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Prefeasibility Report

12/12/2016

PRE-FEASIBILITY REPORT Expansion cum modernization of sugar factory capacity from 4800 to 8000 TCD, cogeneration power plant from 22 MW to 45 MW and distillery 30 KLPD to 95 KLPD capacities

Belawadi-Kalamma, Tal.Kagal, Dist. Kolhapur, Maharashtra.

By

Sar Senapati Santaji Ghorpade Sugar Factory Ltd.

Distillery Consultants

Business Brains

Royal Prestige, E-5, 1127, E Ward, Sykes Extension, Kolhapur 416 001, Maharashtra. Telephone No: +91 (0) 231+2529813 Cell No. : +91 (0) 9823139883 Email: [email protected]; [email protected] web site: www.ethanolindia.net

Environmental Consultant

SMS Envocare Limited

QCI-NABET Accredited Consultant Organization

301, Pentagon P3, Magarpatta city, Hadapsar, Pune 411028, Maharashtra. Tel: 020-66801112/3 Email: [email protected] Website: www.smsenvocare.co.in

mailto:[email protected]


http://www.ethanolindia.net/


http://www.smsenvocare.co.in/

Expansion cum modernization of sugar unit from 4800 TCD to 8000 TCD along with

cogeneration unit from 22 to 45 MW and distillery unit from 30 KLPD to 95 KLPD

at village Belewadi Kalamma, Tal. Kagal, Dist. Kolhapur, Maharashtra



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Content

Sr. No. Items Page no.

1. Executive summary 3

2. Introduction 3

3. Project description 6

4. Site analysis 18

5. Planning in brief 19

6. Proposed infrastructure 20

7. Rehabilitation and resettlement plan 21

8. Project schedule and cost estimate 21

9. Analysis of the proposal 21






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1. Executive summary

Sar Senapati Santaji Ghorpade Sugar Factory Limited (SSSGSFL) is a sugar factory located at

village Belewadi Kalamma, Tal. Kagal, Dist. Kolhapur in Maharashtra State. The present

registered crushing capacity of SSSGSFL is 4800 TCD. In view of sufficient cane availability to

the extent of more than 9-10 lac MT with increased irrigation facilities in the area of

operation from season 2016- 17 and future trends for next five season, SSSGSFL has decided

to carry out modernization cum expansion of sugar plant from 4800 TCD to 8000 TCD along

with expansion of cogeneration from 22 MW to 45 MW and distillery from 30 KLPD to 95

KLPD. All proposed equipment’s of modernization cum expansion along with expansion of

cogeneration project will be commissioned in 2017-2018 season, and technical efficiency

figures considered in Modernization cum Expansion with expansion of cogeneration project

report.

2. Introduction

2.1 Project proponent

Sar Senapati Santaji Ghorpade Sugar Factory Ltd., was registered under the Maharashtra

State Cooperative Societies Act 1960 having registration No. U15421 PN.2011PLC 138600,

dated 04-10-2011. Sar Senapati Santaji Ghorpade Sugar Factory Ltd., is an integrated sugar

mill situated at village Belewadi Kalamma, Tal. Kagal, Dist. Kolhapur at a distance of 70 km

from Kolhapur. The site is about 50 km away from Kagal city towards east direction on

Kolhapur-Goa road in the State of Maharashtra. It is one of the progressive and modern

sugar mills in Maharashtra and was established in the year 2014.

2.2 Nature of the project

The present crushing capacity of SSSGSFL 4800 TCD along with 22 MW cogeneration plant

with 30 KLPD distillery and incineration boiler. Factory proposing modernization cum

expansion project from 4800 TCD to 8000 TCD along with expansion of cogeneration project

from 22 MW to 45 MW and distillery from 30 to 90 KLPD distillery.

2.3 Need of the project and its importance to the country and or region

India was the first to begin with the production of sugar following the process of sugarcane

to extract juice to boil and it to get crystals. India is well known as the original home of sugar






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and sugarcane. The government of India in 1950-51 made serious industrial development

plan and has set many targets for production and consumption of sugar. India is regarded

second after the textile Industry in India as per the agro-processing Industry in the country.

