Chalthan Draft 2012

CONTENTS
SR. NO. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. TITLE List of Annexures Executive Summary General (Section A) Product Details (Section B) Water (Section C) Air (Section D) Hazardous Solid Waste (Section E) Site plan (Section F) Resource recovery (Section G) Health (Section H) Accidents (Section I) Safety measures (Section J) Noise (Section K) Odour (Section L) Cases /Complaints (Section M) Compliance report (Section N) Sulphur storage License ( Section-O) Hazardous chemicals (Section P) Public Liability Insurance Act (Section Q) Water Cess (Section R) Consultant (Section S) Declaration of concerned (Section T) EMS Adequacy (Section U) Annexures / Efficacy PAGE NO. 1 2 7 8 10 12 13 13 13 14 15 15 16 16 16 16 16 16 16 16 16 persons certificate 16 17 18
LIST OF ANNEXURES Sr. No. Title Pag e No.
Chemical Engineering Department (N. G. Patel Polytechnic, Bardoli)
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Details of Sampling & Analysis Month wise number of Workers Employed Month wise Electricity Consumption List of Directors Month wise number of Working Days List of Products along with their Capacity, Yield and Purity Month wise Products & By products produced Month wise Raw Material Consumption Process Flow Chart and description and Mass Balance diagram Waste Consumption & Waste Water Generation Water Balance diagram Particulars of ETP Hydraulic & Flow Diagram of ETP Month wise Energy Consumption for ETP List of Operators / Chemists in ETP (Sugar & Distillery Unit) Consolidated Consent Details of Flue Gas Stack & Consumption of Fuel Details of Solid Waste Generation Storage and pretreatment of solid waste Factory Site Plan Sulphur storage License Noise Measurement Compliance report Details of Insurance policy Details of Water Cess Analysis of GPCB
EXECUTIVE SUMMARY Honble High court of Gujarats order for the Environmental Audit Scheme dated 20th December 1996 and modified vide its order dated Oct- 2008, N.G.Patel category. INTRODUCTION: M/s. Shree Chalthan Vibhag Khand Udyog Sahakari Mandali Ltd, Chalthan (Here in after will be termed as Chalthan Sugar) (Registration No. S/8, Industrial licensee No. 081758) located at Chalthan, At Post chalthan.Taluka: Palsana engaged in the manufacturing sugar with installed cane crushing capacity of 5000 MT/ Day. It was established in 1971 as a co-operative mandali to protect the social & economic interest of small farmers. Mandali is also trying to get good quality crop on continuous basis in order to get good quality sugar. Chalthan Sugar approached N.G.Patel Ploytechnic for the Environmental Audit work of its plant. After successive meetings Chalthan Sugar Factory has attributed the work of environmental Audit to N.G.Patel Polytechnic, Surat. Ours is self-financed polytechnic affiliated to Gujarat Technological University, Ahmedabad catering five diploma courses with intake capacity of 420 per year. Chemical Engineering Department of this polytechnic has been approved by GPCB as a Schedule I environmental auditor since 2002, with full scale laboratory facilities & efficient work force comprising Staff of Chemistry, Chemical Engineers, Environmental Engineer, Chemists, Micro biologist. Chalthan Sugar has six numbers of boilers in which Baggase is used as a fuel. Wet Scrubbers are provided as pollution control equipment. The height of stacks is observed to be adequate for effective dispersion of air pollutants. Ash generated from burning of bagasse is stored within Polytechnic, Isroli, Bardoli, is nominated to carry out Environmental Audit work for the industries falling under Schedule I
premises. ETP sludge generated from treatment of effluent is separately stored within premises and dried sludge is used in making of Biocompost. The records of sludge generation are maintained. Material, Water & Energy consumption details are included in this audit report from the records maintained by Chalthan Sugar along with Health & Safety aspects.
OBJECTIVES: 1) To check the adequacy & efficacy of the effluent treatment plant, gaseous emission, solid waste, ambient air, noise, health and safety systems of Chalthan Sugar. 2) To check various records of Environment Management System. 3) To check whether Chalthan Sugar, meets with all required norms of state regulatory agency that is Gujarat Pollution Control Board regarding environmental pollution control. OPERATIONAL BRIEFING: The above mentioned objectives have been fulfilled through meaningful inspection visits of Chalthan Sugar and precise study of its manufacturing system & pollution control facilities. Most representative grab effluent samples, ambient air samples, air samples of stacks were taken, analyzed and reported in this report; noise pollution level was also measured using imported kit. Above mentioned samples were taken during the surprise visits of Chalthan sugar by our team at different intervals over a long period of time. Technical information regarding the ETP & other details of environmental management systems were provided from the management. The findings reported in this Audit report are entirely based on data furnished by the industry & data collected by the audit team during the audit surveys in the client factory, presuming that during our surveys all the EMS and manufacturing operations were at normal conditions. The
auditors shall not be in a position to comment on the EMS and its performance for the period other than the period of audit surveys. Thus the findings reported in this audit report are strictly limited to the period when the audit team conducted the surveys. The details of the team members responsible for this work are enclosed in profile of capabilities.
PROFILE OF CAPABILITIES 1. Dr. P. R. Patel: A Doctorate in Chemistry is senior member of this audit cell. He is Head of Science & Humanities Department of N. G. Patel polytechnic. He has published 06 research papers in various national and international journals like Tailor & Francis, High Performance polymer & Iranian Polymer Journal. He is chiefly responsible for overall laboratory coordination and scheduling of Monitoring work. 2. Dr. L. B. Chaudhari: A Doctorate in Chemical Engineering & is working as Coordinator of Envirochem Audit Cell of N. G. Patel Polytechnic. He is Coordinator of Nodal Institute (Chemicals & Petrochemicals sector) under Anchor Institute, D.D.U., Nadiad. He is responsible for industry assessment and relationship, different Analytical work aspects of Audit work. He is able to cope up the responsibilities of analysis of Chemical Parameter and study of manufacturing process. He has published 10 research papers in various national & international journals like Chemical Engineering Journal, Journal of Hazardous Materials, Desalination, International Journal of Environmental Engineering, Journal of Environmental Management, etc. 3. Mr. K. R. Desai: A Post Graduate in Chemical Engineering & is working as a Sr. lecturer in Chemical Engineering Department. Being In-charge of Safety & Effluent treatment laboratory, he is well conversant with solid & liquid waste analysis and industrial safety aspects. 4. Mr. S. J. Patel: A Post Graduate in Environmental Engineering & is working as a member of Envirochem Audit Cell of N. G. Patel Polytechnic. 5. Mr. T.C. Padhiyar: A Graduate in Chemical Engineering is working as a lecturer in Chemical Engineering Department and is pursuing is PostGraduation in Chemical Engineering. 6. Mr. M. B. Dhangar: A Graduate in Chemical Engineering is working as a lecturer in Chemical Engineering Department. 7. Mr. D. B. Chaudhari: A Graduate in Environment engineering is familiar with important aspects of environment pollution strategies & legislation. He is familiar with treatment plant design and its operation.
8. Mr. B. G. Tailor: A Post Graduate in Medical technology with Microbiology is capable to look in to the biological aspects of environmental studies & is in the environment audit team as Environmental microbiologist. 9. Mrs. K. I. Champaneriya: A Graduate in Microbiology is capable to look in to the biological aspects of environmental studies & is in the environment audit team as Environmental microbiologist. 10. Mr. H. S. Desai: A Graduate in Chemical Engineering is working as a lecturer in Chemical Engineering Department. 11. Mr. P. B. Patel: A Graduate in Chemistry & is working as a laboratory assistant is part of environmental monitoring work.
OBSERVATIONS & RECOMMENDATIONS: 1) Chalthan Sugar has three power turbines (2500 KW x 2 and 1500 KW x 1).Steam required for power generation is meeting through six numbers of boilers. Bagasse produced within the plant is used as fuel in boiler. Two D.G. set of (625 KVA each) are installed to be used for emergency. Demineralization plant of 20 T / hr is also installed to produce D.M. Water as boiler feed. 2) The source of water supply in Chalthan Sugar is Bore well. Major usage of water is in process, utilities & domestic.
3) Wastewater generated from the plant is treated in effluent treatment plant. Treated Effluent is used for in house farming on 82 acres area of farming land owned by company. Separate energy meters are provided for ETP. Domestic wastewater generated is treated along with Trade effluent. The company has installed magnetic flow meters at the inlet and outlet of the ETP . A team of qualified personnel looks after environmental aspects.
4) Chalthan Sugar
has a quality control laboratory equipped with
instruments to carry out day to day analysis of effluent for different parameters (eg.- pH, Temp., TSS, TDS, BOD & COD).Daily record of treated effluent sample are maintained by company. Instruments for effluent analysis available at Chalthan Sugar includes TDS meter, BOD & COD apparatus, pH meter, Thermometer, Electronic balance, Oven, Turbidity meter, Spectro-photo meter. Chalthan Sugar has appointed private consultant for monthly monitoring of stack gas, ambient air and effluent water. 5) Solid waste at Chalthan Sugar is generated from ETP ( Secondary dried on separate sludge drying beds. Dried sludge to make Bio-compost. The company has obtained necessary
Sludge). Sludge is is used
license for storage and handling of Sulphur within the premises. (Details are as per Annexure No.21) 5) Chalthan Sugar has installed adequate numbers of fire
extinguishers at different locations within premises to meet any fire hazard & minimize damage to environment, Human beings & properties. 6) However, Chalthan Sugar has a full fledge dispensary to give medical treatment to its employees as and when required. Chalthan Sugar has also appointed a medical officer. No major accident was reported during audit period according to the company representative. 7) The noise level at certain locations like turbines, boiler house tends to be high, however suitable protective devices are provided to the person exposed to those areas. 8) For unavoidable oil spillages, company has installed Two numbers of belt type oil skimmers in ETP inlet channels to recollect it.
9) Handling of scrap is fair enough. It is collected frequently and sent to scrap yard time 10) 11) ETP. 12) 13) It is recommended to keep clean area near by all stacks. During the second monitoring the parameters of effluents like to time. Used oil and containers are handled in the prescribed manner. It is recommended to prepare on site & Off-Site Emergency The ETP of Chalthan Sugar is in good condition and well Plan as soon as possible maintained. Signboard is provided indicating name of each unit in
BOD & COD were found slightly higher than the prescribed limit, however the company has modified ETP by installing series of Air diffusers, Sand filter and Carbon filter to achieve the norms. 14) During audit period surprise sampling by GPCB officials have been done and results of those are mostly complying the norms
ENVIRONMENTAL AUDIT REPORT (JANUARY 2012 TO DECEMBER 2012)

