SOP Sugar Industries EMPRI 2005 01

Standard Operating Procedures
For
Sugar Industry
A Draft Report
January 2005
Environmental Management
B:
Policy Research Institute
TABLE OF CONTENTS
ITEM
1
CHAPTER
INTRODUCTION
1.1
1.2
2
2.1
2.2
2.3
2.4
2.4.1
2.4.2
2.4.3
2.4.4
2.4.5
2.4.6
2.4.7
2.4.8
2.4.9
2.5
2.5.1
2.5.2
2.6
2.6.1
2.6.2
2.6.3
3
3.1
3.2
4
4.1
5
6
6.1
7
7.1
Background
Gist Of Environmental Acts, Rules And
Notifications
LEGAL AND REGULATORY FRAMEWORK
Fundamental Rights And Duties Of A
Citizen
State Policy
Legislative Authority
Relevant Legislations
Factories Act, 1948
Environment Protection Act 1986.
The Water (Prevention And Control Of
Pollution) Act, 1974 And Rules
The Water (Prevention And Control Of
Pollution) Cess Act, 1977 And Rules
The Air (Prevention And Control Of
Pollution) Act, 1981 And Rules
The Environment Impact Assessment
Notification 1994 & 1997
The Noise Pollution (Regulation And
Control) Rules, 2000
The Hazardous Waste (Management &
Handling Rules), 2000
The Manufacture, Storage and Import of
Hazardous Chemicals Rules, 1989
Relevant Policies
The National Environmental Policy
The National Industrial Policy
Relevant Institutions
Ministry Of Environment And Forest,
Government Of India
Department Of Ecology And Environment,
Government Of Karnataka
Karnataka State Pollution Control Board
RESPONSIBILITIES OF THE SUGAR
INDUSTRIES
Approvals
Responsibilities
WATER AND AIR (PREVENTION & CONTROL
OF POLLUTION) ACTS
Consent Procedure
WATER (PREVENTION & CONTROL OF
POLLUTION) CESS ACT
ENVIRONMENTAL STATEMENT PROCEDURES
Contents Of Environmental Statement
ENVIRONMENTAL AUDITING
Features Of A Good Environmental Audit
PAGE
NUMBER
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3
3
4
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7
8
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14
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ITEM
7.2
CHAPTER
Audit Procedure
CHARTER ON CORPORATE RESPONSIBILITY

FOR ENVIRONMENTAL PROTECTION (CREP)
ENVIORONMENTAL PERFORMANCE
VERIFICATION EXERCISE
TYPES, SOURCES AND NATURE OF POLLUTION
FROM SUGAR INDUSTRY
9
10
10.1
10.2
10.2.1
10.2.2
10.2.3
10.2.4
10.3
10.4
10.4.1
10.4.2
10.4.3
10.4.4
10.4.5
10.4.6
10.4.7
10.4.8
10.4.9
10.4.10
10.4.11
10.5
PAGE
NUMBER
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18
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19
Process involved in Sugar Industry

