PRE-FEASIBILITY REPORT · 2018-10-22 · PRE-FEASIBILITY REPORT “Proposed Expansion of Sugarcane Crushing Capacity from 9000 TCD to 15000 TCD, Distillery Capacity from 60 KLPD to

PRE-FEASIBILITY REPORT

“Proposed Expansion of Sugarcane Crushing Capacity from 9000 TCD to 15000 TCD, Distillery

Capacity from 60 KLPD to 90 KLPD and Establishing 21MW Co-generation Power Plant based on Bagasse and 5 MW from incineration

boiler”

At

Dattanagar, Tal. Shirol, Dist. Kolhapur in Maharashtra State, by

M/s. Shree Datta Shetkari 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 Datta Shetakari Sahakari Sakhar Karkhana Ltd Pre-feasibility report

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CONTENTS

CONTENTS ................................................................................................................................................... i

LIST OF FIGURES ..................................................................................................................................... iv

LIST OF TABLES ........................................................................................................................................ v

LIST OF ABBREVIATIONS ...................................................................................................................... vi

1. EXECUTIVE SUMMARY................................................................................................................... 1

2. INTRODUCTION OF THE PROJECT / BACKGROUND INFORMATION .................................... 4

2.1. Identification of Project and Project proponent ................................................................................ 4

2.1.1. Project Proponent .......................................................................................................................... 5

2.1.2. Project Consultant ......................................................................................................................... 6

2.2. A brief description of the nature of the project ................................................................................. 6

2.2.1. Environmental Clearance of existing Sugar and Distillery Plants ................................................ 7

2.2.2. Consent to Operate of existing Sugar and Distillery Plants .......................................................... 7

2.3. Need for the project and its importance to the country and or region ............................................... 7

2.4. Demand-Supply Gap ......................................................................................................................... 8

2.5. Imports vs. Indigenous products ....................................................................................................... 8

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 ................................................................................................................... 8

3.1. Type of project including interlinked and interdependent projects, if any. ...................................... 8

3.2. Location with coordinates ................................................................................................................. 9

3.3. Details of alternate sites considered and the basis of selecting the proposed site (particularly the environmental considerations gone into should be highlighted) ................................................................. 14

3.4. Size or magnitude of the operation ................................................................................................. 15

3.5. Project description with process details .......................................................................................... 15

3.5.1. Process Details ............................................................................................................................ 15

3.5.1.1. White Sugar Manufacturing Process ....................................................................................... 15

Manufacturing Process ................................................................................................................................ 16

3.5.1.2. Distillery Process .................................................................................................................... 17

Process for the manufacture of alcohol: ...................................................................................................... 17

3.5.1.3. Cogeneration Power Plant ....................................................................................................... 24


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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. .. 26

3.8. Availability of water its source, Energy / Power requirement and source ...................................... 26

3.9. The quantity of waste to be generated (liquid and solid) and scheme for their Management/Disposal ................................................................................................................................. 27

4. SITE ANALYSIS ............................................................................................................................... 28

4.1. Background of the Site Location .................................................................................................... 28

4.2. Connectivity .................................................................................................................................... 28

4.3. Land Form, Land use and Land ownership ..................................................................................... 28

4.4. Topography (along with a map) ...................................................................................................... 29

4.5. Existing Infrastructure..................................................................................................................... 29

4.6. Soil Classification ........................................................................................................................... 29

4.7. Climatic data from stationary sources ............................................................................................. 29

4.8. Social Infrastructure available ........................................................................................................ 29

5. PLANNING BRIEF ............................................................................................................................ 30

5.1. Planning Concept (a type of industries, facilities, transportation etc.) Town and country planning / Development authority Classification ......................................................................................................... 30

5.2. Population Projection ...................................................................................................................... 30

5.3. Land use planning (breakup along with green belt etc) .................................................................. 30

5.4. Assessment of Infrastructure Demand (Physical and Social) ......................................................... 30

5.5. Amenities / Facilities ...................................................................................................................... 30

6. PROPOSED INFRASTRUCTURE .................................................................................................... 30

6.1. Industrial Area (Processing Area) ................................................................................................... 30

6.2. Residential Area (Non-Processing Area) ........................................................................................ 30

6.3. Greenbelt ......................................................................................................................................... 31

6.4. Social Infrastructure ........................................................................................................................ 31

6.5. Connectivity (Traffic and Transportation Road/Rail/Metro/Waterways etc.) ................................ 31

6.6. Drinking Water Management (Source and Supply of water) .......................................................... 31

6.7. Sewerage System ............................................................................................................................ 31

6.8. Industrial Waste Management ........................................................................................................ 31

6.9. Solid Waste Management ............................................................................................................... 31

