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Shree Pandurang SSK Ltd., Shreepur, Tal- Malshiras, Dist- Solapur Pre-Feasibility Report
i
PRE-FEASIBILITY REPORT
“Proposed Expansion of Sugarcane Crushing Capacity from 6000 TCD to 10000 TCD, Distillery Capacity from 45 KLPD to 90 KLPD, Ethanol 45 to 90 KLPD and Co-generation Power plant from 22
MW to 34 MW”
At
Shreepur, Tal. Malshiras, Dist. Maharashtra, by M/s.
Shree Pandurang Sahakari Sakhar Karkhana Limited.
Report Prepared By:
DR. SUBBARAO’S ENVIRONMENT CENTER ‘Arundhati’, Opp. Sahyognagar, MSEB Road, Vishrambag, Sangli-416415
Phone: 0233-2301857, (M) 9372109522, 9890992118 QCI-NABET Accredited EIA Consultant Organization Certificate No. NABET/EIA/1619/RA0057
NABL Quality Assurance Laboratory Accreditation Certificate No. TC-6121
Shree Pandurang SSK Ltd., Shreepur, Tal- Malshiras, Dist- Solapur Pre-Feasibility Report
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TABLE OF CONTENTS
TABLE OF CONTENTS ........................................................................................................................... i
LIST OF TABLES .................................................................................................................................... iv
LIST OF FIGURES ................................................................................................................................... v
LIST OF ABBREVIATIONS ................................................................................................................. vi
1. EXECUTIVE SUMMARY............................................................................................................... 1
2. INTRODUCTION OF THE PROJECT / BACKGROUND INFORMATION ........................ 3
2.1 Identification of Project and Project proponent ..................................................................... 3
2.1.1. Project Proponent ............................................................................................................... 4
2.1.2. Project Consultant .............................................................................................................. 5
2.2 Brief description of the nature of the project .......................................................................... 5
2.2.1. Environmental Clearance of existing Sugar and Distillery Plants ............................... 6
2.2.2. Consent to Operate of existing Sugar and Distillery Plants.......................................... 6
2.3 Need for the project and its importance to the country and the region ............................... 6
2.4 Demand-Supply gap ................................................................................................................... 7
2.5 Imports vs. Indigenous products .............................................................................................. 7
2.6 Export possibility ....................................................................................................................... 8
2.7 Domestic / Export markets ........................................................................................................ 8
2.8 Employment Generation (Direct and Indirect) due to the project ....................................... 8
3. PROJECT DESCRIPTION ............................................................................................................... 9
3.1 Type of project including interlinked and interdependent projects, if any. ........................ 9
3.2 Location with coordinates ......................................................................................................... 9
3.3 Details of alternate sites considered and the basis for selecting the proposed site .......... 13
3.4 Size or magnitude of the operation ........................................................................................ 14
3.5 Project description with process details ................................................................................ 14
3.5.1. Process Details .................................................................................................................. 14
3.6 Raw material required along with estimated quantity, likely source, marketing area
of the final product, Mode of transport of raw material and finished product. ............................ 26
3.7 Resource optimization/recycling and reuse envisaged in the project, should be
briefly outlined...................................................................................................................................... 27
3.8 Availability of water its source, Energy / Power requirement and source ....................... 27
Shree Pandurang SSK Ltd., Shreepur, Tal- Malshiras, Dist- Solapur Pre-Feasibility Report
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3.9 Quantity of waste to be generated (liquid and solid) and scheme for their
Management/Disposal ......................................................................................................................... 28
4. SITE ANALYSIS ............................................................................................................................. 29
4.1. Background of the Site Location ............................................................................................ 29
4.2. Connectivity .............................................................................................................................. 29
4.3. Land Form, Land use, and Land ownership ......................................................................... 30
4.4. Topography ............................................................................................................................... 30
4.5. Existing Infrastructure ............................................................................................................. 30
4.6. Soil Classification .................................................................................................................... 30
4.7. Climatic data from stationary sources ................................................................................... 30
4.8. Social Infrastructure available ................................................................................................ 30
5. PLANNING BRIEF ......................................................................................................................... 31
5.1 Planning Concept Town and country planning / Development authority
Classification ......................................................................................................................................... 31
5.2 Population Projection ............................................................................................................... 31
5.3 Land use planning (breakup along with green belt etc) ...................................................... 31
5.4 Assessment of Infrastructure Demand (Physical and Social) ............................................. 31
5.5 Amenities / Facilities ............................................................................................................... 32
6. PROPOSED INFRASTRUCTURE ............................................................................................... 32
6.1 Industrial Area (Processing Area) .......................................................................................... 32
6.2 Residential Area (Non-Processing Area) .............................................................................. 32
6.3 Greenbelt ................................................................................................................................... 32
6.4 Social Infrastructure ................................................................................................................. 32
6.5 Connectivity (Traffic and Transportation Road/Rail/Metro/Waterways etc.) ................. 32
6.6 Drinking Water Management (Source and Supply of water) ............................................. 32
6.7 Sewerage System ...................................................................................................................... 32
6.8 Industrial Waste Management ................................................................................................ 32
6.9 Solid Waste Management ........................................................................................................ 33
6.10 Power requirement & Supply / Source .................................................................................. 33
7. REHABILITATION AND RESETTLEMENT (R&R) PLAN ................................................. 33
7.1 Policy to be adopted (Central/State) in respect of the project affected persons
including home oustees, land oustees and landless laborers (a brief outline to be given) .......... 33
Shree Pandurang SSK Ltd., Shreepur, Tal- Malshiras, Dist- Solapur Pre-Feasibility Report
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8. PROJECT SCHEDULE AND COST ESTIMATES ................................................................... 33
8.1 Likely date of start of construction and likely date of completion (Time schedule for
the project to be given) ........................................................................................................................ 33
8.2 Estimated project cost along with analysis in terms of the economic viability of the
project .................................................................................................................................................... 33
9. ANALYSIS OF PROPOSAL (Final recommendations) ............................................................ 33
9.1 Financial and social benefits with special emphasis on the benefit to the local people
including tribal population, if any, in the area. ................................................................................. 33
ANNEXURE-I .......................................................................................................................................... 34
WATER BUDGET FOR SUGAR, CO-GENERATION POWER PLANT, AND
DISTILLERY UNIT ............................................................................................................................ 34
ANNEXURE II......................................................................................................................................... 37
ENVIRONMENTAL CLEARANCE-DISTILLERY ..................................................................... 37
ENVIRONMENTAL CLEARANCE- SUGAR AND COGENERATION ................................. 46
ANNEXURE III ....................................................................................................................................... 63
CONSENT TO OPERATE: SUGAR AND COGENERATION .................................................. 63
CONSENT TO OPERATE: DISTILLERY DIVISION ................................................................. 71
Shree Pandurang SSK Ltd., Shreepur, Tal- Malshiras, Dist- Solapur Pre-Feasibility Report
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LIST OF TABLES
Table 1 Products and By-Products of Existing Unit ........................................................................3
Table 2 List of Board of Directors ...................................................................................................4
Table 3 Change in Existing Quantity after Proposed Expansion .....................................................6
Table 4 Size of Operation (Existing and Proposed) .......................................................................14
Table 5 Bagasse Characteristics and Consumption .......................................................................25
Table 6 Chemical Composition of Bagasse ...................................................................................25
Table 7 Turbine details of the plant ...............................................................................................26
Table 8 Land Breakup Details .......................................................................................................31
Table 9 Water Budget -Sugar and Co-generation Power Plant .....................................................34
Table 10 Water Budget - Distillery ................................................................................................36
Shree Pandurang SSK Ltd., Shreepur, Tal- Malshiras, Dist- Solapur Pre-Feasibility Report
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LIST OF FIGURES
Figure 1 Location Map 10
Figure 2 Layout plan for Sugar, Co-gen, and Distillery 11
Figure 3 Toposheet View 12
Figure 4 10 Km Radius Map 13
Figure 5 Sources of Waste Generation & Cane Sugar Manufacturing Process (Sulphitation
Process) 17
Figure 6 The Distillery process 20
Figure 7 Continuous Fermentation 20
Figure 8 Process Flow Diagram (typical) of Multi Pressure Distillation Plant 22
Figure 9 Steam Balance Diagram (Typical) of Multi Pressure Distillation Plant 22
Figure 10 Power generation by Cogeneration unit 25
Shree Pandurang SSK Ltd., Shreepur, Tal- Malshiras, Dist- Solapur Pre-Feasibility Report
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LIST OF ABBREVIATIONS
BCS Black Cotton Soil
CDM Clean Development Mechanism
CPCB Central Pollution Control Board
CPU Condensate Polishing Unit
CSR Corporate Social
Responsibilities
CTO Consent to Operate
ENA Extra Neutral Alcohol
KLPD Kilo Liters per Day
MEE Multiple Effect Evaporator
MoEF Ministry of Environment and
Forests
MPCB Maharashtra Pollution Control
Board
MSEDCL Maharashtra State Electricity
Distribution Corporation
Limited
MW Mega Watt
NH National Highway
SEAC State Level Expert Appraisal
Committee
SEC Dr. Subbarao‟s Environment
Center
SEIAA State Level Environmental
Impact Assessment Authority
SPSSKL Shree Pandurang Sahakari
Sakhar Karkhana Limited
STP Sewage Treatment Plant
TCD Tonnes crushing Per Day
Shree Pandurang SSK Ltd., Shreepur, Tal- Malshiras, Dist- Solapur Pre-Feasibility Report
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1. EXECUTIVE SUMMARY
Shree Pandurang Sahakari Sakhar Karkhana Ltd. (SPSSKL), located at Shreepur in Malshiras
Tehsil of Solapur district in Maharashtra State, was registered as a co-operative sugar factory
under the Maharashtra Co-operative Societies Act 1960, vide registration no.
SUR(PRR)/PRG(A)-7(S) 88-89.Shree Pandurang Sahakari Sakhar Karkhana Ltd., (SPSSKL),
was originally established in the year 1934 with an initial crushing capacity of 250 TCD. The
unit was owned by the private limited company named “Brihan Maharashtra Sugar Syndicate
Limited.” The Brihan Maharashtra Sugar Syndicate Limited sold its unit to a Shree Pandurang
Sahakari Sakhar Karkhana Limited, which is a co-operative company in the year 1993. The first
crushing operations i.e. 1250 TCD under the new management started in the year 1993-94. The
capacity of the sugar plant was expanded to 2500 TCD in the year 1997-98. At present, the
industry is having 6000 TCD sugarcane crushing capacity, 22 MW Cogeneration Power Plant
and 45 KLPD Distillery unit. The industry has established the Distillery unit of 45 KLPD
capacity in the year, for which environmental clearance was obtained from Government of India,
Ministry of Environment and Forest (I.A. Division). (F.No. J-11011/578/2008-IA II (I) dated 11th
Feb 2010). The industry has obtained the Environmental Clearance twice from State level
Environmental Impact Assessment Authority (SEIAA) in the year 2011 and 2016, for the
expansion of sugarcane crushing capacity from 3500 TCD to 4800 TCD, Cogeneration capacity
from 9 MW to 19 MW (No. SEAC-2009/CR.500/TC.2 Dated 26th
Feb 2011) and for 4800TCD
to 6000 TCD sugarcane crushing capacity, 19 MW to 22 MW Co-gen Power Plant (SEAC-
2015/CR-78/TC-2 dated 12th
January 2016) respectively.
