Professional Documents
Culture Documents
For
Sugar Industry
A Draft Report
January 2005
Environmental Management
B:
Policy Research Institute
TABLE OF CONTENTS
ITEM
1
CHAPTER
INTRODUCTION
1.1
1.2
2
2.1
2.2
2.3
2.4
2.4.1
2.4.2
2.4.3
2.4.4
2.4.5
2.4.6
2.4.7
2.4.8
2.4.9
2.5
2.5.1
2.5.2
2.6
2.6.1
2.6.2
2.6.3
3
3.1
3.2
4
4.1
5
6
6.1
7
7.1
Background
Gist Of Environmental Acts, Rules And
Notifications
LEGAL AND REGULATORY FRAMEWORK
Fundamental Rights And Duties Of A
Citizen
State Policy
Legislative Authority
Relevant Legislations
Factories Act, 1948
Environment Protection Act 1986.
The Water (Prevention And Control Of
Pollution) Act, 1974 And Rules
The Water (Prevention And Control Of
Pollution) Cess Act, 1977 And Rules
The Air (Prevention And Control Of
Pollution) Act, 1981 And Rules
The Environment Impact Assessment
Notification 1994 & 1997
The Noise Pollution (Regulation And
Control) Rules, 2000
The Hazardous Waste (Management &
Handling Rules), 2000
The Manufacture, Storage and Import of
Hazardous Chemicals Rules, 1989
Relevant Policies
The National Environmental Policy
The National Industrial Policy
Relevant Institutions
Ministry Of Environment And Forest,
Government Of India
Department Of Ecology And Environment,
Government Of Karnataka
Karnataka State Pollution Control Board
RESPONSIBILITIES OF THE SUGAR
INDUSTRIES
Approvals
Responsibilities
WATER AND AIR (PREVENTION & CONTROL
OF POLLUTION) ACTS
Consent Procedure
WATER (PREVENTION & CONTROL OF
POLLUTION) CESS ACT
ENVIRONMENTAL STATEMENT PROCEDURES
Contents Of Environmental Statement
ENVIRONMENTAL AUDITING
Features Of A Good Environmental Audit
PAGE
NUMBER
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2
2
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2
2
3
3
4
4
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5
6
7
8
8
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11
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11
11
12
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12
13
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14
14
15
15
ITEM
7.2
CHAPTER
Audit Procedure
9
10
10.1
10.2
10.2.1
10.2.2
10.2.3
10.2.4
10.3
10.4
10.4.1
10.4.2
10.4.3
10.4.4
10.4.5
10.4.6
10.4.7
10.4.8
10.4.9
10.4.10
10.4.11
10.5
PAGE
NUMBER
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18
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19
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19
21
21
21
21
21
22
22
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23
23
23
24
24
25
Sulphitation
Liming Station
Crystallization Station
Segregation of Effluents
General Points
Good Housekeeping Practices Dos &
Donts
Appendix I
Appendix II
Appendix III
Appendix IV
Annexure Maintaining Log Books
Verification Guidelines
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26
26
26
27
27
27
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34
36
38
48
54
57
INTRODUCTION
1.1
BACKGROUND
Sugar industries are classified under seventeen category highly polluting
industries as per the Government of India notification. In the last fifty years numerous
sugar units have been established in the country and also in the state and as of today 56
units are working in different parts of the state. However the environmental problems
of the sugar industries are quite unique and pose a challenge despite the fact that a well
developed production technology is available. The problem is quite acute with units
having old technology of crushing and sugar production. The process of sugar
manufacture has many stages with most of the stages generating pollutants in different forms
like waste water, solid wastes and air pollutants. The causes of these forms of pollution
include leakages, spill-over, overloading, indifferent handling and crushing operations,
improper molasses handling, etc.
Under these circumstances an attempt has been made to evolve a suitable standard
operation procedure (SOP) to help the manufacturers to understand the current legal
requirements and adopt the procedures to minimize the pollution as per the consent
conditions. Presently, as per Rule 14 of the Environment Protection Rules, 1986, it is
mandatory for persons carrying out an industry or operation or process which require consent
under Water Act, 1974 or Air Act, 1981 or authorization under the Hazardous Waste Rules,
1989, to submit every year an Environmental Statement to the concerned State Pollution
Control Board. However, the existing mechanism does not provide for rigorous analysis of
Environmental Statement by the industries. Hence, it was felt that an effective institutional
arrangement for implementing the Environmental Audit is necessary.
This document is a reference guide which provides for guidelines to sugar industries
to standard procedures for environmental clearances, procedures for taking appropriate
consents for establishing and operation of industries, the compliance standards set for the
mining sector ensuring the consent conditions for discharges of effluent are met, best
practices for cleaner production, etc.
This document also puts forth the linkages between the Environmental Impact
Assessment document which is prepared at the initialisation of the project and the
Environmental Statement to be provided by the project proponent. Also the document
defines the responsibilities of the project proponent (internal auditor) and external and
regulators, the precautionary measures to the taken, the method to be followed and records to
be maintained by the project proponent.
1.2 GIST OF ENVIRONMENTAL ACTS, RULES AND NOTIFICATIONS
In the Sugar Sector the following Acts, Rules and Notifications
are
applicable:
Environmental Legislations:
1. The Water (Prevention and Control of Pollution) Act, 1974 and Rules
2. The Water (Prevention and Control of Pollution) Cess Act, 1977 and Rules
3. The Air (Prevention and Control of Pollution) Act, 1981 and Rules
4. Relevant provisions under Environmental Protection Act and Rules, 1986
The Noise Pollution (Regulation and Control) Rules, 2000
The Municipal Solid Waste (Management & Handling) Rules, 2000
The Hazardous Waste (Management & Handling) Amendment Rules, 2003
5. Factories Act, 1948
LIST
NO.
NAME
List
SUBJECT
NO. IN
LIST
14
SUBJECT
Agriculture, protection against
pest and prevention of plant
diseases
Land, colonization, etc.
Fisheries
Regulation of mines and mineral
development subject to the
provision of List I
Industries subject to the
provision of List I
Forests
Protection of wild animals and
birds
Economic and social planning
Population control and family
planning
18
21
23
24
III
Concurrent
List
17 A
17 B
20
20 A
The Parliament has powers to legislate on subjects not covered by the three Lists [Article
248].
The Parliament is also empowered to legislate in the national interest on matters
enumerated in the State List [Article 249].
In event of a conflict between the Central law and State law on a concurrent subject the
former prevails [Article 254 (1)].
In case of a State law passed subsequent to the Central law, the State law shall prevail in
that State only if it has received Presidential Assent under Article 254 (2) of Part XI of
Constitution.
From an environmental standpoint, the allocation of legislative authority is an
important one as some environmental problems such as sanitation and waste disposal are best
tackled at local level, while others like water pollution and wildlife protection are better
regulated by uniform national laws.
2.4 RELEVANT LEGISLATIONS
As stated earlier, the working environment within the factory is regulated by the Factories
Act, 1948 while the environment (air & water emissions, noise, waste) are governed by
environmental legislations.
2.4.1 Factories Act, 1948.
The Factories Act, 1948 sets the duties of the occupier to maintain the safety and
health of all workers at work.
The occupier of every factory involving a hazardous process shall disclose all
information regarding dangers, including health hazards and the measures to overcome such
hazards arising from the exposure to or handling of the material or substances in the
manufacture, transportation, storage and other processes to the workers employed in the
factory, the Chief Inspector, the local authority within whose jurisdiction the factory is situate
and the general public in the vicinity. The occupier of the factory shall draw up an on-site
3
emergency plan and detailed disaster control measure for his factory and make it known to all
stakeholders.
For factory involving a hazardous process or for the expansion of any such factory,
the State Government may appoint a Site Appraisal Committee. The committee would
examine application from the proponent and given recommendations. Where the State
Government has granted approval to an application for the establishment or expansion of a
factory involving hazardous process, it shall not be necessary for an applicant to obtain a
further approval from the Central Board or the State Board established under the Water
(Prevention and Control of Pollution) Act, 1974 and the Air (Prevention and Control of
Pollution) Act, 1981.
2.4.2 Environment Protection Act 1986.
The Environment Protection Act 1986 section 3 provides for fixing standards for
emission or discharge of environmental pollutants. The standards of emissions or
discharge of environmental pollutants from the industries, operations or processes shall
be as specified in (schedules 1 to IV). Since the KSPCB is not insisting on any of the
provisions while issuing the consent only the EIA needs to be done to get the licenses.
2.4.3 The Water (Prevention and Control of Pollution) Act, 1974 and Rules
As per this Act the occupier or the operator of a mining activity has to fulfil the
following obligations and duties to protect the environment and to prevent any
environmental damage or pollution. Act makes it mandatory the occupier to discharge any
trade effluent to the land or water body by treating it to the level of the standards prescribed
by the Regulatory authority. (the standards are given in the annexure). Any violation of
this section attracts legal action under the section 41 to of the Water Act.