6.10. Power requirement & Supply / Source ....................................................................................... 31

7. REHABILITATION AND RESETTLEMENT (R&R) PLAN .......................................................... 31


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7.1. Policy to be adopted (Central/State) in respect of the project affected persons including home outstees, land outstees and landless laborers (a brief outline to be given) .................................................. 31

8. PROJECT SCHEDULE AND COST ESTIMATES .......................................................................... 32

8.1. Likely date of start of construction and likely date of completion (Time schedule for the project to be given) ..................................................................................................................................................... 32

8.2. Estimated project cost along with analysis in terms of the economic viability of the project ........ 32

9. ANALYSIS OF PROPOSAL (Final recommendations) .................................................................... 32

9.1. Financial and social benefits with special emphasis on the benefit to the local people including tribal population, if any, in the area. ........................................................................................................... 32

ANNEXURE-I ............................................................................................................................................ 33

WATER BUDGET FOR SUGAR, CO-GENERATION POWER PLANT, AND DISTILLERY UNIT . 33

ANNEXURE II ........................................................................................................................................... 35

ANNEXURE III.......................................................................................................................................... 53


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LIST OF FIGURES

Figure 1 General Location Map .................................................................................................................. 10

Figure 2 Map of Sugar & Cogeneration SDSSSK Ltd., Shirol ................................................................... 11

Figure 3 Layout Map of Distillery SDSSSK Ltd., Shirol ........................................................................... 12

Figure 4 Toposheet View ............................................................................................................................ 13

Figure 5 10 Km Radius Map ....................................................................................................................... 14

Figure 6 Sources of Waste Generation & Cane Sugar Manufacturing Process (Sulphitation Process) ...... 17

Figure 7 The Distillery process ................................................................................................................... 20

Figure 8 Continuous Fermentation ............................................................................................................. 20

Figure 9 Process Flow Diagram (typical) of Multi Pressure Distillation Plant .......................................... 22

Figure 10 Steam Balance Diagram (Typical) of Multi Pressure Distillation Plant ..................................... 22

Figure 11 Power generation by Cogeneration unit ..................................................................................... 25


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LIST OF TABLES

Table 1 Expansion of sugarcane crushing capacity with respect time .......................................................... 1

Table 2 Expansion in capacities for a various unit of industry ..................................................................... 1

Table 3 Fresh Water requirement of the Sugar Complex ............................................................................. 2

Table 4 Products and By-Products of Existing Unit ..................................................................................... 4

Table 5 List of Board of Directors ................................................................................................................ 5

Table 6 Change in Existing Quantity after Proposed Expansion .................................................................. 6

Table 7 Details of the Existing Environment Clearances ............................................................................. 7

Table 8 Size of Operation (Existing and Proposed) .................................................................................... 15

Table 9 Bagasse Characteristics and Consumption .................................................................................... 24

Table 10 Chemical Composition of Bagasse .............................................................................................. 24

Table 12 Land use planning ........................................................................................................................ 30

Table 13 Water Budget -Sugar and Co-generation Power Plant ................................................................. 33

Table 14 Water Budget - Distillery ............................................................................................................. 34


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LIST OF ABBREVIATIONS 0BX Degrees Brix

CPCB Central Pollution Control Board

CSR Corporate Social Responsibilities

EIA Environmental Impact Assessment

ENA Extra Neutral Alcohol

ESP Electrostatic Precipitator

ETP Effluent Treatment Plant

GCV Gross Calorific Value

KLPD Kilo Liter Per Day

KVA Kilo-Volt-Ampere

MCR Maximum Continuous Rating

MEE Multiple Effect Evaporator

MoEF Ministry of Environmental Forest

MSEDCL Maharashtra State Electricity Distribution Corporation Limited.

MW Mega Watt

MWh Mega Watt Hours

NABET National Accreditation Board for Education and Training

NH-4 National Highway Number – 4

SDSSSKL Shree Datta Shetakari Sahakari Sakhar Karkhana Ltd

SEC Dr. Subbarao‟s Environment Center

STP Sewage Treatment Plant

TCD Tonnes Crushing per Day

TPH Tonns per Hours


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1. EXECUTIVE SUMMARY

Shree Datta Shetakari Sahakari Sakhar Karkhana Ltd., (SDSSSKL), located at Dattanagar was established in the year 1969 with an initial sugarcane crushing capacity of 1250 TCD. The factory is situated at Dattanagar, Tal. Shirol, Dist. Kolhapur in Maharashtra.

SDSSSKL has its registered office at Dattanagar, Taluka Shiroli, District Kolhapur, in Maharashtra State.

The availability of sugarcane is very high so industry increases its sugarcane crushing capacity periodically, the expansion of sugarcane crushing capacity with respect time as shown in the following table.