There are no sensitive, historic places, critically polluted areas, CRZs and wildlife sanctuaries
etc. within 05 km radius of the factory site. The latitude and longitude are 17051‟ N and 75
06‟
E. the elevation above mean sea level is 495 m. The estimated cost towards expansion activities
would be around Rs.150 Corers. Nira Right bank canal is the source of water. Due to the excess
condensate available from Sugar unit, there is no requirement of water for sugar and
Cogeneration unit. In fact an excess amount 560 m3/day is saved and is being utilized for
Distillery and other usages. Thus the fresh water requirement would be only for Distillery
which is 166 m3/day for the existing 45 KLPD and proposed 45 KLPD. This shall be drawn
from Nira right bank canal. The permission for lifting the water from Nira right bank canal is
already being obtained from the Irrigation Department.
SPSSKL has organized a separate cane development cell to impart advanced knowledge of
cane development activities. Industry makes efforts to get the sugarcane properly harvested,
cleaned and immediately transported to the factory, in order to maintain the recovery and
overall profitability.
The industry at present obtains the power from its own 22 MW Cogeneration power plant. At
present the power requirement of the industry is 12 MW and remaining 10 MW power is
exported to the State Grids. The same practice shall be adopted after the proposed expansion.
Shree Pandurang SSK Ltd., Shreepur, Tal- Malshiras, Dist- Solapur Pre-Feasibility Report
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The power requirement of the industry will be 18 MW after expansion and the remaining 16 MW
power shall be exported to state grid
At present, three boilers are installed, out of which two boilers of capacity 55 TPH at a pressure
of 67 kg/cm2, 45 kg/cm2 respectively and one boiler of capacity 20 TPH at a pressure of 45
kg/cm2. Additionally, one boiler of capacity 80 TPH at 87 Kg/Sq.cm will be installed for the
cogeneration unit. ESP shall be provided as Air Pollution Control equipment for the proposed
boiler.
Sugar ETP consists of Preliminary treatment (Oil & Grease trap, screen, “V” notch), anaerobic
lagoon, Aeration Tank, Clarifier, Monthly Washing Holding Tank, Sludge Drying Bed and
Treated Sump. The existing ETP is of 450 m3/day capacity which is adequate for the treatment
of the effluent generated after the proposed expansion.
At present, Spent wash treatment from its 45 KLPD distillery unit is based on Anaerobic
Digestion followed by MEE followed by Composting. The treatment of spent wash generated
due to the proposed 45 KLPD Distillery shall be based on Concentration and Incineration
Principle.
The total quantity of effluent generated after expansion of the sugar and co-generation capacity
shall be 405 m3/day (300 m3/day- Sugar unit, 85 m3/day-Cogeneration Power Plant and 20
m3/day- Domestic). The sugar effluent of 300 m3/day shall be treated in existing sugar ETP,
which has a treatment capacity of 450 m3/day and the cogeneration effluent of 85 m3/day along
with treated sugar factory effluent of 300 m3/day shall be disposed off on land for irrigation. The
Distillery effluent shall be 308 m3/day, out of which 158 m3/day (150 m3/day- Spentwash and 8
m3/day-Domestic effluent) from existing 45 KLPD Distillery is treated based on Composting
principle and remaining 150 m3/day due to proposed 45 KLPD Distillery shall be treated based
on Concentration and incineration principles. At present, Domestic effluent of 28 m3/day is
treated in septic tanks followed by an anaerobic filter. It is proposed to install STP for the
treatment of domestic effluent of 28 m3/day.
The total area available for the project is 30.66 Hectares, the details of which are given in the
section 5.3. 11.00 hectares of area is reserved for Greenbelt. According to CPCB guidelines,
minimum 1500 trees per hectare are required for the development of greenbelt, and as such
minimum 16500 trees are to planted by the industry. Till date, the industry has planted 15000
trees and remaining 1500 tress shall be planted during this year. However, the industry has
proposes to plant 1000 to 1500 trees every year in order to increase the greenbelt over and above
33% of the total factory area.
Cost of the project is 150 Crore rupees, EMP cost is estimated as Rs. 20 Crore, recurring
expenditures per annum is around Rs. 2 Crore and 0.75 % of the total project cost (Ref: Office
Memorandum Dated 1st May 2018 F. No- 22-65/2017-IA.III) will be spent on Corporate Social
Responsibilities (CSR) over a period of 5 years.
Shree Pandurang SSK Ltd., Shreepur, Tal- Malshiras, Dist- Solapur Pre-Feasibility Report
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2. INTRODUCTION OF THE PROJECT / BACKGROUND INFORMATION
2.1 Identification of Project and Project proponent
Shree Pandurang Sahakari Sakhar Karkhana Ltd., (SPSSKL), Shreepur, Taluka Malashiras, Dist
Solapur, was originally established in the year 1934 with an initial crushing capacity of 250
TCD. The unit was owned by the private limited company named “Brihan Maharashtra Sugar
Syndicate Limited.” The Brihan Maharashtra Sugar Syndicate Limited sold its unit to a Shree
Pandurang Sahakari Sakhar Karkhana Limited, which is a co-operative company in the year
1993. The first crushing operations i.e. 1250 TCD under the new management started in the year
1993-94. The capacity of the sugar plant was expanded to 2500 TCD in the year 1997-98.
The command area of the sugar factory has excellent cane potential and the sugarcane grown in
this area is rich in sucrose content. Sugarcane potential of SPSSKL from its command area is
around 8 lakh tonnes. In view of this, the factory management had further expanded its crushing
capacity to 3500 TCD in the year 2006. It has also installed a 9.0 MW co-gen facility suitable for
operation during the crushing season as well as off-season and the same is working satisfactorily
since the year 2006. SPSSKL has established 45 KLPD Molasses based Distillery in the year
2010, and Environmental Clearance was obtained from the Ministry of Environment and Forests
(MoEF).
The industry has expanded its capacity from 3500 TCD to 4800 TCD and co-generation capacity
from 9 MW to 19 MW in the year 2011 and obtained the Environmental Clearance from the
Maharashtra State Expert Appraisal Committee. The industry has further expanded the sugar
plant capacity from 4800 TCD to 6000 TCD and cogeneration capacity from 19 MW to 22 MW
using the existing 3 MW turbine in the year 2016, for which the Environmental Clearance was
obtained from the Maharashtra State Expert Appraisal Committee, and the consent to operate
from Maharashtra Pollution Control Board. At present, SPSSKL has a sugar unit of crushing
capacity 6000 TCD, Cogeneration of 22 MW capacity and Distillery unit of 45 KLPD capacity.
Table 1 Products and By-Products of Existing Unit
Sr. No. Products/ By-Products Quantity
1 Sugar 18200 MT/M
2 Molasses 7280 MT/M
3 Pressmud 6590 MT/M
4 Bagasse 52325 MT/M
5 Electric Power 22 MW
6 Rectified Spirit/ ENA/ Ethanol 1282.5 KL/M
7 Fusel Oil 2.67 KL/M
8 Impure Spirit 67.5 KL/M
SPSSKL intends to expand the Sugarcane crushing capacity from 6000 TCD to 10000 TCD,
Distillery capacity from 45 KLPD to 90 KLPD. It has existing Co-generation power plant of
Shree Pandurang SSK Ltd., Shreepur, Tal- Malshiras, Dist- Solapur Pre-Feasibility Report
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capacity 22 MW. The industry proposes to expand its cogeneration power plant capacity to 34
MW by discarding its existing 3MW power turbine and adding 15 MW back pressure turbine.
SPSSKL is today one of the best professionally managed and financially sound co-operative
sugar factory in Maharashtra. It is also the only sugar factory in Maharashtra to have been
granted CDM credits for its co-gen plant which is generating additional revenue for the factory.
SPSSKL has also installed a commercial scale facility for baling of cane trash in the fields,
transportation of the baled trash to the factory, shredding of the bales at the bagasse yard and
mixing it with bagasse for use as fuel in the boilers. Use of cane trash as supplementary fuel for
the boiler was started in Jan 2009 and continued for about 3 months during the season 2008-09
and continued thereafter. The management wishes to continue use of this supplementary fuel in
future.
Backed by a proven managerial and financial track record, SPSSKL management now propose to
implement further expansion programme to operate the sugar, distillery and co-gen plant at
optimum capacity with high uptime and lower captive energy consumption with a view to
enhance the financial capability of the factory to pay better cane price to its members.
2.1.1. Project Proponent
Name of the Industry: Shree Pandurang S.S.K. Ltd.
Address: Shreepur, Taluka- Malshiras District-Solapur, Maharashtra- 413112
Phone: (0) (02185) 255233, 255344, 255355
Fax: (0) (02185) 255435
This enterprise is a legal co-operative entity. The project proponents are known for their track
records of honest and transparent businesses. The company is well aware of energy crises and
takes various steps for conservations of energy. This industry is committed to prevent pollution,
continually improve environmental performance, comply with environmental legislation and
regulations, health care etc. reducing the spillages and fugitive pollution emissions, conserving
energy and other resources with waste minimizations. List of Board of Directors is detailed
below:
Table 2 List of Board of Directors
Sr. No. Name Role
1 Shri. Sudhakar Ramchandra Paricharak Chairman
2 Shri. Vasantrao Daulatrao Deshmukh Voice Chairman
3 Shri. Prashant Prabhakar Paricharak Director
4 Shri. Dinkarrao Ambadas More Director
5 Shri. Diliprao Trimbak Chavan Director
6 Shri. Harish Bhaskarrao Gaikwad Director
7 Shri. Shivaji Machchhindra Salunkhe Director
Shree Pandurang SSK Ltd., Shreepur, Tal- Malshiras, Dist- Solapur Pre-Feasibility Report
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8 Shri. Dnyandeo Shrirang Dhobale Director
9 Shri. Suresh Rajaram Agavane Director
10 Shri. Balasaheb Dada Yalmar Director
11 Shri. Shivajirao Dagadu Gavali Director
12 Shri. Tanaji Maruti Waghamode Director
13 Shri. Mahibub Kamruddin Shaikh Director
14 Shri. Namdeo Chintu Zambare Director
15 Shri. Dinkar Dnyandeo Kavade Director
16 Shri. Anandrao Ramdas Aarkile Director
17 Shri. Parmeshwar Bajrang Ganage Director
18 Shri. Nagannath Savata Shinde Director
19 Sau. Sangita Gulab Pore Director
20 Sau. Parvati Kantilal Narsale Director
21 Sau. Shindhu Brahamdeo Pawar Director
22 Shri. Yashwant Shankarrao Kulkarni Managing Director
2.1.2. Project Consultant
To seek Environmental clearance, SPSSKL has appointed Dr. Subbarao‟s Environment Center
(SEC), Sangli, Maharashtra (formerly known as Water and Wastewater research center). SEC is
a QCI-NABET accredited consulting organization, for conducting EIA studies, encompassing
baseline scenario with respect to different components of environment viz. air, noise, water, land,
biological and socio-economic etc. SEC is serving for more than 45 years in the field of
Environmental Services. The company was established by an entrepreneur Dr. B. Subbarao in
the year 1972.