Pollution Effect
Wastes Water
Solid Waste
Air Pollutants
Molasses
Good Operating Practices
Steps To Be Taken At Different Stations Of
A Sugar Mill In Order To Reduce The
Pollution
Cane Yard & Cane unloading section
Cane carrier section
Milling Station
Boilers - Boiler operation, Boiler Ash
Clarification & Evaporation Station
Entrainment from Pans and Evaporator
-------------------------
19
21
21
21
21
21
22
22
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23
23
23
24
24
25
Sulphitation
Liming Station
Crystallization Station
Segregation of Effluents
General Points
Good Housekeeping Practices Dos &
Donts
Appendix I
Appendix II
Appendix III
Appendix IV
Annexure Maintaining Log Books
Verification Guidelines
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26
26
26
27
27
27
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34
36
38
48
54
57
Standard Operating Procedures for Sugar Industries
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
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 States 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
52
Industries
I
Union
53
Regulation and development of
List
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
6
Public health and sanitation
II
State
2
LIST
NO.
NAME
List
SUBJECT
NO. IN
LIST
14
SUBJECT
Agriculture, protection against
pest and prevention of plant
diseases
Land, colonization, etc.
Fisheries
Regulation of mines and mineral
development subject to the
provision of List I
Industries subject to the
provision of List I
Forests
Protection of wild animals and
birds
Economic and social planning
Population control and family
planning
18
21
23
24
III
Concurrent
List
17 A
17 B
20
20 A
The Parliament has powers to legislate on subjects not covered by the three Lists [Article
248].
The Parliament is also empowered to legislate in the national interest on matters
enumerated in the State List [Article 249].
In event of a conflict between the Central law and State law on a concurrent subject the
former prevails [Article 254 (1)].
In case of a State law passed subsequent to the Central law, the State law shall prevail in
that State only if it has received Presidential Assent under Article 254 (2) of Part XI of
Constitution.
From an environmental standpoint, the allocation of legislative authority is an
important one as some environmental problems such as sanitation and waste disposal are best
tackled at local level, while others like water pollution and wildlife protection are better
regulated by uniform national laws.
2.4 RELEVANT LEGISLATIONS
As stated earlier, the working environment within the factory is regulated by the Factories
Act, 1948 while the environment (air & water emissions, noise, waste) are governed by
environmental legislations.
2.4.1 Factories Act, 1948.
The Factories Act, 1948 sets the duties of the occupier to maintain the safety and
health of all workers at work.
The occupier of every factory involving a hazardous process shall disclose all
information regarding dangers, including health hazards and the measures to overcome such
hazards arising from the exposure to or handling of the material or substances in the
manufacture, transportation, storage and other processes to the workers employed in the
factory, the Chief Inspector, the local authority within whose jurisdiction the factory is situate
and the general public in the vicinity. The occupier of the factory shall draw up an on-site
3
emergency plan and detailed disaster control measure for his factory and make it known to all
stakeholders.
For factory involving a hazardous process or for the expansion of any such factory,
the State Government may appoint a Site Appraisal Committee. The committee would
examine application from the proponent and given recommendations. Where the State
Government has granted approval to an application for the establishment or expansion of a
factory involving hazardous process, it shall not be necessary for an applicant to obtain a
further approval from the Central Board or the State Board established under the Water
(Prevention and Control of Pollution) Act, 1974 and the Air (Prevention and Control of
Pollution) Act, 1981.
2.4.2 Environment Protection Act 1986.
The Environment Protection Act 1986 section 3 provides for fixing standards for
emission or discharge of environmental pollutants. The standards of emissions or
discharge of environmental pollutants from the industries, operations or processes shall
be as specified in (schedules 1 to IV). Since the KSPCB is not insisting on any of the
provisions while issuing the consent only the EIA needs to be done to get the licenses.
2.4.3 The Water (Prevention and Control of Pollution) Act, 1974 and Rules
As per this Act the occupier or the operator of a mining activity has to fulfil the
following obligations and duties to protect the environment and to prevent any
environmental damage or pollution. Act makes it mandatory the occupier to discharge any
trade effluent to the land or water body by treating it to the level of the standards prescribed
by the Regulatory authority. (the standards are given in the annexure). Any violation of
this section attracts legal action under the section 41 to of the Water Act.
2.4.4 The Water (Prevention and Control of Pollution) Cess Act, 1977 and Rules
The purpose of Water (Prevention & Control of Pollution) Cess Act is levy and
collect cess on water consumed by 16 categories of industries specified in the act and also by
local bodies with a view to augment the resources of the Central and State Pollution Control
Boards. Water cess is levied based on the water consumed for domestic and specified
industry.
2.4.5 The Air (Prevention and Control of Pollution) Act, 1981 and Rules
The objective of this Act is to provide for the prevention, control and abatement of air
pollution, for the establishment, with a view to carrying out the afore said purposes, of
boards, for conferring on and assigning to such boards powers and functions relating thereto
and for matters connected therewith. Decisions were taken at the United Nations Conference
on the Human Environment held in Stockholm in June 1972, in which India participated, to
take appropriate steps for the preservation of the natural resources of the earth which among
other things, includes the preservation of the quality of air and control of air pollution.
The Central and State Pollution Control Boards are entrusted to perform the functions
under the Act. As per the Act, Air Pollution is defined means the presence in the atmosphere
of any air pollutant. Air pollutant means any solid, liquid or gaseous substance (including
noise) present in the atmosphere in such concentration as may be or tend to be injurious to
human beings or other living creatures or plants or property or environment.
The primary responsibility of controlling air pollution is on the Board. The very first
measure to be adopted in this respect is the declaration of any area or areas within the State as
air pollution control area. In respect the Sate government has declared entire State as air
pollution control area. The air pollution from industrial plants is controlled through consent
mechanism by stipulating standards in respect of air pollutants. In case of non compliance,
the act has made provisions for issuing directions to any person, officer or authority, and such
4
person, officer or authority shall bound to comply with such directions. Power to issue
direction includes the power to direct:
Closure, prohibition or regulation of any industry, operation or process or
The stoppage or regulation of supply of electricity, water or any other service
In addition to this, Provisions exist to make application to courts for restring persons
from causing air pollution and punish the offender with imprisonment and fine.
2.4.6 The Environment Impact Assessment Notification 1994 & 1997
As per the notification it is mandatory on part of 30 categories of industries (list given
below) to obtain environmental clearance from Ministry of Environment and Forest, GOI
before establishment or expansion or modernization. It should be noted that sugar industries
do not have to obtain clearance.
2.4.7 The Noise Pollution (Regulation and Control) Rules, 2000
The State Government shall categorize the area into industrial, commercial,
residential or silence area/zones for the purpose of implementation of noise,
standards for different area. The ambient air quality standards in respect of noise
for different areas/zones shall be such as specified in the Schedule annexed to these
rules.
The noise levels in any area/zone shall not exceed the ambient air quality standards in
respect of noise as specified in the Schedule.
The authority shall be responsible for the enforcement of noise pollution control
measures and the due compliance of the ambient air quality standards in respect of noise.
2.4.8 The Hazardous Waste (Management & Handling Rules), 2000
These rules apply to handling of hazardous wastes specified in the Schedules 1, 2, &
3 of the rules. These rules do not apply to waste water and exhaust gases as covered
under the provisions of the Water and Air Act and Rules made there under, wastes
arising out of the operation from ships beyond five kilometers as covered under the
provisions of the Merchant Shipping Act and radioactive wastes covered under the
provisions of the Atomic Energy Act.
2.4.9 The Manufacture, Storage and Import of Hazardous Chemicals Rules, 1989
These rules apply to any industrial activity in which a hazardous chemical (criteria
given in Schedule 1 of the Rules) is involved and where the isolated storage of a
hazardous chemical is equal to or more than the threshold quantity specified (chemical and
threshold listed in Schedule 2 of the Rules). The rules also specify the responsibility of the
occupier to provide evidence to show that he has identified the major accident hazards and
also taken adequate to prevent major accidents and provide adequate information, training,
and equipment including antidotes necessary for safety. In case of a major accident occurring
on the site or pipelines the occupier should notify the concerned authorities (Schedule 5 of
the Rules, also see annexures)
2.5 RELEVANT POLICIES
The following list of the policies related to environment and sugar industries:
1. The National Environmental Policy
2. The Industrial Policy, 1991
3. The Policy Statement for Abatement of Pollution, 1992
4. The Export-Import Policy, 1997
It is evident that the Policies being pursued presently have been evolved with
experience and with the considerations of various national and international developments
5
and the country's requirements for development. The Policies outline the guiding principles
for the various developmental and industrial activities.
2.5.1 The National Environmental Policy
Although since long there was a concern for the environmental management in the
country as evident from the various Policies and Legislation the lead was given in the Sixth
Plan when a Chapter on 'Environment and Development' was included in the Plan document.
The Chapter laying emphasis on the problems of environmental degradation provided
guidelines to the administrators for formulating and implementing the development programs
incorporating environmental concerns and laying down the institutional arrangements for
environmental management, administration and protection. The Eighth Plan on the basis of
the overview of the environmental and forest scenario identified the eight major tasks to meet
the challenge of environmental degradation.
To complement the Constitutional sanctions, outlines earlier, MoEF in 1992 brought
out a Policy Statement for Abatement of Pollution and the National Conservation Strategy
and Policy Statement on Environment and Development which provides instruments in the
form of legislation and regulation, fiscal incentives, voluntary agreements, educational
programs and information campaigns for preventing, controlling and reducing environmental
pollution. The overall objective of the Policy was to integrate environmental considerations
into decision making at all levels and to achieve this, the following specific steps were
identified.
1. Prevent pollution at source.
2. Encourage, develop and apply the best available practical solutions.
3. Ensure that polluter pays for the pollution control arrangements.
4. Focus protection on heavily polluted areas and river stretches.
5. Involve public in decision making.
6. Increase the safety of industrial operations.
The MoEF issued the Environmental Action Program in 1993 with the objective of
integrating the environmental concerns into the process of development. The various issues
addressed were reducing pollution at source, assistance for adaptation of the best available
and practicable technologies, mass based standards, fiscal measures, environmental audit,
environmental statistics, and public participation.
The National Conservation Strategy and Policy Statement on Environment and
Development, 1992 formulated with a view to reinforcing traditional ethos and to building up
a conservation society living in harmony with nature and making efficient use of the
resources guided by the best available scientific and technical knowledge aimed at the
following.
1. Ensuring sustainable and equitable use of the resources for meeting the basic needs
of the present and future generations without causing damage to the environment.
2. Preventing and controlling the future deterioration of the life support systems.
3. Taking steps for restoration of ecologically degraded areas and for environmental
improvement in the rural and urban settlements.
4. Ensuring that the developmental projects are correctly cited with least adverse
environmental consequences.
5. Conserving and protecting the coastal areas and marine eco-systems.
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.
The New Industrial Policy lays stress on the following for the sustained development
and growth of the industry in the country.
1. Substantial reduction in the scope of industrial licensing.
2. Simplification of procedures, rules and regulations.
3. Reforms in the Monopoly and Restrictive Trade Practices Act.
4. Reduction of the areas reserved exclusively for the public sector.
5. Disinvestment of selected public sector enterprises.
6. Enhancing limits of foreign equity participation in domestic industrial undertakings.
7. Liberalization of trade and exchange rate policies.
8. Rationalization and reduction of customs and excise duties.
9. Extension of the scope of modified value added tax (MODVAT).
2.6 RELEVANT INSTITUTIONS
Three departments are directly involved in the protection of environment due to
sugar industries in the state, including the Ministry of Environment and Forest, Govt.
of India; The Department of Forests, Ecology and Environment, Govt. of Karnataka; and
Karnataka State Pollution Control Board
2.6.1 Ministry of Environment and Forest, Government of India
Ministry of Environment and Forest (MoEF) is the nodal agency at national level, in
the administrative structure for environmental protection and forest conservation. MoEF is
assisted by the Central Pollution Control Board (CPCB), a statutory authority at the central
level in executing responsibilities of prevention and control of pollution. Implementation of
relevant Acts and Rules and policy issues at the State level is overseen by the State Pollution
Control Boards (SPCB) and the State Department of Environment and Forest (DOEF). The
governing Acts and Rules are: Environment Protection Act-1986, Forest Conservation Act1980 and rules there under.
2.6.2 Department of Ecology and Environment, Government of Karnataka
Department of Ecology and Environment (DEE) is the state nodal regulating agency
responsible for environmental management of the state and can exercise promotional and
regulatory functions in mining sector under the Air, Water and Environment Protection and
Forest Conservation Acts. The department also houses the State Environmental Clearance
Committee (SECC) which gives clearances to projects. The applications seeking
environmental clearances as per the EIA notifications are routed through DEE.
2.6.3 Karnataka State Pollution Control Board
KSPCB has regulatory and enforcement responsibilities with respect to air, water
pollution control and hazardous waste management in mines under the Water (Prevention &
Control of Pollution) Act, 1974, the Air (Prevention & Control of Pollution) Act, 1981 and
rules there under, the Environment Impact Assessment Notification, 1994 & 1997 and
Hazardous Waste (Management & Handling) Rules, 1989 & amendments rules 2000.
KSPCB is responsible for conducting public hearing under Environmental Impact
Assessment (EIA) notification for any developmental or new projects, including the mining
sector.
At present the Karnataka State Pollution Control Board is issuing consent to the
mining industries with only the stipulations for treating domestic wastewaters, as there is no
generation of any trade effluent from any mining activity. However, in case where
purification and beneficiation of the ore is to be taken up at the mining area, prior consent
from the KSPCB should be taken and in such cases consent conditions for the disposal of
trade effluents will be specified by the Board. Under The Air (Prevention and Pollution
Control) Act, at present no compliance provision are indicated in the consent letter. However
8
the following Acts that are still valid and applicable are discussed here as they are relevant to
the sector. The Standards of Service of Karnataka State Pollution Control Board are given in
Annexure I.
2.6.3.1 Condition prescribed by the KSPCB in the Consents to Establish and Operate
1. The maximum quantity of water consumed in a sugar factory shall not exceed 2 cubic
meter per tonne of cane crushed.
2. The factory shall ensure treatment of all the wastewater generated in the factory
before it is discharged.
3. The treated water shall be used in the irrigation and shall not be discharged into the
stream or water bodies.
4. The application of the treated effluent shall be controlled so as to avoid either
flooding of land or ground water contamination. Before allowing the usage of treated
water for irrigation the State Pollution Control Board shall ensure that the factor shall
submit a report on geophysical characteristics and assimilation capacity of land.
Adequate number of bore wells shall be provided by the factory in and around the
irrigated area to monitor ground water quality.
5. Chimneys of required height and other air pollution controlling equipments should be
provided by the factory.
6. Biogases shall be collected and stored properly by the factory to avoid the fugitive
emissions.
7. The factory shall ensure that the noise levels are within the stipulated limits and shall
conduct periodic monitoring of noise levels at a designated location at specified
intervals.
8. Press mud generated can be sold without treatment. However in case it is not sold it
shall be collected composted within the factory under the supervision of the factorys
scientists.
9. Lime sludge shall be collected and disposed off by the factory scientifically.
10. Ash from the boilers shall be collected and disposed off by the factory scientifically.
11. The factory shall install water meters to measure the water consumed for different
purposes as per the Water (Prevention and Control Pollution) Cess Act, 1977; as
amended and pay water cess.
12. The factory shall submit an Environmental Statement Report for the financial year
ending the 31st March in the prescribed format to the state to the state pollution
control board on or before the 30th day of September every year beginning 1993.
13. All tanks used for the storage and treatment of effluent shall be made impervious by
providing adequate cement concrete/stone masonry/ stone slab lining with leak proof
joints in the bottom and sides. Observation bores with pipes shall be provided around
such tanks and monitored for leakage.
14. The factory shall store the molasses generated in adequately sized steel tanks
provided with the roof cover.
15. The factory shall upgrade the pollution control systems as and when new technologies
become available.
16. The factory shall ensure continuous and effective operation and maintenance of
pollution control systems by employing qualified engineers.
17. The factory shall ensure continuous and uninterrupted power supply to see that the
pollution control systems functions uninterruptedly. Separate energy meter shall be
provided for the pollution control system.
18. A fully equipped laboratory shall be established by the factory with appropriate
equipments to monitor the performance of pollution control systems and to test the
effluents, emissions and soil for pollution related parameters.
9
19. Every new factory shall submit the Environment Impact assessment report and
Environmental management plan to the state pollution.
20. If the occupier has not taken consents under the Water (prevention and pollution
control) Act 1974 and the Air (prevention and control of pollution) Act 1981, and the
clearance under the Environment (protection) Act 1986, he shall not be allowed to run
the factory. Action shall be taken by writing to the concerned Departments to stop
supplies such as electricity, water etc.
21. For convenience the standards stipulated by the Karnataka sate pollution control
Board both under the water (prevention and control of pollution) Act 1974 and the Air
(prevention and control of pollution) Act 1981 for the effluents and emissions
discharged respectively are given below.
The standards for effluents and emissions discharged from sugar industry.
1 Effluent.
Concentration
not
to
exceed
Milligram/lit
Bio-chemical oxygen Demand.
100 for disposal on land.
Suspended solids
100 for disposal on land.
2 Emissions.
Bagasse-fired Boilers.
250
Horse shoe/pulsating Grate.
500 (12% CO2).
Spreader stroker.
800 (12% CO2).
10
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.
11
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
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
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 companys 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 industrys 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
ENVIRONMENTAL AUDITING
Environmental Audit has become a step to comply with the requirement to furnish the
Environmental Statement, though the importance of Environmental audit lies in achieving
increased productivity and reduced waste generation. Auditing in general is a methodical
examination involving analysis, tests and confirmation of local procedures and practices
whose goal is verify whether they comply with legal requirements, internal polices and
accepted practices. Auditing differs from assessment in that it requires collection and
documentation of competent and sufficient evidence rather than an opinion based primarily
on professional judgement.
Environmental Audit is a technique being introduced for integrating the interest of
the industry and the environment so that there could be mutually supportive. This technique
is basically a part of industrys internal procedures to meet their responsibilities towards
better environment. Environment Auditing is a management tool comprising a systematic
documented periodic and objective evaluation of how well the management systems are
performing with the aim of:
Waste preventive and reduction
Assessing compliance with regulatory requirements
Facilitating control of environmental practices by a companys management, and
Placing environmental information in the public domain.
Environmental Audit in India is different from that in developed countries and the
definition of International Chamber of Commerce (ICC) is accepted. ICC defines
Environmental Audit is It is a management tool comprising a systematic, documented,
periodic and objective evaluation of how well environmental organization, management and
equipment are performing with the aim of helping to safe guard the environment by:
Facilitating management control of environmental practices.
Assessing compliance with company policies, which would include meeting,
regulatory requirement.
Environmental Statement which is a part of the Environmental Audit.
Environment Policy means a statement of a companys overall aims and principles
of action with respect to the environment.
7.1 FEATURES OF A GOOD ENVIRONMENTAL AUDIT
A good Environmental Audit
defines sources, quantities & types of waste generation
Collates information on unit operations, raw materials, products, water usage and
wastes and increases knowledge of the process.
Highlights process deficiencies and poor management
Helps to set targets for waste reduction
Permits the development of effective waste management strategies.
Rises awareness in the workforce regarding the benefits of waste reduction
Helps to improve process efficiency
Enables legislative compliance & avoids litigation.
7.2
AUDIT PROCEDURE
15
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