Table 1 Expansion of sugarcane crushing capacity with respect time

Sr, No.

Sugarcane crushing capacity in TCD Year of Expansion

1 1250 – 2000 1978 2 2000 – 2500 1986 3 2500 – 5000 1988 4 5000 – 7500 2001 5 7500 – 9000 2018

SDSSSKL established 30 KLPD molasses based distillery unit in the year 1983, as molasses is the by-product from the sugar industry, there was an increase in availability of molasses due to the subsequent capacity expansions of the sugar unit. In order to meet the demand, the capacity of the distillery init was expanded to 60 KLPD in the year 2002

SDSSSKL has an existing sugar complex with 9000 TCD sugarcane crushing capacity and 60 KLPD distilleries. In this region sugarcane availability is very high; therefore industry wants to further expand the capacities of its various units as follows

Table 2 Expansion in capacities for a various unit of industry

Sr. No Description Existing Capacity

Proposed capacity

Total

1 Sugarcane crushing (TCD) 9000 6000 15000 2 Ethanol/RS/ENA (KLPD) 60 30 90

3 Cogeneration Power Plant

(MW) 0

21 (Co-generation Boiler + 5 (Incineration Boiler)

26

SDSSSKL 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.

Krishna/Panchganga River is the main source of fresh water. The industry has the water lifting permission from Govt. of Maharashtra. The total fresh water requirement of the sugar complex after expansion shall be 660m3/day. Due to excess condensate available from Sugar unit, there is no requirement of water for sugar unit. In fact, an excess amount of 1425 m3/day is saved and is being utilized for Distillery and other usages. The freshwater requirements for each operation are given in the following Table.


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Table 3 Fresh Water requirement of the Sugar Complex

Sr. No Description Quantity (m3/day)

1 Sugar unit Nil 2 Makeup water for Boilers 200 3 Distillery unit 360 4 Domestic 100

Total 660

The quantity of effluent generated after the proposed expansion of Sugarcane crushing capacity from 9000 TCD to 15000 TCD and establishment of 26 MW Cogeneration power plant shall be 615 m3/day (Sugar effluent- 375 m3/day, Cogeneration power plant effluent-160m3/day and Domestic effluent 80m3/day). The designed capacity of the existing Sugar ETP is 700m3/day, which is adequate for the treatment of the effluent generated after the proposed expansion. Cogeneration Power Plant effluent of 160 m3/day shall be treated along with sugar effluent and treated effluent shall be disposed on land for irrigation.

It is proposed to install STP for 80 m3/day of domestic effluent based on Septic tank followed by anaerobic filter followed by Root Zone Technology for the treatment of domestic wastewater.

The Distillery unit is based on Zero Liquid Discharge. At present, the spent wash generated from the existing 60 KLPD Distillery is treated based on composting Principles. After the proposed expansion of distillery capacity from 60 KLPD to 90 KLPD, the spent wash generated due to 60 KLPD distillery shall be treated based on Concentration and incineration principles, and the spent wash generated due to proposed 30 KLPD distillery shall be treated based on present composting principle.

The industry has its own land of 85.46 hectares out of which 29.64 Ha of land is reserved for Greenbelt development, 4.61 ha is under built-up area of sugar and distillery units, 12.98 Ha. of land is under parking and internal Roads, 13 Ha. of land is under ETP facilities of sugar and distillery units, 10 Ha. of land is vacant. About 2 ha of land shall be required/utilized for the proposed expansion. No displacement of habitation or acquisition of private land is required.

There are no sensitive, historic places, critically polluted areas, CRZs and wildlife sanctuaries, Heritages etc. within a 10 km radius of the factory site. The latitude and longitude are 160

45‟4.04”N &

74035‟19.38”E respectively. The Elevation above the Mean Sea Level is 542 m.

The power requirement of the existing sugar complex is 11.2 MW which is taken from Urjankur Shree Datta Power Limited Company which is operating on BOOT principles. The additional 7.5 MW shall be required after the proposed expansion. Therefore, the total Power requirement of the sugar complex shall be 18.7 MW, which shall be met through the Proposed 21MW Co-generation Power Plant based on Bagasse and 5 MW from incineration boiler. The remaining power shall be sold to State Grids.