2.2 Brief description of the nature of the project
SPSSKL is an agro-based company focused on the manufacturing of sugar and allied by-
products. The proposed plant units will be established in the existing premises of SPSSKL. 30.66
hectares of land is available with the industry which is sufficient for the proposed expansion.
Bagasse and Molasses to be generated will be utilized in co-generation and distillery
respectively.
SPSSKL intends to expand sugarcane crushing capacity from 6000 TCD to 10000 TCD,
Distillery capacity from 45 KLPD to 90 KLPD and also Co-generation capacity from 22 MW to
34 MW in order to increase productivity and profitability in addition to abating pollution. Along
with the expansion of Sugarcane crushing and Co-generation Power Plant, it is economically and
environmentally sustainable to expand distillery capacity and to generate power plant so as to
utilize molasses and bagasse which otherwise are harmful to Environment. Products and By-
products of existing and proposed units are presented as follows.
Shree Pandurang SSK Ltd., Shreepur, Tal- Malshiras, Dist- Solapur Pre-Feasibility Report
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Table 3 Change in Existing Quantity after Proposed Expansion
Sr.
No Description
Existing
Quantity
Proposed
Deletion
Proposed
Addition Total
1 Sugarcane Crushing
capacity 6000 TCD
-- 4000 TCD 10000 TCD
2 Sugar (MT/M) 18200 -- 12133 30333
3
Rectified Spirit (KL/M ) OR 1282.5 -- 1282.5 2565
Extra Neutral Alcohol
(KL/M) OR 1282.5
-- 1282.5 2565
Ethanol (KL/M ) 1282.5 -- 1282.5 2565
4 Bagasse (MT/M) 52325 -- 34884 87209
5 Molasses (MT/M) 7280 -- 4853 12133
6 Fusel Oil (KL/M ) 2.67 -- 2.67 5.34
7 Impure Spirit (KL/M ) 67.5 -- 67.5 135
8 Electric Power 22 MW 03 MW 15 MW 34 MW
2.2.1. Environmental Clearance of existing Sugar and Distillery Plants
The SPSSKL has obtained Environmental Clearance for its existing 45 KLPD Distillery (F. No.
J-11011/578/2008-IA II (I) dated 11th
Feb 2010.) from MoEF. The industry has obtained the
Environmental Clearance twice from State level Environmental Impact Assessment Authority
(SEIAA) in the year 2011 and 2016, for the expansion of sugarcane crushing capacity from 3500
TCD to 4800 TCD, Cogeneration capacity from 9 MW to 19 MW ( No. SEAC-
2009/CR.500/TC.2 Dated 26th
Feb 2011) and for 4800TCD to 6000 TCD sugarcane crushing
capacity, 19 MW to 22 MW Co-gen Power Plant (SEAC-2015/CR-78/TC-2 dated 12th
January
2016) respectively.
2.2.2. Consent to Operate of existing Sugar and Distillery Plants
Sugar division of SPSSKL has obtained Consent to Operate from MPCB (Format 1.0/BO/CAC-
CELL/UAN No.-0000028079/R/CAC-1804000345) dated 07/04/2018 for existing 6000 TCD
crushing capacity and 22 MW Co-gen Power and Consent to Operate (Format-1.0/BO/CAC-
CELL/UAN No. 0000028596/R/CAC-1804000326) dated 07/04/2018 is obtained by Distillery
division for 45 KLPD capacity., under section 26 of the Water (Prevention & Control of
Pollution) Act, 1974 & under Section 21 of the Air (Prevention & Control of Pollution) Act,
1981 and Authorization under Rule 6 of the Hazardous & Other Wastes (M & T M) Rules 2016.
2.3 Need for the project and its importance to the country and the region
The sugar industry is one of the major agro-based manufacturer industries. India being the
largest Sugarcane producer country after Brazil, it is inevitable and unavoidable for India to
grow as the largest sugar and allied products manufacturing country. The major shareholder of
this sector is the farmer, producer of raw material sugarcane and it is estimated that around 45
millions of people in India are sugarcane growers. Sugarcane Potential, agro-climatic conditions
Shree Pandurang SSK Ltd., Shreepur, Tal- Malshiras, Dist- Solapur Pre-Feasibility Report
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and the cost of conversion and overheads etc. are the major deciding factors for fixing the
crushing capacity of a sugar plant. It has been established that wages and other overhead costs
per ton of sugar get reduced substantially with higher plant sizes.
As there is excess cane available in the command area, industry shall have to make arrangement
for the timely crushing of sugarcane of not only its shareholders but also entire farmer‟s
community in the command area. Incidentally, the economic viability would also improve not
only by producing sugar more but also to generate power which can be exported to the state grid
and additional money can be distributed to farmers as cane price.
Besides the direct benefit, the expansion would help to crush sugarcane in time so that the high
recovery due to timely crushing would further improve the economy of the farmers. Apart from
this, the establishment of such institutions brings employment and other developmental
opportunities for the entire region. In the case of SPSSKL, the proposed expansion in sugarcane
crushing, distillery capacity and co-generation of power would greatly increase the productivity
and profitability of the industry. By the means of newly proposed cogeneration and expanded
distillery capacity, bagasse and molasses to be generated (due to additional crushing) will be
utilized in co-generation and distillery expansion, respectively. Production of alcohol from
molasses based distilleries is not only helpful in abating pollution by utilizing molasses but also
helpful in partly fulfilling the need for petrol by blending ethanol in the petrol. The co-generation
power plant produces power, which helps in reducing the load on state electricity grids and
fulfilling the necessity of electricity for society. Thus, the proposed project would immensely
benefit not only it shareholders but also to the people of the entire region around SPSSKL.
To implement the above program, the management of SPSSKL has appointed consultants with
the objective of expansion & capacity optimization of sugar plant, with emphasis on reduction in
the cost of production through improvement in milling efficiency and reduction in process
steam/energy consumption.
2.4 Demand-Supply gap
Sugarcane availability in the command area of SPSSKL surpasses the existing crushing capacity
due to the availability of an adequate amount of water by the courtesy of River Bhima. Ujani
dam, Nira Bhatgar Dam, Sonake Tisangi Dam and Manganga River. Also, Sugar, Alcohol, and
Power are having high demand and monetary value as well. Hence, the efforts to supplement to
the demands of society are necessary in order to achieve profitability.
2.5 Imports vs. Indigenous products
Major products to be manufactured in this sugar complex are Sugar, Alcohol, and Power. Sugar
and Alcohol from this industry are qualitatively better and competitive against imported
products. Hence, the benefit of foreign exchange saving could be achieved.
Shree Pandurang SSK Ltd., Shreepur, Tal- Malshiras, Dist- Solapur Pre-Feasibility Report
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2.6 Export possibility
Sugar is mostly sold in the local market. Depending on the international market conditions and
prices, sugar could be exported. Alcohol produced is mainly utilized in blending with petrol
(additives).
2.7 Domestic / Export markets
Domestic markets are found to be more suitable, by the observations made over the years.
Convenience and profitability are always preferred by the management of SPSSKL.
2.8 Employment Generation (Direct and Indirect) due to the project
After the proposed expansion project, direct employment of about 50 people will be generated
and indirect employment of around 100 people is possible. Also, around 20 % increase in
indirect employment is expected due to the additional transportation required after the proposed
expansion.
Shree Pandurang SSK Ltd., Shreepur, Tal- Malshiras, Dist- Solapur Pre-Feasibility Report
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3. PROJECT DESCRIPTION
3.1 Type of project including interlinked and interdependent projects, if any.
It is an expansion in existing sugarcane crushing capacity from 6000 TCD to 10000 TCD,
Distillery capacity from 45 KLPD to 90 KLPD and Co-generation capacity from 22 MW to 34
MW. Expansion of existing sugarcane crushing would contribute to additional molasses and
bagasse generation. Hence, to utilize these by-products, it is advisable and essential to expand
Distillery and Cogeneration capacities. SPSSKL is expanding distillery and Co-generation power
plant capacities to scope up with the increased production of Bagasse and Molasses.
3.2 Location with coordinates
There are no sensitive, historical, forest reserves and wildlife sanctuaries etc within 10 Km radius
of the factory site. The Pune – Solapur National Highway (N.H. 9) is 25 Km away from the
factory site. The latitude and longitude are 17051‟ 12” N & 75
05‟ 56” E respectively. The
Elevation above the Mean Sea Level is 495 m.
The Project Site is conveniently located for development of the Project.
110 Km away from Solapur, which is a district place.
Other important towns nearby are
Akluj, at a distance of 9 km
Pandharpur, at a distance of 30 km
Kurduwadi is nearest Railway station 38 km away from factory site.
Solapur is nearest Airport 110 Km away from factory site.
Environmental Setting-
Location –17051‟ 12” N and 75
05‟ 56” E
Nearest Village – Shreepur
Nearest town – Akluj – 9 Km
Nearest City – Pandharpur – 30 Km
Nearest Head Quarters – Solapur – 110 Km
Nearest National Highway – NH-9 – 25 Km
Nearest Railway Station – Kurduwadi – 38 Km
Nearest Airport – Solapur – 110 Km
Nearest River – Bhima River – 5 Km
Seismicity – Seismic Zone III 6 to 8 Richter Scale
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Figure 1 Location Map
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Figure 2 Layout plan for Sugar, Co-gen, and Distillery
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Figure 3 Toposheet View
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Figure 4 10 Km Radius Map
3.3 Details of alternate sites considered and the basis for selecting the proposed site
It is an existing industry which was established in 1934 considering the following features:
The site is well connected by Road
Proximity to Raw Material (Sugar Cane)
Availability of sufficient land
Availability of power evacuation facilities
Availability of water for industrial use
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Modern infrastructure support and amenities at par with industry including:
Efficient transport facilities.