waste reuse/recycling
Step 9 Account for gaseous emissions

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
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 industryspecific interaction meetings organised by the Ministry of Environment and Forests. During
interaction meetings, the representatives of some industrial sectors sought extension of time
to meet the regulatory norms because of techno-economic constraints. In case of units falling
in such industrial sectors, time bound action has been proposed in the Charter. This measure
has been agreed on the understanding that a bank guarantee would be furnished by the
concerned units indicating the commitment to the action plan. However, this is without any
prejudice to the stipulations made in the existing standards and action already taken/initiated
for non-compliance and area-specific requirements warranting stringent actions. The
industrial units which are not complying with the national standards notified under the
Environment (Protection) Act, 1986, will submit action plan to meet the standards and bank
guarantee to respective State Pollution Control Board within 3 months (by June, 2003). The
Maharashtra Pollution Control Board on 03.01.2003 held the consultation for sugar industries
at Mumbai. Following are the stipulations for Sugar Industries
1. Waste Water Management
Operation of ETP shall be started atleast one month before starting of cane crushing to
achieve desired MLSS so as to meet the prescribed standards from day one of the
operation of mill.
Reduce wastewater generation to 100 litres per tonne of cane crushed by April 2004.
To achieve zero discharge in inland surface water bodies by December 2004.
To provide 15 days storage capacity for treated effluent to take care of no demand for
irrigation by April 2004.
2. Emission Control
To install ESP/bag filter/high efficiency scrubber to comply with standards for particulate
matter emission to <150 mg/Nm3 by April 2004.
17
ENVIRONMENTAL PERFORMANCE
VERIFICATION EXERCISE
Though the sugar industries do not have to obtain clearance under the EIA
Notification, the sugar industries are required to submit yearly Water Cess Returns and
Environmental Statement to the concerned State Pollution Control Boards. As of now,
there is no provision to analyse the Environmental Statement which is submitted yearly.
However, this is an important step which would not only give the yearly compliance but also
the status of the environment over a period of time.
In this chapter we are suggesting the following activities which would provide a rigorous
analysis of environmental statement submitted by the sugar industries and develop an
effective institutional arrangement for implementing Environmental Audit in the state.
1. Verification of Environmental Audit by the Sugar Industry
2. Verification of Environmental Audit by the Regulatory Authorities
3. Verification of Environmental Audit by the Third Party
For the verification process the following steps are suggested:
Step 1: Verification of maintenance of Log Books
Step 2: Verification of maintenance of Yearly Resource Auditing Books
Step 3: Verification of compliance of Environmental Plan and Consent Aspects
Step 4: Verification of Environmental Aspects
Step 5: Verification of Environmental Statement in line with the data provided
18
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.
No
1
2
Source
Cane yard
unloading and
carrier section
Mill House
(milling
section)
Bagasse
handling
Activities causing
pollution
Resulting form
of waste
Unloading of cane, cow

