New 60 KLPD Molasses Based Distillery Unit of M/s. Kukadi … · 2018-09-15 · iii) The present site meets the guidelines for sitting of an industry prescribed by MoEF&CC 2.4 Size

PRE FEASIBILITY REPORT

New 60 KLPD Molasses Based Distillery Unit of

M/s. Kukadi Sahakari Sakhar Karkhana Ltd.

A/P. Pimpalgaon Pisa, Tal. Shrigonda, Dist. Ahmednagar,

Maharashtra-413703

Prepared By

VASANTDADA SUGAR INSTITUTE Manjari (Bk), Pune, Maharashtra 412 307

Telephone: (020) 26902100, 26902343/7/6, Fax (020) 26902244

Web Site:www.vsisugar.com

Accredited by QCI/NABET for EIA consultancy services, (Certificate No.

NABET/EIA/1720/RA 0096)

Recognized R & D Center by Department of Scientific and Industrial Research (DSIR),

Ministry of Science and Technology, Government of India

Recognized as Post Graduate & Research Center by Savitribai Phule Pune University

September 2018

http://www.vsisugar.com/

Prefeasibility Report: M/s. Kukadi Sahakari Sakhar Karkhana Ltd.,

New 60 KLPD Molasses Based Distillery Unit 2

1.0 INTRODUCTION

1.1 Identification of project and project proponent

This distillery project is proposed by M/s. Kukadi Sahakari Sakhar Karkhana Ltd., (KSSKL).

The is a cooperative sugar mill. It is located at village Pimpalgaon Pisa, Tal-Shrigonda District

Ahmednagar of Maharashtra. It is one of the progressive co-operative sugar factories in

Maharashtra, set up in the year 2002-03.The factory is registered under the Government of

Maharashtra Co-operative Societies Act, having reg. no. ANR/SGA/PRG/A/S-84, dated

01/08/1997. Shri Rahul Kundalikrao Jagtap-Patil, is Chairman of the factory who is also a

Member of Legislative Assembly (MLA) of Maharashtra. Over the last 10 years, this factory has

modernized the sugar unit. Due to which the factory could tap co-product like Cogeneration

(power plant). The management of the factory has undertaken extensive cane development

activities. Due to increase in sugarcane plantation in area of operation, the factory has decided to

expand its crushing capacity from 3,500 TCD to 5,500 TCD and cogeneration unit from 12 to 27

MW. Environmental clearance for the said expansion was received from SEIAA (129th meeting on

dated May 10, 2018-SEIAA-EC-0000000298) and the project implementation will be commenced

from the next crushing season i.e. 2018-19.

Because of increase in the crushing capacity, the production of byproduct like molasses, bagasse

etc. will also increase. Considering all these aspects and to gain more benefits from this setup, the

management of KSSKL has decided to install a new 60 KLPD molasses based distillery plant with

evaporation followed by incineration boiler for treatment and disposal of effluent like spent wash.

1.2 Project Setting

Easy availability of raw materials, water, power as well as adequate land in the existing campus

encouraged the Management, to install the proposed unit within the existing industrial premises.

The site meets the guidelines prescribed by Ministry of Environment, Forest and Climate Change

for sitting of an industry. It is located approximately 5 km off State Highway No. 10. The

geographical coordinates of the site are 18047’49”N, 74037’11” E.

1.3 Highlights of the Project

Table 1.1: Project Highlights

1 Project Proponent

M/s. Kukadi Sahakari Sakhar Karkhana Ltd.,(KSSKL)

2 Project Location Pimpalgaon Pisa, Tal-Shrigonda Dist- Ahmednagar, Maharashtra 413703

3 Land Land allocated for distillery: seven acre (includes evaporation unit

and incineration boiler, finished product storage area, spentwash

storage lagoon etc.)



Greenbelt : Proposed 2.5 acres (Existing 20 acres)

No need of acquisition of additional land as the proposed project

will be set up in existing factory premises only

Total land available with the factory = 117 acres

4 Project New60 KLPD Molasses based distillery

5. Product Rectified spirit / Extra Neutral Alcohol/Anhydrous Alcohol

6 Operation days

per annum

Distillery - 300 Days (Evaporation followed by incineration boiler

technology for treatment and disposal of distillery spent wash)