(A) GENERAL 1 Name of the Industry 2 3 4 Location Registered Office Address Month & year of establishment Sugar factory Distillery (a) No. of Workers employed (b)Male / Female (a) No. of electrical connection & service numbers Sugar factory Distillery ETP of distillery (b) Total connected load Sugar factory from GEB Distillery from GEB Sugar factory (c) Electrical consumption per KL of effluent treated. Number of D.G. Sets & their capacity Name & residential address of all directors / partners Telephone Nos (Residential & Industrial), Fax No. & E - mail address of industry & partners / directors No. of shifts & timings M/s. Shree Chalthan Vibhag Khand Udyog Sahakari Mandali Ltd, Chalthan Village: Chalthan, Ta. Palsana, Dist. Surat Village: Chalthan, Ta. Palsana, Dist. Surat March 1971 December 1978 Male only. As per Annexure 2
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Three connection, Service No.: 10008 0097/10015 06513/00003/3 & 06513/00202/89 376 KW (Self: 480 KVA/384 KW) 447 KVA (Self: 480 KVA/384 KW) 5000 KW As per Annexure 3 Two D.G. Set , 625 KVA each As per Annexure 4 (O) 02622 281050, 281112, 282312 Fax No.: 02622 - 281120 As per Annexure 4 04:0 to 0 2nd Shift 12:0 to 0 3rd Shift 08:0 to 0 General 08:0 to Shift 0 Mr. S. M. Patel (Distillery 1st Shift 12:0 0 08:0 0 04:0 0 05:0 0 Manager)
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Name and address of the in charge
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of Environment / safety Division / Cell / Unit 12
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Mr. M. N. Prajapati (Chief Chemist) Mr. G. J. Rajput (Chief Engineer) Mr. M. C. Mistry (Safety Officer) No. of days during which treatment As per Annexure 5 activities were in operation during the period covered for it (for audit) Has the industry obtained ISO NIl 900 / ISO 14000 / OSHAS 18000 / Any other EM accreditation / Certification recognition? Whether the industry has adopted NIl cleaner production / Cleaner technology / CDM? As per Annexure - 6 As per Annexure - 7 Sugar-march 1971 Rectified spirit January 1983 Ethanol December 2002 As per Annexure 8 Continuous process (Seasonal)
(B) PRODUCTION DETAILS 1 Name of products & production per month and recovery 2 Name of all by - products and its quantity per month 3 Date of commencement of production for each product. (Effluent Treatment) 4 All auxiliary materials consumed (MT) 5 Whether the manufacturing process is continuous or batch wise. Indicate the batch size. If the process is batch wise, no. of batches / month along with the duration for completion of each batch 6 Detailed treatment process with flow diagram, list of unit operations & processes with all chemical reactions, along with the time required (in hrs) for completion of each unit operation / process and the total time for completion of the entire batch. Mass balance in respect of the quantity of effluent,
As per Annexure 9
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input of materials and wastewater generation. (C) WATER 1 The quantity of water consumed As per Annexure 10 per day as well as per ton of waste Domestic : 43.277 KL/day water treated. (Please also enclose Process Water : 385.890 KL/day water balance diagram) ( Sugar) 192.648 KL/day ( Distillery) Water Balance Diagram as per annexure - 11 2 The quantity of wastewater (trade As per Annexure 12 waste) generated per ton of each product per day, as well as per batch 3 The particulars of effluent treatment i.e. As per Annexure 12 i. Name & size of the Effluent Treatment Plant (ETP) 700 m3/Day ii. The capacity of the ETP As per Annexure 13 iii. Flow diagram & hydraulic Yes, sufficient lightning arrangement is diagram provided around ETP. iv. Whether lighting Yes, As per Annexure 14 arrangement around ETP is provided v. Whether the separate energy meter for effluent treatment Yes, Magnetic flow meters are installed at plant area is installed. If the inlet and outlet of ETP. provided reading of the meter for consumption every month. vi. Whether flow meter is provided at the inlet & outlet of ETP. Please indicate the type of the flow meter. 4 The method of disposal of effluent Treated effluent is used for in-house & the final point of disposal of farming on 82 acre area of farming land effluent (Please Attach Sketch) owned by company and also used in wet scrubber as makeup water.
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The quality of trade effluent before & after treatment as well as at the end of each stage of treatment (Attach Separate Sheets) The quantity and quality of sewage & its method of disposal (Attach separate sheet) a) As per Norms b) Total Pollution load
As per Annexure- 1
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Quantity of Sewage: 30.29 KL/Day Disposal of Sewage : During crushing season Treated in ETP other wise through septic tank & Soak pit Quality of Sewage : The Sewage is generated from canteen and the use of WC's and bathroom and therefore the quality would be same as that of any domestic sewage. The open area available for 24 acres area if farm land available for disposal of the effluent disposal of the effluent. Whether the quality of treated Yes, as per annexure 1 effluent meets the specified norms. If no, the extent of deviation and reasons thereof Improvement in effluent quality Quantity and quality of effluent has been and quantity since previous almost same with respect to previous environmental audit based on audit performance evaluation of effluent management systems. If yes provide details. (Attach separate sheet) Retrofitting undertaking to improve Nil performance of ETP. If yes, provide details Major problems encountered Nil during operation of effluent treatment facilities, if any and reasons thereof The details of operator / chemists As per Annexure 15 responsible for operation and maintenance of effluent treatment plant i. Name of the operators / employees ii. Qualification & experience of
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each operator / employee iii. Salary of operators / employees The current status of consent The industry is in possession of under the Water Act 1974 consolidated consent. The CCA No. 35652 is valid up to 20/05/2014. As per Annexure 16.
(D) AIR 1 No. of the flue gas stacks, their As per Annexure 17 height (from ground level), nature & consumption of fuel 2 The details pertaining to the stack Industry has provided adequate stack monitoring facilities monitoring facilities as sampling ports, sampling platform, and electrical connections with approach ladder. 3 Number of process stacks, their No process stacks provided. height (from ground level) source, expected pollutants & the details of pertaining to the provision of stack monitoring facilities (S.M.F.) 4 The quality of emission from each As per Annexure 1 flue gas stack & the process stack & the extent of deviation from them 5 The ambient air quality within the As per Annexure 1 factory premises, along with the number of ambient air quality monitoring stations outside the industry 6 The status of consent under the Air The industry is in possession of Act 1981 consolidated consent. The CCA No. 35652 is valid up to 20/05/2014. As per Annexure 16. 7 The details of air pollution control As per Annexure 17 measures for all process & flue gas stacks 8 Improvement in emission quality Quantity and quality of emission has been since previous environmental audit almost same with respect to previous based on performance evaluation audit
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of air pollution management system. If yes, provide details. (Attach separate sheet) Retrofitting undertaken to improve Nil emission quality. If yes, provide details Major problems encountered Nil during operation of control device, if any and reasons thereof ETP Sludge: 132 MT/Year (Approx.) Fly ash: 53.813 MT/Day (Wet Collection) Details are As per Annexure - 18
(E) HAZARDOUS (SOLID) WASTE 1 The quantity, sources & composition of Hazardous waste / solid waste from each process / sources over the last three years. (The sludge generation per tone of product) whether it is as per the consented quantity 2 a. The method of storage, treatment & disposal of Hazardous / solid waste. The details should include area of storage and disposal and whether storage and disposal system is covered made impervious (pucca). Please inform about treatment for leachate and Solid Waste b. The data/information about leachate generation, quantity and characteristics and treatment facilities. 3 The status of authorization under the EPA-86 for Solid Waste
ETP sludge and bio mass generated from distillery unit are utilized for making bio compost fertilizers. Collection, storage, transportation and ultimate disposal of used oil & discarded containers are done by selling to registered reporcesors. As per Annexure - 19
Not Applicable
The industry is in possession of consolidated consent. The CCA No. 35652 is valid up to 20/05/2014. As per Annexure 16. Plan if any to reduce hazardous Nil waste generation or its recycling.
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(F )
The site plan showing the location Site plan showing all these details is of effluent treatment plant, final enclosed As per Annexure 20 point of disposal of effluent, sampling point, drainage line, stacks, solid waste storage disposal area & green belt (its width) i. The details regarding resource recovery from Environmental pollution control system including effluent treatment plant. ETP sludge is used for making Bio-compost and treated effluent is used for irrigation in factory farm. Bagasse is recovered which is used as fuel in boiler, moreover pres mud and molasses is also recovered. Molasses is used in manufacturing Rectified Spirit and Press Mud is used in manufacturing Bio-compost.
(G )
ii.
The details regarding resource recovery / by - None product recovery
(H) HEALTH 1 Whether any hazard is involved in the manufacturing or from the work environment. If yes, the details there of Month wise. 2 Whether industry has pre employment & periodical medical examination facilities 3 Whether health records are maintained regarding adverse effect on the health of workers. 4 Whether industry has appointed a factory medical officer. If yes, full time or part time. Please also include the details about the name, address and qualification of the factory medical officer 5 Details of medical facilities available:
No.
Yes
No
Yes, industry has appointed a full-time medical officer. Dr. G. N. Mehta, (B.A.M.S.) C/o. Chalthan Sugar Factory
First Aid Boxes are available at workshop, Boiler house, Chief Chemist & Chief Engineers office. Ambulance / Vehicle is
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Whether sanitary facilities latrine, urinals, bathroom provided & satisfactory
available round the clock. Intensive hospital treatment is available at near by hospital, Sanjivani round the clock. like Yes. Satisfactorily provided. are
(I) ACCIDENTS 1 The details of accident in the No major accident was reported during factory & remedial measures audit period according to company taken representative. (J) SAFETY MEASURE General Environment of the factory. Please tick () the appropriate column House Good Fair Poor keeping 1 Dustiness High Mediu Low m Lightning Good Fair Poor Ventilation Good Fair Poor 2 Whether the following protective appliances are provided to all the persons Ye Goggles s Ye Gloves s Ye Safety Gumboot s Ye Helmet s Ye Portable Stature s Ye Ear Plug s Ye Cotton dust Masks s Ye Clothing s Ye Face Shield s Ye Aprons cotton s
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Ye s Ye Gas Mask s Ye Fire Extinguisher s Ye Fire Hoses s Ye First Aid Box s Emergency Siren Ye Switch s The details of facilities for disaster Fire extinguishers are available. 50 Nos. of management / gas leakage Fire extinguishers, 20 pts of fire hydrant will all facilities are available. Whether on site / off site On-site Emergency plan and Off-site emergency plans are prepared and emergency plan preparation is in are being implemented / upgraded progress. regularly, Please give details Whether records of occupational No hazards are maintained? Preventive measures adopted to Yes as per need. minimize occupational hazard Safety shoes As per Annexure 22
(K) REMEDIAL MEASURES The details of sources; monitoring & measures taken for control of 1 noise pollution in and around the industrial premises The measures taken for prevention treatment and control of odour 2 nuisance in & around the industrial premises The details in respect of cases / complaints under the Water Act, 3 1974, Air Act, 1981 & EPA Act,1986 The compliance report with respect 4 to all the conditions of NOC / Consent (under all the Acts) 5 Indicates of spillages, leakages, etc
No strong odour nuisances found in and around industry premised.
According to company officials, No cases of complaints have been launched under Water Act74, Air act81 & EPA86. As per Annexure 23
Nil
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and remedial measures thereof Whether insurance policy obtained Yes. Industry has purchased valid PLI under PLI Act? Yes / No If yes, Give Policy for the audit period. Details as per details As per Annexure 24
(L) WATER CESS The detail regarding the payment of the Water Cess for the previous and the current year. (M ) The name and address of the consultant engaged by the company / Industry
Water Cess paid for the year 2011-2012 As per Annexure 25
M/s En-vision enviro engineers pvt ltd. 208,G-Tower,Shankheshwar complex,Sagrampura,Surat
(N) It is hereby declared that all the information submitted in and with respect to this format is correct and we will be responsible for any lapse regarding incorrect or incomplete information. (A) (B)
Name & Signature of the responsible persons of the industry/organization/institute/CETP TSDF with the stamp. Name Signature Mr. V. Subburathinam ( Managing Director) Mr. M. N. Prajapati (Chief Chemist) Mr. G. J. Rajput ( Chief Engineer) Mr. S. M. Patel (Distillery Manager)
Name & Signature of all the members of Audit Team Name Dr. L. B. Chaudhari, Co-ordinator Audit Cell Mr. K. R. Desai, Chemical Engineer, Audit Cell Mr. M. B. Dhangar, Chemical Engineer, Audit Cell Mr. D. B. Chaudhari, Environment Engineer, Audit Cell Mr. P. B. Patel, Signature
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Chemist, Audit Cell Mrs. K. I. Champaneriya, Microbiologist, Audit Cell
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Adequacy Certificate of Environmental Management System