2.4.4 The Water (Prevention and Control of Pollution) Cess Act, 1977 and Rules
The purpose of Water (Prevention & Control of Pollution) Cess Act is levy and
collect cess on water consumed by 16 categories of industries specified in the act and also by
local bodies with a view to augment the resources of the Central and State Pollution Control
Boards. Water cess is levied based on the water consumed for domestic and specified
industry.
2.4.5 The Air (Prevention and Control of Pollution) Act, 1981 and Rules
The objective of this Act is to provide for the prevention, control and abatement of air
pollution, for the establishment, with a view to carrying out the afore said purposes, of
boards, for conferring on and assigning to such boards powers and functions relating thereto
and for matters connected therewith. Decisions were taken at the United Nations Conference
on the Human Environment held in Stockholm in June 1972, in which India participated, to
take appropriate steps for the preservation of the natural resources of the earth which among
other things, includes the preservation of the quality of air and control of air pollution.
The Central and State Pollution Control Boards are entrusted to perform the functions
under the Act. As per the Act, Air Pollution is defined means the presence in the atmosphere
of any air pollutant. Air pollutant means any solid, liquid or gaseous substance (including
noise) present in the atmosphere in such concentration as may be or tend to be injurious to
human beings or other living creatures or plants or property or environment.
The primary responsibility of controlling air pollution is on the Board. The very first
measure to be adopted in this respect is the declaration of any area or areas within the State as
air pollution control area. In respect the Sate government has declared entire State as air
pollution control area. The air pollution from industrial plants is controlled through consent
mechanism by stipulating standards in respect of air pollutants. In case of non compliance,
the act has made provisions for issuing directions to any person, officer or authority, and such
4
person, officer or authority shall bound to comply with such directions. Power to issue
direction includes the power to direct:
Closure, prohibition or regulation of any industry, operation or process or
The stoppage or regulation of supply of electricity, water or any other service
In addition to this, Provisions exist to make application to courts for restring persons
from causing air pollution and punish the offender with imprisonment and fine.
2.4.6 The Environment Impact Assessment Notification 1994 & 1997
As per the notification it is mandatory on part of 30 categories of industries (list given
below) to obtain environmental clearance from Ministry of Environment and Forest, GOI
before establishment or expansion or modernization. It should be noted that sugar industries
do not have to obtain clearance.
2.4.7 The Noise Pollution (Regulation and Control) Rules, 2000
The State Government shall categorize the area into industrial, commercial,
residential or silence area/zones for the purpose of implementation of noise,
standards for different area. The ambient air quality standards in respect of noise
for different areas/zones shall be such as specified in the Schedule annexed to these
rules.
The noise levels in any area/zone shall not exceed the ambient air quality standards in
respect of noise as specified in the Schedule.
The authority shall be responsible for the enforcement of noise pollution control
measures and the due compliance of the ambient air quality standards in respect of noise.
2.4.8 The Hazardous Waste (Management & Handling Rules), 2000
These rules apply to handling of hazardous wastes specified in the Schedules 1, 2, &
3 of the rules. These rules do not apply to waste water and exhaust gases as covered
under the provisions of the Water and Air Act and Rules made there under, wastes
arising out of the operation from ships beyond five kilometers as covered under the
provisions of the Merchant Shipping Act and radioactive wastes covered under the
provisions of the Atomic Energy Act.
2.4.9 The Manufacture, Storage and Import of Hazardous Chemicals Rules, 1989
These rules apply to any industrial activity in which a hazardous chemical (criteria
given in Schedule 1 of the Rules) is involved and where the isolated storage of a
hazardous chemical is equal to or more than the threshold quantity specified (chemical and
threshold listed in Schedule 2 of the Rules). The rules also specify the responsibility of the
occupier to provide evidence to show that he has identified the major accident hazards and
also taken adequate to prevent major accidents and provide adequate information, training,
and equipment including antidotes necessary for safety. In case of a major accident occurring
on the site or pipelines the occupier should notify the concerned authorities (Schedule 5 of
the Rules, also see annexures)
2.5 RELEVANT POLICIES
The following list of the policies related to environment and sugar industries:
1. The National Environmental Policy
2. The Industrial Policy, 1991
3. The Policy Statement for Abatement of Pollution, 1992
4. The Export-Import Policy, 1997
It is evident that the Policies being pursued presently have been evolved with
experience and with the considerations of various national and international developments
5
and the country's requirements for development. The Policies outline the guiding principles
for the various developmental and industrial activities.
2.5.1 The National Environmental Policy
Although since long there was a concern for the environmental management in the
country as evident from the various Policies and Legislation the lead was given in the Sixth
Plan when a Chapter on 'Environment and Development' was included in the Plan document.
The Chapter laying emphasis on the problems of environmental degradation provided
guidelines to the administrators for formulating and implementing the development programs
incorporating environmental concerns and laying down the institutional arrangements for
environmental management, administration and protection. The Eighth Plan on the basis of
the overview of the environmental and forest scenario identified the eight major tasks to meet
the challenge of environmental degradation.
To complement the Constitutional sanctions, outlines earlier, MoEF in 1992 brought
out a Policy Statement for Abatement of Pollution and the National Conservation Strategy
and Policy Statement on Environment and Development which provides instruments in the
form of legislation and regulation, fiscal incentives, voluntary agreements, educational
programs and information campaigns for preventing, controlling and reducing environmental
pollution. The overall objective of the Policy was to integrate environmental considerations
into decision making at all levels and to achieve this, the following specific steps were
identified.
1. Prevent pollution at source.
2. Encourage, develop and apply the best available practical solutions.
3. Ensure that polluter pays for the pollution control arrangements.
4. Focus protection on heavily polluted areas and river stretches.
5. Involve public in decision making.
6. Increase the safety of industrial operations.
The MoEF issued the Environmental Action Program in 1993 with the objective of
integrating the environmental concerns into the process of development. The various issues
addressed were reducing pollution at source, assistance for adaptation of the best available
and practicable technologies, mass based standards, fiscal measures, environmental audit,
environmental statistics, and public participation.
The National Conservation Strategy and Policy Statement on Environment and
Development, 1992 formulated with a view to reinforcing traditional ethos and to building up
a conservation society living in harmony with nature and making efficient use of the
resources guided by the best available scientific and technical knowledge aimed at the
following.
1. Ensuring sustainable and equitable use of the resources for meeting the basic needs
of the present and future generations without causing damage to the environment.
2. Preventing and controlling the future deterioration of the life support systems.
3. Taking steps for restoration of ecologically degraded areas and for environmental
improvement in the rural and urban settlements.
4. Ensuring that the developmental projects are correctly cited with least adverse
environmental consequences.
5. Conserving and protecting the coastal areas and marine eco-systems.
The New Industrial Policy lays stress on the following for the sustained development
and growth of the industry in the country.
1. Substantial reduction in the scope of industrial licensing.
2. Simplification of procedures, rules and regulations.
3. Reforms in the Monopoly and Restrictive Trade Practices Act.
4. Reduction of the areas reserved exclusively for the public sector.
5. Disinvestment of selected public sector enterprises.
6. Enhancing limits of foreign equity participation in domestic industrial undertakings.
7. Liberalization of trade and exchange rate policies.
8. Rationalization and reduction of customs and excise duties.
9. Extension of the scope of modified value added tax (MODVAT).
2.6 RELEVANT INSTITUTIONS
Three departments are directly involved in the protection of environment due to
sugar industries in the state, including the Ministry of Environment and Forest, Govt.
of India; The Department of Forests, Ecology and Environment, Govt. of Karnataka; and
Karnataka State Pollution Control Board
2.6.1 Ministry of Environment and Forest, Government of India
Ministry of Environment and Forest (MoEF) is the nodal agency at national level, in
the administrative structure for environmental protection and forest conservation. MoEF is
assisted by the Central Pollution Control Board (CPCB), a statutory authority at the central
level in executing responsibilities of prevention and control of pollution. Implementation of
relevant Acts and Rules and policy issues at the State level is overseen by the State Pollution
Control Boards (SPCB) and the State Department of Environment and Forest (DOEF). The
governing Acts and Rules are: Environment Protection Act-1986, Forest Conservation Act1980 and rules there under.
2.6.2 Department of Ecology and Environment, Government of Karnataka
Department of Ecology and Environment (DEE) is the state nodal regulating agency
responsible for environmental management of the state and can exercise promotional and
regulatory functions in mining sector under the Air, Water and Environment Protection and
Forest Conservation Acts. The department also houses the State Environmental Clearance
Committee (SECC) which gives clearances to projects. The applications seeking
environmental clearances as per the EIA notifications are routed through DEE.
2.6.3 Karnataka State Pollution Control Board
KSPCB has regulatory and enforcement responsibilities with respect to air, water
pollution control and hazardous waste management in mines under the Water (Prevention &
Control of Pollution) Act, 1974, the Air (Prevention & Control of Pollution) Act, 1981 and
rules there under, the Environment Impact Assessment Notification, 1994 & 1997 and
Hazardous Waste (Management & Handling) Rules, 1989 & amendments rules 2000.