7. Main Raw Material

Raw material Quantity

Molasses 222 TPD

Nutrient N,P 100 Kg/d

Turkey Red Oil (TRO) 300 Kg/d

8. Water

Requirement

554 m3/day

9. Fuel Concentrated Spent wash: 130 m3/day = 161.2 TPD

Source: Process effluent after MEE

Bagasse: 48.2 TPD

OR Coal: 26.5 TPD

Coal Source: Indian coal from Chandrapur coal blocks or as per

availability

Bagasse Source: Own sugar mill

10. Steam Total: Maximum 412 TPD

Source: Proposed incineration boiler: 22 TPH

Steam utilization: Distiller + SMEE + Boiler de-aerator & SCAPH +

losses

11. Power 1.32 MW; Source: Captive

12. Effluent Treatment

System

Multi-effect evaporation (MEE) followed by incineration for spent

wash and

Condensate polishing unit (CPU) for spent lees and process

condensate

13. Manpower 68 (permanent) + 40 (seasonal) = 108

14. Project Cost Rs. 7,954.03 lakhs (Rounded to Rs. 7954.00 lakhs)

15. Capital expenses

for Environment

management

Rs. 2,820.00 lakhs



1.4 Need of project and its importance to the country and region

In India, sugar industry is dependent on monsoon. Its financial viability drastically affected due

to weather conditions as well as market. Therefore, it is need to explore the alternative products

from the available resources so as to improve its financial stability. Molasses based distillery is

one of such alternative because raw material availability i.e. molasses and power is fulfilled in-

house by the sugar mill.

In India, mainly three types of alcohols are popularly produced i.e. rectified spirit (RS), extra

neutral alcohol (ENA) and anhydrous alcohol (AA) (Fuel Ethanol). Of these, RS used for large

number of industrial, scientific, laboratory, medical and many other applications. Thus, demand

for the same is immense and it is ever increasing. ENA used for making liquors and other alcoholic

beverages. AA is a fuel alcohol; it used for blending with petrol in the ratio of maximum 1:10.

Table 1.2: Expected performance of sugar factory for next five years

SN

Particular Estimates for season (MT)

2018-19 2019-20 2020-21 2021-22 2021-23

1 Area under sugarcane cultivation in Ha

10,200 10,250 10,300 10,350 10,400

2 Yield MT/Ha 80 85 90 95 100

3 Cane availability 8,16,000 8,71,250 9,27,000 9,83,250 10,40,000

4 Recovery (% cane) 11.20 11.20 11.20 11.20 11.20

5 Sugar production (TPA)

91,392 97,580 1,03,824 1,10,124 1,16,480

6

Molasses (C) production @4% OR Molasses (B) production @6%

32,640 34,850 37,080 39,330 41,600

48,960 52,275 55,620 58,995 62,400

7 Press-mud production @4%

32,640 34,850 37,080 39,330 41,600

Molasses is a byproduct of sugar industry. The above table shows the expected availability of

molasses and thereby. Proposes distillery unit required molasses is around the 66,000

MT/annum, expected molasses production is around 34,000 to 38,000 MT/annum if used

molasses ‘C’ (4% on cane) and 50,000 to 60,000 MT/annum if used molasses ‘B’ (6% on cane) . It

indicates, ~ 76-91% molasses will be available from own source and therefore, it has decided to

install a new distillery of 60 KLPD. Remaining 6,000 to 16,000 MT molasses will be fulfill by

purchasing molasses from nearby sugar factory. The Four nearby sugar factory assure to sell their

molasses to KSSKL



The distillery unit will be producing, RS/ENA which are very significant for other industries,

medical services, etc. Ethanol (AA) used to blend with petrol, thus able to save valuable foreign

exchange on import of fossil fuel.

1.5 Steam and Power

Steam required for the proposed unit will be the max. 412 MT/day, it will be fulfilled from

proposed independent incineration boiler of 22 TPH along with 2 MW TG set. The required power

i.e. 1.32 MW for distillery and ETP will fulfilled from proposed 2MW TG set. Likewise proposed

distillery unit will produce required steam and power itself.

1.6 Import vs. Indigenous production

The process of manufacturing for distillery is simple and straight line, available indigenously. The

technologies even for the pollution control/disposal are also available indigenously.

1.7 Export Possibility

The finished goods viz. Rectified Spirit (RS), Extra Neutral Alcohol (ENA) and Anhydrous Alcohol

(AA or fuel ethanol) are having excellent potential of export.

1.8 Domestic / export markets

Domestic market for RS and ENA - Osmanabad, Latur, Ahmednagar, Pune, Mumbai, Solapur,

Hyderabad, Bengaluru, Goa etc. are the domestic markets. For fuel ethanol, petro-chemical

industries are the major buyers.

1.9 Employment Generation

Proposed distillery project will provide direct employment to 68 persons and about 40 seasonal

employment to unskilled workers. However, it has a great potential to generate large number of

indirect employment.