India is the largest sugar consumption and second largest producer of sugar in the world

according to the USDA foreign Agricultural services.

The industry currently has more than 550 operating sugar mill in different part of the

country. Indian sugar industry has always been a focal point for socioeconomic development

in the rural areas. Today nearly 550 million sugarcane farmers and large number of

agricultural labors are involved in sugarcane cultivation and ancillary activities contributing

to 7.5% of the rural population.

Indian Sugar Industry generates power to its own requirement and even gets surplus power

to the grid based on byproduct bagasse. There is even production of ethanol, an ecology

friendly and renewable energy for blending with petrol.

The existing licensed crushing capacity of SSSGSFL is 4800 TCD, which is effected from the

year 2014. Last two years performance of SSSGSFL is tabulated in Table 1.

Table 1: Last two years performance of SSSGSFL

Sr. No. Particulars Seasons

2014-15

1. Cane Crushed (Lac MT) 4.76

2. Sugar Produced (Lac Qtls.) 6.16

3. Recovery % Cane 12.92

4. Molasses Produced (MT) 19585

5. Press-mud produced (MT) 19060

Based on proposed expansion cum modernization programme of the SSSGSFL, the expected

performance in the coming five years is indicated in Table 2. Cane molasses is produced by

SSSGSFL @ 4.50 % on cane crushed based on last two years molasses production. Hence,

future molasses production is also calculated based on previous data.

Table 2: Predicted future five years performance of SSSGSFL

# Particulars

Seasons

2016-17 2017-18 2018-19 2019-20 2020-21

1 Cane to be Crushed (Lac MT) 6.50 12.00 12.00 12.00 12.00

2 Sugar to be Produced (Lac Qtls.)

8.26

15.24

15.24

15.24

15.24

3 Recovery % Cane 12.75 12.70 12.70 12.70 12.70






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# Particulars

Seasons

2016-17 2017-18 2018-19 2019-20 2020-21

4 Molasses to be Produced (MT) 29250 54000 54000 54000 54000

5 Press-mud to be produced (MT)

26000

48000

48000

48000

48000

As per cane availability potential and considering the present sugarcane productivity and

existing area of 24000 hectares under sugarcane; with enrollment of new sugarcane

members and nonmembers will be available for crushing.

In view of the above, modernization cum expansion project from 4800 TCD to 8000 TCD for

SSSGSFL has been considered.

Distillery

The policy of Central Government is to increase percentage of ethanol blending with petrol

from the present 10% to 20% by the year 2017. Therefore, it is important to all distilleries in

the country to increase its ethanol production to meet the demand & supply.

The performance of SSSGSFL is expected to improve in coming few years. To exploit more

benefit from this industrial complex, the management of the SSSGSFL has decided to

modernize and expand its distillery capacity from 30 KLPD to 95 KLPD. For proper and

complete treatment of spent wash after proposed expansion of distillery SSSGSFL

management has also decided to install integrated evaporation followed by multiple effect

evaporation plant followed by incineration system, TG set and process condensate polishing

unit to achieve “Zero Spent Wash Discharge”.

2.5 Demand- Supply Gap and Import V/s Indigenous generation

Indian domestic sugar market is one of the largest markets in the world; in volume terms. It

remains a key growth driver for world sugar, growing above the Asian and world

consumption growth average. Sugar is one of the most important cash crops in the world

and hence there is always a wrestle to control its imports/export.

India, sugar is an essential item of mass consumption and the cheapest source of energy,

supplying around 10 percent of the daily calorie intake. India is the second largest producer

of sugar (16.3 million ton production in 2008 ‐ 09).It, however, ranks 15th in export rankings

(0.23 million ton exports in 2008 ‐ 09) as India is the largest consumer of sugar in the world.






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Raw as well as refined sugar prices plunged this year on expectation that output in Brazil

and India, the second‐biggest producer, will increase.

The world's largest consumers of sugar are India, China, Brazil, USA, Russia, Mexico,

Pakistan, Indonesia, Germany and Egypt. Brazil & India are the largest sugar producing

countries followed by China, USA, Thailand, Australia, Mexico, Pakistan, France and

Germany.

