Standard Operating Procedures For Sugar Industry PDF

Standard Operating Procedures
For
Sugar Industry
A Draft Report
January 2005
Environmental Management
B:
Policy Research Institute
TABLE OF CONTENTS
ITEM CHAPTER PAGE
NUMBER
1 INTRODUCTION ---- 1
1.1 Background ---- 1
1.2 Gist Of Environmental Acts, Rules And ---- 1
Notifications
2 LEGAL AND REGULATORY FRAMEWORK ---- 2
2.1 Fundamental Rights And Duties Of A ---- 2
Citizen
2.2 State Policy ---- 2
2.3 Legislative Authority ---- 2
2.4 Relevant Legislations ---- 3
2.4.1 Factories Act, 1948 ---- 3
2.4.2 Environment Protection Act 1986. ---- 4
2.4.3 The Water (Prevention And Control Of ---- 4
Pollution) Act, 1974 And Rules
2.4.4 The Water (Prevention And Control Of ---- 4
Pollution) Cess Act, 1977 And Rules
2.4.5 The Air (Prevention And Control Of ---- 4
Pollution) Act, 1981 And Rules
2.4.6 The Environment Impact Assessment ---- 5
Notification 1994 & 1997
2.4.7 The Noise Pollution (Regulation And ---- 5
Control) Rules, 2000
2.4.8 The Hazardous Waste (Management & ---- 5
Handling Rules), 2000
2.4.9 The Manufacture, Storage and Import of ---- 5
Hazardous Chemicals Rules, 1989
2.5 Relevant Policies ---- 5
2.5.1 The National Environmental Policy ---- 6
2.5.2 The National Industrial Policy ---- 7
2.6 Relevant Institutions ---- 8
2.6.1 Ministry Of Environment And Forest, ---- 8
Government Of India
2.6.2 Department Of Ecology And Environment, ---- 8
Government Of Karnataka
2.6.3 Karnataka State Pollution Control Board ---- 8
3 RESPONSIBILITIES OF THE SUGAR ---- 11
INDUSTRIES
3.1 Approvals ---- 11
3.2 Responsibilities ---- 11
4 WATER AND AIR (PREVENTION & CONTROL ---- 12
OF POLLUTION) ACTS
4.1 Consent Procedure ---- 12
5 WATER (PREVENTION & CONTROL OF ---- 13
POLLUTION) CESS ACT
6 ENVIRONMENTAL STATEMENT PROCEDURES ---- 14
6.1 Contents Of Environmental Statement ---- 14
7 ENVIRONMENTAL AUDITING ---- 15
7.1 Features Of A Good Environmental Audit ---- 15
ITEM CHAPTER PAGE
NUMBER
7.2 Audit Procedure ---- 16
8 CHARTER ON CORPORATE RESPONSIBILITY ---- 17
FOR ENVIRONMENTAL PROTECTION (CREP)
9 ENVIORONMENTAL PERFORMANCE ---- 18
VERIFICATION EXERCISE
10 TYPES, SOURCES AND NATURE OF POLLUTION ---- 19
FROM SUGAR INDUSTRY
10.1 Process involved in Sugar Industry ---- 19
10.2 Pollution Effect ---- 21
10.2.1 Wastes Water ---- 21
10.2.2 Solid Waste ---- 21
10.2.3 Air Pollutants ---- 21
10.2.4 Molasses ---- 21
10.3 Good Operating Practices ---- 22
10.4 Steps To Be Taken At Different Stations Of ---- 22
A Sugar Mill In Order To Reduce The
Pollution
10.4.1 Cane Yard & Cane unloading section ---- 23
10.4.2 Cane carrier section ---- 23
10.4.3 Milling Station ---- 23
10.4.4 Boilers - Boiler operation, Boiler Ash ---- 24
10.4.5 Clarification & Evaporation Station ---- 24
10.4.6 Entrainment from Pans and Evaporator ---- 25
10.4.7 Sulphitation ---- 26
10.4.8 Liming Station ---- 26
10.4.9 Crystallization Station ---- 26
10.4.10 Segregation of Effluents ---- 27
10.4.11 General Points ---- 27
10.5 Good Housekeeping Practices – Do’s & ---- 27
Don’ts
Appendix I ---- 34
Appendix II ---- 36
Appendix III ---- 38
Appendix IV ---- 48
Annexure Maintaining Log Books ---- 54
Verification Guidelines ---- 57
Standard Operating Procedures for Sugar Industries
1 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
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2 LEGAL AND REGULATORY FRAMEWORK

To put the whole regulatory framework of India in perspective, a gist of constitutional
provisions that relate to the environment is given below.
2.1 FUNDAMENTAL RIGHTS AND DUTIES OF A CITIZEN
1. Under the Indian Constitution, Part III [Fundamental Rights] Article 21 states the
fundamental right of protection of life and personal liberty of an individual, “No
person shall be deprived of his life or personal liberty except according to procedure
established by law”. It should be noted that though this Article does not explicitly
mention the term ‘environment’, it is a fundamental norm recognized by the court that
every person enjoys the right to a wholesome environment, which is a facet of right to
life under the above-mentioned Article.
2. Part IV – A [Fundamental Duties] Article 51 – A (g) states that “It shall be the duty of
every citizen of India to protect and improve the natural environment including forests,
lakes, rivers and wildlife and to have compassion for living creatures”. This Article
was inserted by the Constitutional (42nd Amendment) Act, 1976
2.2 STATE POLICY
The State’s responsibility has been laid down in the Part IV – ‘Directive Principle of
State Policy’ of the Constitution. The Article 48 –A concerns the Environmental
responsibility of the State and was inserted by the Constitutional (42nd Amendment) Act,
1976. The Article states that “The State shall endeavour to protect and improve the
environment and to safe guard the forests and wild life of the country”.
2.3 LEGISLATIVE AUTHORITY
The Part XI of Constitution states the relationship between the Union and the States
for sharing the legislative and administrative powers. Under this Part, the Article 245 of the
Constitution gives the extent of the laws made by the Parliament and the State Legislatures.
The Parliament has the power to legislate for the whole country while the State legislatures
are empowered to make laws for their respective states. The Article 246 of the Part XI of
Constitution divides the areas of legislation (subject wise) between the Union [List 1 or
Union List in 7th Schedule, 97 subjects], State Legislatures [List II or State List in 7th
Schedule, 66 subjects] and both Parliament and State Legislatures [List III or Concurrent List
in 7th Schedule, 52 subjects]. The subjects related to environment in the 7th Schedule under
the three lists are summarized below:
LIST NAME SUBJECT SUBJECT
NO. NO. IN
LIST
I Union 52 Industries
List 53 Regulation and development of
oil fields and mineral oil
resources
54 Regulation of mines and mineral
development
55 Regulation and development of
Inter-State rivers and river
valleys
56 Fishing and fisheries beyond
territorial waters
II State 6 Public health and sanitation
2
LIST NAME SUBJECT SUBJECT

NO. NO. IN
LIST
List 14 Agriculture, protection against
pest and prevention of plant
diseases
18 Land, colonization, etc.
21 Fisheries
23 Regulation of mines and mineral
development subject to the
provision of List –I
24 Industries subject to the
provision of List – I
III Concurrent 17 A Forests
List 17 B Protection of wild animals and
birds
20 Economic and social planning
20 A Population control and family
planning
♦ 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
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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
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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.
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6. Protecting the scenic landscapes, areas of geomorphological significance, unique