2.0 PROJECT DESCRIPTION

2.1 Type of project

Proposed project is a new 60 KLPD molasses based distillery. The project is placed under 5 (g) -

for distillery unit as ‘A’ category as per EIA Notification, 2006 (as amended in 2009) and Will be

appraised at Ministry of Environment Forests & Climate Change, New Delhi.



2.2 Location with coordinates

Figure 2.1: Location Map

Project coordinates: 18047’49”N, 74037’11” E.

Figure 2.2: Satellite Image of the project site



Figure 2.3: Master Plan of Sugar factory with proposed distillery plant

Proposed distillery site



Figure 2.4: Proposed distillery Layout



2.3 Details of alternative site considered and basis of selecting the proposed site

Alternative sites for the proposed project are not considered, because of the following reasons.

i) The project proponent is already having adequate land available for the proposed activity

ii) The land is adequate for accommodating ancillary units such as storage lagoons,

treatment, disposal units, etc.

iii) The present site meets the guidelines for sitting of an industry prescribed by MoEF&CC

2.4 Size or magnitude of operation

New 60 KLPD molasses based distillery unit.

2.5 Project description with process details

Process: Distillery

KSSKL decided to adopt the latest technology to achieve Zero Liquid Discharge (ZLD) for the

proposed 60 KLPD unit; the peculiarities of manufacturing process are as follows

Manufacturing Process

The production process involves the following stages

1. Fermentation

2. Distillation

Fermentation- Molasses is the chief raw material used for production of alcohol. Molasses

contains about 50% total sugars, of which 30 to 33% are cane sugar and the rest are reducing

sugar. During the fermentation, yeast strains of the species Saccharomyces cerevisieae, a living

microorganism belonging to class fungi converts sugar present in the molasses such as

sucrose or glucose in to alcohol. The continuous fermentation process involves addition of

fresh nutrients medium either continuously or intermittent withdrawal of portion of nutrient

for recovery of fermentation products. In continuous process fermenter is in constant usage

with little shut down and after initial inoculation of yeast culture, further inoculation is not

necessary.

Distillation- After fermentation the next stage in the manufacture is to separate alcohol from

fermented wash and to concentrate it to 95% this is called Rectified Spirit(RS). For this

purpose, method of distillation is employed. After separation of alcohol, the remaining part

is the effluent of the process i.e. spentwash and spent lees.

Re-distillation to manufacture Extra Neutral Alcohol (ENA)



ENA is prepared by re-distillation of the rectified spirit (RS) for the removal of impurities like

higher alcohols, aldehydes and methyl alcohol. This is done by, remixing rectified spirit with

soft water and distilling it in the ENA column.

Anhydrous Alcohol (AA)

Anhydrous alcohol is an important product required by industry. As per IS specification it is

nearly 100% pure or water free alcohol. Alcohol as manufactured by Indian distilleries is

rectified spirit, which is 94.68% alcohol. It is not possible to remove remaining water from

rectified spirit by straight distillation as ethyl alcohol forms a constant boiling mixture with

water at this concentration and is known as azeotrope. Therefore, special process for removal

of water is required for manufacture of anhydrous alcohol.

The various processes used for dehydration of alcohol are as follows.

I) Azeotropic Distillation

II) Molecular Sieves

III) Pervaporation / Vapour permeation system.

Figure 2.4: Schematic of RS /ENA / AA manufacturing process

Fermented Wash

Distillation

Analyzer column

PR Column

RE Column

Exhaust column

Re-boiler

Fermentation

Yeast propagate with molasses in

sterilize separate Vessel

Molasses Storage (MS tank)

Molasses weighed and diluted

Spent wash/ Spentlees

Yeast sludge to

bio-compost

CO2 scrubber

RS/ENA/AA&

Fusel oil



2.6 Raw Materials for Finished Products

Raw materials for the proposed project will be available from the local market. Bagasse used as a

fuel and molasses as raw material will be available from in-house only. Product wise raw material

consumption is given below.

Table 2.1: Availability raw materials & finish good product and transport mode

Raw

material

s

Estimate

d

quantity

/day

Source Final product Estimate

d

quantity

KL/day

Source

market

Transpo

rt mode

Molasses 222 TPD Own factory and supplementary from nearby sugar mills

RS + Impure

spirit (5%) OR

ENA +Impure

spirit (6 %) OR

Ethanol +

Impure spirit

(5%)

60 KLPD Maharashtra/India

By road

Nutrients N, P

100 Kg Local - - - By Road

Turkey Red Oil (TRO)

300 Kg Pune, Ahmednagar, Mumbai

- - - By Road

Coal (Indian)

OR

Bagasse

26.5 TPD Chandrapur or as per availability

- - - By Road/rail

48.2 TPD Own Sugar mill

- - - By Road



2.7 Resource optimization / recycle and reuse envisaged in the project

In the proposed project, optimum utilization of the available resource is strived by the management,

by using effluent i.e. spentwash as fuel with coal. Molasses is a by-product of sugar factory, spentwash

and coalwill be used as a fuel for boilers that produces process steam. 2 MW TG set will be run with

this steam to produce power then the steam will be used for process and axillery unit.