dung etc
Cane trash, cut

pieces, cow dung
etc
Containing oil,
grease and sugar
juice from spills
and leaks,
overflows
Bagasse dust
particulate on
Continuous gland cooling

and intermittent floor
washings spill over from
leakage of grease and oil
from bearings.
Movement of bagasse
through conveyors
19
Vol m3/
tonne of
cane
-
Parameters of
concern
Suspended solid,
odour, foul smell
0.03 to
0.05
Suspended solids,
oil and grease foul
smell
Dust particles,
suspended solids
burning
4
5
6
Boiler house
and boiler
section
Boiler blow down, boiler

station fuel (bagasse)
Clarification
section rotary
filter
Evaporator &
Pan Boiling
Washing
(juice heaters,
pan
evaporators
cleaning)
Evaporators,
centrifugal
house, pumps,
pipes, floor
washings,
molasses
spillover etc
Sulphur &
lime houses
Periodical washings,
overflows spillage etc
Pump leakage,
entrainments, through
vapours from pan boiling
and evaporator (mill
overloading) & poor
operating condition)
Washings from scale
removal & cleaning
Occasional spills and leaks

due to poor house keeping
and maintenance.
Overflows
Washings of sulphur and

lime houses
10
Molasses
storage tanks
(pan house)
Poor storage handling,

leakage & overflows from
tank
11
Sugar house
Transportation through
conveyors (Movement),
packing process etc
air pollutants fibres

(un burnt)
TDS, Ash can be
used for
agricultural lands.
Particulate matter
from chimney
SS, TDS, BOD,
COD
Waste with
inorganic salt
generation
Boiler ash
0.03
Waste contains
inorganic &
organic matter
Sugar loss into
condensate
pollutes water
0.04
-
BOD effluent
loading
Waste
discharged into
drains (high
inorganic & low
organic content)
Waste
discharged into
drains
TDS, BOD effluent

loading
Very high SS,

BOD, oil and
grease
Inorganic waste
water,
carbonates/
sulphates
Pollution load of
effluents is
increased (too
much)
Sugar dust
TDS
Very high BOD &

COD
Dust, sugar loss
0.01
Note: Spray pond and cooling water overflows and condensates are not included since these can be
recycled/reused and any surplus flowing out will be mixed with the treated effluent.
The effluents of intermittent and regular nature from different sources are shown in
Tables below:
Table 10.2: Sources of Waste Water Generation
Regular
Sources
Mill House Effluent
Parameters of concern
SS, O & G
Spray Pond
Overflow
TDS, BOD,
COD
Floor Washings
SS, BOD, O & G
Boiler Blow
Down
TDS
Intermittent
Sources
Pump
Leakage
Overflows
Excess
Condensat
e
Soda and
Acid Wash
Waste
Sulphur &
Lime House
Molasses
Spillage
(Prohibited)
Parameters of
concern
BOD
BOD
BOD
TDS, BOD
TDS
Very high
BOD &
COD
20
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
1.
Good operating practices

Waste segregation/
separation
Preventive maintenance
Training and awareness

building programme
Effective supervision
Employee participation
Production scheduling
Cost allocation and

accounting
Nature of activity for pollution prevention

Prevent mixing of wastes of low, medium and high
concentration
Isolate liquid waste from solid wastes
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.
Provide training to employees/staff for:
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.
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.
Use Quality Circles (free forums/ groups between
employees and operators, supervisors) to identify
ways and methods to reduce wastes.
Optimise production rates (crushing rate) to reduce
wastage, overflows and other losses and to maintain
high efficiency at all stations.
Charge direct and indirect costs of all air, land and
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
Low Pollution
No Pollution
i) Effluent flowing out of mill station

ii) Floor washings of clarification station
iii) Floor washings of boiling, crystallization and centrifugal
house.
i) Laboratory washings etc
ii) Normal cleaning and floor washings etc
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 DOS & DONTS

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 & Donts

Waste origin/
Sections
Before milling i.e. cane
receiving cane yard,
can unloading cane
carrier section
Waste type
Pollution prevention measures mainly from the point of Good Housekeeping
Donts
Inadvertent spills, can

pieces (small) and
wastage, cow dung
Use just in time ordering system

Maintain a clean, even surface in yard area
Inspect material (cane) for quality, quantity etc., before unloading
Concrete road for vehicles/ carts to stand and automatic unloading of can will
reduce spillage
Set up written procedure for loading/ unloading
Remove cane trash and cow dung then and there
Failing cut cane pieces/powder must be removed from below the cane carrier.
Dont overload
Do not mix up many operations
at the same time.
Do not allow to accumulate can
trash material and cow dung
Do not allow water seepage in
this
area
under
any
circumstances
Mill Section
Effluent
continuous
gland cooling and
intermittent
floor
washings, leakage of
oil, grease and spill
over, leakage of juice,
leakage of bearing
cooling water, spillage
of bagasse and can
juice from rollers,
whirling
tanks,
pipelines, overflow of
juice from whirling
tanks.
do not hold waste water for long

at one place.
Do not allow to get mixed oil,
grease, juice and water waste.
Do not keep drains open. Let it
be closed with proper slope and
lining.
Do not use excess oil and grease
Avoid improper application of
lubricants.
O/G pit should not be much
away from the mill
Do not use too much of water
for mill washings
Do not use overdoses of
disinfectants.
Juice Dilution and

Chemical areas of
work
Tank bottoms: off spec

and excess material;
spill residues leaking
vessels, pumps, valves,
tanks, pipes, damaged
containers,
dirt
accumulation,
floor
hi
Prevent concrete sweating by raising the drum of storage tank pads

Construct concrete drains closed with steel jellies having lids at intermittent
places for inspection and maintenance
Drains leading to the effluent collection pit in the mill house should have proper
slope and drain time of liquid should be adequate.
Inspect regularly glands, valves and pumps for leakage and attend repairs
immediately.
Use lubricants judiciously and properly
Schedule production rate to achieve maximum efficiency.
As a precautionary measure keep trays of proper design and shape to collect oil
and grease spillages/ wastes.
Install overflow alarms for tanks/vessels
For bagasse, use closed transfer system (hoods)
Provide system with guards/guides for bearing cooling water
Dry clean at places wherever possible
Separate oil, grease and bagasse from effluents using proper grits
Use disinfectants judiciously
Use seal less pumps or pumps with metallic seals.
Instruct operators not to bypass alarms, signs or significantly alter set points
without authorization.
Document all spillage
Set up control points to dispense chemicals and wastes
Store containers/vessels/tanks in such a way as to allow for visual inspection for
corrosion and leaks.
28
Do not use excess water, which

may prove to be wastage.
Tanks and containers should not
be left without monitoring for
overflows, spills, leaks etc.,
washings etc.,
Clarification
(Sedimentation)
Section and Vacuum
filters
Leakage from pump

gland,
overflows.
Leakage from pipe,
tanks etc
Boiler house
Waste with inorganic

salt
concentration
boiler blow down
contaminant,
boiler
dust from flue gases,
boiler ash
Provide adequate light and ventilation in the storage area.

Maintain distance between different types of chemicals to prevent cross
contamination.
Follow manufacturers 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)
Install secondary containment areas.
Segregation of effluents will reduce pollution loading.
PH controller, temperature gauges and overflow indicator and water meter at
appropriate places will help in control of overdoses, identification of leakage
spots i.e. increase use of instrumentation.
Use closed storage and transfer system.
Use cleaning systems those avoid or minimize solvents and clean only when
needed. If possible use high pressure water cleaning or dry cleaning or dry
Adhere to regular preventive maintenance and monitoring
Have some pucca tank/ pit to collect effluents with oil and grease.
Install overflow alarms for all tanks/vessels
Maintain physical integrity of all tanks and vessels
Clean drains at regular intervals
Boiler blow down can be recycled for use in lower pressure boiler as make up
water. If needed, some segregation may be required.
Regular inspection and preventive maintenance of boiler and its accessories for
leakages, corrosion, scaling mush be done.
Cleaning of boiler should be done properly and on the basis of deposit
thickness, so as to reduce frequent waste generation.
Improve equipment seals to prevent air and cooling water leaks into the boiler.
Use wet scrubbers, fly ash arrestors properly and effectively.
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
Do not allow waster to stagnate