and representative bio-mass and eco-systems and wild life habitats, heritage sites/structures
and areas of cultural heritage/importance.
For achieving the above the following actions were envisaged in the Policy.
1. Environmental impact assessment of all the developmental projects right from the
planning stage and integrating it with their cost-benefit considerations.
2. Compulsory prior environmental clearance of all projects above a certain size and for
those proposed to be constructed in ecologically sensitive and fragile areas.
3. Incorporation of environmental safeguards and protection measures in policies,
planning, site selection, choice of technology and implementation of the developmental
projects, i.e., industries, mining and mineral processing, forestry and human
settlements.
4. Encouraging research and developmental activities, adaptation of environmentally
compatible technologies, and to promote application of the modern tools of science and
technology for conservation, bridging of large gaps in supply and demand as well as
controlling and monitoring of the natural resources.
5. Encouraging public participation in environmental improvement programs and
integrating the environmental concerns in planning and implementation of the
developmental programs.
6. Creating environmental consciousness through education and mass awareness
programs.
7. Aiming at the modernization of the process of demand unleashed by the development
process itself by taking measures to recycle waste materials and natural resources,
conserving energy and the use of the natural resources in the industrial products by
measures like wood substitution and generally trying to reach moderation in life style
consistent with the sustainable development and the human dignity.
8. Developing appropriate organizational structure and a pool of professional manpower
to serve as the cadre for environmental management services.
9. Efficiently implementing the various environmental laws and regulations for
environmental protection through creation or strengthening of requisite enforcement
machinery.
It is evident that the Policy directives mean effective protection and management of
environment in all the developmental and industrial activities while keeping the goal of
sustainable development in view. Since mining of minerals and fossil fuels is an important
industrial activity essential for the development of the society and invariably mining is
considered to be an environmentally unfriendly activity the directives of the Policy are to be
taken into consideration not only in planning the mining and associated activities but also
during and after the completion of the mining activities.
2.5.2 The National Industrial Policy
The New Industrial Policy, 1991 was formulated to provide an impetus to the pace of
industrialization in the country. This resulted in abolition of all industrial licensing for all the
industries except some specified industrial sectors. The Policy addresses the environmental
concerns along with objectives of sustainable development and states:
“The major objectives of the new industrial policy package will be to build on the
gains already made, correct the distortions or weaknesses that my have crept in, maintain
sustained growth in productivity and gainful employment and attain international
competitiveness. The pursuit of these objectives will be tempered by the need to preserve the
environment and ensure the efficient use of available resources.”
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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 Act-
1980 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 factory’s
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.
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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).
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3 RESPONSIBILITIES OF THE SUGAR INDUSTRY AUTHORITIES

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.
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4 WATER AND AIR (PREVENTION & CONTROL OF POLLUTION) ACTS

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
5 WATER (PREVENTION & CONTROL OF POLLUTION)

CESS ACT
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
6 ENVIRONMENTAL STATEMENT PROCEDURES
Environmental Management in industries hitherto based on and off pipe waste

treatment, is now based on the emerging philosophy of waste prevention and reduction. In
order to prevent or reduce waste generation, one needs to examine the production processes,
to identify the origins of wastes, the operational problems associated with the process and the
areas requiring improvement. As per the notification issued by the Ministry of Environment
& Forest, Government of India on 13th March, 1992 (amended vide notification no. GSR 386
(E) dtd. 22.04.1993) under the Environment (Protection) Act, 1986, all those carrying on an
industry, operation or process requiring consent to operate under section 25 of the Water
(Prevention & Control of Pollution) Act, 1974 and / or under section 21 of the Air
(Prevention & Control of Pollution) Act, 1981 and/ or authorization issued under the
Hazardous Waste (Management & Handling) Rules, 1989 and the Environment (Protection)
Act, 1986 are required to submit the environmental statement for every financial year ending
31st March in the prescribed form [Form V] to the concerned State Pollution Control Boards
on or before 30th day of September every year beginning 1993. Non-compliance with this
mandatory requirement amounts to violation of the Environment (Protection) Act, 1986.
6.1 CONTENTS OF ENVIRONMENTAL STATEMENT
A statement prepared by the industry shall include the following;
i. A description of the company’s activities at site considered
ii. An assessment of all the significant environmental issues relevant to there activities
iii. A summary of the figures on energy consumption, water consumption, raw materials
consumption, pollutant emissions, waste generation and other significant
environmental aspects.
iv. The industry’s environmental policy objectives and targets
v. Details of the programme to be followed and the environmental management system.
Environmental Statement helps industry to take a comprehensive role at their
industrial operations and facilities, understanding of material flows and focus on areas where
waste reduction and consequently saving input costs, if possible. Environmental Statement is
to be prepared by every industry by filling up one “Environmental Statement Form V
(enclosed vide Annexure ) supplied by Pollution Control Board.
For the preparation of Environmental Statement, log book need to be maintained by the
mining authorities in their premises which would make the statement summarising easier.
The log book list is provide below
1. Water log book
2. Raw Material log book
3. Energy log book
4. Pollutant log book
5. Hazardous log book
The day to day summary from the log book can be summarised on monthly basis. A sample
log book is provided in Annexure
14
7 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 industry’s 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 company’s 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 company’s 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
A step-by-step methodology for Environmental Audit as recommended by the United

Nations Environment Programme and the United Nations Industrial Development
Organisation (UNIDO) is illustrated in figure 1.
Phase 1: Pre-Assessment 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
Phase 2: Material Balance

PROCESS INPUTS PROCESS OUTPUTS
Step 4 Determine inputs Step 7 quantify products / by-products
Step 5 Record water usage Step 8 Account for waste water
Step 6 Measure current levels of Step 9 Account for gaseous emissions
waste reuse/recycling
Step 10 Account for offsite wastes
DESERVE A MATERIAL BALANCE

Step 11 Assemble input and output Information
Step 12 Derive a preliminary material balance
Step 13 and 14 evaluate and refine material balance
IDENTIFY WASTE REDUCTION OPTIONS

Step 15 Identify obvious waste reduction measures
Step 16 target and characterize problem wastes
Step 17 Investigate the possibility of waste segregation
Step 18 Identify the long term waste reduction measures
EVALUATE WASTE REDUCTION OPTIONS

Step 19 Undertake environmental and economic
evaluation of waste reduction options, list viable options
Phase 3: Synthesis
WASTE REDUCTION ACTION PLAN
Step 20 Design and implement a waste reduction
action plan to achieve improved process efficiency
Quick Reference Audit Guide
16
8 CHARTER ON CORPORATE RESPONSIBILITY FOR ENVIRONMENTAL

PROTECTION (CREP)
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 industry-
specific 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
9 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
10 TYPES, SOURCES, AND NATURE OF POLLUTION FROM SUGAR INDUSTRY

10.1 PROCESSES INVOLVED IN SUGAR INDUSTRY
The sugar industry is of a seasonal nature and operates for 120 to 240 days in a year,
beginning from early November and ending on May or June. Large volumes of effluents and
wastes are produced during manufacture of sugar and effluents contain a high pollution load.
Because of the sugar mills being located mostly in rural areas where there are no suitable
options like large flowing water courses for effective disposal of the effluents by dilution and
because of the rainfall during the major part of the crushing season being practically nil,
extreme pollution of small rivers, foul smell in the vicinity of sugar mills, and unpleasant
look inside the mill are commonly experienced. Variation in volume of the effluent, its
pollution load is due to various causes like poor housekeeping, condition of plant and
machines, mode of their operation and maintenance, and water use.
As the process of sugar manufacture has many stages and in most of the stages
pollution/wastes are generated in different forms like wastewater, solid wastes and air
pollutants. The causes of these forms of pollution are leakage, spillover, overloading,
indifferent handling and crushing operations, improper molasses storage and handling and so
on. The different sources/stations where generation of pollution is of concern are: cane yard
& cane unloading section, cane carrier section, milling station, bagasse handling, boilers,
washings, clarification and evaporation section, filter washings, sugar house and so on. The
sources & types of pollution from sugar industry are shown in adjoining figure. Sugar
industry generates three types of effluents.
♦ Effluents requiring pre-treatment like oil and grease separation, pH correction etc.,
before going to ETP.
♦ Effluents which do not require any pre-treatment, but highly polluted and need
treatment in ETP.
♦ Effluents with little or no pollution, which do not require treatment.
From all such sources/operations, the pollution load can be reduced considerably by
adopting various pollution prevention measures. These measures could include good
housekeeping practices, change in the materials/process/ design, improving current operation
and maintenance procedures, waste minimization, clean technology options and so on. Since
our focus in this course will be on good housekeeping practices, which include aspects like
proper maintenance practices, inventory management, good operating practices, storage,
segregation of wastes, cleaning operations etc., we will be discussing more about all these.
But before we go in details let us see the sources, volume of effluents/waste and parameters
of concern (refer Table 10.1).
Table 10.1: Wastes and Effluents From Different Sources.
Sl. Source Activities causing Resulting form Vol m3/ Parameters of
No pollution of waste tonne of concern
cane
1 Cane yard Unloading of cane, cow Cane trash, cut - Suspended solid,
unloading and dung etc pieces, cow dung odour, foul smell
carrier section etc
2 Mill House Continuous gland cooling Containing oil, 0.03 to Suspended solids,
(milling and intermittent floor grease and sugar 0.05 oil and grease foul
section) washings spill over from juice from spills smell
leakage of grease and oil and leaks,
from bearings. overflows
3 Bagasse Movement of bagasse Bagasse dust - Dust particles,
handling through conveyors particulate on suspended solids
19
burning air pollutants fibres