M/s. N. G. Patel Polytechnic of Isroli-Afwa, Bardoli, Gujarat, is recognized by the GPCB, Gandhinagar under the Environmental Audit Scheme introduced by the Honble High Courte Gujarat, vide its order dtd. 20/12/1996 and 13/3/1997 and modified order dtd. 16/9/1999, as an environmental auditor for the purpose of the auditing, having carried out the Environmental audit of, M/s. Shree Chalthan Vibhag Khand Udyog Sahakari Mandali Ltd., Located at: At & Po Chalthan, Tal: Palsana, Dist: Surat. Manufacturing products: Sr. No. 1 2 3 Particulars Vacuum Pan Sugar Rectified Spirit Absolute Alcohol Consent Quantity (Qty./Month) 20000 MT 1500 KL 750 KL Actual Quantity (Qty./Month) 13144.83 680.946 278.133
Having completed the environmental audit based on personal monitoring, and audit report, prepared as per the direction of the Honble High Courte in Environmental Audit Scheme, it is certified that the Environmental Management System (EMS) provided by this industry for the products manufactured and capacity as stated above is adequate and efficacious to achieve the quality of effluents (Air + Waste Water + Solid Waste) as specified in consent / Notification by GPCB, Gandhinagar for the following quantity of waste generation: Liquid Effluent Sewage generated Solid / Hazardous Waste Air emission (flue gas stacks as well as process stacks) : : : : 443.50 KL/Day 30.29 M3/Day 132 MT/Year Adequate , efficacious
The certificate is valid for the audit period only. However it is subjected to automatic cancellation in case of any change in product profile/capacity, quality and quantity of effluent emission (Air + Waste Water + Solid Waste) and efficiency of EMS equipment. This Certificate forms part of environmental audit report . N. G. Patel Polytechnic, At: Isroli, Po: Afwa, Tal: Bardoli, Dist: Surat 394620. Gujarat
Principal N. G. Patel Polytechnic, At: Isroli, Po: Afwa, Tal: Bardoli, Dist: Surat 394620. Gujarat
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Date: Place: Bardoli
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ANNEXURE 01 DETAILS OF SAMPLING AND ANALYSIS
Certificate for sampling and analysis