at any open place in case of
spillage overflow etc.
Do not keep tanks and vessels in
direct contact with floor, it
becomes difficult to clean
Do not go for poor quality of
gland packing material.
Do not push/allow dirt/leaked
material into drains.
Do not allow sudden surge of
effluent into ETP
Avoid
stacking
containers
against processing equipment
Do not allow scaling, corrosion
on surrounding/surface areas of
boiler.
Boiler ash should not be allowed
to accumulate.
Do not allow too much of air for
combustion, to prevent fly ash to
escape.
Sulphitation
(Bleaching)
Possible SO2 leakage,

overflow of juice from
tanks, spillage etc.
Crystallization and Pan

Boiling
Leakage
from
pumps
Leakage
/spills
from gutters
Inlet and outlet
vents losses
Oil and grease
from
equipment
cleaning
and
maintenance
Spray pond overflow
Overflow
water
form spray ponds,
oil & grease from
equipment
cleaning/
poor
maintenance
Use properly designed tanks and vessels (juice receiving and reaction tanks) for
their intended purposes.
Install overflow alarms for all tanks/vessels.
Document all spillage.
Place tanks/ vessels in such a way as to allow for visual inspections.
Use adequate scrubbing arrangements in sulphitation tank to absorb sulphur
dioxide (SO2) to gas.
Chimney from sulphitation vessels should extend above roof to an adequate
height.
Adequate lighting and ventilation around the sulphitation area is must.
Use steel pipes of good quality and proper seals for collar positions.
Improve cleaning efficiency.
Install SO2 detectors at possible leakage points/ sources
Adequate open area/ventilation must be provided to avoid any accident due to
SO2 leakage (if any)
Arrange layout such that visual inspection for leakage and spills must be
possible
Maintain pumps, tanks, wheel and gear arrangements as per preventive
maintenance plan/schedule.
Segregate effluents as per loading.
Water leaving crystallizers and sulphur burners can be sent to condenser water
cooling system (injection water).
Inlet and outlet vents must be checked for leakage/losses.
Check cooling elements regularly for the leak proof working.
Maintain physical integrity of crystallizers, centrifuges and pans.
Isolate equipment or process lines, pipes etc, those leak or not in service. Use
seal less pumps or metallic seals.
Use clean in place systems.
Adopt dry cleaning using bagasse.
Use mechanical wipers on mixing tanks.
Use improved seals for pipes, valves, pumps etc.
This can be reused for irrigation through segregation of streams in lined
drains/channels.
Regular inspection and preventive maintenance is essential.
Water channels/drains must be leak proof. Inspect for leakage, stagnation and
take immediate measures (cleaning, disinfectant etc)
Check for the minimum depth of water in spray pond.
30
Do not overcrowd the place of

sulphitation area
Do not neglect monitoring work.
Do not neglect the maintenance
of sulphitation vessels/ tanks
and accessories.
Do not allow flow and pressure
of compressed air to fluctuate
too much.
Do not pump cold C

massecuties.
Do not dilute massecuties.
Do not undermine habit/attitude
of inspection and preventive
maintenance.
Do not allow spilling/ leaking
lubricants material to trickle
down on floor..
Do not allow spilled water to

stagnate at spots/ corners
activities
Evaporation
Section
and Pan Boiling
Evaporator,
Pans
&Juice heater cleaning
Molasses storage tanks

(final molasses)
Sugar loss in the

condensates
through
entrainment, thus
pollutes
cooling
water.
Leaking
pumps,
valves & vessels
and pipes.
Poor operating &
maintenance
conditions.
Caustic soda scrap
scales
Oil and grease
from
equipment
cleaning/ operation
and maintenance
The
wastewater
from cleaning of
scales
increases
pollution load of
effluent streams
Poor
handling,
leakage, improper
Check pipes/valves/pumps/nozzles for leakage/losses and spillage.

Use sealless pumps with metallic seals.
Maintain pumps/ valves as per manufacturers suggestions
Continuous automatic recording and indication of brix of syrup will be useful
for supervisory staff.
Use sealless pumps.
Use good quality seals and valves
Provide adequate lighting and ventilation near storage area
Provide segregation drains and collection pits for water wastes from evaporators
and pans.
Inspect regularly pumps, gauges, valves, vessels, pipes for choking leakage,
spillage and splashes etc.
Preventive maintenance schedule must be adhered to.
Check the catch all in evaporator and pans frequently.
Reduce frequency of cleaning of evaporator using desealants.

Cleaning of scales by electric driven flexible shafts using compressed air.
Improve cleaning efficiency
Segregate and collect the wastewater in lined drains.
Explore alternative cleaning methods without using chemicals.
Holding tank used for avoiding shock loadings in ETP should be leak proof
with overflow alarms.
Establish spill prevention, control & countermeasures (SPCC/plans).
Maintain physical integrity of all tanks vessels.
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
Provide collecting pits/ chambers around the tank for collecting cold water used
for spray and also any foam overflowing etc.
31
Do not overload mill avoid

erratic crushing
Do not neglect good operating
conditions.
Do not overlook the preventive
maintenance
schedule
of
equipment/ machines/ pumps
etc,
Do not allow mixing of high
pollution effluent, oil or grease
into this water.
Do not allow entrainment of
sugar solutions
Do not keep very high level of
juice in evaporators.
Do
not
allow
vacuum
fluctuations in vacuum pans.
Avoid scaling of tubes by
keeping proper watch on control
parameters at set/identified points.
Do not use cutter tools to remove
scales unless scales are very hard. It
may damage tubes.
Brushes can be used with care.
Do not leave scales unremoved
on cleaning day.
Do not allow overflow/ spillage

of molasses
storage, overflows
from tank.
Solid Waste Bagasse
Bagasse fibres find

their way into
waste streams.
Storage
of
bagasses in open
area may create
pollution problems
Press mud or filter

cake (obtained at juice
clarification
station
from rotary vacuum
filters)
Contains inorganic
salts and organic
materials.
Due to spillage
(while
transportation and
collection)
from
conveyors,
unloading etc)
Handling of molasses should be careful without spillage/ losses.

Store molasses on storage tanks fitted with all accessories/fittings as prescribed
including overflow alarm, inlet valve, washout valve, outlet for pump, temperature
gauges, manhole vent.
Arrangement for spraying cold water spray coil, level indicator etc.
Properly label all tanks,. containers.
Conduct periodic analysis of molasses
Provide lids and vents on tanks (fixed roof type)
Thoroughly clean the tanks with water whenever they are empted
Use splash guards
Inspect/ check for losses, spills around tanks & immediately attend it.
Immediately clean floors using dry cleaning or other appropriate cleaning
system.
Regular lifting of molasses should be monitored.
Prefer intact and closed transportation/ conveyance system
Keeping segregated waste through streams/drains/channels closed having
(inspection points open) proper slope and lining will prevent fall of bagasse fibres
into streams (i.e. closed transfer system).
Use industrial vacuum cleaners/dry cleaners/clean in place system and these
should be routine features of the mill.
Automatic transportation feeding of bagasse must be there as per required
quantity
Storage of bagasse (if any) should be in proper storage yards.
5% of total bagasse can be used for other by products like paper and pulp,
paperboard etc,
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
Automatic and closed transfer systems/ conveyors will reduce this problem.
Provide splashguards.
Automatic unloading through hopper bottom directly on to the trucks can help
in keeping the floors and premises clean.
Clean equipment after use.
Maintain a clean, even surface (concreted) in transportation/ movement areas.
32
Do not keep the storage areas

unattended as far as routine
cleaning is concerned.
Do not store molasses in open
areas or kutcha pits.
Do not neglect regular inspection
and maintenance of storage tanks.
Do not forget to label tanks
appropriately.
Do not allow trickling of
molasses from storage tanks, pipes,
valves etc.
Do not allow bagasse fibres to

remain on floor for long by not
cleaning it.
Do not allow water seepage in
this area at any cost.
Do not allow can trash materials
and bagasse particles to fall on
juice/water
Do not allow accumulation of
dust at bottom of blower.
Avoid spillage of mud during its

movement on conveyor and
during unloading operations.
Do not allow to accumulate the
fallen (if any) filter cake prices/
splashes (remove them, then &
there)
AIR POLLUTION
Sugar dust from sugar
house and particulates
from bagasse burning
(boiler house)
Sugar
dust
is
explosive
and
pollutes
inside
atmosphere.
They
fly
ash
particles are likely
to escape out.
Use closed conveyor and transportation system

