakhs)
38 Equity (Rs. in Lakhs) 2310.9
39 Term Loan (Rs. Lakhs) 20798.12
40 Average DSCR 1.65
41 IRR - Post tax (%) 20.75
42 Net Present Value (NPV) (Rs.in Lakhs) 19541.82
43 Return on Equity (ROE) % 92.62
44 Payback period (years) 4.2

21
1.7 LOCATION (MAP SHOWING GENERAL LOCATION,
SPECIFICLOCATION AND PROJECT BOUNDARY & PROJECT SITE LAYOUT)
WITH COORDINATES

 Location map of project site is given in the Fig.1.1

 Satellite imagery of the project site is given in the Fig.1.2
 Topo Map of the project site is given in the Fig1.3
 Layout of the project site is given in the Fig. 1.4
 Location(coordinates)of project site are detailed below:

Latitude : 11° 35' 52.64" N

Longitude : 77° 40' 27.92" E

PROJECT
SITE

Fig 1.1 Location Map of the Project Site

22
 Fig.1.2. Satellite imagery of the project site

Fig.1.3 Topography Map of the Project site (10kmRadius)

23
Fig. 1.4 Layout of the Project Site

24
1.8 NATURE, SIZE, INVESTMENT COST, DEMAND AND CATEGORY OF THE
PROJECT
1.8.1 Nature and Size of the Project
The project is for setting up of a Grain based distillery production to the tune
of 160 KLD under Ethanol Blended Petrol Programme of GoI. The project activity is
covered under “5G (a) (Grain based distilleries producing ethanol, solely to be used
for Ethanol Blended Petrol Programme of the Government of India) in the Schedule
of EIA Notification, 2006 and subsequent amendment vide gazette notification
S.O. 2339(E) dated 16.06.2021.
PRODUCTION DETAILS
Quantity
S. No. Particulars
Broken Rice Maize
1. Fuel Grade Bio Ethanol 160 KLPD
2. Technical Alcohol 5240 LPD
3. DDGS 65.84 TPD 113.84 TPD
4. Carbon-di-oxide 132.6 TPD
5. Fusel Oil 160 LPD
6. Co-gen Power 4.6 MW

Raw Materials
Table 1.2 List of raw materials
Raw Materials Starch Content (%) Quantity (T/D)
Broken Rice 68 375
Maize 60 425

Table 1.3 List of Chemicals and Enzymes Used

Sl. No. DESCRIPTION Quantity (tons)

1 Sodium Hydroxide 1.782

2 Lime 0.377

3 Urea 0.107

4 DAP 0.053

25
 5 Micro nutrient 0.107

6 Dewatering Polymer 0.007

7 Sodium Hypochlorite 0.137

8 Coagulant 0.082

9 Polyelectrolyte 0.002

10 De-chlorination dosing for RO 0.006

11 Antiscalant dosing for RO 0.006

12 Hydrochloric acid dosing for RO 0.093

13 pH correction 0.001

1.8.2 Demand and Supply Gap

Alcohol manufactured from Grains, by virtue of its renewable nature is an
eco-friendly fuel which will be a worthy substitute for gasoline to prevent global
warming. Many countries have taken up aggressive usage of absolute alcohol, also
commercially called as Ethanol, to reduce the dependence on petroleum. Presently,
ethanol is blended with gasoline in varying proportions to get the motor spirit.
Brazil has done pioneering work in this direction, followed by many countries.
United States has launched an aggressive ethanol manufacturing program and
European Union is also showing keen interest in ethanol. India already has a policy
to achieve the mandatory blending of 20% by 2025. Alcohol, after limited
purification, finds wide usage in industrial applications and also in blending
alcoholic drinks.
(Source:https://vikaspedia.in/energy/policy-support/renewable-energy/biofuels/ethanol-
blended-petrol-programme.)

1.8.3 EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO

THE PROJECT
M/s. SPAC Starch Products (India) Private Limited proposed distillery unit
will generate direct and indirect of job opportunity for 125 people (approx.).

26
 CHAPTER II
PROJECT AND BACKGROUND INFORMATION
2.1TYPE OF PROJECT
M/s. SPAC Starch Products (India) Private Limited has proposed to establish
a Distillery Unit with the capacity of 160 KLPD (Fuel Grade Bio Ethanol) & 4.6 MW
Co-gen Plant at SF. No. 118/2, 118/3, 118/4, 118/7, 118/8, 118/9, 118/10, 118/11,
118/12, 118/13, 118/14, 118/18, 119/13, 188/1A, 189/8, 189/9, Mugasipudhur
Village, Anthiyur Taluk, Erode District, Tamil Nadu. The nearest major human
settlement is Anthiyur (10.5 km). The nearest railway station is Erode Railway
Junction (37 km). The nearest airport is Coimbatore Airport (95.2 km) from the
project site. Total project area 9.12 Hectares (22.55 Acre). Total Project cost is 231.09
crores.
2.2 NEED FOR THE PROJECT
 Government of India has issued a National Policy on biofuel in 2018 vide
notification No. F. No. P 13032(16) 18/2017 dated 4.6.2018. Under this policy,
the Ethanol Blending with Petrol Programme is proposed to reduce emission
from vehicles and import burden of petroleum crude. It is planned to achieve
10% blending of ethanol with petrol by 2022 and 20% by the year 2025. To
achieve this target, the Government of India is encouraging distilleries to
produce more ethanol. This intervention also seeks to reduce import
dependence for energy requirements and give boost to agriculture sector.

 Under this Ethanol Blended Petrol Programme, a special dispensation was

provided for expansion of sugar manufacturing or distillery units, intended
for production of Ethanol vide notifications numbers S.O. 345(E), dated the
17th January, 2019 and S.O. 750(E), dated the 17thFebruary, 2020. In view of the
Government‟s commitment to achieve 20% blending of ethanol in petrol by
the year 2025, it was decided to continue further with this dispensation and it
was notified vide notification number S.O. 980(E) dated the 2nd March, 2021.

 India‟s petrol consumption was 2995 MT during the financial year 2019-20
(December - November) [(Source: Petroleum Planning & Analysis Cell

27
 (MOPNG-GOI)]. Sugar mills have supplied to oil marketing Companies
(OMCs) 189 Crore Litres of Ethanol for blending with petrol during 2018-19
achieving 5% blending. During 2019-20 it was planned to increase by 190-200
Crore litres of ethanol to achieve 5.6% blending against 10% blending target.
The government targets an ethanol production and supply target of 300-350
crore litres in 2020-21.

 The Cabinet Committee on Economic Affairs (CCEA) chaired by the Prime

Minister Shri Narendra Modi has approved fixing higher ethanol price
derived from different sugarcane-based raw materials under the Ethanol
Blended Petrol (EBP) Programme for the sugar season 2020-21 during Ethanol
Supply Year (ESY) 2020-21 from December 1, 2020 to November 30, 2021:

 Further, it is approved by the CCEA; in order to offer a fair opportunity to the

localized industry within the State and reduce crisscross movement of
ethanol, Oil Marketing Companies (OMCs) shall decide the criteria for the
priority of ethanol from various sources taking in account various factors like
cost of transportation, availability, etc. This priority will limit to the excisable
boundaries of the State/UT for production in that State/UT. Same order of
preference will be given thereafter for import of ethanol from other States
wherever required.

 Distilleries will be able to take benefit of the scheme and large numbers of
them have planned to increase the capacity to produce ethanol to supply for
the EBP programme. Remunerative price to ethanol suppliers will help in
reduction of cane farmer‟s arrears, in the process contributing to minimizing
difficulty of sugarcane farmers.

 To meet the deficiency in production of ethanol in the country there is a need

to enhance the production by expanding the present operational capacity.
This will contribute to reduce the demand as far as possible.

 In order to promote Ethanol manufacturing in the country, the Central

Government (Ministry of Consumer Affairs, Food & Public Distribution)

28
 notifies modified scheme namely–“Scheme for extending financial assistance
to project proponents for enhancement of their ethanol distillation capacity or
to set up distilleries for producing 1st Generation (1G) ethanol from feed
stocks such as cereals (rice, wheat, barley, corn & sorghum), sugarcane,
sugarbeet, etc.
 Due to increasing demand for alcohol in the country in the last few years and
also due to shortage of molasses, the prices of alcohol are increasing day by
day. Potable grade Rectified spirit (produced from molasses) price went up to
almost Rs.35.0 to 36.0 per liter. In the last two-three years the availability of
alcohol has become very difficult. The present basic price of molasses and
extra neutral alcohol (produced from molasses) isRs.5,000 to 5,500/MT and
Rs.40.00 to 42.00/liter respectively. These prices are expected to remain high
in the coming years due to increasing demand for alcohol. It has become
difficult for liquor manufacturing units to purchase good quality alcohol from
the open market and run economically.
 Therefore, many potable alcohol and liquor manufacturing units are looking
for alternate raw materials. One of the well-established routes to manufacture
potable alcohol and liquors is to use grains as feedstock. Grain alcohol and
liquors made from grain alcohol have special value and can fetch higher price
in the market. Also it will be worthwhile to note that there are abnormal
variations in the price & availability of rectified spirit & molasses depending
upon the availability of basic raw material, i.e. sugar Maize. There is also no
assurance of good return for molasses based rectified spirit. To fulfill this
demand the management has decided to establish a new distillery unit based
on grains as the feedstock to produce superior quality of potable alcohol
(Rectified spirit and Extra Neutral Alcohol).
 Hence, SPAC Starch Products (India) Pvt. Ltd., proposes to install a 160 Kilo
Litres per Day (KLPD) capacity Ethanol plant in a newly procured land in
Mugasipudhur village, Anthiyur Taluk, Erode District. This proposed
distillery plant will be capable of producing 160 KLPD of Fuel Grade Bio
Ethanol. Latest technologies for ethanol will be adopted in this project, which

29
 will ensure high efficiency, optimum operating costs & environmental
sustainability for the proposed project.

2.3 PROCESS DESCRIPTION

Considering the present encouraging prices announced by Govt. of India for
Absolute Alcohol produced from Grains, M/s. SPAC Starch Products (India) Private
Limited would like to implement a Grain to ethanol distillery project at a newly
identified land near Anthiyur Taluk in Erode District of Tamilnadu. The Capacity of
the Distillery plant will be to produce 160 KLPD AA during grain mode of
operation. The grain based distillery will operate for 330 days in a year.

The distillery will be designed as a Zero Effluent discharge plant. The high pressure
steam generated in the boiler will enable adequate power generation in a turbo
generator for meeting the requirements of the distillery operations and will also
provide the process steam required for the distillery operations. The distillery design
will employ the multi pressure technology with the distillation columns operating
under various pressures to economize on the energy consumption in the distillation
process. This distillery project will also include an effluent treatment plant, based on
anaerobic digestion, aeration, clarification and Reverse Osmosis, to treat the
condensate generated in the spent wash concentration plant and the spent lees
generated in the distillation process. The permeate from the RO system will be used
as process water, thus reducing the dependence on external water and the
concentrated RO reject will be mixed with the influent spent wash upstream of the
concentration plant.

About Ethanol
Ethyl Alcohol commonly known as Ethanol, with the molecular formula of
C2H5OH, is an important organic compound which has wide use, in industrial
applications, as fuel for internal combustion engines and as an intoxicating
ingredient of alcoholic beverages. In the Industrial applications it is used as solvents
and in the synthesis of varied organic chemicals like ethylene. Acetone,

30
acetaldehyde, acetic acid, poly styrene, PVC etc. Even though the major
consumption as of now is for alcoholic beverages, Ethyl alcohol has the potential to
fuel the future relegating gasoline to a secondary place. Brazil has pioneered the
blending of Ethyl alcohol with gasoline to be used as automotive fuel, followed by
United States of America and many other countries. Many countries, including
India, have implemented policies to ensure that the bio-fuels become important
element of their transport fuel mix. Bio-ethanol, unlike petroleum, is a form of
renewable energy that can be produced from agricultural feed stocks. Ethanol can be
produced from several raw materials like sugarcane or sugar beet molasses, cassava,
maize and other grains. Concerns about its production, from raw materials other
than sugar cane molasses, relate to increased food prices, the large amount of arable
land required for crops etc. However the latest developments with cellulosic ethanol
production may allay some of these concerns relating to the food security.
Alcohol manufactured from Grains, by virtue of its renewable nature is an Eco-
friendly fuel which will be a worthy substitute for gasoline to prevent global
warming. Many countries have taken up aggressive usage of absolute alcohol, also
commercially called as Ethanol, to reduce the dependence on Petroleum. Presently,
ethanol is blended with gasoline in varying proportions to get the motor spirit.
Brazil has done pioneering work in this direction, followed by many countries.
United States has launched an aggressive ethanol manufacturing program and
European Union is also showing keen interest in ethanol. India already has a policy
to achieve the mandatory blending of 20% by 2025. Alcohol, after limited
purification, finds wide usage in industrial applications and also in blending
alcoholic drinks.
Manufactured Products
During operation with Grains as feed stock, in addition to the 160,000 Liters per day
of AA, The distillery plant will produce by products such as Fusel Oil and Technical
Alcohol. By including quantity of these by products, the total production capacity of
Distillery plant will be 160,000 Liters per day. For the production of 160,000 Litres of
alcohol per day, the distillery needs 375 MT of Broken Rice per day or 425 MT of
Maize per day.

31
The distillation process is the separation of ethyl alcohol from impurities like the
acetaldehydes, acetones, esters and amyl alcohols etc. Operating for 330 days in
Anhydrous Alcohol (AA) mode, with the plant capacity utilization of 95%, the plant
could produce 250.80 Lakh Liters per Annum of AA. Apart from the above, the plant
will also produce 5240 Litres of Technical Alcohol and 160 Litres of Fusel Oil per
day. The fermentation process will produces carbon-Di-Oxide as a by-product and it
proposed to sell this gas as raw CO2. There are companies which put up CO2
purification plants adjacent to the distillery taking the raw CO2 from the distillery. It
is estimated that about 92.82 TPD of purified CO2 is recoverable from the distillery
which could find usage in beverage industry, welding process, pharmaceutical and
other chemical processing industries. Liquid CO2 is a good refrigerant and it finds
wide usage in food industry for warehouse storage and for storage during
transportation.
Process and Technology
The various sections involved in the process of Manufacture of Alcohol in a multi-
product zero effluent discharge distillery are,
 Grain receiving, storage and handling section
 Liquefaction and saccharification section
 Feed stock weighing, distribution and Fermentation Section.
 Distillation section for the production of RS and Absolute Alcohol.
 Molecular Sieve Dehydration section ( MSDH)
 Decantation and Evaporation
 DDGS drying section
 AA, TA & FO Daily Receiver & Bulk Storage Section
 Utilities comprising of Boiler, TG, DM water plant, Cooling towers,
compressed air system and Electrical Section
 Laboratory, stores.
 Fire-fighting and alarm systems for the plant
 Civil and structural work for the complete plant

32
Description of the process plant
1. Grain handling and Dry Milling Process
Grains are stored in the Silos & from there they are conveyed through Screw
Conveyor to Bucket Elevator. Bucket Elevator lifts the grains to approximately 15 m
height and then passes the grains through Vibrating Screen, Destoner and Magnetic
Separator to remove dust and stones. The flow through the equipment is under
gravity. The cleaned grains are then again conveyed by bucket elevator to an
intermediate Hopper, which is provided with rotary air lock system for controlled
flow in Hammer Mill. In Hammer Mill the particle size is reduced to as required by
the process. From hammer mill the flour is pneumatically conveyed to Flour Bin
(Intermediate storage for flour). From flour bin the flour is carried to Premasher unit.
In Premasher, flour is mixed with water.
2. Slurry Preparation & Liquefaction
Slurry from pre-masher is taken to Slurry preparation tank where slurry is further
diluted by addition of water and recycles streams. Slurry is taken to Initial
liquefaction tank where liquefying enzyme is added. This slurry is then “cooked” in
the jet cooker. The slurry is continuously pumped to a steam jet cooker where high-
pressure steam rapidly raises the slurry temperature. The mixture of slurry and
steam is then passed through the retention vessel (cook tube) having sufficient
capacity to provide the desired retention time at a given flow rate. The cooked mash
is discharged to a flash tank. The cooking process, accomplished in the above
manner, converts the slurry into a hydrated, sterilized suspension (as starch
molecule is solubilized) and is therefore susceptible to enzyme attack for
liquefaction.

