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CONTENTS
SR.
NO.TITLE
PAGE
NO.
1. List of Annexures 12. Executive Summary 23. General (Section A) 74. Product Details (Section B) 85. Water (Section C) 106. Air (Section D) 127. Hazardous Solid Waste (Section E) 138. Site plan (Section F) 139. Resource recovery (Section G) 13
10. Health (Section H) 1411. Accidents (Section I) 1512. Safety measures (Section J) 1513. Noise (Section K) 1614. Odour (Section L) 1615. Cases /Complaints (Section M) 1616. Compliance report (Section N) 1617. Sulphur storage License ( Section-O) 1618. Hazardous chemicals (Section P) 16
19.Public Liability Insurance Act (Section
Q)16
20. Water Cess (Section R) 1621. Consultant (Section S) 16
22.Declaration of concerned persons
(Section T)16
23.EMS Adequacy / Efficacy certificate
(Section U)17
24. Annexures 18
LIST OF ANNEXURES
Sr.No.
TitlePag
eNo.
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1 Details of Sampling & Analysis
2 Month wise number of Workers Employed
3 Month wise Electricity Consumption
4 List of Directors
5 Month wise number of Working Days
6List of Products along with their Capacity, Yieldand Purity
7 Month wise Products & By products produced
8 Month wise Raw Material Consumption
9Process Flow Chart and description and MassBalance diagram
10 Waste Consumption & Waste Water Generation
11 Water Balance diagram
12 Particulars of ETP
13 Hydraulic & Flow Diagram of ETP
14 Month wise Energy Consumption for ETP
15List of Operators / Chemists in ETP (Sugar &Distillery Unit)
16 Consolidated Consent
17 Details of Flue Gas Stack & Consumption of Fuel
18 Details of Solid Waste Generation
19 Storage and pretreatment of solid waste
20 Factory Site Plan21 Sulphur storage License
22 Noise Measurement
23 Compliance report
24 Details of Insurance policy
25 Details of Water Cess
26 Analysis of GPCB
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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 Polytechnic, Isroli, Bardoli, is nominated to carry out
Environmental Audit work for the industries falling under Schedule I
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)locatedat 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
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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.
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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
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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 inprofile ofcapabilities.
PROFILE OF CAPABILITIES
1. Dr. P. R. Patel: A Doctorate in Chemistry is senior member of this auditcell. He is Head of Science & Humanities Department of N. G. Patelpolytechnic. He has published 06 research papers in various national andinternational journals like Tailor & Francis, High Performance polymer &Iranian Polymer Journal. He is chiefly responsible for overall laboratorycoordination and scheduling of Monitoring work.
2. Dr. L. B. Chaudhari: A Doctorate in Chemical Engineering & is workingas Coordinator of Envirochem Audit Cell of N. G. Patel Polytechnic. He isCoordinator of Nodal Institute (Chemicals & Petrochemicals sector) underAnchor Institute, D.D.U., Nadiad. He is responsible for industry assessmentand relationship, different Analytical work aspects of Audit work. He is ableto cope up the responsibilities of analysis of Chemical Parameter andstudy of manufacturing process. He has published 10 research papers invarious national & international journals like Chemical Engineering Journal,
Journal of Hazardous Materials, Desalination, International Journal ofEnvironmental Engineering, Journal of Environmental Management, etc.
3. Mr. K. R. Desai: A Post Graduate in Chemical Engineering & is working asa Sr. lecturer in Chemical Engineering Department. Being In-charge ofSafety & 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 & isworking 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 alecturer in Chemical Engineering Department and is pursuing is Post-Graduation in Chemical Engineering.
6. Mr. M. B. Dhangar: A Graduate in Chemical Engineering is working as alecturer in Chemical Engineering Department.
7. Mr. D. B. Chaudhari: A Graduate in Environment engineering is familiarwith important aspects of environment pollution strategies & legislation.He is familiar with treatment plant design and its operation.
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8. Mr. B. G. Tailor: A Post Graduate in Medical technology with Microbiologyis capable to look in to the biological aspects of environmental studies & isin the environment audit team as Environmental microbiologist.
9. Mrs. K. I. Champaneriya: A Graduate in Microbiology is capable to lookin to the biological aspects of environmental studies & is in theenvironment audit team as Environmental microbiologist.
10.Mr. H. S. Desai: A Graduate in Chemical Engineering is working as alecturer in Chemical Engineering Department.
11.Mr. P. B. Patel: A Graduate in Chemistry & is working as a laboratoryassistant 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.
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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
Sludge). Sludge is dried on separate sludge drying beds. Dried sludge
is used to make Bio-compost. The company has obtained necessary
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 theperson 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.
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9) Handling of scrap is fair enough. It is collected frequently and sent
to scrap yard time to time. Used oil and containers are handled in
the prescribed manner.
10) It is recommended to prepare on site & Off-Site Emergency
Plan as soon as possible
11) The ETP of Chalthan Sugar is in good condition and well
maintained. Signboard is provided indicating name of each unit in
ETP.
12) It is recommended to keep clean area near by all stacks.
13) During the second monitoring the parameters of effluents like
BOD & COD were found slightly higher than the prescribed limit,
however the company has modified ETP by installing series of Airdiffusers, 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
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ENVIRONMENTAL AUDIT REPORT(JANUARY 2012 TO DECEMBER 2012)
(A) GENERAL1 Name of the Industry M/s. Shree Chalthan Vibhag Khand
Udyog Sahakari Mandali Ltd, Chalthan2 Location Village: Chalthan, Ta. Palsana, Dist. Surat3 Registered Office Address Village: Chalthan, Ta. Palsana, Dist. Surat4 Month & year of establishment
Sugar factory
Distillery
March 1971
December 19785 (a)No. of Workers employed
(b)Male / Female
Male only. As per Annexure 2
6 (a) No. of electrical connection
& service numbers
Sugar factoryDistillery
ETP of distillery
(b) Total connected load
Sugar factory from GEB
Distillery from GEB
Sugar factory
(c) Electrical consumption per
KL of effluent treated.