The world consumption is projected to grow to 160.7 MMT in 2010 and 176.1 MMT by

2015. India is predominantly an agro based economy. Sugarcane plays a very vital role in

this agro based economy by providing sugar, the main sweetener used in India. With the

growing demand for sugar, the emphasis has been on increasing sugar production.

In India the annual per capita consumption of white crystal sugar and that of non-centrifugal

sugar is 15 kg per annum and 23 kg per annum respectively. The annual overall consumption

of the centrifugal and non- centrifugal sugar in the country comes to more than 25 million

tons. Thus, there is vast untapped potential for growth in the area of sugar production.

Alcohol/Ethanol

Alcohol has assumed very important place in the country’s economy. It is vital raw material

for a number of chemicals. It has been a source of large amount of revenue by way of Excise

Duty levied by State Government on Alcoholic liquors. It has a potentiality as fuel in the

form of fuel ethanol for blending with petrol in the ratio of maximum 26:74.

The world total ethanol production in the year 2015-16 was 117.52 billion liters and major

consumption of alcohol was for fuel purpose. Many countries, including Brazil, USA, Canada,

Sweden and China have already started using anhydrous ethanol for blending with petrol. In

our country, the Central Government has taken a policy decision to start using anhydrous

alcohol (fuel ethanol) for blending with petrol as explained above. Thus, it is expected that

the demand of alcohol for fuel purpose is going to increase in coming years.

Domestic / Export Markets

A huge demand of sugar and huge demand of alcohol is in the national and international

market. Indians by nature have a sweet tooth and sugar is a prime requirement in every

household. Almost 75% of the sugar available in the open market is consumed by bulk

consumers like bakeries, candy makers, sweet makers and soft drink manufacturers.






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Khandsari sugar is less refined and is typically consumed by sweet makers. Gur, an unrefined

form of lumpy brown sugar, is mostly consumed in rural areas, with some quantities illegally

diverted for alcohol production. Greater urbanization & rising standard of living have

sparked of a rising trend in usage of Sugar. Industrial consumption for sugar is also growing

rapidly particularly from the food processing sector & sugar based bulk consumers such as

soft drink and ice cream manufacturers.

Alcohol

Export Possibility

Export possibility for sugar is totally dependent on government’s policies.

2.6 Employment generation (Direct & Indirect)

The total man power required for sugar, cogeneration 80-100 and for proposed distillery

100 Skilled and unskilled.

3. Project description

3.1 Type of the Project

Proposed project is of expansion and modernization of existing sugar & cogeneration power

plant by 4800 TCD to 8000 TCD for sugar, 22 MW to 45 MW cogeneration power plants and

distillery capacity from 30 KLPD to 95 KLPD.

As per EIA Notification dated 14th September, 2006 and its amendment thereof, the Sugar

expansion project comes under category “B”, activity - 5(j) (≥5000 TCD cane crushing

capacity); cogeneration plant expansion is under category “B”, Activity-1(d) (Thermal power

plants) and distillery expansion from 30 KLPD to 95 KLPD is falls under Category “A” activity

5(g) (All molasses based distillery)

Hence, we are putting our combine / integrated expansion cum modernization proposal of

Sugar, cogeneration and distillery to Expert Appraisal Committee (EAC) Ind-II of MoEF&CC

for the grant of ToR.






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3.2 Location of the project

The project site is located at village Belewadi Kalamma, Taluka. Kagal, Dist. Kolhapur at a

distance of 70 km from Kolhapur. Site is geographically located at Long:16°16' 55.00" N, Lon:

74°14' 48.56" E and 685 m above MSL. Location map of the project is given in Figure 1.

Figure 1: Proposed project location map

Figure 1: General location of the project


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Figure 2: Project Layout

Expansion cum modernization of sugar unit from 4800 to 8000 TCD along with





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3.3 Details of the alternate sites

No alternate sites have been examined, as proposed project will be located in existing factory

premises.

3.4 Size or magnitude of operation

Size and magnitude of proposed expansion is briefed in Table 3.

Table 3: Project information in brief

Sr. No.

