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Form 1& Prefeasibility Report for Environmental Clearance
Submitted to Expert Appraisal Committee
Proposed Expansion of Sugar 6000 TCD to 13000 TCD, Co-generation Plant
21 MW to 90 MW & Proposed New Molasses based Distillery of 150 KLPD
For
M/s Shri Gurudatt Sugars Ltd.
Gut No. 61/A, Akiwat Takaliwadi Road, Takaliwadi,
Tal.-Shirol, Dist. - Kolhapur (MS)
Report Prepared by
sd engineering services pvt.ltd.,
14 Age Arcade, New Osmanpura,
Near Sant Eknath Rang Mandir, Aurnagabad-431005 (MS)
Tel: No. (Office) 91-240-2333622, 233064, (Cell) 91-9960634559
Email ID: [email protected]
May 2017
M/s Shri Gurudatt Sugars Ltd., Kolhapur (MS) Prefeasibility
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1 sd engineering services pvt. ltd. Aurangabad
INDEX
1. EXECUTIVE SUMMERY
2. INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION
Identification of the project and Project Proponent
Nature of the Project
Need of project with description for region and country
Demand and Supply gap
Imports vs. Indigenous production
Export Possibility
Domestic/ Export Markets
Employment Generation due to Project
3. PROJECT DESCRIPTION
Type of Project
Location of Project
Details of Alternate sites
Size of magnitude of Operation
Project Description
Raw material and Finished Products
Resources optimization
Availability of Resource (Water, Energy/ Power Requirement)
Quantity of Waste to be generated
4. SITE ANALYSIS
Connectivity
Land form, Land use, Land ownership
Topography
Existing land use pattern
Existing Infrastructure
Soil classification
Climatic data for secondary sources
Social Infrastructure available
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5. PLANNING BRIEF
Population Projection
Land use planning
Assessment of Infrastructure Demand
Amenities/ Facilities
6. PROPOSED INFRASTRUCTURE
Industrial area
Residential area
Green Belt
Social Infrastructure
Connectivity
Drinking Water Management
Sewerage System
Industrial Waste management
Air Pollution
Solid waste Management
Power Requirement & Supply/ Source
7. REHABILATION AND RESETTLEMENT (R & R PLAN)
Policy to be adopted
8. PROJECT SHEDULE & COST ESTIMATES
Time schedule for the Project
Estimated project cost (Economic viability of the project)
9. ANALYSIS OF PROPOSAL
Financial and Social benefit
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CHAPTER 1
EXECUTIVE SUMMARY
M/S SHRI GURUDATT SUGARS LTD is proposing an expansion of Sugar plant, Co-
Generation, Refinery & distillery. Shri Gurudatt Sugars is desirous to produce sugar &
energy in this Large Size Industrial (LSI) sector at Gut No.61/A, Akiwat, Takaliwadi Road,
Takaliwadi, Taluka-Shirol, Dist- Kolhapur Maharashtra. Capacity of the complex will be
Sugar manufacturing from 6000 TCD to 13000 TCD
Refining the sugar produced to refining sugar – 1755 TPD
Refining RAW SUGAR to refining sugar -1755 TPD
Co-generation from 21 MW to 90 MW
Proposed new molasses based Distillery- 150 KLPD
The Notification no S. O. 1533 promulgated on 14th September 2006 have covered these
types of industries under its entry 5(j) & 1(d) & 5(g).
The land is on Gut No. 61 admeasuring area of 36.72 Hectare. Proposed Layout Plan is
attached. The Land is already changed to Industrial Land use. Thus there is a no change
in the status. The main river, city, Railway line, National Highway is sufficiently at a safe
distance. Local Authority has provided all infrastructures like assured Electrical Power,
Continuous water supply, the internal road network, external approach road and
networking. There is no sensitive establishment in the vicinity (study zone) such as
health resort, hospital, archaeological monuments, sanctuaries etc. All villages are
provided with drinking water from wells or Government Water Supply Schemes.
There will be no nuisance from noise. Machinery and Equipments will be provided with
Acoustic Enclosure. There will not be crushing, pulverizing operations. Labor strength is
also limited in this LSI unit. In this case input is odorless. No nuisance generation.
Shri Gurudatt Sugars Ltd is desirous to produce the products like sugars and Power.
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List of Products
Sr.
No.
Product Name Quantity Unit
Existing
1. Sugar Cane Crushing 6000 TCD
2. Power generation 21 MW
Capacity after Expansion
1. Sugar Cane Crushing 13000 TCD
2 Refining the raw
sugar to refining
sugar
1755 TPD
3 Refining the sugar
produced
1755 TPD
4 Power generation 90 MW
5. Molasses Based
Distillery
150 KLPD
Whereas, during production water input requires 892 M3/day. Fuel used will be
bagasse, coal & concentrated spent wash.
In Shri Gurudatt Sugars Ltd Safety and occupationally Health will be dealt carefully. A
disciplined approach is natural to this industry. Safety policy will be in place. This unit is
registered under Factories Act and is bounded by State Factory Rules. Thus, first aid
trained and Fire– fighting trained person will be available in every shift. Safety Officer
will be appointed. Wherever necessary, provisions of other Acts, like petroleum Act,
Explosive Act etc. will be obeyed. Firefighting system is kept as per norms of Insurance
Company and CIF.
DMP (Disaster Management Plan) and off-site emergency plan will be in place.
Accordingly, Personal protection equipment will be given and use will be insisted.
Consulting physician will be retained to attain the factory.