Three connection, Service No.:
100080097/10015
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
7 Number of D.G. Sets & theircapacity Two D.G. Set , 625 KVA each
8 Name & residential address of all
directors / partners
As per Annexure 4
9 Telephone Nos (Residential &
Industrial), Fax No. & E - mail
address of industry & partners /
directors
(O) 02622 281050, 281112, 282312
Fax No.: 02622 - 281120
As per Annexure 4
10 No. of shifts & timings 1st Shift 04:0
0to
12:0
0
2nd Shift 12:00
to 08:00
3rd Shift 08:0
0to
04:0
0General
Shift
08:0
0to
05:0
011 Name and address of the in charge Mr. S. M. Patel (Distillery Manager)
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of Environment / safety Division /
Cell / Unit
Mr. M. N. Prajapati (Chief Chemist)
Mr. G. J. Rajput (Chief Engineer)
Mr. M. C. Mistry (Safety Officer)12 No. of days during which treatment
activities were in operation during
the period covered for it (for audit)
As per Annexure 5
13 Has the industry obtained ISO
900 / ISO 14000 / OSHAS 18000 /
Any other EM accreditation /
Certification recognition?
NIl
14 Whether the industry has adopted
cleaner production / Cleaner
technology / CDM?
NIl
(B) PRODUCTION DETAILS
1 Name of products & production permonth and recovery
As per Annexure - 6
2 Name of all by - products and its
quantity per month
As per Annexure - 7
3 Date of commencement of
production for each product.
(Effluent Treatment)
Sugar-march 1971
Rectified spirit January 1983
Ethanol December 20024 All auxiliary materials consumed
(MT)
As per Annexure 8
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
Continuous process (Seasonal)
6 Detailed treatment process with
flow diagram, list of unit operations
& processes with all chemical
reactions, along with the timerequired (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) WATER1 The quantity of water consumed
per day as well as per ton of waste
water treated. (Please also enclose
water balance diagram)
As per Annexure 10
Domestic : 43.277 KL/day
Process Water : 385.890 KL/day
( Sugar)
192.648 KL/day
( Distillery)
Water Balance Diagram as per
annexure - 112 The quantity of wastewater (trade
waste) generated per ton of each
product per day, as well as per
batch
As per Annexure 12
3 The particulars of effluent
treatment i.e.
i. Name & size of the Effluent
Treatment Plant (ETP)
ii. The capacity of the ETP
iii. Flow diagram & hydraulic
diagram
iv. Whether lighting
arrangement around ETP isprovided
v. Whether the separate energy
meter for effluent treatment
plant area is installed. If
provided reading of the
meter for consumption every
month.
vi. Whether flow meter is
provided at the inlet & outletof ETP. Please indicate the
type of the flow meter.
As per Annexure 12
700 m3/Day
As per Annexure 13
Yes, sufficient lightning arrangement is
provided around ETP.
Yes, As per Annexure 14
Yes, Magnetic flow meters are installed at
the inlet and outlet of ETP.
4 The method of disposal of effluent
& the final point of disposal of
effluent (Please Attach Sketch)
Treated effluent is used for in-house
farming on 82 acre area of farming land
owned by company and also used in wet
scrubber as makeup water.
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5 The quality of trade effluent before
& after treatment as well as at the
end of each stage of treatment
(Attach Separate Sheets)
As per Annexure- 1
6 The quantity and quality of sewage
& its method of disposal (Attachseparate sheet)
a) As per Norms
b) Total Pollution load
Quantity of Sewage: 30.29 KL/Day
Disposal of Sewage : During crushingseason 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.7 The open area available for
disposal of the effluent
24 acres area if farm land available for
disposal of the effluent.8 Whether the quality of treated
effluent meets the specified
norms. If no, the extent of
deviation and reasons thereof
Yes, as per annexure 1
9 Improvement in effluent quality
and quantity since previous
environmental audit based on
performance evaluation of effluent
management systems. If yes
provide details. (Attach separatesheet)
Quantity and quality of effluent has been
almost same with respect to previous
audit
10 Retrofitting undertaking to improve
performance of ETP. If yes, provide
details
Nil
11 Major problems encountered
during operation of effluent
treatment facilities, if any and
reasons thereof
Nil
12 The details of operator / chemists
responsible for operation and
maintenance of effluent treatment
plant
i. Name of the operators /
employees
ii. Qualification & experience of
As per Annexure 15
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each operator / employee
iii. Salary of operators /
employees13 The current status of consent
under the Water Act 1974
The industry is in possession of
consolidated consent. The CCA No.
35652 is valid up to 20/05/2014. As perAnnexure 16.
(D) AIR1 No. of the flue gas stacks, their
height (from ground level), nature
& consumption of fuel
As per Annexure 17
2 The details pertaining to the stack
monitoring facilities
Industry has provided adequate stack
monitoring facilities as sampling ports,
sampling platform, and electrical
connections with approach ladder.3 Number of process stacks, their
height (from ground level) source,
expected pollutants & the details
of pertaining to the provision of
stack monitoring facilities (S.M.F.)
No process stacks provided.
4 The quality of emission from each
flue gas stack & the process stack
& the extent of deviation from
them
As per Annexure 1
5 The ambient air quality within the
factory premises, along with the
number of ambient air quality
monitoring stations outside the
industry
As per Annexure 1
6 The status of consent under the Air
Act 1981
The industry is in possession of
consolidated consent. The CCA No.
35652 is valid up to 20/05/2014. As per
Annexure 16.
7 The details of air pollution controlmeasures for all process & flue gas
stacks
As per Annexure 17
8 Improvement in emission quality
since previous environmental audit
based on performance evaluation
Quantity and quality of emission has been
almost same with respect to previous
audit
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of air pollution management
system. If yes, provide details.
(Attach separate sheet)9 Retrofitting undertaken to improve
emission quality. If yes, provide
details
Nil
10 Major problems encountered
during operation of control device,
if any and reasons thereof
Nil
(E) HAZARDOUS (SOLID) WASTE1 The quantity, sources &
composition of Hazardous waste /
solid waste from each process /
sources over the last three years.
(The sludge generation per tone ofproduct) whether it is as per the
consented quantity
ETP Sludge: 132 MT/Year (Approx.)
Fly ash: 53.813 MT/Day (Wet
Collection)
Details are As per Annexure - 18
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 coveredmade impervious (pucca).