It is proposed to install 1* 120 TPH Boiler at a pressure of 87 Kg/cm2 5150C ± 50C for the proposed expansion of Sugarcane crushing capacity & establishment of 21 MW from Co-generation Boiler and 5 MW from Incinerator Boiler. ESP shall be provided as APC equipment with min stack height of 60 meters.1*25 TPH boiler at a pressure of 45 kg/cm2 to fulfill the steam requirements of the distillery unit and the concentration Plant (MEE).Two D.G. sets of 500 KVA and 1000 KVA shall be DG installed as a power backup for sugar and Distillery units. 1*21 MW bleed cum back pressure type suitable to 87


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Kg/cm2 pressure at 5150C±50C, and 1*5 MW Double extractions cum condensing type suitable to 45 Kg/cm2 pressure at 4000C±50C shall be installed.

The Co-generation unit and Distillery units shall be operated for maximum 330 days and the Sugar unit shall operate 180 – 200 days. Fly ash quantity of 17.30 T/day from the Co-generation Boiler will be sold to brick manufacturers and also used in composting process. The Incinerator Boiler Ash quantity of 40 MT/day which is generated by burning 9 T/hr of concentrated spent wash and 3.2 T/hr of coal in Incinerator Boiler shall be sold to fertilizer manufacturers as potash-rich value-added material/ added to enrich compost

SDSSSKL 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.

According to CPCB guidelines, 1500 trees should be available per hectare of land for Greenbelt development. Total 29.64 Hectares of land is reserved for greenbelt development; hence there should be minimum 44460 no. of trees. The industry has already planted about 30000 Trees, and remaining 14460 trees shall be planted within two years.

Cost of the project is 270.23 Crore rupees, EMP cost is estimated as Rs. 35.0 Crore, recurring expenditures per annum is around Rs. 4.0 Crore and 0.75 % of the total project cost of Rs.2.026 crores (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.


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2. INTRODUCTION OF THE PROJECT / BACKGROUND INFORMATION

2.1. Identification of Project and Project proponent

Shree Datta Shetakari Sahakari Sakhar Karkhana Ltd., (SDSSSKL), Shirol, Taluka Shirol, Dist Kolhapur is a Co-operative sugar factory with an installed Sugarcane crushing capacity of 9000 TCD and 60 KLPD Distillery. The average crushing rate of the Sugar Factory is 9000 TCD and crushes around 16 lakh MT per annum. After the proposed expansion up to 15000 TCD, the crushing shall be around 25 to 27 lakh MT per annum.

The growth of Sugar Industries in the state of Maharashtra started prior to Independence in the private sector and in the Co-operative sector since 1950. Maharashtra State assumes a leadership position in India in terms of area under sugarcane cultivation, a number of Sugar factories, sugarcane production, yield, recovery, and Sugar production in the country. Almost 85% of the Sugar factories in Maharashtra are in the Co-operative sector. The growth of this Industry in the Co-operative sector has certainly helped to improve Socio-economic conditions of the rural parts of the State.

Shree Datta Shetakari Sahakari Sakhar Karkhana Ltd., (SDSSSKL), Shirol, Taluka Shirol, Dist Kolhapur, was established on 9th June 1969 with an initial installed capacity of 1250 TCD. The first crushing operations started in the 10th June 1970. The capacity of the sugar plant was expanded from 1250 TCD to 2000 TCD in 31st May 1978. The capacity of the sugar plant further expanded from 2000 TCD to 2500 TCD in 7th May 1986. The capacity of the sugar plant 2500 TCD to 5000 TCD was commissioned in 9th

December 1988. The capacity of the sugar plant from 5000 To 7500 TCD was commissioned on 1st

August 2001, The environment clearance was obtained from the Government of Maharashtra, Environment Division (Vide File No. ENV (NOC)/2000/130/CR-21/D-I dated 23rd March 2000). With the increasing demand of Sugar, the SDSSSKL has expanded its crushing capacity from 7500 TCD to 9000 TCD in the year 2018 the proposal was approved by SEIAA in its 130th Meeting and EC was granted for the same. (SEIAA-EC-0000000326 dated 1st June 2018). The industry now proposes to expand the sugar plant capacity from 9000 TCD to 15000 TCD.

The SDSSSKL has started its distillery operations in September 1983 as a by-product industry with its capacity of 30,000 liters per day. Subsequently, the capacity was expanded to 60,000 liters per day in the year of February 2002 due to the excess availability of Molasses.

Table 4 Products and By-Products of Existing Unit

Sr. No. Products/ By-Products Quantity

1 Sugar 27600 MT/M 2 Refined Sugar 5000 MT/M 3 Molasses 10800 MT/M 4 Pressmud 10800 MT/M 5 Bagasse 78300 MT/M 6 Industrial Alcohol 1800 KL/M 7 Ethanol 900 KL/M 8 Fusel Oil 2.4 KL/M


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SDSSSKL intends to expand the Sugarcane crushing capacity from 9000 TCD to 15000 TCD, Distillery capacity from 60 KLPD to 90 KLPD and establish Proposed 21MW Co-generation Power Plant based on Bagasse and 5 MW from incineration boiler. SDSSSKL is today one of the best professionally managed and financially sound co-operative sugar factory in Maharashtra.