Particulate Description

1. Project Expansion cum modernization of sugar from 4800 to 8000 TCD along with cogeneration expansion from 22 MW to 45 MW and distillery from 30 KLPD to 95 KLPD

2. Available land Total plot area : 85 acres Sugar and cogeneration: 33 acres Distillery area: 15 acres Other Misc: 10 acres Green belt area: 27 acres

3. Product Products Existing Total Proposed

Cane crushing 4800 TCD 8000 TCD

Sugar 600 TPD (12.05% on cane)

1000

Bagasse 1368 TPD 2280 TPD

Molasses 192 TPD 307 TPD

Press mud 192 TPD 320 TPD

Power generation 22 MW 45 MW

Pure Rectified Spirit/ Impure Spirit/ENA

30.0 KLPD 95 KLPD

4. Operation days Sugar factory season: 160 day Cogeneration : 330 (Seasonal operational days 160 and off season operational days 170) Distillery: 330 days

5. Sugarcane required 8000 TPD

6. Molasses requirement 562.5 TPD

7. Water requirement Sugar and cogeneration

Existing sugar and cogeneration fresh water requirement: 482 CMD

For expansion Sugar 188 CMD

For expansion cogeneration 1186 CMD (Initial startup)

Distillery

Existing 260 CMD

Expansion 563 CMD for proposed expansion






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8. Source of water Chikotra river. Permission is available from Executive Engineer, Kolhapur Irrigation department, Kolhapur

9. Boiler Exiting boiler: 120 TPH X 1 Proposed: 120 TPH X 1 Distillery existing incineration boiler 10 TPH Proposed incineration boiler 20 TPH (2.2 MW TG)

10. TG Exiting TG : 22 MW Proposed TG: 23 MW Distillery incineration boiler 2.2 MW TG

11. Electricity # Particulate Quantity

Season

1 Total power generation 43.070 MW

2 Sugar plant including boiler(New + Old)

8.184 MW

3 Cogeneration plant (New + Old) 3.61 MW

4 Office /Colony / other 0.20 MW

5 Existing distillery and spent wash boiler

0.80 MW

6 Total captive power consumption 12.794 MW

7 Surplus exportable power 30.276 MW

8 Power requirement for distillery 2.2 MW

Off season

1. Power Generation form TG set 22 MW

2. Cogeneration plant 1.96 MW

3. Office /Colony / other 0.20 MW

4. Distillery and spent wash boiler 0.80 MW

5. Total captive power consumption 2.96 MW

6. Surplus exportable power 20.04 MW

12. Fuel- Bagasse

Total (Exiting + proposed) Bagasse balance

1. Bagasse production(28.5% on cane) 97.185 TPH

2. bagasse available for the steam generation 27.5% on cane

93.775 TPH

3. Bagasse used for 120 TPH existing boiler

44.98 TPH

4. Bagasse used for 120 TPH new boiler 42.81 TPH

5. Total bagasse required as fuel for boiler

87.79 TPH

6. Saved bagasse (1.75% on cane) during season

5.985 TPH i.e. 21000 T

Off season

1. Total bagasse saved during the season 21000 T

2. Bagasse used for 120 TPH x 01 nos boiler having 88.25 TPH load (steam to bagasse ratio 2.65)

33.30 TPH






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13. Coal Existing 30 KLPD distillery Coal: 1.25 TPH Proposed 65 KLPD distillery Coal : 2.75 TPH

14. Steam S. No

Particulate Quantity

1. Steam from existing boiler 120 TPH

119.23 TPH

2. Steam from proposed 120 TPH

113.45 TPH

3. Existing and proposed Steam requirement

20 TPH (New 20 TPH and old 10 TPH incineration boilers.

15. Total effluent generation Sugar + Cogeneration Factory Existing effluent generation: 500 CMD Proposed generated effluent: 300 CMD ETP capacity: 800 CMD Distillery Existing effluent generation 288 CMD Existing CPU : 288 CMD Proposed effluent generation 640 CMD Proposed CPU capacity: 640 CMD (Process condensate, blow down, excess condensate Misc.)

16. Effluent treatment system Existing 500 CMD ETP from sugar unit & co-generation power plant is being treated in proposed ETP capacity 800 CMD and treated water is recycled/reused in greenbelt development and ferti-irrigation. Effluent from distillery spent wash generation will be ~ 950 CMD. Generated spent wash will be concentrated in integrated evaporation and burn in spent wash fired boiler.

