Addendum Document

For Spent Wash Treatment of 160 KLPD Molasses based Distillery Unit at Village Shetphalgade, Tal. Indapur,

Dist. Pune, Maharashtra

Ref:(Environmental Clearance F. No. J-11011/106/2016-IA- II (I) dated 20th March 2017.)

BARAMATI AGRO LTD. Village Shetphalgade, Tal.Indapur,

Dist. Pune, Maharashtra

PREPARED BY ULTRA-TECH

(Environmental Consultancy & Laboratory GazzetedByMoEF,

Saudamini Complex, C3-201 Right Bhusari Colony, Paud Road, Kothrod Pune

1.0 Introduction:

M/s Baramati Agro Ltd. is an agro based Company focused on the

manufacture of sugar, power and allied products. The company has

established and running a 4500 TCD sugar, 20 MW cogeneration power

plant and 60 KLPD molasses based distillery at Shetphalgade, Tal.

Indapur, Dist. Pune, Maharashtra.

The expansion work of sugar capacity up to 12000 TCD (7500 TCD

expansion), cogeneration up to 70 MW (50 MW expansion) and molasses

based alcohol distillery up to 160 KLPD (100 KLPD expansion) is proposed

and the Environmental clearance is also obtained for the same.

(F.No.J11011/106/2016-IA-II (I) dated 20th March 2017).

Details of Existing and Proposed Capacity No. Product Capacity

Existing New Total Working days

1 Sugar Unit (TCD)

4500 7500 12000 -

2 Co-gen Power (MW)

20 50 70 240

3 Distillery (KLPD )

60 100 30 270

130 365

As per Environment clearance received on 20th march 2017, spent wash

treatment and disposal treatment was Bio- methanation – MEE followed

by bio-composting.

A change is proposed in the treatment and disposal pattern for distillery

spent wash, for major capacity portion (130 KLPD out of 160 KLPD ) for

the following reasons:

• Operate the distillery unit upto capacity 130 KLPD for 365 days

• For which, to fulfill the steam requirement (Steam Requirement 32

TPD for 365 days, we have to establish a boiler to work mainly for

non-working days of sugar factory. This is possible by incorporating

technology of concentration-incineration.

• The remaining 30 KLPD equivalent spent wash to be composted to

fulfill the demand by member farmers of organic fertilizer.

Proposed Spent wash treatment of distillery given below

• 30 KLPD : Bio- methanation – MEE – bio-composting: 270 Days

• 130 KLPD: Concentration in MEE followed by Incineration Boiler:

365 Days

The 30 KLPD and 130 KLPD distillery units will be operated for 270 days &

365 days respectively.

The major contribution of pollution in a proposed distillery unit is aqueous

effluent i.e, spent wash. The air pollution is mostly from Boiler stacks.

Other sources of pollution are solid waste & noise.

1.1 Spent wash Treatment:

For 30 KLPD: Spentwash – Bio– MEE – bio-composting

Spent Wash Treatment Flow Sheet

For 130 KLPD: Spent wash is concentrated in multi-effect

evaporator (MEE) to reduce the volume & concentrate.

Concentrated spent ash will be used in 32 TPH slop fired boiler as

fuel

The spent wash generated in the RS/ENA plant will be treated in following

stages, to meet the SPCB / CPCB / MoEF&CC norms.

The spent wash of a distillery process is a serious problem by way of

threat to the environment.

The spent wash evaporation technology is a multiple effect evaporator

system in which heat recovered from one effect is used to concentrate

spent wash in second effect evaporator with continuous recirculation of

concentrated spent wash within the system until desired concentration is

obtained. This entire concentration process is carried out under vacuum

leading to less consumption of steam and maximum concentration of

spent wash with in less period of time.

The concentrated spent wash generated after entire process of

evaporation is then sprayed in a furnace with auxiliary fuel such as coal

and is then burnt in a boiler.

Spent wash Generation and Treatment

Sr. No.

Particular Details

1. Spent wash Generation 1024 kl/day 2. Sent to Multi effect evaporator 1024 kl/day 3. Quantity of spent wash remaining 256 kl /day 4. Sent to slop fired boiler Boiler capacity 32 TPH Stack height 70 mts. Pollution control equipment ESP of efficiency 99.9 %

5. Hence zero discharge is achieved

BAL proposes to go for spent wash Concentration and Incineration

Technology simultaneously generating Steam and Power for the process

and Distillery.