Backed by a proven managerial and financial track record, SDSSSKL 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 Datta S. S.S.K. Ltd. Address: Dattanagar, Taluka- Shirol, District-Kolhapur, Maharashtra- 416120 Phone: 02322 - 236551 Fax: 02322 - 236600

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 5 List of Board of Directors

Sr. No. Name Designation

1 Hon. Shri Ganapatrao Appasaheb Patil Chairman 2 Hon. Shri Sidgauda Gurusidgauda Patil Voice Chairman 3 Hon. Sou. Vinaya Ramesh Ghorpade Director 4 Hon. Shri Anilkumar Dinakarao Yadav Director 5 Hon. Shri Shrenik Jaygaunda Patil Director 6 Hon. Shri Babaso Shankar Patil Director 7 Hon. Shri Sharadchandra Vishwnath Pathak Director 8 Hon. Shri Arunkumar Shankar Desai Director 9 Hon. Shri Raghunath Devgaunda Patil Director

10 Hon. Shri Vishwanath Dhondi Mane Director 11 Hon. Shri Shekhar Kalgaunda Patil Director 12 Hon. Shri Basgaunda Malgaunda Patil Director 13 Hon. Shri Pramod Vasant Patil Director 14 Hon. Shri Annaso Appaso Pawar Director 15 Hon. Sou Yashoda Balaso Koli Director 16 Hon. Sou Sangita Sanjay Patil Director 17 Hon. Shri Indrajit Pasgaunda Patil Director 18 Hon. Shri Ranjit Ashok Kadam Director 19 Hon. Shri Raosaheb Giryappa Naik Director


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20 Hon. Shri Vijay Nivruti Suryawanshi Director 21 Hon. Shri Raosaheb Annaso Bhosale Director 22 Regional Deputy Director (Sugar), Kolhapur Director 23 Hon. Shri Mahadev Vithal Patil Managing Director

2.1.2. Project Consultant

To seek Environmental clearance, SDSSSKL 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. A brief description of the nature of the project

SDSSSKL 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 SDSSSKL. 85.46 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.

SDSSSKL intends to expand sugarcane crushing capacity from 9000 TCD to 15000 TCD, Distillery capacity from 60 KLPD to 90 KLPD and also Establish Proposed 21MW Co-generation Power Plant based on Bagasse and 5 MW from incineration boiler., in order to increase productivity and profitability in addition to abating pollution. Along with the expansion of Sugarcane crushing plant, it is economically and environmentally sustainable to expand distillery capacity and to Establishing Co-generation 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.

Table 6 Change in Existing Quantity after Proposed Expansion

Sr. No

Description Existing Quantity

Proposed Deletion

Proposed Addition

Total

1 Sugarcane crushing capacity (TCD)

9000 --

6000 15000

2 Sugar (MT/M) 27600 -- 23400 51000 3 Refined Sugar (MT/M) 5000 -- Nil 5000 4 Molasses (MT/M) 10800 7200 18000 5 Pressmud (MT/M) 10800 7200 18000 6 Bagasse (MT/M) 78300 -- 52200 130500 7 Industrial Alcohol (KL/M) 1800 -- 900 2700 8 Ethanol (KL/M) 900 -- 900 1800 9 Fusel Oil (KL/M) 2.4 -- 1.6 4.0

10 Electric Power (MW) -- -- 21+5 MW 26 MW


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2.2.1. Environmental Clearance of existing Sugar and Distillery Plants

The SDSSSKL has obtained Environmental Clearance time to time from respective authorities the details are as under

Table 7 Details of the Existing Environment Clearances

Sr. No Description Authority Vide File No Date

1 Sugarcane crushing capacity expansion from 5000 TCD to 7500 TCD

Gov. of Maharashtra, Environment Department

ENV(NOC)/2000/130/CR-21/D-I

23rd March 2000

2 Distillery capacity expansion from 30 KLPD to 60 KLPD

MOEF J-11011/33/2001-IA II(I) 11th December 2001

3 Sugarcane crushing capacity expansion from 7500 TCD to 9000 TCD

SEIAA SEIAA-EC-0000000326 1st June 2018

2.2.2. Consent to Operate of existing Sugar and Distillery Plants

SDSSSKL is issuing Consent to operate, time to time from MPCB for its existing Sugar and Distillery units. Format 1.0/BO/CAC-CELL/UAN No.-0000029971/R/CAC-1805001083 dated 22/05/2018, and Format-1.0/BO/CAC-CELL/UAN No. 0000028806 & 0000010582/R/CAC-1804000530 dated 10/04/2018 respectively.