Please inform about
treatment for leachate and
Solid Waste
b. The data/information about
leachate generation,
quantity and characteristics
and treatment facilities.
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
3 The status of authorization under
the EPA-86 for Solid Waste
The industry is in possession of
consolidated consent. The CCA No.
35652 is valid up to 20/05/2014. As per
Annexure 16.4 Plan if any to reduce hazardous
waste generation or its recycling.
Nil
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(F
)
The site plan showing the location
of effluent treatment plant, final
point of disposal of effluent,
sampling point, drainage line,
stacks, solid waste storage
disposal area & green belt (itswidth)
Site plan showing all these details is
enclosed As perAnnexure 20
(G)
i. The details regarding
resource recovery from
Environmental pollution
control system including
effluent treatment plant.
ii. The details regardingresource recovery / by -
product recovery
ETP sludge is used for making Bio-compostand treated effluent is used for irrigationin factory farm. Bagasse is recoveredwhich is used as fuel in boiler, moreoverpres mud and molasses is also recovered.Molasses is used in manufacturingRectified Spirit and Press Mud is used inmanufacturing Bio-compost.
None
(H) HEALTH1 Whether any hazard is involved in
the manufacturing or from the
work environment. If yes, the
details there of Month wise.
No.
2 Whether industry has pre -
employment & periodical medical
examination facilities
Yes
3 Whether health records are
maintained regarding adverse
effect on the health of workers.
No
4 Whether industry has appointed a
factory medical officer. If yes, full
time or part time. Please also
include the details about thename, address and qualification of
the factory medical officer
Yes, industry has appointed a full-time
medical officer.
Dr. G. N. Mehta, (B.A.M.S.)
C/o. Chalthan Sugar Factory
5 Details of medical facilities
available:
First Aid Boxes are available at workshop,
Boiler house, Chief Chemist & Chief
Engineers office. Ambulance / Vehicle is
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available round the clock. Intensive
hospital treatment is available at near by
hospital, Sanjivani round the clock.6 Whether sanitary facilities like
latrine, urinals, bathroom are
provided & satisfactory
Yes. Satisfactorily provided.
(I) ACCIDENTS1 The details of accident in the
factory & remedial measures
taken
No major accident was reported during
audit period according to company
representative.
(J) SAFETY MEASURE
1
General Environment of the factory. Please tick () the appropriate column
House
keeping
Good Fair Poor
Dustiness High Mediu
m
Low
Lightning Good Fair PoorVentilation Good Fair Poor
2 Whether the following protective appliances are provided to all the persons
GogglesYe
s
GlovesYe
s
Safety Gumboot Yes
HelmetYe
s
Portable StatureYe
s
Ear PlugYe
s
Cotton dust MasksYe
s
ClothingYe
s
Face ShieldYe
s
Aprons cottonYe
s
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Safety shoesYe
s
Gas MaskYe
s
Fire ExtinguisherYe
sFire Hoses
Ye
s
First Aid BoxYe
sEmergency Siren
Switch
Ye
s
3
The details of facilities for disaster
management / gas leakage
Fire extinguishers are available. 50 Nos. of
Fire extinguishers, 20 pts of fire hydrant
will all facilities are available.
4
Whether on site / off siteemergency plans are prepared and
are being implemented / upgraded
regularly, Please give details
On-site Emergency plan and Off-siteemergency plan preparation is in
progress.
5Whether records of occupational
hazards are maintained?
No
6Preventive measures adopted to
minimize occupational hazard
Yes as per need.
(K) REMEDIAL MEASURES
1
The details of sources; monitoring& measures taken for control of
noise pollution in and around the
industrial premises
As per Annexure 22
2
The measures taken for prevention
treatment and control of odour
nuisance in & around the industrial
premises
No strong odour nuisances found in and
around industry premised.
3
The details in respect of cases /
complaints under the Water Act,1974, Air Act, 1981 & EPA
Act,1986
According to company officials, No cases
of complaints have been launched underWater Act74, Air act81 & EPA86.
4
The compliance report with respect
to all the conditions of NOC /
Consent (under all the Acts)
As per Annexure 23
5 Indicates of spillages, leakages, etc Nil
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and remedial measures thereof
6
Whether insurance policy obtained
under PLI Act? Yes / No If yes, Give
details
Yes. Industry has purchased valid PLI
Policy for the audit period. Details as per
As per Annexure 24
(L) WATER CESSThe detail regarding the payment
of the Water Cess for the previous
and the current year.
Water Cess paid for the year 2011-2012
As per Annexure 25
(M)
The name and address of theconsultant engaged by thecompany / Industry
M/s En-vision enviro engineers pvt ltd.208,G-Tower,Shankheshwarcomplex,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 theindustry/organization/institute/CETPTSDF with the stamp.
Name & Signature of all the members of
Audit Team
Name Signature Name SignatureMr. V.Subburathinam( Managing Director)
Dr. L. B. Chaudhari,Co-ordinatorAudit Cell
Mr. M. N. Prajapati(Chief Chemist)
Mr. K. R. Desai,Chemical Engineer,Audit Cell
Mr. G. J. Rajput( Chief Engineer)
Mr. M. B. Dhangar,Chemical Engineer,Audit Cell
Mr. S. M. Patel(Distillery Manager)
Mr. D. B. Chaudhari,Environment Engineer,Audit CellMr. P. B. Patel,
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Chemist,Audit CellMrs. 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 recognizedby the GPCB, Gandhinagar under the Environmental Audit Scheme introduced bythe Honble High Courte Gujarat, vide its order dtd. 20/12/1996 and 13/3/1997and modified order dtd. 16/9/1999, as an environmental auditor for the purposeof 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.