This is to certify that the following samples of Ambient Air, Flue Gas & Waste Water have been collected and analyzed as per the following details Sample details Ambient Air SPM,SO2,NOx Flue Gas SPM,SO2,NOx SPM,SO2,NOx SPM,SO2,NOx Waste Water ETP Inlet Secondary Final Outlet Sampling Location Near Laboratory Stack No 1 Stack No 2 Stack No 3 ETP Plant ETP Plant ETP Plant Collected by Mr.B.G.Tailor Mr.B.G.Tailor Mr.B.G.Tailor Mr.B.G.Tailor Mr.P.B. Patel Mr.P.B. Patel Mr.P.B. Patel Sample collection Date Time 22/03/2012 02:00 PM 22/03/2012 02:20 PM 22/03/2012 02:55 PM 22/03/2012 03:25 PM 22/03/2012 04:10 PM 22/03/2012 04:20 PM 22/03/2012 04:35 PM
Parameter analyzed on site: pH, Temperature Parameter analyzed off site: Color, TDS, TSS, BOD (5 Days, 20oC), COD, Oil & Grease, Phenolic Compounds, and Sulphide. Whether samples were preserved as per standard procedure for off site analysis: Yes Parameters analyzed by third party: As mentioned above Name and address of the laboratory: N. G. Patel Polytechnic At: Isroli, Po: Afwa, Tal: Bardoli. Dist: Surat 394620 Gujarat. Whether the laboratory is classified under Schedule I of the GPCB: Yes Method followed for analysis of Waste Water: APHA Standards. This is to certify that the third party laboratory in which the analysis has been done is recognized under Schedule I of GPCB.
(Mr.A.B.Suthar) Principal Date:03/04/2012 Place: Bardoli
(Dr. L. B. Chaudhari) Co-ordinator
(Dr. P. R. Patel) Member
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EFFLUENT SAMPLE ANALYSIS REPORT Name of Industry Date of Sampling Sr. No. 1 2 3 4 5 6 7 8 9 10 11 : Chalthan Sugar Factory : 22/03/2012 ETP inlet 29.6 5.94 210 1042 503 431 1246 7.6 1.4 10.7 45 Secondar y 28.7 6.85 126 811 429 148 437 3.2 0.4 2.3 34 Final Outlet 27.6 7.14 84 605 74 28 93 1.1 0.15 0.7 21
Parameters Temperature pH Colour TDS TSS BOD(5days, 20 oC) COD Oil & Grease Phenolic Compound Sulphide % Sodium
Unit C -Pt-Co Scale mg/lit mg/lit mg/lit mg/lit mg/lit mg/lit mg/lit mg/lit
o
STACK ANALYSIS REPORT Stack attached to Boiler No. 4 & 5 132.7 0.24 0.9
Sr. No. 1 2 3
Parameters SPM Sox NOx
Unit mg/Nm3 Ppm Ppm
Boiler No. 1,2 & 3 121.5 0.20 1.6
Boiler No. 6 92.7 0.17 0.8
AMBIENT AIR QUALITY MONITORING REPORT
Sr. No 1 2 3
Parameters SPM SOx NOx
Near Laboratory 94.2 8.4 18.1
NOTE: - ALL RESULTS ARE IN G/M3
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CERTIFICATE FOR SAMPLING AND ANALYSIS
This is to certify that the following samples of Ambient Air, Flue Gas & Waste Water have been collected and analyzed as per the following details Sample details Ambient Air SPM,SO2,NOx Flue Gas SPM,SO2,NOx SPM,SO2,NOx SPM,SO2,NOx Waste Water ETP Inlet Secondary Final Outlet Sampling location Near Laboratory Stack No 1 Stack No 2 Stack No 3 ETP Plant ETP Plant ETP Plant Collected by Mr.S. J. Patel Mr.P. B. Patel Mr.P. B. Patel Mr.P. B. Patel Mr.S. J. Patel Mr.S. J. Patel Mr.S. J. Patel Sample collection Date Time 21/12/2012 10:30 AM 21/12/2012 10:45 AM 21/12/2012 10:20 AM 21/12/2012 11:10 AM 21/12/2012 12:05 PM 21/12/2012 12:10 PM 21/12/2012 12:15 PM
Parameter analyzed on site: pH, Temperature Parameter analyzed off site: Color, TDS, TSS, BOD (5 Days, 20oC), COD, Oil & Grease, Phenolic Compounds, and Sulphide. Whether samples were preserved as per standard procedure for off site analysis: Yes Parameters analyzed by third party: As mentioned above Name and address of the laboratory: N. G. Patel Polytechnic At: Isroli, Po: Afwa, Tal: Bardoli. Dist: Surat 394620 Gujarat. Whether the laboratory is classified under Schedule I of the GPCB: Yes Method followed for analysis of Waste Water: APHA Standards. This is to certify that the third party laboratory in which the analysis has been done is recognized under Schedule I of GPCB.
(Mr.A.B.Suthar) Principal Date:28/12/2012 Place: Bardoli
(Dr. L. B. Chaudhari) Co-ordinator
(Dr. P. R. Patel) Member
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EFFLUENT SAMPLE ANALYSIS REPORT Name of Industry Date of Sampling Sr. No. 1 2 3 4 5 6 7 8 9 10 11 : Chalthan Sugar Factory : 21/12/2012 ETP inlet 28.7 5.89 215 1025 486 426 1186 7.5 1.3 10.6 42 Secondar y 28.5 6.91 124 802 415 145 418 3.1 0.3 2.2 31 Final Outlet 27.8 7.24 81 596 72 32 107 0.9 0.12 0.6 20
Parameters Temperature pH Colour TDS TSS BOD(5days, 20 oC) COD Oil & Grease Phenolic Compound Sulphide % Sodium
Unit C -Pt-Co Scale mg/lit mg/lit mg/lit mg/lit mg/lit mg/lit mg/lit mg/lit
o
STACK ANALYSIS REPORT Stack attached to Boiler No. 4 & 5 127.5 0.25 0.8
Sr. No. 1 2 3
Parameters SPM Sox NOx
Unit mg/Nm3 ppm ppm
Boiler No. 1,2 & 3 118.6 0.21 1.5
Boiler No. 6 89.5 0.16 0.7
AMBIENT AIR QUALITY MONITORING REPORT Sr. No 1 2 3 Parameters SPM SOx NOx Near Laboratory 98.4 8.2 17.8
NOTE: - ALL RESULT ARE IN G/M3
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ANNEXURE 02 MONTH WISE NUMBER OF WORKERS EMPLOYED
Month Jan 2012 Feb 2012 Mar 2012 Apr 2012 May 2012 June 2012 July 2012 Aug 2012 Sep 2012 Oct 2012 Nov 2012 Dec 2012
Male Distiller Sugar y 946 64 946 946 517 555 571 522 538 542 928 991 997 64 64 52 52 52 52 52 52 52 64 64
Total 1010 1010 1010 569 607 623 574 590 594 980 1055 1061
27
ANNEXURE 03 MONTH WISE ELECTRICITY CONSUMPTION
MONTHS
TOTAL POWER GENERATED (KWH)
TOTAL POWER PURCHASE D (KWH)
POWER CONSUMED AT TOTAL POWER (KWH) DISTILLERY (KWH) SUGAR (KWH)
Jan 2012 Feb 2012 Mar 2012 Apr 2012 May 2012 June 2012 July 2012 Aug 2012 Sep 2012
2869240 2976960 1978100 6900 8100 7920 5500 10160 NIL
72962 21630 136002 151176 114168 141258 133890 119220 153858
294220 2 299859 0 211410 2 158076 122268 149178 139390 129380 153858
249054 192178 222062 36266 17222 18342 5770 3600 14670
269314 8 280641 2 189204 0 121810 105046 130836 133620 125780 139188
28
Oct 2012 Nov 2012 Dec 2012 TOTAL Note:
771282 3055364 3082786 14772312
149322 156138 67896 1417520
920604 321150 2 315068 2 161898 32
23310 190826 315030 1288330
897294 302067 6 283565 2 149015 02
Total Electricity Consumption Set Units
= GEB Units + Turbine Generating = 1417520 KWH + 14772312 KWH = 16189832 KWH
Total electricity Consumption per MT of Sugar = Consumption
Total
Electricity
Total production per Year = 14901502 KWH / 78869 MT = 188.940 KWH/ MT Total electricity consumption per KL of Alcohol = Total Electricity Consumption Total production per Year = 1288330 / 8171.359 (KWH / KL) = 157.664 KWH/ KL ANNEXTURE 04 LIST OF BOARD OF DIRECTORS
SR. NO. 1 NAME Shri Ishwarbhai Gopalbhai Patel
DESIGNATION ViceChairman
ADDRESS & PHONE N0S. At.& Po : Choryasi, kumbhariya Ta.
29
2 3 4 5 6 7 8 9 10 11 12 13
Shri Tejaskumar Chhitubhai Patel Shri Shantilal Kalyanji Patel Shri. Hemantbhai Jagdishbhai Nayak Shri Jayeshbhai Dahyabhai Patel Shri Maheshbhai Ishwarbhai Patel Shri Ashwinbhai Gopalbhai Patel Shri. Tansukhbhai jaikishanbahi.Patel Shri Arjunbhai Balubhai Patel Shri Arvindbhai Tulsibhai Bhakt Shri. Sunilbhai Thakorbhai Patel Shri. Kiritbhai Ranchodji Desai Shri Manharbhai Maganbhai Patel
Director Director Director Director Director Director Director Director Director Director Director Chairman Shree Kamrej VKUSM Ltd.
Jt. Agriculture Director Director of Sugar
14 15 16
Jt. Agriculture Director (Extn) Shri J M Karata Shri V Subburathinam
Managing Director
Dist: Surat. Po. Sisodra, Ta: Choryasi, Dist: Surat. At & Po. Bagumara, Ta. Palsana, Dist: Surat. At : Karara ,Po. Chalthan, Ta : Palsana.,Dist : Surat. At & Po. Mota, Tal. Bardoli, Dist: Surat. At.& Po. Kosamadi, Ta. Kamrej, Dist: Surat. At & Po. Parab, Ta. Kamrej, Dist: Surat. At &Po: Saniya hemad Tal.: Choryasi, Dist: Surat. At & Po. Chalthan, Ta. Palsana, Dist: Surat. At & Po. Vav, Ta. Kamrej, Dist: Surat. At.& Po: Netrang . Tal: Kamrej Dist: Surat. At. & Po: Palsana Tal : Palsana Dist: Surat. (Rep. Sugar Industry Sangh) Chairman, Shri Shree Kamrej Vibhag Khand Udyog Sahakari Mandli Ltd., Navi Pardi, Tal. Kamrej, Dist: Surat Lal bungalow, Athwalines, Surat. Dr. Jivraj Mehta Bhavan, Block No. 8, 2nd floor, Ghandhinagar-382016. Shree Chalthan Vibhag Khand Udyog Sahakari Mandli limited, Chalthan.
30
ANNEXURE 05 MONTH WISE NUMBER OF DAYS DURING PRODUCTION ACTIVITIES WAS IN OPERATION:
MONTH
SUGAR
Jan 2012 Feb 2012 Mar 2012 Apr 2012 May 2012 June 2012 July 2012 Aug 2012 Sep 2012 Oct 2012 Nov 2012 Dec 2012 TOTAL DAYS
31 29 31 --11 30 31 163
DISTILLERY Rectifie Absolute d alcohol Spirit 31 31 29 14 29 9 -07 ----30 28 26 27 145 116
31
ANNEXURE 06 LIST OF PRODUCTS & BYPRODUCTS ALONGWITH THEIR CAPACITY, YIELD & PURITY
Name of Product Sugar Bagasse Press Mud Molasses Rectified Spirit Absolute alcohol Note: (1) (2) (3) (4)
Capacity (MT / Month) 20000 58000 6100 7000 1500000 L/Month 750 KL/Month 1 1 1 1 1 Yield kg Cane = 0.11kg Sugar kg Cane = 0.30 kg Bagasse kg Cane = 0.035 kg Press mud kg Cane = 0.042 kg Molasses Ton Molasses = 267 Lit.
Purit y (%) 99.80 ---95.00 99.80
Rectified Spirit ---
Press mud is used to produce Bio- Compost during crushing season. Bagasse is used as fuel in boiler and remaining is sold to farmers Purity is mentioned for A type sugar. The composition of exhausted molasses would be as follows: Dry substance Sucrose Nonsucrose Brix : : : 80% 36% : 44% 90
during crushing season.