Environment-friendly zone as the habitation is remote and surrounded by Agricultural
activities.
Uninterrupted power supply from Own Co-generation Power Plant
3.4 Size or magnitude of the operation
Table 4 Size of Operation (Existing and Proposed)
Sr.
No Description
Existing
Quantity
Proposed
Deletion
Proposed
Addition Total
1 Sugarcane Crushing
capacity (TCD) 6000
-- 4000 10000
2 Sugar (MT/M) 18200 -- 12133 30333
3
Rectified Spirit (KL/M ) OR 1282.5 -- 1282.5 2565
Extra Neutral Alcohol
(KL/M) OR 1282.5
-- 1282.5 2565
Ethanol (KL/M ) 1282.5 -- 1282.5 2565
4 Bagasse (MT/M) 52325 -- 34884 87209
5 Molasses (MT/M) 7280 -- 4853 12133
6 Fusel Oil (KL/M ) 2.67 -- 2.67 5.34
7 Impure Spirit (KL/M ) 67.5 -- 67.5 135
8 Electric Power 22 MW 03 MW 15 MW 34 MW
3.5 Project description with process details
SPSSKL intends to expand its sugarcane crushing capacity from 6000 TCD to 10000 TCD,
Distillery capacity from 45 KLPD to 90 KLPD and Co-generation power plant capacity from 22
MW to 34 MW by discarding its existing 3MW power turbine and adding 15 MW back pressure
turbine.
3.5.1. Process Details
3.5.1.1. White Sugar Manufacturing Process
Cane harvest and Transport:
Matured cane is harvested and brought to the factory through Trucks, and Bullock carts.
Cane Weight:
Cane is weighed on automatic weighing scales at the factory gate. Net weight of cane is
determined by subtracting tare weight of the vehicle from its gross weight.
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Unloading:
Cane is unloaded by means of mechanical unloaded in the carrier and Passed through leveler,
vibrator and prepared cane are subjected for milling.
Milling:
The prepared cane is subjected for extraction of the juice in the milling System for successive
compressing followed by imbibitions. The extracted juice is weighed automatically and
subjected for sugar.
3.5.1.1.1. Manufacturing Process
A by-product of milling system which is known as bagasse is passed for the boiler as a fuel for
generation of steam. Steam is used for running the prime movers and turbo generations for
power production. The exhaust generated from prime movers is utilized for heating of the juice
massecuite.
Clarification:
The weighed juice is heated and subjected to automatic liming and Sulphitation process where
the pH of the juice is kept neutral. This sulphinated juice is heated and settled in the clarifier.
The supernatant liquid is taken for evaporation where it is concentrated up to 600 BX and passed
for crystallization in the vacuum pans.
Crystallization:
The concentrated syrup is again sulphinated and used as a pan boiling system. The three
massecuite boiling system is adopted for the production of white sugar the process is given
below:
A Massecuite boiling:
Syrup 600
BX and 85% purity excess melt is boiled under vacuum or Crystallization after
adequate exhaustion and attending proper growth of BX and purity above 89% the crystal l-e
massecuite dropped in the crystallization where atmospheric cooling is affected and same is
taken for centrifugation wherein crystallization are separated from its mother liquor under
centrifugal force in the centrifugal machine. The mother Liquor is known as a heavy and a light
molasses which is send back for the process. The crystals are dried and cooled on the hopper and
carried for graduation.
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B Massecuite:
A heavy molasses is used to develop to cooling and material for B massecuite id developed on a
heavy molasses + B light molasses. It is exhausted to the optimum condition and sufficiently
brought together to have a BX of 94 and purity 75%. It is dropped to crystallizer for achieving
the further exhaustion the same is taken for curing in the continuous machines where a sugar and
its mother liquor is known as B heavy molasses which is send back for the process. The B sugar
is taken as a speed for a Massecuite boiling and excess is melted.
C Massecuite:
The grain is made in the C light and B heavy keeping 62 Purity and BX 70. After establishing
grain it is subject for hardening and its further developments. One part of the grain is kept
footing material of “c” massecuite and two parts are stored in vacuum crystallizer. The footing is
developed on B heavy molasses. The mother liquor is completely exhausted followed successive
drink of molasses after achieving proper exhaustion l-e 100-102 BX and purity 56 to 58. The
same cured is continuous to centrifugal machines where crystals are separated from its mother
liquor and liquor is known as final molasses which are weighed automatically and send for
storage in a steel tank. The C fore worker sugar is mixed with water known as C fore magma
and sent for further curing. The double cured sugar is maintained and used for developing C
massecuite. The separated crystals are then graded according to their size as “A” sugar “B” sugar
and “C” sugar.
Packaging:
Separated crystals are packaged in the gunny bags and stitched and are send to the godown.
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Figure 5 Sources of Waste Generation & Cane Sugar Manufacturing Process (Sulphitation
Process)
3.5.1.2. Distillery Process
The existing 45 KLPD distillery unit is based on Continuous Fermentation Process. The
proposed 45 KLPD unit shall be based on the same technology. Description of the process is
given below.
LEGENDS
1. Cane washing
2. Bearing Cooling,
Turbine cooling, Floor
washing, oily waste
water
3. Condensate,
floor/equipment
washing
4. Condensate,
floor/equipment
washing
5. Floor washing
6, 7, 8 & 9:Condensate
Floor washing/
Equipment washing
10. Floor equipment
washing
11. Floor washing
12. Boiler blowdown, fly
ash water, oily waste water
13. Turbine cooling water,
oily waste water
14. Sulphur burner cooling
water
15. Sulphur aie compressor
cooling water
16. Vacuum filter
condenser, floor washing
17. Evaporator condensate
water
18 & 19. Sulphur burner &
Compressar cooling water
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Process for the manufacture of alcohol:
Molasses is the chief raw material used for the 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 to the species Saccharomyces Cerevisiae, a living microorganism
belonging to class fungi converts sugar present in the molasses such as sucrose or glucose into
alcohol. Chemically this transformation for sucrose to alcohol can be approximated by the
equation:
I) C12H22O11+ H2O 2C6H12O6
Cane Sugar Invertase Glucose +Fructose
II) C6H12O6 2C2H5OH +2CO2
180 Zymase 2 x 46 + 2 x44
Glucose/Fructose Ethyl alcohol + Carbon dioxide
Thus, 180 gm of sugar on reaction gives 92 gm of alcohol. Therefore, 1 MT of sugar gives 511.1
kg of alcohol. The specific gravity of alcohol is 0.7934. Therefore, 511.1 kg of alcohol is
equivalent to 511.1 / 0.7934 = 644.19 liters of alcohol. During fermentation other by-products
like glycerin, succinic acids etc. also are formed from sugars. Therefore, actually, 94.5% total
fermentable sugars are available for alcohol conversion. Thus, one MT of sugar will give only
644 x 0.945 = 608.6 liters of alcohol, under ideal condition theoretically.
Normally only 80 to 82% efficiencies are realized in a batch type plant. One MT of molasses
containing 47% fermentable sugars gave an alcoholic yield of 283 liters per MT. Molasses,
diluted with water to the desired concentration is supplied continuously to a fermenter. Additives
like urea and de-foaming oil are also introduced in the fermenter as required. There are an
automatic foam level sensing and dosing system for de-foaming oil. Every kilogram of alcohol
generates about 290 Kilocalories of heat. This excess heat is removed by continuous circulation
of fermented wash through an external plate heat exchanger called the fermenter cooler. The
fermenter temperature is always maintained between 32-34 0C, the range optimum for efficient
fermentation. The yeast for the fermentation is initially developed in the propagation section.
Once propagated, yeast recycling and continuous aeration of fermenter maintain viable cell
populations of about 350 to 500 million cells/ml. Fluctuations in the yeast count of ± 20 % have
little effect on overall fermenter productivity. Yeast cell vitality, which is usually above 70% in
times of stress drop to 50% without affecting the fermentation.
Propagation:
A propagation section is a feeder unit to the fermenter. Yeast, either Saccharomyces cerevisiae
or Schizosaccharomyces pombe (the choice being determined by other process parameters,
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mainly the downstream effluent treatment system) is grown in three stages. The first two stages
are designed for aseptic growth. Propagation vessel III develops the inoculums using pasteurized
molasses solution as the medium. This vessel has the dual function. During propagation, it serves
for inoculums built-up. When the fermenter enters the continuous production mode, propagation
vessel III is used as an intermediate wash tank. Propagation is carried out only to start up the
process initially or after very long shutdowns during which the fermenter is emptied.
CO2 Scrubber and Recovery:
The carbon dioxide produced during fermentation is scrubbed with water in the packed-bed
scrubber, to recover alcohol. The water from the scrubber is returned to the fermenter. In some
industries, carbon dioxide is captured by, scrubbing the gas from the fermenter. A part of the
wash is drawn into a separate vessel and is aerated there. This external aeration allows the
recovery of CO2 un-contaminated with air.
Yeast Recycling:
The yeast in the fermenter wash is removed as 45 to 55% v/v slurry and is returned to the
fermenter. This feature ensures that a high yeast cell concentration is achieved and maintained in
the fermenter. Mature active yeast will be recycled so as to reduce the excess consumption of
sugar by growing yeast. Thus, it makes available for ethanol production and ensuring high
process efficiency.
Fermentation parameters (typical):
The pH of the fermenter is maintained within 4.0 to 4.8 usually by the addition of an acid. The
alcohol concentration is maintained between 7.0 to 8.5% v/v unless a highly concentrate effluent
is to be produced.
Conversion of sugar to ethanol is instantaneous and the residual sugar concentration is
maintained below 0.2% w/w as glucose. This usually corresponds to a residual reducing
substances concentration of 2.0 to 2.5% w/w in the wash.
Weak wash/ spent wash recycling (Optional- depends upon yeast strain)
Recycling of weak wash helps to maintain the desired level of dissolved solids in the fermenters
so that an adequately high osmotic pressure is achieved. Osmotic pressure and the concentration
of alcohol in the fermenter, together with keep off infections and minimize sugar losses. Weak
wash recycling also reduces the quantity of effluent spent wash and reduces the process water
requirement of the plant.