3. Saccharification and fermentation

Yeast seed material is prepared in Yeast Activation Vessel (Pre-fermentor) by
inoculating sterilized mash with yeast. Optimum temperature is maintained by
circulating cooling water. The contents of the Yeast Activation Vessel are then
transferred to Fermenter. The saccharification and fermentation reaction are carried
out simultaneously using enzymes and yeast. The purpose of fermentation is to
convert the fermentable sugars to alcohol. During fermentation, sugars are broken

33
down into alcohol and carbon dioxide. Significant heat release take place during
fermentation. The fermentation temperature is maintained between 32-34°C by
recirculation of cooling water through plate heat exchangers. The fermentation
system has a provision for addition of anti-foam, nutrients etc. Alcohol concentration
of 12% v/v in fermenter, CO2 is collected and is passed through CO2 Scrubber in
order to recover any alcohol, escaping the gas. The alcohol containing the water is
returned to the system and mixed with the fermented wash. At the end of
fermentation process, Fermented wash is received in a wash holding tank from
where it is sent to the distillation column.

4. Distillation - Fermented Wash to Rectified Spirit

Following columns will be under operation
 Analyser Column (Partial Vacuum)
 Degasifying Column (Partial Vacuum)
 Rectifier cum Exhaust Column (Under Pressure)
 Recovery Column (Atmospheric)
Pre-heated fermented wash will be fed to Degasifying column. Fermented wash is
stripped off alcohol by ascending vapors in Analyzer column. Rectifier vapors
provide energy to Analyzer column through a Thermosyphon reboiler. Vapors of
Degasifying column are condensed and taken to Recovery Feed Tank. Analyzer
vapors are condensed in its three condensers.. The condensed Analyzer vapors are
taken to Rectifier Feed Tank. Rectifier column, which operates under pressure,
concentrates the condensate of Analyzer column to 95% v/v concentration.
Condensing steam provides energy to rectifier column through a vertical
Thermosyphon reboiler. Fusel Oil Draws are taken from appropriate trays and fed to
Recovery Column. Recovery Column concentrates the fusel oil streams and
Degasifying condensate to 95% v/v concentration. An impure spirit cut of about 2-
3% of total spirit production is taken out from the top of the recovery column.
Rectified Spirit draw of 95.5 % v/v is taken out from the upper trays of Rectifier
Column.

34
5. Decantation
Decantation section consists of a Decanter centrifuge for separation of suspended
solids from the whole stillage obtained in the final distillation process. Wet cake is
removed from the bottom of the Decanter. Thin slops coming out of De-canter
centrifuge are partly recycled into the process and rest is evaporated in Multiple
Effect Evaporator for concentration up to 30% w/w solids. The concentrated thin
slops called as Thick Syrup is mixed with wet grain soluble from Decanter is dried in
a DDGS Dryer and sold in dry form as Cattle Feed.

6. Integrated Evaporation System

In Integrated Evaporation System Multiple Effect Evaporators with falling film and
forced circulation are being used for Thin slops Evaporation. The Product at desired
concentration of 30% w/w total solids is obtained at the outlet of the final effect.
Each effect is provided with re-circulation and transfer pumps.
7. DDGS Dryer
The concentrated cake from the evaporator and wet cake from the decanter is mixed
in the mixing tank and taken to the dryer where substantial percentage of the
moisture is removed. The final product from the dryer is called as Distillers Dried
Grain Soluble (DDGS). It contains 90% w/w solids. It is packed in the polythene
bags and used as an animal feed. The approximate quantity of DDGS produced from
rice is 65.84 MT/Day and 113.84 MT / Day respectively during Broken rice and
Maize operation respectively.
8. Condensate Polishing Unit
Two streams of liquid discharges from the distillery, with the Thin stillage
evaporation system are the evaporator process condensate and the spent lees from
the distillation section. These two streams are proposed to be treated in a system
with the combination of Anaerobic reactor (conventional UASB reactor / high rate
reactor), extended aeration system, Clarification, media filtration, Ultra filtration and
Reverse osmosis (RO) system. The plant is designed for removal of organic acids,
COD, BOD, colloidal and reactive Silica and total dissolved solids. The condensate
treated by such system can be reused in the alcohol manufacturing process as
process water for Fermentor dilution and as cooling water make-up thereby

35
reducing the requirement of fresh water as well as solving the problem of waste
disposal to a great extent.
The proposed treatment methodology is based on following principle operating
systems:
Up flow Anaerobic Sludge Blanket (UASB) reactor is provided for the primary
anaerobic treatment of Condensate & Spent lees effluent. The UASB reactor shall be
constructed in MS with suitable epoxy coating inside the tank. The liquid to be
treated enters into the bottom through influent distribution zone and uniformly
distributed in the tank. In the reaction zone the anaerobic bacteria are maintained in
the form of sludge blanket. When the upward rising waste water penetrates through
the sludge blanket, the organic matter in the waste water comes in contact with the
bacterial population and is degraded anaerobically to methane rich biogas, the end
product of anaerobic digestion. The biogas so produced is bubbled through the
effluent and is separated out in the third section.

Gas-Solid-Liquid separation zone

The suspended solids, rich in bio-mass, are retained to prevent escape of biomass
from the reactor. In gas solid liquid separation a hood fabricated in Mild Steel and
duly painted with corrosion resistant paint is provided. The hood separates the solid
from the overflowing reactor content. Gas collectors are provided for collection and
conveyance of gas. Similarly, High rate reactors instead of conventional reactors
with some internal arrangements to facilitate the above described activities may also
be engaged. High rate reactors are preferred over conventional reactors due to their
easy operation and better efficiency, all but with some additional capital cost. BOD,
COD & volatile acids are reduced at the outlet of the anaerobic reactor. The treated
effluent overflows through a launder/overflow line and will be taken to
downstream treatment systems.
The anaerobic reactor outlet is taken to holding tank to retain the biomass carried
over. The same is then fed to extended aeration tank for aerobic reaction to further
reduce the organic acids, BOD & COD. The outlet of extended aeration system is
taken to secondary clarifier for settling and to tertiary clarifier for coagulation and

36
flocculation. It is to be noted that the Inorganic effluents like process plant and slop
fired cogen plant cooling tower blow down, boiler blow down and side stream filter
backwash is introduced in tertiary clarifier and treated along with biologically
treated process condensate and spent lees. Turbidity is reduced to the desired level
at the outlet of tertiary clarifier and is fed to multi grade filter and activated carbon
filter and stored in filtered water storage tank. Part quantity of filtered water storage
tank is taken through Ultraviolet system for fermentor dilution and the balance
quantity is fed to ultrafiltration and reverse osmosis system to reduce dissolved
solids, colloidal silica and reactive silica to the desired level. The permeate of the RO
system, will be collected in RO permeate tank and is used as make up water for the
process plant cooling towers. The sludge generated from clarifier will be collected in
the sludge pit and taken to decantation system for separation of solids and the
separated solids will be disposed off suitably. The filtrate from the decantation
system will be recycled to equalization tank/clarifier.

9. Alcohol Storage
Alcohol from the plant shall be transferred to daily receivers. After gauging, alcohol
shall be transferred to respective bulk storage tank. A minimum of 15 days storage of
Alcohol is considered.

Co-gen Power Plant (4.6 MW)

Proposed co-generation plant consists of a high-pressure water tube steam
boiler steam turbine. Fuel in the steam boiler will be burnt with the help of air in the
boiler furnace. Water will be circulated in the boiler drum and tubes thus getting
heated by the flame burning in the boiler furnace. Water comes out of the boiler
drum located at the top of the boiler as steam. Flue gases rise in the boiler furnace
and come in contact with the steam coming out of boiler drum.
Steam after coming in contact with flue gases gets heated up further thus
getting superheated. Super- heated steam leaves the boiler in a pipe. Flue gases after
super heating the steam pass through economizer where they pre-heat the boiler
feed water before it enters the boiler drum. After economizer, flue gases pass

37
through air pre-heaters where they heat the air which is fed to the boiler furnace for
burning the fuel. After air pre heaters flue gases pass through an Electro Static
Precipitator (ESP) where the dust particles are collected on charged electrodes. The
dust is collected from the bottom of the ESP. High pressure superheated steam from
boiler is passed through a steam turbine and at the lower pressure goes to the
condenser. The part of the steam is extracted from the extraction points provided
on the turbine, which is used for distillery. The condensed steam returns to the
steam boiler as condensate and is again boiled as steam. While passing through the
turbine, the high pressure and temperature steam rotates the turbine rotor and an
electric alternator mounted on the same shaft. Electric power is generated by the
alternator. This electric power generated is consumed in house i.e. for running the
distillery and utilities like boilers auxiliaries etc. and surplus power can be exported
to the state grid.

38
 160 KLPD

Fig 2.5 Grain Plant Process Flow

39
 Table 2.1 Air pollution sources fuel requirement and APC measures
Sl. No. Stack Fuel consumption APC equipment and
attached to stack height in m
Broken Maize
Rice
1 40 TPH Boiler 5.3 TPH 5.6TPH ESP and stack of
(Rice Husk) (Rice Husk) height 68 m
1.8 TPH 1.9 TPH
(Coal) (Coal)
2 DG sets 1000 KVA 180 Ltr/Hr @ 80 % Load Stack of height 15 m
(2 No.s)

Table 2.2 Types of fuel & mode of transportation for distillery

Sl. No. Fuel Quantity (TPD) Transport

Broken Rice Dry Maize
1 Rice Husk 127.2 134.4 Trucks
2 Imported Coal 43.2 45.6 Trucks

2.5 BULK STORAGE FACILITY

Grain storage is planned for thirty days of storage in silos. The silos will be installed
inside the distillery premises. Details are tabulated below.
Table 2.3 Storage of Raw Materials
Sl. No. Description Storage Quantity (TPD)
Broken Rice 375 (60% Starch)
1. 2 Silo (5000 Tons.)
Maize 425 (68% Starch)

2.6 POWER REQUIREMENT

SPAC intends to install Captive Power plant with below equipment configuration
for 160 KLPD AA capacity. The total power requirement will be 3380 KW for Broken
Rice operations & 3550 KW for Dry Maize operations. The proposed project power
requirements will be met out from Captive Power Plant of capacity 4.6 MW. The
design of the AFBC boiler shall be of single drum, natural circulation, two stage
superheater with inter-stage De-superheater and balanced draft with MCR 40 TPH,

40
operating steam pressure 45 Kg/cm2 (g) and temperature 440°C with all accessories
and Auxiliary equipment. There will be no power requirement from Tamilnadu
Electricity Board.

2.7 STEAM REQUIREMENT

The steam requirement for the distillery plant shall be given below,
Quantity (TPH)
S. No. Description Broken Rice
Maize Operation
Operation
1. Distillation & Evaporation 17.84 19.37
2. Liquefaction & DDGS Dryer 7.64 8.3
Total 25.48 27.67

2.8 QUANTITY OF WATER REQUIREMENT, WASTEWATER GENERATION

AND SCHEME FOR MANAGEMENT
2.8.1 Source of Water
Water requirement of the plant is proposed to be met from the Kaveri River where
the order is obtained from Public Works Department, Erode. The average raw water
requirement is 2899 KLD with Broken rice as feed stock without recycling during
startup process. However, since CPU treated water of about 1863 KLD will be
recycled; the fresh water requirement from the river shall be 1036 KLD. The water is
required for the distillery process in the fermentation section, cooling tower make up
for the distillery cooling towers. The above quantities are based on the usage of fresh
raw water for meeting all the needs without any consideration for the condensate
recycle. To optimize the water usage, the 160 KLPD distillery section will have a
process condensate and spent lees treatment and polishing unit, the recovered water
of which will be used for process make up or cooling tower make up. To optimize
the water usage, the 160 KLPD distillery section will have a process condensate and
spent lees treatment and polishing unit, the recovered water of which will be used
for process make up or cooling tower make up.

41
 Table 2.5 Water Requirement Details
S. No. Description Quantity (KLD)
Distillery Plant
1. Cooling Tower Make up 967
2. Process water to liquefaction (Fermentation) 1264
Raw water required for FO Decanter, Alcohol
3. 328
Scrubber, Vacuum Pump Sealing
Co-generation Plant
1. Cooling tower Make up 71
Raw water required for co-gen power plant
2. 172
boiler make up
Other Requirements
1. Domestic Usage 2
2. Green Belt Development 95
Total 2899

2.8.2 Water Balance

A water balance chart compares the total water supplied to the site, the actual water
consumed within all the water end uses in the site, and the total water leaving the
site. This will help to identify areas of significant water usage and problem areas,
including leaks and uncontrolled losses. Here, the water balance for various
processes are given which includes,
a. Water Treatment Plant
b. Power Plant
c. Distillery Plant
d. Condensate Polishing Unit
e. Cooling Tower

42
Fig 2.6 Water Balance for WTP

43
Fig 2.7 Water Balance for Power Plant

44
Fig 2.8 Water Balance for Distillery Plant

45
Fig 2.9 Water Balance for Cooling Tower

46
Fig 2.10 Water Balance for CPU

47
2.8.3 Wastewater Generation
Table 2.6 Wastewater Generation
S. No. Description Quantity (KLD)

1 Cooling water blow down from Distillery 103.12

Plant
2 Cooling water blow down from 7.62
Cogeneration Plant
3 Boiler blow down 10.16
4 WTP effluent/reject 234
5 Multiple Effect Evaporator condensate 924
6 Dryer Vapour Condensate 244
7 Sewage water 20
Total 1543

2.8.4 SOLIDWASTE GENERATION

Table 2.7 Details of Solid Waste Generation
S.
Description Quantity Method of Disposal
No.
The concentrated
Sludge from the CPU sludge shall be Bio-
1. 2 TPD
& WTP Composting and used
as a manure
Boiler Ash : 2.98 TPD
of Ash /43.2 TPD of
Imported Coal
Will be used for
2. Boiler Ash &
making fly ash bricks
22.80 TPD of Ash
/127.2 TPD of Rice
Husk (Broken Rice)
Boiler Ash : 3.15 TPD
of Ash /45.6 TPD of
Imported Coal
Will be used for
3. Boiler Ash &
making fly ash bricks
24.19 TPD of Ash
/134.4 TPD of Rice
Husk (Dry Maize)

48
2.9 CONDENSATE POLISHING TREATMENT SYSTEM
Two streams of liquid discharges from the distillery, with the thin stillage
evaporation system are the evaporator process condensate and the spent lees from
the distillation section. These two streams are proposed to be treated in a system
with the combination of anaerobic reactor (conventional UASB reactor / high rate
reactor), extended aeration system, Clarification, media filtration, Ultra filtration and
Reverse osmosis (RO) system. The plant is designed for removal of organic acids,
COD, BOD, colloidal and reactive Silica and total dissolved solids. The condensate
treated by such system can be reused in the alcohol manufacturing process as
process water for fermentor dilution and as cooling water make-up thereby reducing
the requirement of fresh water as well as solving the problem of waste disposal to a
great extent.
The proposed treatment methodology is based on following principle operating
systems:
Up flow Anaerobic Sludge Blanket (UASB) reactor is provided for the primary
anaerobic treatment of Condensate & Spent lees effluent. The UASB reactor shall be
constructed in MS with suitable epoxy coating inside the tank. The liquid to be
treated enters into the bottom through influent distribution zone and uniformly
distributed in the tank. In the reaction zone the anaerobic bacteria are maintained in
the form of sludge blanket. When the upward rising waste water penetrates through
the sludge blanket, the organic matter in the waste water comes in contact with the
bacterial population and is degraded anaerobically to methane rich biogas, the end
product of anaerobic digestion. The biogas so produced is bubbled through the
effluent and is separated out in the third section
Gas-Solid-Liquid separation zone
The suspended solids, rich in bio-mass, are retained to prevent escape of biomass
from the reactor. In gas solid liquid separation a hood fabricated in Mild Steel and
duly painted with corrosion resistant paint is provided. The hood separates the solid
from the overflowing reactor content. Gas collectors are provided for collection and
conveyance of gas. Similarly, High rate reactors instead of conventional reactors
with some internal arrangements to facilitate the above described activities may also

49
be engaged. High rate reactors are preferred over conventional reactors due to their
easy operation and better efficiency, all but with some additional capital cost. BOD,
COD & volatile acids are reduced at the outlet of the anaerobic reactor. The treated
effluent overflows through a launder/overflow line and will be taken to
downstream treatment systems.
Table 2.8 List of Equipments Used in CPU
SL.NO TAG EQUIPMENT MOC
ORGANIC STREAM - (BIOLOGICAL BASED TREATMENT STREAM)
1 ISM INLINE STATIC MIXER SS316
2 EQT-1 EQUALIZATION TANK RCC
AIR BLOWER FOR EQUALIZATION
3 B1-A&B TANK CI
4 P1-A&B EFFLUENT TRANSFER PUMP SS 304
5 BT BUFFER TANK RCC
6 AG-1 AGITATOR-BUFFER TANK SS 316
7 DT-1 LIME PREPARATION TANK FRP
AGITATOR-LIME PREPARATION
8 AG-2 TANK SS 316
9 DT-2 LIME DOSING TANK FRP
10 AG-3 AGITATOR-LIME DOSING TANK SS 316
11 DP1-A&B LIME DOSING PUMP PP
12 DT-3 NAOH PREPARATION TANK MS
13 AG-4 AGITATOR-NAOH DOSING TANK SS 316
14 DT-4 NAOH DOSING TANK MS
AGITATOR-NAOH PREPARATION
15 AG-5 TANK SS 316
16 DP2-A/B NAOH DOSING PUMP PP
17 DT-5 UREA PREPARATION TANK FRP
AGITATOR-UREA PREPARATION
18 AG-6 TANK SS 316
19 DT-6 UREA DOSING TANK FRP
20 AG-7 AGITATOR- UREA DOSING TANK SS 316
21 DP3-A&B UREA DOSING PUMP PP
22 DT-7 PHOSPHORIC ACID DOSING TANK FRP
23 AG-8 AGITATOR- UREA DOSING TANK SS 316
24 DP4-A&B PHOSPHORIC ACID DOSING PUMP PP
25 DT-8 NUTRIENT DOSING TANK FRP
26 AG-9 AGITATOR NUTRIENT DOSING TANK SS 316
27 DP5-A&B NUTRIENT DOSING PUMP PP