This proposed project is located at village Akiwat, Takaliwadi Road, Takaliwadi, Tal:-
Shirol, Dist. Kolhapur, Maharashtra. The infrastructure like road transmission lines is
made available by local authority and the raw material is easily available. The Kolhapur
M/s Shri Gurudatt Sugars Ltd., Kolhapur (MS) Prefeasibility
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city has Railway station and Air port. State Highway is passing adjacent to the project
site.
The industry is manufacturing Sugar and power for growing needs of India. This will not
disturb the present land use because our area occupied will be only small % of influence
zone of 10 km. There will be no problematic waste materials as all will be disposed as
per CPCB norms.
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CHAPTER 02
INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION
2.1 Identification of the project and Project Proponent
Shri Gurudatt Sugars Ltd, acronymic (SGSL), a limited company is floated and
promoted by a reputed well-known Industrial family in Kolhapur District in
Maharashtra state.
The group is managing sugar factories has been the recipient of many prestigious
awards from government and Sugar Institutes for efficient management and
attaining excellent results and efficiencies.
M/s Shri Gurudatt Sugars Ltd. factory will be promoted at Gut No. 61/A Village
Akiwat Takaliwadi Road, Takaliwadi in Shirol tahesil of Kolhapur District (MS).
Application has been made to MPCB for the Consent to establish. The
manufacturing site is located on Gut No. : - 61/A village Akiwat, Takaliwadi Road,
Takaliwadi in Shirol tahsil of Dist.:- Kolhapur in Maharashtra. The plot
admeasures about 36.72 hectares. The company shall manufacture sugar and
power.
Form I, as is prescribed by the EIA Notification, 2006 amendment 2009 is duly
filled up and submitted. This Pre-feasibility Report is an accompaniment to the
same.
The Form I & Prefeasibility report generally covering Justification, Nearby Land
Use, Resources, Process, Pollution Control, Aesthetics, Risk Involved, Consequent
Developments and Environmental Sensitive Issues.
2.2 Nature of the Project
M/s Shri Gurudatt Sugars Ltd. (SGSL) is proposing expansion Project with
capacity to manufacture sugar from 6000 TCD to 13000 TCD, Refinery Produced
Sugar 1755 TPD, Refining the raw sugar to Refining sugar 1755 TPD & Power 21
MW to 90 MW & Alcohol- 150 KLPD. This level of production will not be
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commenced from day one, but will be commissioned smoothly. This is an
optimum site for us because it is manageable from production, pollution control
and quality assurance point of view.
Need of project with description for region and country
1. In India sugar is a prime requirement in every house hold. Almost 75 % of
the sugar available in the open market is consumed by bulk consumers
like bakeries, candy makers, sweet makers & soft drink manufactures.
2. The crushing season in the country starts from October and reaches its
peak in January before finally ending in March or April of the next year.
But based on cane availability, the start of crushing season may
postponed by one to one and half months in different states of the
country.
3. The period of November to March, 150 days is an ideal one for sugar
recovery in general, more particularly in Bihar & Uttar Pradesh. From
April onwards, sugar recovery shows a down ward trend and in June the
percentage of sugar recovery comes to lowest levels.
4. Sugar cane and sugar production in India typically follows a cyclic pattern,
wherein 2 to 3 years of higher production are followed by 3 to 4 years of
lower production.
5. The production of sugar cane in India has increased during the last ten
years and is still on an increasing trend. The productivity of cane in the
northern areas of the country is lower than the productivity in southern
areas. In India, sugar is grown over 4 million hectares of land
6. After two consecutive years of decline in sugar production i.e. MY
2008/09 & MY 2009/10 (Marketing Year), production has started to
resurge in MY 2010/11 & is gained in 2011/12. The gap between demand
& supply is narrow and depends mainly on climatic conditions and cane
sugar price, Fair and Remunerative Price (FRP) declared by the
government.
7. Maharashtra has huge deficit in power generation & requirement.
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8. The power generation from biomass is eco- friendly compared to other sources.
9. Investment for power generation is minimum as compared to other sources of
power.
Justification
1. In the industry, effluent produced is only water. Therefore, problems of
pollution hazard are nil.
2. Consent from State Pollution Control Board can be easily obtained as a
matter of routine.
3. Cane growing needs a longer time to get the crop. The management of
sugar factory is implementing lift irrigation schemes for sugar cane
growers under the cane development program.
4. They have decided to implement drip irrigation scheme to irrigate more
land in minimum water quantity. Thus large water is conserved.
5. It is proposed to use water from cane for power generation thus reducing
water requirement practically.
How this project is economically strong.
How the wastage and scrap arising out of one development activity can
serve as raw material for us, in turn again to be useful to serve further
national development in building, bridges, factories etc.
How the pollution generated from this unit can be successfully managed
through EMP implementation.
How the residual pollution can be successfully managed through
common facilities like, though it is hardly needed in this instant case.
2.4 Demand and Supply gap
As per the increase in population demand in the Market for sugar always prevail.
As far as the products like sugar, powers are concerned; there is a huge gap in
our country in demand and supply.
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2.5 Imports vs. Indigenous
Sugar Statistics (All India)
Year 2006/07 2007/08 2008/09 2009/10 2010/11 2011/12
Total sugar
production*
(000,tones)
28361 26356 14538 18912 24394 25500
Sugar import/export Export and Import depends up on
Production, Supply & Demand
*includes Khandsari Sugar 2006/07-500, 2007/08-425, 2008/09-435, 2009/10-343, 20010/11-420
World Scenario
1. Over 3/4ths of the total sugar produced is consumed domestically in the
countries in which it is produced, and the rest is treaded around the globe
which is often termed as World Sugar.
2. The world exports of sugar however around 40 million tons and the
leading sugar exporting country is Brazil exporting to around 55 % of its
total produce.