ParticularsConsentQuantity
(Qty./Month)
ActualQuantity
(Qty./Month)
1Vacuum PanSugar
20000 MT 13144.83
2 Rectified Spirit 1500 KL 680.946
3Absolute
Alcohol
750 KL 278.133
Having completed the environmental audit based on personal monitoring, andaudit report, prepared as per the direction of the Honble High Courte inEnvironmental Audit Scheme, it is certified that the Environmental ManagementSystem (EMS) provided by this industry for the products manufactured andcapacity as stated above is adequate and efficacious to achieve the quality ofeffluents (Air + Waste Water + Solid Waste) as specified in consent / Notificationby GPCB, Gandhinagar for the following quantity of waste generation:
Liquid Effluent : 443.50 KL/Day
Sewage generated : 30.29 M3/Day
Solid / HazardousWaste
: 132 MT/Year
Air emission (flue gas
stacks as well as
process stacks)
: Adequate , efficacious
The certificate is valid for the audit period only. However it is subjected toautomatic cancellation in case of any change in product profile/capacity, qualityand quantity of effluent emission (Air + Waste Water + Solid Waste) andefficiency 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
PrincipalN. 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 havebeen collected and analyzed as per the following details
Sample detailsSampling
LocationCollected by
Sample collection
Date Time
Ambient Air
SPM,SO2,NOx Near Laboratory Mr.B.G.Tailor 22/03/2012 02:00 PM
Flue Gas
SPM,SO2,NOx Stack No 1 Mr.B.G.Tailor 22/03/2012 02:20 PM
SPM,SO2,NOx Stack No 2 Mr.B.G.Tailor 22/03/2012 02:55 PM
SPM,SO2,NOx Stack No 3 Mr.B.G.Tailor 22/03/2012 03:25 PMWaste Water
ETP Inlet ETP Plant Mr.P.B. Patel 22/03/2012 04:10 PM
Secondary ETP Plant Mr.P.B. Patel 22/03/2012 04:20 PM
Final Outlet ETP Plant Mr.P.B. Patel 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) (Dr. L. B. Chaudhari) (Dr. P. R. Patel)
Principal Co-ordinator Member
Date:03/04/2012
Place: Bardoli
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EFFLUENT SAMPLE ANALYSIS REPORT
Name of Industry : Chalthan Sugar Factory
Date of Sampling : 22/03/2012
Sr.
No.Parameters Unit
ETP
inlet
Secondar
y
Final
Outlet
1 Temperature oC 29.6 28.7 27.6
2 pH -- 5.94 6.85 7.14
3 Colour Pt-Co Scale 210 126 84
4 TDS mg/lit 1042 811 605
5 TSS mg/lit 503 429 74
6 BOD(5days, 20 oC) mg/lit 431 148 28
7 COD mg/lit 1246 437 93
8 Oil & Grease mg/lit 7.6 3.2 1.1
9 Phenolic Compound mg/lit 1.4 0.4 0.1510 Sulphide mg/lit 10.7 2.3 0.7
11 % Sodium mg/lit 45 34 21
STACK ANALYSIS REPORT
Sr.
No.Parameters Unit
Stack attached to
Boiler No.
1,2 & 3
Boiler
No. 4 & 5
Boiler
No. 6
1 SPM mg/Nm
3
121.5 132.7 92.72 Sox Ppm 0.20 0.24 0.17
3 NOx Ppm 1.6 0.9 0.8
AMBIENT AIR QUALITY MONITORING REPORT
Sr.
NoParameters
Near
Laboratory
1 SPM 94.2
2 SOx 8.4
3 NOx 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 detailsSampling
locationCollected by
Sample collection
Date Time
Ambient Air
SPM,SO2,NOx Near Laboratory Mr.S. J. Patel 21/12/2012 10:30 AM
Flue Gas
SPM,SO2,NOx Stack No 1 Mr.P. B. Patel 21/12/2012 10:45 AM
SPM,SO2,NOx Stack No 2 Mr.P. B. Patel 21/12/2012 10:20 AM
SPM,SO2,NOx Stack No 3 Mr.P. B. Patel 21/12/2012 11:10 AM
Waste WaterETP Inlet ETP Plant Mr.S. J. Patel 21/12/2012 12:05 PM
Secondary ETP Plant Mr.S. J. Patel 21/12/2012 12:10 PM
Final Outlet ETP Plant Mr.S. J. Patel 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 PolytechnicAt: 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) (Dr. L. B. Chaudhari) (Dr. P. R. Patel)
Principal Co-ordinator Member
Date:28/12/2012
Place: Bardoli
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EFFLUENT SAMPLE ANALYSIS REPORT
Name of Industry : Chalthan Sugar Factory
Date of Sampling : 21/12/2012
Sr.
No.Parameters Unit
ETP
inlet
Secondar
y
Final
Outlet
1 Temperature oC 28.7 28.5 27.8
2 pH -- 5.89 6.91 7.24
3 Colour Pt-Co Scale 215 124 81
4 TDS mg/lit 1025 802 596
5 TSS mg/lit 486 415 72
6 BOD(5days, 20 oC) mg/lit 426 145 32
7 COD mg/lit 1186 418 107
8 Oil & Grease mg/lit 7.5 3.1 0.9
9 Phenolic Compound mg/lit 1.3 0.3 0.1210 Sulphide mg/lit 10.6 2.2 0.6
11 % Sodium mg/lit 42 31 20
STACK ANALYSIS REPORT
Sr.
No.Parameters Unit
Stack attached to
Boiler No.
1,2 & 3
Boiler
No. 4 & 5
Boiler
No. 6
1 SPM mg/Nm
3
118.6 127.5 89.52 Sox ppm 0.21 0.25 0.16
3 NOx ppm 1.5 0.8 0.7
AMBIENT AIR QUALITY MONITORING REPORT
NOTE: - ALL RESULT ARE IN G/M3
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Sr.