(un burnt)
4 Boiler house Boiler blow down, boiler Waste with 0.03 TDS, Ash can be
and boiler station fuel (bagasse) inorganic salt used for
section generation agricultural lands.
Boiler ash 0.01 Particulate matter
from chimney
5 Clarification Periodical washings, Waste contains 0.04 SS, TDS, BOD,
section rotary overflows spillage etc inorganic & COD
filter organic matter
6 Evaporator & Pump leakage, Sugar loss into - BOD effluent
Pan Boiling entrainments, through condensate loading
vapours from pan boiling pollutes water
and evaporator (mill
overloading) & poor
operating condition)
7 Washing Washings from scale Waste - TDS, BOD effluent
(juice heaters, removal & cleaning discharged into loading
pan drains (high
evaporators inorganic & low
cleaning) organic content)
8 Evaporators, Occasional spills and leaks Waste - Very high SS,
centrifugal due to poor house keeping discharged into BOD, oil and
house, pumps, and maintenance. drains grease
pipes, floor Overflows
washings,
molasses
spillover etc
9 Sulphur & Washings of sulphur and Inorganic waste - TDS
lime houses lime houses water,
carbonates/
sulphates
10 Molasses Poor storage handling, Pollution load of - Very high BOD &
storage tanks leakage & overflows from effluents is COD
(pan house) tank increased (too
much)
11 Sugar house Transportation through Sugar dust - Dust, sugar loss
conveyors (Movement),
packing process etc
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 Mill House Effluent Spray Pond Floor Washings Boiler Blow
Overflow Down
Parameters of concern SS, O & G TDS, BOD, SS, BOD, O & G TDS
COD
Intermittent
Sources Pump Overflows Excess Soda and Sulphur & Molasses
Leakage Condensat Acid Wash Lime House Spillage
e Waste (Prohibited)
Parameters of BOD BOD BOD TDS, BOD TDS Very high
concern BOD &
COD
20
10.2 POLLUTION EFFECT

10.2.1 Wastes Water
Pollution load at the end of the manufacturing processes is increased if pollution and
waste generation is not prevented at source during the input and process stages. Apart from
odour, shabby look inside the factory and economic loss of sugar and energy, and wastage of
water, generation of liquid wastes, the final effluent from a sugar mill, many times carry
heavy pollution load. The organic pollutants present in the effluent remain in solution, being
mainly sugar and other carbohydrates. When the effluent stagnates in an area for few hours,
biological action starts and obnoxious condition soon develops in the region. The septic
condition results in production of hydrogen sulphide gas, imparting black colour to the
effluent. If the effluent is discharged in a small stream its oxygen is rapidly exhausted,
resulting in the death of fish and other aquatic life.
10.2.2 Solid Waste
Bagasse: Generally bagasse does not pose a problem of disposal of waste as it is
almost fully (90-96 %) used as fuel in boilers for steam generation and remaining is sold to
paper mills or hand processing paper mills and cardboard manufacturing units or, as fuel for
cogeneration factories. Sometimes fibres from the bagasse find their way into waste stream
via surface drains particularly during rainy season. However, entry of such fibres into waste
steam can be avoided by proper housekeeping and should not cause any specific problem.
Press mud: Press mud originates from the settled sludge in the juice clarification
process. It contains all non-sucrose impurities in the juice along with CaCO3, precipitates
and sulphates. As the press mud of double sulphination process contains valuable nutrients
like nitrogen, phosphorus, potassium etc., it is used mainly as organic manure and does not
pose any problem of disposal. The press mud from the units using double carbonation
process is used for land filling, and is not used as manure. The possibility of spillage cannot
be ruled out, where press mud is collected. But good housekeeping, maintenance, and proper
timely disposal of press mud can very well prevent this spillage/wastage.
10.2.3 Air Pollutants
The bagasse on burning produces particulate, viz. unburned, carbon particles and
gaseous pollutants like oxides of nitrogen, water vapour and other organic compounds of the
particulate waste, the heavier particles slowly settle down in the surrounding area. Such dust
fall leads to the problems of cleaning, reduction in property value, effect on vegetation etc.
The main gaseous pollutant is CO and CO2 reported to be in the range of 12 % to l4%.
Inside sugar factory, at sugarhouse, the sugar dust gradually settles on machines,
floors, conveyors etc., giving an unpleasant look and also it leads to poor working conditions
inside the factory. However, to a large extent the release of sugar dust can be controlled by
use of proper dust collectors, wet scrubbers and good housekeeping practices.
10.2.4 Molasses
Molasses have an extremely high BOD; hence proper care should be taken so that
there are no chances in the mill for the molasses to spill over into the wastewaters. It is
observed that in some sugar mills, molasses are stored in unlined (kutcha) pits, which is
environmentally unsound practice. During rainy season and also owing to the ground water
table conditions molasses get diluted and become unsuitable for fermentation. Sometimes,
sugar mill discharge unsuitable molasses into the natural river bodies thereby causing
pollution and damage to aquatic life. At no stage should molasses be allowed to accumulate
in the sugar factory area in an open pit/nallah.
21
10.3 GOOD OPERATING PRACTICES

A general approach of pollution prevention through good operating practices is given
in the following Table 10.3
Table 10.3: Pollution Prevention Through Good Operating Practices
Sl.No Good operating practices Nature of activity for pollution prevention
1. Waste segregation/ ♦ Prevent mixing of wastes of low, medium and high
separation concentration
♦ Isolate liquid waste from solid wastes
2 Preventive maintenance ♦ Maintain equipment/ machines history cards on
equipment location, characteristics and maintenance.
♦ Maintain a master Preventive Maintenance (PM)
schedule
♦ Keep vendor/ supplier maintenance manual handy
♦ Have regular inspection for leakage, losses, overflows
etc.
3 Training and awareness Provide training to employees/staff for:
building programme ♦ Operation of the equipment to minimize material
waste and energy use.
♦ Proper materials handling to reduce waste and spill
♦ Awareness of the importance of pollution prevention
by explaining the economic and environmental
ramifications of waste generation and disposal.
♦ Detecting and minimizing material loss to air, land or
water.
4 Effective supervision ♦ Closer supervision may improve production efficiency
and reduce inadvertent waste generation
♦ Centralize waste management. Appoint a safety/
waste management officer. Educate staff on the
benefits of pollution prevention. Establish pollution
prevention goals and perform pollution prevention
assessments.
5 Employee participation ♦ Use “Quality Circles” (free forums/ groups between
employees and operators, supervisors) to identify
ways and methods to reduce wastes.
6 Production scheduling ♦ Optimise production rates (crushing rate) to reduce
wastage, overflows and other losses and to maintain
high efficiency at all stations.
7 Cost allocation and ♦ Charge direct and indirect costs of all air, land and
accounting water discharges to specific processes or products.
♦ Allocate waste treatment and disposal costs to the
operations that generate the waste.
10.4 STEPS TO BE TAKEN AT DIFFERENT STATIONS OF A SUGAR MILL IN ORDER TO

REDUCE THE POLLUTION.
10.4.1 Cane Yard & Cane unloading section:
The above areas accumulate lot of cane trash materials and cow dung. The cow dung
accumulation is more in the factories, which are getting higher percentage of cane through
bullock carts. The materials should not be allowed to accumulate and rot. The same must be
removed from the yard then and there or at least in regular intervals. The removal can be
done departmentally or through contractor. The above waste material, if composted together
22
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 i) Effluent flowing out of mill station
ii) Floor washings of clarification station
iii) Floor washings of boiling, crystallization and centrifugal
house.
2 Low Pollution i) Laboratory washings etc
ii) Normal cleaning and floor washings etc
3 No Pollution i) Spray pond overflow water
ii) Bearing cooling water
iii) Hot condensate
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
10.5 GOOD HOUSEKEEPING PRACTICES – DO’S & DON’TS