3. Contribution of sugar production (%) of India in total world sugar
production
European Union 10.42 % Brazil 22.66 % India 14.49 % China 8.23 % USA 4.53 % Australia 2.74 % Thailand 4.59 % Mexico 3.3 % Pakistan 2.39 % Russia 2.20 % Rest World 24.44 %
As per the increase in demand of products, need of Imports may get increased.
But if production is done in self sufficient manner at the national level
(indigenously), there is no need of dependency on the other resources for the
Import of goods. Power generation with bagasse helps to reduce solid waste
quantity as also will be the best use of bio-waste to energy generation concept.
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Export Possibility
1. Marketing will be done at national level as well as international level.
Requirement of alcohol and Sugar globally is always be there.
2. There is a huge potential for these products in global market. Around 30-
40 % finished goods can be exported to the Regulated and non regulated
international Market.
2.5 Domestic / Export Markets
Marketing will be done at the local level as well as finished goods will be
exported to the Regulated and non- regulated International Market. Power will
be consumed locally.
Employment Generation due to Project
Employments generated for administration and production purposes will be
recruited locally without any difficulty. Indirect employment is done through
road-side business & allied activities.
Sr. No. Types of
Worker
No. of Workers
Existing
No. of
Workers
Proposed
Total
1. Skilled 336 200 536
2. Unskilled 175 100 275
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CHAPTER 3
PROJECT DESCRIPTION
3.1 Type of Project
Shri Gurudatt Sugars Ltd is proposing an expansion of Sugar plant, Refinery
Sugar & Co-generation & distillery. Shri Gurudatt Sugars is desirous to
produce sugar, energy & alcohol in this Large Size Industrial (LSI) sector at Gut
No. 61/A Village Akiwat, Takaliwadi Road, Takaliwadi, Taluka:-Shirol, Dist:-
Kolhapur Maharashtra. Proposed capacity of the project Capacity of the
complex will be
Sugar manufacturing from 6000 TCD to 13000 TCD
Refining the sugar produced to refining sugar – 1755 TPD
Refining RAW SUGAR to refining sugar -1755 TPD
Cogeneration from 21 MW to 90 MW
Proposed new molasses based Distillery- 150 KLPD.
With Screening it is necessary for GSL to approach Delegated Authority from
Ministry of Environment and Forest (MoEFCC), New Delhi for Environment
Clearance for guidance for this unit. This Pre-feasibility report however, is
prepared for forming a framework for EIA study, Scoping and finalizing the Terms
of Reference, as may be required.
The Local Authority has a desire to improve status of this District and has
encouraged Industrial establishments at Takaliwadi. In order to have a sustainable
development, the pollution generation from this industry is finally made
insignificant having taken all the precautions right from raw material selection up
to low or no waste generation and conversion.
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3.2 Location of Project
The proposed production shall be at Gut no. 61 of Village Akiwat, Near Takaliwadi
Road Takaliwadi Taluka: - Shirol of Dist.:- Kolhapur in Maharashtra state. Area is
around 36.72 hectares.
The Geographical Location of this Industry is 16037’15.5 N latitude and
74o
35’39.5 E Longitude with an elevation of 540m. Local Authority has assured to
provide all infrastructures like assured Electrical power, continuous water supply,
the internal road network, external approach road etc.
So e i porta t air dista ces fro proposed site are as u der…..
1. Nearest air port Kolhapur – 35.50 km towards West direction
2. Nearest Railway Jaysingpur – 15 km towards North West direction.
3. Nearest Habitat is village Takaliwadi at 01.20 km towards NE direction.
4. Nearest River is Krishna 04.19 km towards South East direction.
GPS Location and Google Imagery of the proposed site are attached (Annexure I)
Site Analysis
As this is an expansion project hence there is no new site selection.
Lay-Out
Layout is designed properly. It is proposed to make construction to house storage
yards for Raw Material and finished products, ware houses, utility building,
Canteen and administrative offices etc. The Layout of facility is prepared based on
following:
1. There will be sufficient space for the movement of vehicles especially fire
tender.
2. Shortest route for transfer of Raw material & Products from one
department to other.
3. Consideration of prevalent Wind speed & direction for dispersion of
Pollutants.
4. Optimum Utilization of utilities.
5. Use of Natural gradient to transport waste water.
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Proposed Layout Plan is given as (Annexure IV)
3.4 Size or Magnitude of Operation
Shri Gurudatt Sugars Limited (SGSL) is proposing expansion with capacity as, sugar
6000 TCD to 13000, Power 21 MW to 90 MW & Alcohol 150 KLPD. This level of
production will not be commenced from day one, but will be commissioned
smoothly. This will not disturb the present land use because our area occupied will
be only small % of influence zone of 10 km. Landscape and greenery will be
developed in 33% area and only native species will be promoted. No Rehabilitation
is required.
3.5 Project Description with Processes Details
Proposed Product Details
Sr.
No. Product name Quantity Unit
1. Sugar cane crushing 13000 TCD
2 Refining the sugar produced to
refining sugar
1755 TPD
3 Refining RAW SUGAR to refining
sugar
1755 TPD
4 Power Generation 90 MW
5. Alcohol 150 KLPD
The Plant will house the following equipments
Plant and Machinery
➢ Co-generation Unit
Machinery & Hardware
1. Turbo generating set based on Double Extraction cum condensing mode
and with generation capacity of total 90 MW.
➢ Ancillary machinery
1. Single entry condensers & Cooling Towers, for co-generation units, which
M/s Shri Gurudatt Sugars Ltd., Kolhapur (MS) Prefeasibility
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360MT
11 MW
184MMT
154 MT
~ ~
High Pressure
Use Steam Turbine
Bank‐ 90 MW
340MT
0 MT 0 MT 323MTT
~ ~
High Pressure
Use Steam Turbine
Bank‐ 90 MW
consume less water and hence less power.