NoParameters
Near
Laboratory
1 SPM 98.4
2 SOx 8.2
3 NOx 17.8
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ANNEXURE 02
MONTH WISE NUMBER OF WORKERS EMPLOYED
MonthMale
TotalSugar
Distillery
Jan 2012
946 64 1010
Feb 2012
946 64 1010
Mar 2012
946 64 1010
Apr
2012
517 52 569
May 2012
555 52 607
June 2012
571 52 623
July 2012
522 52 574
Aug 2012
538 52 590
Sep 2012
542 52 594
Oct 2012
928 52 980
Nov 2012
991 64 1055
Dec 2012
997 64 1061
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ANNEXURE 03
MONTH WISE ELECTRICITY CONSUMPTION
MONTHS
TOTALPOWER
GENERATED(KWH)
TOTALPOWER
PURCHASED
(KWH)
TOTALPOWER(KWH)
POWER CONSUMEDAT
DISTILLERY(KWH)
SUGAR(KWH)
Jan 2012 2869240 72962 2942202 249054 2693148Feb 2012
2976960 21630 2998590
192178 2806412
Mar 2012
1978100 136002 2114102
222062 1892040
Apr 2012
6900 151176 158076 36266 121810
May 2012
8100 114168 122268 17222 105046
June
2012
7920 141258 149178 18342 130836
July 2012
5500 133890 139390 5770 133620
Aug 2012
10160 119220 129380 3600 125780
Sep 2012
NIL 153858 153858 14670 139188
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Oct 2012
771282 149322 920604 23310 897294
Nov 2012
3055364 156138 3211502
190826 3020676
Dec 2012
3082786 67896 3150682
315030 2835652
TOTAL 14772312 1417520 16189832
1288330 14901502
Note:
Total Electricity Consumption = GEB Units + Turbine Generating
Set Units
= 1417520 KWH + 14772312 KWH
= 16189832 KWH
Total electricity Consumption per MT of Sugar = Total Electricity
Consumption
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.
NAME DESIGNATION ADDRESS & PHONE N0S.
1 Shri Ishwarbhai GopalbhaiPatel
Vice-Chairman
At.& Po : kumbhariya Ta.Choryasi,
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Dist: Surat.2 Shri Tejaskumar Chhitubhai
PatelDirector Po. Sisodra, Ta: Choryasi,
Dist: Surat.3 Shri Shantilal Kalyanji Patel Director At & Po. Bagumara, Ta.
Palsana,Dist: Surat.
4 Shri. Hemantbhai JagdishbhaiNayak Director At : Karara ,Po. Chalthan,Ta : Palsana.,Dist : Surat.5 Shri Jayeshbhai Dahyabhai
PatelDirector At & Po. Mota, Tal. Bardoli,
Dist: Surat.6 Shri Maheshbhai Ishwarbhai
PatelDirector At.& Po. Kosamadi, Ta.
Kamrej,Dist: Surat.
7 Shri Ashwinbhai GopalbhaiPatel
Director At & Po. Parab, Ta. Kamrej,Dist: Surat.
8 Shri. Tansukhbhaijaikishanbahi.Patel
Director At &Po: Saniya hemad Tal.:Choryasi,Dist: Surat.
9 Shri Arjunbhai Balubhai Patel Director At & Po. Chalthan, Ta.Palsana,Dist: Surat.
10 Shri Arvindbhai Tulsibhai Bhakt Director At & Po. Vav, Ta. Kamrej,Dist: Surat.
11 Shri. Sunilbhai Thakorbhai Patel Director At.& Po: Netrang . Tal: KamrejDist: Surat.
12 Shri. Kiritbhai Ranchodji Desai Director At. & Po: Palsana Tal : PalsanaDist: Surat.
13 Shri Manharbhai MaganbhaiPatel
ChairmanShree Kamrej
VKUSM Ltd.
(Rep. Sugar Industry Sangh)Chairman, Shri Shree Kamrej
Vibhag Khand Udyog SahakariMandli Ltd., Navi Pardi, Tal.Kamrej, Dist: Surat
14 Jt. Agriculture Director (Extn) Jt. AgricultureDirector
Lal bungalow, Athwalines,Surat.
15 Shri J M Karata Director ofSugar
Dr. Jivraj Mehta Bhavan,Block No. 8, 2nd floor,Ghandhinagar-382016.
16 Shri V Subburathinam ManagingDirector
Shree Chalthan Vibhag KhandUdyog Sahakari Mandlilimited, Chalthan.
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ANNEXURE 05
MONTH WISE NUMBER OF DAYS DURING PRODUCTION ACTIVITIES
WAS IN OPERATION:
MONTH SUGAR DISTILLERY Rectifie
dSpirit
Absolutealcohol
Jan 2012 31 31 31Feb 2012 29 29 14
Mar 2012 31 29 9Apr 2012 - - -
May 2012 - - -June 2012 - - -July 2012 - - -Aug 2012 -- -- 07Sep 2012 -- -- --Oct 2012 11 -- --Nov 2012 30 30 28Dec 2012 31 26 27
TOTALDAYS
163 145 116
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ANNEXURE 06
LIST OF PRODUCTS & BYPRODUCTS ALONGWITH THEIR CAPACITY,
YIELD & PURITY
Name of
Product
Capacity
(MT /
Month)
Yield
Purit
y
(%)
Sugar 20000 1 kg Cane = 0.11kg Sugar 99.80Bagasse 58000 1 kg Cane = 0.30 kg Bagasse --
Press Mud 6100 1 kg Cane = 0.035 kg Press mud --Molasses 7000 1 kg Cane = 0.042 kg Molasses --
Rectified Spirit1500000
L/Month
1 Ton Molasses = 267 Lit.
Rectified Spirit95.00
Absolute
alcohol
750
KL/Month--- 99.80
Note:
(1) Press mud is used to produce Bio- Compost during crushing season.
(2) Bagasse is used as fuel in boiler and remaining is sold to farmers
during crushing season.
(3) Purity is mentioned for A type sugar.
(4) The composition of exhausted molasses would be as follows:
Dry substance : 80%Sucrose : 36%Nonsucrose : 44%Brix : 90
(1)Absolute alcohol was produced during audit period.
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ANNEXURE 07
MONTH WISE PRODUCT AND BYPRODUCTS
MONTH
PRODUCT BY PRODUCTS
SUGAR
(MT)
RECTIFIED
SPIRIT
(KL)
ABS.