Table l0.4 specifically provides pollution prevention measures attributed to good
housekeeping practices with respect to different sections/ stages of operation in sugar
industry.
•
27
Table 10.4: Good Housekeeping Practices - Do's & Don’ts

Waste origin/ Waste type Pollution prevention measures mainly from the point of ‘Good Housekeeping’ Dont’s
Sections
Before milling i.e. cane Inadvertent spills, can • Use just in time ordering system • Don’t overload
receiving cane yard, pieces (small) and • Maintain a clean, even surface in yard area • Do not mix up many operations
can unloading cane wastage, cow dung • Inspect material (cane) for quality, quantity etc., before unloading at the same time.
carrier section • Concrete road for vehicles/ carts to stand and automatic unloading of can will • Do not allow to accumulate can
reduce spillage trash material and cow dung
• Set up written procedure for loading/ unloading • Do not allow water seepage in
• Remove cane trash and cow dung then and there this area under any
• Failing cut cane pieces/powder must be removed from below the cane carrier. circumstances
Mill Section Effluent continuous • Prevent concrete ‘sweating’ by raising the drum of storage tank pads • do not hold waste water for long
gland cooling and • Construct concrete drains closed with steel jellies having lids at intermittent at one place.
intermittent floor places for inspection and maintenance • Do not allow to get mixed oil,
washings, leakage of • Drains leading to the effluent collection pit in the mill house should have proper grease, juice and water waste.
oil, grease and spill slope and drain time of liquid should be adequate. • Do not keep drains open. Let it
over, leakage of juice, • Inspect regularly glands, valves and pumps for leakage and attend repairs be closed with proper slope and
leakage of bearing immediately. lining.
cooling water, spillage • Use lubricants judiciously and properly • Do not use excess oil and grease
of bagasse and can • Schedule production rate to achieve maximum efficiency. • Avoid improper application of
juice from rollers, • As a precautionary measure keep trays of proper design and shape to collect oil lubricants.
whirling tanks, and grease spillages/ wastes. • O/G pit should not be much
pipelines, overflow of away from the mill
• Install overflow alarms for tanks/vessels
juice from whirling • Do not use too much of water
• For bagasse, use closed transfer system (hoods)
tanks. for mill washings
• Provide system with guards/guides for bearing cooling water
• Dry clean at places wherever possible • Do not use overdoses of
• Separate oil, grease and bagasse from effluents using proper grits disinfectants.
• Use disinfectants judiciously
Juice Dilution and Tank bottoms: off spec • Use seal less pumps or pumps with metallic seals. • Do not use excess water, which
Chemical areas of and excess material; • Instruct operators not to bypass alarms, signs or significantly alter set points may prove to be wastage.
work spill residues leaking without authorization. • Tanks and containers should not
vessels, pumps, valves, • Document all spillage be left without monitoring for
tanks, pipes, damaged • Set up control points to dispense chemicals and wastes overflows, spills, leaks etc.,
containers, dirt • Store containers/vessels/tanks in such a way as to allow for visual inspection for
accumulation, floor corrosion and leaks.
hi
28
washings etc., • Provide adequate light and ventilation in the storage area.
• Maintain distance between different types of chemicals to prevent cross
contamination.
• Follow manufacturer’s suggestions in storage and handling of chemicals.
• Use mechanical wipers on mixing tanks.
• Use closed storage and transfer system.
• Use clean-in place systems.
• Improve cleaning efficiency.
• If possible, use large containers with height to diameter ratio equal to one (1)
Clarification Leakage from pump • Install secondary containment areas. • Do not allow waster to stagnate
(Sedimentation) gland, overflows. • Segregation of effluents will reduce pollution loading. at any open place in case of
Section and Vacuum Leakage from pipe, • PH controller, temperature gauges and overflow indicator and water meter at spillage overflow etc.
filters tanks etc appropriate places will help in control of overdoses, identification of leakage • Do not keep tanks and vessels in
spots i.e. increase use of instrumentation. direct contact with floor, it
• Use closed storage and transfer system. becomes difficult to clean
• Use cleaning systems those avoid or minimize solvents and clean only when • Do not go for poor quality of
needed. If possible use high pressure water cleaning or dry cleaning or dry gland packing material.
• Adhere to regular preventive maintenance and monitoring • Do not push/allow dirt/leaked
• Have some pucca tank/ pit to collect effluents with oil and grease. material into drains.
• Install overflow alarms for all tanks/vessels • Do not allow sudden surge of
• Maintain physical integrity of all tanks and vessels effluent into ETP
• Clean drains at regular intervals • Avoid stacking containers
against processing equipment
Boiler house Waste with inorganic • Boiler blow down can be recycled for use in lower pressure boiler as make up • Do not allow scaling, corrosion
salt concentration water. If needed, some segregation may be required. on surrounding/surface areas of
boiler blow down • Regular inspection and preventive maintenance of boiler and its accessories for boiler.
contaminant, boiler leakages, corrosion, scaling mush be done. • Boiler ash should not be allowed
dust from flue gases, • Cleaning of boiler should be done properly and on the basis of deposit to accumulate.
boiler ash thickness, so as to reduce frequent waste generation. • Do not allow too much of air for
• Improve equipment seals to prevent air and cooling water leaks into the boiler. combustion, to prevent fly ash to
• Use wet scrubbers, fly ash arrestors properly and effectively. escape.
• Use modern multicyclone type dust collectors. Use of ESP can also be
considered.
• Regularly inspect for choking etc.
• Allow adequate quantity of air for proper combustion.
• Remove boiler ash to designated locations in closed conveyors/ transportation
systems.
29
Sulphitation Possible SO2 leakage, • Use properly designed tanks and vessels (juice receiving and reaction tanks) for • Do not overcrowd the place of
(Bleaching) overflow of juice from their intended purposes. sulphitation area
tanks, spillage etc. • Install overflow alarms for all tanks/vessels. • Do not neglect monitoring work.
• Document all spillage. • Do not neglect the maintenance
• Place tanks/ vessels in such a way as to allow for visual inspections. of sulphitation vessels/ tanks
• Use adequate scrubbing arrangements in sulphitation tank to absorb sulphur and accessories.
dioxide (SO2) to gas. • Do not allow flow and pressure
• Chimney from sulphitation vessels should extend above roof to an adequate of compressed air to fluctuate
height. too much.
• 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)
Crystallization and Pan • Leakage from • Arrange layout such that visual inspection for leakage and spills must be • Do not pump cold ‘C’
Boiling pumps possible massecuties.
• Leakage /spills • Maintain pumps, tanks, wheel and gear arrangements as per preventive • Do not dilute massecuties.
from gutters maintenance plan/schedule. • Do not undermine habit/attitude
• Inlet and outlet • Segregate effluents as per loading. of inspection and preventive
vents losses • Water leaving crystallizers and sulphur burners can be sent to condenser water maintenance.
• Oil and grease cooling system (injection water). • Do not allow spilling/ leaking
from equipment • Inlet and outlet vents must be checked for leakage/losses. lubricants material to trickle
cleaning and • Check cooling elements regularly for the leak proof working. down on floor..
maintenance • 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.
Spray pond overflow • Overflow water • This can be reused for irrigation through segregation of streams in lined • Do not allow spilled water to
form spray ponds, drains/channels. stagnate at spots/ corners
oil & grease from • Regular inspection and preventive maintenance is essential.
equipment • Water channels/drains must be leak proof. Inspect for leakage, stagnation and
cleaning/ poor take immediate measures (cleaning, disinfectant etc)
maintenance • Check for the minimum depth of water in spray pond.
30
activities • Check pipes/valves/pumps/nozzles for leakage/losses and spillage.