2.7.1 Water Requirement and Its source

Necessary water requirement for the proposed project will be met from Moharwadi Reservoir. Water

will be required for domestic, process and utility purpose. Daily fresh water requirement for the

proposed distillery unit will be of 554m3.

Table 2.2: Water Balance: Distillery of 60KLPD (Quantities in cum/day)

WATER INPUT Cum/day

Process Water for Fermentation section and CO2 scrubber 720

Boiler feed water 454

DM Water For RS Dilution 240

Soft Water For Vacuum Pump & Others 100

Soft Water Makeup For Cooling Towers 360

Other Domestic Usage 20

Total Water Input at start-up 1,894

WATER OUTPUT

Spent Lees (PR & Rect.) 240

CT Evaporation & Drift Losses 360

Domestic Consumption loss 20

Water In Spent Wash (5% solids) 650

Soft Water For Vacuum Pump & Others 100

Boiler water steam loss 50

Steam condensate 480

Miscellenous loss 50

Total Water Output 1,970

RECYCLE STREAMS

Lees Recycle For RS Dilution (after CPU) 240



Process Condensate (after CPU) 520

Steam condensate recycled to boiler 480

Soft Water For Vacuum Pump & Others cooling water 100

Total Recycling /Re-utilisations of water per day 1340

Total Daily Water requirement/Input = (1894 - 1340 = 495) 554

The fresh water requirements per lit of Alcohol including

domestic water

9.23 lit/lit of RS

Table 2.3: Summary of water budget

Particulars In-take (one

time start-up

requirement)

Losses (KLD)

Discharged as waste

water (KLD)

Recycled (KLD)

Day-to-day requirement

(KLD)

Domestic 20 4 16 - 20 Industrial Consumption

Process 960 70 130 400 560

Cooling tower make up water

360 360 -- 360 (from CPU)

----

Cooling# 100 -- --- 100 --

Boiler 454 50 --- 480 50

Total 1894 484 146 1340 554

+Net fresh water requirement for the distillery unit will be the 554 cum per day

2.7.2 Power & Fuel requirement and Its source

KSKL has proposed to install an independent incineration boiler of 22 TPH with steam pressure of

45 Kg/cm2. It will fulfill the steam requirement of 17 TPH of distillery unit. An independent turbine

generator set of 2.0 MW proposed to generate required power. The power required for the proposed

distillery unit will be 1.32 MW to be by the above-mentioned TG set and additional 0.68 MW will be

export to state electricity board’s grid.



Table 2.4: Power and Fuel requirement

Sr.

No.

Particulars

Power and Fuel

Requirement Source

Proposed TG set of

incinerator boiler

1. Power Requirement 2 MW

Captive: 1.32 MW

In-house, incineration boiler

2. Concentrated

Spentwash

130 m3/day Effluent from process

3.

Coal (Indian)

OR

Bagasse

26.5 TPD Chandrapur or as per

availability

48.2 TPD Own Sugar mill

2.8 Waste generation &disposal scheme

Quantity of waste to be generates & scheme for their disposal are given in following chart:

A. Liquid waste

Distillery

Estimated daily water requirement of distillery (60 KLPD) will be 630m3 after condensate and spent

lees recirculation as mentioned in Table 2.2. Spent wash generation will be 650 m3/day (12% solids).

Spentwash will be sent to integrated evaporation system where its volume will reduced to325

m3/day@24% of solids. Concentrated spent wash will sent to standalone evaporation plant for

further reduction of volume up to 130 m3/day @ 60% solids. This spent wash @ 60% solids will be

incinerated in specially designed incinerator boiler.

Ash generated will be sold to nearby brick manufacturing units. The spent lees 240m3/day and

process condensate from evaporators of 520m3/day will treated in condensate polishing unit (CPU),

and recycled in the process, and cooling tower make up water. Sewage of 16m3/day will be disposed

through septic tanks and soak pit system.

B. Solid waste

The proposed industrial activity at KSSKL gives solid waste in the form of yeast sludge, CPU sludge

and boiler ash. The solid waste will be used as a filler material in the composting process and boiler

ash will be sold to brick manufacturing units.