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Figure 6 The Distillery process
Figure 7 Continuous Fermentation
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Pressure Vacuum Distillation:
Vacuum distillation system consists of three to four distillation columns namely,
Analyzer column: Operated under vacuum
Pre rectifier column: Operated under vacuum
Rectifier cum Exhaust column: Operated under pressure
Fusel oil concentration may be added to improve quality of alcohol further. Fermented wash is
preheated in fermented wash preheater and fed at the top of the analyzer column. Analyzer
column is fitted with thermosyphon reboiler. Top vapors of analyzer column are sent to the pre-
rectifier column. Rest of the fermented wash flows down and is taken as spent wash from the
analyzer column bottom. The pre-rectifier bottom liquid is preheated with spent-less and fed to
rectifier cum exhaust column. Low boiling impurities are concentrated in the pre-rectified
column. A top draw is taken out as impure alcohol from the pre-rectified column. The bottom of
pre-rectifier is sent to rectifier feed tank. Rectifier exhaust is operated under pressure and heats
the analyzer column through re-boiler. Alcohol is enriched towards the top and is drawn out as
Rectified Spirit. Fusel oil built up is avoided in the rectifier column by withdrawing outside
streams of fusel oil. These are sent to the fusel oil concentration column from where the fusel oil
is recycled back to the column. A top draw is taken out as impure alcohol from the top of fusel
oil column and pre-rectifier column.
Benefits of Pressure vacuum Distillation:
The advantages of this technology are as follows;
Since the analyzer column operates under vacuum, the formation of by-products such as
„acetyl‟ may minimize thereby improvement in the quality of alcohol.
Pre-rectification column ensures removal of unwanted substances and also reduces the
load of lower boiling volatile compounds passing on to the rectifier cum exhaust column.
The chances of scaling due to invert solubility of certain precipitating inorganic salts are
minimized in vacuum distillation.
Vacuum distillation requires low steam consumption i.e. 2 kg/lit. of Recited Spirit and
around 3.2 kg/lit. of ENA.
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Figure 8 Process Flow Diagram (typical) of Multi Pressure Distillation Plant
Figure 9 Steam Balance Diagram (Typical) of Multi Pressure Distillation Plant
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The process of Manufacturing of Extra Neutral Alcohol (ENA):
Extra neutral alcohol is manufactured from Rectified Spirit. The impurities in Rectified Spirit are
reduced to a considerable extent by properly diluting and redistilling the spirit. The impurities
like aldehydes, acids, Esters, higher alcohols are minimized by controlled condition and tapping
impurities at appropriate points during distillation.
The main stages in the manufacturing of Extra Neutral Alcohol are:
Dilution of Rectified Spirit with filtered soft water in the ratio of 1:3 to 1:4.
The diluted spirit may be treated with potassium permanganate.
Separation of low boiling impurities in the purifying column.
Separation of esters and other volatile in rectifying column and concentration of alcohol.
Removal of excess water in exhaust column.
The concentration of low boiling impurities and their removal takes place in the head
concentration column.
The design of the re-distillation plant is made in such a way that the Extra neutral alcohol quality
and the production does not get disturbed due to the varying quality of rectified spirit. The plant
may be preferably in copper. As the plant deals with the rectified spirit, there is no risk of
corrosion and the quality of spirit produced will be superior.
The manufacturing process for Anhydrous (Fuel) Alcohol:
Anhydrous alcohol is an important product required by industry. As per IS Specification, it is
nearly 100% pure / water-free alcohol. Alcohol, as manufactured by Indian distilleries, is
rectified spirit, which is 94.68 % alcohol, and rest is water. It is not possible to remove the
remaining water from rectified spirit by straight distillation as ethyl alcohol forms a constant
boiling mixture with water at this concentration and known as an azeotrope. Therefore, a special
process for the removal of water is required for the manufacture of anhydrous alcohol.
In order to extract water from alcohol, it is necessary to use some dehydrant or entrainer, which
is capable of separating water from alcohol.
Simple dehydrant is un-slacked lime, Industrial alcohol is taken in a reactor and quicklime is
added to that and the mixture is left overnight for complete reaction. It is then distilled in the
fractionating column to get anhydrous alcohol. Water is retained by quicklime. This process is
used for the small-scale production of anhydrous alcohol by a batch process.
The various processes used for dehydration of alcohol are as follows:
1. Azeotropic Distillation
2. Molecular Sieves
3. Pervaporation / Vapor permeation system:
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4. Dehydration with Molecular Sieve Process:
Factory has decided to adopt the Molecular Sieve process, as there is less operating cost and
energy requirement as compared to other processes.
Dehydration with Molecular Sieve Process:
The rectified spirit from the rectifier is superheated with steam in feed superheater. Superheated
rectified spirit from feed superheater is passed to one of the pair of molecular sieve beds for
several minutes. On a time basis, the flow of superheated anhydrous ethanol vapor leaving the
fresh adsorption bed is used to regenerate the loaded bed. A moderate vacuum is applied by
vacuum pump operating after condensation of the regenerated ethanol-water mixer. This
condensate is transferred from recycling drum to the Rectified Column in the hydrous distillation
plant via Recycle pump. The anhydrous absolute alcohol draw is condensed in product condenser
and passed to product storage.
3.5.1.3. Cogeneration Power Plant
Cogeneration is a process that simultaneously produces two or more forms of useful energy, such
as electric power and steam. It harnesses the thermal and electrical energy that is released as part
of the production process in the industry. When a fuel is burnt to generate heat, and that heat is
exploited in a thermodynamic cycle to produce electricity, a great deal of energy is wasted. This
wasted energy (which can be up to two-thirds of the energy content) of the fuel emerges as heat.
If this heat can be utilized for space heating, for making hot water or in a manufacturing process,
it could reduce the amount of additional energy needed for such purposes. This makes the
economics of cogeneration extremely favorable. The process flow sheet for cogeneration power
plant is presented in Figure
The co-generation plant is selected to utilize bagasse as a fuel. The plant will consume 450000
MT of bagasse for 180 days of operation of sugarcane crushing season, and 225000 MT of
bagasse during offseason. The power generation will be
The steam generating system for the proposed Cogeneration project consists of one multi fuel
fired boiler with a maximum continuous rating of 80 TPH, with the outlet steam parameters at 87
Kg/cm2 and 5250C. The tolerance on the superheater outlet temperature shall be +5 to -5 0C.
Fuel for Boiler
Fuel for the boiler is bagasse. The bagasse requirement is 675000 MT/year. Bagasse shall be
reserved for bagacillo and start-up operation of the boiler for supplying steam to the distillery.
Bagasse percent of cane shall be an average of 47%-48% moisture content.
The characteristics of bagasse produced are given in the table below
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Table 5 Bagasse Characteristics and Consumption
Average bagasse percentage on the cane: 28%, 8% Bagacillo requirement
Fuel consumption for boiler 104 TPH
Sugar in Bagasse 0.6-0.7%
Moisture in Bagasse 47-48%
Steam to Bagasse Ratio 2.25
Steam to bagasse Percentage 71% Minimum
Table 6 Chemical Composition of Bagasse
Description Quanity
Carbon 23.5 %
Hydrogen 3.25 %
Oxygen 21.75 %
Moisture 48 %
Ash 1.5 %
GCV with 50% Moisture 2250 Kcal/Kg
The Flowchart of the process of Cogeneration power plant is given as below.
Figure 10 Power generation by Cogeneration unit
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Plant Machinery and other requirements:
Boiler:
The steam generating system for the proposed Cogeneration Project comprises one multi-fuel
fired boiler with a Maximum Continuous Rating (MCR) of 80 TPH with the outlet steam
parameters at 87 kg/cm2 and 5000C. The tolerance on the super-heater outlet temperature shall
be 50C. The combustion system of the boiler is dumping grate, with the pneumatic system. The
boiler efficiency, firing 100% bagasse, shall be a minimum of 71% of the Gross Calorific Value
(GCV) basis. The dust concentration in the flue gases leaving the boiler shall be a maximum of
100 mg/Nm3.
Turbine:
There is one 15 MW turbo generator. The turbogenerator is extraction cum back pressure type.
The extraction shall be uncontrolled at 1.5 kg/cm2 and the exhaust at 0.1 kg/cm2. For better
control and minimum vibrations, the recommended speed of the turbine shall be less +8than
6800 RPM. The salient features of the proposed 15 MW turbo generator are given as below.
Table 7 Turbine details of the plant
Item No 15 MW TG
Steam Flow at turbine stop valve 78
steam pressure at the turbine stop valve kg/cm2 85
steam temperature at the turbine stop valve 0C 510
First Extraction 1.5 kg/cm2
Exhaust pressure 0.1 kg/cm2 450C
Power factor (lagging) 0.9
Generation Voltage KV 11
Ambient temperature for electrical equipment
design, 0C
50
Steam:
Steam requirements shall be 87 kg/cm2 for power generation unit.
3.6 Raw material required along with estimated quantity, likely source, marketing area
of the final product, Mode of transport of raw material and finished product.
Raw material, sugarcane is purchased from farmers. Sugarcane is available in the command area
around SPSSKL in plenty of amount as this region is having water availability due to River
Bhima, Ujani dam, Nira Bhatgar Dam, Sonake Tisangi Dam and Manganga River.
Approximately 1800000 Tons of sugarcane shall be required after the proposed expansion,
which is available in the command area of SPSSKL. Also, lime and sulphur are purchased from
the open market and transported by road.
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Final products sugar, alcohol, and power etc. are having their market available locally. Finished
products are transported in closed containers, whereas sugarcane is brought to the industry from
farms by the means of trucks, tractors and bullock carts etc.
In the case of Distillery, molasses formed in the sugarcane crushing will be utilized as a raw
material. Bagasse shall be utilized in Cogeneration power plant. Transport of both bagasse and
molasses would be by internal means. Power is transferred to state electricity grids, Distillery
products shall be transported using closed containers. The estimated quantity of molasses to be
utilized after the proposed expansion is around 12133 MT/Month. Bagasse quantity to be utilized
in Co-generation after expansion of 22 MW to 34 MW Co-generation power plant would be
around 87209 MT/Month.
3.7 Resource optimization/recycling and reuse envisaged in the project, should be
briefly outlined.
It is proposed to expand existing 22 MW co-generation power plant to 34 MW capacity with
high-pressure boilers in order to save raw material bagasse. It is proposed to treat the spray pond
overflow and also recycle as process water so that around 1925 m3/day of fresh water can be
saved for the process. The industry will recycle all excess condensates which shall be further
improved to recycle excess condensate and use it as a boiler feed and process water. It is also
proposed to adopt high-pressure water jet cleaning for evaporator bodies, process equipment so
that the water requirement can be minimized.