• Use sealless pumps with metallic seals.
• Maintain pumps/ valves as per manufacturer’s suggestions
Evaporation Section • Sugar loss in the • Continuous automatic recording and indication of brix of syrup will be useful • Do not overload mill – avoid
and Pan Boiling condensates for supervisory staff. erratic crushing
through • Use sealless pumps. • Do not neglect good operating
entrainment, thus • Use good quality seals and valves conditions.
pollutes cooling • Provide adequate lighting and ventilation near storage area • Do not overlook the preventive
water. • Provide segregation drains and collection pits for water wastes from evaporators maintenance schedule of
• Leaking pumps, and pans. equipment/ machines/ pumps
valves & vessels • Inspect regularly pumps, gauges, valves, vessels, pipes for choking leakage, etc,
and pipes. spillage and splashes etc. • Do not allow mixing of high
• Poor operating & • Preventive maintenance schedule must be adhered to. pollution effluent, oil or grease
maintenance • Check the ‘catch all’ in evaporator and pans frequently. into this water.
conditions. • Do not allow entrainment of
• Caustic soda scrap sugar solutions
scales • Do not keep very high level of
• Oil and grease juice in evaporators.
from equipment • Do not allow vacuum
cleaning/ operation fluctuations in vacuum pans.
and maintenance
Evaporator, Pans • The wastewater • Reduce frequency of cleaning of evaporator using desealants. • Avoid scaling of tubes by
&Juice heater cleaning from cleaning of • Cleaning of scales by electric driven flexible shafts using compressed air. keeping proper watch on control
scales increases • Improve cleaning efficiency parameters at set/identified points.
pollution load of • Segregate and collect the wastewater in lined drains. • Do not use cutter tools to remove
effluent streams • Explore alternative cleaning methods without using chemicals. scales unless scales are very hard. It
• Holding tank used for avoiding shock loadings in ETP should be leak proof may damage tubes.
with overflow alarms. • Brushes can be used with care.
• Establish spill prevention, control & countermeasures (SPCC/plans). • Do not leave scales unremoved
• Maintain physical integrity of all tanks vessels. on cleaning day.
• Document all spillage
• Preferably use seal less pumps for all purposes or use quality seals.
• Keep aisles clear of obstructions
• Scales can be partially softened/ or partially dissolved before high pressure
cleaning
Molasses storage tanks • Poor handling, • Provide collecting pits/ chambers around the tank for collecting cold water used • Do not allow overflow/ spillage
(final molasses) leakage, improper for spray and also any foam overflowing etc. of molasses
31
storage, overflows • Handling of molasses should be careful without spillage/ losses. • Do not keep the storage areas
from tank. • Store molasses on storage tanks fitted with all accessories/fittings as prescribed unattended as far as routine
including overflow alarm, inlet valve, washout valve, outlet for pump, temperature cleaning is concerned.
gauges, manhole vent. • Do not store molasses in open
• Arrangement for spraying cold water spray coil, level indicator etc. areas or kutcha pits.
• Properly label all tanks,. containers. • Do not neglect regular inspection
• Conduct periodic analysis of molasses and maintenance of storage tanks.
• Provide lids and vents on tanks (fixed roof type) • Do not forget to label tanks
• Thoroughly clean the tanks with water whenever they are empted appropriately.
• Use splash guards • Do not allow trickling of
• Inspect/ check for losses, spills around tanks & immediately attend it. molasses from storage tanks, pipes,
• Immediately clean floors using dry cleaning or other appropriate cleaning valves etc.
system.
• Regular lifting of molasses should be monitored.
• Prefer intact and closed transportation/ conveyance system
Solid Waste Bagasse • Bagasse fibres find • Keeping segregated waste through streams/drains/channels closed having • Do not allow bagasse fibres to
their way into (inspection points open) proper slope and lining will prevent fall of bagasse fibres remain on floor for long by not
waste streams. into streams (i.e. closed transfer system). cleaning it.
• Storage of • Use industrial vacuum cleaners/dry cleaners/clean in place system and these • Do not allow water seepage in
bagasses in open should be routine features of the mill. this area at any cost.
area may create • Automatic transportation feeding of bagasse must be there as per required • Do not allow can trash materials
pollution problems quantity and bagasse particles to fall on
• Storage of bagasse (if any) should be in proper storage yards. juice/water
• 5% of total bagasse can be used for other by products like paper and pulp, • Do not allow accumulation of
paperboard etc, dust at bottom of blower.
• Keep wet while storage and use closed transportation systems and conveyors
• Clean the screens used on conveyors properly at regular intervals.
• Clean bottom of blower properly and regularly
Press mud or ‘filter • Contains inorganic • Automatic and closed transfer systems/ conveyors will reduce this problem. • Avoid spillage of mud during its
cake’ (obtained at juice salts and organic • Provide splashguards. movement on conveyor and
clarification station materials. • Automatic unloading through hopper bottom directly on to the trucks can help during unloading operations.
from rotary vacuum • Due to spillage in keeping the floors and premises clean. • Do not allow to accumulate the
filters) (while • Clean equipment after use. fallen (if any) filter cake prices/
transportation and • Maintain a clean, even surface (concreted) in transportation/ movement areas. splashes (remove them, then &
collection) from there)
conveyors,
unloading etc)
32
AIR POLLUTION • Sugar dust is • Use closed conveyor and transportation system • Do not allow untrained
Sugar dust from sugar explosive and • Use closed loading & unloading system for sugar packing. operators to handle pollution
house and particulates pollutes inside • Vacuum cleaning/dry cleaning will keep the area neat and clean. control devices. Only trained
from bagasse burning atmosphere. • Proper handling of equipment, better operations and maintenance practices will operators and supervisors must
(boiler house) • They fly ash reduce release of sugar dust. be allowed to operate/supervise
particles are likely • Adequate light and ventilation near sugar packing area will not suffocate the pollution control devices.
to escape out. environment inside the plant. • Do not go in for manual packing
• Efficient and effective air pollution control devices like dust collectors, fly ash of sugar
collectors, cyclones/wet scrubber type fly ash arrestors and bag filters of • Sugar loss is more in manual
required efficiency and effectiveness shall preferably be used appropriately. packing.
33
Standard Operating Procedure for Sugar Industries
Appendix I: Continued . . .
Appendix I: Standards of Service of Karnataka State Pollution Control Board
The Karnataka State Pollution Control Board deals with Government, individuals, community groups, NGOs, local bodies, industries and
businesses. The Board has set its standards for various services
SR. IMPLEMENTING OBJECTIVE OF ACTS OR KSPCB’S

NAME OF ACT OR RULES KSPCB’S STANDARDS
NO AGENCIES RULES SERVICE
A written response within 7
working days of receiving letter
or e-mail including the
Responding to information sought will be sent.
1 General request for In cases which need more time to
Information respond correspondence will be
dispatched immediately followed
by the information within 2
calendar months
An immediate response where
Responding to possible. A written response
complaints within 15 working days of receipt
of complaint
Provides for the control and Decisions will be made within 21
abatement of air pollution. Responding to an days of receiving a filled-in
Air (Prevention and Control Board issues consent to application application and supporting
2 KSPCB, CPCB
of Pollution) Act, 1981 industry which emit air submitted by the information. (Form No I ). In
pollutants with emission stakeholder case of refusal of consent the
limits reasons will be intimated
Establishes an institutional
Decisions will be made within 21
structure for preventing and
Responding to an days of receiving a filled-in
Water (Prevention and abating water pollution.
application application and supporting
3 Control of Pollution) Act, KSPCB, CPCB Board issues consent to
submitted by the information. (Form No XIII ). In
1974 and Rules industry and local bodies
stakeholoder case of refusal of consent the
which discharge effluent
reasons will be intimated
with effluent limits
Provides for the levy and Scrutinising the
Water (Prevention and
collection of cess on water returns submitted
4 Control of Pollution) Cess KSPCB, CPCB Decision
consuming industries and and to issue
Act, 1977 and Rules
local bodies. Collection of assessment order
34
SR. IMPLEMENTING OBJECTIVE OF ACTS OR KSPCB’S
NAME OF ACT OR RULES KSPCB’S STANDARDS
NO AGENCIES RULES SERVICE
cess enhances the funds of to enable
the Board for effective stakeholders to
implementation of file cess returns
environmental legislation
The Noise Pollution
5 (Regulation and Control KSPCB, CPCB
Rules), 2000
Environmental Protection
6 KSPCB, CPCB
Act, 1986
35
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. Classificationi Category Capital Investment by Consent Fee Consent Applicationiv Periodicity of
No. Industries in Rupeesii in Rupeesiii Monitoring
1 Redv Large > 1000 Crores 2,00,000 Every Year Once in a month
>500 < 1000 Crores 1,50,000
>250 < 500 Crores 1,00,000
>50 < 250 Crores 75,000
>25 < 50 Crores 50,000
>10 < 25 Crores 30,000
>5 < 10 Crores 20,000
Medium >1 < 5 Crores 15,000 Every Year Once in two months
Small >50 lakhs < 1 Crore 6,000 Every Year (option of Once in 3-4 months
>25 lakhs < 50 lakhs < 3,000 once in 3 years by
>10 lakhs < 25 lakhs 2,000 paying 3 years fee)
>5 lakhs < 10 lakhs 1,500
>1 lakh < 5 lakhs 500
< 1 lakh 200
2 Orangevi Large > 1000 Crores 1,75,000 Every Year Once in two months
>500 < 1000 Crores 1,25,000
>250 < 500 Crores 90,000
>50 < 250 Crores 60,000
>25 < 50 Crores 40,000
>10 < 25 Crores 25,000
>5 < 10 Crores 17,500
Medium >1 < 5 Crores 12,500 Every Year (option of once in 2 Once in 3 months
years by paying 2 years fee)
Small >50 lakhs < 1 Crore 5,000 Every Year (option of Once in 4-6
>25 lakhs < 50 lakhs < 2,500 once in 3 years by months
36
i iv
Sr. Classification Category Capital Investment by Consent Fee Consent Application Periodicity of
No. Industries in Rupeesii in Rupeesiii Monitoring
< 1 lakh 150
3 Greenvii Large > 1000 Crores 1,50,000 Every Year Once in 3 months
>500 < 1000 Crores 1,00,000
>250 < 500 Crores 75,000
>50 < 250 Crores 50,000
>25 < 50 Crores 30,000
>10 < 25 Crores 20,000
>5 < 10 Crores 15,000
Medium >1 < 5 Crores 10,000 Every Year (option of once in 2 Once in 6 months
years by paying 2 years fee)
Small >50 lakhs < 1 Crore 4,000 Every Year (option of Once in 12 months
>25 lakhs < 50 lakhs < 2,000 once in 3 years by
< 1 lakh 100
i
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
ii
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)
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 Concentration not to exceed Milligram/lit
Bio-Chemical Oxygen Demand. 100 for disposal on land, 30 for disposal in surface
waters
Suspended solids 100 for disposal on land, 30 for disposal in surface
waters
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)
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.
♦ Indian Institute of Petroleum, Dehradun.
♦ Indian Oil Corporation, R&D Centre, Faridabad.
♦ Vehicle Research Development Establishment, Ahmednagar.
These organisations shall submit the testing and certification details to the Central Pollution
Control Board annually. The Central Pollution Control Board may send the experts in the field
to oversee the testing.
38
Appendix III: Continued . . .
Noise Limit for Generator Sets run with Petrol or Kerosene