(1)Absolute alcohol was produced during audit period.
32
ANNEXURE 07 MONTH WISE PRODUCT AND BYPRODUCTS
PRODUCT MONTH
SUGAR (MT) RECTIFIED SPIRIT (KL) ABS. ALCOHOL (KL) BAGASSES (MT)
BY PRODUCTS
FITER CAKE (MT) MOLASSES (MT)
Jan 2012 Feb 2012 Mar 2012 Apr 2012 May 2012 June 2012 July 2012 Aug 2012 Sep 2012 Oct 2012 Nov 2012 Dec 2012 TOTAL Avg./Mon th Avg./ Day
16430 15372 9090 ------2475 17020 18482 78869 13144.8 33 483.86
1870.976 1635.354 1632.562 -------1515.679 1516.788 8171.359 680.946 56.354
919.895 417.457 253.127 ----183.210 --817.106 746.812 3337.607 278.133 28.772
44789.15 9 40918.16 6 24507.17 5 ------9697.947 45414.91 0 51143.14 3 216470.5 00 36078.41 7 1328.04
5322.330 4974.040 2743.890 ------1172.610 5284.380 5588.560 25085.81 0 4180.968 153.90
7176 6339 3597 ------1146 7767 7539 33564 5594 205.91
33
Note: 1) (---) Indicates no production in given month. 2) All data were made available from company representatives. ANNEXURE - 08 MONTH WISE RAW MATERIAL CONSUMPTION FOR SUGAR PRODUCTION
Month Jan 2012 Feb 2012 Mar 2012 Apr 2012 May 2012 June 2012 July 2012 Aug 2012 Sep 2012 Oct 2012 Nov 2012 Dec 2012 TOTAL Avg./Mont h Avg./ Day
Sugar Cane, (MT) 149610 133380 71798.270 ---38610 167020 169820 730238.2 70 121706.3 78 4479.989
Lime (MT) 245.50 0 230.00 0 125.72 0 ---48.700 232.80 0 238.50 0 1121.2 20 186.87 0 6.88
Sulphu r (MT) 63.400 63.000 38.240 ---17.200 75.300 77.600 334.74 0 55.760 2.05
Phospho ric Acid (KGS) 10235 9065 4985 ---2600 10195 9705 46785 7797.500 287.025
CAUSTIC SODA (KGS) 4150 8200 5800 ---350 8050 1500 26550 4425.000 162.883
34
RECTIFIED SPIRIT SR. NO 1 2 3 4 5 6 7 8 9 10 11 12 MONTH Jan 2012 Feb 2012 Mar 2012 Apr 2012 May 2012 June 2012 July 2012 Aug 2012 Sep 2012 Oct 2012 Nov 2012 Dec 2012 TOTAL Avg./Month Avg./ DAY MOLASSES (MT) 6451 5635 5654 ----5356 5408 28504 5700.80 196.579
ANNEXURE - 08 MONTH WISE RAW MATERIAL CONSUMPTION FOR SUGAR PRODUCTION
FLOCCULAN MONTHS T (KGS)
MILL SANITATIO N (KGS)
ANTISCALEN T (KGS)
VISCOSIT Y REDUCER (KGS)
WASHIN G SODA (KGS)
Jan 2012 Feb 2012 Mar 2012 Apr 2012 May 2012 June 2012 July 2012 Aug 2012 Sep 2012 Oct 2012
100 125 75 ---25
720 990 700 ---360
1430 1200 610 ---350
150 660 500 ----
50 800 500 ---50
35
Nov 2012 Dec 2012 TOTAL AVG./MONTH AVG./ DAY
125 125 575 95.833 3.528 Raw material Sugar cane Lime Sulphur Phosphoric acid Caustic soda
1280 1100 5150 858.333 31.595
1810 1745 7145 1190.833 43.834
115 40 1465 244.167 8.988
1150 50 2550 425.00 0 15.644
Quantity consumed per MT product (Sugar) 9.259 0.01422 0.0042 0.00059 0.3366
ANNEXURE - 09 PROCESS DESCRIPTION FOR MANUFACTURING OF SUGAR FROM SUGARCANE Matured cane according to plantation calendar is harvested from the fields, trashes, tops and roots removed and clean cane is transported to factory by means of trucks and bullock-carts. The cane is weighed and dumped on feeder tables by means of sling hoist cane unloaded. At mill for macceration hot water of 75
0
C is applied to extract maximum amount
of sugar cane juice (sugar) from the cane. The residual obtained after milling (Bagasse) is fed to boilers to generate the steam for running the different prime movers for milling and electrical power generation. The mixed juice obtained from mills is weighed and phosphoric acid is added to it. After addition of phosphoric acid mixed juice is heated to 75
0
C in multipass vertical tubular juice heaters where from it is sent to juice sulphitor where milk of lime and SO2 gas is mixed in it and final pH is
36
maintained to 7.0 (+ or - 0.2). Sulphited juice is heated to 102
C (+ or -
2) and then sent to Dorr or clarifier for settling to flock formed. The overflow of the Dorr Clarifier is clear juice and underflow is mud. The mud is filtered through vacuum filter, mud is used as manure and the filtrate is recycled and mixed with the mixed juice for reprocessing. The clear juice obtained from Dorr Clarifier is concentrated to 60-65 0Bx. In vapour cell and quintiple effect evaporators. The juice so concentrated i.e. Syrup is sent to Syrup Sulphitor where it is sulphited with SO 2 and its pH is brought down to 5.0 to 5.2. Thus sulphited syrup is sent to pans supply tank for further processing. A massectuite is boiled with syrup melt and A light, Dry seed footing is taken for A massecuite boiling in vacuum pans where sugar crystals are developed for bagging. A massecuite of 94 Bx. And 86-88 purity is finally dropped in the crystallizers. From crystallizer this A massecuite is sent to centrifugal machines where sugar crystals. A heavy molasses and A light molasses are separted, sugar is sent to graded through grass hoppers where sugar is separated in different grains, sizes S- 30, M- 30 & L -30 are bagged, weighed in 100 Kgs. bags for domestic market and 50 Kgs. for export. molasses are sent to pans storage tanks. A light is used in A massecuite and A heavy is used for boiling B massecuite. 95-96
0
Bx. and 71-73
purity. After purging B massecuite B heavy molasses and B sugar is obtained. B sugar is melted and sent to pans and fed to A massecuite pans. B heavy molasses is sent to pan storage tanks and is used for boiling C massecuite of 100 0Bx. and 55-56 purity. C massecuite is purged in C fore workers where final molasses solution of 45 0Bx. is used for lubrication, molasses obtained from C fore centrifugals is final molasses it is weighed and is stored in five steel molasses storage tanks. C fore cured sugar is affinated with C light molasses and sent to C After worker centrifugals where hot water is applied and C after sugar and C light
37
molasses is obtained. C after sugar is melted and sent to pans for A massecuite boiling and C light molasses used for C fore magma and boiling C massecuite. PROCESS DESCRIPTION OF DISTILLERY UNIT: 1. Fermentation: Pump the Molasses from molasses weighment it is pumped to fermentors. Fermentation process is of three fermentators with an overall residence time of around 18-22 hrs, the fermentors are purged with air required inputs like nutrients and biocides are fed to the fermentors along with the molasses and process water. Carbon dioxide laden with alcohol vapors during reaction is scrubbed in a scrubber with water to prevent loss of alcohol. After fermentation process the fermented wash from third fermentor is pumped to wash settling tank. The clear juice liquid from wash settling tank over flows to clarifier wash tank and the bottom sludge subjected to further settling an then it goes to filter beds. The clear wash is then pumped to distillation section.
2. Distillation Section: The fermented wash from clarified wash tank is taken to bear heater where the wash preheated by the vapors from rectified column after preheating the wash is heated in the plate heat exchanger by out going effluent. The heated wash is taken to wash boiling column where wash is boiled with steam. Heated wash is fed to boiling column from the top and
38
steam is fed at the bottom. This rises to the top and in this process stripping the alcohol from fermented wash. The vapors coming out from the top of the column are fed to the bottom of rectifier column via the liquid separator. The vapors coming out of the rectifier columns are condensed, first in the beer hater then in the principal condenser and finally in the vent condenser. The condenser is fed back as a reflux. The product is withdrawn from the top of the rectifier column cooled in ht spirit cooler and then flows to the rectified spirit receiver. BRIEF PROCESS DESCRIPTION FOR ABSOLUTE/ANHYDROUS
ALCOHOL: (MOLECULAR SEIVE PROCESS) 95-96% v/v alcohol (rectified spirit) is fed to evaporation column where it will get vaporized and then fed to super heater to get vapor temperature up to 120oC. This vapor is passed through the molecular sieve bed where water molecules is retained and only alcohol is passed through the bed which is collected as a final product absolute alcohol. There are two beds of molecular sieves. At a time one is under process and the other is under vacuum. This cycle changes at every five minutes. During vacuum retained water content is removed. This is a simple process and no chemical reaction is involved in this process. PROCESS DESCRIPTION FOR BIO-COMPOSTING OF DISTILLARY EFFLUENT: The company has started bio-composting system for treatment of effluent generated from distillery plant. Layout for bio-compost plant may be referred in annexure. Distillery waste has partly been utilized in biocomposting.
39
In bio-composting of distillery effluent, the press mud is formed into windrows, left for few days in the yard to supply oxygen using Hi-tech compost machine as shown specially cultured bacteria are added. Then after, the windrows are aerated and effluent is sprayed on them daily. The windrows temperature increase to around 60-70 oC during the second week of composting. Because of this high temperature, all dieses causing germs are killed and effluent consumption increases. The end product, compost or humus is removed from the yard and left for curing. Curing is the phase, where the demand of oxygen is less. Later, it is sold to farmers.
40
PROCESS FLOW DIAGRAM OF SUGAR Cane