Table 2.5: Solid waste generation and disposal

# Waste Quantity/a

nnum MT

Treatment Disposal Remark

1 Yeast sludge 50 Bio-composting Used as a soil enriching material

Organic

2 Incineration Boiler Ash (9.27 TPD coal and 30.62 SW /day) OR Ash (0.964 TPD Bagasse and 30.62 SW T/day)

11,967 OR 9,475

- Used as a soil enriching material/ Sold to brick manufacturing units

Inorganic

3 CPU 70 Bio-composting Used as a soil enriching material

Organic



Figure 2.4: Flowchart for effluent generation from distillery

60 KLPD Distillery Unit

MPV Distillation System

Raw spentwash 650 m3/ day spentwash/ day with 12% T.S.

Integrated spentwash evaporation plant concentrated spentwash generation 325 m3/ day with 24% T.S.

325 m3/ day process

condensate

325 m3/ day, conc.

Spentwash with 24% T.S.

Standalone spentwash evaporation plant concentrated spentwash generation 130 m3/ day with 60% T.S.

Steam

195 m3/ day process

condensate

130 m3/ day, conc. Spentwash with

60% T.S.

Incineration Boiler 22

MT/hr, 45 Kg/ cm2 (g) Supplementary coal

1.1TPH OR bagasse 2 TPH

Condensate Polishing Unit (CPU) 760 m3/ day

TG Set 2 MW

Ash 39.9TPD Or 31.58 TPD

Steam & Power to distillery

Supplement for fertilizer and manufacture of

Briquette

Treated water 684 m3/ day, (Recycle for dilution of

molasses for distillery fermentation process or

cooling tower make-up)

Alcohol Vapours

Spent lees 240 m3/ day

Steam



Figure 2.5: Process flow diagram of CPU

Evaporation Condensate & Spent lees

520 + 240 = 760 m3/day

Equalization Tank

Primary Clarifier

Aerobic Treatment Tank

Secondary Clarifier

Anaerobic Filter/ Anaerobic Digester

Multimedia Filter & Activated Carbon Filter

Ultrafiltration

Treated water sent to process and cooling tower

makeup water

Neutralization Tank



2.9 Air Emission & Control

An independent incineration boiler of 22 TPH with pressure of 45 Kg/cm2and 2MW TG set will be

installed for distillery unit. Concentrated spent wash and coal or bagasse will be used as a fuel in

incineration boiler. ESP system will be used as air pollution control device.

There are existing two DG set of capacity 320 kVA each with adequate stack height and acoustic

enclosures. It will be used as a standby power supplier for proposed distillery.

2.10 Noise Control

Steam turbine generator will be the major noise source of the proposed project. Apart from that,

anticipated noise from pumps, motor drives, utilities etc. The plant and equipment will be the

specified and designed with a view to minimize noise pollution. The major noise producing

equipment will provided with soundproof devices and silencers. Ear Plugs and earmuffs will be

provided to the workers in utility section. Greenbelt will be developed around the proposed industry

unit.

2.11 Health and Safety Measures

Being a cooperative sugar mill KSSKL is committed to the Health and Safety of all its employees. It

strives to provide hygienic & safe work place and continually improve the effectiveness of Health &

Safety system.

To meet these objectives the KSSKL will.

Comply all relevant Laws, regulation, statutory provisions & codes of practice.

Continually asses risks & hazards to evolve establish & upgrade hazard control measures,

emergency preparedness, & risks mitigation and correct the deficiency identified in timely

manner.

Ensure safe handling, storage, use and disposal of all substance & materials which are

classified as hazardous to health & environment.

Create awareness in employees by providing appropriate training, motivation information’s

so as to create individual sense of duty, responsibility & participations and an institutionalize

culture of continually improvement in Safety , Health & Environment matters.

Make HOD responsible to communicate the safety policy to all concerned in his department.

Make supervisors responsible or implementation of the safety precautions, use of safety

devices, & the safety of the people.

Empower employees at all levels to be responsible & accountable for their personal health &

safety.



Fire protection system shall be provided in accordance to the LPA regulations. The

firefighting system shall consist of a hydrant network.

The mill has installed a fire protection system including electric driven pump, one diesel

engine pump, and one jockey pump.

Portable fire extinguishers shall be provided in strategic locations in proposed unit.