Use closed loading & unloading system for sugar packing.
Vacuum cleaning/dry cleaning will keep the area neat and clean.
Proper handling of equipment, better operations and maintenance practices will
reduce release of sugar dust.
Adequate light and ventilation near sugar packing area will not suffocate the
environment inside the plant.
Efficient and effective air pollution control devices like dust collectors, fly ash
collectors, cyclones/wet scrubber type fly ash arrestors and bag filters of
required efficiency and effectiveness shall preferably be used appropriately.
33
Do
not
allow
untrained
operators to handle pollution
control devices. Only trained
operators and supervisors must
be allowed to operate/supervise
pollution control devices.
Do not go in for manual packing
of sugar
Sugar loss is more in manual
packing.
Standard Operating Procedure for Sugar Industries
Appendix I: Continued . . .
Appendix I:
SR.
NO
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
NAME OF ACT OR RULES
IMPLEMENTING
AGENCIES
OBJECTIVE OF ACTS OR
RULES
KSPCBS
SERVICE
Responding to
request for
Information
General
Responding to
complaints
Air (Prevention and Control

of Pollution) Act, 1981
Water (Prevention and

Control of Pollution) Act,
1974 and Rules
Water (Prevention and

Control of Pollution) Cess
Act, 1977 and Rules
KSPCB, CPCB
KSPCB, CPCB
KSPCB, CPCB
Provides for the control and

abatement of air pollution.
Board issues consent to
industry which emit air
pollutants with emission
limits
Establishes an institutional
structure for preventing and
abating water pollution.
Board issues consent to
industry and local bodies
which discharge effluent
with effluent limits
Provides for the levy and
collection of cess on water
consuming industries and
local bodies. Collection of
34
Responding to an
application
submitted by the
stakeholder
KSPCBS STANDARDS
A written response within 7
working days of receiving letter
or e-mail including the
information sought will be sent.
In cases which need more time to
respond correspondence will be
dispatched immediately followed
by the information within 2
calendar months
An immediate response where
possible. A written response
within 15 working days of receipt
of complaint
Decisions will be made within 21
days of receiving a filled-in
application and supporting
information. (Form No I ). In
case of refusal of consent the
reasons will be intimated
Responding to an
application
submitted by the
stakeholoder
Decisions will be made within 21

days of receiving a filled-in
application and supporting
information. (Form No XIII ). In
case of refusal of consent the
reasons will be intimated
Scrutinising the
returns submitted
and to issue
assessment order
Decision
SR.
NO
5
6
NAME OF ACT OR RULES
The Noise Pollution

(Regulation and Control
Rules), 2000
Environmental Protection
Act, 1986
IMPLEMENTING
AGENCIES
OBJECTIVE OF ACTS OR
RULES
cess enhances the funds of
the Board for effective
implementation of
environmental legislation
KSPCB, CPCB
KSPCB, CPCB
35
KSPCBS
SERVICE
to enable
stakeholders to
file cess returns
KSPCBS STANDARDS
Appendix II: Consent Fee to be paid by the Industries based on the capital investment, frequency of consent application and the periodicity of monitoring
based on the classification of industries
Sr.
No.
1
Classificationi
Redv
Category
Large
Medium
Small
Orangevi
Large
Medium
Small
Capital Investment by
Industries in Rupeesii
> 1000 Crores
>500 < 1000 Crores
>250 < 500 Crores
>50 < 250 Crores
>25 < 50 Crores
>10 < 25 Crores
>5 < 10 Crores
>1 < 5 Crores
>50 lakhs < 1 Crore
>25 lakhs < 50 lakhs <
>10 lakhs < 25 lakhs
>5 lakhs < 10 lakhs
>1 lakh < 5 lakhs
< 1 lakh
> 1000 Crores
>500 < 1000 Crores
>250 < 500 Crores
>50 < 250 Crores
>25 < 50 Crores
>10 < 25 Crores
>5 < 10 Crores
>1 < 5 Crores
>50 lakhs < 1 Crore
Consent Fee
in Rupeesiii
2,00,000
1,50,000
1,00,000
75,000
50,000
30,000
20,000
15,000
6,000
3,000
2,000
1,500
500
200
1,75,000
1,25,000
90,000
60,000
40,000
25,000
17,500
12,500
5,000
2,500
1,750
36
Consent Applicationiv
Every Year
Periodicity of
Monitoring
Once in a month
Every Year
Every Year (option of
once in 3 years by
paying 3 years fee)
Once in two months

Once in 3-4 months
Every Year
Once in two months
Every Year (option of once in 2

years by paying 2 years fee)
once in 3 years by
paying 3 years fee)
Once in 3 months
Once in 4-6
months
Sr.
No.
Classification
Greenvii
Category
Large
Medium
Small
Capital Investment by
Industries in Rupeesii
>5 lakhs < 10 lakhs
>1 lakh < 5 lakhs
< 1 lakh
> 1000 Crores
>500 < 1000 Crores
>250 < 500 Crores
>50 < 250 Crores
>25 < 50 Crores
>10 < 25 Crores
>5 < 10 Crores
>1 < 5 Crores
>50 lakhs < 1 Crore
>5 lakhs < 10 lakhs
>1 lakh < 5 lakhs
< 1 lakh
Consent Fee
in Rupeesiii
1,250
250
150
1,50,000
1,00,000
75,000
50,000
30,000
20,000
15,000
10,000
4,000
2,000
1,500
1,000
200
100
iv
Consent Application
Periodicity of
Monitoring
Every Year
Once in 3 months
Every Year (option of once in 2

years by paying 2 years fee)
once in 3 years by
paying 3 years fee)
Once in 6 months
Once in 12 months
Categories of industries is as per GOI, MoEF, Official Memorandum No J20011 / 15/ IA/ dated 27th Sept 1988 read with amendment issued time to time
Capital investment on land, building, staff quarters, plant and machinery including all movable and immovable assets as detailed in the project report for new industry or
audited report for existing industry or twenty times the annual lease value in case where land and/or buildings are taken on lease
iii
Notification No FEE 115 ENV 95 (P) dated 19th February 1998, published in Karnataka Gazette dated 2nd April 1998. Fees shall be paid by Bank Draft in favour of
KSPCB, Bangalore encashable at Bangalore. Fees are the same for Consent for Establishment and Consent for Operation
iv
Form I and Form XIII under the Air Act (1981) and Water Act (1974), respectively. Tiny industries have to renew consent once in ten year by paying one year consent fee.
v
Consent for establishment and operation to be obtained from Head Office for large and medium category. However Consent for operation can be obtained either from
Divisional or Regional Office for investments < Rs. 1.00 Crores.
vi
Consent for establishment and operation to be obtained from Head Office. However Consent for operation can be obtained either from Divisional (investment Rs. 1.00 to
20.00 Crores) or Regional Office (investment < Rs. 1.00 Crores)
vii
Consent for establishment and operation to be obtained from Head Office (investment > 20.00 Crores), Divisional (investment Rs. 1.00 to 20.00 Crores) or Regional Office
(investment < Rs. 1.00 Crores)
ii
37
Appendix III.
STANDARDS FOR DISCHARGE OF EFFLUENTS FOR SUGAR INDUSTRY
(Extracts From Environment Protection Rules, 1986)
(Rule 3 (2))
Rule 3 of the Environment Protection Rules, 1986 provides for the Standard for emission or
discharge of environmental pollutants. The standards are specified in Schedules I to IV for
various emissions or discharges of environmental pollutants from the industries, operations or
processes. Those pertaining to the sugar industry have been complied below
Schedule I: Sl No 4
Effluent
Bio-Chemical Oxygen Demand.
Suspended solids
Concentration not to exceed Milligram/lit

100 for disposal on land, 30 for disposal in surface
waters
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
Note- 1
Note- 2
Note- 3
Note- 4
Area Code
Category of Area
A
B
C
D
Industrial area
Commercial area
Residential area
Silence Zone
Limits in dB (A) Leg.

Day Time Night Time
75
70
65
55
55
45
50
40
Day time is reckoned in between 6 a.m. and 9 p.m.