2.3. Need for the project and its importance to the country and or 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 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 SDSSSKL, 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 co-generation and expanded distillery capacity, bagasse and molasses to be


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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 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 SDSSSKL.

To implement the above program, the management of SDSSSKL 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 SDSSSKL surpasses the existing crushing capacity due to the availability of an adequate amount of water by the courtesy of River Krishna, and Panchaganga. 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 (After establishing Cogeneration power plant). Sugar and Alcohol from this industry are qualitatively better and competitive against imported products. Hence, the benefit of foreign exchange saving could be achieved.

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 SDSSSKL

2.8. Employment Generation (Direct and Indirect) due to the project

After the proposed expansion project, direct employment of about 200 people will be generated and indirect employment of around 500 people is possible. Also, around a 25 % increase in indirect employment is expected due to the additional transportation required after the proposed expansion.

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 9000 TCD to 15000 TCD, Distillery capacity from 60 KLPD to 90 KLPD by establishing Incinerator Boiler capacity of 35 TPH at 45 Kg/Sq.cm and TG set of 5.0 MW. The Cogeneration Power Plant produces 21 MW from the expansion of Sugar factory capacity by 6000 TCD 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 Establishing Cogeneration power plant. SDSSSKL is expanding distillery and Establishing Co-generation power plant capacities to cope up with the increased production of Bagasse and Molasses


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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 Mumbai – Bangalore National Highway (N.H. 4) is 45 km away from the factory site. The latitude and longitude are 160

45‟4.04”N & 74035‟19.38”E respectively. The Elevation above the Mean Sea Level is 542 m. The Project Site is conveniently located for development of the Project.

45 Km away from Kolhapur, which is district place Other important towns nearby are

Jaysingpur - 06 km. Sangli - 16 km. Miraj – 10 km. Ichalkarnji – 15 km.

Environmental Setting- Location –160

45‟4.04”N & 74035‟19.38”E

Nearest Village – Dattanagar – 0.0 km Nearest town – Jaysingpur - 06 km Nearest City – Sangli – 16 km Nearest Head Quarters – Kolhapur – 45 Km Nearest National Highway – (NH- 4) – 45 Km Nearest Railway Station – Jaysingpur – 07 Km Nearest Airport – Kolhapur – 43 km Nearest River – Krishna River – 5 km, Panchaganga River – 03 km Seismicity – Seismic Zone III 6 to 8 Richter Scale


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Figure 1 General Location Map


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Figure 2 Map of Sugar & Cogeneration SDSSSK Ltd., Shirol


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Figure 3 Layout Map of Distillery SDSSSK Ltd., Shirol


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Figure 4 Toposheet View


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Figure 5 10 Km Radius Map

3.3. Details of alternate sites considered and the basis of selecting the proposed site (particularly the environmental considerations gone into should be highlighted)

It is an existing industry which was established in 1969 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 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.


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Uninterrupted power supply from its own Co-generation Power Plant

3.4. Size or magnitude of the operation

Table 8 Size of Operation (Existing and Proposed)

Sr. No

Description Existing Quantity

Proposed Deletion

Proposed Addition

Total

1 Sugarcane crushing capacity (TCD)

9000 --

6000 15000

2 Sugar (MT/M) 27600 -- 23400 51000 3 Refined Sugar (MT/M) 5000 -- Nil 5000 4 Molasses (MT/M) 10800 7200 18000 5 Pressmud (MT/M) 10800 7200 18000 6 Bagasse (MT/M) 78300 -- 52200 130500 7 Industrial Alcohol (KL/M) 1800 -- 900 2700 8 Ethanol (KL/M) 900 -- 900 1800 9 Fusel Oil (KL/M) 2.4 -- 1.6 4.0

10 Electric Power (MW) -- -- 21+ 5 MW 26 MW

3.5. Project description with process details

SDSSSKL intends to expand its sugarcane crushing capacity from 9000 TCD to 15000 TCD, Distillery capacity from 60 KLPD to 90 KLPD and Establish 21MW Co-generation Power Plant based on Bagasse and 5 MW from incineration boiler.

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.

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.


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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 90% 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.

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 78%. 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.


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Packaging:

Separated crystals are packaged in the gunny bags and stitched and are send to the godown.

Figure 6 Sources of Waste Generation & Cane Sugar Manufacturing Process (Sulphitation Process)

3.5.1.2. Distillery Process

The existing 60 KLPD distillery unit is based on the Continuous Fermentation Process. The proposed 30 KLPD unit shall be based on the same technology. Description of the process is given below.