KSPCB is responsible for conducting public hearing under Environmental Impact
Assessment (EIA) notification for any developmental or new projects, including the mining
sector.
At present the Karnataka State Pollution Control Board is issuing consent to the
mining industries with only the stipulations for treating domestic wastewaters, as there is no
generation of any trade effluent from any mining activity. However, in case where
purification and beneficiation of the ore is to be taken up at the mining area, prior consent
from the KSPCB should be taken and in such cases consent conditions for the disposal of
trade effluents will be specified by the Board. Under The Air (Prevention and Pollution
Control) Act, at present no compliance provision are indicated in the consent letter. However
8
the following Acts that are still valid and applicable are discussed here as they are relevant to
the sector. The Standards of Service of Karnataka State Pollution Control Board are given in
Annexure I.
2.6.3.1 Condition prescribed by the KSPCB in the Consents to Establish and Operate
1. The maximum quantity of water consumed in a sugar factory shall not exceed 2 cubic
meter per tonne of cane crushed.
2. The factory shall ensure treatment of all the wastewater generated in the factory
before it is discharged.
3. The treated water shall be used in the irrigation and shall not be discharged into the
stream or water bodies.
4. The application of the treated effluent shall be controlled so as to avoid either
flooding of land or ground water contamination. Before allowing the usage of treated
water for irrigation the State Pollution Control Board shall ensure that the factor shall
submit a report on geophysical characteristics and assimilation capacity of land.
Adequate number of bore wells shall be provided by the factory in and around the
irrigated area to monitor ground water quality.
5. Chimneys of required height and other air pollution controlling equipments should be
provided by the factory.
6. Biogases shall be collected and stored properly by the factory to avoid the fugitive
emissions.
7. The factory shall ensure that the noise levels are within the stipulated limits and shall
conduct periodic monitoring of noise levels at a designated location at specified
intervals.
8. Press mud generated can be sold without treatment. However in case it is not sold it
shall be collected composted within the factory under the supervision of the factorys
scientists.
9. Lime sludge shall be collected and disposed off by the factory scientifically.
10. Ash from the boilers shall be collected and disposed off by the factory scientifically.
11. The factory shall install water meters to measure the water consumed for different
purposes as per the Water (Prevention and Control Pollution) Cess Act, 1977; as
amended and pay water cess.
12. The factory shall submit an Environmental Statement Report for the financial year
ending the 31st March in the prescribed format to the state to the state pollution
control board on or before the 30th day of September every year beginning 1993.
13. All tanks used for the storage and treatment of effluent shall be made impervious by
providing adequate cement concrete/stone masonry/ stone slab lining with leak proof
joints in the bottom and sides. Observation bores with pipes shall be provided around
such tanks and monitored for leakage.
14. The factory shall store the molasses generated in adequately sized steel tanks
provided with the roof cover.
15. The factory shall upgrade the pollution control systems as and when new technologies
become available.
16. The factory shall ensure continuous and effective operation and maintenance of
pollution control systems by employing qualified engineers.
17. The factory shall ensure continuous and uninterrupted power supply to see that the
pollution control systems functions uninterruptedly. Separate energy meter shall be
provided for the pollution control system.
18. A fully equipped laboratory shall be established by the factory with appropriate
equipments to monitor the performance of pollution control systems and to test the
effluents, emissions and soil for pollution related parameters.
9
19. Every new factory shall submit the Environment Impact assessment report and
Environmental management plan to the state pollution.
20. If the occupier has not taken consents under the Water (prevention and pollution
control) Act 1974 and the Air (prevention and control of pollution) Act 1981, and the
clearance under the Environment (protection) Act 1986, he shall not be allowed to run
the factory. Action shall be taken by writing to the concerned Departments to stop
supplies such as electricity, water etc.
21. For convenience the standards stipulated by the Karnataka sate pollution control
Board both under the water (prevention and control of pollution) Act 1974 and the Air
(prevention and control of pollution) Act 1981 for the effluents and emissions
discharged respectively are given below.
The standards for effluents and emissions discharged from sugar industry.
1 Effluent.
Concentration
not
to
exceed
Milligram/lit
Bio-chemical oxygen Demand.
100 for disposal on land.
Suspended solids
100 for disposal on land.
2 Emissions.
Bagasse-fired Boilers.
250
Horse shoe/pulsating Grate.
500 (12% CO2).
Spreader stroker.
800 (12% CO2).
10
3.1 APPROVALS
Approval for setting up Sugar Industries include:
1. Should obtain prior Consent for Establishment approval from the State Pollution
Control Board under the Water (Prevention and Control of Pollution) Act, 1974 and
the Air (Prevention and Control of Pollution) Act, 1981.
2. Should obtain prior approval from the competent authorities for industries.
3.2
RESPONSIBILITIES
Should comply with the consent conditions laid down by State Pollution Control
Board
Should maintain relevant log books for daily water consumption, raw material used
and products manufactured, energy use and consumption, hazardous and solid waste
generated, waste water generated, air emissions, etc.
Should submit yearly Environmental Statement to the concerned State Pollution
Control Board
Should submit yearly Water Cess Returns to the concerned State Pollution Control
Board
Should provide for waste water treatment facility, air pollution control devices and
noise pollution abatement measures.
11
The Water (Prevention & Control of Pollution) Act is an act to provide for prevention
of control of water pollution and maintaining or restoring of wholesomeness of water while,
the Air (Prevention & Control of Pollution) Act provides for the prevention, control and
abatement of air pollution. Under these two acts any new industry prior to commissioning
should obtain consent of the concerned State Pollution Control Board to establish and to
operate.
4.1 CONSENT PROCEDURE
All new establishments like industries, water and wastewater treatment systems, sewage
treatment systems are required to obtain Consent for Establishment and subsequently
obtain Consent for Operation under the Air and Water Acts. All the consent applications
received will be subject to technical evaluation and conditions imposed to protect the
environment. Application Form I and Form XIII, under the Air and Water Act, respectively,
to be filled by the applicant along with the consent fee and relevant documents. Pass Book
system has been introduced for renewal of consents.
Depending upon the industries varying in pollution potential (red, orange, and green) and
capital investment (small scale, medium scale, and large scale) the consent fees varies.
The industries under large scale and medium scale RED category are required to
obtain consent every year.
Medium scale ORANGE and GREEN category industries are required to obtain
consent every year with an option for once in two years by paying two years fee.
Small scale RED ORANGE and GREEN category have to obtain consent every year
with an option of once in three years by paying three year fee.
Tiny industries have to renew consent once in ten years by paying one year consent
fee. See Annexure II for Consent fee, frequency of consent application and the periodicity of
monitoring based on the classification of industries
12
The purpose of Water (Prevention & Control of Pollution) Cess Act is levy and
collect cess on water consumed by 16 categories of industries specified in the schedule I of
the act and also by local bodies with a view to augment the resources of the Central and State
Pollution Control Boards. Water cess is levied based on the water consumed for domestic
and specified industry. Cess is calculated on rate specified in Schedule II of the Act for
different water users. As per section 4 of the act the concerned industries are required to
install standard water meters at such places as may be required by the concerned authority for
measuring and recording the quantity of water consumed by the industry. The industry
consuming water shall furnish the cess returns in the prescribed form on or before 5th of every
month to the Member Secretary of the State Pollution Control Board. The returns filed are
assessed by the authority after due verification and amount payable is intimated to the user,
which should be paid by demand draft by the user.
If the industry complies with the regulation by providing effluent treatment plant which
meets the standards prescribed in terms of quantity and quality, it is entitled to a rebate of
25%.
13
14
ENVIRONMENTAL AUDITING
Environmental Audit has become a step to comply with the requirement to furnish the
Environmental Statement, though the importance of Environmental audit lies in achieving
increased productivity and reduced waste generation. Auditing in general is a methodical
examination involving analysis, tests and confirmation of local procedures and practices
whose goal is verify whether they comply with legal requirements, internal polices and
accepted practices. Auditing differs from assessment in that it requires collection and
documentation of competent and sufficient evidence rather than an opinion based primarily
on professional judgement.
Environmental Audit is a technique being introduced for integrating the interest of
the industry and the environment so that there could be mutually supportive. This technique
is basically a part of industrys internal procedures to meet their responsibilities towards
better environment. Environment Auditing is a management tool comprising a systematic
documented periodic and objective evaluation of how well the management systems are
performing with the aim of:
Waste preventive and reduction
Assessing compliance with regulatory requirements
Facilitating control of environmental practices by a companys management, and
Placing environmental information in the public domain.
Environmental Audit in India is different from that in developed countries and the
definition of International Chamber of Commerce (ICC) is accepted. ICC defines
Environmental Audit is It is a management tool comprising a systematic, documented,
periodic and objective evaluation of how well environmental organization, management and
equipment are performing with the aim of helping to safe guard the environment by:
Facilitating management control of environmental practices.