3.8 Availability of water its source, Energy / Power requirement and source
Nira right bank canal is the main source of raw water. There shall not be any water requirement
after the proposed expansion of Sugar and Cogeneration Unit. Net water requirement for after
the proposed expansion of the Distillery 166 m3/day. The detailed water budget of the Sugar
unit, Cogeneration Power Plant and Distillery unit is given as an Annexure-I in this report.
Power requirements shall be fulfilled by the means of existing Co-generation power plant. At
present 22 MW cogeneration power plant and two 500 KVA, DG sets are utilized to fulfill power
requirements.
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3.9 Quantity of waste to be generated (liquid and solid) and scheme for their
Management/Disposal
Sr. No. Waste to be generated Quantity Scheme for Management/ Disposal
1
Industrial Wastewater
a. Sugar
300 m3/day
Sugar ETP consists of Preliminary
treatment (Oil & Grease trap, screen, “V”
notch), anaerobic lagoon, Aeration Tank,
Clarifier, Monthly Washing Holding
Tank, Sludge Drying Bed and Treated
Sump. Treated effluent will be disposed
on land for irrigation. The existing ETP is
designed for 450 m3/day, which is
adequate for future expansion.
b. Cogeneration Division
85 m3/day
The effluent generated from the Co-
generation power plant shall be treated
along with Sugar Factory effluent and
disposed on land for irrigation.
c. Distillery Division
308 m3/day
Distillery ETP for existing 45 KLPD
consists of Bio-digester followed by MEE
and Bio-composting. The raw spent wash
generated due to the proposed 45 KLPD
distillery shall be treated based on the
concentration and incineration principle.
2 Domestic Waste
(Combined) 28 m3/day
Proposed to install STP for treatment of
domestic effluent.
3 Hazardous waste
5.1 Spent oil
1.01 MT/A
Mixed with bagasse and burnt in the boiler
4
Non-Hazardous Waste/ Solid waste
a. Fly/Boiler Ash 1308 MT/M
Sale to brick manufacturers and used for
compost production
b.ETP Sludge 100 MT/M Disposed in Composting
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4. SITE ANALYSIS
4.1. Background of the Site Location
Shree Pandurang Sahakari Sakhar Karkhana Ltd., (SPSSKL), Shreepur, Taluka Malashiras, Dist
Solapur, was originally established in the year 1934 & later converted to the co-operative sector
in the year 1993 with the initial installed capacity of 1250 TCD. The first crushing operations
under the new management started in the year 1993-94. The capacity of the sugar plant was
expanded to 2500 TCD in the year 1997-98.
The command area of the sugar factory has excellent cane potential and the sugarcane grown in
this area is rich in sucrose content. Sugarcane potential of SPSSKL from its command area is
around 8 lakh tonnes. In view of this, the factory management had further expanded its crushing
capacity to 3500 TCD in the year 2006. It has also installed a 9.0 MW co-gen facility suitable for
operation during the crushing season as well as off-season and the same is working satisfactorily
since the year 2006. SPSSKL has established 45 KLPD Molasses based Distillery in the year
2010. The industry has expanded its capacity from 3500 TCD to 4800 TCD and cogeneration
capacity from 9 MW to 19 MW in the year 2011. The industry has further expanded the sugar
plant capacity from 4800 TCD to 6000 TCD and cogeneration capacity from 19 MW to 22 MW
using the existing 3 MW turbine in the year 2016. At present, SPSSKL has a sugar unit of
crushing capacity 6000 TCD, Cogeneration of 22 MW capacity and Distillery unit of 45 KLPD
capacity.
SPSSKL is procuring sugarcane from Malshiras Taluka of Solapur District, Pandharpur Taluka
of Solapur district & Indapur Taluka of Pune District. There are a total of 97 villages in the area
of operation of the factory. Around 85% of the total sugarcane is estimated to be available within
15 km radius of the factory and the rest of 15% is within the 30 Km radius of the factory. The
factory thus has a very favorable sugarcane availability scenario.
4.2. Connectivity
The site is conveniently located in many aspects. This proposed expansion project has a plant
area of about 30.66 hectares having a connecting road and approachability. Pune – Solapur
national highway (NH-9) is 25 km away from the site. Bhima River is 5 km from industry. There
are no sensitive, historical, forest reserves and wildlife sanctuaries etc within 10 Km radius of the
factory site.
The Project Site is conveniently located for development of the Project.
110 Km away from Solapur, which is a district place.
Other important towns nearby are
Akluj, at a distance of 9 km
Pandharpur, at a distance of 30 km
Kurduwadi is nearest Railway station 38 km away from factory site.
Shree Pandurang SSK Ltd., Shreepur, Tal- Malshiras, Dist- Solapur Pre-Feasibility Report
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Solapur is nearest Airport 110 Km away from factory site.
Hence, the site is very convenient in terms of connectivity.
4.3. Land Form, Land use, and Land ownership
Total land of 30.66 Ha in the existing premise is owned by the industry. The detailed land
breakup along with the provision for Green Belt Development is given in Chapter 5.
4.4. Topography
The average elevation of the industry is 495 m. The study area is located on the bank of the
Bhima River hence having average plane topography. There is no important hill system in the
region. However, there are a few scattered hills in the area under study with no significant relief.
The area is thus characterized by flat and at the places slightly undulating topography
4.5. Existing Infrastructure
The expansion can be accommodated in the Existing infrastructure facilities to the maximum
possible extent. Additional land is available adjacent to the existing infrastructure to facilitate the
use of utilities without much additional cost.
4.6. Soil Classification
The Malshiras taluka consists of different types of soil such as light black, reddish and the black
cotton soil (BCS) which contains high alumina and carbonates of Ca and Mg. A typical
characteristic of the soil is that it swells when wet and dries up with cracks on losing moisture.
The thickness of the soil cover shows a large variation and ranges from a few centimeters to 5
meters. The soil is mostly nonretentive in nature.
4.7. Climatic data from stationary sources
Malshiras is one of the eleven tehsils in Solapur district and is situated towards the west of the
district place. It is also one of the most developed agriculture zones of the district. The zone
reveals a considerable variation in climate. The summer is long and very severe. The average
mean daily maximum temperature goes up to 390C and the average daily minimum is 12
0C. The
rainfall is also highly variable. The rainfall is received mostly from Southwest monsoon during
June to August and during August to September from Northeast monsoon.
4.8. Social Infrastructure available
Availability of infrastructure and facilities denote the level of overall development in the study
area. The availability of facilities with regard to education, health, transport and communication,
water supply and availability of electricity are dealt with in the following.
a) Education Facilities: Good educational infrastructure in Solapur district. It includes not only
school and colleges but also engineering, medical pharmacy, and dentistry colleges.
b) Health Services: There are excellent hospitals, nursing homes and dispensaries available.
Shree Pandurang SSK Ltd., Shreepur, Tal- Malshiras, Dist- Solapur Pre-Feasibility Report
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c) Drinking Water: The villages in the study area are drawing water from mainly from river,
according to the sources of drinking water used by the villages are Water tank, Well, River,
Hand Pump, Tap lake, etc
d) Transport and Communication: Pune- Solapur (N.H. – 9) Highway 25 Km away from
Industry.
e) Post & Telegraph: Most of the villages are well connected by post and telegraph facilities.
f) Electricity: All villages have a power supply from Maharashtra State Electricity Distribution
Corporation Limited., (MSEDCL)
5. PLANNING BRIEF
5.1 Planning Concept Town and country planning / Development authority
Classification
SPSSKL is a Co-operative industry. Existing facilities, transportation, and infrastructure etc. are
adequate. Hence, no additional planning is required.
5.2 Population Projection
Not Applicable.
5.3 Land use planning (breakup along with green belt etc)
Detailed land use planning along with green belt is given as below
Table 8 Land Breakup Details
Sr.
No Description
Existing
(sq. m.)
Proposed
(sq. m.)
Total Area
(sq. m.)
1 Built up Area( Sugar Cogen and
Distillery) 31000 18000 49000
2 Storage of Bagasse 8000 2000 10000
3 Sugar Godown 16500 -- 16500
4 Parking Area 37215 -- 37215
5 Colony Residential 35368 35368
6 ETP 8093 8093
7 Green Belt 82500 27500 110000
8 Vacant Land 87924 -47500 40424
Total 306600 0 306600
5.4 Assessment of Infrastructure Demand (Physical and Social)
The civil structures supporting Distillation Column, fermenter, anaerobic digesters and MEE for
spent wash treatment for the proposed Distillery, the housing of the equipment required for the
Shree Pandurang SSK Ltd., Shreepur, Tal- Malshiras, Dist- Solapur Pre-Feasibility Report
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expansion of the Sugar factory capacity, foundations etc., the new high-pressure boiler of 87
kg/sq. cm2 with a back pressure turbine of 15 MW capacity etc for Cogeneration Power Plant.
5.5 Amenities / Facilities
Existing amenities would be adequate for the proposed expansion.
6. PROPOSED INFRASTRUCTURE
6.1 Industrial Area (Processing Area)
Total of 2 hectare would be utilized for the processing area of the proposed project.
6.2 Residential Area (Non-Processing Area)
Residential area available is adequate for the proposed expansion.
6.3 Greenbelt
Greenbelt development is undertaken in the area provided separately. According to CPCB
guidelines, 1500 trees should be available per hectare of land for Greenbelt development. Total
11 Hectares of land is reserved for greenbelt development; hence there should be minimum
16500 no. of trees. The industry has already planted about 15000 Trees, and remaining 1500
trees shall be planted during this year. The industry proposes to plant 1000 to 1500 trees per year
in order to increase the greenbelt over and above 33% of the total factory area.
6.4 Social Infrastructure
At present, several basic amenities are adequately available at the site. Hence, there is no need
for the additional social infrastructure facilities.
6.5 Connectivity (Traffic and Transportation Road/Rail/Metro/Waterways etc.)
The present site is adequate in terms of connectivity. Transportation and traffic management
facilities are sufficiently present at the existing site.
6.6 Drinking Water Management (Source and Supply of water)
Drinking water facilities are already provided for the employees as well as for the people
residing in the nearby area. There shall not be any additional demand for drinking water after the
proposed expansion.
6.7 Sewerage System
Existing sewerage system shall also be adequate after expansion.
6.8 Industrial Waste Management
Industrial waste management facilities are adequate even for the expansion capacities.
Shree Pandurang SSK Ltd., Shreepur, Tal- Malshiras, Dist- Solapur Pre-Feasibility Report
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6.9 Solid Waste Management
Solid waste management and disposal facilities are not required additionally after expansion.
6.10 Power requirement & Supply / Source
At present, the power requirement by the industry is 12 MW. Additional 6 MW of power will be
required after the proposed expansion. Therefore the total power requirement after the proposed
expansion will be 18 MW. The industry intends to expand its cogeneration capacity to 34 MW.