MACCERATION WATER WEIGH WEIGHED
Milling Plant Mixed Juice pH 5 to 5.5 Automatic Weighment Bagasse

Excess Bailed Solid for Paper Industries
Boilers High Press Steam
Receiving Tank Primary juice Heater 70oC
Phosphoric Acid.
Primover
Power Turbine
Continuous lime and Sulphitation unit pH 7 to 7.2
Low Pressure Steam
Secondary juice heater 100o to 102oC Contd. Settler Mud Mud Mixer
Condensed Low Pressure Water

Electricity
Produced to Run the Plant
Clear juice pH 6.9 to 7.0 Temp 95oC Evaporators
Syrup pH 6.5-6.8 Vacuum Filter

Filter Cake
41
To Process
Weight & Sold as Farm Yard Manure
Cont. Syrup Sulphiter

SO2 Gas
A Heavy & A Light Filter
Sulphide syrup pH 4.8-5.2
Crystallization Centrifugation
SUGAR SHREE CHALTHAN VIBHAG KHAND UDYOG SAHAKARI MANDLI LTD, CHALTHAN
MOLASSES
42
MASS BALANCE DIAGRAM
( JAN-2012TO DEC-2012 )
CANE 730238 FIBRE 97611.042
MILL
WATER 516426.218 116200.740 116200.740
WATER IN BAGASSES 112509.257
CLARIFIER
SOLID IN FILTER CAKE 8060.071
WATER IN FILTER CAKE. 17323.553
108140.669
CENTRIFUGAL
SOLID IN MOLASSES 43 29629.884
WATER IN FINAL MOLASSES 4137.694 SUGAR 78510.785
WATER IN PROCESS + BOILER & COOLING
382455.714
ALL FIGURES ARE IN MT/YEAR
SHREE CHALTHAN VIBHAG KHAND UDYOG SAHAKARI MANDLI LTD.
DISTILLERY MASS BALANCE DIAGRAM

(PERIOD JANUARY-2010TO DECEMBER-2010)
44
45
CO2 5475 MT MOLLASSES(MT) 28504 WATER(KL) 31291 Condensate 28600 DILUTER 102499 CO2 SCRUBBER
FERMENTER 97024
CONDENSATE TO BFW TANK 17969
DIST.COLUMN
EVA. LOSSES 2615 MT 8492 M T M T ALCOHOL 95% 8171.359 KL or 6619 MT
STEAM 17969
633135
EVAPORATOR
87790
14104 MT
SPENT WASH 59190

SPENT WASH AT E.T.P. 45086 MT
ANNEXURE - 10 WATER CONSUMPTION & WASTE WATER GENERATION: WATER CONSUMPTION:
46
Months Jan 2012 Feb 2012 Mar 2012 Apr 2012 May 2012 June 2012 July 2012 Aug 2012 Sep 2012 Oct 2012 Nov 2012 Dec 2012 TOTAL AVG./day
Cooling KL 10905 8943 5775 ---3112 12230 12512 53477 328.080
Process KL 1701 2030 1019 ---638 1827 2208 9423 57.810
Domestic KL 1321 1254 1331 1289 1288 1301 1354 1327 1340 1350 1307 1334 15796 43.277
Distillery Water Stea KL m KL 6358 4114 5559 3597 5712 3590 ------5151 3333 5154 3335 27934 17969 192.6 123.9 48 24
DETAILS OF WASTE WATER GENERATION:

Waste water generatio n in sugar plant (KL) 14727.63 13150.36 7870.83 ------3875 15970 16697 72290.720 -443.50 Waste water generatio n per ton of sugar (KL/T) 0.896 0.855 0.866 ------1.566 0.938 0.903 -1.004 -Waste water generatio n in Distillery M3 10285 8992 9139 -------8332 8338 45086 -310.938 Waste water generatio n per KL of Alcohol 5.5 5.5 5.6 -------5.5 5.5 -5.52 --------8332 8338 45086 -310.938
Month
Dist. Eff. Used at the Bio Compost 10285 8992 9139
Jan 2012 Feb 2012 Mar 2012 Apr 2012 May 2012 June 2012 July 2012 Aug 2012 Sep 2012 Oct 2012 Nov 2012 Dec 2012 TOTAL Avg./ MT AVG./day
47
` ANNEXURE 11: WATER BALANCE DIAGRAM (FOR SUGAR PLANT) SHREE CHALTHAN VIBHAG KHAND UDYOG SAHAKARI MANDLI LIMITED, CHALTHAN.
35
36
ANNEXURE 12 PROCESS OF EFFLUENT TREATMENT WITH CAPACITY OF UNITS
The capacity of ETP Sugar Unit: 1500 M3/Day. 1) Name and Size of each unit: Vacuum Pan Sugar: Effluent water coming out of the sugar factory, Collected in pit after oil and grease separation by 2 Nos. Online mechanical oil skimmer. Form pit, water is pumped and passed though DSM screen where fibrous particles removed. Then again oil & grease are separated in a masonary oil separator . After oil & grease removed, it leads to the reaction tank where milk of lime treatment done for neutralization. Neutral effluent then goes to anaerobic digestion in the equalization tank. From the equalization tank water goes to first stage PP discs course bubble aeration lagoon. Then it pass to second stage fine bubble aeration lagoon. Aeration tank effluent water collected in secondary clarifier Activated sludge recirculation system used. Clear water collected in collection pit and passed through pressure sand filter and activated carbon filter by pumping. Treated effluent water used for irrigation and in side factory purpose. sludge is removed and dried on sludge drying bed. Dried Sludge is used to make bio-compost. Hydraulic Adequacy of ETP Unit for flow of: 700 m3/day Name of the Unit Oil Skimmers Anaerobic Lagoon Course diffuser pond Fine diffuser pond Holding pond Secondary clarifier Sludge drying bed Treated water storage pond Pressure sand filter Capacity 02 Nos. 3000 m3. 2550m3 3000m3 1000m3 10mt. dia X 2.5mt. depth 15mtr. X15mtr. X 1mtr. 12000m3 1.7mtr.dia X1.8 HP( Air Blower) Air Blower 1 No. -15H.P 2 Nos 40HP
4nos
30m3 / Hrs.
36
Activated carbon filter
Mtr.HOS 1.7mtr.dia.X1.8 Mtr.HOS
30m3 / Hrs.
37
DISTILARY UNIT: COMPOSTING PROCESS: The treatment of spent wash by anaerobic and followed by aerobic composting appears to be most promising and appropriate technology to obtain pollution control by it. By this method, treatment and disposed both the problems of spent wash are totally solved. A want is more; the much-needed organic compost with many essential nutrients is produced. The press mud and Bagasse which is available by the byproduct of the sugar industry is used as the major absorbent. How ever, it is also possible to use boiler ash and dried yeast sludge to act as a filter. The unit has R.C.C. tanks and the leachate is pumped out, the remaining sludge is removed and stored at factory premises and only after it get dried, it is used as filler material in compost. PROCESS DETAILS: The cooled spent wash is pumped through high density polythene pipes to the site and composting the heaps of press-mud and Bagasse are made in large containers (200mt x 3.0 mt x 1.2 mt) and the ratio of press-mud is 90:10 approx. A special micro bio culture is added along with the spent wash and dried yeast sludge as a filler material in the compost. The press-mud and Bagasse can absorb spent wash up to 2.5 3 times its volume. This can be achieved by spraying the spent wash in three to four lots. The heaps are then subjected to anaerobic condition for a period of 12 to 15 days. The temperature of the mixture in the heap rises to about 60oC 75oC. This help in killing the pathogens seeds and speeds up the degradation of the organic matters. After the initial 15 days, churning is given with mixing machine and the composting is allowed to proceed, then the temperature starts to decline, aerobic condition is created for further degradation and deodorization. The compost gets ready in 32-35 days. Pucca Lagoon for storage of Effluent 50 mt. x 50 mt. x 4.5 mt. 25 mt. x 25 mt. x 4.5 mt. Total 8 Nos. lagoons : : 4 Nos. 4 Nos.
38
39
ANNEXURE 13 HYDRAULIC & FLOW DIAGRAM OF ETP
40
ANNEXURE 14 MONTH WISE ENERGY CONSUMPTION FOR EFFLUENT TREATMENT PLANT
SR. NO. 1
MONTHS
ELECTRICAL CONSUMPTIO N SUGAR(KWH) 34568 29768 26712 ------12808 29504 27588 160948 0.0022 987.411
Jan 2012 2 Feb 2012 3 Mar 2012 4 Apr 2012 5 May 2012 6 June 2012 7 July 2012 8 Aug 2012 9 Sep 2012 10 Oct 2012 11 Nov 2012 12 Dec 2012 TOTAL KWH/L of Treated Effluent Avg./ Day
ELECTRICAL CONSUMPTIO N DISTILLARY (KWH) 7412 10180 5161 3032 2712 4073 1005 1907 1860 3110 5960 4890 51302 0.001 140.55
41
ANNEXURE 15 DETAILS OF OPERATOR/ CHEMIST FOR ETP
SUGAR UNIT:
SR. NO. NAME OF OPERATORS QUALIFICATIONS EXPERIENC E (IN YEAR) SALARY / MONTH
1 2 3 4 5 6
Hemant R Mistry Arjun S Borse Sharad Khalop Pravinsinh C.Vansia Ramnaresh A Yadav Ramkeval R Yadav
B.Sc SSC SSC SSC SSC SSC
4 24 28 18 2 2
9863 10912 11133 10618 10693 10693
DISTILLERY UNIT:
SR. NO. NAME OF OPERATORS QUALIFICATIONS EXPERIENCE (IN YEAR) SALARY / MONTH
1. 2. 3. 4.
Mr. Dipak Desai Mr. Jayanti D. Desai Mr. Parbhubhai R. Ahir Mr. Mahendra M. Yadav
BSC SSC SSC SSC
30 29 28 28
14400 10933 10693 10813
42
5. 6.
Mr. Pravin N. Patel Mr. Bhulabhai C. Rathod
SSC 5
th
22 23
11000 10813
43
ANNEXURE 16 CONSOLIDATED CONSENT
44
45
46
47
48
49
ANNEXURE 17 NO. OF THE FLUE GAS STACKS, THEIR HEIGHT NATURE AND CONSUMPTION OF FUEL.
SR. NO . 1 2 3
STACK ATTACHE D TO BOILER NO 1,2,3 BOILER NO 4,5 BOILER NO 6
TYPE OF FUEL
MO C MS
PROBABLE POLLUTAN T SPM SPM SPM
HEIGHT IN (MTS.) 40 40 45
INTERNA L DIA. (MTS.) 2.46 2.46 2.0
AIR CONTRO L MEASUR E DEVICE Wet scrubber Wet scrubber Wet Scrubber
BAGASSE / FIRE WOOD
MS MS
MONTH WISE CONSUMPTION OF FUEL MONTH Jan 2012 Feb 2012 Mar 2012 Apr 2012 May 2012 June 2012 July 2012 Aug 2012 Sep 2012 Oct 2012 Nov 2012 FUEL CONSUMPTION BAGASSE FIRE WOOD (MT) (MT) 39398.748 -34584.022 -22432.580 -------9431.280 40068.555 ------150.000 --
50
Dec 2012 TOTAL MT/Hr. MT/day
43558.899 189474.084 48.434 1162.418
-150.000 0.03834 0.9202
ANNEXURE - 18 DETAILS OF HAZARDOUS (SOLID) WASTE GENERATION
MONTHS
QUANTITY OF ETP SLUDGE (MT)
QUANTITY OF FLY ASH (MT)
QUANTITY OF DEAD CELL BIOMASS (MT)
Jan 2012 Feb 2012 Mar 2012 Apr 2012 May 2012 June 2012 July 2012 Aug 2012 Sep 2012 Oct 2012 Nov 2012 Dec 2012 TOTAL Avg. Day
32 27 21 -------16 36 132 0.81
1831.35 1443.94 999.48 ------204.910 2036.680 2255.220 8771.580 53.81
22 16 18 -------20 23 99 0.683
51
52
ANNEXURE - 19 STORAGE & PREATMENT OF SOLID WASTE
53
ANNEXURE - 20 FACTORY SITE PLAN
54
ANNEXURE - 21 SULPHUR STORAGE LICENSE
55
56
ANNEXURE 22 NOISE MEASUREMENT Noise level measurement on: 22.03.2012 Sr.No Noise level in Location . dB(A) 1. Store and laboratory gate 68 2. Boiler house 85 3. Mill House 82 4. Cane unloader 73 5. Power house 75 6. Centrifugal house 79 7. Sugar house 60 8. Security cabin 53 9. Distillery gate 58 10. Fermentator 62 11. Distillery 68 Noise level measurement on: 21.12.2012 Sr. Noise level in dB(A) Location No. 1. Near Boiler 1, 2 & 3 78 2. Near Power house 87 3. Near centrifugal 1, 2 & 3 74 4. Near centrifugal 4, 5 & 6 80 5. Near pan area 68 6. Near evaporator 77 7. Near boiling house 83 8. Final packaging 65 9. Near stack of 4, 5 & 6 78 10. ETP area 61 11. Near guest house 53
57
ANNEXURE 23 COMPLIANCE REPORT Status of Consent and Authorization: The unit has valid Consolidated Consent and Authorization as per GPCB Consent no. 35652 dated 14/06/2011, which is valid up to 20/05/2014 . 1. 1. 1 PRODUCTION The production capacities granted by GPCB and actual production by the unit during Audit period are compared in the following table. It may be seen that the actual production does not exceed the consented quantities. Products Vac. Pan Rectified Spirit 15,00,000 Lit/Month 680946 Lit/Month Absolute Alcohol 750 KL/Month 278.133 KL/Month Fusel Oil 1200 Lit/Month
Sugar Production 20,000 Capacities as MT/Month per CCA. Actual 13144.833 average MT/Month Production. 2. WATER not exceed the
2.1 Total quantity of effluent from industrial process (Sugar plant) does quantity mentioned in the consent (1500 m3/day) during Audit period. 2.2 Total quantity of effluent from industrial process (Distillery plant) does not exceed the quantity mentioned in the consent (559 m 3/day) during Audit period. 2.3 Total quantity of sewage (for Sugar plant) does not exceed the quantity mentioned in the consent (45000 Litre / day) during Audit period. 2.4 The Distillery effluents utilized partly for Bio-composting & remaining used for dilution purpose in distillery plant. 2.5 Daily records for water consumption in different usages and
58
wastewater generation are maintained. 2.6 The Sugar effluent confirming to the above standards is utilized for Plantation/irrigation and on the land within the premises of the industry. 2.7 Magnetic flow meters are provided at the inlet and the outlet of the ETP. 2.8 Regular sampling and analysis of waste water is carried out by the company and Authorized consultant, the records are maintained. 2.9 All the chemicals and nutrients required in the ETP are added, 2.1 manually. Sign boards at units of ETP are provided
0 2.1 Company is in possession of necessary factory license. 1 2.1 The consent (Consolidated) under the Water Act, 1974 is valid for the 2 3. 3. 1 3. 2 3. 3 3. 4 3. 5 3. 6 3. 7 4. 4. 1 audit period (Order No: 35652 valid up to 20.05.2014). As per Annexure-16 AIR Wet Scrubbers (5 Nos.) are installed as pollution control devices. Facilities for stack monitoring like port hole and platform are provided. The height of stacks is observed adequate for effective dispersion of emission. Routine ambient air quality & Stack gas monitoring are regularly carried out by company. Sampling, analysis and results carried out by the audit team are within the specified norms. Bagasse handling is done by covering that area under the roof to avoid the dusting in the ambient air. The consent (Consolidated) under the Air Act is valid. 35652 valid up to 20.05.2014).As per Annexure-16 HAZARDOUS WASTE The quantity of sludge generated during audit period is 132 MT, whereas fly ash generation has been 53.813 MT/Month. The sludge (Order No:
59
4. 2 4. 3 4. 4 4. 6
generated from ETP and fly ash are used in mfg. of Bio- compost. The records of quantity of sludge generation are maintained by the company. The industry has been issued valid authorization No.35652 for solid and hazardous waste handling valid up to 20.05.2014. (As per Annexure-16) Collection, storage, transportation & Ultimate disposal of used oil & discarded containers are done by selling it to registered reprocessor. The company is in possession of Valid Sulphur storage license for handling and storage of Sulphur. (As per Annexure 21)
ANNEXURE 24 DETALIS OF INSURANCE POLICY
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ANNEXURE 25 DETALIS OF WATER CESS
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ANNEXURE 26 DETAILS OF HAZARDEOUS WASTE HANDLING
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ANNEXURE 27 GPCB ANALYSIS REPORTS
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CONTENTS