I. MANUFACTURING PROCESS
Cogeneration Process (During Season)
A. Co-generation Unit
(180 + 180) TPH – 125 Kg/cm2
Pressure Boilers
77.4 MW
To Grid
195 MT
Exhaust
Steam for
Process
15 MW
for Use
Cogeneration Process (During Season)
A. Co-generation Unit:
180+ 180 TPH – 125 Kg/cm2
Pressure Boiler
323 MT
Exhaust
Steam for
Condensation
72.4 MW
To Grid
12.8MW
for Use
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B.Sugar Manufacturing Process
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Manufacturing Process of Alcohol
(A) Manufacturing Process of Alcohol:- (Molasses–based)
Molasses, a by-product of sugar industry is used as raw material by most of the distilleries
for production of alcohol by fermentation and distillation processes. The molasses contains
about 40-50% sugar, which is diluted to bring sugar contents to 10- 15% sugar, 20-250
Brix
for further fermentation process. The pH is adjusted by addition of sulphuric acid, if
necessary.
Yeast culture is done in the laboratory and propagated in a series of fermenters, each about
10 times larger than the previous one. The diluted molasses is inoculated with about 10%
by volume of yeast inoculums. In the fermenters the reducible sugars are broken down to
ethyl alcohol and carbon di oxide (CO2). The reaction is exothermic and cooling water is
sprayed on fermenter walls to maintain the temperature at 29-300
C. Sludge is produced
and discharged from the bottom, while the clear fermented beer from sent to degasifying
section of the analyser which is a bubble-Cap-fractionating column, the beer is heated by
live steam and fractionated to give a 40% alcohol stream from the top. This stream is
further fractionated in the rectifier column to obtain rectified spirit. Part of the rectified
spirit is sent back to the column, and the condensed water from this stage, known as spent
lees is usually pumped back to the analyzer column. The bottom discharge from the
analyzer column is known as the spent wash, which is drained off after heat exchange with
the incoming beer from the fermenters.
In general the layout of, most distilleries is similar and can be divided into two broad
sections. The first section houses laboratory; yeast propagation vessels, diluters, pre-
fermenters and fermentation vessels. The second section houses all the distillation columns
condensers and heat exchangers.
The yeast propagation vessels are generally closed reactors where strict temperature
control is maintained. The diluter in most of the distilleries is of continuous type where the
molasses and water streams are pumped into two coaxial tubes in a closed vessel. The two
streams get thoroughly mixed by the high turbulence before they flow into the fermenter.
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A single diluter with a diameter of about 300-400 m, an overall height of about 3,0000101
and a capacity of about 15,000 to 30,000 L of diluted molasses per hour is commonly used
for continuous dilution. Generally, the continuous diluter is cleaned once in a day with
water and steam. There is no process waste stream produced from yeast propagation
vessels, diluter and pre- fermenters except the wash waters used for cleaning after
processing cycles. Most of the distilleries have open top fermenters where CO2 is generally
not recovered.
Manufacturing process for Alcohol:
In India, Alcohol is manufactured by below mentioned processes:
Continuous Process
In this process yeast is recycled. Fermentation and distillation is coupled to get a continuous
supply of fermented beer for the distillation column. The advantage of the process is that a
highly active yeast cell initiates the fermentation rapidly and the alcohol yield is also much
higher compared to the batch process.
Bio-still process is one of the continuous processes, which is a trade name in which
molasses is fed to the fermenter at a constant flow rate. The flow rate of molasses is
controlled to maintain the sugar and alcohol concentrations in the wash at 0.2% or lower
and 6-7% respectively.
The waste streams comprise spent wash which is the main source of waste water, spent
lees and yeast sludge. Spent lees are usually mixed with the spent wash. The yeast sludge is
disposed separately after drying. In addition wastewater may be generated from the
bottling, fermentation tank cooling and washing and utility sections of the plant, which is
used as a diluents for the treated spent wash.
Raw Material for finished Product
List of Raw Materials:
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A. For sugar production
Sr. No. Raw Material Quantity/day
1. Sugarcane 13000 TCD
2. Lime 20.8 MT
3. Sulphur 7.8 MT
B. For power generation
Sr. no. Raw Material Quantity /day
1. Baggase 3648 MT
C. For Alcohol
Sr. no. Raw Material Quantity /day
1. Molasses 520 MT
Source for Raw Material Procurement: Raw Material is easily available in area
around the sugar factory.
Mode of Transport of Raw Materials: The raw materials will be transported locally by
way of road.
Storage at the site: The raw material which is cane shall be crushed as early as
possible to have maximum sugar recovery. A terminus is provided to hold vehicles
bringing in sugar cane.
3.8 Availability of Resources (Water, Energy/Power Requirement)
Power: The total power generation here will be 90 MW/day. The power required
for the factory will be consumed from the in-house production and excess will be
sold to MSEB.
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Water: The water requirement is about 892 M3 for domestic, greenery, process,
and part cooling purposes. The source of water is already available from Krishna
River and the same is adequate and satisfactory. The source is dependable and
reliable.
Manpower: The manpower required for administration and production purposes
will be recruited locally without any difficulty. The requirement will be variable as
per phase of working but will be about 300 Nos. workforces including staff
members will work in shifts.
Land: Approximately 36.72 hectare of land is already in the possession of proponent
Project Cost: 350 Cr.
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3.9 Quantity of waste
Water & wastewater
The water supply will be through the Krishna River. The water & wastewater
generated in the factory will be as follows:
Effluent Generations
Sr.