ALCOHOL
(KL)
BAGASSES
(MT)
FITER CAKE
(MT)
MOLASSES
(MT)
Jan 201216430
1870.976 919.895 44789.15
95322.330 7176
Feb 2012 15372
1635.354 417.457 40918.16
64974.040 6339
Mar 2012 9090
1632.562 253.127 24507.17
52743.890 3597
Apr 2012 -- -- -- -- -- --May 2012
-- -- -- -- -- --
June 2012
-- -- -- -- -- --
July 2012
-- -- -- -- -- --
Aug 2012
-- -- 183.210 -- -- --
Sep 2012
-- -- -- -- -- --
Oct 2012 2475 -- -- 9697.947 1172.610 1146Nov 2012 17020
1515.679 817.106 45414.91
05284.380 7767
Dec
2012 18482
1516.788 746.812 51143.14
3 5588.560 7539
TOTAL 788698171.359 3337.607 216470.5
00
25085.81
033564
Avg./Mon
th
13144.8
33
680.946 278.133 36078.41
74180.968 5594
Avg./ Day 483.86 56.354 28.772 1328.04 153.90 205.91
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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
MonthSugarCane,(MT)
Lime(MT)
Sulphur
(MT)
Phosphoric Acid(KGS)
CAUSTICSODA (KGS)
Jan 2012149610
245.500
63.400 10235 4150
Feb 2012133380
230.000
63.000 9065 8200
Mar 201271798.270
125.720
38.240 4985 5800
Apr 2012
-
- - - -
May 2012 - - - - -June 2012
- - - - -
July 2012 -- -- -- -- --Aug 2012 -- -- -- -- --Sep 2012 -- -- -- -- --Oct 2012 38610 48.700 17.200 2600 350Nov 2012
167020232.80
075.300 10195 8050
Dec 2012 169820 238.500
77.600 9705 1500
TOTAL730238.2
701121.2
20334.74
046785 26550
Avg./Month
121706.378
186.870
55.760 7797.500 4425.000
Avg./ Day 4479.989 6.88 2.05 287.025 162.883
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RECTIFIED SPIRIT
SR. NO MONTH MOLASSES (MT)
1 Jan 2012 64512 Feb 2012 56353 Mar 2012 56544 Apr 2012 -5 May 2012 -6 June 2012 -7 July 2012 --8 Aug 2012 --9 Sep 2012 --
10 Oct 2012 --11 Nov 2012 535612 Dec 2012 5408
TOTAL 28504Avg./Month 5700.80Avg./ DAY 196.579
ANNEXURE - 08
MONTH WISE RAW MATERIAL CONSUMPTION FOR SUGAR
PRODUCTION
MONTHS
FLOCCULAN
T
(KGS)
MILL
SANITATIO
N
(KGS)
ANTISCALEN
T
(KGS)
VISCOSIT
Y
REDUCER
(KGS)
WASHIN
G SODA
(KGS)
Jan 2012 100 720 1430 150 50Feb 2012 125 990 1200 660 800Mar 2012 75 700 610 500 500Apr 2012 - - - - -May 2012 - - - - -
June 2012 - - - - -July 2012 -- -- -- -- --Aug 2012 -- -- -- -- --Sep 2012 -- -- -- -- --Oct 2012 25 360 350 - 50
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Nov 2012 125 1280 1810 115 1150Dec 2012 125 1100 1745 40 50
TOTAL 575 5150 7145 1465 2550AVG./MONTH 95.833 858.333 1190.833 244.167 425.00
0
AVG./ DAY 3.528 31.595 43.834 8.988 15.644
Raw materialQuantity consumed per
MT product (Sugar)Sugar cane 9.259Lime 0.01422Sulphur 0.0042Phosphoricacid
0.00059
Caustic soda 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
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maintained to 7.0 (+ or - 0.2). Sulphited juice is heated to 102 0 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 SO2 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 0Bx. 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 450
Bx. is used forlubrication, 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
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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 tofurther 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 heaterwhere 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
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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 effluentgenerated from distillery plant. Layout for bio-compost plant may be
referred in annexure. Distillery waste has partly been utilized in bio-
composting.
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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 60-70oC 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.
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PROCESS FLOW DIAGRAM OF SUGAR
WEIGH WEIGHED
MACCERATION WATER
Excess Bailed Solid for Paper Industries
Phosphoric Acid.
ElectricityProduced to Run the Plant
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Cane
Milling Plant
Continuous lime and
Sulphitation unit pH 7 to 7.2
Primary juice Heater 70oC
Receiving Tank
Automatic Weighment
Mixed Juice
pH 5 to 5.5
Secondary juice heater 100o to 102oC
Bagasse
Boilers
High Press Steam
Primover Power
Turbine
Low Pressure Steam
Condensed Low
Pressure Water
Contd.
Settler
Mud
Clear juice pH 6.9 to 7.0
Temp 95o
C
Mud MixerEvaporators
Vacuum Filter
Filter
Cake
Syrup pH 6.5-6.8
To ProcessWeight & Sold
as Farm Yard
Manure
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SO2 Gas
SHREE CHALTHAN VIBHAG KHAND UDYOG SAHAKARI MANDLILTD, CHALTHAN
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A Heavy &A Light Filter
Cont. Syrup Sulphiter
Sulphide syrup
pH 4.8-5.2
Crystallization
Centrifugation
MOLASSES SUGAR
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MASS BALANCE DIAGRAM ( JAN-2012TO DEC-2012 )
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CANE
730238
CENTRIFUGAL
FIBRE
97611.042MILL
SOLID IN MOLASSES
29629.884
CLARIFIER
SUGAR
78510.785
WATER IN
FILTER CAKE.
17323.553
WATER IN FINAL
MOLASSES
4137.694
WATER IN
BAGASSES
112509.257
WATER
516426.218
SOLID IN FILTER CAKE
8060.071
116200.740
108140.669
116200.740
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SHREE CHALTHAN VIBHAG KHAND UDYOG SAHAKARI MANDLILTD.
DISTILLERY MASS BALANCE DIAGRAM
(PERIOD JANUARY-2010TO DECEMBER-2010)
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WATER IN PROCESS + BOILER & COOLING
382455.714
ALL FIGURES ARE IN MT/YEAR
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ANNEXURE - 10
WATER CONSUMPTION & WASTE WATER GENERATION:
WATER CONSUMPTION:
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DILUTER
102499CO
2SCRUBBER
FERMENTER
97024
DIST.COLUMN
633135
SPENT WASH
59190
SPENT WASH
AT E.T.P.