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

LEGENDS Cane washing Bearing Cooling, Turbine cooling, Floor washing, oily waste water Condensate, floor/equipment washing Condensate, floor/equipment washing 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 air compressor cooling water 16. Vacuum filter condenser, floor washing 17. Evaporator condensate water 18 & 19. Sulphur burner & Compressar cooling water


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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) II) 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, 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 a 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

C12H22O11+ H2O Cane Sugar

Invertase

2C6H12O6 Glucose +Fructose

C6H12O6

180 Glucose/Fructose

2C2H5OH +2CO2

2 x 46 + 2 x44 Ethyl alcohol + Carbon dioxide

Zymase


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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 of2.0 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 7 The Distillery process

Figure 8 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 9 Process Flow Diagram (typical) of Multi Pressure Distillation Plant

Figure 10 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 do 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: 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.


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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 a cogeneration power plant is presented in Figure 11.

The co-generation plant is selected to utilize bagasse as a fuel. After the establishing 26 MW Cogeneration power plant the bagasse consumption will be around 207300 MT of bagasse for 180 days of operation of sugarcane crushing season, and 115000 MT of bagasse during offseason.

The steam generating system for the proposed Cogeneration project consists of one multi fuel-fired boiler with a maximum continuous rating of 120 TPH, with the outlet steam parameters at 87 Kg/cm2 and 5150C±50C. 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 280000 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 48%-50% moisture content. The characteristics of bagasse produced are given in the table below

Table 9 Bagasse Characteristics and Consumption

Average bagasse percentage on the cane: 29% Fuel consumption for boiler 52.17 TPH Sugar in Bagasse 0.6-0.7 % Moisture in Bagasse 48-50%

Steam to Bagasse Ratio 2.25 Steam to bagasse Percentage 71% Minimum

Table 10 Chemical Composition of Bagasse

Description Quanity Carbon 23.5 % Hydrogen 3.25 %


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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 11 Power generation by Cogeneration unit

Plant Machinery and other requirements:

Boiler:

The steam generating system for establishing 21+ 5 MW Cogeneration Project comprises one multi-fuel fired boiler with a Maximum Continuous Rating (MCR) of 120 TPH with the outlet steam parameters at 87 kg/cm2 and 5150C±50C. 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.


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Turbine:

1*21 MW bleed cum back pressure type suitable to 87 Kg/cm2 pressure at 5150C±50C, and 1*5 MW Double extractions cum condensing type suitable to 45 Kg/cm2 pressure and at temperature 4000C±50C

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 SDSSSKL in plenty of amount as this region is having water availability due to Krishna River, and Panchaganga River. Approximately 2700000 Tons of sugarcane shall be required after the proposed expansion, which is available in the command area of SDSSSKL. Also, lime and sulphur are purchased from the open market and transported by road. Final products sugar, alcohol, and power (after the establishment of cogeneration power plant) 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 will be utilized in Cogeneration power plant. Transport of both bagasse and molasses would be by internal means. Power shall be taken from its own 21MW Co-generation Power Plant based on Bagasse and 5 MW from incineration boiler. The remaining power after its active consumption shall be sold to state electricity grid. Distillery products shall be transported using closed containers. The estimated quantity of molasses to be utilized after the proposed expansion is around 10000 MT/Month. Whereas the industry can generate its own molasses of 18000 MT/month and as such the Distillery can operate for 330 days if sugarcane crushing season is taken 180 days. After the expansion of an additional bagasse quantity of 52000 MT/month would be available. Thus the Cogeneration plant can operate with the saved bagasse even after the crushing of sugarcane season for around 130 days.

3.7. Resource optimization/recycling and reuse envisaged in the project should be briefly outlined.

It is proposed to establish 21MW Co-generation Power Plant based on Bagasse and 5 MW from incineration boiler capacities 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 2500m3/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

Krishna/Panchaganga River is the main source of raw water. There shall not be any water requirement after the proposed expansion of Sugar, due to excess condensate available from Sugar unit; there is no requirement of water for sugar unit. In fact, an excess amount of1425 m3/day is saved and is being utilized for Distillery and other usages. For Co-generation unit fresh water requirement for Boiler make-up water 200m3/day and water requirement for Domestic purpose around 100m3/day. Total Fresh water requirement after the proposed expansion of the Distillery would be 360m3/day. Thus the total


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requirement of water for all unit shall be 660m3/day. The detailed water budget of the Sugar unit, Cogeneration Power Plant and Distillery unit is given as an Annexure-I in this report. At present power is taken from Urjankur Shree data Power Company Ltd. Co-generation power plant. Nearly 11.20 MW power is required for the existing sugar and Distillery units. For the proposed expansion of Sugar and Distillery, the power requirement will be around 7.5 MW. Thus the total requirement of power would be 18.70 MW which would be taken from its proposed 21MW Co-generation Power Plant based on Bagasse and 5 MW from incineration boiler. Distillery expansion with establishing incineration boiler of the capacity of 35 MW/hr, 45 Kg/cm2 and TG set of 5.0 MW.