Assessing compliance with company policies, which would include meeting,
regulatory requirement.
Environmental Statement which is a part of the Environmental Audit.
Environment Policy means a statement of a companys overall aims and principles
of action with respect to the environment.
7.1 FEATURES OF A GOOD ENVIRONMENTAL AUDIT
A good Environmental Audit
defines sources, quantities & types of waste generation
Collates information on unit operations, raw materials, products, water usage and
wastes and increases knowledge of the process.
Highlights process deficiencies and poor management
Helps to set targets for waste reduction
Permits the development of effective waste management strategies.
Rises awareness in the workforce regarding the benefits of waste reduction
Helps to improve process efficiency
Enables legislative compliance & avoids litigation.
7.2
AUDIT PROCEDURE
15
AUDIT PREPARATION
Step 1 Prepare and organise audit team and resources.
Step 2 Divide Process into unit operation
Step 3 Construct process flow diagram linking unit
operation
PROCESS OUTPUTS
Phase 3: Synthesis
16
As it is necessary to comply with the regulatory norms for prevention and control of
pollution, it is also imperative to go beyond compliance through adoption of clean
technologies and improvement in management practices. Commitment and voluntary
initiatives of industry for responsible care of the environment will help in building a
partnership for pollution control. For this very purpose a Charter on Corporate
Responsibility for Environmental Protection (CREP) was prepared by a series of industryspecific interaction meetings organised by the Ministry of Environment and Forests. During
interaction meetings, the representatives of some industrial sectors sought extension of time
to meet the regulatory norms because of techno-economic constraints. In case of units falling
in such industrial sectors, time bound action has been proposed in the Charter. This measure
has been agreed on the understanding that a bank guarantee would be furnished by the
concerned units indicating the commitment to the action plan. However, this is without any
prejudice to the stipulations made in the existing standards and action already taken/initiated
for non-compliance and area-specific requirements warranting stringent actions. The
industrial units which are not complying with the national standards notified under the
Environment (Protection) Act, 1986, will submit action plan to meet the standards and bank
guarantee to respective State Pollution Control Board within 3 months (by June, 2003). The
Maharashtra Pollution Control Board on 03.01.2003 held the consultation for sugar industries
at Mumbai. Following are the stipulations for Sugar Industries
1. Waste Water Management
Operation of ETP shall be started atleast one month before starting of cane crushing to
achieve desired MLSS so as to meet the prescribed standards from day one of the
operation of mill.
Reduce wastewater generation to 100 litres per tonne of cane crushed by April 2004.
To achieve zero discharge in inland surface water bodies by December 2004.
To provide 15 days storage capacity for treated effluent to take care of no demand for
irrigation by April 2004.
2. Emission Control
To install ESP/bag filter/high efficiency scrubber to comply with standards for particulate
matter emission to <150 mg/Nm3 by April 2004.
17
ENVIRONMENTAL PERFORMANCE
VERIFICATION EXERCISE
Though the sugar industries do not have to obtain clearance under the EIA
Notification, the sugar industries are required to submit yearly Water Cess Returns and
Environmental Statement to the concerned State Pollution Control Boards. As of now,
there is no provision to analyse the Environmental Statement which is submitted yearly.
However, this is an important step which would not only give the yearly compliance but also
the status of the environment over a period of time.
In this chapter we are suggesting the following activities which would provide a rigorous
analysis of environmental statement submitted by the sugar industries and develop an
effective institutional arrangement for implementing Environmental Audit in the state.
1. Verification of Environmental Audit by the Sugar Industry
2. Verification of Environmental Audit by the Regulatory Authorities
3. Verification of Environmental Audit by the Third Party
For the verification process the following steps are suggested:
Step 1: Verification of maintenance of Log Books
Step 2: Verification of maintenance of Yearly Resource Auditing Books
Step 3: Verification of compliance of Environmental Plan and Consent Aspects
Step 4: Verification of Environmental Aspects
Step 5: Verification of Environmental Statement in line with the data provided
18
Source
Cane yard
unloading and
carrier section
Mill House
(milling
section)
Bagasse
handling
Activities causing
pollution
Resulting form
of waste
19
Vol m3/
tonne of
cane
-
Parameters of
concern
Suspended solid,
odour, foul smell
0.03 to
0.05
Suspended solids,
oil and grease foul
smell
Dust particles,
suspended solids
burning
4
5
6
Boiler house
and boiler
section
Clarification
section rotary
filter
Evaporator &
Pan Boiling
Washing
(juice heaters,
pan
evaporators
cleaning)
Evaporators,
centrifugal
house, pumps,
pipes, floor
washings,
molasses
spillover etc
Sulphur &
lime houses
Periodical washings,
overflows spillage etc
Pump leakage,
entrainments, through
vapours from pan boiling
and evaporator (mill
overloading) & poor
operating condition)
Washings from scale
removal & cleaning
10
Molasses
storage tanks
(pan house)
11
Sugar house
Transportation through
conveyors (Movement),
packing process etc
Waste with
inorganic salt
generation
Boiler ash
0.03
Waste contains
inorganic &
organic matter
Sugar loss into
condensate
pollutes water
0.04
-
BOD effluent
loading
Waste
discharged into
drains (high
inorganic & low
organic content)
Waste
discharged into
drains
Inorganic waste
water,
carbonates/
sulphates
Pollution load of
effluents is
increased (too
much)
Sugar dust
TDS
0.01
Note: Spray pond and cooling water overflows and condensates are not included since these can be
recycled/reused and any surplus flowing out will be mixed with the treated effluent.
The effluents of intermittent and regular nature from different sources are shown in
Tables below:
Table 10.2: Sources of Waste Water Generation
Regular
Sources
Parameters of concern
SS, O & G
Spray Pond
Overflow
TDS, BOD,
COD
Floor Washings
SS, BOD, O & G
Boiler Blow
Down
TDS
Intermittent
Sources
Pump
Leakage
Overflows
Excess
Condensat
e
Soda and
Acid Wash
Waste
Sulphur &
Lime House
Molasses
Spillage
(Prohibited)
Parameters of
concern
BOD
BOD
BOD
TDS, BOD
TDS
Very high
BOD &
COD
20
21
Preventive maintenance
Effective supervision
Employee participation
Production scheduling
would become very good organic manure, which can be sold profitably.
10.4.2 Cane carrier section:
There would be almost continuous & regular accumulation of cut cane pieces,
powdery materials below the cane carrier. This material contains juice and hence must be
regularly removed and put on the carrier before the mill at a convenient place. Care also
must be taken to see that there is no water seepage in this area. Any water entering in this
area is to be pumped out as the same gets mixed up with prepared cane particles, and carries
some sugar also and hence creating liquid effluent with high BOD. Hence,
Fall of the cut particles from the carrier down must be minimized.
The fallen particle materials should be removed at regular intervals.
Water should not be allowed to flow into the area below the can carrier.
During rainy season even if water enters, if the area is kept cleaned of the cut cane
materials, the effluent generated will be of lesser pollution concentration.
The water if enters, must be pumped out then and there itself.
The spillage of cut/ prepared can pieces from the carrier edges and from the rake
elevator must be avoided.
10.4.3 Milling Station
The following are contributing to generation of effluents in the milling station.
Leakage of lubricating oil and grease materials.
Leakage of bearing cooling water
Spillage of bagasse and bagaillo materials.
Spillage of can juice from rollers, DSM screens and also whiles pumping the diluted
juices for recirculation.
Leakage of juices from gutters, whirling tanks, pipelines etc.
Overflow of juice from whiling tanks.
Washing of the mills with hot water for mill sanitation purpose.
Use of lubricants should be judicious. Excess and improper application of lubricants
will result in waste of lubricants and the same will find/its way into effluent. Bearing cooling
water must be properly guided back into troughs or funnels without allowing the same to
flow out creating effluents. The leaked water along with spilled over juice and bagasse
particles and also the leaked lubricants will cause highly polluted effluent. If water leakage is
avoided, the mill can be subjected to dry cleaning to remove the bagasse particles from
spillage of juice and leak of oils etc., if any. The spillage of bagasse and also juice should be
avoided by properly guiding the delivery pipelines of juices (imbibition, DSM screens etc.).
Similarly the spurting and spilling of juices from rollers must be avoided by suitable guide
plate wherever necessary.