45086 MT
CONDENSATE TO
BFW TANK 17969
MOLLASSES(MT)
28504
WATER(KL)
31291
CO2
5475 MT
EVA. LOSSES
2615 MT 8492M
T
M
T95% ALCOHOL
8171.359 KL or
6619 MT
Condensate
28600
STEAM
17969
EVAPORATOR
87790
14104 MT
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MonthsCooling
KLProcess
KLDomestic
KL
DistilleryWater
KLStea
mKL
Jan 2012 10905 1701 1321 6358 4114
Feb 2012 8943 2030 1254 5559 3597Mar 2012 5775 1019 1331 5712 3590Apr 2012 - - 1289 - -May 2012 - - 1288 - -June 2012 - - 1301 - -July 2012 -- -- 1354 -- --Aug 2012 -- -- 1327 -- --Sep 2012 -- -- 1340 -- -Oct 2012 3112 638 1350 - --Nov 2012 12230 1827 1307 5151 3333Dec 2012 12512 2208 1334 5154 3335
TOTAL 53477 9423 15796 27934 17969AVG./day 328.080 57.810 43.277 192.648
123.924
DETAILS OF WASTE WATER GENERATION:
Month
Wastewater
generation in sugar
plant(KL)
Wastewater
generation per tonof sugar(KL/T)
Wastewater
generation in
DistilleryM3
Wastewater
generation per KL
of Alcohol
Dist. Eff.Used at theBio Compost
Jan 2012 14727.63 0.896 10285 5.5 10285Feb 2012 13150.36 0.855 8992 5.5 8992Mar 2012 7870.83 0.866 9139 5.6 9139Apr 2012 -- -- -- -- --May 2012 -- -- -- -- --
June 2012 -- -- -- -- --July 2012 -- -- -- -- --Aug 2012 -- -- -- -- --Sep 2012 -- -- -- -- --Oct 2012 3875 1.566 -- -- --Nov 2012 15970 0.938 8332 5.5 8332
Dec 2012 16697 0.903 8338 5.5 8338TOTAL 72290.720 -- 45086 -- 45086
Avg./ MT -- 1.004 -- 5.52 --AVG./day 443.50 -- 310.938 -- 310.938
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`ANNEXURE 11: WATER BALANCE DIAGRAM (FOR SUGAR PLANT)SHREE CHALTHAN VIBHAG KHAND UDYOG SAHAKARI MANDLI LIMITED, CHALTHAN.
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ANNEXURE 12
PROCESS OF EFFLUENT TREATMENT WITH CAPACITY OF UNITS
The capacity of ETPSugar 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 oiland grease separation by 2 Nos. Online mechanical oil skimmer. Form pit,water is pumped and passed though DSM screen where fibrous particlesremoved. Then again oil & grease are separated in a masonary oil
separator . After oil & grease removed, it leads to the reaction tank wheremilk of lime treatment done for neutralization. Neutral effluent then goesto anaerobic digestion in the equalization tank. From the equalizationtank water goes to first stage PP discs course bubble aeration lagoon.
Then it pass to second stage fine bubble aeration lagoon. Aeration tankeffluent water collected in secondary clarifier Activated sludge re-circulation system used. Clear water collected in collection pit and passedthrough 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 CapacityHP( AirBlower)
Oil Skimmers 02 Nos.Air Blower1 No. -15H.P2 Nos 40HP
Anaerobic Lagoon 3000 m3.Course diffuser pond 2550m3
Fine diffuser pond 3000m3
Holding pond 1000m3
Secondary clarifier 10mt. dia X2.5mt. depth
Sludge drying bed 15mtr. X15mtr.X 1mtr.
4nos
Treated water storagepond
12000m3
Pressure sand filter 1.7mtr.dia X1.8 30m3 / Hrs.
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Mtr.HOSActivated carbon filter 1.7mtr.dia.X1.8
Mtr.HOS30m3 / Hrs.
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DISTILARY UNIT:
COMPOSTING PROCESS:
The treatment of spent wash by anaerobic and followed by aerobiccomposting appears to be most promising and appropriate technology toobtain pollution control by it. By this method, treatment and disposedboth the problems of spent wash are totally solved. A want is more; themuch-needed organic compost with many essential nutrients is produced.
The press mud and Bagasse which is available by the byproduct of thesugar industry is used as the major absorbent. How ever, it is alsopossible to use boiler ash and dried yeast sludge to act as a filter. The unithas R.C.C. tanks and the leachate is pumped out, the remaining sludge isremoved and stored at factory premises and only after it get dried, it isused as filler material in compost.
PROCESS DETAILS:
The cooled spent wash is pumped through high density polythene pipes tothe site and composting the heaps of press-mud and Bagasse are made inlarge containers (200mt x 3.0 mt x 1.2 mt) and the ratio of press-mud is90:10 approx. A special micro bio culture is added along with the spentwash 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 itsvolume. This can be achieved by spraying the spent wash in three to fourlots. The heaps are then subjected to anaerobic condition for a period of12 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 thedegradation of the organic matters. After the initial 15 days, churning isgiven with mixing machine and the composting is allowed to proceed,then the temperature starts to decline, aerobic condition is created forfurther degradation and deodorization. The compost gets ready in 32-35days.
Pucca Lagoon for storage of Effluent
50 mt. x 50 mt. x 4.5 mt. : 4 Nos.
25 mt. x 25 mt. x 4.5 mt. : 4 Nos.Total 8 Nos. lagoons
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ANNEXURE 13
HYDRAULIC & FLOW DIAGRAM OF ETP
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ANNEXURE 14
MONTH WISE ENERGY CONSUMPTION FOR EFFLUENT TREATMENTPLANT
SR.NO.
MONTHS
ELECTRICALCONSUMPTIO
NSUGAR(KWH)
ELECTRICALCONSUMPTIO
NDISTILLARY
(KWH)1 Jan
201234568 7412
2 Feb 2012
29768 10180
3 Mar 2012
26712 5161
4 Apr 2012
-- 3032
5 May 2012
-- 2712
6 June 2012
-- 4073
7 July 2012
-- 1005
8 Aug 2012
-- 1907
9 Sep 2012
-- 1860
10 Oct 2012
12808 3110
11 Nov 2012
29504 5960
12 Dec 2012
27588 4890
TOTAL 160948 51302KWH/L ofTreatedEffluent
0.0022 0.001
Avg./ Day 987.411 140.55
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ANNEXURE 15DETAILS OF OPERATOR/ CHEMIST FOR ETP
SUGAR UNIT:
SR. NO. NAME OF OPERATORS QUALIFICATIONSEXPERIENC
E(IN YEAR)
SALARY /MONTH
1 Hemant R Mistry B.Sc 4 98632 Arjun S Borse SSC 24 10912
3 Sharad Khalop SSC 28 111334 Pravinsinh C.Vansia SSC 18 106185 Ramnaresh A Yadav SSC 2 106936 Ramkeval R Yadav SSC 2 10693
DISTILLERY UNIT:
SR.NO.