17. Ash Sugar

Existing bagasse ash generation: 19 TPD (2% on total bagasse consumption)

Proposed bagasse ash generation: 18-19 TPD Distillery

Coal ash from existing distillery: 7.5 TPD (Max 25 % of coal consumption)

Coal ash from proposed distillery: 16.5 TPD

Spent wash ash from existing distillery: 9-10 TPD (Max 15% of spent wash consumption)

Spent wash ash from proposed distillery: 20 TPD

Bagasse and spent wash ash collected from the furnace bottom hoppers can be used as landfill or the high potash






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content in the bagasse ash is good manure. Coal ash will be sold to the brick manufacturer.

18. ETP sludge The sludge from primary clarifies, settling tank and secondary clarifier will be sent to sludge drying beds. Sludge will be dried in natural heat of sunlight. The dried cakes will be scrapped off periodically and can be utilized for as manure.

19. Air pollution control measures

Proposed: Electrostatic precipitators Existing: Electrostatic precipitator Proposed Stack height: 85 m Existing stack height: 85 m

20. Man-power For Sugar and cogeneration 80-100 Skilled and unskilled For proposed distillery 100 Skilled and unskilled

21. Total project cost Sugar expansion: 3810.40 lacs Cogeneration expansion: 871.43 lacs Project cost of the distillery : 84.2546 cr.

22. Total EMP cost Sugar proposed: 1.78 Cr. Distillery : 2.05 Cr.

Environment Sensitivity

23. Nearest Village Belewadi Kalamma

24. Nearest Town / City Gargoti 12.0 km Gadhinglaj 12.2 km

25. Nearest National Highway NH-4 (Mumbai- Chennai) 17.31 km towards north east

26. Nearest Railway station Chhatrapati Shahu Maharaj Terminus railway station 46.15 km

27. Nearest Airport Belgavi airport: 62 km Kolhapur airport: 42.67 km

28. National Parks, Reserved Forests (RF) / Protected Forests (PF), Wildlife Sanctuaries, Biosphere Reserves, Tiger/ Elephant Reserves, Wildlife Corridors etc. within 10 km radius

Higher Elevation of Village Murukate 8.30 km is at the end of Eco-sensitive area declared in MoEFCC notification S.O. 2435(E).–4th September, 2015 Latitudes and Longitudes of prominent points on the outer boundary of Eco-sensitive area point number 94, Lat. 74.1853 Long. 16.2414.

29. River / Water Body (within 10 km radius)

Chikotra river : 1.16 km






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3.5 Manufacturing process details

A: Sugar and cogenration power plant

B: Distillery manufacturing process details

Fermentation

Weighed & prepared sugarcane

Milling/ crushing

Juice

Juice Clarification

Juice Sulphitation

Syrup boiling

Centrifugation

Crystallizer

Drying

Sugar

Molasses

Bagasse Power

To grid

To factory

Press mud

Mix with boiler ash and use as manure

Distillery

Boiler

Turb

ine

Alternator

Condenser To Feed water

heater/ Cooling Tower

Steam to

Effluent

Alcohol (Rectified Spirit /

Extra Neutral Alcohol)

Dehydration using Molecular Sieve

RS/ENA/TA Used as Boiler Fuel

Concentrated Spent wash

Evaporation in Multi-Effect

Spent Wash Multi-pressure Distillation

Fermented Wash

Molasses, Yeast, water






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3.6 Raw material requirement

The raw material requirement is given below,

Table 2: Raw materials

Sr. No. Raw material Existing Proposed

1. Sugarcane 4800 TCD 8000 TCD

2. Lime 6.72 TPD 11.2T

3. Sulphur 1.92TPD 3.2 TPD

4. Molasses 192 TPD 320 TPD

5. Coal 1.25 TPH 2.75 TPH

3.7 Resource Optimization / recycling and reuse

Required water source is Chikotra River. There is no ground water extraction. Waste water

generated in sugar and cogeneration power plant will be treated in aerobic ETP and the

treated effluent will be used for irrigation purpose. Water will be recycle and reuse at each

possible. Effluent generation from distillery will be treated in condensate polishing unit;

treated waste water will be recycled in process. Spent wash will be concentrated in

integrated evaporation and burned in spent wash fired boiler.