No.
Effluent Generation M3/day
1. Domestic 100
2. Sugar 1300
3. Co-gen 168
4. Distillery 2000
Water Balance
Water
Source
Qty
Available
(m3/day)
UTILIZATION
Qty
Required
(m3/day)
Condensat
e Qty Used
(m3/day)
Raw
Water
Requirem
ent
(m3/day)
Sugar, Co-Gen. And Distillery Operation
Sugar
Condensate 3120
1. Fermenter Makeup 1785 1785 -
2. Cooling Tower Makeup (Co-Gen) 864 864 -
3. Other Uses ( Sugar) 471 471 -
Distillery
Condensate 1500
1. Cooling Tower make-up (Dist.) 1080 1080 -
2. Vacuum pump sealing (Dist.) 120 120 -
3. Floor Washing 60 60 -
Raw Water
1. Advanced WTP (Co-Gen) 480 - 480
2. Distillation Column 240 - 240
3. Boiler makeup( Distillery) 72 - 72
4. Domestic 100 - 100
Net Raw Water Requirement 892
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Water Pollution Control
Domestic Wastewater
a) Constraint Conditions
pH : 7.0 – 7.5
C.O.D. : 450 – 500 mg/l
B.O.D. : 200 – 250 mg/l
The domestic effluent shall be treated in septic tank followed by soak pit. The
overflow of soak pit shall be mixed with co-gen and DM water plant.
Industrial Waste (Co-generation)
a) Constraint
Conditions
Flow: 48 cum/d
pH: 6.5 – 7.5
C.O.D.: 100 mg/l
B.O.D.: 20 – 40 mg/l
Treatment Approach for Effluent Treatment
All the effluent streams contain inorganic matter in suspended solids or in
dissolved form and there is no organic matter concentration. The boiler
blow downstream contains suspended solids to large extent besides having
temperature. Settling tank is therefore proposed before the stream is
connected to collection tank.
All the other streams contain inorganic matter in dissolved form, besides
having variable pH.
Effluent from co-gen: The boiler blow down shall be allowed to settle in a
settling tank and over flow shall be mixed with other effluent from septic
tank & DM plant. The effluent from DM Plant shall be neutralized & mixed
with above effluent. The mixed effluent is used for green belt.
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Effluent from Sugar Plant
Sr.
No.
Parameter Unit Design Value Performance
Parameters
1. Flow m3/hr 600 600
2. pH -- 5-6.5 7 – 7.5
3. C.O.D. mg/L 2000-3500 < 150 4. B.O.D mg/L 1000-1600 <50
5. O& G Mg/L 10-20 <1
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=================
Domestic
Effluent
Septic Tank Anaerobic Filter
Boiler Blow Down
Settling Tank
Collection Tank
DMF
Disposal
on land
for
irrigation
DM Regeneration
Neutralization Tank
Schematic Process Flow Diagram for Effluent Treatment at
Shri Gurudatta Sugars Ltd.
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Mill
House
Effluent
DSM
Screen
Boiling House
Effluent
O&G(Skimmer)
Equalization
Tank
Anaerobic Filter
Disposal on Land
Treated Sump Clarifier Aeration Tank
Clarifier
Aeration Tank
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Effluent Treatment System for the Distillery:
In this process, the Spent wash from the distillation column is subjected to evaporation
and concentrated to about 65% solids. The concentrate is then incinerated. The
incineration system consists of specially designed burners and furnace in a boiler.
Secondary fuel is also used in small proportion. The system yields steam and ash, which is
rich in potash. The steam can be utilized advantageously in the ethanol plant unit and the
ash can be sold as fertilizer. The condensate is treated and reutilized for non process
applications like cooling tower make-up.
Typical Calculation for Mass Balance for Conc.-Incineration Process
Distillery Capacity = 150 KLPD
S.W. = 1723 m3/day (12% w/w)
= 1775 MT/day
Solids :- 1775 x 0.12 = 213 MT/d
With Evaporation to Solids Conc. 60% w/w
Volume = 213/0.6 = 355 cum
At 60 % Solids ,Water Evaporated= 1368 m3/d
355 cum with 60% Solids has Calorific Value of 1600 – 1750 Kcal/ Kg (Av.1675)
This will produce steam = 595 MT/day = 24.77 MT/hr
With 70:30 ratio, The Secondary Fuel used (Coal)used is 152.14 T/day
Which shall produce steam = 760.71 T/day = 31.70 MT/hr
Taken together – This shall produce = 56.47 TPH steam
Provide a boiler of 60 TPH
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Details of Existing and proposed boiler
Parameter Existing Proposed Impact
I ii I ii
Capacity TPH 70 40 Ҳ Nil, Since No Change
Fuel Consumption TPH 47.8 152 Nil, Since No Change
Steam Temperature
(0c)
500 ---- Positive, As Power
Generation Shall
Improve For The Same
Steam Quantity
Co‐Ge eratio Capacity 20.5 MW 83.4 MW Positive, since increase
is without any
additional fuel
burning and emissions
Stack Attached (Dia. In M)
2.3 Ҳ 5.5 Nil, Since No Change
Height (M) 65 Ҳ 7 Nil, Since No Change
Control Equipment Wet Scrubber &
ESP
Wet Scrubber &
ESP
Positive Since Better
Efficiency Control
Equipments Are
Provided
i. Solid Waste
The main solid waste from this factory will be of non-hazardous from office, garden and
Sewage Treatment Plant. Non hazardous waste will be segregated as compostable and
saleable. This will be so done.
SGSL has in place the following mitigation policy future
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Waste minimization at all levels of operations.