50
 CI- CASING,
28 P2-A/B ANAEROBIC FEED PUMP SS 304 IMPELLER
UPFLOW ANAEROBIC SLUDGE
29 UASBR BLANKET REACTOR MS / RCC

CI- CASING,
30 P3-A&B BIOMASS RECIRCULATION PUMP CF 8 IMPELLER
31 FS BIOGAS FLARE SYSTEM MSEP
32 BMST BIO MASS STORAGE TANK RCC
CS BODY
33 P4-A&B BIO MASS TRANSFER PUMP ALLOY ROTOR
34 BMHT BIOMASS HOLDING TANK RCC
35 BGH BIOGAS HOLDER MSEP
36 CT BIOGAS CONDENSATE PIT RCC
CI- CASING,
37 P5-A&B SLUDGE TRANSFER PUMP CF 8 IMPELLER
38 EAT EXTENDED AERATION TANK RCC
39 B2-A&B AIR BLOWER FOR EAT CI
40 SC SECONDARY CLARIFIER RCC
41 RD RAKE DRIVE MSEP
SECONDARY CLARIFIER SLUDGE CI- CASING,
42 P6-A&B PUMP CF 8 IMPELLER
43 DT-9 NaOCL DOSING TANK-1 FRP
44 DP6-A&B NaOCL DOSING PUMP-1 PP
45 DT-10 COAGULANT PREPARATION TANK-1 FRP
46 AG-10 AGITATOR FOR DT-10 SS 316
47 DT-11 COAGULANT DOSING TANK-1 FRP
48 AG-11 AGITATOR FOR DT-11 SS 316
49 DP7-A&B COAGULANT DOSING PUMP-1 PP
50 DT-12 POLYMER PREPARATION TANK-1 FRP
51 AG-12 AGITATOR FOR DT-12 SS 316
52 DT-13 POLYMER DOSING TANK-1 FRP
53 AG-13 AGITATOR FOR DT-13 SS 316
54 DP8-A&B POLYMER DOSING PUMP-1 PP
55 TC TERTIARY CLARIFIER RCC
56 TD-1 TURBINE DRIVE MSEP
57 RD-1 RAKE DRIVE MSEP
TERTIARY CLARIFIER SLUDGE CI- CASING,
58 P7-A&B TRANSFER PUMP CF 8 IMPELLER
59 CWST-1 CLEAR WATER STORAGE TANK-1 RCC
CF 8- CASING,
60 P8-A&B MGF FEED PUMP CF 8 IMPELLER
61 MGF-1 MULTIGRADE FILTER MSEP
62 B3-A&B AIR BLOWER FOR MGF 1 & 2 CI

51
63 ACF-1 ACTIVATED CARBON FILTER-I MSEP
64 PWST PROCESS WATER STORAGE TANK MSEP
65 FWST FILTERED WATER STORAGE TANK MSEP
CF 8- CASING,
66 P21-A&B UV FEED PUMP CF 8 IMPELLER
67 CF-1 CARTRIDGE FILTER SS 316
68 UV UV SYSTEM -
INORGANIC WASTE WATER TREATMENT STREAM
EQUALISATION TANK-2 (INORGANIC
EFFLUENT & INTERNAL CF 8- CASING,
69 EQT-2 CF 8 IMPELLER
EFFLUENT COLLECTION PIT)
CF 8- CASING,
70 P9-A&B HRSCC FEED PUMP CF 8 IMPELLER
71 DT-14 NaOCL DOSING TANK-2 FRP
72 DP9-A&B NaOCL DOSING PUMP-2 PP
73 DT-15 COAGULANT PREPARATION TANK-2 FRP
74 AG-14 AGITATOR FOR DT-15 SS 316
75 DT-16 COAGULANT DOSING TANK-2 FRP
76 AG-15 AGITATOR FOR DT-16 SS 316
77 DP10-A&B COAGULANT DOSING PUMP-2 PP
78 DT-17 POLYMER PREPARATION TANK-2 FRP
79 AG-16 AGITATOR FOR DT-17 SS 316
80 DT-18 POLYMER DOSING TANK-2 FRP
81 AG-17 AGITATOR FOR DT-18 SS 316
82 DP11-A&B POLYMER DOSING PUMP-2 PP
83 DT-19 LIME PREPARATION TANK MSEP
84 AG-18 AGITATOR FOR DT-19 SS 316
85 DT-20 LIME DOSING TANK MSEP
86 AG-19 AGITATOR FOR DT-20 SS 316
87 DP12-A&B LIME DOSING PUMP PP
88 DT-21 DOLAMITE PREPARATION TANK MSEP
89 AG-20 AGITATOR FOR DT-21 SS 316
90 DT-22 DOLAMITE DOSING TANK MSEP
91 AG-21 AGITATOR FOR DT-22 SS 316
92 DP13-A&B DOLAMITE DOSING PUMP PP
HIGH RATE SOLID CONTACT
93 HRSCC CLARIFIER RCC
94 TD-2 TURBINE DRIVE MSEP
95 RD-2 RAKE DRIVE MSEP
TERTIARY CLARIFIER SLUDGE CI- CASING,
96 P10-A&B TRANSFER PUMP CF 8 IMPELLER
97 CWST-2 CLEAR WATER STORAGE TANK-2 RCC

98 P11-A&B MGF FEED PUMP CF 8- CASING,

52
 CF 8 IMPELLER
99 MGF-2 MULTIGRADE FILTER-2 MSEP
100 ACF-2 ACTIVATED CARBON FILTER-2 MSEP
ULTRA FILTRATION (UF) & REVERSE OSMOSIS (RO) BASED TREATMENT STREAM
CF 8- CASING,
101 P12-A&B UF FEED PUMP CF 8 IMPELLER
102 BSF BASKET STRAINER FILTER SS 316
103 UF ULTRA MEMBRANEMODULE PVDF
CF 8- CASING,
104 P13-A&B BACKFLUSH PUMP CF 8 IMPELLER
105 CIPT-1 CLEANING IN PROCESS TANK MSRL / FRP
106 AG-22 AGITATOR FOR CIPT SS 316
CF 8M- CASING,
107 P14-A&B CIP PUMP FOR UF CF 8M IMPELLER
108 DT-23 NaOCI DOSING TANK (CEB-1) FRP
109 DP14-A&B NaOCI DOSING PUMP (CEB-1) PP
110 DT-24 HCI DOSING TANK (CEB-2) FRP
111 DP15-A&B HCI DOSING PUMP (CEB-2) PP
112 DT-25 NaOH DOSING TANK (CEB-3) MSEP
113 DP16-A&B NaOH DOSING PUMP (CEB-3) PP
114 AG-23 AGITATOR FOR DT7 SS 316
115 UFPWT UF PERMEATE WATER TANK MSEP
CF 8- CASING,
116 P15-A&B RO FEED PUMP CF 8 IMPELLER
117 DT-23 SMBS DOSING TANK FRP
118 AG-24 AGITATOR FOR DT4 SS 316
119 DP17-A&B SMBS DOSING PUMP (AUTO) PP
120 DT-24 ANTISCALANT DOSING TANK FRP
121 AG-25 AGITATOR FOR DT8 SS 316
122 DP18-A&B ANTISCALANT DOSING PUMP PP
123 DT-25 HCI DOSING TANK FRP
124 DP19-A&B HC DOSING PUMP (AUTO) PP
125 CF-2 CARTRIDGE FILTER SS 316
126 P16-A&B HIGH PRESSURE PUMP SS 316
127 RO REVERSE OSMOSIS PLANT FRP/MSEP
CF 8M- CASING,
128 P17-A&B CLEANING SOLUTION PUMP CF 8M IMPELLER
129 AG-26 AGITATOR FOR CST SS 316
130 CIPT-1 CLEANING SOLUTION TANK MSRL / FRP
131 CF-3 CARTRIDGE FILTER SS 316
132 ROPWT RO PERMEATE WATER TANK MSEP
RO PERMEATE WATER TRANSFER CF 8- CASING,
133 P18-A&B PUMP CF 8- IMPELLER

53
 134 RORWT RO REJECT WATER TANK RCC
CF 8M- CASING,
135 P19-A&B RO REJECT WATER TRANSFER PUMP CF 8M IMPELLER
COMMON SLUDGE HANDLING SYSTEM
136 SP SLUDGE PIT RCC
DECANTER CENTRIFUGE FEED CI- CASING,
137 P20-A&B PUMP CF 8 IMPELLER
138 DC DECANTER CENTRIFUGE SS 304
DEWATERING POLYMER
139 DT-26 PREPARATION TANK FRP
140 AG-26 AGITATOR FOR DT-17 SS 316
141 DT-27 DEWATERING DOSING TANK FRP
142 AG-27 AGITATOR FOR DT-18 SS 316
143 DP20-A&B DEWATERING DOSING PUMP-2 PP
BULK CHEMICAL HANDLING SYSTEM IN CPU AREA
BULK HYDROCHLORIC ACID
144 BHAST STORAGE TANK FRP
POLYPROPYLEN
E- CASING,
HYDROCHLORIC ACID UNLOADING
145 DP22-A&B POLYPROPYLEN
PUMP
E- IMPELLER
146 BCST BULK CAUSTIC STORAGE TANK MS
CF 8M- CASING,
147 DP23-A&B CAUSTIC UNLOADING PUMP CF 8M IMPELLER

2.8 ENVIRONMENTAL MANAGEMENT PLAN

A comprehensive environmental management plan will be implemented to keep the
pollution levels within prescribed standards. Following measures will be practiced.
2.8.1 AIR ENVIRONMENT
Dust will be generated during clearing of ground, levelling of site, dumping of earth
and fill material generated from site during drilling for ground water extraction,
construction of foundations waste pit construction and other grading activities.
During ground excavation site preparation in readiness for construction work may
require vegetation clearance stripping off of over burden material, ground levelling
and compaction. These activities will open-up the ground to wind action and will
result in dust generation. Impact on Air Quality -The air quality in the project area
may slightly deteriorate for the time being during construction due to poorly paved
service lane, excavation, delivery of building materials, mixing of construction
materials, construction of temporary structures etc. Movement of trucks bringing

54
plant and machinery shall also generate dust and noise. During construction phase,
dust generation will be the main pollutant, which would generate from the site
development activities and vehicular movement on the road. However,
concentration of NOx and CO may slightly increase temporarily due to increased
vehicular traffic movement.
Air Pollution Control Measure
The aerial emissions would be from Boiler, D.G. Sets and movement of
vehicles during transportation of raw materials and finished goods. Following
mitigation measures has to be undertaken like:
 The exhaust gases and oxides generated through burning to be discharge
through stack of the boiler. A 45-meter-high stack equipped with the bag
Filter has to be provided with the boiler. Generally, the temperature of the
exhaust gases is approx 180°c
 Similarly stack for DG set should be installed with approx height of 30m as
per the Pollution Control board guidelines
 Boiler House shall be totally enclosed with brick-sheet walls and covered with
sheet roofing
 Transfer Points shall be provided with dust collector
 All Internal Road will be made PUCCA
 Covered storage shall be provided for storage of raw material
 Dust mask shall be provided to all workers
 Water sprinkling system shall be installed along the roads
 Ambient air quality and stack emission will be regularly monitored to
maintain the ambient air quality standards
Electro Static Precipitator
Electro Static Precipitator with stack height of 68 Mtr will be provided for the
proposed Boiler (40 TPH).
Table 2.9 Specification for Electro Static Precipitator
Sr. No Description Unit Value
Indonesian Coal(Imp coal )/Rice husk
1 Fuel
/Indian Coal

2 Design Gas flow m3/sec 20/ 20 / 19

55
 3 Emission (all fields in service) mg/Nm3 50
Emission (with 1 field out of NA
4 mg/Nm3
service)
5 Type of ESP Top Rapped ESP
Maximum pressure drop across 30
6 mmWC
ESP
Maximum flue gas velocity across <1
7 m/sec
ESP
8 Design Pressure mmWC ±400
Minimum thickness of CRCA 1.21
9 mm
collecting plate
10 Minimum electrode spacing mm 400

11 No. of ash collection hoppers 1Nos for each Hopper

12 Combined ash storage capacity hrs 4

Casing / Funnel / Hopper 5/5/6
13 mm
Thickness
Ash density considered for Indian 1100
14 Kg/m3
coal
15 Hopper Valley angle Deg 60
Casing Mechanical Design 250
16 Deg C
Temperature
Insulation surface temperature Higher of the Ambient +20 (or)
17 Deg C
with wind velocity as 1 m/s less than 60 Deg C.

18 Material for insulation Mineral wool

19 Material for Cladding Corrugated aluminium sheeting

20 Cladding thickness SWG 24

Minimum clear width of Platform 1000
21 mm
and stairs
22 Staircase Inclination angle deg 45

23 Head Room along Staircase mm Above 2200

24 Field Transformer type Three phase- 95KV (4 x 500mA)

25 Electromagnetic vibrator Applicable- 1Nos per Hopper

SS 409 Lining for bottom 1/3rd Applicable- MOC-SS 409 of
26 part of hopper of 1.6mm thk TE &
2mm thick for complete hopper
TIC
2.8.2 Odour Control Measures
Odour may be caused due to bad management of fermentation house, long
retention of fermented wash, process waste and unattended drains. To mitigate the
odour from the facility below mentioned activities should be adopted:

56
  Better housekeeping by regular steaming of all process equipment‟s.
 Use of efficient biocides to control bacterial contamination.
 Control of temperature during process.
 Avoiding storage of process waste.
 Regular use of bleaching powder in the drains to avoid generation of
putrefying micro- organisms.
1.8.3 Water Environment
Temporary drainage work will be maintained, removed and reinstated as required,
and all other precautions will be taken for avoidance of damage by flooding and silt.
Sedimentation pit of sufficient capacity will be constructed to trap silt-laden water
during monsoon. The wastewater will be reused for dust suppression.
2.8.4 Water Pollution Control
Well planned sewage system will be provided for the proposed unit. Effluent
Treatment plant will be proposed to treat effluent generated from process the treated
water will be recycled to process and etc. Rain water harvesting will be done for
optimum utilization of natural resources.
2.8.5 Solid Waste Management
The waste to be generated from the proposed distillery unit (Solid waste,
waste water, effluent from process) will be treated as per MoEF/PCB norms and
disposed of as per the same. The effluent generated from the process will be treated
in the proposed ETP.
The solid waste will be generated from this unit is as follows.
Table 2.13 Solid Waste Management

S. No. Description Quantity Method of Disposal

The concentrated
Sludge from the CPU sludge shall be Bio-
1. 2 TPD
& WTP Composting and used
as a manure
Boiler Ash : 2.98 TPD
of Ash /43.2 TPD of
Imported Coal
Will be used for
2. Boiler Ash &
making fly ash bricks
22.80 TPD of Ash
/127.2 TPD of Rice
Husk (Broken Rice)

57
 Boiler Ash : 3.15 TPD
of Ash /45.6 TPD of
Imported Coal
Will be used for
3. Boiler Ash &
making fly ash bricks
24.19 TPD of Ash
/134.4 TPD of Rice
Husk (Dry Maize)

2.8.6 NOISE ENVIRONMENT

The noise generated during the constructed phase will be due to the movement of
vehicles and construction equipment. Construction equipment and transport
vehicles will be properly maintained so that noise generation is minimized. Regular
maintenance schedule will be adopted for all constructed equipments and vehicles.
Noise Pollution Control
To mitigate the impact of noise from process equipment‟s such as mill, turbine,
diesel generator sets during the operational phase, following measures are
recommended for implementation,
 Provision of noise shield
 DG set will have inbuilt enclosures
 Use of personal protective devices such as ear-muffs, ear-plugs etc. will be
strictly enforced for the workers engaged in high noise areas, viz. ball mill,
turbine etc.,
 Green belt is good noise barrier and the same shall be developed in and
around plant premises
2.8.7 GREENBELT DEVELOPMENT AND PLANTATION
Greenbelt will be developed inside the factory premises covering a total area of
about 3.01 Hectares (7.44 Acres). The inter-spaces are laid with shrubs. The inter-
space between trees planted is about 5 m.
Local plant species with pollution abating characteristics will be selected for
plantation programme and to improve aesthetic environment of the area.