3.8 Project requirement

3.8.1 Availability of Water

Existing water requirement of sugar and cogeneration plant is water requirements for the

proposed project will be met from Chikotra River. Water extraction permission for the same

is available. A water storage tank is at the place to ensure adequate water supply. Efforts

will be taken to minimize & conserve water.

3.8.2 Power requirement

Total power requirement for the existing and proposed plant will be 12.794 MW (sugar,

cogeneration, existing distillery boiler and other colony etc.).Total power generation from

existing and proposed cogeneration power plant will be 43.070 MW. Thus the cogeneration

plant will export 30.276 MW power. Total power requirement for distillery will be 2.2 MW






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3.8.3 Steam balance

S. No Particulate Quantity

Steam Generation

1. Steam generation from existing boiler 120 TPH 119.23 TPH

2. Steam generation from proposed 120 TPH 113.45 TPH

Steam Consumption proposed

1. H.P. heater II 10.20 TPH

2. H.P. heater I 9.00 TPH

3. Sugar plant process 88.00 TPH

4. De-aerator 06.10 TPH

5. Total 113.3

Steam Consumption existing

1. H.P. heater II 10.71 TPH

2. H.P. heater I 8.73 TPH

3. distillery operation 8.00 TPH

4. Sugar plant process (34.5% on cane) 64.72 TPH

5. De-aerator 6.49 TPH

6. Extracted steam 20.52 TPH

7. Total 119.17 TPH

3.8.4 Boiler details

S. No.

Boiler Capacity TG set capacity Fuel type Stack height (m)

1. Existing sugar & Cogeneration boiler

120 TPH 22 MW(Condensing)

Bagasse 85

2. Proposed boiler for expansion of sugar & cogeneration

120 TPH 23 MW (Back pressure)

Bagasse 85

3. Existing distillery spent wash fired boiler

10 TPH -- Concentrated spent wash and coal

-

4. Proposed new spent wash fired boiler

20 TPH 2.2 MW Concentrated spent wash and coal

-

3.9 Quantity of wastes generation

3.9.1 Liquid Waste Generation

The existing crushing capacity of factory is 4800 TCD and generation of effluent is about

500 CMD. The existing effluent treatment plant is suitable for treatment of waste water






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of 800 CMD. After segregation of cooling water & condensate water, the quantity of

sugar factory effluent to be treated during the sugar factory season is about 800 CMD.

Considering proposed quantity of effluent, it is proposed to treat through existing

aerobic treatment. The treated effluent will be useful for irrigation purpose.

Molasses is effluent generated from Sugar industry. This is being/will be used as raw

material in distillery for alcohol production.

Aqueous discharges arise from cogeneration sources includes cooling tower blow down,

sluice water from the bottom ash handling system, boiler chemical cleaning solutions, ion

exchange regeneration solutions from the dematerializing water plants, boiler blow

down, sewerage system discharges from buildings and plant floor drains.

Blow down will be put into excess condensate. The condensate does not normally

contain any pollutant. It is used as boiler feed water and for the washing operations or

water can directly be used for irrigation, after cooling it to ambient temperature.

Effluent from water treatment plant

RO + DM Plant: Hydrochloric acid and sodium hydroxide will be used as regenerates in

the proposed demineralizing water plant. The acid and alkali effluents generated during

the regeneration process of the ion-exchangers would be drained into an epoxy lined

underground neutralizing pit. Generally these effluents are self-neutralizing. However

provisions will be made such that the effluents will be neutralized by addition of either

acid or alkali to achieve the required pH of about 7.0. Quantity of effluent will be 50

CMD. The effluent will then be pumped into the effluent treatment plant which form part

of the sugar plant's effluent disposal system.

Sewage from various buildings in the power plant area will be conveyed through separate

drains to the septic tank. The effluent from the septic tank will be disposed in soil by

providing disposing trenches. There will be no ground pollution because of leaching due

to this. Sludge will be removed occasionally and disposed of as land fill at suitable places.

The existing system in the plant will be used and there will be no new addition.