The power required by the industry is met from its owned cogeneration power plant. Excess
electricity produced will be supplied to the state electricity grids.
7. REHABILITATION AND RESETTLEMENT (R&R) PLAN
7.1 Policy to be adopted (Central/State) in respect of the project affected persons
including home oustees, land oustees and landless laborers (a brief outline to be given)
Not applicable as the project does not fall under project affected areas.
8. PROJECT SCHEDULE AND COST ESTIMATES
8.1 Likely date of start of construction and likely date of completion (Time schedule for
the project to be given)
Project activities will be initiated as soon as Environmental clearance is obtained. And it would
take around two years for the completion of the project.
8.2 Estimated project cost along with analysis in terms of the economic viability of the
project
Cost of the project is 150 Crore rupees, EMP cost is estimated as Rs. 20 Crore, recurring
expenditures per annum is around Rs. 2 Crore and 0.75 % of the total project cost (Ref: Office
Memorandum Dated 1st May 2018 F. No- 22-65/2017-IA.III) will be spent on Corporate Social
Responsibilities (CSR) over a period of 5 years.
9. ANALYSIS OF PROPOSAL (Final recommendations)
9.1 Financial and social benefits with special emphasis on the benefit to the local people
including tribal population, if any, in the area.
Due to the expansion, productivity and the profitability of the industry are going to be affected in
a positive manner. The financial benefits are diverted directly to the farmers, by the higher cane
prices due to timely crushing and high recovery. Hence, this project would immensely help
farmers. Along with that, direct employment opportunities are generated for the local people due
to this expansion project. Due to the increased transportation and other activities inside the
industry premises, indirect employment generation is also possible. Hence, this project is
beneficial to the entire region around the SPSSKL.
Shree Pandurang SSK Ltd., Shreepur, Tal- Malshiras, Dist- Solapur Pre-Feasibility Report
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ANNEXURE-I
WATER BUDGET FOR SUGAR, CO-GENERATION POWER PLANT, AND DISTILLERY UNIT
Table 9 Water Budget -Sugar and Co-generation Power Plant
Sr.
No. Details
Water Requirement
(m3/day)
Consumption/Losses
(m3/day) Reuse / Recovery (m3/day)
Waste Generation
(m3/day)
Present
6000
TCD &
19 MW
4000 TCD
&
Expansion
15 MW
Total
10000
TCD &
34 MW
Present
6000
TCD &
19 MW
4000 TCD
&
Expansion
15 MW
Total
10000
TCD &
34 MW
Present
6000
TCD &
19 MW
4000 TCD
&
Expansion
15 MW
Total
10000
TCD &
34 MW
Present
6000
TCD &
19 MW
4000 TCD
&
Expansion
15 MW
Total
10000
TCD &
34 MW
1(a) Boiler 55 TPH 1310 -- 1310 90 -- 90 1210 -- 1210 10 -- 10
1(b) Boiler 55 TPH 1310 -- 1310 90 -- 90 1220 -- 1220 -- -- --
1(c) 20 TPH Boiler
at 46 Kg/Sqcm 600 -- 600 50 -- 50 545 -- 545 05 -- 05
1(d) Boiler 80 TPH -- 1910 1910
100 100
1800 1800 -- 10 10
2 For Cooling of
Mill Bearing 150 100 250 30 20 50 120 80 200 -- -- --
3 Washing of
equipment 55 20 75 -- -- -- -- -- -- 55 20 75
4
Air
compressors &
pumps
75 50 125 05 05 10 70 45 115 -- -- --
5 Spray pond
blowdown 200 100 300 125 50 175 -- -- -- 75 50 125
6 Cooling tower
blowdown 125 -- 125 65 -- 65 -- -- -- 60 -- 60
7 Domestic 30 -- 30 10 -- 10 -- -- -- 20 -- 20
8
Colony fire
fighting &
Gardening
295 -- 295 295 -- 295 -- -- -- -- -- --
9
Recycling of
Excess
Condensate
-- -- -- -- -- -- 1000 800 1800 50 50 100
Total 4150 2180 6330 760 175 935 4165 2725 6890 275 130 405
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Net Water Requirement: 6330-6890= -560 m3/day
(Due to excess condensate available from Sugar unit, there is no requirement of water for sugar unit. In fact an excess amount 560 m3/day is saved
and is being utilized for Distillery and other usages)
Effluent Generation: 405 m3/day (Sugar Effluent- 300 m3/day and Cogeneration Power Plant effluent- 85 m3/day Domestic Effluent 20
m3/day)
Remarks: Sugar effluent shall be treated in the existing ETP (Primary and Secondary Treatment) and disposed on land for irrigation.
Cogeneration Power Plant effluent shall be treated along with sugar effluent and disposed on land for irrigation.
Shree Pandurang SSK Ltd., Shreepur, Tal- Malshiras, Dist- Solapur Pre-Feasibility Report
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Table 10 Water Budget - Distillery
Sr.
No. Details
Water Requirement
(m3/day)
Consumption/Losses
(m3/day) Reuse / Recovery (m3/day) Waste Generation (m3/day)
Present
45
KLPD
Proposed
45
KLPD
Total
90
KLPD
Present
45
KLPD
Proposed
45
KLPD
Total
90
KLPD
Present
45
KLPD
Proposed
45 KLPD
Total
90
KLPD
Present
45
KLPD
Proposed
45 KLPD
Total
90
KLPD
1. Process Water 450 450 900 -- -- -- 330*
330*
+
305*
660*
+
305*
120 120 240
2.
Cooling
Tower Make-
up Water
345 345 690 80 80 160 245 245 490 20 20 40
3 Fermenter
Washing 10 10 20 -- -- -- -- -- -- 10 10 20
4
Miscellaneous
such as pump
and gland
cooling etc.
10 10 20 -- -- -- 10 10 20 -- --- --
5 Evaporator
Condensate -- -- -- -- -- -- 330 330 660 -- -- --
6.
Condensate
from Storage
tank
-- -- -- -- -- -- 0 305 305 -- -- --
7. Domestic 11 -- 11 03 -- 03 -- -- -- 08 -- 08
Total 826 815 1641 83 80 163 585 890 1475 158 150 308
Remarks: *: 965 m3/day is recycled into the process from evaporator condensate obtained after concentration of digester effluent and
Proposed Condensate Storage tank.
Net water requirement: 1641-1475= 166 m3/day
Effluent Generation: 308 m3/day
Remarks:
Present 158 m3/day of effluent shall be treated based on composting principle.
The effluent from the proposed 45 KLPD distillery (150 m3/day) shall be treated based on Concentration and Incineration principle.
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ANNEXURE II
ENVIRONMENTAL CLEARANCE-DISTILLERY
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Shree Pandurang SSK Ltd., Shreepur, Tal- Malshiras, Dist- Solapur Pre-Feasibility Report
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Shree Pandurang SSK Ltd., Shreepur, Tal- Malshiras, Dist- Solapur Pre-Feasibility Report
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Shree Pandurang SSK Ltd., Shreepur, Tal- Malshiras, Dist- Solapur Pre-Feasibility Report
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Shree Pandurang SSK Ltd., Shreepur, Tal- Malshiras, Dist- Solapur Pre-Feasibility Report
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Shree Pandurang SSK Ltd., Shreepur, Tal- Malshiras, Dist- Solapur Pre-Feasibility Report
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COMPLIANCE REPORT OF EC CONDITIONS OF 45 KLPD DISTILLERY
Shree Pandurang SSK Ltd., Shreepur, Tal- Malshiras, Dist- Solapur Pre-Feasibility Report
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Shree Pandurang SSK Ltd., Shreepur, Tal- Malshiras, Dist- Solapur Pre-Feasibility Report
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Shree Pandurang SSK Ltd., Shreepur, Tal- Malshiras, Dist- Solapur Pre-Feasibility Report
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ENVIRONMENTAL CLEARANCE- SUGAR AND COGENERATION
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Shree Pandurang SSK Ltd., Shreepur, Tal- Malshiras, Dist- Solapur Pre-Feasibility Report
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Shree Pandurang SSK Ltd., Shreepur, Tal- Malshiras, Dist- Solapur Pre-Feasibility Report
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Shree Pandurang SSK Ltd., Shreepur, Tal- Malshiras, Dist- Solapur Pre-Feasibility Report
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Shree Pandurang SSK Ltd., Shreepur, Tal- Malshiras, Dist- Solapur Pre-Feasibility Report
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Shree Pandurang SSK Ltd., Shreepur, Tal- Malshiras, Dist- Solapur Pre-Feasibility Report
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Shree Pandurang SSK Ltd., Shreepur, Tal- Malshiras, Dist- Solapur Pre-Feasibility Report
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Shree Pandurang SSK Ltd., Shreepur, Tal- Malshiras, Dist- Solapur Pre-Feasibility Report
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Shree Pandurang SSK Ltd., Shreepur, Tal- Malshiras, Dist- Solapur Pre-Feasibility Report
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Shree Pandurang SSK Ltd., Shreepur, Tal- Malshiras, Dist- Solapur Pre-Feasibility Report
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COMPLIANCE REPORT OF THE EC CONDITIONS OF SUGAR (6000 TCD) AND
COGENERATION UNIT (22 MW)
General Conditions for Pre-construction Phase
Sr. No General EC Conditions ( For Pre-construction
Phase)
Compliance
i No additional land shall be used/acquired for any
activity of the project without obtaining proper
permission
No additional land was
acquired. Existing land of 25.00
Ha. is adequate.
ii This Environmental Clearance is issued subject to
implement continuous online air monitoring and
water quality monitoring before operational phase.
Continuous online monitoring
for water quality monitoring
was installed. As per the CPCB
guidelines, Continuous online
monitoring for stack emissions
is not required.
iii Implement online air monitoring facility
equipment.
Not applicable, as per the CPCB
guidelines.
iv For controlling fugitive natural dust, regular
sprinkling of water and wind shields at appropriate
distances in vulnerable areas of the plant shall be
ensured
Sprinkling of water is done
regularly and wind shields were
provided at construction
activity.
v The Molasses from the sugar factory as a by-
product shall be taken directly to the distillery
through a pipeline and spent wash shall be stored
in RCC Ponds which will be HDPE lined to avoid
any seepage to polluter the sub soil water. The
spent wash shall be stored for 30 Days.