1. Noise limit
Noise limit for new generator sets run with petrol or kerosene shall be as given below:
Noise Limit from
September 1, 2001 September 1, 2002
Sound Power 90 dBA 86 dBA
Level Lwa
2. Applicability
These rules shall apply to all new generator sets using petrol or kerosene as fuel, manufactured
in or imported into India:
Provided that these rules shall not apply to:
(a) Any genset manufactured or imported for the purpose of exports outside India, or
(b) The genset is intended for the purpose of sample only and not for sale in India.
3. Requirement of certification
Every manufacturer or importer (hereinafter referred to as “supplier”) of genset (hereinafter
referred to as “product”) to which these rules apply must have a valid certificate of type
approval for all the product models being manufactured or imported after the specified dates.
4. Verification of conformity of production (COP)
Every supplier shall subject its products to the verification for conformity of production, by
certification body specified in clause 8, every year.
5. Sale of generator sets not complying with. these rules
The sale of a product model, not having valid type approval certificate, or not complying with
the noise limits, as determined by the verification for conformity of production, shall be
prohibited, in India.
6. Requirement of conformance labeling
6. (1) 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.
6. (2) The conformance label must contain the following information:
a. Name and address of the supplier (if the address is described in the owners
manual, it may not be included in the label)
b. Statement that “this product conforms to the Environment (Protection) Rules,
1986.
c. Type approval certificate number and time phase (i.e. September 2001 or
September 2002).
7. Nodal agency
1. The Central Pollution Control Board shall be the nodal agency for implementation
of these rules.
2. In case of any dispute or difficulty in implementation of these rules the matter
shall be referred to the nodal agency.
3. The nodal agency shall constitute a Standing Committee to advise it on all matters;
including the disputed matters, related to the implementation of these rules.
8. Certification body
The following agencies are authorized for type approval and for verification of conformity of
production.
39
Automotive Research Association of India, Pune;

National Physical Laboratory, New Delhi;
Naval Science & Technology Laboratory, Visakhapatnam;
Fluid Control Research Institute, Palghat; and
National Aerospace Laboratory, Bangalore.
9. Compliance and testing procedure
The compliance and testing procedure shall be prepared and published by Central Pollution
Control Board, with the help of the certification agencies.
Noise Limit for Generator Sets run with Diesel
1. Noise limit for diesel generator sets (upto 1000 KVA) manufactured on or after the 1st
July, 2003.
The maximum permissible sound pressure level for new diesel generator (DG) sets
with rated capacity up to 1000 KVA, manufactured on or after the 1st July, 2003
shall be 75 dB(A) at 1 metre from the enclosure surface.
The diesel generator sets should be provided with integral acoustic enclosure at the
manufacturing stage itself.
The implementation of noise limit for these diesel generator sets shall be regulated
as given in paragraph 3 below.
2. Noise limit for DG sets not covered by paragraph 1.
Noise limits for diesel generator sets not covered by paragraph 1, shall be as follows:
2.1 Noise from DG set shall be controlled by providing an acoustic enclosure or by treating
the room acoustically, at the users end.
2.2 The acoustic enclosure or acoustic treatment of the room shall be designed for minimum
25 dB(A) insertion loss or for meeting the ambient noise standards, whichever is on the
higher side (if the actual ambient noise is on the higher side, it may not be possible to
check the performance of the acoustic enclosure/acoustic treatment. Under such
circumstances the performance may be checked for noise, reduction up to actual
ambient noise level, preferably, in the night time). The measurement for Insertion Loss
may be done at different points at 0.5m from the acoustic enclosure/room, and then
averaged.
2.3 The DG set shall be provided with proper exhaust muffler with insertion loss of
minimum 25 dB(A).
2.4 These limits shall be regulated by the State Pollution Control Boards and the State
Pollution Control Committees.
2.5 Guidelines for the manufacturers/users of Diesel Generator sets shall be as under:
01. The manufacturer shall offer to the user a standard acoustic enclosure of 25 dB
(A) insertion loss and also a suitable exhaust muffler with insertion loss of 25
dB (A).
02. The user shall make efforts to bring down the noise levels due to the DG set,
outside his premises, within the ambient noise requirements by proper siting
and control measures.
03. Installation of a DG set must be strictly in compliance with the
recommendations of the DG set manufacturer.
04. A proper routine and preventive maintenance procedure for the DG set should
be set and followed in consultation with the DG set manufacturer which would
help prevent noise levels of the DG set from deteriorating with use.
3. Limits of Noise for DG sets (upto 1000 KVA) manufactured on or after the 1st July,
2003.
40
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
Schedule III: (See rule 3)

Ambient Air Quality Standards in Respect of Noise
Area Code Category of Area Limits in dB (A) Leg.

Day Time Night Time
A Industrial area 75 70
B Commercial area 65 55
C Residential area 55 45
D Silence Zone 50 40
Note- 1 Day time is reckoned in between 6 a.m. and 9 p.m.