The plant will produce very less amount of scrap material. All these will
however be stored carefully on raised platform, with dwarf toe-walls all around
and an overhead roof.
The main solid waste from sugar unit will be in form of bagasse which is utilized
completely for power generation.
The hazardous waste will be disposed scientifically as per the norms.
(a) Non Hazardous Solid Waste
Based on above working, the summery is:
Sr.
No.
Waste Quantity kg/day Treatment Disposal Remark
1. Canteen - Compost Own garden Organic
2. Garden Trash 500 Compost Land filling ----
3. Office waste 200 Collection Sales For Recycle
4. ETP Sludge 250 --- --- Used as
manure
5. Boiler Ash 365 MT/day ----- --- Sold to
brick
manufactur
ers
(b) Hazardous Waste:
Sr.
No.
Sch.- I / II Type of Waste Quantity Treatment / Disposal
1. 5.1/5.2 Used/ Spent oil 600 kg/lit. Reuse in own boiler as fuel
Aesthetics: Boiler Turbine, Cane Crusher, Centrifuges etc. shall be source of noise and
vibrations. Sturdy foundations and anti vibration arrangements shall be provided to
reduce the effect. Acoustic enclosures and enclosures shall be done to reduce noise level.
Tree plantation will be carried out. PPF’s will be provided to the workers in this area.
There will be no nuisance from noise as the machinery and equipments are acoustically
enclosed. DG sets will run occasionally. No nuisance will go to surrounding area.
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CHAPTER 04
SITE ANALYSIS
4.1 Connectivity
The proposed expansion will be at Gut No. 61/A of Village Akiwat,Takaliwadi Road
Takaliwadi in Taluka – Shirol of Dist.:- Kolhapur in Maharashtra state. Total area is
around 36.72 acres.
The Geographical Location of this Industry is 16037’15.5 N latitude and 74035’39.5 E
Longitude with an elevation of 540m. Local Authority has assured to provide all
infrastructures like assured Electrical power, continuous water supply, the internal road
network, external approach road etc.
So e i porta t air dista ces fro proposed site are as u der…..
1. Nearest air port Kolhapur – 35.50 Km towards West direction.
2. Nearest Railway station Jaysingpur – 15 Km towards North West direction.
3. Nearest Habitat is village Takaliwadi at 1.20 Km towards NE direction.
4. Nearest River is Krishna 4.19 Km towards South East direction.
GPS Location and Google Imagery of the proposed site are attached.
4.2 Land form, Land use and Land ownership
Land Form: Although land is on the upper elevation compared to the surrounding area,
the said Land has a large portion with plain contour. Slope is gentle to moderate type.
Land Ownership: Land ownership is with project proponents. Total area is about 36.72
hectare.
Existing Land use Pattern: The Land is agricultural and is barren with no cultivation. This
agricultural land will be now used for the industrial purpose. This being expansion
project on same land there is a no change in land use pattern. This Project will
participate in improvement of the physical infrastructure of this area by incorporating
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Roof rain water harvesting, Storm water management and green belt development.
4.3 Topography
Proposed site is located on the topographically flat terrain with very less undulations.
There is no river or stream or natural drainage line is passing through the area.
4.2 Soil Classification
The dry eastern zone with precarious rainfall is covered with medium to deep black
fertile soils of varying depths. This zone consists of Gandhinglaj, Kagal, Karveer,
Hatkanangale and Shirol taluka. In this zone the crops like jawar and groundnut are
cultivated on a large scale as well as the crops like paddy, sugarcane and vegetables are
grown with the help of irrigation water.
4.2 Climate data from secondary sources
The climate of the Kolhapur plain is temperate and similar to the other district of
Bombay Deccan adjoining the ghats. In the western part of Kolhapur near the Sahyadris,
it is always cooler than that in the eastern part which is liable to hot winds during April
and May. The nights over the whole district are generally cool due to the influence of
the sea breezes which set in during the afternoons and continue till late in the evening.
The whole year climate of Kolhapur district may be divided into three periods as follows:
- (i) hot weather period from March to May; (ii) rainy period from June to October and
(iii) cold weather period from November to February.
Temperature: The climate of the Kolhapur plain is temperate and similar to the other districts of
Bombay Deccan adjoining the ghats. In the western part of Kolhapur near the Sahyadris it is
always cooler than that in the eastern part which is liable to hot winds during April and May. The
nights over the whole district are generally cool due to the influence of the sea breezes which set
in during the afternoons and continue till late in the evening. There is a rapid rise in temperature
in March, reaching the maximum in May. May is the hottest month of the year, with a mean
maximum temperature of 99°F. The corresponding figures for March and May are 96 °F. and 95
°F. respectively. Daily maximum temperatures exceeding 100°F. are fairly frequent in
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May. On an average there are 12 such days. The highest temperature recorded at
Kolhapur during the last decade is 107°F. Temperatures exceeding 110°.F. are unlikely
in this district. The mean daily maximum: temperature varies from 66 °F to 72 °F the
diurnal variation of temperature is large and the mean value ranges from 30.7°F in March
to 22.7°F in May.
Rainfall
The district receives rain from the South-West as well as North-East monsoons. The
proportion of rainfall decreases very sharply from the west to east ranging between the
maximum of 6000 mm in the west to the minimum of 600 mm in the east. Hence we can
have three broad divisions as far as rainfall is concerned i) the western zone receiving
heavy and assured rainfall. ii) The central zone receiving moderate rainfall and iii) the
eastern zone receiving low, irregular and uncertain rainfall. The southwest mansoon
commences by the first week of June and lasts till the end of September.
