SUMMARY ON ENVIRONMENTAL IMPACT

ASSESSMENT REPORT
OF

NSL SUGARS LIMITED

Submitted To

KARNATAKA STATE POLLUTION CONTROL BOARD

BENGALURU.

EXECUTIVE SUMMARY
1.0 INTRODUCTION
NSL Sugars Limited is operating 5000 TCD sugar plant, 26 MW Cogeneration
power plant and a 45 KLPD Molasses based Distillery plant at Hurugalawadi &
Chikkonahalli Villages, Maddur Taluk, Mandya District, Karnataka. The existing
plant is having Consent to operate from KSPCB which is valid till 30 th June, 2011.
The existing distillery plant is producing 45 KLPD of Rectified spirit/ ENA/
Ethanol with Molasses as raw material. We have obtained the Environmental
Clearance earlier for expansion of Distillery plant from 45 KLPD Molasses
based to a total capacity of 120 KLPD with installation of 75 KLPD of cane juice
based or 37.5 KLPD of Grains based to manufacture RS/ENA/Ethanol from the
Ministry of Environment & Forests, New Delhi wide Letter no. F.No.J11011/499/2006-IA II (I), dated 24th October, 2008.
Now as a part of proposal of Change feed stock with Molasses based distillery
production

capacity

to

manufacture

Rectified

Spirit/Extra

Neutral

Alcohol/Ethanol from 45 KLPD to 60 KLPD without any major changes in the

equipment with a provision to use cane juice to generate 60 KLPD

and

installation of a 60 KLPD grain based distillery so that the total production

capacity of Rectified Spirit/Extra Neutral Alcohol/Ethanol will be 120 KLPD
(No change in the total capacity as per EC obtained in 2008) the existing plant
premises only.
Total land in possession of the management is 110 acres. Surveys Numbers of the
plant consisting of 110 acres are 60 to 62, 88 to 98 & 100 to 105 of Chikkonahalli
village and Sy Nos 55, 78 to 83 & 86 of Hurugalawadi. The additional capital
investment for the proposed change in feed stock composition project will be
approximately Rs. 20 crores in addition to 22 Crores proposed in the earlier
expansion.
Pioneer Enviro Laboratories & Consultants Pvt. Ltd., Hyderabad (NABET QCI
accreditated EIA Consultant organization) have prepared Draft Environmental

Impact Assessment Report for the present proposal of change of feed stock. The
report contains detailed description of the following
a. Detailed characterization of status of environment in the area of 10 km. radius
from the plant for major environmental components including air, water,
noise, soil, flora, fauna and socio-economic environment.
b. Assessment of air emissions, liquid waste and solid waste from the present
proposal along with the noise level assessment.
c. Environmental Management Plant (EMP) consisting of Air emission
management, waste water management, Noise level management, solid
waste management, etc.
d. Post project Environmental Monitoring Plan.
2.0 PROJECT DETAILS
2.1 RAW MATERIALS
The following will be the raw material requirement for the present proposal.

S.NO.

RAW
MATERIAL

SOURCE

REQUIREMENT

METHOD
OF
TRANSPORT

Own Sugar plant

/ purchased
from sugar
plants

62.5 TPD *

Through Pipe
line / tankers

Local area

60 TPD **

Through
Covered
trucks by road

For 15 KLPD Molasses based :

1

Molasses
(for 15 KLPD)

For 22.5 KLPD Grain based :

1

Grains
(Maize, Corn,
Sorghum Grain,
Broken rice and
Starch based
grains, etc.)