Distillery

The low strength effluent generated i.e. process condensate will be treated through

condensate polishing unit and recycled back to process and non-process applications. DM

water requirement for boiler and steam condensate water recycle back to boiler.






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Spent wash will be concentrated in integrated evaporation and concentrated spent wash

will be incinerated in spent wash fired boiler.

3.9.2 Solid waste generation and management

The sludge from primary clarifies, settling tank and secondary clarifier will be sent to

sludge drying beds. Sludge will be dried in natural heat of sunlight. The dried cakes will be

scrapped off periodically and can be utilized for as manure.

Fly ash collected from the ESP hoppers and the air heater hoppers and the ash collected

from the furnace bottom hoppers can be used as landfill. The ash content in bagasse is

less than two percent (2%). The total fly ash collected could be used as a landfill or the

high potash content in the bagasse ash makes it good manure also.

Sugar

Existing bagasse ash generation: 19 TPD (2% on total bagasse consumption)

Proposed bagasse ash generation: 18-19 TPD

Distillery

Coal ash from existing distillery: 7.5 TPD (Max 25 % of coal consumption)

Coal ash from proposed distillery: 16.5 TPD

Spent wash ash from existing distillery: 9-10 TPD (Max 15% of spent wash

consumption)

Spent wash ash from proposed distillery: 20 TPD

Bagasse and spent wash ash collected from the furnace bottom hoppers can be used as

landfill or the high potash content in the bagasse ash is good manure. Coal ash will be sold

to the brick manufacturer.

3.9.3 Air pollution

Bagasse based co-gen project is environmental friendly as bagasse being a biomass

renewable fuel does not add any net carbon-di-oxide to the atmosphere, because of

the carbon recycling during the growth of cane.

The air pollutant that are discharged from the proposed unit are;

- Dust particulate from fly ash in flue gas

- Nitrogen oxide in flue gas






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- Sulphur-di-Oxide in the flue gas

The proposed plant operates during cane crushing season and off-season by using

bagasse generated by the factory during season. Electrostatic precipitators are

proposed for the plant steam generator, to contain the dust emission from plant to a

level less than 150 Mg/Ncum during bagasse firing.

Bagasse contains very less sulphur and hence the criteria for fixing stack height based

on sulphur-di-oxide emissions are not applicable here for bagasse firing. The

temperatures encountered in the steam generator while burning high moisture bagasse

are low enough to minimize the nitrogen-oxides production. Moreover, the tender

specification for steam generator will stipulate over fire air system with staged

combustion which will also ensure reduction in nitrogen-oxide emission. Hence, no

separate measures are taken to contain the nitrogen oxide pollutants.

3.10 Schematic representation of the feasibility drawing which give information of EIA

purpose

Sugar Expansion from 4800 TCD to 8000 TCD

Category “B” Activity - 5(j) (≥5000 TCD cane crushing capacity)

Integrated proposal to EAC-II for grant for ToR

Expansion of cogeneration from 22 MW to 45 MW

Category “B”, Activity-1(d) >15 MW plants based on

biomass fuel

Screening category for combine project Cat A

Scoping by EAC Ind-II Committee, MoEFCC

ToR application: Form I & Pre- Feasibility study to MOEFCC

for grant of ToR

Expansion distillery from 30 KLPD to 95 KLPD

Category “A”, Activity-5(g) All molasses based on

distillery






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4.0 Site analysis

4.1 Connectivity

Details of connectivity towards proposed site is given below,

Road NH-4 (Mumbai- Chennai) 17.31 km towards north east

Belewadi Kalamma- Dhamne road adjacent to the factory

Gadhinglaj-Gargoti road 1.64 km

Nipani- Ajara Link road 4.45 km

Railway Chhatrapati Shahu Maharaj Terminus railway station 46.15 km

Air Belgavi airport: 62 km

Kolhapur airport: 42.67 km

Nearest town/city Nipani: 20 km

Kagal : 35 km

4.2 Land form, land use and land ownership

The total land is in possession with management. Land is with undulating topography.

Proposed expansion will be in the exiting factory premises only.

4.3 Topography

The topography of the land is with undulating patches.

4.4 Existing land use pattern

The existing land is used for industry purpose.