58
 Table 2.14 List of Big Trees for Proposed Plantation

Common Name Scientific Name Family No of Trees

1. Arjun Terminalia arjuna Combretaceae 600

2. Ashwatha Ficus religiosa Moraceae 500

3. Akashmoni Acacia moniliformis Mimosaceae 350

4. Aam Mangiferaindica Anacardiaceae 425

5. Pipal Ficus benghalensis Moraceae 380

6. Chatim Alstonia scholaris Apocynaceae 375

7. Debdaru Polyalthia longifolia anonaceae 300

8. Ghora neem Meliaazedarch Meliaceae 550

9. Ashok Saraca asoca Fabaceae 450

10. Jarul Lagerstroemia speciosa Lythraceae 300

11. Karanj Derris indica Fabaceae 320

12. Krishnachura Delonix regia Caesalpinaceae 425

13. Neem Azadirachta indica Meliaceae 600

Total 5575

59
 CHAPTER III
ANTICIPATED ENVIRONMENTAL IMPACTS DUE TO PROJECT
3.1 GENERAL
The purpose of this Chapter is to identify the sources that will have impacts
on Environment with various Environmental attributes. Identifying the impacts will
help in suggesting mitigation measures to ensure that the baseline status of the
surrounding environment will be maintained even after the activity resumes
whether for short term or long term.
Environmental impact in the study area alters environmental conditions or creation
of new set of environmental conditions, adverse or beneficial, reversible or
irreversible caused or induced by the activity of the project. But, the impact should
be kept at minimal by incorporating mitigation measures.
a. Air Environment
b. Noise Environment
c. Water Environment
d. Land Environment
e. Socio-Economic Environment
f. Ecology and Biodiversity

3.1.1 Identification, Quantification and Rating of Impacts

Identification and quantification of environmental impacts has been made,
based on understanding of cause-condition-effect relationship between an activity
and the impact. The activities identified as sources having potential to cause impact
upon the environmental parameters due to proposed project during the construction
and operation phase. The impacts are quantified/rated using the following matrix
with due consideration to SSPD i.e., scale of impact, severity of impact, probability of
occurrence of impact and duration of impact. The purpose is to segregate the vital
impacts from trivial ones and to focus with additional attention on the vital impacts
for suggesting mitigation measures.

60
3.1.2 Rating of Impacts
The proposed matrix for identification and rating of impacts is given in Table 3.0 and
Criteria for rating - scale, severity, probability and duration is given in Table 3.1.
Table 3.1 Matrix for identification and rating of impacts
Cause/
Sl. No Activity
Aspect Impact
Scale Severity - Probability Duration Significance Rating =
1 to 5 1 to 5 1 to 5 1 to 5 SxSxPxD

Table 3.2 Criteria for rating - scale, severity, probability and duration

Scale S Rating Severity S Rating

At the work area 1 Minor Injury requiring first 1

aid

Within premises 2 Injury requiring 2

hospitalization

Outside Premises in 1 km 3 Temporary disability 3

radius

Outside Premises beyond 1 4 Permanent disability 4

km & less than 5 km radius

Beyond 5 km radius 5 Loss of life/s 5

Probability of Occurrence P Rating Duration D Rating

Once a Year 1 Less than 1 hour 1

Once a month 2 Less than 4 hours 2

Once a week 3 One day 3

Daily but intermittently 4 More than a day 4

Continuous 5 Few months 5

Significance is arrived at by multiplying the individual ratings assigned to scale,

severity, probability and duration as the impact is interdependent on each of these
parameters. Higher the number, higher is the significance; the significance rating

61
varies from min 01 to max 256. The Matrix and rating will be done at the end of this
chapter after the impacts are identified and mitigation measures are proposed.
3.2 Project Location
M/s. SPAC Starch Products (India) Private Limited has proposed to establish
a Distillery Unit with the capacity of 160 KLPD (Absolute Alcohol) and 4.6 MW Co-
gen plant at SF. No. 118/2, 118/3, 118/4, 118/7, 118/8, 118/9, 118/10, 118/11,
118/12, 118/13, 118/14, 118/18, 119/13, 188/1A, 189/8, 189/9, Mugasipudur
Village, Anthiyur Taluk, Erode District, Tamil Nadu. The project site is bounded
within the unclassified area. Primarily it is necessary to study the environmental
setting, land use and land cover around the industrial activity to identify the
sensitive receptors and to identify the impact due to proposed expansion on each
environmental attribute. Suitable mitigation measures are then proposed to ensure
that there is minimal environmental impact from the industry.

3.2.1 Land Use and Land Cover in the Study Area

Land-use refers to the way in which the land has been used by humans and
their habitat, usually with accent on the functional role of land for economic
activities. It is the intended employment of management strategy placed on the land-
cover type by human agents, and/or managers. Land-cover refers to the physical
characteristics of earth‟s surface, captured in the distribution of vegetation, water,
soil and other physical features of the land, including those created solely by human
activities; for example;- settlements. The land use and land cover are complex and
largely continuous pattern and in order to understand its complexity, it is necessary
to characterize them. The satellite remote sensing, with its synoptic view and
repetitively, is very helpful in order to cover large areas within a short time to
characterize land use/land cover qualitatively. Remote sensing is a powerful and
accurate means of collecting data. The study of satellite imagery gives an excellent
opportunity to monitor the quantitative extent of vegetation cover as well as
qualitative changes due to changes in environment.

62
3.3 Objectives of Environmental Management Plan
Objectives of environmental management plan is to,
 Identify the key environmental issues to be encountered during construction
and operation phases of the project.

 Provide guidelines for appropriate mitigation measures.

 Ensure that the mitigation measures are implemented to comply with all legal
requirements while meeting the sustainable development and social
obligation.

 Establish systems and procedures for implementing mitigation measures to,

 Treat and dispose-off all the pollutants viz. air, liquid gaseous
and solid waste

 Promote green-belt development

 Ensure good working condition for employee

 Monitor the effectiveness of mitigation measures.

 Take necessary prompt action when unforeseen impact occurs.

3.4 Environmental Management Cell (EMC)

The most important component of the environment is to fix the responsibility
of implementation of the EMP, for which there should be an organizational set-up
i.e., Environmental Management Cell (EMC). The unit will assign responsibility to
officers to perform and co-ordinate the activities concerned with management,
different departments in the factory and implementation of environmental control
measures.

A. Structure of Environmental Management cell

Environmental cell will be constituted in the industry for effective management of
environmental protection and pollution control. It will consist of senior factory staff
members.
B. Environmental Cell:
Members with designation of EMC are given in Table 3.3.

63
 Table 3.3 Environment Management Cell
Sl. No. Designation Member
1 Chairman Mr. N. Ramalingam
2 Managing Director Mr. R. Suryakanth
3 Chief Operating Officer Mr. E. Vetrivel
4 Other Department Heads Associate Vice President
(Operation & Maintenance)
Project Manager

i) Purpose of Environmental Management Cell

The main aim of environmental cell is to plan, implement and monitor the measures
related to:
i. Pollution control and environmental protection
ii. Continual efforts and planning for sustainable development through
cleaner technology
iii. Conservation of natural resources
iv. Statutory provisions.
ii) Activities
i. Collection of information regarding-
 Implementation of Environmental Management Plan
 Identify activities causing adverse impacts on environment
 Measures to prevent or reduce the waste at source
ii. Financial provisions for installation of pollution control and environmental
protection facilities.
iii. To provide staff and labour for management of environment and also for the
operation and maintenance of pollution control facilities and self-monitor system.
iv. Ensure routine monitoring within industry premises.

64
 Table 3.4 Responsibilities of Environment Cell personal & others
Sl. No Designation Responsibility
1 Environmental Engineer In charge of operation and maintenance of
pollution control facilities.
2 Environmental Officer In charge of environmental management,
liaison with Environmental Cell,
responsible for statutory compliances,
maintenance of records, interaction other
departments of the industry and guidance
to environmental staff.
3 AGM (Production) Maintaining lab facilities, monitoring of
discharges, ambient environment
parameters etc.
4 ETP Operators Operation and maintenance the ETP.
5 APC Supervisors Operation and maintenance ESPs.
6 Supervisor (Greenery) Operation and maintenance of green belt.
7 Safety Officer In-charge for safety activities for entire
factory.
8 Medical Officer Maintain factory dispensary and providing
first aid medical care.

D. Records to be maintained
Following records will be maintained by the environmental department in respect of
operation of pollution control facilities
 Log sheet for operating ETP for wastewater
 Log sheet for operation of APC equipments
 Instruction manual for operation and maintenance of ETP, APC, etc.
 Log sheets for self-monitoring of ETP, APC etc.
 Manual for monitoring of air, water and soil for ambient conditions

65
  Instruction manual for monitoring of water, solid and gaseous parameters
discharged from the factory and also for various parameters of pollution
control facilities.
 Statutory records as per the Environmental Acts.
 Monthly and annual progress reports.

3.5 Environmental Policy

 To attend to the environmental concerns, Environmental Cell and
Environmental Department will be created in the industry. Environmental
Management System, ISO 14001 will be implemented during operation phase.
 Ensure the allocation of sufficient financial, human and technological
resources along with organizational infrastructure for its implementation.
 Prepare and maintain site specific, list of all the applicable regulations legal
records, compliance requirements and compliance status.
 Develop and implement innovative processes focused on reducing
consumption of energy and water and minimizing quantity of waste disposal.
 Review facilities and programs on a regular basis and establish monitorable
targets, quantified as appropriate for continual improvement of our
environmental performance.
 As far as practicable, purchase products and services that will have minimum
impact on the environment.
 Communicate the environmental commitment and performance of the
organization to the stakeholders.
 Establish an organizational structure to oversee the effective implementation
of corporate environment policy. Define key responsibilities with the various
levels of organization for policy implementation.

3.5 Environmental Training

EMC would be responsible for the implementation of the EMP, needs to be trained
on the effective implementation of the environmental issues. To ensure the success of
the implementation set up proposed, there is a high requirement of training and skill

66
up-gradation. For the proposed project, additional training facilities will be
developed for environmental control. For proper implementation of the EMP, the
officials responsible for EMP implementation will be trained accordingly.
To achieve the overall objective of pollution control it is essential not only to provide
latest pollution control and monitoring systems but also to provide trained
manpower resources to operate and maintain the same. Therefore, apart from the
EMC, specific training will be provided to personnel handling the operation and
maintenance of different pollution control equipment. In-plant training facilities will
be developed for environmental control. The training will be given to employees to
cover the following fields:
 Awareness of pollution control and environmental protection to all.
 Operation and maintenance of specialized pollution control equipment.
 Organize field monitoring, maintenance and calibration of pollution
monitoring instruments.
 Laboratory testing of pollutants.
 Repair of pollution monitoring instruments.
 Occupational health/safety.
 Disaster management.
 Environmental management.
 Afforestation /plantation and post care of plants.
 Knowledge of norms, regulations and procedures.
 Risk assessment and Disaster Management.

3.6 Other Responsibilities of the Cell Will Include

MOEF&CC approved lab will be retained to generate the environment quality data
in respect of air, water, noise, soil and meteorology and prepare the Environmental
Report.
 Timely renewal of Consents & Authorization will be taken care of.
 Submitting environmental monitoring report to SPCB. The cell will also take
corrective measures as required or suggested by the Board.
 Conduct and submit annual Environmental Statement to SPCB.

67
  Prepare and submit six monthly report on the compliance with the conditions
of the environmental clearance
 Keeping the management updated on regular basis about the findings/
results of monitoring activities and proposes measures to improve
environmental performance.
 Conducting regular safety drills and training programs to educate employees
on safety practices. A qualified and experienced safety officer will be
responsible for the issues related to occupational safety and health.
 Conducting safety and health audits to ensure that recommended safety and
health measures are followed.
3.7 Anticipated Accidents and Mitigation Measures
During construction phase: Accidents during fabrication and erection.
During operation phase:
 Spillage during handling, loading and unloading into tanks.

 Accident during raw material and finished product

transportation/conveyance.

 Process/utility accidents

 Overflow from storage tank

3.9 Mitigation measures

For prevention of accidents during construction phase contractor will be
instructed in the work order that meeting shall be conducted prior to taking up any
work to apprise the workmen of the probable accidents and the preventive action to
be taken. Personal Protection Equipment to be provided to all construction workers.
During operation phase, only trained workmen will be engaged. All process
operations will be carried out based on SOPs. Untrained workers will be made to
work along with trained workers to get hands on experience before they are
assigned independent job. Personal Protection Equipment will be provided to all
workers. All the employees will be imparted refresher training periodically. Onsite
and offsite emergency plans will be drawn and followed. Adequate number of fire-
fighting equipment will be provided at strategic locations.

68
3.10 Safety/Environmental Impact and Mitigation Measure
The project will be designed to minimize the Environmental Impact keeping safety
and environment in priority. Construction activities are going on for approved
capacities and the industry is yet to be commissioned.
3.11 Environmental Impacts during Construction and Operation Phase
Project impacts are divided in two phases:
A. Construction phase: These impacts are temporary or short term and cease
with implementation of the project.

B. Operation phase: These impacts are continuous and warrant built-in

permanent measures for mitigation and monitoring.
Project will have an impact on environmental parameters both during construction
and operation phases. Sources have been studied to identify the impacts on
environment and suitable mitigation measures suggested.
The following aspects are considered in prediction of impact on environment during
the construction and operation of the project and prepare environment management
plan:
 Nature (Positive/negative/direct/indirect/ cumulative impacts)
 Size of the impact (severe, moderate, low)
 Location and extent area (volume/covered/distribution)
 Timing (during construction, operation, immediate, delayed, rate of change,
decommissioning etc.).
 Duration (short term, long term, intermittent, continuous)
 Reversibility/irreversibility
 Likelihood (probability, uncertainty or confidence in the prediction)
 Significance (local, regional, global)
3.11.1 Construction Phase
Activities during construction phase include fabrication, erection & civil works.
Impact during Construction Phase:
Major Construction activities related to our project of Grain based Distillery are as
mentioned below,
1. Land and Site Clearance

69
2. Internal Roads Construction
3. Building, Civil and Structural Construction
4. Machinery and Mechanical Installation
5. Material Handling and Storage
6. Transportation and machinery movement
7. Temporary Sheds Construction
3.11.2 Environmental Impact during Operation Phase
The main impacts during the operation phase are the safe operation of plant and
machinery, Ethanol storage and transportation and utilities viz., wastewater
handling, treatment and disposal, air pollution from the boilers and emission control
measure and the solid and hazardous waste handling and disposal.
The major activities during the operation of the plant contributing to the impact are
as under:
 Raw material storage and transportation
 Manufacturing activity
 Operation of boilers viz., fugitive emission during feeding of fuel to boiler,
boiler emission, solid waste (fly ash and bottom ash) handling and disposal
 Water aspects viz., DM plant and softener back wash, spent wash, spent lees,
condensate from evaporator, boiler blow-down, cooling tower bleed &
washing.
 Conservation of water, maximizing the recycle water and thus reducing the
fresh water consumption.
 Reduction of steam loss
 Solid and hazardous waste handling and disposal
 Noise due to operation of plant and machineries Storage of RS/Ethanol.

70
 Table 3.5 Environmental impacts & mitigation measures during construction phase
Sl. No. Activity Impact Duration Mitigation measure Significance
Air environment • On ambient air Short term • To use well-maintained Low and
1  Civil work like levelling, quality generation of construction machinery & reversible
excavation, material airborne particles. vehicles.
unloading, construction, • Effect on respiratory • Construction materials to
erecting etc. system of the workmen. be stored in a barricaded area
 Vehicles used for • Deposit on the and covered to avoid dust
transporting construction vegetation/ green belt. getting air borne.
material could result in • To sprinkle water to
emissions to environment. suppress the dust generated
 Gas cutting and welding during levelling, excavation,
jobs – the release of and other operations.
gaseous pollutants. • The welding and cutting
 Construction debris jobs to be carried out with
unloading and loading. adequate ventilation/
exhaust arrangement.
• Collection of debris at
designated places and to
cover in order to avoid
71
 fugitive emissions. The
debris to be disposed at low
laying areas or used in road
making in consultation with
local body.
• Water sprinkling on
internal roads to avoid
fugitive dust due to vehicle
movement.
• To deploy transport
vehicles having emission
under control test report.
 Vehicular movement • Increased noise level Short term • To cover the work zone Low and
2 carrying construction at work zone. with barricades. reversible
materials. • Hearing impairment • To provide suitable PPE to
 Some intermittent noise is • Irritation personnel.
expected during • To carry out the civil works
fabrication at site and only during day time and to
erection of equipment. monitor and regulate the
 Erection of machineries. vehicular movement.