Close monitoring is essential on any leakage of juice from gutters, pipe lines and
pump glands etc. Any leak must be arrested then and there. All the juice in the mill house
and also the imbibition water pump must be regularly monitored for its proper working
without leakage. Regular renewal of gland packing, bushes etc., to avoid leakage of juice
through glands are necessary. A preventive maintenance system with proper schedule shall
be introduced. Similarly monitoring is necessary for avoiding leakage in gutters and from
pipelines. Overflow from whirling tanks should be avoided. This can be done to a great
extent by maintaining whirling action by recirculation of juice and avoiding big pieces of
bagasse coming into tank. Often there would by heavy foaming in the whirling tanks
requiring frequent washing thereby generating effluents. The bagasse dust entering the
factory. If due to too fine preparation of cane, there is dust found flying out even inside the
factory (which is observed in some sugar mills) dust collectors are to be installed in strategic
23
locations say when bagasse is transferred from one carrier to the other. (When it leaves
bagasse elevator and falls on to the return carrier etc.). The screens, which are used to collect
on the bagasse conveyor, must be cleaned properly at regular intervals. The bagailo blower
must be checked for its efficient working. Any accumulation of bagasse dust at the bottom of
blower should be cleaned regularly. The above steps will avoid/reduce the pollution inside
the factory.
10.4.4 Boilers - Boiler operation, Boiler Ash
No washing need to be done anywhere in the boiler station, and hence no liquid
effluent is generated in the station. But there is hot water with certain amount of dissolved
solids discharged from the boilers either continuously or at regular intervals through blow
downs. However it is desirable and preferable to allow steady and continuous blow down so
that the same can be let out for mixing with the treated effluent. Excess air allowed should be
just adequate to have proper combustion. Too much of excess air; pressurising the furnace
and overloading the boiler should be avoided in order to minimize the fly ash escape.
The boiler station generates solid waste in the form of boiler ash. However, the
bagasse which is used as a fuel contains very little ash (2.5 to 3 %). Boiler ash from the sugar
factories is generally used for land filling and sometimes applied to agricultural lands in
measured quantities. Boiler ash should not be allowed to accumulate and it must be removed
as and when produced and should be transported to the designated locations.
Generally the modern boilers are provided with multi-cyclone mechanical dust
collectors. There should be regular checking to see that there is no accumulation/choking in
their drain pipes. Some factories are using wet scrubbers for collecting the dust from the flue
gas called fly ash arrestors. Here, again regular monitoring is necessary to see that the water
spray is steady and adequate quantity. The collected ash must be removed and transported to
the designated place.
10.4.5 Clarification & Evaporation Station:
This station normally generates effluents in the following form.
Over flows
Leakage from pumps, tanks, pipelines etc
Floor washings
Cleaning day washing
There is more number of pumps in this station than in Mill house and hence this
station is more vulnerable for creation of pollution from pump leakage, through glands. Here
again regular maintenance and monitoring can arrest the pollution due to pump leakage.
Selection of proper material for gland packing is also necessary. Poor quality gland packing
will result in frequent gland leakage. Metallic packing is found useful in case of perpetually
leaking pumps like clear juice, vapour cell juice pumps etc. Besides regular preventive
maintenance system has to be adopted for repairing and replacing the pump parts or the pump
itself when becomes necessary.
Any leakage observed from any tank or pipelines (even water leakage) should be
arrested then and there. Similarly, care must be taken to avoid overflows. Level indicators,
limit switches, overflow alarms and automatic level controllers are available, by installation
of which (wherever necessary), it should be possible to avoid overflows. However, it is
desirable to have some small pits near each cluster of pumps vulnerable to leakage in order to
collect leakage if any taking place in between periods escaping observation. The liquids so
collected must be pumped back to the process source according to convenience. Steam
ejectors can be used for pumping back the solutions. On no occasion the leaked materials
should be washed into the drains. This will increase the pollution load. Any accidental
24
overflows, leakage etc. if take place the same may be contained with in a reasonable area
using bagasse and the area must be dry cleaned. This bagasse so used must be transferred
on to the mills or on to bagasse conveyor depending upon the juice content in such bagasse.
It is normal practice to clean the heating surfaces in evaporator vessels and juice
heaters periodically. On such days the process will be stopped and all the equipment and
vessels are flushed well using huge quantities of water. It will form substantial quantity of
effluent with fairly high pollution load. Most sugar mills use chemical solution containing
caustic soda & common salt for cleaning the heating surfaces and the same is let out after
cleaning. It is preferable to have a separate storage tank for collecting the cleaning day
washings and allows the same to mix with normal effluent slowly and steadily in order to
avoid sudden surge into the effluent treatment plant. It is a normal practice in many sugar
factories to clean the juice heaters at regular intervals without waiting for cleaning days. The
cleaning of juice heaters generates effluents with pollution. This can be mixed with the
regular inflow to the E.T.P.
All gland-cooling waters from the pumps must be collected separately for reuse for
inhibition purpose. This station produces a by-product called Filter Cake or Filter Mud,
which is a residual material after filtering out the juice from the muddy juice in the vacuum
filters. This mud from the Vacuum filter should be conveyed through the conveyors
(preferably through rubber belt conveyors) into a storage bin at a comfortable height from
where the filter mud can be unloaded on to trucks/tractors/bullock carts. The system should
avoid spillage of the mud totally.
The filter mud is good manure if used after little composting (allowing it for a
month or two). Generally the sugar-cane farmers would be willing to collect/purchase the
same as produced in the sugar mill and heap it in their fields for use as and when they
require. If the growers do not lift the same, the factory can have a dumping yard suitably for
this purpose. Some sugar mills are having technology to convert the same into bio-fertilizers.
In any case the spillage of this material should be avoided as otherwise the same may get
mixed with wash water/rain water etc. and may create effluents of high pollution.
In the same station, some small quantities of lime grits are also generated as waste
after slaking the burnt lime. The quantity depends upon the type and quality of burnt lime
used. This material being very small can be used for land filling and also for road
repairing/construction works. This has no pollution value.
10.4.6 Entrainment from Pans and Evaporator
Entrainment of sugar solutions while boiling in evaporators or pans would cause
contamination of sugar in the injection water making the entire spray pond polluted. The
following steps are necessary to be taken to avoid entrainment.
The catch all in evaporator and pans should be checked frequently for any choking of
the pipes/holes meant for draining back the collected liquid.
High level of juice in evaporator should be avoided.
Vaccum fluctuations should be avoided.
There should be Tell Tale bottles fitted on the vapour pipes of all the pans and the last
body of the evaporator. Regular test must be made for finding our any sugar getting
entrained with the vapours. If any observed, steps must be taken to locate the reason and
rectification of the same immediately.
While soda boiling on cleaning days in evaporators and pans, care should be taken to
see that the vapours are led outside the building through separate vent pipes, which are
extended to go beyond the roof level.
25
10.4.7 Sulphitation
The sulphur dioxide gas generation, which is bubbled through (i). Juice Sulphitation
Vessel and (ii). Syrup Sulphitation Vessel, should be continuous and as uniform as possible.
The flow and also the pressure of the compressed air should be steady. Both the vessels
should have chimneys extending to over the roof of the building, so that any traces of gas
carried along with the air and vapour is released to the atmosphere above the building.
However the sulphitation vessels should be designed properly with scrubbing arrangement to
absorb the sulphur dioxide gas fully and only the air and vapour, free of gas goes out of
chimney.
10.4.8 Liming Station
A tall chimney should be provided in the lime-slaking drum at the point where the
lime is added to the rotary drum. The lime dust created while transferring the lime should- be
evacuated through the chimney, which again should be extended to above the roof level.
10.4.9 Crystallization Station
Generally the lubricating oil would leak/overflow from the wirm wheel tray or wirm
wheel and gear arrangement of the crystalisers. Regular maintenance will avoid such leakage
and spillage. However any such spilled/leaked lubricant material should not be allowed to
trickle down on the ground floor. Such materials should be dry cleaned using bagasse and
should be transferred to bagasse carrier leading to boiler.
10.4.10 Segregation of Effluents
There are different kinds of effluents generated in a sugar mill ranging from highly
polluted to pure water, which can be listed as below;
1
High Pollution
Low Pollution
No Pollution
Out of the above, item (1) & (2) are normally mixed and are fed to the effluent
treatment plant. However some of the effluents may need pretreatment like oil and grease
removal etc., before going to ETP. Such effluents can be segregated (e.g. mill house
effluents), and subjected to pretreatment, after which, can be mixed with those effluents
going to ETP (without pretreatment). Out of the item no. 3, above the spray pond water
overflow must be mixed with the treated effluent before going out. The bearing cooling
water, though re-circulated to a large extent, a portion of the same is sent out regularly for
maintaining the temperature. This water can be added to the spray pond water, which works
out as make up water. The hot condensate even after recirculation and reuse is often found in
excess. If there is a cooling arrangement, this water can be cooled and reused in place of fresh
water, or else this has to be let out which is wastage of water. This outlet can be connected to
the outflow of the E.T.P.
10.4.11 General Points
Plenty of trees must be planted all around the factory.
There should be no hose pipe allowed inside the factory for floor washing. Once the
hose connection is given the floor washing and through that the pollution load will
increase. All floor cleaning must be dry cleaning. Any water required must be
carried through buckets.
26
27
Waste type
Donts
Dont overload
Do not mix up many operations
at the same time.