Molasses is directly taken to
distillery during the sugar
season operations. However,
during the off-season, molasses
stored in steel tanks is pumped
in closed pipe to the Distillery
unit, which is in the same
campus of the factory. The
spentwash storage pond
capacity is not only 30 days and
made seepage proof by HDPE
lining and concreting as per the
CPCB guidelines.
vi Regular monitoring of the air quality, including
SPM and So2 levels both in work zone and
ambient air shall be carried out in and around the
power plant and records shall be maintained. The
location of monitoring stations and frequency of
monitoring shall be decided in consultation with
MPCB and submit report accordingly to MPCB
Monthly air quality sampling is
carried out and the locations of
the monitoring station are fixed
in consultation with the MPCB
authorities
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vii Necessary arrangements shall be made to adequate
safety and ventilation arrangement in furnace area.
All the employees are given
safety equipment such as heat
resisting aprons, gloves, boots,
helmets etc. and besides
adequate natural ventilation in
the working area.
viii Proper Housekeeping programmers shall be
implemented
Housekeeping is maintained by
avoiding spillages, leakages and
cleaning with hot condensates to
avoid bacterial contamination.
ix In the event of the failure of any pollution control
system adopted by the unit, the unit shall be
immediately put out of operation and shall not be
restarted until the desired efficiencies has been
achieve.
Pollution control systems are
interlinked with the process
operations
x A stack of adequate height based on DG set
capacity shall be provided for control and
dispersion of pollutant from DG set, (if
appliacable)
Stack height of DG sets are 6
meters above the roof level.
xi A detailed scheme for rainwater harvesting shall be
prepared and implemented to recharge ground
water.
rainwater harvesting is
implemented and stored in a
well designed rain water
harvesting pond.
xii Arrangement shall be made that the effluent and
storm water does not get mixed.
Storm water and effluents are
taken separately
xiii Periodic monitoring of Ground water shall be
carried out and the results are analyzed to ascertain
any change in the quality of water. Results shall be
regularly submitted to the MPCB.
Ground water quality
monitoring is done once in a six
months.
xiv Noise levels shall be maintained as per standards.
For people working in the high noise area, requisite
personal protective equipment like earplugs etc.
shall be provided
Noise levels are monitored
regularly and ambient noise
levels are within the standards.
At work places such as
compressors, boilers, turbines,
mill house etc. workers are
provided with earmuffs/plugs.
xv The overall noise levels in and around the plant are
shall be kept well within the standards by
providing noise control measures including
acoustic hoods, silencers, enclosures etc. on all
sources of noise generation. The ambient noise
Noise levels are monitored
regularly and ambient noise
levels are within the standards.
At work places such as
compressors, boilers, turbines,
Shree Pandurang SSK Ltd., Shreepur, Tal- Malshiras, Dist- Solapur Pre-Feasibility Report
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levels shall confirm to the standards prescribed
under Environment (Protection) Act, 1986 Rules,
1989.
mill house etc.
xvi Greenbelt shall be developed and maintained
around the plant periphery. Greenbelt
Development shall be carried out considering
CPCB guidelines including selection of plant
species and in consultation with the local
DFO/Agriculture Dept.
Greenbelt development at 1500
trees per hectare in the one third
area as per the CPCB
Guidelines.
xvii Adequate safety measures shall be provided to
limit the risk zone within the plant boundary, in
case of an accident. Leak detection devices shall
also be installed at strategic places for early
detection and warning.
All the safety measures as per
the factory act are strictly
followed.
xviii Occupational health surveillance of the workers
shall be done on a regular basis and record
maintained as per Factories Act.
Regular health checkup of the
employees working at
vulnerable places is carried out.
xix The company shall make the arrangement for
protection of possible fire hazards during
manufacturing process in material handling.
Fire Brigade is available at the
Industry. Besides, fire
extinguishers are provided
within the factory as well as at
Bagasse storage area.
xx The project authorities must strictly comply with
the rules and regulations with regard to handling
and disposal of hazardous wastes in accordance
with the Hazardous Waste (Management and
Handling) Rules, 2003 (amended). Authorization
from the MPCB shall be obtained for
collection/treatment/storage/disposal of hazardous
wastes.
The only hazardous waste
produced is spent oil which is
mixed with bagasse and burnt in
boilers.
xxi The management shall undertake following waste
minimization measures
a) Metering of quantities of active ingredients to
minimize waste
b) Reuse by products from the process
c) Maximizing recoveries
d) Use of automated material transfer system to
minimize spillage
a) Weighing is done for all
active ingredients to minimize
wastage.
b) Molasses is used for
producing Rectified Spirit.
Pressmud and Ash are used in
Composting.
c) Industry has implemented
modern technologies in the
process, both in Sugar and
Distillery units to maximize the
recovery.
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the Industry has secured the
Rank 1 for the recovery of
Sugar in Solapur District.
d) Automation is implemented,
both in Sugar and Distillery
units.
xxii Regular mock drills for the onsite emergency
management plan shall be carried out.
Implementation of charges/improvements required,
if any, in the on-site management plan shall be
ensured.
The Safety Department
conducts regular mock Drills
and no vehicle is permitted to
park inside the factory and all
the visitors are required to wear
helmets.
xxiii A separate environment management cell with
qualified staff shall be set up for implementation of
the stipulated environmental safeguards.
A separate management cell
with all the Heads of the
Departments is constituted and a
senior Environment Consultant
is engaged to supervise the
activities and implementation of
Environment Protection
Measures.
xxiv Transportation of ash will be through closed
containers and all measures should be taken to
prevent spilling of the ash.
Majority of the Fly Ash is
utilized in composting and the
rest is sold to the Brick
Manufacturers, which are
advised to transport in a closed
containers
xxv Separate silos will be provided for collecting and
storing bottom ash and fly ash
Ash is disposed daily and as
such no storage is required.
xxvi Separate funds shall be allocated for
implementation of environmental protection
measures/EMP along with item-wise breaks-up.
These costs shall be included as part of the project
cost. The funds earmarked for the environment
protection measures shall not be diverted for other
purposes and year-wise expenditure should
reported to the MPCB and this department.
Separate budgetary allocation is
earmarked for the environment
protection measures and the
funds are not diverted for any
other purpose.
xxvii the project management shall advertise at least in
two local newspapers widely circulated in the
region around the project, one of which shall be in
Marathi language of the local concerned within
seven days of issue of this letter, informing that the
project has been accorded environmental clearance
Published in the Local
Newspapers in Marathi and in
English.
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and the copies of clearance letter are available with
the MPCB and may also be seen at website at
http://ec.maharashtra.gov.in
xxviii project management should submit half yearly
compliance reports in respect of the stipulated prior
environment clearance terms and conditions in
hard and soft copies to the MPCB and this
department, on 1st June and 1
st December of each
calendar year.
Six Monthly Compliance
reports are submitted.
xxix A copy of the clearance letter shall be sent by
proponent to the concerned Municipal Corporation
and the local NGO, if any, from whom
suggestions/representations, if any, were received
while processing the proposal. The clearance letter
shall also be put on the website of the Company by
the proponent.
The copy of the Environmental
Clearance was given to the local
Gram Panchayat and put in the
Company website.
xxx The proponent shall upload the status of
compliance of the stipulated EC conditions,
including results of monitored data on their website
and shall update the same periodically. It shall
simultaneously be sent to the Regional Office of
MoEF, the respective Zonal Office of CPCB and
the SPCB. The criteria pollutant levels namely;
SPM,RSPM,SO2,NOx (ambient levels as well as
stack emissions) or critical sectoral parameters,
indicated for the project shall be monitored and
displayed at convenient location near the main gate
of the company in the public domain.
The monitored data is uploaded
on the website and sent to RO,
MoEF, Nagpur, CPCB and the
SPCB. The results are also
displayed at the Main Gate.
xxxi The project proponent shall also submit six
monthly reports on the status of compliance of the
stipulated EC conditions including results of
monitored data (both in hard copies as well as by
e-mail) to the respective Regional Office of MoEF,
the respective Zonal Office of CPCB and the
MPCB
Six Monthly compliance reports
are regularly submitted.
xxxii The environmental statement for each financial
year ending 31st March in Form-V as is mandated
to be submitted by the project proponent to the
concerned State Pollution Control Board as
prescribed under the Environment (Protection)
Rules, 1986, as amended subsequently, shall also
be put on the website of the company along with
Environmental Statement,
Form-V is submitted regularly
to the MPCB every year on or
before 30th
September and also
put in the website of the
company.
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the status of compliance of EC conditions and shall
also be sent to the respective Regional Offices of
MoEF by e-mail.
4 The environmental clearance is being issued
without prejudice to the action initiated under EP
Act or any court cases pending in the court of law
and it does not mean that project proponent has not
violated any environmental laws in the past and
whatever decision under EP Act or of the Hon‟ble
court will be binding on the project proponent.
Hence this clearance does not give immunity to the
project proponent in the case filed against him, if
any or action initiated under EP Act.
Noted.
5 The Environment department reserves the right to
revoke the clearance if conditions stipulated are not
implemented to the satisfaction of the department
or for that matter, for any other administrative
reason.
Noted.
6 Validity of Environment Clearance: The
environmental clearance accorded shall be valid
for a period of 7 years as per MoEF&CC
Notification dated 29th
April, 2015 to start of
production operations.
Noted.
7 In case of any deviation or alterations in the project
proposed from those submitted to this department
of clearance, a fresh reference should be made to
the department to assess the adequacy of the
condition(s) imposed and to incorporate additional
environmental protection measures required, if
any.
Noted.
8 The above Stipulations would be enforced among
others under the Water (Prevention and Control of
Pollution) Act, 1974, the Air (Prevention and
Control of Pollution) Act, 1981, the Environment
(Protection) Act, 1986 and rules there under,
Hazardous Wastes (Management and Handling)
Rules, 1989 and its amendments, the public
Liability Insurance Act, 1991 and its amendments.
Noted.
9 Any appeal against this environmental clearance
shall lie with the National Green Tribunal (Western
Zone Bench, Pune), New Administrative Building,
1st Floor, D-Wing, Opposite Council Hall, Pune, if
Noted.
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preferred, within 30 days as prescribed under
Section 16 of the National Green Tribunal Act,
2010.
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ANNEXURE III
CONSENT TO OPERATE: SUGAR AND COGENERATION
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Shree Pandurang SSK Ltd., Shreepur, Tal- Malshiras, Dist- Solapur Pre-Feasibility Report
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Shree Pandurang SSK Ltd., Shreepur, Tal- Malshiras, Dist- Solapur Pre-Feasibility Report
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Shree Pandurang SSK Ltd., Shreepur, Tal- Malshiras, Dist- Solapur Pre-Feasibility Report
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Shree Pandurang SSK Ltd., Shreepur, Tal- Malshiras, Dist- Solapur Pre-Feasibility Report
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CONSENT TO OPERATE: DISTILLERY DIVISION
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