Concentrated Spent Wash fired Boiler:

• Capacity: 32 TPH • Pressure: 45 Kg/Cm2 • Temperature : 400 0C

Description UOM Values

Spent wash concentration % Solids 52

Concentrated spent wash quantity

Kg/hr 12000

Calorific value of Concentrated spent wash at 52 % Solid Concentration

Kcal/kg 1612

Qty od Support indian Coal for firing spent wash at 52 % solid

Kg/hr 2800

GCV Indian Coal Kcal/kg 3800

Gross Steam generation @ MSSV outlet

Kg/hr 31300

Boiler capacity at MSSV outlet

Kg/hr 32000

Steam pressure at MSSV outlet

Kg/cm2 g 45

Steam temperature at MSSV outlet

OC 400

Water temp at Economizer inlet

OC 130

Stack Height Calculation:

Based on Sulphur Consent in Slop and Coal

H=14(Q)0.3

where Q is emission rate of SO2 in kg/hr, and H is stack height in meters

Considering the feeding rate of coal and slop ( Coal feeding Rate: 2.8 TPH & Slop : 12 TPH)

Sulphur Content: 0.38 + 0.62 =1.0 %

Boiler Feed = 14.8 X 0.65 X 1000 = Kg/Hr

Q = [Quantity of fuel (Kg/hr) X sulphur content (%) X 2] / 100

= (9620 x 1 x 2)/100 = 14(192.4)0.3 = 67.82 m = 69 M

We are providing 70 m stack

Stack Details

Parameters Unit Incinerator Boiler (32 TPH) Stack Attached to Proposed

Stack height m 70 Stack diameter at exit / top

m 2.2

Stack exit gas velocity m/s 18

Stack gas temperature at exit

Deg. C 180

Fuel requirement Coal – 2.8 TPH • Ash – 36.18% • S – 0.38%

& Slop – 12 TPH • Ash : 18.66% • S – 0.62%

PM Emission mg/Nm3 50

g/sec 2.25

SO2 Emission g/sec 47.24

NOx Emission g/sec 10.63

Air pollution control equipment

ESP – 98%

Detailed Air Quality Mathematical Modeling for Proposed Expansion of Sugar & Distillery Plant is attached as annexure I

Air Quality Mathematical Modeling For

Proposed Expansion of Sugar & Distillery Plant

of

M/s. Baramati Agro Ltd.at

Village Shetphalgade, Tahsil-Indapur Dist. Pune, Maharashtra.

Prepared by

Anjali Singam

May 2018

1.0 Impact on Air Quality Baramati Agro Ltd. is located at Shetphalgade village, Tal. Indapur of Pune dist. in Maharashtra. It has proposed an expansion of Sugar (from 4500 to 12000 TCD), Distillery (from 60 to 160 klpd) and Co-gen plant (from 20 to 70 MW) in the existing premises. Air quality impact is envisaged due to operation of proposed additional boilers attached to Co-gen (110 TPH using bagasse as fuel), Distillery (40 TPH using bagasse & biogas as fuel) and Incinerator (32 TPH using coal & slop) units. Hence, Particulate Matter (PM), Sulphur Dioxide (SO2) and Oxides of Nitrogen (NOx) are expected as pollutants from operations. Ground level concentrations (GLCs) have been predicted using AERMODCloud software. The application incorporates popular U.S. EPA air dispersion models AERMOD and ISCST3 into one integrated graphical interface. 1.1 Input to Model The stack details and flue gas characteristics of proposed Boilers are provided below:

Table-1: Stack Emission

Parameters Unit Stack Attached to Proposed Co-gen Boiler

(110 TPH) Distillery Boiler

(40 TPH) Incinerator Boiler

(32 TPH) Stack height m 67 40 70 Stack diameter at exit / top

m 4 2 2.2

Stack exit gas velocity

m/s 8 8 18

Stack gas temperature at exit

Deg. C 110 170 180

Flue gas quantity Kg/hr 2,25,000 90,000 --

Fuel requirement -- Bagasse – 46 TPH

Ash–1.5%

Bagasse – 17 TPH

Ash–1.5%

Biogas – 30000 m3/day

Coal – 2.8 TPH

Ash – 36.18% S – 0.38%

Slop – 12 TPH Ash –

18.66% S – 0.62%

PM Emission mg/Nm3 50 50 50 g/sec 1.92 0.662 2.25 SO2 Emission g/sec -- 8.99 47.24 NOx Emission g/sec -- -- 10.63

Air pollution control equipment

ESP – 98% ESP – 98% ESP – 98%

Hourly meteorological data recorded at site for February-March-April 2016 on wind speed, direction and temperature is used as input. Site specific wind-rose for this

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season is shown in Figure-1. Average hourly data for 24 hrs used for modeling is tabulated in Table-2.