Do not allow to accumulate can
trash material and cow dung
Do not allow water seepage in
this
area
under
any
circumstances
Mill Section
Effluent
continuous
gland cooling and
intermittent
floor
washings, leakage of
oil, grease and spill
over, leakage of juice,
leakage of bearing
cooling water, spillage
of bagasse and can
juice from rollers,
whirling
tanks,
pipelines, overflow of
juice from whirling
tanks.
28
washings etc.,
Clarification
(Sedimentation)
Section and Vacuum
filters
Boiler house
29
Sulphitation
(Bleaching)
Leakage
from
pumps
Leakage
/spills
from gutters
Inlet and outlet
vents losses
Oil and grease
from
equipment
cleaning
and
maintenance
Overflow
water
form spray ponds,
oil & grease from
equipment
cleaning/
poor
maintenance
Use properly designed tanks and vessels (juice receiving and reaction tanks) for
their intended purposes.
Install overflow alarms for all tanks/vessels.
Document all spillage.
Place tanks/ vessels in such a way as to allow for visual inspections.
Use adequate scrubbing arrangements in sulphitation tank to absorb sulphur
dioxide (SO2) to gas.
Chimney from sulphitation vessels should extend above roof to an adequate
height.
Adequate lighting and ventilation around the sulphitation area is must.
Use steel pipes of good quality and proper seals for collar positions.
Improve cleaning efficiency.
Install SO2 detectors at possible leakage points/ sources
Adequate open area/ventilation must be provided to avoid any accident due to
SO2 leakage (if any)
Arrange layout such that visual inspection for leakage and spills must be
possible
Maintain pumps, tanks, wheel and gear arrangements as per preventive
maintenance plan/schedule.
Segregate effluents as per loading.
Water leaving crystallizers and sulphur burners can be sent to condenser water
cooling system (injection water).
Inlet and outlet vents must be checked for leakage/losses.
Check cooling elements regularly for the leak proof working.
Maintain physical integrity of crystallizers, centrifuges and pans.
Isolate equipment or process lines, pipes etc, those leak or not in service. Use
seal less pumps or metallic seals.
Use clean in place systems.
Adopt dry cleaning using bagasse.
Use mechanical wipers on mixing tanks.
Use improved seals for pipes, valves, pumps etc.
This can be reused for irrigation through segregation of streams in lined
drains/channels.
Regular inspection and preventive maintenance is essential.
Water channels/drains must be leak proof. Inspect for leakage, stagnation and
take immediate measures (cleaning, disinfectant etc)
Check for the minimum depth of water in spray pond.
30
activities
Evaporation
Section
and Pan Boiling
Evaporator,
Pans
&Juice heater cleaning
Poor
handling,
leakage, improper
31
storage, overflows
from tank.
Contains inorganic
salts and organic
materials.
Due to spillage
(while
transportation and
collection)
from
conveyors,
unloading etc)
32
AIR POLLUTION
Sugar dust from sugar
house and particulates
from bagasse burning
(boiler house)
Sugar
dust
is
explosive
and
pollutes
inside
atmosphere.
They
fly
ash
particles are likely
to escape out.
33
Do
not
allow
untrained
operators to handle pollution
control devices. Only trained
operators and supervisors must
be allowed to operate/supervise
pollution control devices.
Do not go in for manual packing
of sugar
Sugar loss is more in manual
packing.
Appendix I: Continued . . .
Appendix I:
SR.
NO
IMPLEMENTING
AGENCIES
OBJECTIVE OF ACTS OR
RULES
KSPCBS
SERVICE
Responding to
request for
Information
General
Responding to
complaints
KSPCB, CPCB
KSPCB, CPCB
KSPCB, CPCB
34
Responding to an
application
submitted by the
stakeholder
KSPCBS STANDARDS
A written response within 7
working days of receiving letter
or e-mail including the
information sought will be sent.
In cases which need more time to
respond correspondence will be
dispatched immediately followed
by the information within 2
calendar months
An immediate response where
possible. A written response
within 15 working days of receipt
of complaint
Decisions will be made within 21
days of receiving a filled-in
application and supporting
information. (Form No I ). In
case of refusal of consent the
reasons will be intimated
Responding to an
application
submitted by the
stakeholoder
Scrutinising the
returns submitted
and to issue
assessment order
Decision
Appendix I: Continued . . .
SR.
NO
5
6
IMPLEMENTING
AGENCIES
OBJECTIVE OF ACTS OR
RULES
cess enhances the funds of
the Board for effective
implementation of
environmental legislation
KSPCB, CPCB
KSPCB, CPCB
35
KSPCBS
SERVICE
to enable
stakeholders to
file cess returns
KSPCBS STANDARDS
Appendix I: Continued . . .
Appendix II: Consent Fee to be paid by the Industries based on the capital investment, frequency of consent application and the periodicity of monitoring
based on the classification of industries
Sr.
No.
1
Classificationi
Redv
Category
Large
Medium
Small
Orangevi
Large
Medium
Small
Capital Investment by
Industries in Rupeesii
> 1000 Crores
>500 < 1000 Crores
>250 < 500 Crores
>50 < 250 Crores
>25 < 50 Crores
>10 < 25 Crores
>5 < 10 Crores
>1 < 5 Crores
>50 lakhs < 1 Crore
>25 lakhs < 50 lakhs <
>10 lakhs < 25 lakhs
>5 lakhs < 10 lakhs
>1 lakh < 5 lakhs
< 1 lakh
> 1000 Crores
>500 < 1000 Crores
>250 < 500 Crores
>50 < 250 Crores
>25 < 50 Crores
>10 < 25 Crores
>5 < 10 Crores
>1 < 5 Crores
>50 lakhs < 1 Crore
>25 lakhs < 50 lakhs <
>10 lakhs < 25 lakhs
Consent Fee
in Rupeesiii
2,00,000
1,50,000
1,00,000
75,000
50,000
30,000
20,000
15,000
6,000
3,000
2,000
1,500
500
200
1,75,000
1,25,000
90,000
60,000
40,000
25,000
17,500
12,500
5,000
2,500
1,750
36
Consent Applicationiv
Every Year
Periodicity of
Monitoring
Once in a month
Every Year
Every Year (option of
once in 3 years by
paying 3 years fee)
Every Year
Once in 3 months
Once in 4-6
months
Appendix I: Continued . . .
Sr.
No.
Classification
Greenvii
Category
Large
Medium
Small
Capital Investment by
Industries in Rupeesii
>5 lakhs < 10 lakhs
>1 lakh < 5 lakhs
< 1 lakh
> 1000 Crores
>500 < 1000 Crores
>250 < 500 Crores
>50 < 250 Crores
>25 < 50 Crores
>10 < 25 Crores
>5 < 10 Crores
>1 < 5 Crores
>50 lakhs < 1 Crore
>25 lakhs < 50 lakhs <
>10 lakhs < 25 lakhs
>5 lakhs < 10 lakhs
>1 lakh < 5 lakhs
< 1 lakh
Consent Fee
in Rupeesiii
1,250
250
150
1,50,000
1,00,000
75,000
50,000
30,000
20,000
15,000
10,000
4,000
2,000
1,500
1,000
200
100
iv
Consent Application
Periodicity of
Monitoring
Every Year
Once in 3 months
Once in 6 months
Once in 12 months
Categories of industries is as per GOI, MoEF, Official Memorandum No J20011 / 15/ IA/ dated 27th Sept 1988 read with amendment issued time to time
Capital investment on land, building, staff quarters, plant and machinery including all movable and immovable assets as detailed in the project report for new industry or
audited report for existing industry or twenty times the annual lease value in case where land and/or buildings are taken on lease
iii
Notification No FEE 115 ENV 95 (P) dated 19th February 1998, published in Karnataka Gazette dated 2nd April 1998. Fees shall be paid by Bank Draft in favour of
KSPCB, Bangalore encashable at Bangalore. Fees are the same for Consent for Establishment and Consent for Operation
iv
Form I and Form XIII under the Air Act (1981) and Water Act (1974), respectively. Tiny industries have to renew consent once in ten year by paying one year consent fee.
v
Consent for establishment and operation to be obtained from Head Office for large and medium category. However Consent for operation can be obtained either from
Divisional or Regional Office for investments < Rs. 1.00 Crores.
vi
Consent for establishment and operation to be obtained from Head Office. However Consent for operation can be obtained either from Divisional (investment Rs. 1.00 to
20.00 Crores) or Regional Office (investment < Rs. 1.00 Crores)
vii
Consent for establishment and operation to be obtained from Head Office (investment > 20.00 Crores), Divisional (investment Rs. 1.00 to 20.00 Crores) or Regional Office
(investment < Rs. 1.00 Crores)
ii
37
Appendix III.
STANDARDS FOR DISCHARGE OF EFFLUENTS FOR SUGAR INDUSTRY
(Extracts From Environment Protection Rules, 1986)
(Rule 3 (2))
Rule 3 of the Environment Protection Rules, 1986 provides for the Standard for emission or
discharge of environmental pollutants. The standards are specified in Schedules I to IV for
various emissions or discharges of environmental pollutants from the industries, operations or
processes. Those pertaining to the sugar industry have been complied below
Schedule I: Sl No 4
Effluent
Bio-Chemical Oxygen Demand.