2.12 Schematic representation of the feasibility drawing which give information of EIA purpose

Figure 2.6: Categorization of Proposed Project as per EIA Notification

Categorization as per EIA notification Sept 2006 –

Category A; project activity 5 (g)

Screening category- A Molasses base Distillery 5(g)

Application (Form I) and Pre-

Feasibility study as project proposal

Scoping EAC Industrial

project of MoEF&CC

Submitted to Ministry of Environment and Forest (MoEF),

Govt. of India for obtaining ‘Environmental Clearance’



3.0 SITE ANALYSIS

3.1 Connectivity

The site is well connected by road, railway as well as air network. It is approx.4.0 km away from the

state highway no. 10 (Ahmednagar- Daund), and Visapur railway station (on Daund-Manmad route

of central railway) is approx. 4 km from the project site. The international Airport of Pune (approx.

80 km) is the nearest air ports to the site.

3.2 Land form, land use and ownership

The sugar factory is holding more than 117 acres of land. The land is flat, open and already under the

industrial use (i.e. sugar factory and allied units). Total 9.5 acres is allocated for proposed distillery.

Of which main process unit will be installed in approx. 7 acre i.e. distillery, evaporation unit, finished

product storage area, spentwash lagoon, CPU and incineration boiler. For green belt development 2.5

acres is allocated, which is 33% of the plot area.

3.3 Topography

The terrain is almost flat, no hills in the surroundings. The geographical coordinates of the area are

18047’49”N, 74037’11” E. The proposed site is 629 meter above the mean sea level.

3.4 Salient Features

The proposed project will be installed within existing sugar mill premised and doesn’t require

additional land. Therefore, no social issues are involved. There won’t be change in the land use

pattern since the land is already used for industrial purpose. There is no sanctuary, national park or

biosphere reserve within the 10km radius. The project surrounding land is either fallow land or used

for agricultural purpose. There are 23 villages in the study area 10 km radius. Moharwadi small-scale

reservoir is approx. 1.5 km and another small-scale reservoir at Visapur is approx. 3.0 km away from

the project site.

Table 3.1: Salient features of the project location

Roads State Highway No.10 (Ahmednagar – Daund) is approx. 4 km and

State Highway No.50 (Shrigonda – Shirur) is approx. 16 km from the

site

Nearest settlement Village Pimpalgoan Pisa is approx. 2 km from the project site.

Railway Station Visapur railway station approx. 4 km from the site.



Air Port Pune airport is the nearest airport approx. 80 km from the site.

River Moharwadi small scale reservoir is approx. 1.5 km and Visapur small

scale reservoir is approx. 3.0 km away from the project site.

Schools Saikrupa English Medium School, Kolgaon is at approx. 5 km from

project site, Zila Parishad School is available in the village for primary

education.

Colleges Savitribai college of Arts, is at approx. 8 km from project site.

Medical and health

care centers

Vatsalya Hospital, Pimpalgoan Pisa is approx. 3.0 km from the project

site.

Banks State Bank of India, Loni Vyankanath is approx. 14 km from the

project site.

Market places Pimpalgoan Pisa is a nearest market place at approx. 2 km and

Ahmednagar from the project site.

Protected Area/

Sanctuaries/NP

Within 10km -none

Bhimshankar sanctuary, Pune is approx. at 120 km from the project

site.

Rehekuri Blackbuck sanctuary located in Karjat Taluka of

Ahmednagar 35 km, southeast of the site

Kalsubai Sanctuary located in Akola Taluka of Ahmednagar 130 km,

northwest of the site

CRZ applicability Not applicable

Seismicity Seismic Zone- III

Note: All the above-mentioned distances are the aerial distance from the project site.

3.5 Existing Infrastructure

The nearest residential area to the factory is village Pimpalgaon Pisa at a distance of 2 km towards

west.

Table 3.2: Existing Infrastructure

Land 7 acre (Already in possession of factory)

Water Source: Moharwadi Talav (Water drawl permission available from irrigation department for 78,700 m3 per annum)

Power Captive power supply from proposed boiler



Road State highway no.10 approx. 4.0 km from the site

Fuel Fuel required for steam generation will be concentrated spentwash and coal or bagasse

Steam generator

New 22TPH incinerators boilers

3.5.1 Raw Material: Molasses

Proposes distillery unit required molasses is around the 66,000 TPA, expected molasses production

is around 34,000 to 38,000 TPA if used molasses ‘C’ (4% on cane) and 50,000 to 60,000 TPA if used

molasses ‘B’ (6% on cane). It indicates, ~ 76-91% molasses will be available from own source and

therefore, it has decided to install a new distillery of 60 KLPD. Remaining molasses of 6,000 to 16,000

MT will be fulfilled by purchasing it from nearby sugar factory. There are four nearby sugar factories

assured to sell their molasses to KSSKL

3.5.2 Irrigation and transportation facilities

The KSSKL is located in the vicinity of Moharwadi and Visapur small scale reservoirs (approx. 1.5

&3.0 km from project site). For sugar cane grown under well, bore well, lift and canal irrigation in the

area.