* Molasses requirement for 60 KLPD Distillery 250 TPD

** Grains requirement for 60 KLPD Distillery 160 TPD

2.2 MANUFACTURING PROCESS

Rectified Spirit / ENA / Ethanol

a) With Molasses
The rectified spirit will be manufactured by Yeast propagation, Fermentation and
Distillation processes. Continuous fermentation with yeast recycling will be
adopted in the distillery plant. The spent wash generation will be restricted to 8
KL/KL of spirit production. Spent wash from the Molasses/cane juice based
distillery will be treated in the existing Biomethanisation plant followed by
Evaporation, which is sufficient for 60 KLPD capacity also. Latter it will be sent
to Biocomposting / spray drying to achieve zero discharge as per CREP
recommendations. Ethanol will be produced from Rectified Spirit through
dehydration process by using Molecular Sieve technology.
b) With Grains
Initially grains will be sent through the milling section to reduce the size,
followed by the liquification which converts starch into simple molecules of
dextrin. Then this dextrin undergoes saccharification process and fermentation.
The spent wash generation will be restricted to 6KL/KL of spirit production.
The rectified spirit will be taken to molecular sieve to dehydrate and produce
Ethanol.
B) Carbon dioxide recovery system (By product)
Carbon dioxide produced during fermentation will be recovered by means of
scrubbing arrangement, and the recovered CO2 will be supplied to soft drink
manufactures in cylinders. The scrubber blowdown will be recycled into the
fermenters.
2.3 WATER ENVIRONMENT
Total water requirement for existing and present proposal will be 4198 cum/day
which is lower than already permitted quantity of 4423 cum/day as per
Environmental clearance granted in 2008. There is no increase in water
requirement after the present proposal. The water requirement for Cane Juice
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Distillery operation is not considered for calculation due to cane juice is optional
feed stock and at any given point of time either Molasses based distillery (or)
cane juice based distillery will be in operation along with Grain based distillery.
As water requirement for Molasses based Distillery operation is higher
compared to cane juice based, the same is considered for water consumption
calculation. Hence no additional water will be required for the present proposal
of change of feed stock of distillery plant. The existing plant water requirement is
being met from Shimsha River which is situated at a distance of 3.0 Kms. from
the plant. A pipeline has already been laid to transport the water from the river
bed to the plant. The existing pipeline will be sufficient to transport the water for
the present proposal. Existing water permission is adequate after present change
in feed stock also. The water allocation agreement is renewed by Irrigation
department, Govt. of Karnataka and is valid till 26-06-2012. The following is
water requirement.
WATER REQUIREMENT FOR INTEGRATED PLANT

ITEM

WATER CONSUMPTION (in cum/day)

Existing
/ EC granted in
2008

Present
proposal

After
implementation of
present proposal

Sugar plant

1560

--

1560

Co-gen power plant

1413

--

1413

For Molasses

625

No increase

625

For Cane Juice (optional)

825

-225

600 *

For Grain

825

-225

600

Total Water consumption

(Sugar, Cogen, Distillery)

4423

-225

4198

Distillery plant

Additional Water
requirement

The total water requirement after the present proposal of

change of feed stock of distillery will be less (225 KL)
than that of already permitted quantities as per earlier
Environmental clearance.

The water requirement for Cane Juice Distillery operation is not considered
due to cane juice is optional feed stock and at any given point of time either
Molasses based distillery (or) cane juice based distillery will be in operation
along with Grain based distillery. As water requirement for Molasses based
Distillery operation is higher compared to cane juice based, the same is
considered for water consumption calculation
BRAEK UP OF WATER CONSUMPTION FOR TOTAL 60 KLPD DISTILLERY
DESCRIPTION
Process water
Make up water for Boiler
DM/soft water for R.S dilution
and Cooling tower make up
Domestic
Total

60 KLPD MOLASSES
/ CANE JUICE
BASED DISTILLERY
320
50
240

60 KLPD GRAIN
BASED DISTILLERY

15
625

10
600

240
50
300

WASTE WATER GENERATION FROM INTEGRATED PLANT

ITEM

WASTE WATER GENERATION (in cum/day)

Existing/EC
granted in 2008

Present
proposal

After
implementation of
present proposal

Sugar plant

700

--

700

Co-gen power plant

105

--

105

For Molasses

360

+120

480

For Cane Juice (optional)

225

- 45

180 *

For Grain

225

Total Wastewater
generation

1390

Distillery plant (Spent wash)

Additional wastewater
generation

+135
+ 255

360
1645

225 KL of additional waste water will be generated

* The wastewater generation from Cane Juice Distillery operation is not

considered due to cane juice is optional feed stock. Hence the maximum
wastewater generation from Molasses based Distillery operation is only
considered for wastewater generation calculation.