NAME OF OPERATORS QUALIFICATIONSEXPERIENCE
(IN YEAR)SALARY /MONTH
1. Mr. Dipak Desai BSC 30 14400
2. Mr. Jayanti D. Desai SSC 29 10933
3. Mr. Parbhubhai R. Ahir SSC 28 10693
4. Mr. Mahendra M. Yadav SSC 28 10813
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5. Mr. Pravin N. Patel SSC 22 11000
6. Mr. Bhulabhai C. Rathod 5 th 23 10813
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ANNEXURE 16CONSOLIDATED CONSENT
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ANNEXURE 17
NO. OF THE FLUE GAS STACKS, THEIR HEIGHT NATURE AND
CONSUMPTION OF FUEL.
SR.NO.
STACKATTACHE
D TO
TYPE OFFUEL
MOC
PROBABLEPOLLUTAN
T
HEIGHTIN
(MTS.)
INTERNAL DIA.(MTS.)
AIRCONTRO
LMEASURE DEVICE
1 BOILER NO1,2,3
BAGASSE/
FIREWOOD
MS SPM 40 2.46 Wetscrubber
2 BOILER NO
4,5
MS SPM 40 2.46 Wet
scrubber3 BOILER NO
6MS SPM 45 2.0 Wet
Scrubber
MONTH WISE CONSUMPTION OF FUEL
MONTHFUEL CONSUMPTION
BAGASSE
(MT)
FIRE WOOD
(MT)Jan 2012 39398.748 --Feb 2012 34584.022 --
Mar 2012
22432.580 --
Apr 2012 -- --May 2012
-- --
June 2012
-- --
July 2012 -- --Aug 2012
-- --
Sep 2012
-- --
Oct 2012 9431.280 150.000Nov 2012
40068.555 --
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Dec 2012
43558.899 --
TOTAL 189474.084 150.000MT/Hr. 48.434 0.03834MT/day 1162.418 0.9202
ANNEXURE - 18
DETAILS OF HAZARDOUS (SOLID) WASTE GENERATION
MONTHSQUANTITY OF ETP
SLUDGE(MT)
QUANTITY OFFLY ASH
(MT)
QUANTITY OFDEAD CELLBIOMASS
(MT)Jan 2012 32 1831.35 22Feb 2012 27 1443.94 16
Mar 2012
21 999.48 18
Apr 2012 -- -- --May 2012
-- -- --
June 2012
-- -- --
July 2012 -- -- --Aug 2012
-- -- --
Sep 2012
-- -- --
Oct 2012 -- 204.910 --Nov 2012
16 2036.680 20
Dec 2012
36 2255.220 23
TOTAL 132 8771.580 99
Avg. Day 0.81 53.81 0.683
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ANNEXURE - 19
STORAGE & PREATMENT OF SOLID WASTE
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ANNEXURE - 20
FACTORY SITE PLAN
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ANNEXURE - 21
SULPHUR STORAGE LICENSE
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ANNEXURE 22
NOISE MEASUREMENT
Noise level measurement on: 22.03.2012Sr.No
. Location
Noise level in
dB(A)1. Store and laboratory gate 682. Boiler house 853. Mill House 824. Cane unloader 735. Power house 756. Centrifugal house 797. Sugar house 608. Security cabin 539. Distillery gate 58
10. Fermentator 6211. Distillery 68
Noise level measurement on: 21.12.2012Sr.
No.Location
Noise level in dB(A)
1. Near Boiler 1, 2 & 3 782. Near Power house 873. Near centrifugal 1, 2 & 3 744. Near centrifugal 4, 5 & 6 805. Near pan area 686. Near evaporator 777. Near boiling house 838. Final packaging 659. Near stack of 4, 5 & 6 78
10. ETP area 6111. Near guest house 53
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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. PRODUCTION
1.
1
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
Sugar
Rectified
Spirit
Absolute
Alcohol
Fusel Oil
ProductionCapacities asper CCA.
20,000MT/Month
15,00,000Lit/Month
750KL/Month
1200Lit/Month
ActualaverageProduction.
13144.833MT/Month
680946Lit/Month
278.133KL/Month
2. WATER
2.1 Total quantity of effluent from industrial process (Sugar plant) does
not exceed the 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 m3/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
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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,
manually.2.1
0
Sign boards at units of ETP are provided
2.1
1
Company is in possession of necessary factory license.
2.1
2
The consent (Consolidated) under the Water Act, 1974 is valid for the
audit period (Order No: 35652 valid up to 20.05.2014). As per
Annexure-163. AIR
3.
1
Wet Scrubbers (5 Nos.) are installed as pollution control devices.
3.
2
Facilities for stack monitoring like port hole and platform are
provided.
3.
3
The height of stacks is observed adequate for effective dispersion
of emission.3.
4
Routine ambient air quality & Stack gas monitoring are regularly
carried out by company.3.
5
Sampling, analysis and results carried out by the audit team are
within the specified
norms.3.
6
Bagasse handling is done by covering that area under the roof to
avoid the dusting in the ambient air.3.
7
The consent (Consolidated) under the Air Act is valid. (Order No:
35652 valid up to 20.05.2014).As per Annexure-164. HAZARDOUS WASTE
4.
1
The quantity of sludge generated during audit period is 132 MT,
whereas fly ash generation has been 53.813 MT/Month. The sludge
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generated from ETP and fly ash are used in mfg. of Bio- compost.4.
2
The records of quantity of sludge generation are maintained by the
company.4.
3
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)4.
4
Collection, storage, transportation & Ultimate disposal of used oil &
discarded containers are done by selling it to registered reprocessor.
4.
6
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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