State Highway (NH 10) and network of state and local roads in the operating area of the KSSKL.

3.5.3 Fuel

Proposed distillery require spentwash (from own process as effluent) and Coal or bagasse as fuel. In

case of Coal, it will be procure from Chandrapur/Dhanbad or as per availability. Bagasse will be made

available from own sugar mill.

3.5.4 Water

The water requirement for proposed project will be around 554m3/day for distillery. Water

conservation will be achieved by recycling of water. Excess condensate water from the sugar unit or

treated effluent will be used.

3.5.5 Power

Power generation and consumption of the proposed project will be as follows.

Table 3.3: Power details: generation, captive power need and export

Particular Power (MW)



2 MW TG set

Distillery captive 1.32

Surplus power to be exported to State grid 0.68

3.6 Soil classification

The soils in the district can generally be classified into three groups, viz., black or kali, red

or tambat, and laterite and the gray of inferior quality locally known as Baradincluding white

or pandhari. Of these, Barad soils are very poor in fertility. Two specially barren tracts may be

noticed, one on the borders of Karjat and Shrigonda and the other north of a line drawn east to west

through Takli-Dhakeshvar, ten miles north of Parner, and as far north as the slopes down to the Mula.

Near the range of the hills that runs south-east down the centre of the Shrigonda and Karjat sub-

divisions, the land is very poor with occasional patches of good light soil near Karjat, Koregaon and

other places.

3.7 Social Infrastructure available

The present project is proposed by one of the leading and progressive cooperative sugar industry

from western Maharashtra. The sugar factory has already initiated several activities for the

development of the region. Some of the prime activities are as follows.

The factory is providing medical aid to the employees and their dependents at very low cost

It provides primary school educational facilities to the children of workers

It helps member farmers by supplying fertilizers, press-mud and the developed cane seeds

approved by VSI. The factory also arranges field demonstration to educate the farmers in

sugarcane cultivation through application of scientific methods

It provides drip irrigation facilities to the sugarcane growers on subsidized basis

It has also established ‘Om Gurudev Mahila Sahakari Patsanshtha’ (Credit society) at site for

women in the area of operation

It provides insurance policy facilities for members and workers

To facilitate better transport of sugarcane, the factory has undertaken major program to

construct roads in its area of operation

Infrastructure such as road and electricity are available to all the villages in 10km

surrounding area



Schools, colleges and other educational setup is also well developed

Healthcare facilities are also available to an adequate extent

All the villages in the surrounding area are connected through bus routes as well as auto-

rickshaw services are available

4.0 PLANNING BRIEF

4.1 Planning concept

A project is proposed by one of a leading cooperative sugar mill from Ahmednagar district. Due to

expansion of sugar factory from 3,500 TCD to 5,500 TCD, it is anticipated that molasses availability

will also be increased. Almost 85 % of molasses will be available from own sugar unit and remaining

will be procured from the nearby factories. Hence, the management has decided to establish a new

molasses based distillery of 60 KLPD. It will be based on incineration technology for disposal of spent

wash.

4.2 Facilities for Transport

KSSKL is situated just 4.0 Km off the State highway 10. All the villages from the command area of

KSSKL are accessible by asphalted (pucca) road, operational year around. Hence, public

transportation is available. State transport (ST) buses ply on schedule and connect almost all the

villages of the command area.

4.3 Town and country planning / Development authority classification

The project is located at taluka Shrigonda of Ahmednagar district, village Pimpalgaon Pisa.

Grampanchyat is the local authority where the actual project will be developed. The Grampanchyat

has issued “No Objection Certificates (NOC) “for this proposed project. Since, the land used is already

for industrial purpose and will be used for the same purpose only.

4.4 Population projection

No population flux is projected because the distillery will employ candidates from local areas. Only

for exceptional posts it may employ candidates from other areas. In that case existing colony, have

the facilities to accommodate the additional man power for the new activity.

4.5 Land use Planning

Total land available with sugar mill is 117 acre. Out of which distillery, evaporation plant,

incineration and CPU unit required built up area will be of ~7 acre and 2.5 acres is for green belt area.



Around 9.5acres of land required for the proposed activity which already available in existing

industrial complex.

4.6 Assessment of infrastructure Demand (Physical & Social)

The basic infrastructure such as roads, electricity, transportation, drinking water supply, health

centers and hospitals, school, colleges, sanitation facilities are available in the vicinity. The proposed

project is not going to exert any unbearable load on any of these resources.