72
3 Water environment Increase in turbidity Short term • Construction debris to be Low and
 Run off carrying silt from and suspended solids of stored in a designated place reversible
accumulated debris, surface water quality. and covered to avoid
construction material etc. washing off with rain water.
 Domestic sewage from • The debris to be disposed
workers. at low laying areas or used in
road making to avoid water
logging at construction site
and also at disposal sites.

Land environment Long term •To adopt soil conservation Low and
4  Disposal of excavated soil • Siltation of drains by proper management viz., reversible
and debris may result in •Deposition on the excavated earth collected
water logging and loss of vegetation and property and used for foundation,
fertile topsoil. leveling, plinth and disposed
 Spillage of oil and grease. to low laying areas, road
works.
• To separate the top soil and
use it for gardening.

73
 • To collect the spillage if any
and dispose scientifically.
5 Ground water & surface water • Accumulation of Short term • Proper drainage system Low and
debris and runoff will be provided. reversible
during rains. •Providing and
• Domestic sewage strengthening greenbelt in
from construction and around plant.
Workers contaminating • Storage of construction
surface drains. material and debris in a
secured manner, to avoid
runoff with rain water.
Socio economics Employment Short term •Employment opportunities Low and
6 opportunities for skilled and unskilled beneficial
manpower.
7 Ecology and biodiversity Flora, fauna, terrestrial No impact • As project site is vacant -
and aviation species. land, there will be no impact
on ecology and bio diversity.

74
 Table 3.6 Environmental Impact and Mitigation Measures During Operation Phase

Sl. No. Environmental Source of impact Predicted impacts Mitigation measures Remarks
components
1 Air quality • CO2 emission from • Anticipated • To provide ESP and chimney Low adverse
fermentation. Impact in the height of 68 m AGL for boiler impact
• Emissions from boilers baseline • To provide for water (localized in
• Emissions from DG set concentration due to sprinkling on internal roads to nature).
• Vehicular movement the industry are PM, avoid fugitive dust due to
• ETP area SO2 & NOx vehicle movement.
• Solid and hazardous waste envisaged. • To deploy transport vehicles
storage area •Emissions will having „emission under control‟
impact the air test report.
quality. Increase in • To maintain the air pollution
particulate matter control equipments provided to
concentration in boilers.
AAQ, results in • Finished product ethanol to be
respiratory transferred using automatic
problems in pumping system to the storage
humans, deposits tanks provided with tank farms.
on vegetation and • To maintain good

75
agricultural crops housekeeping in the process
affecting area and also inside industry
photosynthesis, premises.
plant growth, yield • To maintain the DG set and
etc. stacks of 15 m for 1000 kVA
• Greenhouse gas • To practice regular
emission maintenance of vehicles, regular
contributing to cleaning and watering of
global warming. internal roads and to regulate
•Odour nuisance the movement of vehicles.
•Effect on human • To clean the spent wash, drain
health like nausea, periodically.
asthma, eye •To reduce the storage time of
irritation spent wash to avoid odour.
• Fragrance flowering trees or
shrubs to be planted near odour
generating areas like ETP etc.

76
2 Noise • Noise from operation of The nearest place of • Ambient noise levels to be Low adverse
machineries, motor pumps, habitation from the monitored at industry boundary impact
compressors industry Anthiyur at regular intervals. (localized in
• Operation of boiler and DG (10.5 km). • To make mandatory for the nature)
set. workers and officers to use PPE
• Vehicular movement. (ear plugs)/ear muffs in high
• Process section. noise areas.
• Transportation of raw • To house motor pumps,
materials and finished compressors in enclosures.
products. • To maintain machineries and
• Operation of utilities. conveying system by following
routine and periodic
maintenance to reduce noise
generation.
• DG set with acoustic
enclosures.
• Boilers – silencers to be
provided to steam safety valves
and steam straps are to be
provided to main pipelines.

77
 • To regulate the speed limit
inside plant and transportation
to be done only during peak
hours.
• To develop and maintain
greenbelt at the project site
boundary.
3 Water Discharge of process effluents 1. Cooling water • To adopt ZLD concept for Low adverse
environment from distillery viz., spent blow down from treatment and use for distillery impact
wash and spent lees, utility Distillery Plant effluent. (localized in
effluent boiler blow down, 2. Cooling water • To store the raw materials and nature)
cooling tower bleed, blow down from finished products in dedicated
condensate from MEE etc. Cogeneration Plant storage area/tank will be
Boiler blow down constructed with suitable PCB
3. WTP norms to avoid percolation.
effluent/reject
4. Multiple Effect
Evaporator
condensate
5. Dryer Vapour

78
 Condensate
6. Sewage water
Water pollution
affecting surface
and ground water
quality.
4 Land • Accidental spillage of Land • Soil quality to be tested and No significant
finished products. contamination. studied each season. impact
• Spillage/ disposal of Leaching into • To follow the concept of ZLD
hazardous waste ground. for distillery effluent
• Disposal of yeast sludge. Eye sore. management; treated
• Disposal of sludge from the wastewater reused in cooling
ETP. tower makeup and for dilution.
• To segregate domestic solid
wastes at source. The wet waste
be composted and the inert dry
waste be disposed to authorized
recyclers.
• To store the used oil in the
secured manner and dispose to

79
 authorized vendors.

5 Solid waste • Disposal of boiler ash. • Anticipated solid Low adverse

• Disposal of used oil. waste generation • To collect the solid waste in a impact
• Disposal of DDGS. 1. Boiler Ash secured manner. (localized in
• Disposal of ETP sludge 2. Sludge from the nature)
CPU & WTP Disposal and management as
• Land detailed above.
contamination. Sludge from ETP will be used
• Leaching into as manure
ground.
•Eye sore to the
public.

80
6 Socio-economic • Employment of local • Socio economic • To employ locally available Strongly
people. impact manpower to the maximum beneficial
possible extent. (positive)
• To engage the local people for impact
raw material supply,
transportation and security
system.
• To aim at capacity building by
skill development to encourage
the local people to take up job in
the factory.
• To aim at development of
local infrastructure facility
• To take up development of
social facilities like construction
of temple, educational facilities
etc.

81
7 Biodiversity • Operation of distillery, and Impact on flora, and • To keep all the pollution No significant
cogeneration fauna due to the control facilities in operating impact
noise and emission condition and to meet the
from the boilers regulatory compliance and
beyond to ensure that the
biodiversity is not affected.
• No trees shall be cut.

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3.12 Pollution Control Measures and Management Plan
3.12.1 Air Pollution Management Plan
Stack emissions
 Online stack monitoring system will be provided to keep a check on
emissions and implement proper measures in case of any failure or violation
of prescribed standards.
 Regular cleaning, inspection and maintenance of air pollution control
equipment will be carried out.
 Ensuring preventive maintenance of equipment.
 Workers will be trained regarding emergency actions to be taken during
equipment failure.
 The whole distillery unit will be provided with facility of inter locking so that
any failure of equipment or APCE will result in instant shut down of the
complete process.
DG sets will be used only for emergency purpose and in case of power failure
3.12.2 Action Plan for Control and Monitoring of Fugitive Emissions
The fugitive dust (PM) emissions shall occur from road, raw material unloading and
loading, vehicle movement leading the re-suspension of settled dust, etc. Following
mitigation measures are recommended for its control:
 Apply water to suppress dust generation
 Stabilized concreted earthworks with stone, soil, geo textiles, vegetation,
compacting.
 Use enclosures – covering for stockpiles – tarpaulin, plastic, fences, screens
 Keep proper shape of stockpiles (avoid steep slopes and faces)
 Remove muck from truck tyres and under bodies prior to leaving the plant
premises
 Minimize the drop height of raw materials
 All road surfaces for permanent movement of trucks shall be paved
 Use mechanical road sweeping machine for regular cleaning of roads
 Use industrial vacuum cleaner for cleaning all shop floors and roofs.

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3.12.3 Noise Pollution Management Plan
During proposed project, the major noise-generating source will be machinery and
equipment. The proposed equipment of the project would be designed in such a way
that noise levels do not exceeding the stipulated standard as prescribed by
SPCB/CPCB.
In general the following methods will be adopted to control the noise pollution.
 The use of barricades
 The use of vibration insulation techniques at foundation of fans and other
moving machinery.
 The use of mufflers, and acoustic louvers in DG sets.
 Proper plantation of trees.
 Providing earmuffs and earplugs to the plant personnel.
 Avoiding continuous (more than 8 hrs) exposure of workers to high noise
areas.
3.12.4 Water Requirement
The entire raw water (2899 KLD) for the unit will be met from the Kaveri River at
6.34 km form the project site. In order to reduce the water requirement, it is also
proposed to use rainwater harvesting structure within the industry. From the use of
collected rain water, the total water requirements can be reduced.
Water Quality Management
The entire wastewater from the plant will be reused and there will be no discharge
of waste water outside the plant premises under normal circumstances. The
distillery will be based on “Zero Liquid Discharge” concept. Following measures
will be followed:
 Online monitoring System consisting of flow meter to analyse ETP/CPU
effluent quality will be installed.
 Proper maintenance of state of the art ETP/CPU will be carried out.
 Regular testing of samples at every outlet of ETP/CPU will be carried out to
monitor the outcome after every treatment process.
 Regular monitoring and maintenance of equipment/machineries will be done
and records maintained.

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  Periodic checking to find out any leakages or areas susceptible to leaching
will be undertaken in order to save the ground water contamination.
 Regular cleaning of all equipment and machineries will be done in order to
avoid water clogging areas or any corrosion in the machinery and equipment.
Action plan to control ground water pollution
The distillery will be based on “Zero Liquid Discharge”. The following measures
will be adopted to prevent groundwater pollution:
 During operation phase, spent wash will be treated and will not be discharged
on soil/water.
 Treatment of secondary streams like spent lees, condensates, blow downs, etc.
shall be in closed loop & any discharge outside the distillery shall not be done.
 Spillage of chemicals/ oils/ etc. will be avoided as best possible.
 The spent wash holding tank will be made up of RCC & steel.
 Regular checking of spent wash storage lagoon will be carried out in order to
check for any leakages or leaching.
 Monthly monitoring of ground water will be done in and around spent wash
storage lagoon under environmental monitoring program and parameters will
be checked in correlation with drinking water standards IS 10500-1991.
 In case of accidental spillage, proper measures will be undertaken immediately
in order to prevent the substance from entering into ground water route.
 Storm water drains will be made along the plant boundary. Sedimentation pits
will be provided along the storm water drains. The runoff will be discharged
to municipal sewer.
 Garland drains will be provided along the raw material stock yard. The water
will be collected in sedimentation tank, treated and then reused for dust
suppression.
Water Conservation
The following measures will be adopted to minimize use of ground water-
Maximum recycling and reuse of wastewater after treatment. Condensate water will
be re used & recycled.
 Total percentage saving due to rain water will be reused in distillery process.

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  Tracking of consumption of water.
 Periodic preventive maintenance of water distribution system.
 Optimum use of process cooling water.
 Training and awareness on water conservation measures.
 In addition to above, rainwater harvesting will be done at project site to
harvest rainwater from the roof tops and use for various activities at the plant
site to conserve fresh water and reduce the water requirement from other
sources. Rain water will be collected through open channel & pipelines in to
storage tank.
3.12.5 Solid Waste Generation & Disposal
The following will be the solid waste generation from the existing plant and method
of disposal:-
 Maximum re-cycling and utilization of generated solid waste shall be done as
per the guidelines.
 Unit will prepare Hazardous waste disposal plan, as per applicable statutory
conditions under the Hazardous Wastes Act, 2016 and same will be
implemented accordingly.
 EMC will keep a record of quantity of solid and hazardous waste generated
and their proper disposal.
 A separate designated storage area shall be provided with sign boards/labels
for storage of hazardous waste.
 The concerned person will prepare a site manual on the total program and
activities of solid/hazardous waste management.
 Regular training of employees engaged in solid waste management works.
3.12.6 Hazardous waste generation, storage & disposal
Waste oil generation: 80 L/500 hours
The used oil from the DG set will be given to the authorized recyclers. The lead acid
battery or dry battery will be given to authorized recycler having authorization from
competent authority. E-waste generated from the plant will be given to authorized
recycler having authorization from competent authority; the other wastes i.e.
Municipal solid wastes and their proposed management is given below table.

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 3.6 Municipal Solid Waste Generation and its Disposal
Type of Municipal Solid Waste Proposed Method of Disposal
Construction debris (generated Used for landfill within the plant site to the
during construction phase) extent possible and recyclables will be given
to authorized recyclers.
Canteen waste  Used in composting/Vermi culture.
 Used as manure for greenbelt
development within the premises.
Recyclable materials Dispose through SPCB authorized
dealers/vendors.

3.12.7 Waste Minimization, (Reuse, Recycle & Recover Techniques), Energy and
Natural Resource Conservation Measures
(A) Reuse
 Yeast sludge will be added to wet cake.
 ETP sludge will be disposed off as per applicable norms
(B) Recycle
 Spent Lees and PR lees will be recycled to fermentation column
 Recycling or usage of recycled water at every stage of the process
 The process water will be treated in CPU and recycled in the process and
within plant premises.
 Used oil and grease from machineries/equipment will be treated and used.
(C) Recovery
 Concentrated spent wash will be used for the recovery of DWGS followed by
DDGS to be used as cattle feed.
 CO2 generated during the fermentation process will be recovered by CO2
Scrubbers and sold to beverage & packaging industry.
 Water conservation & recirculation system shall be installed for recovery of
cooling water.

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3.13 Storm Water Management
3.13.1 Storm Water and Irrigation Management Plan
It is seen from the drainage and elevation map of the area that there are many first,
second and third order streams within 10 km radius from the industry. Possibility of
rain water runoff carrying the residue/from the irrigation fields or excess irrigated
water flowing in the natural drain. Even the rain water received in the factory area is
expected to flow into the natural drain. Therefore, a well-drawn storm water
management plan is required.
3.13.2 Storm Water Generated Within Factory Premises
Rainwater Harvesting Potential
The total amount/quantity of water i.e. received in the form of rainfall over an area
is called the rain water endowment of that area, out of which the amount of water
that can be effectively harvested is called the rain water harvesting potential.
Rain water harvesting potential = rainfall (mm) x collection efficiency.
The collection efficiency accounts for the fact that all the rain water falling over an
area cannot be effectively harvested due to losses on account of evaporation, spillage
or runoff etc. Adequate rainwater harvesting will be adopted to management of
storm water drains.
3.14 Greenbelt Belt Development
Development of greenbelt in and around industrial activity is an effective way to
check pollutants and their dispersion into surrounding areas. The degree of
pollution attenuation by greenbelt depends on its height and width, foliage surface
area, density, dry deposition, velocity of pollutants and the average wind speed
through the green belt. The main objective of green belt around the
factory is:
 Preventing land degradation and erosion of topsoil.
 Containment of pollution in the industrial environment, capturing of fugitive
emissions if any and thereby improving the quality of the surrounding
environment

 Substantially reducing the adverse environmental impacts due to the

proposed industrial activity.
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  Serving as a barrier for attenuating the intensity of noise generated.

 Adding aesthetic value to the project area.

Keeping in view the soil and availability of water in and around the industry, the
topography of land; green belt is developed in the industrial complex. Out of 22.55
Acres of the project site, 33% i.e., 7.44 Acres is earmarked for the greenbelt
development. Number of trees to be planted at the rate of 1,500 trees per hectare as
per guidelines.
The plants exhibiting the following desirable characteristics will be selected for
plantation;
 Local species
 Fast growing
 Wind-firm and deep rooted
 Dense canopy
 Species tolerant to air pollutant like Neem tree are preferred
 Flowering trees
 Fruit bearing trees to attract birds
 Medicinal plants
Plantation: This will include digging pits with proper spacing, filling pits with
prepared soil, plantation of seedlings and watering. The size of the pit will be 1m x
1m x 1 m for trees and 0.5 m x 0.5 m x 0.5 m for shrubs. The pits will be filled with
soil mixture. The soil will be irrigated soaking wet prior to placing of seedling. The
water required for greenbelt development will be met from the treated effluents
generated during plant operation. During construction period water supply will be
met from available sources. Plantation will start from the beginning of construction
activity (after the site is made clear and demarcating the green portion). Soil
proposed to be filled in the pit after plantation will be mixed with compost (1:1).
Plantation will be done after first rainfall. Adequate protection will be ensured for
achieving high survival rate of the planted saplings. Water and nutrients/manure
will be given at appropriate intervals.