WASTEWATER GENERATION FROM MOLASSES BASED DISTILLERY

SECTION

Spent wash

Cooling tower
blow down
Spent Leese
Total

EXISTING
45 KLPD

PROPOSED
15 KLPD

360

120

60

20

60

20

480

160

MODE OF TREATMENT /
DISPOSAL
Bio methanation, MEE followed by
Spray Dryer Spent wash powder
incineration in the 25 TPH Boiler along
with Bagasse / biomass
Green Belt development
Partial make up to CT and balance
recycling along with Sugar condensate

WASTEWATER GENERATION FROM GRAIN BASED DISTILLERY

SECTION
Spent wash
Cooling tower
blow down
Spent Leese
Total

PROPOSED
60 KLPD
360

MODE OF TREATMENT / DISPOSAL

Decanter, MEE, DDGS Dryer
disposed as cattle feed
Green Belt development

60
60

Partial make up to Cooling Tower and balance

recycling along with Sugar condensate

480

EFFLUENT CHARACTERISTICS
The characteristics of spent wash with Molasses, cane juice, Thin Slop from
grains and sanitary waste water are shown below.

CHARACTERISTICS OF SPENT WASH

CHARACTERISTICS OF
SPENT WASH
(MOLASSES)

CHARACTERISTICS OF THIN
SLOP (GRAINS)

4.2 4.8

CHARACTERISTICS
OF SPENT WASH
(CANE JUICE
SYRUP)
3.5-4.0

80,000-1,00,000

20,000-25,000

25,000-30,000

70,0001,20,000

30,000-35,000
20,000-25,000

55,000- 60,000

S.N

PARAMETER

1.

pH

2.

Total Dissolved
Solids(mg/l)
COD(mg/l)
BOD(mg/l)

45,000 55,000

3.
4.

3.8 7.5

30,000-35,000

CHARACTERISTICS OF SANITARY WASTEWATER

S.NO.
1.
2.
3.
4.
2.4

CHARACTERISTI-CS
pH
T.D.S. (mg/l)
B.O.D. (mg/l)
C.O.D. (mg/l)

SANITARY WASTE WATER

7.0 8.5
800 900
200 250
300 400

EFFLUENT TREATMENT PROCESS

Distillery
With Molasses as raw material:
Spent wash generation will be 480 cum/day, Spent wash from the
Molasses/cane

juice

based

distillery

will

be

treated

in

the

existing

Biomethanisation plant followed by Evaporation, which is sufficient for 60 KLPD

also. Latter it will be sent to Biocomposting / spray drying to achieve zero
discharge as per CREP recommendations. This is a zero discharge based
technology approved by the Central Pollution Control Board.
With Grains as raw materials:
When grains are used as raw materials, Spent wash generation will be 360
cum/day, which will be treated in Decanter followed by concentration in
Multiple Effect Evaporators to 30 % solids followed by Drying in a Dryer to

obtain 90 % solids. It is a totally zero discharge system. This treatment

technology is approved by Central Pollution Control Board.
The non process effluent will be treated in ETP and after ensuring the
compliance with CPCB/KSPCB standards, the treated effluent will be used for
ash conditioning, dust suppression and for greenbelt development.
2.6 AIR EMISSIONS
Distillery Boiler:
The Steam required for proposal of change of feed stock of distillery will be taken
from 25 TPH Boiler, for which Environmental Clearance has already been
obtained in the earlier expansion in 2008. Hence no separate Boiler will be
required for the present proposal pertaining to distillery. A stack height of 55 m
will be provided for 25 TPH boiler as per CPCB norms for effective dispersion of
pollutants into the atmosphere. High efficiency Electro Static Precipitator will be
provided for bringing down SPM emission to less than 100 mg/Nm3.
2.7 SOLID WASTE MANAGEMENT
The following table shows that the generation, disposal during the operation of
the distillery.
Item