LIST OF ANNEXURES Sr. No. Title Pag e No.

Chemical Engineering Department (N. G. Patel Polytechnic, Bardoli)

Chemical Engineering Department (N. G. Patel Polytechnic, Bardoli)

Chemical Engineering Department (N. G. Patel Polytechnic, Bardoli)

Chemical Engineering Department (N. G. Patel Polytechnic, Bardoli)

Chemical Engineering Department (N. G. Patel Polytechnic, Bardoli)

Chemical Engineering Department (N. G. Patel Polytechnic, Bardoli)

Chemical Engineering Department (N. G. Patel Polytechnic, Bardoli)

has a quality control laboratory equipped with

Sludge). Sludge is is used

Chemical Engineering Department (N. G. Patel Polytechnic, Bardoli)

Chemical Engineering Department (N. G. Patel Polytechnic, Bardoli)

ENVIRONMENTAL AUDIT REPORT (JANUARY 2012 TO DECEMBER 2012)

Name and address of the in charge

Chemical Engineering Department (N. G. Patel Polytechnic, Bardoli)

of Environment / safety Division / Cell / Unit 12

Chemical Engineering Department (N. G. Patel Polytechnic, Bardoli)

Chemical Engineering Department (N. G. Patel Polytechnic, Bardoli)

Chemical Engineering Department (N. G. Patel Polytechnic, Bardoli)

Chemical Engineering Department (N. G. Patel Polytechnic, Bardoli)

Chemical Engineering Department (N. G. Patel Polytechnic, Bardoli)

The details regarding resource recovery / by - None product recovery

Chemical Engineering Department (N. G. Patel Polytechnic, Bardoli)

Whether sanitary facilities latrine, urinals, bathroom provided & satisfactory

Chemical Engineering Department (N. G. Patel Polytechnic, Bardoli)

No strong odour nuisances found in and around industry premised.

Chemical Engineering Department (N. G. Patel Polytechnic, Bardoli)

Water Cess paid for the year 2011-2012 As per Annexure 25

M/s En-vision enviro engineers pvt ltd. 208,G-Tower,Shankheshwar complex,Sagrampura,Surat

Chemical Engineering Department (N. G. Patel Polytechnic, Bardoli)

Chemist, Audit Cell Mrs. K. I. Champaneriya, Microbiologist, Audit Cell

Chemical Engineering Department (N. G. Patel Polytechnic, Bardoli)

Adequacy Certificate of Environmental Management System

Chemical Engineering Department (N. G. Patel Polytechnic, Bardoli)

Date: Place: Bardoli

Chemical Engineering Department (N. G. Patel Polytechnic, Bardoli)

ANNEXURE 01 DETAILS OF SAMPLING AND ANALYSIS

Certificate for sampling and analysis

(Mr.A.B.Suthar) Principal Date:03/04/2012 Place: Bardoli

(Dr. L. B. Chaudhari) Co-ordinator

(Dr. P. R. Patel) Member

Chemical Engineering Department (N. G. Patel Polytechnic, Bardoli)

Parameters SPM Sox NOx

Unit mg/Nm3 Ppm Ppm

Boiler No. 1,2 & 3 121.5 0.20 1.6

Boiler No. 6 92.7 0.17 0.8

AMBIENT AIR QUALITY MONITORING REPORT

Parameters SPM SOx NOx

Near Laboratory 94.2 8.4 18.1

NOTE: - ALL RESULTS ARE IN G/M3

Chemical Engineering Department (N. G. Patel Polytechnic, Bardoli)

CERTIFICATE FOR SAMPLING AND ANALYSIS

(Mr.A.B.Suthar) Principal Date:28/12/2012 Place: Bardoli

(Dr. L. B. Chaudhari) Co-ordinator

(Dr. P. R. Patel) Member

Chemical Engineering Department (N. G. Patel Polytechnic, Bardoli)

Parameters SPM Sox NOx

Unit mg/Nm3 ppm ppm

Boiler No. 1,2 & 3 118.6 0.21 1.5

Boiler No. 6 89.5 0.16 0.7

NOTE: - ALL RESULT ARE IN G/M3

Chemical Engineering Department (N. G. Patel Polytechnic, Bardoli)

ANNEXURE 02 MONTH WISE NUMBER OF WORKERS EMPLOYED