Night time is reckoned in between 9 p.m. and 6 a.m.
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.
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 .
NO
I
PARAMETER
Colour and Odour
INLAND
SURFACE
WATER
See Note I
PUBLIC
SEWERS
LAND FOR
IRRIGATION
See Note I
MARINE
COASTAL
AREAS
See Note I
--2
Suspended Solids mg/l,

Max.
100
Particular size of
Suspended Solids
Shall pass 850

micron IS
Sieve
pH value
5.5 to 9.0
Temperature
Shall not
exceed 50C
above the
receiving
water
temperature
10
20
10
20
1.0
1.0
50
50
50
Oil and Grease mg/l, Max
Total Residual Chlorine

mg/l, Max.
Ammonical Nitrogen (as
600
200
5.5 to 9.0
5.5 to 9.0
---
---
43
(a) For process

wastewater 100
(b) For cooling
water effluent,
10% above total
suspended matter
of influent
(a) Floatable
solids max. 3
mm
(b) Settleable
solids, max 850
microns
5.5 to 9.0
Shall not exceed
50C above the
receiving water
temperature
METHOD
No.2120 Visual comparison Method
Spectrophotometeric Method
No. 2150 Threshold odour test
No. 2130 Nephlometric Method
No. 4500- H+
Electrometric Method
No. 2550 Laboratory and field methods
No.5520 Partition Gravimetric method

Extraction method for sludge samples
No. 4500-Cl Iodometric method- Amperotric titration
method
No4500- NH3 Primary distillation steps Titrimetric

STANDARDS
SL .
NO
9
10
12
13
14
15
16
17
18
19
PARAMETER
N), mg/l, Max.
Total Kjeldhal Nitrogen
(as NH3), mg/l, Max.
Free Ammonia (as NH3),
mg/l), Max.
Chemical Oxygen
Demand, mg/l, Max.
Arsenic (as As), mg/l,
Max.
Mercury (as Hg), mg/l,
Max.
Lead (as Pb), mg/l, Max.
Cadmium (as Cd), mg/l,
Max.
Hexavalent Chromium (as
Cr+6), mg/l, Max.
Total Chromium (as Cr),
mg/l, Max.
Copper (as Cu), mg/l,
Max.
INLAND
SURFACE
WATER
PUBLIC
SEWERS
MARINE
COASTAL
AREAS
LAND FOR
IRRIGATION
100
100
5.0
5.0
250
250
0.2
0.2
0.2
0.2
0.01
0.01
0.01 .
0.1
1.0
2.0
2.0
1.0
2.0
0.1
2.0
1.0
2.0
2.0
2.0
3.0
3.0
3.0
20
Zinc (as Zn), mg/l, Max.
5.0
15
15
21
Selenium (as Se), mg/l,

Max.
0.05
0.05
0.05
22
Nickel (as Ni), mg/l, Max.
3.0
3.0
5.0
0.2
2.0
0.2
0.2
2.0
15
15
5.0
23
24
25
Cyanide (as CN), mg/l,

Max.
Fluoride (as F), mg/l,
Max.
Dissolved Phosphates (as
P), mg/l, Max. .
44
METHOD
method Phenate method
No. 4500 N-org Macro kjeldhal Method
Semimicro Kjeldhal Method
No. 5220 Titrimetric method, Colorimetric method
No. 3500- As Atomic absorption spectrometric method
No. 3500- Hg, Cold Vapour Atomic absorption Method,
Dithizone Method
No. 3550-Pb AAS Method, Dithizone Method
No. 3550-Pb AAS Method, Dithizone Method
No. 3550-Cr, AAS Method, Colorimetric method, Ion

Chromatographic method
No. 3550-Cu, AAS Method, Neo cuproine Method
No. 3550-Zn, AAS Method, Inductively coupled plasma
method, Dithizone Method, Zincon method
No. 3500- Se, Colorimetric method, Fluorometric method
No. 3550-Zn, AAS Method,
Inductively coupled plasma method
No. 4500, Titrimetric method, Cyanide- Selective
Electrode Method, Colorimetric method
4500- F-, Ion- selective electrode method
Ion Chromatographic method
No. 4500- P Vandomolybdo phosphori acid
Colorimetric method
Stannous chloride method

STANDARDS
SL .
NO
PARAMETER
INLAND
SURFACE
WATER
PUBLIC
SEWERS
MARINE
COASTAL
AREAS
LAND FOR
IRRIGATION
26
Sulphide (as S), mg/l,

Max.
2.0
5.0
27
Phenolic Compounds (as

C6H5OH), mg/l, Max.
1.0
5.0
5.0
10-7
10-7
10-8
10-7
28
Radioactive materials:
(a) Alpha emitter Micro
curie/ml
(b) Beta emitter Micro
curie/ml
10-6
10-6
10-7
10-6
90% survival
of fish after 96
hours in 100%
effluent
90% survival
of fish after
96 hours in
100%
effluent
90% survival of
fish after 96
hours in 100%
effluent
29
Bio-assay test
90% survival
of fish after 96
hours in 100%
effluent
30
Manganese (as Mn)
2 mg/l
2 mg/l
2 mg/l
31
Iron (as Fe)
3 mg/l
3 mg/l
3 mg/l
32
Vanadium (as V)
0.2 mg/l
0.2 mg/l
0.2 mg/l
33
Nitrate Nitrogen
10 mg/l
20 mg/l
2100
2100
2100
1000
1000
1000
34
35
Dissolved Solids
(Inorganic), mg/l, Max.
Sulphate (as SO.), mg/l,
Max.
NOTE:
45
METHOD
Ascorbic acid method
No. 4500- S2 Methylene blue method
Iodometric method, Ion selective electrode method
No. 6420 Liquid Liquid extraction gas Chromatographic
method
Mass Spectrometric method
No. 7110 Evaporation method for grass alpha, beta
No. 3500- Mn AAS Method

Persulphate Method
No. 3550-Fe AAS Method
Phenanthroline method
No. 3550-V AAS Method
Gallic acid method
4500- NO2- Ion Chromatographic method
Colorimetric Method
4500- NO2- Ion Chromatographic method Gravimetric
method with ignition of residues Turbidimetric method

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

Sl. No. Industry
Quantum
2
Sugar
0.4 [m3 / tonne] of cane crushed
46
NATIONAL
Pollutant
Sulphur
(SO2)
Time
Weighted
average
Annual
Average*
24 Hours**
[SCHEDULE VII]
[See rule 3(3B)]
AMBIENT AIR QUALITY STANDARDS
Concentration in ambient air (in ug/m3

for all pollutants except carbon monoxide
which is in mg/m3)
Industrial
Residential
Sensitive
Area
Rural &
Area
Other areas
80
60
15
120
80
30
Oxides of
Nitrogen as
NO2
Annual
Average*
80
60
15
24 Hours**
120
80
30
Suspended
Particulate
Matter
Annual
Average*
360
140
70
24 Hours**
Annual
Average*
500
120
200
60
100
50
24 Hours**
150
100
75
Annual
Average*
24 Hours**
1.0
0.75
0.50
1.5
1.00
0.75
8 hours**
5.0
2.0
1.0
8 hours**
5.0
2.0
1.0
Respirable
Particulate
matter (size
less than
10m)
Lead (Pb)
Carbon
Monoxide
(CO)
Method of measurement
1. Improved West and Gaeke

Dioxide method.
2. Ultraviolet fluorescence
Jacob & Hochheiser
Modified (Na-Arsenite)
method.
Gas Phase
Chemiluminescence.
(Average flow rate not less
than 1.1 m3/minute)
AAS Method after sampling

using EPM 2000 or
equivalent filter paper.
Non-dispersive infrared
Spectroscopy.
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
materials
Name of products
Consumption of raw material per unit of

output
during the previous
during the current
financial year
financial year
* Industry may use codes if disclosing details of raw material would violate contractual
obligations, otherwise all industries have to name the raw materials used.
Pollutants
PART C
POLLUTION DISCHARGED TO ENVIRONMENT/ UNIT OF OUTPUT
(Parameter as specified in the consent issued)
Quantity of
Concentrations of
Percentage of
pollutants
pollutants in
variation from
discharged
discharges (mass/
prescribed
(mass/day)
volume)
standards with
reasons
(a) Water
(b) Air
48
PART D
HAZARDOUS WASTES
(as specified under the Hazardous Wastes/ Management and Handling Rules, 1989)
Hazardous wastes
Total quantity (kg.)
during the previous
during the current
financial year
financial year
(a) From process
(b) From Pollution control facilities
PART E
SOLID WASTES
Total quantity
during the previous
financial year
(a)
(b)
(c)
during the current