Solid waste generation

Present
After
proposal
implementation
of present
proposal
3 TPD
1 TPD
4 TPD

Disposal

Existing

Yeast Sludge

DDGS
(with 90% solids,
when Grains are
used)
Ash from 25 TPH
Boiler
a)When
concentrated spent
wash / powder
used as fuel in

--

43.2 TPD

43.2 TPD

--

10 TPD

10 TPD

Mixed with
pressmud in
Biocomposting
Used as cattle
fed

Given to brick
manufacturers

Boiler
Along with Bagasse
/ Biomass
3.0 PREDICTION OF IMPACTS
3.1 PREDICTION OF IMPACTS ON AIR QUALITY

Emissions from 25 TPH boiler are considered for prediction of GLCs for which
EC has been obtained in 2008 and is yet to be commissioned. The anticipated
emissions from the boiler are PM10, SO2 & NOx. The predictions of Ground Level
Concentrations have been carried out using Industrial Source Complex Model
(ISC-3). Meteorological data such as wind direction, wind speed, max. & min.
temperatures collected at the plant site have been used as input data to run the
model.
It is observed that the maximum predicted incremental rise in PM10
concentration after commissioning of plant will be 0.4 g/cum, max. Predicted
incremental rise in SO2 concentration will be 3.1 g/cum and that of NOx will be
0.4 g/cum at a distance of 650 m from the origin stack in the downwind
direction.
The predicted results show that the net resultant concentrations (Max. Baseline
conc. + Max. incremental rise in conc.) of PM10, SO2 & NOx due to the entire
integrated sugar complex (after the present proposal) will be well within the
revised National Ambient Air Quality Standards. Hence there will not be any
adverse impact on air environment due to the present proposal.
3.2 PREDICTION OF IMPACTS ON NOISE QUALITY
The major noise generating sources are Machinery & DG set. The Ambient Noise
levels during operation of the plant will not exceed the standards prescribed by
MOE&F, GOI vide Notification dated 14-02-2000 under the Noise pollution
(regulation & control) Rules, 2000 i.e. less than 75 dBA during day time and less
than 70 dBA during night time. Extensive greenbelt proposed to be developed in
the plant premises in addition to the existing greenbelt will further attenuate the

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noise levels. Hence there will not be any adverse impact on population in
surrounding areas due to the noise levels from the present proposal.
3.3 PREDICTION IMPACTS ON WATER ENVIRONMENT
The effluent will be treated as per CPCB norms to achieve zero discharge. No
effluent will be discharged outside the premises. There will be no contamination
of ground water or surface water bodies due to the present proposal. Ground
water will not be used for the present proposal. Hence no ground water
depletion due to the present proposal. Rain water harvesting will be taken up in
consultation with the State Ground water Board to conserve the precious water.
3.4. PREDICTION OF IMPACTS ON BIOLOGICAL ENVIRONMENT
There are no rare & endangered species in the area. All the required pollution
control systems will be installed and operated to comply with the norms. The
effluent will be treated as per norms and zero discharge will be complied . Solid
waste disposal will be in accordance with the MOEF/CPCB/KSPCB. Once all the
norms are complied with then there will not be any adverse impact on flora,
fauna due to the present proposal.
3.5. PREDICTION OF IMPACTS ON SOCIO ECONOMIC ENVIRONMENT
With the establishment of the present proposal, employment potential will
increase. Land prices in the area will further increase. The Socio - economic
status of the people in the area will further improve due to the present proposal
Periodic medical checkups will be carried out. Top priority will be given to local
people in providing employment to semiskilled and unskilled as per
qualification & experience.
4.0 BASELINE DATA
Baseline data has been collected on ambient air quality, water quality, noise
levels, flora & fauna and socio-economic details of the people within 10 km.
radius of the plant.