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3.15 Energy Conservation Measures
Energy conservation measures are implemented through:
 Regular maintenance of equipment to ensure optimum operations and fuel
efficiency.
 Employing renewable energy sources such as solar lighting.
 Efficient work scheduling and methods that minimize equipment idle time.
 Using energy efficient electrical appliances.
 Good insulation practices to prevent heat losses.
 Installation of energy efficient lightings. Use of energy saving light fittings.
 Installation of LED/CFL lighting.
 Use of Low-pressure sodium lamps for outdoor lighting along the road and
security lighting with Solar Street Lights mix.
 Use of energy efficient electric motors complying IEE3 Standards.
 Designing the structures having proper ventilation and natural light. Use of DCS
controls
 Use of highly efficient VFD, minimizing idle running of machines.
 Optimizing loads and periodic preventive maintenance & lubrication
 Prevention of leakages of compressed air
 Optimized compressed air pressure.
 Periodic energy audits.
 Training, awareness and motivational programmes.
 Plant is designed for very low steam and power consumption with the use of
state of art technology
3.16 Good Housekeeping
Good housekeeping practice is changing existing practices or introducing new ways
of operating and maintaining the equipment in the industry. Good housekeeping
can prevent accidents, spillages and leakages, raw material & product loses. For
good housekeeping following practices are adopted:
 All the materials are stored in compatible groups

 Appropriate tools are provided for handling of materials

 All the passages and floors are maintained in good condition

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3.17 Environment, Health and Safety (EHS)
Health related issues can occur in the industry due to long term exposure in dusty,
noisy area and gaseous emissions. It is of utmost concern for a industry to conduct
its business in a manner that will promote the protection of the occupational health
& safety of its employees and others involved in or affected by its business
operations and address the environmental concerns.
Occupational health centre, ambulance in case of emergency and fire engine shall be
provided in the campus.
Safety measures proposed to prevent occupational health hazards:
 Electrical equipment shall be properly earthed and electrical isolation
method are developed & displayed at required locations.

 Training to be given to all the employees initially and refresher trainings

to be repeated at regular intervals as required improving awareness. Ex.
Medical, fire and safety trainings.

 Work rotation for the workers in high noise area to no / low noise areas to
ensure that there is no impact on audibility and mental health.

 Drinking water and sanitation facilities to be ensured.

 Work area specific personal protective equipment to be provided.

 Pre-employment and annual health check-ups for the workers and records
maintenance.

 Commitment by the industry to provide and implement environmental

management system.

1.18 Work Zone Monitoring

Following measures are incorporated at process area;
 Molasses and finished products will be stored at temperatures as per the
prescribed storage condition.

 All containers to be provided with secondary containment/tank form.

 Specific and adequate protection to be provided to employees in the form of

PPEs, protective gear etc.

 Adequate ventilation to be provided at all work places.

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  Work zone noise monitoring to be carried out at regular intervals.

3.19 Odour Sources and Control Measures

Odour is generated from fermentation area, storage tanks, grain handling area, and
compost area, effluent treatment facility of distillery plant and yeast
handling and storage area.
The odour control measures are as follows;
 Better housekeeping by regular steaming of all process equipment‟s.
 Use of efficient biocides to control bacterial contamination.
 Control of temperature during process.
 Avoiding storage of process waste.
 Regular use of bleaching powder in the drains to avoid generation of

putrefying microorganisms.
 Odour is controlled at source by GMP practices.
 Fermenter lids to be closed, gaskets and seals to be periodically checked.
 Odour producing materials such as RS/ENA/Ethanol are stored in tanks
with proper safety measures, as per standard practices and regular
monitoring of the fixtures such as gaskets, seals etc. to be carried out.
 Regular monitoring to be done for checking of any leakages in piping and
fittings.
 Better housekeeping maintained to ensure good hygienic condition in the
premises.
 Effluent drains of distillery and sugar plant to be kept clean for easy flow.
 Effluent treatment plant maintained on regular basis.
 Fragrance flowering trees or shrubs to be planted near odour generating areas
like fermenter tanks, ETP etc.
 Odour from sources such as holding ponds/lagoons to be controlled by
atomized spray of chlorine dioxide.
 Better cane management to avoid staling of sugar.
 Regular steaming of all fermentation equipment.
 Control of temperature during fermentation to avoid in-activation / killing of
yeast.
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3.20 Traffic Management
3.20.1 Connectivity
The site is suitably located with respect to availability of raw material, water, road
network, skilled/semi-skilled/unskilled and professional manpower etc. All
communication facilities such as telephone, tele fax & internet are available in the
vicinity of the plant site. Site connectivity is as follows:-

Connectivity -

Railways
The nearest railway station is Erode Railway Junction which is 37 km
away from the site.
Roads
The site is connected by the State highway (SH - 28). The raw material
needed for the industry can be conveniently transported via this road.
Airways
The nearest airport is located at Coimbatore around 95.2 km away from
the project site.

Communication
Already this area is well connected with the district headquarters (Erode
28.9 km).So there will not be any constraints for communications like telephone,
telefax, etc.
3.20.2 Impact of Transportation
The movement of personnel from their residence to industry and movement of raw
materials and finished products will result in marginal increase in the existing traffic
and noise levels in the area.
The main mode of transportation of raw materials
 To distillery is by the trucks at intermittent period and designated area is
earmarked for unloading and parking of vehicles.
 By conveyer and Mechanical handling system for the grain movement from
storage area to the process plant

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  Finished products are stored in tanks and further transported through tankers
and other vehicles leading to movement to and from the factory. Designated
area is earmarked as parking space for tankers.
The increase in traffic due to the proposed project will be marginal. The existing well
laid broad roads are adequate to take the additional load.
3.21 Summary of Impacts
Based on the assessment made in the preceding sections the overall impacts due to
the proposed project are summarized in the Table 3.7 and Criteria for rating Scale,
Severity, Probability and Duration is detailed in Table 3.8

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 Table 3.7 Rating of Environmental Impacts

Rating of Environmental Impact

Impact
Sl.
Activity Cause/Aspect Scale Probability Duration Significance Rating
No. Severity 1 to 5
1 to 5 1 to 5 1 to 5 =SxSxPxD
Construction Phase
Dust getting air borne 1 1 3 2 6
Noise nuisance 1 1 3 2 6
Erection of machineries
1 Spillage of oil 1 1 1 2 2
Gaseous emissions 1 1 1 1 1
Domestic waste generation 1 1 3 2 6
Operation Phase
Air emissions 2 2 3 2 24
1 Operation of boilers
Wastewater generation 1 1 3 1 3
Operation of DG set and TG Air Emission 2 1 2 2 8
2 sets
Noise Nuisance 1 1 5 1 5

Fugitive emissions 2 1 2 2 8
Noise due to machinery 1 1 3 1 3
Manufacturing activity and Domestic Sewage 2 1 5 1 10
3 ZLD operation Wastewater from utility 2 1 4 1 8
Wastewater from process 2 2 2 2 16
Domestic Solid waste 1 1 3 1 3
Hazardous Waste 1 1 2 1 2
*Those impacts with SSPD score of 24 and above are considered as most significant

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 3.8 Severity, Probability and Duration of Environmental Impacts
Scale S Rating Severity S Rating
At the work area 1 Minor Injury requiring first aid 1
Within premises 2 Injury requiring hospitalization 2
Outside Premises in 1 km radius 3 Temporary disability 3
Outside Premises beyond 1 km & 4
4 Permanent disability
less than 5 km radius
Beyond 5 km radius 5 Loss of life/s 5
Probability of Occurrence P Rating Duration D Rating
Once a Year 1 Less than 1 hour 1
Once a month 2 Less than 4 hours 2
Once a week 3 One day 3
Daily but intermittently 4 More than a day 4
Continuous 5 Few months 5

Significance is arrived at by multiplying the individual ratings assigned to Scale,

Severity, Probability and Duration as the impact is interdependent on each of these
parameters. Higher the number, higher is the significance; the significance rating
varies from min 01 to max 24.
The Matrix and rating will be done at the end of this chapter after the impacts are
identified and mitigation measures are proposed.
3.22 Risk Assessment Studies
The study includes risk assessment by estimating maximum damage distance by
Maximum Credible Accident (MCA) analysis. The study helps in drawing damage
contours to assess the consequence of an event. The analysis does not consider
probability of occurrence. The probability is therefore rated on experience and
previous similar experience elsewhere.
3.22.1 Risk Assessment for Boiler, Turbines and Compressors Boiler
The risk associated with boiler operation and turbine operations and its appropriate
mitigation measures are as given in Table 3.9 and Table 3.10 respectively. The
associated with compressor and mitigation measures are represented in Table 3.11.

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Table 3.9 Risk Associated with Boiler Operation and Mitigation Measures
Identified hazard Precautions taken Mitigation measures
Fire & explosion • Boilers will be equipped  Portable fire
with safety valves used to extinguishers will be
release excess pressure. fixed at strategic points.
• All the steam lines will be  Wet risers will be
insulated. provided with suitable
• Silencers will be provided hose reel at strategic
for all start up vent lines and points.
safety valves.  Fire hydrant pump will
be connected with an
independent power
source (D.G) to provide
uninterrupted service in
case of emergency.

Other risks from boiler operation are detailed below

Bursting of tubes:
The steam generated in the boiler goes to the turbo-generator to drive the prime
mover, i.e., the turbine. In this turbine, the steam is condensed and that condensate is
returned back to the boiler again. This process is repeated continuously. Due to this,
the dissolved salts present initially in small amount in the water gets concentrated,
which attains its threshold limit over a period of time. This results in scale formation
in the tubes, which drastically reduces the heat transfer rate. This in turn leads to the
localized overheating of the tubes. This overheating makes the tube material soft and
starts bulging, eventually leading to bursting of the tubes. Control is periodical
steam blow and periodical inspection and maintenance.
Bursting of pipeline joints:
The water required for boiler is pumped and transferred by using high-pressure
pumps. Also, the high-pressure steam generated in the boiler is sent to the turbine
through the pipelines. This pipeline will have flanged joints, with sandwich gaskets

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in between for better sealing. At times, due to water hammering this gasket fails and
leads to bursting of the flange joint. Therefore, proper design of the pipeline is
necessary for avoiding water hammering.
Table 3.10 Risk Associated with Turbine Operation and Mitigation Measures
Identified hazard Precautions taken Mitigation measures
Fire & noise •Smoke detector system • Portable fire extinguishers
provided. will be fixed at strategic
• All the turbines will be points.
covered in acoustic • Fire alarm system will be
enclosures reduce noise. installed.
• Noise level in the turbine • PPEs will be provided as
area will be monitored required.
regularly. Efforts will be • Fire-fighting training will
made to control the noise be imparted to employees.
wherever possible by
installing noise generating
sources inside the building,
providing double air lock
doors, double frame glass
windows reducing the noise
of blower etc. Use of ear
plugs/muffs will be
mandatory for the workers
working in high noise zones
and caution boards will be
displayed.

Compressor: It used for operation of Various Pneumatic Devices

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 Table 3.11 Risk Associated with Compressor Operation and Mitigation Measure
Impacts Identified Precautions taken Mitigation measures
Explosion/ Noise • All compressors will be • To reduce noise
installed in room/s. compressor room doors will
• Pressure test of all be provided with door
compressor tanks, wall closers.
thickness tests and hydro • Warning signs will be
tests will be conducted as displayed at entrance of
per statutory requirements compressors room.
and guidelines by • All compressor vessels are
competent persons. equipped with pressure
• All compressor vessels gauges and safety valves.
will be equipped with safety • The test date and due
testing date will be painted
on compressors vessel.
• Un-authorized entry will
be restricted in compressor
room/s.

3.22.2 Inference
According to the ALOHA simulation analysis, the consequential impacts from each
incident scenarios can be though flammable vapour cloud and thermal radiation.
The damage distance indicates the distance of consequential impacts for flammable
vapour cloud release would on plant personnel, equipment and machinery. All
scenarios will be within the plant site. The storage of ethanol needs utmost
attention owing to the magnitude of the impact. Risk associated with distillery unit
and mitigation measures are given in Table 3.12.

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 Table 3.12 Risk Mitigation Measure for Ethanol Plant

Identified Hazard Precaution Taken Mitigation Measures

Fire and Explosion • There shall not be any Portable fire extinguishers
electrical overhead lines in will be provided at
ethanol storage tank area. identified locations in
• All ethanol storage area distillery section.
pipelines will have jumper • Sand buckets will be
for avoiding static provided.
electricity. • Entire plant will be
• All tank thickness tests covered with fire hydrant
will be done by competent line and foam monitor
person. system.
• All tanks and motors will • Warning and informatory
have proper earthing signage‟s will be displayed.
system and double
earthing.
• Flameproof type lighting
system will be provided for
controlling of spark.
Fire and Noise • Mobile usage prohibited • Fire-fighting training will
in distillery plant. be provided to all
• No smoking allowed in employees.
factory premises. • Mock drill will be
•Flameproof motors will conducted once in 2
be provided in distillery months.
section.
• Welding and gas cutting
prohibited in distillery
section premises.
• Work permit followed for
all high risk work.

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3.22.3 Risk Mitigation Measures -Safety Measures for Transportation, Storage &
Handling of Chemicals
 Follow standard loading and unloading procedure for safe loading of
chemicals into tanker.

 Provide static earthing provision for tanker.

 Provide display boards on all storage tanks to communicate the material of

construction, name of the chemical stored and MSDS.

 Provide on-site detectors for fire & smoke detection with alarm system as
required.

 Provide relevant fire extinguishers at accessible places

 Provide first aids boxes in all control rooms/cabins.

 Declare the entire premises as “NO SMOKE ZONE”.

 Ensure that, hazardous material handling is done by using all requisite PPEs,
with proper ventilation and under supervision.

Safety Measures to Prevent Spillage/Leakage of Toxic Chemicals

 Provide requisite PPEs like goggles, gloves, protective clothes to those
handling toxic chemicals.

 Store finished products under safe condition.

 All tanks storing hazardous chemicals tested periodically for the thickness.

 All pipe joints provided with heavy duty gaskets to prevent any leakage.

 Dyke wall to areas where hazardous chemicals are stored.

 Provide spare barrels of sufficient quantity kept ready for any emergency
spillage or leakage.

 All storage tanks to be constructed in line with PESO guidelines.

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3.22.5 Specific Recommendations Based on Hazard and Severity Mapping
The specific engineering or management recommendations based on the simulation
analysis are as under:
3.22.5.1 Mechanical and Equipment Integrity
Following are the engineering recommendations:
 The material of construction and thickness of storage vessels are designed
to accommodate the maximum pressure.

 The tanks are located in isolated areas where there is no/minimum

personnel would be working in the downwind direction at any given
point of time.

 To ensure no equipment sensitive to thermal radiation are installed in the

downwind direction of these tanks.

 The tanks will be provided with dyke wall with arrangement to recover
the spillage/leakage.

 Provide with high pressure detector with interlock to the incoming

material.

 Provide high temperature alarm with an interlock to cut off the heat
source.

3.22.5.2 Management Approach

Following are the management recommendations:
 The operating personnel are trained on the consequential impacts and the
action to be taken under different scenarios.
 The operating personnel have relevant PPEs.
 List of do‟s and don‟ts will be displayed.
 These storage tanks are tested every 6 months to confirm that there is no
loss of material of construction and the tank thickness is intact. Record of
such testing is maintained for reference.
3.23 Occupational Health and Safety
The project proponent strongly believes in the safety and health of the workers. The
company will conduct regular medical check-ups of the workers and for the safer

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 side there will always be a rotation of the workers where the exposure to dust and
chemicals is high.
Table 3.13 Preventive Action and Corrective Action for Impacts
Sl. No. Activity Aspect Impact Preventive Corrective
action action
1 Coal and husk Air borne On respiratory i. To provide Periodic
handling/ dust system like close conveyor Medical
conveying chronic system for Coal Examination
obstructive / husk to boiler. –
pulmonary ii. To sprinkle Spirometer/P
disease (COPD) water over FT /Pulse
Coal/Husk oxymetry
iii. To transport
fly-ash in closed
trucks
2 Boilers/ DG Noise Noise Induced i. Reduce Audiometry
sets operation/ Hearing Loss noise at
compressors (NIHL) / source by
cardiovascular changing
disease/ design /
hypertension proper
maintena
nce/
providing
acoustic
enclosure
s
ii.Provide PPE
3 Boiler operation Exposure Heat Proper Job rotation
to heat exhaustion location/design
of operator cabin

3.23.1 Occupational Health and Safety Precautions

Provision of all necessary equipment like portable detectors, online detectors and
other laboratory equipment for regular monitoring of workplace air and other
conditions (temperature, humidity and light intensity etc.) shall be made. All the
work places will be provided with MSDS of chemicals & materials being handled.
The concerned employees will be trained and all the employees will be made aware
of the hazards in handling chemicals.
 Inspection and preventive & breakdown maintenance of all the equipment
including pollution control equipment will be undertaken.