financial year
From process
From pollution control facilities
(1)
Quantity recycled or
reutilized within the units
(2)
Solid
(3)
Disposed
PART F
Please specify the characterizations (in terms of composition and quantum) of
hazardous as well as solid wastes and indicate disposal practice adopted for both these
categories of wastes.
PART G
Impact of the pollution abatement measures taken on conservation of natural
resources and on the cost of production.
PART H
Additional measures/ investment proposal for environmental protection including
abatement of pollution, prevention of pollution.
PART I
Any other particulars for improving the quality of the environment.
49
FORM XIII
APPLICATION FOR CONSENT FOR ESTABLISHING OR TAKING ANY STEPS FOR
ESTABLISHMENT OF INDUSTRY OPERATION PROCESS OR ANY TREATMENT DISPOSAL
SYSTEM FOR DISCHARGE, CONTINUATION OF DISCHARGE UNDER SECTION 25 OR
SECTION 26 OF THE WATER (PREVENTION AND CONTROL OF POLLUTION) ACT, 1974
(See Rule 32)
From
Date.
To
The Member Secretary,
Central Pollution Control Board.
Sir,
I/We hereby apply for Consent/Renewal of Consent under section 25 or section 26
of the Water (Prevention and Control of Pollution) Act, 1974 (6 of 1974) for establishing
or taking any steps for establishment of Industry/ operation/ process/ or any treatment/
disposal system to bring into use any new/ altered outlet for discharge of *sewage/ trade
effluent*/ to continue to discharge *sewage/ trade effluent* from land/premises owned by..
The other relevant details are as below:
1. Full name of the applicant..
2. Nationality of the applicant.
3. Status of the applicant:
a. Individual
b. Proprietary concern
c. Partnership firm
(Whether registered or unregistered)
d. Joint family concern
e. Private Limited Company
f. Public Limited Company
g. Government Company
1. State Government
2. Central Government
3. Union Territory
h. Foreign Company
(If a foreign company, the details of registration, incorporation, etc.).
i. Any other Association or Body:
4. Name, Address and Telephone Nos. of the Applicant.
(The full list of individuals, partners, persons, Chairman (full-time or part-time),
Managing Directors, Managing Partners, Directors (full time or part-time), other kinds of
office-bearers are to be furnished with their period of tenure in the respective office with
telephone Nos. and address).
5. Address of the Industry
(Survey No., Khasra No., location as per the revenue records, Village Firka, Tehsil,
District, Police Station or SHQ, jurisdiction of the First Class Magistrate).
6. Details of commissioning, etc.:
a. Approximate date of the proposed commissioning of work.
50
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--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
Address of the
consumer
Purpose for which

water consumed
1
Quantity of water
consumed in
kilolitres
2
If the meter was out
of order the
monthly average
consumption of
water for the
previous 3 months
of the working
period
5
6
1. Industrial cooling spraying in mine
pits or boiler feed.
2. Domestic purpose.
3. Processing whereby water gets

polluted and the pollutants are easily
bio-degradable.
4. Processing whereby water gets
polluted and the pollutants are not
easily bio-degradable and are toxic.
Reading at the
beginning of the
first day of calendar
month under report
3
Quantity of water
qualifying for rebate
according to the
assessee
i.
ii.
iii.
iv.
v.
i.
ii.
iii.
iv.
v.
i.
ii.
iii.
iv.
v.
i.
ii.
iii.
iv.
v.
Reading at the
end of the last day
of calendar month
under report
4
Remarks*
7
8
from Municipal water supply mains
from well/ tube-well
from canal
from river
from any other source
from canal
from river
from canal
from river
from canal
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
perforunder sections 25/26 of consent
of the plant mance
the Water (Prevention
condition
noticed
and Control of
Pollution) Act, 1974
1
2
3
4
5
6
End. : Original Analysis report of Laboratory.
Signature
Date
Name..
Address...
53
A NNEXURE . M AINTAINING L OG B OOKS

Log Book 1: Log Book for Daily Water Balance Sheet (Volume m3)
Mode of Abstraction
of Water
Tanker
Surface Water
Ground Water
Piped Water
Rain Water (harvested)
Total
Mode of Use of Water
of Water
Process
Cooling
Domestic
Water Sprinkling
systems
WATER INTAKE
1/2/04
2/2/04
3/2/04
4/2/04
5/2/04
3/2/04
4/2/04
5/2/04
6/2/04
7/2/04
WATER CONSUMPTION
1/2/04
2/2/04
Total
54
6/2/04
7/2/04
Log Book 2: Log Book for Daily Resources Balance Sheet (Weight Kg)
Type of Raw material
used
RAW MATERIAL INTAKE DATES

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

1/2/04
2/2/04
3/2/04
4/2/04
1/2/04
2/2/04
3/2/04
4/2/04
5/2/04
6/2/04
7/2/04
Grid
Diesel Generator Set
Solar Energy
Any other
Total
Energy Consumption
ENERGY CONSUMPTION DATES

5/2/04
Process
Cooling
Air Pollution Control
Devices
Water Pollution Control
Devices
Water Sprinkling systems
Total
56
6/2/04
7/2/04
C HECK L IST I
(F OR I NTERNAL AND E XTERNAL A UDITORS )
Format 1 (VG1): Verification Guidelines on Resource Auditing Aspects
A. Monthly Water Balance Sheet
WATER INTAKE
WATER CONSUMPTION
[a]
[b]
Mode of Abstraction of Volume Mode of Use of Water Volume
Water
(m3)
(m3)
Tanker
Process
Surface Water
Cooling
Ground Water
Domestic
Piped Water
Rain Water (harvested)
Total
Total
Note: a = b + waste water generated + loss due to evaporation
B. Monthly Raw material consumption
RAW MATERIAL INTAKE
[i]
Type of Raw material
Weight
used
(Kg)
PRODUCT PRODUCED
[ii]
Type of Product
Weight
produced
(Kg)
Total
Total
Note:i = ii + waste products + fugitive losses through air and water
C. Monthly Energy Balance Sheet
ENERGY INTAKE
ENERGY CONSUMPTION
[a]
[b]
Source of Energy
Kilowatts Mode of Use of Energy
Kilowatt
Grid
Process
Diesel Generator Set
Cooling
Solar Energy
Air Pollution Control
Devices
Any other
Water Pollution Control
Devices
Total
Total
Note: a = b + loss due to heat
57

SOP Sugar Industries EMPRI 2005 01

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SOP Sugar Industries EMPRI 2005 01

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Standard Operating Procedures

CHARTER ON CORPORATE RESPONSIBILITY

Process involved in Sugar Industry

Standard Operating Procedures for Sugar Industries

Standard Operating Procedures for Sugar Industries

LEGAL AND REGULATORY FRAMEWORK

To put the whole regulatory framework of India in perspective, a gist of constitutional

Standard Operating Procedures for Sugar Industries

Standard Operating Procedures for Sugar Industries

Standard Operating Procedures for Sugar Industries

Standard Operating Procedures for Sugar Industries

Standard Operating Procedures for Sugar Industries

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

Standard Operating Procedures for Sugar Industries

Standard Operating Procedures for Sugar Industries

Standard Operating Procedures for Sugar Industries

Standard Operating Procedures for Sugar Industries

RESPONSIBILITIES OF THE SUGAR INDUSTRY AUTHORITIES

Standard Operating Procedures for Sugar Industries

WATER AND AIR (PREVENTION & CONTROL OF POLLUTION) ACTS

Standard Operating Procedures for Sugar Industries

WATER (PREVENTION & CONTROL OF POLLUTION)

Standard Operating Procedures for Sugar Industries

ENVIRONMENTAL STATEMENT PROCEDURES

Environmental Management in industries hitherto based on and off pipe waste

Standard Operating Procedures for Sugar Industries

Standard Operating Procedures for Sugar Industries

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

Phase 2: Material Balance

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

DESERVE A MATERIAL BALANCE

IDENTIFY WASTE REDUCTION OPTIONS

EVALUATE WASTE REDUCTION OPTIONS

WASTE REDUCTION ACTION PLAN

Quick Reference Audit Guide

Standard Operating Procedures for Sugar Industries

CHARTER ON CORPORATE RESPONSIBILITY FOR ENVIRONMENTAL

Standard Operating Procedures for Sugar Industries

Standard Operating Procedures for Sugar Industries

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

Unloading of cane, cow

Cane trash, cut

Continuous gland cooling

Standard Operating Procedures for Sugar Industries

Boiler blow down, boiler

Occasional spills and leaks

Washings of sulphur and

Poor storage handling,

air pollutants fibres

TDS, BOD effluent

Very high SS,

Very high BOD &

Dust, sugar loss

Mill House Effluent

Standard Operating Procedures for Sugar Industries

10.2 POLLUTION EFFECT

Standard Operating Procedures for Sugar Industries

10.3 GOOD OPERATING PRACTICES