4.3 Social Infrastructure available
Airport is at the distance of Kolhapur- 35.50 Km towards West Direction
Railway Station is at Jaysingpur- 15 Km towards North West Direction.
Nearest habit is at the distance-1.20 Km in North West Direction
Krishna River 4.19Km towards South East Direction.
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CHAPTER 5
PLANNING BRIEF
5.1Planning Concept
The area covered under study zone comprises of medium to heavy soil quality. Profuse
availability of stored water has encouraged villagers to grow cash crops.
Facilities
This site appeared to be environmentally best as also from the business angle and
therefore this option was finally adopted. This site is inside the campus of the village
Takaliwadi Shivar and means safe transportation, less need of Utilities, less constructing
buildings and roads, less fuel, less water with optimization of infrastructure.
Local Authority has provided all infrastructures like assured Electrical power, continuous
water supply, the internal road network, external approach road.
All surrounding villages are provided with drinking water from wells or Government Water
Supply Schemes RWS. Hence we do not encroach upon their supply.
5.2 Population Projection
An official Census 2011 detail of Kolhapur, a district of Maharashtra has been released by
Directorate of Census Operations in Maharashtra. Enumeration of key persons was also
done by census officials in Kolhapur District of Maharashtra. In 2011, Kolhapur had
population of 3,876,001 of which male and female were 1,980,658 and 1,895,343
respectively. In 2001 census, Kolhapur had a population of 3,523,162 of which males were
1,807,470 and remaining 1,715,692 were females. Kolhapur District population
constituted 3.45 percent of total Maharashtra population. In 2001 census, this figure for
Kolhapur District was at 3.64 percent of Maharashtra population. There was change of
10.01 percent in the population compared to population as per 2001. In the previous
census of India 2001, Kolhapur District recorded increase of 17.85 percent to its
population compared to 1991. The initial provisional data released by census India 2011,
shows that density of Kolhapur district for 2011 is 504 people per sq. km. In 2001,
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Kolhapur district density was at 458 people per sq. km. Kolhapur district administers
7,685 square kilometers of areas. Average literacy rate of Kolhapur in 2011 were 81.51
compared to 76.93 of 2001. If things are looked out at gender wise, male and female
literacy were 88.57 and 74.22 respectively. For 2001 census, same figures stood at 87.47
and 66.02 in Kolhapur District. Total
Literate in Kolhapur District were 2,825,845 of which male and female were 1,559,760
and 1,266,085 respectively. In 2001, Kolhapur District had 2,364,307 in its district.
5.3 Land use planning
The present land has been already converted to industrial purpose from agriculture. The
expansion is going to take place on same land.
Thus there is no change in the status. This is flat land whereby Cutting-filling balances and
there will be No/Low Borrowing from nature.
Proposed site will house the facilities, some part will remain untouched for the Future
Expansion and 33% area will be demarcated for Green belt development.
5.4 Assessment of Infrastructure Demand (Physical and Social)
In SGSL proposed new project will be having only Expansion of sugar and co- generation &
alcohol. As manpower requirement is very less for the proposed project which will not
lead to any additional load on the existing social infrastructure.
5.5 Amenities/ Facilities
GSL is proposing manufacturing products in existing area. Local body provides many basic
facilities like uninterrupted water supply, power and Road Network & solids disposal
facility. This site is having good road means safe transportation, less need of Utilities, less
constructing buildings and roads, less fuel, less water with optimization of infrastructure.
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CHAPTER 6
PROPOSED INFRASTRUCTURE
6.1 Industrial area
There will be only expansion of Products capacity in this proposed project. GSL proposes to use
this past construction in expansion proposal. SGSL proposes Expansion for existing producing
cane crushing from 6000 to 13000 TCD, power generation from 21MW to 90 MW & Alcohol-150
KLPD. SGSL will be developing infrastructure as per requirement for proposed expansion of
production.
6.2 Residential Area
In SGSL has already have a having colony for its key staff & their families.
6.3 Green Belt
About 33% of the total Plot area is demarcated and additional along the boundaries will be
proposed for tree plantation. The selection of trees is based upon the climatologically
conditions of the Study area.
In and around the SGSL project plantation is carried out to develop green belt. The treated
sewage water is used for green belt development within the factory premises. Following are the
status of green belt development.
List of Species for landscape development
Sr. No. Name of Plant Common Name For Dry Region 1 Ailanthus excelsa Maharuhk 2 Albizia lebbeck Siris 3 Azadiracta indica Neem 4 Casuarina equisetifolia Beef- wood/ Saru 5 Dalbergia sissoo Sisham 6 Eugenia jambolana Jamun 7 Grevillea robusta Silver oak 8 Peltophorum ferrugineum Copper pod 9 Tamarindus indica Imli 10 Pongamia glabra Indian beech 11 Tamarix articulate Tamarisk 12 Mangifera indica Mango
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13 Ficus glomerata Umbar 14 Ficus bengalensis Vad 15 Dandrocalamus strictus Cane Bamboo 16 Cassia tora Tarwat 17 Bauhinia varigeta Kanchan 18 Psydium guava Peru 19 Plumbago zeylania Plumbago 20 Santalum album Chandan 21 Acalypha spp. Acalypha 22 Alastonia scolarasis Saptaparni 23 Embelica officinalis Amla 24 Hibiscus spp. Jaswand 25 Jatropha curcus Mogli errand/ Ratanjyot 26 Symbopogon martini Lamon grass 27 Lantana camara Lantana 28 Vinca rosea Sadafuli 29 Jasmine grandiflorum Jasmine 30 Calotropis procera Aak 31 Ipomea purpurea Beshram 32 Dhatura mental Dhatura 33 Vitex nurgundo Nirgudi 34 Ixora parviflora Ixora
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6.4 Social Infrastructure
In SGSL there is no need of providing any Social infrastructure as the proposed expansion
project is involving only very small number of man power. Existing infrastructure will be
sufficient to accommodate the increasing load from the proposed project.