4.7 Amenities/ Facilities

Following amenities/facilities are available at sugar factory

Guest house facility

Petrol pump

Canteen

Medical facility

Separate dedicated parking facility for goods vehicle and personal vehicles at site

Provision of street light within premises as well as on approach road

Rest room

Security check post and round the clock security persons on duty

Fire extinguishing facilities

Housing colony for employees

Drinking water and power supply to housing colony

Diesel generator as a backup facility

water treatment plant

5.0 PROPOSED INFRASTRUCTURE

5.1 Industrial Area

The proposed project will be carried out in the existing factory premises only. The total allocated

land for the proposed project is 9.5 acres.

5.2 Residential Area

The residential colony is already available in the factory premises, it can be accommodate proposed

population.

5.3 Greenbelt Area

The total greenbelt area provided is ~2.5 Acre.

5.4 Social infrastructure



All type of infrastructure is already available in the vicinity.

5.5 Connectivity

State highway 10 as well as Zilla Parishad road infrastructure exists.

5.6 Drinking water

KSSKL draws water from Moharwadi Talav. It operates a special water treatment plant to supply the

drinking water to factory as well as the staff colony.

5.7 Industrial waste management

Distillery spent wash is the major source of liquid waste which will be disposed through incineration

boiler along with coal/bagasse. The Process condensate from evaporators and spent lees from the

process will be treat in Condensate Polishing Unit (CPU) and used for molasses dilution, process and

cooling tower make up water. The sanitary wastewater shall be disposed by using septic tank and

soak pit system. Thus, due to proper treatment of effluent, disposal of treated water within the

factory premises and recycling of it, the issue of wastewater is envisaged to be insignificant.

Table 5.1: Solid/ Hazardous waste generation, treatment & Disposal

# Waste Quantity

MT/annum

Upshot

1 Yeast sludge 80 Used as a soil enriching material

2 Incineration Boiler Ash 11,967or 9,475 sold to brick manufacturing units

3 CPU Sludge 70 Used as a soil enriching material

4 Spent oil from DG 0.1-0.2 KL Spent oil is burnt in boiler

5.8 Power Requirement and Source

Power requirement for proposed unit will be 1.32 MW, which will be fulfilled through captive power

generation. The generation and consumption of power is as follows.

PARTICULAR POWER ( MW)

2 MW TG (DISTILLERY)

DISTILLERY 1.32

SURPLUS POWER TO BE EXPORTED TO STATE GRID 0.68

5.9 Rehabilitation and Resettlement (R & R) Plan



There will be no any issue of rehabilitation and resettlement (R & R) for the proposed project, since

the required land is available with the factory.

5.10 Project Scheduled & Cost Estimates

Table 5.2: Project scheduled & cost estimate

1. Date of start of construction

(Anticipatory)

April2019

2. Date of completion (Anticipatory) December 2019

3. Proposed Project cost Rs. 7,954 lakhs

4. EMP cost Rs. 2,820 lakhs

5.11 Analysis of proposal (Final Recommendations)

I) Benefits

This industry will produce RS, ENA and Anhydrous Alcohol (fuel ethanol) which are useful

products for the country, which will earn & save foreign exchange in the potable alcohol cadre

as well blending in petrol

Shareholders are likely to get good rates for the cane

No external electricity required due to in house power generation in the proposed activity

The evaporation condensate, spent lees and other non-polluting water will be recycle in to

the process and cooling tower makeup water which will minimize the fresh water

requirement

Solid waste like sludge from process and CPU, and ash from incinerator boiler are also a soil

enriching materials

Compatible architecture will be adopted and land is already under industrial use. Trees will

be maintained and not razed down. No Rehabilitation is involved.

The problematic liquid waste materials such as distillery spent wash will disposed in the

incinerator boiler and achieve the ZLD in proposed activity

The process is straight line and the technology even for the pollution control/disposal are

available indigenously

Indirect employment to many since, the project will be exporting electricity to local grid

The aggregate effect of the project is likely to boost the local economy

Direct employment opportunities preferably for local youths. The member farmers will get

proper price to their sugar cane



II) Conclusion

a) New distillery is very necessary for effective utilization of byproducts of sugar factory i.e.

molasses

b) The local people including shareholder sugarcane growers are strongly willing for the project

and have already given the permission to the management to develop and execute the

proposed project.

c) The site is suitable from general MoEFCC guidelines.

d) Water, power, raw material, filler material and market is assured and found available with

ease.

e) Full precautions will be taken for pollution control, resource conservation and environmental

protection.

f) All the units are agro-based and hence promote sustainable development

Documents

New 60 KLPD Molasses Based Distillery Unit of M/s. Kukadi … · 2018-09-15 · iii) The present site meets the guidelines for sitting of an industry prescribed by MoEF&CC 2.4 Size