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4.1 AMBIENT AIR QUALITY

Ambient air quality was monitored for PM10, PM2.5, SO2 & NOx at 6 stations for
one season as per revised MOEF standards on Ambient Air quality Notification
dated 16-11-2009. The following are the concentrations of various parameters at
all the monitoring stations.

PM2.5

19.3 to 34.9 g/m3

PM10

32.1 to 58.4 g/m3

SO2

8.5 to 14.3 g/m3

NOX

15.6 to 27.1 g/m3

4.2 WATER QUALITY

Ground water samples were collected at 6 locations and analyzed for various
physico chemical & Bacteriological parameters. The water samples shows that
they are suitable for potable purpose.
4.3 NOISE LEVELS
Noise levels were measured at 6 stations during day time & night time. The
noise levels are ranging from 46.88 dBA to 54.00 dBA.
5.0 ENVIRONMENTAL MANAGEMENT PLAN
5.1 Air Environment
The following Air emission control systems are proposed for 25 TPH Boiler for
which Environmental Clearance has already been obtained in the earlier
expansion.
S. No.
1.

Stack
attached to
25 TPH Boiler

Control Equipment

Particulate emission at the

outlet

Electro Static
Precipitator

< 100 mg/Nm3

12

5.2 WATER ENVIRONMENT

C) Distillery
With Molasses/cane juice as raw material
Spent wash from the Molasses/cane juice based distillery will be treated in the
existing Biomethanisation plant followed by Evaporation, which is sufficient for
present proposal also. Latter it will be sent to Biocomposting / spray drying to
achieve zero discharge as per CREP recommendations. This is a zero discharge
based technology approved by the Central Pollution Control Board.
With Grains as raw material:
Spent wash from mash column bottom is fed to decanter and it will be
concentrated to 30% solids. The Thin slop generated from the decanter will be
treated in multiple effect evaporators to concentrate the solids to 30% and then to
dryer to concentrate to 90% solids and then the DDGS will be sold as cattle feed.
Hence it will be a totally zero discharge spent wash treatment technology as
approved by CPCB. Non process effluent will be treated to comply with
CPCB/KSPCB norms and utilized for ash conditioning, dust suppression system
and for greenbelt development.
5.3 NOISE ENVIRONMENT
The major noise source in the present proposal will be machinery and DG set.
The employees working near the noise generating sources will be provided with
earplugs. The additional extensive greenbelt proposed to be developed around
the plant will also help in further attenuating the noise levels further. Noise
barriers in the form of trees will be grown around the administrative block, ETP
and other utility buildings.
5.4 LAND ENVIRONMENT
All air emission control systems will be installed and operated to comply with
the CPCB/KSPCB norms. Effluent treatment plant system will be installed and
operated to comply with the norms. All the solid waste will be disposed as per

13

norms. Hence there will not be any adverse impact on land environment due to
the present proposal.
5.5 GREENBELT DEVELOPMENT
Green belt development will further enhance the environment quality through
limitation of air emissions, attenuation of noise levels, balancing Eco
environment, prevention of soil erosion and creation of aesthetic environment. 37
acres of greenbelt (Including existing green belt) will be developed in the plant
premises.
5.6 IMPLEMENTATION OF CREP RECOMMENDATIONS
All

the

Corporate

Responsibility

for

Environment

Protection

(CREP)

recommendations will be strictly followed in the present proposal.

5.7 POST PROJECT ENVIRONMENTAL MONITORING
Ambient Air Quality, Stack monitoring & Effluent analysis will be carried out
regularly as per CPCB norms and the analysis reports will be submitted to
Ministry of Environment & Forests, Bengaluru & Karnataka State Pollution
Control Board regularly.

14