Suspended solids
Schedule I: Sl No 59
Emissions
Agriculture residue fired boilers (including bagasse)
Emissions
Concentration in Milligram/lit
Step grate
Particulate matter
250
Horse shoe/Pulsating Grate Particulate matter
500 (12% CO2)
Spreader stroker
Particulate matter
800 (12% CO2)
(Note: In case of horse shoe and spreader boilers, if more than one boiler is attached to a
single stack, the standard shall be fixed based on added capacity of all the boilers connected
with the stack)
Schedule I: Sl No 88
Emission Standards for new generator sets (upto 19 kilowatt) run on petrol and kerosene with
implementation schedule. The emission standards for portable generator sets run on petrol and
kerosene shall be as follow:
B. From June 1, 2001
Class Displacement (CC) CO (g/kw-hr)
HC + NOx (g/kw-hr)
1
<65
519
54
2
>65<99
519
30
3
>99<225
519
16.1
4
>225
519
13.4
C. Test method shall be as specified in SAE J 1088. Measurement mode shall be D1 Cycle
specified under ISO 8178 (Weighting Factor of 0.3 for 100% load, 0.5 for 75% load and 0.2
for 50% load).
D. Following organisations shall test and certify the generator sets
Automotive Research Association of India, Pune.
3.1. Applicability
01. These rules apply to DG sets upto 1000 KVA rated output, manufactured or
imported in India, on or after 1st July, 2003.
02. These rules shall not apply to
a. DG sets manufactured or imported for the purpose of exports outside
India; and
b. DG sets intended for the purpose of sample and not for sale in India.
3.2. Requirement of Certification
Every manufacturer or importer (hereinafter referred to as "supplier") of DG set
(hereinafter referred to as "product") to which these regulations apply must have valid
certificates of Type Approval and also valid certificates of Conformity of Production
for each year, for all the product models being manufactured or imported from 1st July,
2003 with the noise limit specified in paragraph 1.
3.3. Sale, import or use of DG sets not complying with the rules prohibited
No person shall sell, import or use of a product model, which is not having a valid Type
Approval certificate and Conformity of Production certificate.
3.4. Requirement of Conformance Labelling
i. The supplier' of the 'product' must affix a conformance label on the product meeting
the following requirements:
a. The label shall be durable and legible.
b. The label shall be affixed on a part necessary for normal operation of the
'product' and not normally requiring replacement during the 'product' life.
ii. The conformance label must contain the following information:
a. Name and address of the supplier (if the address is described in the owner's
manual, it may not be included in the label)
b. Statement This product conforms to the Environment (Protection) Rules,
1986".
c. Noise limit viz. 75 dB (A) at 1m
d. Type approval certificate number.
e. Date of manufacture of the product.
3.5. Nodal Agency
i. The Central Pollution Board shall be the nodal agency for implementation of these
regulations.
ii. In case of any dispute or difficulty in implementation of these regulations, the matter
shall be referred to the nodal agency.
iii. The nodal agency shall constitute a Committee to advise it on all matters; including
the disputed matters, related to the implementation of these regulations.
3.6. Authorized agencies for certification
The following agencies are authorized to carry out such tests as they deem necessary
for giving certificates for Type Approval and Conformity of Production testings of DG
sets and to give such certificates:
i. Automotive Research Association of India, Pune
ii. National Physical Laboratory, New Delhi
iii. Naval Science & Technology Laboratory, Visakhapatnam
iv. Fluid Control Research Institute, Palghat
v. National Aerospace Laboratory, Bangalore
3.7. Compliance and Testing Procedure
The compliance and testing procedure shall be prepared and published by the Central
Pollution Control Board, with the help of the certification agencies.
41
Note- 1
Note- 2
Note- 3
Note- 4
Area Code
Category of Area
A
B
C
D
Industrial area
Commercial area
Residential area
Silence Zone
42
PARAMETER
Colour and Odour
INLAND
SURFACE
WATER
See Note I
PUBLIC
SEWERS
LAND FOR
IRRIGATION
See Note I
MARINE
COASTAL
AREAS
See Note I
--2
100
Particular size of
Suspended Solids
pH value
5.5 to 9.0
Temperature
Shall not
exceed 50C
above the
receiving
water
temperature
10
20
10
20
1.0
1.0
50
50
50
600
200
5.5 to 9.0
5.5 to 9.0
---
---
43
METHOD
No.2120 Visual comparison Method
Spectrophotometeric Method
No. 2150 Threshold odour test
No. 2130 Nephlometric Method
No. 4500- H+
Electrometric Method
No. 2550 Laboratory and field methods
PARAMETER
N), mg/l, Max.
Total Kjeldhal Nitrogen
(as NH3), mg/l, Max.
Free Ammonia (as NH3),
mg/l), Max.
Chemical Oxygen
Demand, mg/l, Max.
Arsenic (as As), mg/l,
Max.
Mercury (as Hg), mg/l,
Max.
Lead (as Pb), mg/l, Max.
Cadmium (as Cd), mg/l,
Max.
Hexavalent Chromium (as
Cr+6), mg/l, Max.
Total Chromium (as Cr),
mg/l, Max.
Copper (as Cu), mg/l,
Max.
INLAND
SURFACE
WATER
PUBLIC
SEWERS
MARINE
COASTAL
AREAS
LAND FOR
IRRIGATION
100
100
5.0
5.0
250
250
0.2
0.2
0.2
0.2
0.01
0.01
0.01 .
0.1
1.0
2.0
2.0
1.0
2.0
0.1
2.0
1.0
2.0
2.0
2.0
3.0
3.0
3.0
20
5.0
15
15
21
0.05
0.05
0.05
22
3.0
3.0
5.0
0.2
2.0
0.2
0.2
2.0
15
15
5.0
23
24
25
44
METHOD
method Phenate method
No. 4500 N-org Macro kjeldhal Method
Semimicro Kjeldhal Method
No. 5220 Titrimetric method, Colorimetric method
No. 3500- As Atomic absorption spectrometric method
No. 3500- Hg, Cold Vapour Atomic absorption Method,
Dithizone Method
No. 3550-Pb AAS Method, Dithizone Method
No. 3550-Pb AAS Method, Dithizone Method
PARAMETER
INLAND
SURFACE
WATER
PUBLIC
SEWERS
MARINE
COASTAL
AREAS
LAND FOR
IRRIGATION
26
2.0
5.0
27
1.0
5.0
5.0
10-7
10-7
10-8
10-7
28
Radioactive materials:
(a) Alpha emitter Micro
curie/ml
(b) Beta emitter Micro
curie/ml
10-6
10-6
10-7
10-6
90% survival
of fish after 96
hours in 100%
effluent
90% survival
of fish after
96 hours in
100%
effluent
90% survival of
fish after 96
hours in 100%
effluent
29
Bio-assay test
90% survival
of fish after 96
hours in 100%
effluent
30
2 mg/l
2 mg/l
2 mg/l
31
3 mg/l
3 mg/l
3 mg/l
32
Vanadium (as V)
0.2 mg/l
0.2 mg/l
0.2 mg/l
33
Nitrate Nitrogen
10 mg/l
20 mg/l
2100
2100
2100
1000
1000
1000
34
35
Dissolved Solids
(Inorganic), mg/l, Max.
Sulphate (as SO.), mg/l,
Max.
NOTE:
45
METHOD
Ascorbic acid method
No. 4500- S2 Methylene blue method
Iodometric method, Ion selective electrode method
No. 6420 Liquid Liquid extraction gas Chromatographic
method
Mass Spectrometric method
No. 7110 Evaporation method for grass alpha, beta
Soil Texture
Sandy
Sandy Loam
Loam
Clay loam
Clayey
Loading Rate in
m3/Ha/Day
225 to 280
170 to 225
110 to 170.
055 to 110
035 to 055
46
NATIONAL
Pollutant
Sulphur
(SO2)
Time
Weighted
average
Annual
Average*
24 Hours**
[SCHEDULE VII]
[See rule 3(3B)]
AMBIENT AIR QUALITY STANDARDS
80
30
Oxides of
Nitrogen as
NO2
Annual
Average*
80
60
15
24 Hours**
120
80
30
Suspended
Particulate
Matter
Annual
Average*
360
140
70
24 Hours**
Annual
Average*
500
120
200
60
100
50
24 Hours**
150
100
75
Annual
Average*
24 Hours**
1.0
0.75
0.50
1.5
1.00
0.75
8 hours**
5.0
2.0
1.0
8 hours**
5.0
2.0
1.0
Respirable
Particulate
matter (size
less than
10m)
Lead (Pb)
Carbon
Monoxide
(CO)
Method of measurement
24 hourly/S hourly values should be met 9S% of the time in a year. However, 2%
of the time, it may exceed but not on two consecutive days.
Note.