6.5 Connectivity
This proposed cane crushing, Power generation & Alcohol facility is located at Village Akiwat,
Near Takaliwadi Road, Takaliwadi Tal. Shirol in Kolhapur district, Maharashtra. The Site is 12 km
from Shirol town and 15 km from Jaisingpur railway Station and Air port 35.50 km towards west
direction at Kolhapur. The land and infrastructure is made available by Local Authority and the
raw material is easily available through the easy transport via road connectivity and via Sea
route and Air route. The Shirol –Takaliwadi Road State Highway is passing adjacent to the
project boundary.
6.6 Water Management
The water requirement is about 892 M3/ day for Domestic, Greenery and Processes. The
source of water is already availability from existing water works of local authority and the same
is adequate and satisfactory. We are not encroaching on anybody’s water source.
6.7 Sewage System
The Domestic Effluent will be treated in Effluent Treatment Plant and will be used for green belt
after treatment.
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6.8 Industrial Waste Management
SGSL proposed Expansion for producing cane crushing, power generation and Alcohol. As there
are only 3 products, pollution control work can be much streamlined than a heterogeneous
mixed stream. The details regarding pollution control of water, waste water, air and solid
wastes.
6.9 Air Pollution
The air pollution due to bagasse and coal based high-pressure boiler will be taken care
scientifically by installing highly efficient Electro Static Precipitator.
Electro Static Precipitator Specification
1. Gas flow rate will be corresponding to MCR of boiler.
2. Temp of gas at ESP inlet will be 150oC.
3. Inlet dust concentration will be 5 g/cum.
4. Outlet emission at ESP exit will be < 150 mg/Nm3.
5. Pressure drop across ESP for condition gas side will be < 25 mm water column.
6. ESP shall be installed on suction side of ID fan, has rotary air lock valve. Suitable platform,
staging, ladders, railing, inspection holes.
Fugitive Emissions
A number of mitigation measures are taken to control fugitive emissions, the presence of which
will be noticeable by plain vision if not controlled. The measures are thus taken seriously and
continuously such as:
1. Rubber wheel carts / trucks to bring in Raw Materials not filled high, sides laded, slow
speed travel, avoiding vibrations en-route.
2. Collection of fugitive emissions by suitable suction system at the time of casting etc.
3. Engineering the plant layout in such a way so as to virtually.
4. Internal roads paved, scrap area paved, leveled, no undulations, no sharp curves, slow
speed. No open storage of materials on barren unlined land to the maximum extent
possible.
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6.10 Solid Waste Management
Ash generation will be about 36.5 MT/day.
This will be disposed of using the Ash handling system.
The ash will be sold out to brick manufacturers.
Ash from furnace shall be handled by water impounded submerged belt conveyor
passing to main belt conveyor with cooling spray arrangement.
Other ash points are pre-heating hoppers and ESP hoppers. Here water is sprinkled
on screw conveyors to reduce temp and dust.
(a) Non Hazardous Solid Waste
Based on above working, the expansion uses existing canteen facilities and STP. The canteen
waste goes as manure in landscaping after treatment.
Consented quantities of Solid waste generation are:
i) From Process Manufacture:
The quantity of generation of non-hazardous solid waste from the process of manufacture is
Nil.
ii) From the waste treatment:
Domestic Bio waste (dry leaves, roots & hey) & composting will be carried out for producing
bio- compost & will be used for Green Belt Development.
Power Requirement & Supply/Source
Power Supply:
Existing power requirement: 0.6 MW SELF generations
Proposed power requirement: 4.8 MW
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DG set only in emergency backup
Sr. No. D.G. Set Capacity Fuel Consumption Stack Height
Existing
1. 500 KVA 135 lit./hr. 30 m
2. 500 KVA 135 lit./hr. 30 m
Proposed
1 1000 KVA 135 30 m
M/s Shri Gurudatt Sugars Ltd., Kolhapur (MS) Prefeasibility Report 2017
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CHAPTER 7
REHABILITATION AND RESETTLEMENT (R & R PLAN)
7.1 Policy to be adopted
This project does not require acquisition of Land and the Infrastructure so there is no any kind
of activity of Rehabilitation and Resettlement to be carried out over her
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CHAPTER 8
PROJECT SCHEDULE & COST ESTIMATES
8.1 Time schedule of the Project
SGSL has ability to complete their construction within 12 to 15 Months after getting all relevant
permissions and clearances.
8.2 Estimated project cost (Economic Viability of the Project)
Estimated project cost is 350 Cr. (including cost for land, building, plant and machinery).
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CHAPTER 9
ANALYSIS OF PROPOSAL
9.1 Financial and Social Benefits
M/s Gurudatt Sugars Ltd has proposed expansion for Sugar, Power and Alcohol manufacturing
products which will be used in the market by different industries at National as well as
International levels.
Approximate percentage of 30-40 % manufactured goods will be exported in the national
market. This will be financial benefit to the industry as well as nation for a generation of foreign
revenue.
By doing so, SGSL can participate towards the development of nation by generating the foreign
exchange, and also serve the social community
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Annexure I: Google Image
M/s Shri Gurudatt Sugars Ltd., Kolhapur (MS) Prefeasibility Report 2017
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Annexure II: - Toposheet
M/s Shri Gurudatt Sugars Ltd., Kolhapur (MS) Prefeasibility Report 2017
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Annexure III: Location in Map