Note- 2 Night time is reckoned in between 9 p.m. and 6 a.m.
Note- 3 Silence zone is defined as areas upto 100 metres around such premises as
hospitals, educational institutions and courts. The Silence zones are to be declared
by the Competent Authority.
Use of vehicular horns, loudspeakers and bursting of crackers shall be banned in
these zones.
Note- 4 Mixed categories of areas should be declared as one of the four above-mentioned
categories by the Competent Authority and the corresponding standards shall
apply.]
42
Schedule VI: (See rule 3(3A))

GENERAL STANDARDS FOR DISCHARGE OF EFFLUENTS
Part A: Effluents
STANDARDS
SL . INLAND MARINE
PARAMETER PUBLIC LAND FOR METHOD
NO SURFACE COASTAL
SEWERS IRRIGATION
WATER AREAS
I Colour and Odour See Note I See Note I See Note I No.2120 Visual comparison Method
--- Spectrophotometeric Method
No. 2150 Threshold odour test
2 Suspended Solids mg/l, 100 600 200 (a) For process No. 2130 Nephlometric Method
Max. wastewater 100
(b) For cooling
water effluent,
10% above total
suspended matter
of influent
3 Particular size of Shall pass 850 (a) Floatable
Suspended Solids micron IS solids max. 3
Sieve mm
(b) Settleable
solids, max 850
microns
4 pH value 5.5 to 9.0 5.5 to 9.0 5.5 to 9.0 5.5 to 9.0 No. 4500- H+
Electrometric Method
5 Temperature Shall not Shall not exceed No. 2550 Laboratory and field methods
exceed 50C 50C above the
above the receiving water
--- ---
receiving temperature
water
temperature
6 Oil and Grease mg/l, Max 10 20 10 20 No.5520 Partition Gravimetric method
Extraction method for sludge samples
7 Total Residual Chlorine 1.0 - - 1.0 No. 4500-Cl Iodometric method- Amperotric titration
mg/l, Max. method
8 Ammonical Nitrogen (as 50 50 - 50 No4500- NH3 Primary distillation steps Titrimetric
43
STANDARDS
SL . INLAND MARINE
NO SURFACE COASTAL
SEWERS IRRIGATION
WATER AREAS
N), mg/l, Max. method Phenate method
9 Total Kjeldhal Nitrogen 100 - - 100 No. 4500 N-org Macro kjeldhal Method
(as NH3), mg/l, Max. Semimicro Kjeldhal Method
10 Free Ammonia (as NH3), 5.0 - - 5.0
mg/l), Max.
Chemical Oxygen No. 5220 Titrimetric method, Colorimetric method
12 250 - - 250
Demand, mg/l, Max.
Arsenic (as As), mg/l, No. 3500- As Atomic absorption spectrometric method
13 0.2 0.2 0.2 0.2
Max.
Mercury (as Hg), mg/l, No. 3500- Hg, Cold Vapour Atomic absorption Method,
14 0.01 0.01 - 0.01 .
Max. Dithizone Method
15 Lead (as Pb), mg/l, Max. 0.1 1.0 - 2.0 No. 3550-Pb AAS Method, Dithizone Method
Cadmium (as Cd), mg/l, No. 3550-Pb AAS Method, Dithizone Method
16 2.0 1.0 - 2.0
Max.
Hexavalent Chromium (as
17 0.1 2.0 - 1.0
Cr+6), mg/l, Max.
Total Chromium (as Cr), No. 3550-Cr, AAS Method, Colorimetric method, Ion
18 2.0 2.0 - 2.0
mg/l, Max. Chromatographic method
Copper (as Cu), mg/l, No. 3550-Cu, AAS Method, Neo cuproine Method
19 3.0 3.0 - 3.0
Max.
No. 3550-Zn, AAS Method, Inductively coupled plasma
20 Zinc (as Zn), mg/l, Max. 5.0 15 - 15
method, Dithizone Method, Zincon method
Selenium (as Se), mg/l, No. 3500- Se, Colorimetric method, Fluorometric method
21 0.05 0.05 - 0.05
Max.
No. 3550-Zn, AAS Method,
22 Nickel (as Ni), mg/l, Max. 3.0 3.0 - 5.0
Inductively coupled plasma method
Cyanide (as CN), mg/l, No. 4500, Titrimetric method, Cyanide- Selective
23 0.2 2.0 0.2 0.2
Max. Electrode Method, Colorimetric method
Fluoride (as F), mg/l, 4500- F-, Ion- selective electrode method
24 2.0 15 - 15
Max. Ion Chromatographic method
No. 4500- P Vandomolybdo phosphori acid
Dissolved Phosphates (as
25 5.0 - - - Colorimetric method
P), mg/l, Max. .
Stannous chloride method
44
STANDARDS
SL . INLAND MARINE
NO SURFACE COASTAL
SEWERS IRRIGATION
WATER AREAS
Ascorbic acid method
Sulphide (as S), mg/l, No. 4500- S2 Methylene blue method
26 2.0 - - 5.0
Max. Iodometric method, Ion selective electrode method
No. 6420 Liquid –Liquid extraction gas Chromatographic
Phenolic Compounds (as
27 1.0 5.0 - 5.0 method
C6H5OH), mg/l, Max.
Mass Spectrometric method
Radioactive materials: No. 7110 Evaporation method for grass alpha, beta
(a) Alpha emitter Micro 10-7 10-7 10-8 10-7
28 curie/ml
(b) Beta emitter Micro
10-6 10-6 10-7 10-6
curie/ml
90% survival
90% survival 90% survival 90% survival of
of fish after
of fish after 96 of fish after 96 fish after 96
29 Bio-assay test 96 hours in
hours in 100% hours in 100% hours in 100%
100%
effluent effluent effluent
effluent
No. 3500- Mn AAS Method
30 Manganese (as Mn) 2 mg/l 2 mg/l - 2 mg/l Inductively coupled plasma method
Persulphate Method
No. 3550-Fe AAS Method
31 Iron (as Fe) 3 mg/l 3 mg/l - 3 mg/l Inductively coupled plasma method
Phenanthroline method
No. 3550-V AAS Method
32 Vanadium (as V) 0.2 mg/l 0.2 mg/l - 0.2 mg/l Inductively coupled plasma method
Gallic acid method
4500- NO2- Ion Chromatographic method
33 Nitrate Nitrogen 10 mg/l - - 20 mg/l
Colorimetric Method
Dissolved Solids
34 2100 2100 2100 -
(Inorganic), mg/l, Max.
Sulphate (as SO.), mg/l, 4500- NO2- Ion Chromatographic method Gravimetric
35 1000 1000 1000 -
Max. method with ignition of residues Turbidimetric method
NOTE:
45
1. All efforts should be made to remove colour and unpleasant odour as far as practicable.
2. Parameters at Sl.No.34 & 35 are retained by the State Board, exercising Rule 3(2) of Environment (Protection) Rules, 1986.
3. Hydraulic loading of effluent for application on land for different soils are as under:
Sl.No. Soil Texture Loading Rate in

m3/Ha/Day
1 Sandy 225 to 280
2 Sandy Loam 170 to 225
3 Loam 110 to 170.
4 Clay loam 055 to 110
5 Clayey 035 to 055
Part B: Wastewater Generation Standards

Sl. No. Industry Quantum
2 Sugar 0.4 [m3 / tonne] of cane crushed
46
[SCHEDULE VII]
[See rule 3(3B)]
NATIONAL AMBIENT AIR QUALITY STANDARDS
Pollutant Time Concentration in ambient air (in ug/m3 Method of measurement

Weighted for all pollutants except carbon monoxide
average which is in mg/m3)
Industrial Residential Sensitive
Area Rural & Area
Other areas
Sulphur Annual 80 60 15 1. Improved West and Gaeke
(SO2) Average* Dioxide method.
24 Hours** 120 80 30 2. Ultraviolet fluorescence
Oxides of Annual 80 60 15 Jacob & Hochheiser
Nitrogen as Average* Modified (Na-Arsenite)
NO2 method.
24 Hours** 120 80 30 Gas Phase
Chemiluminescence.
Suspended Annual 360 140 70 (Average flow rate not less
Particulate Average* than 1.1 m3/minute)
Matter
24 Hours** 500 200 100
Respirable Annual 120 60 50
Particulate Average*
matter (size
less than 24 Hours** 150 100 75
10µm)
Lead (Pb) Annual 1.0 0.75 0.50 AAS Method after sampling
Average* using EPM 2000 or
24 Hours** 1.5 1.00 0.75 equivalent filter paper.
Carbon 8 hours** 5.0 2.0 1.0 Non-dispersive infrared

Monoxide Spectroscopy.
(CO) 8 hours** 5.0 2.0 1.0
* Annual Arithmetic mean of minimum 104 measurements in a year taken twice a

week 24 hourly at uniform interval.
** 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) Raw material consumption
Name of raw Name of products Consumption of raw material per unit of

materials output
during the previous during the current
* Industry may use codes if disclosing details of raw material would violate contractual
obligations, otherwise all industries have to name the raw materials used.
PART C
POLLUTION DISCHARGED TO ENVIRONMENT/ UNIT OF OUTPUT
(Parameter as specified in the consent issued)
Pollutants 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.)
(a) From process
(b) From Pollution control facilities
PART E
SOLID WASTES
Total quantity
(a) From process
(b) From pollution control facilities
(c) (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
b. Expected date of production:

7. Total number of employees expected to be employed.
8. Details of license, if any obtained under the provisions of Industrial
Development (Regulation) Act, 1951:
9. Name of the person authorized to sign this form (the original authorization
except in the case of individual/proprietary concern is to be enclosed).
10. (a) Attach the list of all raw materials and chemicals used per month.
(b) Licensed Annual Capacity of the Factory/Industry.
11. State daily quantity of water in kilolitres utilized and its source (domestic/
industrial/ process/ boiler / cooling/ others).
12. (a) State the daily maximum quantity of effluents and mode of disposal (sewer
or drains or river).
Also attach analysis report of the effluents. Type of effluent quantity in kilolitres,
mode of disposal.
i. Domestic
ii. Industrial
(b) Quality of effluent currently being discharged or expected to be discharged.
(c) What monitoring arrangement is currently there or proposed.
13. State whether you have any treatment plant for industrial, domestic or combined
effluents.
Yes/No
If yes, attach a description of the process of treatment in brief. Attach information
on the quality of treated effluent vis-à-vis the standards.
14. State details of sold wastes generated in the process or during waste treatment.
Description Quantity Method of collection Method
of disposal
I/We further declare that the information furnished above is correct to the best of my/our
knowledge.
I/We hereby submit that in case of change either of the point of discharge or the quantity of
discharge or its quality, a fresh application for CONSENT shall be made and until such
CONSENT is granted no change shall be made.
I/We hereby agree to submit to the Central Board an application for renewal of consent one
month in advance of the date of expiry of the consented period for outlet/ discharge if to be
continued thereafter.
I/We undertake to furnish any other information within one month of its being called by the
Central Board.
I/We enclose herewith cash receipt No./bank draft No………………………. dated
…………………... for Rs…………...…..
(Rupees…………………………………………………………………......) in favour of the
Central Pollution Control Board, New Delhi, as fees payable under section 25 of the Act.
Yours faithfully,
Signature of the applicant.
[Note: *Strike out which is not relevant.]
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 Purpose for which Reading at the Reading at the

Address of the water consumed beginning of the end of the last day
consumer first day of calendar of calendar month
month under report under report
1 2 3 4
Quantity of water If the meter was out Quantity of water Remarks*
consumed in of order the qualifying for rebate
kilolitres monthly average according to the
consumption of assessee
water for the
previous 3 months
of the working
period
5 6 7 8
1. Industrial cooling spraying in mine i. from Municipal water supply mains
pits or boiler feed. ii. from well/ tube-well
iii. from canal
iv. from river
v. from any other source
2. Domestic purpose. i. from Municipal water supply mains
ii. from well/ tube-well
iii. from canal
iv. from river
3. Processing whereby water gets i. from Municipal water supply mains
polluted and the pollutants are easily ii. from well/ tube-well
bio-degradable. iii. from canal
iv. from river
4. Processing whereby water gets i. from Municipal water supply mains
polluted and the pollutants are not ii. from well/ tube-well
easily bio-degradable and are toxic. iii. from canal
iv. from river
Signature of the consumer.............................

Name………………………………………..
Address……………………………………..
* 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 perfor-
under 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
A NNEXURE ……. M AINTAINING L OG B OOKS

Log Book 1: Log Book for Daily Water Balance Sheet (Volume m3)
Mode of Abstraction WATER INTAKE
of Water 1/2/04 2/2/04 3/2/04 4/2/04 5/2/04 6/2/04 7/2/04 … …
Tanker
Surface Water
Ground Water
Piped Water
Rain Water (harvested)
Total
Mode of Use of Water WATER CONSUMPTION

of Water 1/2/04 2/2/04 3/2/04 4/2/04 5/2/04 6/2/04 7/2/04 … …
Process
Cooling
Domestic
Water Sprinkling
systems
Total
54
Log Book 2: Log Book for Daily Resources Balance Sheet (Weight Kg)
Type of Raw material RAW MATERIAL INTAKE DATES
used 1/2/04 2/2/04 3/2/04 4/2/04 5/2/04 6/2/04 7/2/04 … …
Total
Type of Products PRODUCTION DATES

manufactured 1/2/04 2/2/04 3/2/04 4/2/04 5/2/04 6/2/04 7/2/0 … …
4
Total
Note:For only mining projects the products includes the ore which is transported
55
Log Book 3: Log Book for Daily Energy Balance Sheet (Kilowatts)
Source of Energy ENERGY INTAKE DATES
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 ENERGY CONSUMPTION DATES

1/2/04 2/2/04 3/2/04 4/2/04 5/2/04 6/2/04 7/2/04 … …
Process
Cooling
Air Pollution Control
Devices
Water Pollution Control
Devices
Water Sprinkling systems
Total
56
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 PRODUCT PRODUCED

[i] [ii]
Type of Raw material Weight Type of Product Weight
used (Kg) 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

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Standard Operating Procedures

2 LEGAL AND REGULATORY FRAMEWORK

LIST NAME SUBJECT SUBJECT

6. Protecting the scenic landscapes, areas of geomorphological significance, unique

3 RESPONSIBILITIES OF THE SUGAR INDUSTRY AUTHORITIES

4 WATER AND AIR (PREVENTION & CONTROL OF POLLUTION) ACTS

5 WATER (PREVENTION & CONTROL OF POLLUTION)

6 ENVIRONMENTAL STATEMENT PROCEDURES

Environmental Management in industries hitherto based on and off pipe waste

7.2 AUDIT PROCEDURE

A step-by-step methodology for Environmental Audit as recommended by the United

Phase 1: Pre-Assessment AUDIT PREPARATION

Phase 2: Material Balance

DESERVE A MATERIAL BALANCE

IDENTIFY WASTE REDUCTION OPTIONS

EVALUATE WASTE REDUCTION OPTIONS

Quick Reference Audit Guide

8 CHARTER ON CORPORATE RESPONSIBILITY FOR ENVIRONMENTAL

10 TYPES, SOURCES, AND NATURE OF POLLUTION FROM SUGAR INDUSTRY

burning air pollutants fibres

10.2 POLLUTION EFFECT

10.3 GOOD OPERATING PRACTICES

10.4 STEPS TO BE TAKEN AT DIFFERENT STATIONS OF A SUGAR MILL IN ORDER TO

10.5 GOOD HOUSEKEEPING PRACTICES – DO’S & DON’TS

Table 10.4: Good Housekeeping Practices - Do's & Don’ts

activities • Check pipes/valves/pumps/nozzles for leakage/losses and spillage.

SR. IMPLEMENTING OBJECTIVE OF ACTS OR KSPCB’S

STANDARDS FOR DISCHARGE OF EFFLUENTS FOR SUGAR INDUSTRY

Noise Limit for Generator Sets run with Petrol or Kerosene

Automotive Research Association of India, Pune;

Schedule III: (See rule 3)

Area Code Category of Area Limits in dB (A) Leg.

Note- 1 Day time is reckoned in between 6 a.m. and 9 p.m.

Schedule VI: (See rule 3(3A))

Sl.No. Soil Texture Loading Rate in

Part B: Wastewater Generation Standards

Pollutant Time Concentration in ambient air (in ug/m3 Method of measurement

Carbon 8 hours** 5.0 2.0 1.0 Non-dispersive infrared

* Annual Arithmetic mean of minimum 104 measurements in a year taken twice a

(ii) Raw material consumption

Name of raw Name of products Consumption of raw material per unit of

Impact of the pollution abatement measures taken on conservation of natural

Additional measures/ investment proposal for environmental protection including

Any other particulars for improving the quality of the environment.

b. Expected date of production:

Name and Purpose for which Reading at the Reading at the

Signature of the consumer.............................

End. : Original Analysis report of Laboratory.

A NNEXURE ……. M AINTAINING L OG B OOKS

Mode of Use of Water WATER CONSUMPTION

Type of Products PRODUCTION DATES

Energy Consumption ENERGY CONSUMPTION DATES

Format 1 (VG1): Verification Guidelines on Resource Auditing Aspects

WATER INTAKE WATER CONSUMPTION

B. Monthly Raw material consumption

RAW MATERIAL INTAKE PRODUCT PRODUCED

C. Monthly Energy Balance Sheet

ENERGY INTAKE ENERGY CONSUMPTION

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