1. National Ambient Air Quality Standard: The levels of an air quality necessary with
an adequate margin of safety, to protect the public health, vegetation and property.
2. Whenever and wherever two consecutive values exceed the limit specified above for
the respective category, it shall be considered adequate, reason to institute
regular/continuous monitoring and further investigations.].
47
ENVIRONMENTAL STATEMENT
(TO BE SUBMITTED AS PER ENVIRONMENT PROTECTION ACT, 1986)
FORM V
Environmental Statement for the financial year ending the 31st March ..
PART A
(i)
Name and address of the owner/ occupier of the industry, operation or process.
(ii)
Industry category primary.- (STC Code) Secondary.- (SIC Code)
(iii)
Production Capacity.- Units.(iv)
Year of establishment
(v)
Date of the last environmental statement submitted
PART B
WATER AND RAW MATERIAL CONSUMPTION:
(i)
Water consumption m3/d
Process
Cooling
Domestic
Name of products
Process water consumption per unit of
product output
During the previous During the current
financial year
financial year
(1)
(2)
(1)
(2)
(3)
(ii)
Name of raw
materials
Name of products
* Industry may use codes if disclosing details of raw material would violate contractual
obligations, otherwise all industries have to name the raw materials used.
Pollutants
PART C
POLLUTION DISCHARGED TO ENVIRONMENT/ UNIT OF OUTPUT
(Parameter as specified in the consent issued)
Quantity of
Concentrations of
Percentage of
pollutants
pollutants in
variation from
discharged
discharges (mass/
prescribed
(mass/day)
volume)
standards with
reasons
(a) Water
(b) Air
48
PART D
HAZARDOUS WASTES
(as specified under the Hazardous Wastes/ Management and Handling Rules, 1989)
Hazardous wastes
Total quantity (kg.)
during the previous
during the current
financial year
financial year
(a) From process
(b) From Pollution control facilities
PART E
SOLID WASTES
Total quantity
during the previous
financial year
(a)
(b)
(c)
From process
From pollution control facilities
(1)
Quantity recycled or
reutilized within the units
(2)
Solid
(3)
Disposed
PART F
Please specify the characterizations (in terms of composition and quantum) of
hazardous as well as solid wastes and indicate disposal practice adopted for both these
categories of wastes.
PART G
Impact of the pollution abatement measures taken on conservation of natural
resources and on the cost of production.
PART H
Additional measures/ investment proposal for environmental protection including
abatement of pollution, prevention of pollution.
PART I
Any other particulars for improving the quality of the environment.
49
FORM XIII
APPLICATION FOR CONSENT FOR ESTABLISHING OR TAKING ANY STEPS FOR
ESTABLISHMENT OF INDUSTRY OPERATION PROCESS OR ANY TREATMENT DISPOSAL
SYSTEM FOR DISCHARGE, CONTINUATION OF DISCHARGE UNDER SECTION 25 OR
SECTION 26 OF THE WATER (PREVENTION AND CONTROL OF POLLUTION) ACT, 1974
(See Rule 32)
From
Date.
To
The Member Secretary,
Central Pollution Control Board.
Sir,
I/We hereby apply for Consent/Renewal of Consent under section 25 or section 26
of the Water (Prevention and Control of Pollution) Act, 1974 (6 of 1974) for establishing
or taking any steps for establishment of Industry/ operation/ process/ or any treatment/
disposal system to bring into use any new/ altered outlet for discharge of *sewage/ trade
effluent*/ to continue to discharge *sewage/ trade effluent* from land/premises owned by..
The other relevant details are as below:
1. Full name of the applicant..
2. Nationality of the applicant.
3. Status of the applicant:
a. Individual
b. Proprietary concern
c. Partnership firm
(Whether registered or unregistered)
d. Joint family concern
e. Private Limited Company
f. Public Limited Company
g. Government Company
1. State Government
2. Central Government
3. Union Territory
h. Foreign Company
(If a foreign company, the details of registration, incorporation, etc.).
i. Any other Association or Body:
4. Name, Address and Telephone Nos. of the Applicant.
(The full list of individuals, partners, persons, Chairman (full-time or part-time),
Managing Directors, Managing Partners, Directors (full time or part-time), other kinds of
office-bearers are to be furnished with their period of tenure in the respective office with
telephone Nos. and address).
5. Address of the Industry
(Survey No., Khasra No., location as per the revenue records, Village Firka, Tehsil,
District, Police Station or SHQ, jurisdiction of the First Class Magistrate).
6. Details of commissioning, etc.:
a. Approximate date of the proposed commissioning of work.
50
51
FORM I
(See rule 4 of Water (Prevention and Control of Pollution) Cess Act, 1974
RETURN REGARDING WATER CONSUMED DURING THE MONTH OF..........
Name and
Address of the
consumer
1
Quantity of water
consumed in
kilolitres
2
If the meter was out
of order the
monthly average
consumption of
water for the
previous 3 months
of the working
period
5
6
1. Industrial cooling spraying in mine
pits or boiler feed.
2. Domestic purpose.
Reading at the
beginning of the
first day of calendar
month under report
3
Quantity of water
qualifying for rebate
according to the
assessee
i.
ii.
iii.
iv.
v.
i.
ii.
iii.
iv.
v.
i.
ii.
iii.
iv.
v.
i.
ii.
iii.
iv.
v.
Reading at the
end of the last day
of calendar month
under report
4
Remarks*
7
8
from Municipal water supply mains
from well/ tube-well
from canal
from river
from any other source
from Municipal water supply mains
from well/ tube-well
from canal
from river
from any other source
from Municipal water supply mains
from well/ tube-well
from canal
from river
from any other source
from Municipal water supply mains
from well/ tube-well
from canal
from river
from any other source
For claiming rebate under column 7 the assessee shall indicate in this column the
analytical and other reports annexed to this return in support of this claim.
52
ANNEXURE TO FORM I
Report of Analysis of treated effluent showing performance of the treatment plant for the
month of....................................................................
Sample collected on...
Sample tested on.
By the Laboratories
SI. Polluting parameters as Maximum
Concentration Date on which
No. mentioned in the
permissible
of range of
There was On which
conditions imposed
limits or ranges parameters as break down under
under consent granted
allowed as per
per report
or failure
perforunder sections 25/26 of consent
of the plant mance
the Water (Prevention
condition
noticed
and Control of
Pollution) Act, 1974
1
2
3
4
5
6
End. : Original Analysis report of Laboratory.
Signature
Date
Name..
Address...
53
WATER INTAKE
1/2/04
2/2/04
3/2/04
4/2/04
5/2/04
3/2/04
4/2/04
5/2/04
6/2/04
7/2/04
WATER CONSUMPTION
1/2/04
2/2/04
Total
54
6/2/04
7/2/04
Log Book 2: Log Book for Daily Resources Balance Sheet (Weight Kg)
Type of Raw material
used
2/2/04
3/2/04
4/2/04
5/2/04
6/2/04
7/2/04
Total
Type of Products
manufactured
PRODUCTION DATES
1/2/04
2/2/04
3/2/04
4/2/04
5/2/04
Total
Note:For only mining projects the products includes the ore which is transported
55
6/2/04
7/2/0
4
Log Book 3: Log Book for Daily Energy Balance Sheet (Kilowatts)
Source of Energy
2/2/04
3/2/04
4/2/04
1/2/04
2/2/04
3/2/04
4/2/04
5/2/04
6/2/04
7/2/04
Grid
Diesel Generator Set
Solar Energy
Any other
Total
Energy Consumption
Process
Cooling
Air Pollution Control
Devices
Water Pollution Control
Devices
Water Sprinkling systems
Total
56
6/2/04
7/2/04
C HECK L IST I
(F OR I NTERNAL AND E XTERNAL A UDITORS )
Format 1 (VG1): Verification Guidelines on Resource Auditing Aspects
A. Monthly Water Balance Sheet
WATER INTAKE
WATER CONSUMPTION
[a]
[b]
Mode of Abstraction of Volume Mode of Use of Water Volume
Water
(m3)
(m3)
Tanker
Process
Surface Water
Cooling
Ground Water
Domestic
Piped Water
Water Sprinkling systems
Rain Water (harvested)
Total
Total
Note: a = b + waste water generated + loss due to evaporation
B. Monthly Raw material consumption
RAW MATERIAL INTAKE
[i]
Type of Raw material
Weight
used
(Kg)
PRODUCT PRODUCED
[ii]
Type of Product
Weight
produced
(Kg)
Total
Total
Note:i = ii + waste products + fugitive losses through air and water
C. Monthly Energy Balance Sheet
ENERGY INTAKE
ENERGY CONSUMPTION
[a]
[b]
Source of Energy
Kilowatts Mode of Use of Energy
Kilowatt
Grid
Process
Diesel Generator Set
Cooling
Solar Energy
Air Pollution Control
Devices
Any other
Water Pollution Control
Devices
Water Sprinkling systems
Total
Total
Note: a = b + loss due to heat
57