Figure-1: Site Specific Wind Rose (Period: Feb-Mar-Apr 2016)

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Table-2: Average Hourly Meteorological Data for 24 Hours used for Modeling

Time W.D. W.S. Temp. Stability M.H. Hr. Deg. m/s Deg. K Class m 1 360 0.10 288 6 50 2 360 0.00 287 6 50 3 360 0.20 286 6 50 4 23 0.00 285 6 50 5 360 0.00 286 6 50 6 15 0.00 284 6 50 7 360 0.00 285 2 50 8 360 0.00 287 2 50 9 360 0.60 292 1 200

10 38 0.50 297 1 500 11 90 0.60 301 1 700 12 215 0.00 304 1 1000 13 287 0.20 305 1 1200 14 360 0.60 304 1 1200 15 333 2.10 304 2 1200 16 321 3.00 303 2 1300 17 270 3.90 303 3 1100 18 288 3.20 301 3 800 19 269 2.20 299 6 600 20 270 0.60 296 6 500 21 182 0.00 292 6 400 22 109 0.00 289 6 300 23 360 0.00 288 6 100 24 360 0.00 287 6 50

In the short-term simulations, the incremental ground level concentrations were estimated to obtain an optimum description of variations in concentrations within 10 km radius w.r.t. stack attached to proposed Cogen Boiler as centre. 1.2 Prediction The predicted results are tabulated below in Table-3 while dispersion trend is shown as isopleths through Figure-2, 3 and 4 for PM, SO2 and NOx respectively.

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Table-3: Predicted 24-Hourly Short Term Maximum Incremental

Ground Level Concentration

Pollutants Maximum Incremental Levels, µg/m3

Distance, km

Direction

PM 1.96 1.2 SE SO2 22.2 1.0 SE NOx 3.9 1.2 SE

The maximum incremental GLCs (Refer Table-3) of PM, SO2 and NOx are superimposed on the baseline concentrations recorded during the study period to arrive at the likely resultant concentrations after operation of boiler. The cumulative concentration (baseline + incremental) is tabulated below in Table-4.

Table-4: Resultant Ambient Concentrations after Expansion

Concentrations are expressed in µg/m3 Pollutants Incremental

Concen- trations

Baseline Concen-trations**

Resultant Concen-trations

CPCB Limit for Industrial, Residential, Rural & Other

Area PM 1.96 66.0 67.96 100 SO2 22.2 15.78 37.98 80 NOx 3.9 28.5 32.4 80 ** - Avg. Baseline concentration in study area Resultant concentrastion at AAQm locations after expansion are tabulated in Table-5. 1.3 Impact Assessment Ambient air quality in study area w.r.t. PM, SO2 and NOx is within NAAQS 2009 as seen from Table-4 above. Hence, any significant impact is not envisaged. 2.0 Mitigation Measures Ambient air quality will be within NAAQS 2009 as mentioned above. ESPs are proposed as air pollution control measures to proposed boilers. Also, stacks of adequate height i.e. 67, 40 and 70 m are proposed attached to Co-gen, Distillery and Incinerator boilers respectively to disperse flue gases.

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Table-5: Resultant Ambient Concentrations at AAQM Locations after Expansion

Concentrations are expressed in µg/m3

Sr. No.

Station Incremental Conc. Baseline Conc. Resultant Conc. CPCB Limit for Industrial, Residential, Rural & Other Area

PM SO2 NOx PM SO2 NOx PM SO2 NOx PM SO2 NOx

1 Project Site 0.70 7.40 0.80 71 23 32 71.70 30.40 32.80

100 80 80

2 Madanwadi 0.35 3.69 0.58 63 15 29 63.35 18.69 29.58

3 Shetphalgade 0.42 5.32 1.22 66 15 28 66.42 20.32 29.22

4 Lamjewadi 0.29 3.37 0.59 62 13 27 62.29 16.37 27.59

5 Katphal 0.24 2.62 0.56 62 14 27 62.24 16.62 27.56

6 Gadkhelwadi 0.34 3.54 0.69 63 14 27 63.34 17.54 27.69

7 Parawadi 0.34 3.55 0.67 68 14 27 68.34 17.55 27.67

8 Khadki 0.14 1.53 0.25 69 18 30 69.14 19.53 30.25

9 Nimbodi 0.31 3.53 0.65 70 16 30 70.31 19.53 30.65

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Figure-2 (a) : Short Term 24 Hourly Incremental GLCs of PM

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Figure-2 (b) : Short Term 24 Hourly Incremental GLCs of PM

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Figure-3 (a) : Short Term 24 Hourly Incremental GLCs of SO2

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Figure-3 (b) : Short Term 24 Hourly Incremental GLCs of SO2

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Figure-4 (a) : Short Term 24 Hourly Incremental GLCs of NOx

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Figure-4 (b) : Short Term 24 Hourly Incremental GLCs of NOx

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