 Compulsory use of necessary PPEs.

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  Installation of fire extinguishers at required places.

 Regular work place monitoring.

 Provision of part time qualified medical officer as per factories act guidelines.

 Regular medical check-up of employees by qualified medical practioners.

 Monitoring of occupational hazard parameters like noise, ventilation,

chemical exposure at frequent intervals.

 Display of various instruction boards, cautionary notices etc., at different

locations.

3.23.2 Fire Protection and Fighting System

The fire protection system for the unit is to provide for early detection, alarm,
containment and suppression of fires. The fire detection and protection system have
to be planned to meet the objectives of statutory as well as insurance requirements of
the governing bodies. As with any process industry, Grain based distillery also have
unique fire risk associated with it. Some of the impacts due to fire in the factory
might be damage to the equipment‟s, process buildings, storage tanks and injury to
workers i.e. overall damages are the high economic losses. This type of losses can be
avoided by preventing and controlling the fire instantly for which fire fighting group
will be established. Distillery is classified as a high hazard industrial occupancy and
hence there is the need for automatic fire protection systems. Fire protection is also
applicable to the storage tanks also where there is the greatest risk of fire and
explosion. Foam System for fire fighting will be provided to control fire from the
alcohol storage tank. The foam thus produced will suppress fire by separating the
fuel from the air (oxygen) and hence avoiding the fire and explosion to occur in the
tank. Foam would blanket the fuel surface smothering the fire. The Ethanol will also
be cooled by the water content of the foam. The foam blanket suppresses the release
of flammable vapours that can mix with the air. Fire extinguishing media will be
provided in the entire factory at the high-risk areas to prevent and the fire incidents.

Fire Extinguishers/ Fire Hydrants

Liquefied Co2 fire extinguisher shall be upright type of capacity 10 kg having
standards marked. The fire extinguisher will be suitable for fighting fire of Oils,

104
Solvents, Gases, Paints, Varnishes, Electrical Wiring, Live Machinery Fires, and all
flammable Liquid & Gas. We will provide 10 numbers of portable fire extinguisher
and fire hydrants as specified.
Fire Fighting Equipment’s
 Hydrant System
 Hose Reel System
 Portable fire extinguishers
 Medium Velocity Water Spray system
 Foam Protection system
 Fire Detection and Alarm System
Tale 3.14 Budget Allocation for Occupational Health and Safety

Sl. No. Particulars Budget

(Rs. per annum)
1 Periodic medical examination 8,00,000
3 Personal Protective Equipment like gloves, 4,00,000
safety shoes, aprons, goggles, Self-contained
breathing apparatus (SCBA)
4 Training on occupational health & safety 1,00,000
Total Rs. 13,00,000/- Lakhs
/Annum

3.24 Occupational Health Centre

• Full time round the clock doctor, para-medical staff (nurse and attendant) will
be appointed.

• Ambulance with round the clock driver will be provided.

• Medical examination room, bed ward room, record and drugs stores with all
the equipments and medicines as prescribed will be provided.

3.24.1 Frequency & Parameters of Health Check-Up

Medical surveillance will be carried out by maintaining the health records.

105
 • Pre-employment health check-up followed by periodical health check-up will
be undertaken every year with special attention to occupational health
hazards for all the employees.
• Special test like eye, audiometry etc., based on the occupational hazards will
be planned.
• This activity will be outsourced to the local hospitals and diagnostic centres.
• Parameters that will be part of pre-employment & annual periodical medical
check-up are given in Table 3.14.
Table 3.15 Health check-up parameters
S.
Test Details
No.
1 Complete Blood Examination Haemoglobin % (Hb%), WBC, RBC etc.
2 Blood Pressure
3 Pulse
4 Physical Fitness Certificate
5 Central Nervous System (CNS)
6 Cardio Vascular System (CVS)
7 Vision
8 Electro Cardio Gram (ECG)
9 Respiratory System-Lung Function (RS)
10 Chest X-ray
11 Total Leucocyte Count (TC)
12 Differential Leucocyte Count (DLC)
13 Absolute Eosinophil Count (AEC)
14 Complete Urine Examination [Physical / Chemical /Albumin, sugar & bile salt etc.
15 Random Blood Sugar (RBS)

106
 CHAPTER IV
ENVIRONMENT MONITORING PLAN
4.1 Technical Aspects of Monitoring the Effectiveness of Mitigation Measures
This chapter contains technical aspects of monitoring the effectiveness of
mitigation measures. It ensures the smooth execution of EMP. Monitoring program
includes the monitoring of the environmental aspects viz., ambient air quality,
emission from the air pollution sources, effluent quantity and quality monitoring
including the treated effluent monitoring, soil quality analysis and noise level
monitoring. Monitoring program also includes the parameters to be monitored for
the various environmental components mentioned above, sampling location and the
frequency of monitoring. It includes laboratory and related facilities required to
monitoring. The capital cost of monitoring is also worked out and presented.
4.2 Purpose of Environmental Monitoring
Monitoring is an essential component for environmental sustainability of any project
and it is an integral part of performance assessment process with respect to the
Environmental Management. Hence, monitoring of critical parameters is essential.
The aim of monitoring is to provide information that will aid impact management
and to achieve a better understanding of cause-effect relationships and to improve
mitigation methods. Both immediate and long-term benefits by undertaking
monitoring as part of EIA are widely recognized.
The following are the main objectives of the environmental monitoring program:
• Ensure day to day activities are conducted in a manner in compliance with
the environmental regulatory requirements, approvals by various statutory
agencies and industry standards.

• Evaluate the adequacy of mitigation and pollution control measures

implemented for reducing the adverse impacts caused during the operation
stage and suggest additional mitigation measures, if appropriate, in the light
of the results.

• Encourage good environmental management practices through planning,

commitment and continual improvement.

107
 • Develop well defined environmental monitoring program designed to assess
the nature and extent of environmental impacts of the proposed operations
and progressively refine such programs against the targets.

• To comply with all regulations stipulated by the State Pollution Control Board
(SPCB) related to air emission and liquid effluent discharge as per Consent
accorded under the Air Act and the Water Act and the standards prescribed
in the Environment Protection Rules.

• Review, improve and update operational procedures and standards.

• Establish response procedures for actual/potential environmental impacts

including community complaints and ensure corrective action is taken.

Monitoring will be used to:

• Measure the impacts that occur during the construction and operation phase;

• Compare the monitoring data with the prescribed standards.

• Determine the accuracy of impact predictions and the effectiveness of

mitigation measures.

• To reduce the mass load of pollutants on the environment.

Main Objectives of the Environment department would be:

 To comply with all the statutory and regulatory requirements.

 To prevent pollution incidental to the Plant Construction and Operations.

 To conserve the Natural resources as is available.

 To encourage and adapt the ecofriendly technology and process in the Plant.

 To implement and improve performance of the EMP

Objective of the Environment Management Plan is to:

 To conserve the Overall Environment

 To Minimize the Waste and Effluent Generation.

 To conserve the Natural Resources and Water.

 To ensure Staff Welfare and Safety of the Manpower and the local

population.
 To ensure effective control of operating parameters

 To monitor the long-term impacts to the environment

108
4.2 Measurement Methodology
Sampling of ambient air, stack emissions, ambient noise, water, soil and wastewater
are to be as per the guidelines issued by the CPCB/standard procedures. Samples
thus collected are to be tested in the laboratory. Testing of all environmental samples
shall be done as per the guidelines provided by MoEF & CC/CPCB/SPCB. The
method followed shall be standard method approved/recommended by MoEF &
CC/CPCB or the standards procedures as appropriate for parameters not covered by
MoEF & CC/CPCB.
4.2.1 Air Environment
It is observed from studies related to prediction of environment impacts that
potential impact on air environment is a significant one.
Measurement methodology and frequency
Ambient air and stack emissions are to be monitored on regular basis as indicated in
the Table 4.1 below. Monitoring shall be done as per the guidelines provided by
MoEF & CC/CPCB/SPCB. The method followed shall be standard method
approved/recommended by MoEF & CC/CPCB.
4.2.1.1 AIR QUALITY
Meteorology
Site Specific Micro Meteorology
This report presents the Environmental Impact Assessment (EIA) findings of the Air
Quality Specialist Study performed for SPAC Starch Products (India) Private
Limited, located in Mugasipudur village, Anthiyur Taluk, Erode District. Monitoring
for micro meteorological parameters was carried out on continuous basis at the
project site. The parameters selected were wind- speed, wind-direction, rainfall,
temperature and relative humidity. Monitoring was carried out using an automatic
weather monitoring station at the project site. The station was installed keeping in
view the free exposure of sensors to atmosphere and minimum interference from the
nearby structures. The monitoring was carried out for a period of 3 months from
March 2022 to May 2022. The variations in the meteorological data are presented in
Table 4.1. The highlights of the meteorological factors considered for monitoring for
the present study are discussed as under:

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 Table 4.1 Site Specific Micro Meteorology Data (March 2022 to May 2022)

Rainfall Relative Humidity

Temperature (0C) Wind Speed (%) Wind
Month (mm) (%)
Direction
Avg. Max. Min. Avg. Max. Min. Avg. Max. Min. Avg.
March 0.01 32 18 25.29 87 23 51.84 4.06 1.39 2.39
April 0 32 16 24.32 79 17 42.91 4.83 1.11 2.88 SE to NE
May 0.01 36 18 26.84 58 17 45.52 3.22 0.83 2.56

Temperature
During the baseline study period the 24 hourly maximum & minimum temperatures
varied in the range of 32.0 to 36.03 0C and 16.0 to 18.0 0C respectively whereas the 24
hourly average temperatures varied in the range of 24.32 to 26.84 0C which is as per
the general expected trend of temperature for the winter seasons.
Relative Humidity
The 24 hourly maximum & minimum relative humidity during baseline period
varied in the range of 58 to 87 % and 17 to 23 % and the hourly average humidity
varied in the range of 42.19 to 51.8% which is in accordance with the humidity
pattern of winter seasons.
Wind Speed and Wind Direction
The 24 hourly maximum & minimum wind speed recorded during baseline study
period varied in the range of 5.83 to 8.06 m/s and 0.83 to 1.39 m/s respectively and
24 hourly average wind speed varied in the range of 3.56 to 4.39 m/s, thus it can be
interpreted that the project surrounding environs largely sustained calm winds.
The wind rose diagram prepared from hourly data recorded at site from March 2022
to May 2022 revealed that prominent wind direction around project plot is NNE
i.e., wind is blowing from SE to NE. Project plot specific wind rose is given as Figure
3.13 & for site specific mixing heights considerations CPCB document
PROBES/88/2002-2003 is followed.

110
 Figure 4.1: Wind Rose for Baseline Monitoring Period

Meteorology forms the base of any dispersion studies. With this understanding
Wind rose diagrams using secondary data obtained from Indian Meteorological
Department (IMD) for annual period March 2022 to May 2022 and for 3 months
sampling period have been plotted.
The wind rose prepared from secondary data for sampling period of March to May,
indicates that about 22% of the time, wind was observed to be blowing from
Northeast direction.
At the same time the wind rose diagram based on primary data (for the monitoring
period) indicates that around 25.8% of the time the wind is blowing from the
Southwest direction.

111
For determining the sampling locations of air quality monitoring it is important to
understand the distribution of wind direction during the monitoring period, i.e.
during the months of March to May. According to the interpretation of the
secondary data for meteorology it is concluded that the prominent upwind direction
is North-east. Therefore the monitoring stations can be selected based on the
prominent wind direction identified.
4.2.2.2 Ambient Air Quality
Monitoring Locations
Criteria pollutants monitoring at the proposed project location & surrounding
environs was done to establish the prevailing ambient air quality, accordingly based
on reconnaissance & field surveys representative monitoring locations were selected
within 10 km radial study area based on EIA manual by MoEF&CC. Based on field
observations it can be said that predominantly study prevail rural settings with
moreover flat terrains.

Figure 4.2 Location of AAQ monitoring Locations

112
Methodology for Sampling
Sampling was carried out at selected locations as per the CPCB guidelines. The
standard methodology used for analysis, details of the detection limits and the
standard methods are provided in Table 3.19 & Table 3.20.

Equipment used for sampling:

Sampling of PM10 was conducted using Envirotech make sampler (Model No.: APM-
460), while that of PM2.5 was carried out using Envirotech make sampler (Model No.
APM-550). Monitoring of Carbon Monoxide was conducted by online instruments of
Rave innovations instruments (Model No.: COA-109). The monitoring of Ambient
VOC was carried out using Envirotech make portable sampler with Model No.:
APM- 802.

Sample Transportation and Sample Preservation:

Proper preservation of samples was done after sampling. The gaseous samples were
preserved in an ice box (below 4°C) and transported to the laboratory for analysis.
The filter papers were collected using forceps and stored in polythene bags and
stored in cool and dry containers during transportation.

113
Fig. 4.3 PM2.5 ISOPLETHS

114
Fig. 4.4 NOx ISOPLETHS

115
Fig. 4.5 SO2 ISOPLETHS

116
Fig. 4.6 PM10 ISOPLETHS

117
 Table 4.2 Air Quality Results

PM10, μg/m3 PM2.5, μg/m3 SO2, μg/m3 NOx, μg/m3

CODE Locations
Min Max Avg 98 (%) Min Max Avg 98 (%) Min Max Avg 98 (%) Min Max Avg 98 (%)
AAQ1 Project Site 37 52 44.5 50.96 15.5 13.5 14.5 13.23 4.96 6.06 5.51 5.94 9.56 12.06 10.81 11.82
AAQ2 Mulianur 41 55 48 53.9 18.4 16.4 17.4 16.07 6.56 8.16 7.36 8.00 11.66 16.26 13.96 15.93
AAQ3 Kurumbapalayam 35 46 40.5 45.08 16.5 14.5 15.5 14.21 4.91 6.56 5.73 6.43 9.96 13.26 11.61 12.99
AAQ4 Olagadam 43 53 48 51.94 19.2 17.2 18.2 16.86 5.26 5.96 5.61 5.84 11.36 14.06 12.71 13.78
AAQ5 Chittar 33 44 38.5 43.12 15 13 14 12.74 4.41 5.81 5.11 5.69 8.96 11.76 10.36 11.52
AAQ6 Sanarapalayam 49 64 56.5 62.72 22.9 20.9 21.9 20.48 6.16 8.36 7.26 8.19 13.36 17.06 15.21 16.72
AAQ7 Siluvampalayam 38 51 44.5 49.98 16.8 14.8 15.8 14.50 4.96 6.16 5.56 6.04 10.06 12.46 11.26 12.21
AAQ8 Sokkanathamalaiyur 46 57 51.5 55.86 17.7 15.7 16.7 15.39 5.46 6.66 6.06 6.53 13.16 16.06 14.61 15.74

CPCB / MoEF & CC Standards

Industrial / Residential/ Rural and

100 60 80 80
Other Area

Locations Latitude Longitude Direction Distance (km)

Project Site 11°35'52.27"N 77°40'27.68"E - -
Mulianur 11°36'45.01"N 77°41'23.85"E NE 2.36
Kurumbapalayam 11°38'10.89"N 77°39'18.19"E NW 4.76
Olagadam 11°33'54.62"N 77°38'35.79"E SW 4.93
Chittar 11°32'54.86"N 77°43'1.00"E SE 7.19
Sanarapalayam 11°31'55.69"N 77°40'2.63"E S 7.27
Siluvampalayam 11°34'40.73"N 77°43'44.60"E E 7.69
Sokkanathamalaiyur 11°35'56.86"N 77°37'45.69"E W 4.91

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Particulate Matter (PM10)
The study reveals that maximum concentration was observed to be in the range 64
µg/m3. The highest 24-hourly concentration was recorded at Sanarapalayam
location. The average concentration of PM10 can be said to be ranged between 38.5 –
56.5 µg/m3. The high concentration of particulate matter recorded at project site
may be due to local vehicular movement on road. It should be noted that the
concentration of PM10 was not observed to be exceeding the standards prescribed by
the CPCB on any occasion.

Particulate Matter (PM2.5)

The major source of PM2.5 is said to be the combustion of fossil fuels, fire wood and
industrial emissions etc, present within study area. The maximum of PM2.5 (22.9
µg/m3) during the study period was recorded at Sanarapalayam, whereas the
minimum value (15 µg/m3 ) concentration was recorded at Chittar . The average
concentration of PM2.5 during the study period was computed to be in the range of
14 – 21.9 µg/m3.