4.5 Existing Infra structure

Maximum resources like water, power etc. is available with the existing factory.

4.6 Soil classification

Medium and Deep Black Soils (madhyam or bhari kali mati) are found in the area.

4.7 Climate

The temperature has a relatively narrow range between 10 °C to 35 °C. Maximum

temperatures rarely exceed 38 °C and typically range between 33 and 35 °C. Lows during

this season are around 24 °C to 26 °C.

The city receives abundant rainfall from June to September due to its proximity to the

Western Ghats. Winter from November to February. Lows range from 9 °C to 16 °C while






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highs are in the range of 26 °C to 32 °C due to its high elevation and being adjacent to the

Western Ghats. Humidity is low in this season making the weather much more pleasant.

Average yearly rainfall is about 764.00 mm.

4.8 Social infrastructure available

Social infrastructures like community center, hospital and electricity are available in the

area.

5.0 Planning Brief

5.1 Planning Concept

The existing unit is Sugar factory along with cogeneration power plant, distillery industry.

Proposed expansion of sugar, cogeneration and distillery will be done within the existing

plant premises by modernization & efficiency improvement. Facilities required for the

proposed capacity enhancement project will be provided as per requirement.

5.2 Population projection

The proposed activity will generate total 80 - 100 for sugar-cogeneration and ~100 for

distillery, skilled and unskilled employee opportunities. No influx, migration of population is

expected as labor shall be deployed from the local villages.

5.3 Land use planning

Total land in possession is 82 acres.

Sugar factory: 20 acres

Cogeneration: 10 acres

Distillery: 15 acres

Colony misc. : 10 acres

Green belt area will be: 27 acres

5.4 Amenities/Facilities

Facilities like canteen, rest rooms and recreation facilities are available with existing unit.






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6. Proposed infrastructure

6.1 Industrial area

No additional infrastructure will be required for the proposed capacity enhancement project

as the same will be done within the existing plant premises by modernization & efficiency

improvement.

6.2 Residential area

No residential area is envisaged. Facilities like canteen, rest room etc., and facilities are

provided in the existing units.

6.3 Green belt

Total 27 acres of Green belt will be developed in proposed project premises.

6.4 Social Infrastructure

Proposed capacity enhancement plant will result in growth of the surrounding areas by

ancillary development and supporting infrastructure in the region. Factory will identify the

need of the villagers and accordingly execute the CSR activity.

6.5 Connectivity

The site is well connected with communication facilities like telephone, fax, and wireless as

such, no constraints are envisaged in this aspect as the tehsil and district headquarters are

near to the site.

6.6 Drinking water management

Total 5-10 CMD water will be required for drinking propos.

6.7 Sewerage system

Domestic waste water generated will be sent to septic tank via soak pit.

6.8 Industrial waste management

Details of waste management are described in point 3.9.

6.9 Solid waste management

Solid waste generation detains described earlier in 3.9.2.






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6.10 Power requirement & Supply / Source

Details of power requirement is described 3.8.2

7.0 Rehabilitation & resettlement plan

No rehabilitation or resettlement will occur. Hence no rehabilitation or resettlement plans.

8.0 Project schedule and cost estimate

The cost of project has been estimated for sugar Rs. 3.810 cr., and for cogeneration Rs.

871.43 lacs which comprises of land, civil construction, plant & machineries, misc. fixed

assets, pre-operative expenses & margin money for working capital. Estimated project cost

for distillery 84.2546 cr. A provision for contingency has been made to take care of inflation

and changes due to delays if any. Cost for environment management has been estimated to

Rs. 1.78 cr. for sugar-cogeneration expansion and for distillery expansion estimated EMP

cost will be 2.05 Cr.

9.0 Analysis of proposal

A financial and social benefit has been considered while analyzing the proposal. The

proposal is environmental compatible and will helps to people improving their financial

status of the local people. Corporate Social Responsible (CSR) program shall be executed on

need base.

Documents

PRE FEASIBILITY REPORT - …environmentclearance.nic.in/writereaddata/Online/TOR/11_Jan_2017...PRE-FEASIBILITY REPORT Expansion cum modernization of sugar factory ... to extract juice