Sulphur Dioxide (SO2)

High level of SOX in ambient air indicates the presence of combustion of fossil fuel in
the vicinity. The ambient air monitoring results indicate that the lowest
concentration of SOX is experienced at Sanarapalayam. The presence of working
industries and fuel burning within village are the principle source of emission for
SOX. The average concentration of SO2 recorded during the study period is 5.11 - 7.36
µg/m3.

Oxides of Nitrogen (NOx)

The various forms of Nitrogen in NO, NO2 and N2O are collectively called as Oxides
of Nitrogen. The highest value of NOX during the monitoring period was observed
at Sanarapalayam (13.36 µg/m3) while the minimum value was recorded at Chittar
(8.96 µg/m3). The average concentration of NOX recorded during the study period is
10.36 – 15.21 µg/m3.

119
4.2.2 Noise Environment
Though noise level impact is not significant the same needs to be monitored to
prevent increase in noise levels due to poor maintenance of equipment and
machinery which generate noise. Noise levels to be monitored using standard noise
level meter. For equipment/machines monitoring shall be done at 3 m distance from
source and at the boundary to measure the ambient noise level due to the activity.
4.2.3 Water Environment
It is observed from prediction of environment impacts that potential impact on water
environment with respect to process effluent is a significant one.
4.3 Measurement Location and Frequency
Environmental attribute, frequency and parameters for monitoring are given in
Table 4.1.
Table 4.3 Environmental Attributes, Frequency and Parameters
Sl. Particulars Monitoring Duration of Important
No. frequency monitoring parameters for
monitoring
Air environment
Ambient air quality within Twice a month during 48 hours (2 PM10, PM2.5,
1 project premises – one each crushing season and consecutive NOx, SO2, CO
at downwind, up wind & bi-monthly during the days)
crosswind directions. rest of the year.
2 Stack monitoring • Monthly for boilers Grab &online SPM, SO2, NOx
a. Boiler stack- 26 TPH & online monitoring monitoring
b. Coal and husk fired • Bi-annually for 750
boiler KVA - DG set
c. DG set stack is attached
1 x 750 KVA
Noise environment
At the boundary of the During crushing Day and night Noise level in
3 factory. season dB (A) Leq.

Water environment

120
 Process Condensate Once a week Grab pH, TSS, TDS,
4 total solids,
COD, BOD,
potash, chloride
and phosphate
5 Spent Lees Once a week Grab pH, COD, BOD,
total solids
6 All intermediate stages of Once a week Grab pH, TSS and
ETP/CPU COD
7 Treated effluent Once a week Grab and pH, TSS, TDS,
online COD, BOD,
monitoring potash, chloride
and phosphate
Online
monitoring of
pH, BOD, COD
and TSS
Min Once a Day Grab pH, MLSS
8 Ground water / Twice a year. Before Grab pH, BOD, COD
piezometer monitoring and after monsoon and total solids
within industry site
Soil environment
9 Within project premises at Once in a year Composite EC, organic
two locations near sample carbon, pH,
hazardous waste storage available NPK
and effluent storage.

121
4.4 Measurement methodology and Cost of Monitoring
Test procedure and budget is given in Table 4.2.
Table 4.4 Cost of Monitoring for Environmental Parameters
Sl. Particulars Methods of Cost of Amount in
No. monitoring monitoring Rs. per year
in Rs.
Air environment
1 Ambient air quality at PM2.5: IS 25,950 per 7,50,000
project premises 5182:part-23: 2006 station. To
PM10: IS 5182:part- monitor three
23: 2006 stations.
SO2: IS 5182:part-
2: 2001
NOx: IS 5182:part-
6: 2006
2 Stack monitoring – PM: IS 11255:part- Rs. 6,650 per 1,25,000
process section 1: 1985 stack. Two
a. Boilers SO2: IS 11255:part- stacks of boiler
b. DG set 2: 1985 (monthly) and
NOx: IS one stack of DG
11255:part-7: 2005 (biannually)
Noise environment
1 Noise level at the Sound level meter Rs. 3,500per 25,000
boundary of the factory. station. Three
stations; four
times per
annum.
Water environment
1 Ground water / Standard Rs. 2,400 per 8,000
piezometer analytical station. Two
piezometers
sampled twice a
year
2 Raw and treated effluent. Procedure for Monitoring in -
water by APHA in-house lab
and AWWA.
Soil environment
1 Soil within project Standard Rs. 3,350 per 6,000
premises analytical sample at two
procedure. locations near
hazardous
waste storage
and effluent
storage.
Total budget for monitoring 9,14,000
Rupees Nine Lakhs Fourteen Thousand Only

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4.5 Other Environment Related Monitoring
Other environment related monitoring required is given in Table 4.3
Table 4.5: Other environment related monitoring activities required
Sl. No. Monitoring particulars Frequency
1 Keep track of the green belt to monitor the survival rate of Once a month
plantation and to confirm that the growth is adequate and on
expected lines.
2 Monitor and review of safety performance of the plant with Once a month
specific reference to incidents/accidents which have impact on
the environment like spillages which can result in air pollution,
water pollution, soil contamination.
3 Monitor the drainage system in the plant to prevent entry of Once a Quarter
storm water to the ETP and vice versa.
4 Monitor drains carrying storm water or wastewater for Once a Quarter
ensuring timely cleaning.
5 Noise generating equipment monitored for increase in noise Once a month
levels to initiate corrective action.
6 Monitor hazardous waste storage sites to ensure good Once a month
housekeeping to avoid cross contamination.
7 Monitor raw material consumption, water consumption, Daily
wastewater generation per unit mass/volume of product to
ensure that they remain within expected norms and to take
action for further reduction.
8 Monitor training imparted to the workforce to ensure that the Once a month
workmen are adequately trained in matters which have
relevance to the impact on environmental attributes like
handling of hazardous waste, handling of pyrophoric
chemicals.
9 Examine the garland canal and leachate collection tank for its After season
intactness to ensure that there is no seepage.
10 Review by top management on the environment monitoring Once a month
compliance every month to avoid slippages and to take
corrective and preventive action.

123
4.6 Online Monitoring
Monitoring of stack emission, ambient air quality, noise, groundwater, soil
Online monitoring facility for stack emission to monitor particulate matter, flow
meters for the spent wash and for MEE concentrate along with IP camera will be
provided. These online monitors are connected to CPCB and TNPCB portals.
The ambient air quality, stack emission, noise, groundwater & soil quality will be
monitored regularly through NABL accredited/MoEF&CC recognized laboratory.
Two piezometers shall be installed around spent wash holding tank to monitor the
ground water quality, which will serve as an indicator to know whether there is any
infiltration of spent wash into the ground.

Table 4.4 indicates online monitoring system proposed to be provided and

connected to CPCB/TNPCB portal.

Table 4.6: Locations where online monitoring is proposed to be provided

Sl. No. Source to which the monitoring Parameter Location of the on-line
system is to be provided monitored monitor
To monitor the effluent entry Surveillance One IP camera with
1. into MEE, flow, and to ensure TILT Zoom, 5x or above
effluent is not bypassed. focal length, with night
vision capability at
spent wash lagoon.
1. CPU Plant outlet (Recycling Flow meter, pH, Flow meters and
water) BOD COD and TSS pollutants monitor at
treated effluent outlet
2. Stack attached to incineration Particulate matter Monitor to be midway
boiler on stack at iso-kinetic
location.

124
4.7 Reporting & Documentation
• All the necessary reports and documents to be maintained for complying with
the statutory rules & regulations.
• Regular and periodic records to be kept in order to ensure easier review and
projection of past and present. Corrective action to be taken if needed in
future for improving the performances.
• Management to ensure maintenance of separate records for water,
wastewater, solid waste, air, emissions and soil regularly and periodically.
• Any changes found in mitigation measures of operation /management/
technology to be brought to the notice of the concerned person immediately
and all possible corrective and preventive actions to be taken.
4.8 Activities and Responsibilities of EMC
The head and all the officers of the EMC team are responsible for total
environmental management of the industry site. The responsibilities include:
• Ensure all the pollution control systems are in continuous operation.
• The Distillery plant ETP to be started with cow dung inoculums and artificial
feed, one month before to develop the MLSS and to be ready to receive and
treat the effluent from day one of Plant operation.
• Collect information from regular monitoring and create database.
• Analyse the data to arrive at practical solutions to environmental problems.
• Discuss the reports of study on environment and disseminate the information.
• Work out action plan for implementation of the recommendations made in
the report.
• Prepare and maintain budget for environment management program.

125
 4.9 Budget for Monitoring and Procurement Schedule
Construction activity is in progress and the industry is yet to be commissioned. The
industry is Budget for monitoring and procurement details are given in
Table 4.5.

Table 4.7 Investments on Environmental Protection Measures (Rs. in Crores)

Capital
Annual Recurring
S. No Particulars Cost In Rs
Cost in Rs crores
crores
Air pollution control system (ESP/Bag filter + Stack)
1 4.5 0.5
on 40 TPH low pressure boiler, ash handling system.
Scrubbing system, compressing system,
liquefying system and storage for CO2 removal
2 2.28 1.9
FOR 60 TPD CAPACITY (Including Civil)
Treatment system for raw stillage, decanter
centrifuge, thin stillage evaporation plant, DWGS +
concentrated stillage and DDGS dryer system
3 27.76 3.4
(Including Civil)

Condensate Polishing unit for water treatment and

4 6 1.5
recycle
5 Rainwater harvesting systems 0.4 0.05
6 Occupational Health Management
Included in Equipment cost
7 Noise Reduction Systems
8 Green Belt Development 0.4 0.06
9 Environment monitoring 0.5 0.2
10 CER 10.5 2.5
Total 52.34 10.11

Total Budget for Environmental Protection Measures capital investment – 52.34

crores
Annual monitoring expenses – 10.11 crores.

126
4.10 Emergency Preparedness and Response Structure
Onsite emergency plan shall be prepared and got approved by the Department of
Factories, Boilers, Safety and Health, Government of Tamil Nadu.

127
 CHAPTER V
PROJECT BENEFITS
5.1 Corporate Environmental Responsibility (CER)
M/s. SPAC Starch Products (India) Private Limited is committed to undertake CER
activities for the welfare of surrounding villages as per the commitment made while
seeking initial prior Environmental Clearance. Budgetary allocations of Rs. 10.5
crores are made which will be spent.

Table 5.1: Budget allocation during proposed expansion for CERs

Fund allocated
Sl. No. Activity
(Rupees in Crores)

1. Health and Education 3.76

2. Electrification including solar power 0.48

Water Treatment Plant and Toilet facility to

3. 6.26
nearby government school
Total 10.5
Rupees Ten Crores Fifty Lakhs Only

5.2 Employment Potential

Project will give employment to local people around the project site by direct and
indirect employment.
5.3 Other Tangible Benefits
The following facilities will be provided to the employees:
• Regular Health check-ups, Medical claim.

• Transportation facilities
• Housing facilities

128
 CHAPTER VI
SUMMARY & CONCLUSION
6.1 Overall Justification for Implementation of the Project
New Grain based Distillery of distillery is proposed under Ethanol blended with
petrol program of GOI. Prior Environment Clearance is sought as per the
Notification issued under EIA Notification 2006 vide No. S.O.2339 (E) dated
16.6.2021 as B2 category.
Environmental Management Plan is drawn for the proposed new project. The study
conducted has covered various facets of the proposed project starting with the
needs, its basic requirements like raw materials, water, availability of land,
manufacturing process, material balance, impacts, mitigation, environment
monitoring etc.
Environmental Management Plan has been prepared covering the environmental
aspect and the mitigation plan required to be adopted by the management during its
construction and operation phase. An environmental monitoring plan is envisaged
based on the aspect of pollution, frequency of monitoring, cost for monitoring, data
analysis, reporting schedules etc. The EMP cost for capital and recurring is worked
out and presented. The capital cost towards EMP is about Rs. 52.34 crores.
Detailed risk assessment study is carried out to evaluate the risks involved due to
storage of various finished products and precautionary measures to be taken for
prevention/management of such risks.
The conclusions drawn from the above study relates to the fact that the
proposed distillery unit of 160 KLPD undertaken by the management of the industry
has certain level of marginal impacts on the core zone of the industry but will not
affect the environment in the immediate neighbourhood either drastically or
otherwise. The industry is adopting Zero Liquid Discharge concept for the distillery
effluent management. Effluent treatment, recycle and reuse are minimizing the
pressure on the natural resource.
There are more beneficial impacts are anticipated in terms of the employment
opportunities created during the operation of the industry. The overall benefit of the
new project will be to augment the requirement of ethanol for mixing with petrol;

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this will enable to bring down the pollution from vehicles. The production of bio fuel
not only benefits the farmers as there will be demand for maize but also benefit the
industry as it will be profitable. There will be economic growth at the regional level
including tangible benefits to the farmers around the industry.
The industry will be establish an Environmental Management Cell to monitor and
implement programs to improve its environmental status from time to time and will
adopt all such technological advances to reduce the impact due to its operation on
the environment.
6.2 Summary of Mitigation Measures
The measures adopted to mitigate the impacts due to the proposed project are
tabulated in Table 6.1.
Table 6.1. Mitigation Measures for Proposed Project
Sl. No. Parameter Mitigation measures
Water pollution sources
1 Domestic sewage For Sewage treatment provision for septic
tank and soak is made.
2 Industrial effluent from distillery Distillery plant to produce 160 KLPD fuel
ethanol with grain as feed stock
• The treated water from CPU is partially
recycled for process and rest is used for
cooling tower makeup.
Air pollution sources
1 Boilers For co-generation boiler of 40 TPH and,
Electro Static Precipitators (ESP) and stack
of height 68 m AGL proposed to be
provided as APC equipment respectively.
2 D.G. sets Stacks as per the consent of the TNPCB
shall be provided with in-built acoustics.
3 Noise pollution sources – DG sets In-built acoustic enclosures are provided.
are the main sources
Solid/Hazardous waste
1 Domestic garbage Organic portion is composted and used for
green-belt development within industry
premises & in-organic portion is sent to
TNPCB authorized recyclers.

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2 Solid waste The solid wastes or by-products yeast
sludge is given to farmers along with
press-mud to compost and reuse. Ash
from incineration boiler ash is given to
brick manufacturers. ETP sludge is
used as manure in greenbelt.

Resource conservation to be attempted by using state of art technology for water use,
effluent treatment and reuse of treated effluent .Fresh water is required for boilers,
cooling and domestic use.
The distillery effluent in respect of process condensate, spent lees and other utility
effluents are treated and re-used for cooling tower water make up and for process
there by achieving "ZERO LIQUID DISCHARGE" concept for wastewater
management as per the protocol of the CPCB and TNPCB. By adopting water
conservation measures;
Environmental management and monitoring plan is proposed to ensure that the
industry operates without giving room for any adverse impacts on the
environment. Emphasis shall be laid on the implementation of the recommendations
of the environmental management plan in true spirits.

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 CHAPTER VII
DISCLOSURE OF CONSULTANTS ENGAGED

7.1 The Name of the Consultant Organization Engaged

Enviro Care India Private Limited
43, 2nd Street, Harvey Nagar, Arasaradi
Madurai –625 016
Phone: 0452-4355103
Enviro Care India Private Limited is an Environmental consultancy servicing
company located at Madurai, Tami Nadu. We are leading solution providers in the
field of Environment. Enviro Care India Private Limited is a specialized solution
provider Metallurgical Industries (Ferrous & Non-Ferrous), Distillery
industries, Thermal Power Plant and Building and Construction projects. Our other
services are Turnkey Projects such as planning, supply, construction, Erection and
Commissioning of Treatment Plants (ETP, STP, WTP, R.O & ZLD) and other
environmental control equipments. We also provide operation and maintenance
services for ETP, STP, WTP, R.O and ZLD. Our in-house
laboratory equipped to analyse environmental parameters (Air, stack, water, noise
and soil).
Quality policy of Enviro Care
Enviro Care India Private Limited, a professional environmental technical
consultancy company are committed to provide highest quality environmental
management associated services within timeframe with highest degree of
uprightness, knowledge and technical know-how in sync with the norms that
consistently conform and fulfil our customer expectations and achieve customer
satisfaction in statutory and regulatory requirements.

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 Declaration for Involvement of EMP Study
Project details
Name and address M/S. SPAC Starch Products (India)
Private Limited,
Mugasipudur Village,
Anthiyur Taluk, Erode District,
Tamil Nadu - 638314.
Status Proposed New Project
Category as per EIA Notification, Project or activity schedule for distillery
2006 is 5Ga under Category „B2‟ as per
MoEF& CC Notification No. S.O. 980 (E)
02.03.2021
NABET Accreditation Sector 22, 4, 8, 38
EMP Consultant
Name & address Enviro Care India Private Limited,
# 43, 2nd Street Harvey Nagar,
Arasaradi, Madurai – 625 016,
Tamilnadu
Status NABET accredited environmental
consultants Accreditation certificate no.
NABET/EIA/1821/RA 0137

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