3.9. The 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

375 m3/day

Sugar ETP consists of Preliminary treatment (Oil & Grease trap, flow meter), Equalization tank Anaerobic Filter, Aeration tank, Secondary Clarifier, Sludge drying beds, 15 days treated storage tank and Treated Sump. Treated effluent will be disposed on land for irrigation. The existing ETP is designed for 700m3/day, which is adequate even after expansion.

b. Cogeneration Division

160 m3/day

The effluent generated after Establishing the 21+5 MW Co-generation power plant shall be treated along with Sugar Factory effluent and disposed on land for irrigation.

c. Distillery Division

Total effluent = 304 m3/day (Spentwash=260m3/day & Cooling make up = 40 m3/day )

At present spentwash from 60 KLPD is treated based on Composting principles. After the proposed expansion of 30 KLPD. After proposed expansion treatment for 60 KLPD shall be MEE and incineration boiler and for 30 KLPD the present treatment Composting shall be continued.

2

Domestic Waste (Combined)

84 m3/day

Proposed to install STP for treatment of domestic effluent. The septic tank followed by anaerobic filter followed by Constructed Wetland treatment (Root zone technique)

3 Hazardous waste 5.1 Spent oil

0.6 MT/A Mixed with bagasse and burnt in the boiler

4

Non-Hazardous Waste/ Solid waste a. Fly/Boiler Ash

520 MT /M Sale to brick manufacturers and used for compost production

b.ETP Sludge 6.50 MT/M Disposed in Composting


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4. SITE ANALYSIS

4.1. Background of the Site Location

Shree Datta Shetakari Sahakari Sakhar Karkhana Ltd., (SDSSSKL), Shirol, Taluka Shirol, Dist Kolhapur was established on June 1969 with an initial installed capacity of 1250 TCD. The command area of the sugar factory has excellent cane potential and the sugarcane grown in this area is rich in sucrose content. The factory initially started crushing at a rate of 1250 TCD in the year of 1969. Sugarcane potential of SDSSSKL from its command area is very high. As the time passed away and the demand increased, to meet this required demand, the sub-sequential expansions were undertaken by the factory and it crawled up to 9000 TCD crushing capacity today. The capacity of the sugar plant was expanded from 1250 TCD to 2000 TCD in 31st May 1978. The capacity of the sugar plant further expanded from 2000 TCD to 2500 TCD in 7th May 1986. The capacity of the sugar plant 2500 TCD to 5000 TCD was commissioned in 9th December 1988. The capacity of the sugar plant from 5000 To 7500 TCD was commissioned on 1st August 2001. The environmental clearance for the expansion of sugar factory from 7500 TCD to 9000 TCD was approved by SEIAA on 25th may 2018 in its 130th meeting. The industry now proposes to expand the sugar plant capacity from 9000 TCD to 15000 TCD.

There are a total of 49 villages in the area of operation of the factory. The SDSSSKL is procuring sugarcane from total area under and of the study area are 75832.70 ha). The general land use classes are ranging from minimum 148.70 ha. (0.20) i.e. land under miscellaneous tree crops on the contrary maximum is 32094.50 ha (42.32%) which is the net sown area. 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 85.46 hectares having a connecting road and approachability. There are no sensitive, historical, forest reserves and wildlife sanctuaries etc within 10 Km radius of the factory site. The Mumbai – Bangalore National Highway (N.H. 4) is 45 km away from the factory site. Krishna river and Panchaganga river nearly 5 km and 3 km away from the factory site respectively.

The Project Site is conveniently located for development of the Project.

45 Km away from Kolhapur, which is district place Other important towns nearby are Nearest town – Jaysingpur - 06 km Nearest City – Sangli – 16 km Nearest Head Quarters – Kolhapur – 45 Km Nearest Railway Station – Jaysingpur – 07 Km Nearest Airport – Kolhapur – 43 km

Hence, the site is very convenient in terms of connectivity

4.3. Land Form, Land use and Land ownership

Total land of 85.46 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. Most of the land in the operational area of the factory is suitable for cane cultivation. The average sugarcane yield is 115-120 tonnes/hectare in the operational area of SDSSSKL. Study of land use pattern and cropping pattern is primarily based on the information obtained from Government Departments, field interviews and discussions with farmers.


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4.4. Topography (along with a map)

The average elevation of the industry is 542 m. The study area is located on the bank of the Krishna River and Panchaganga River hence having average plane topography. There is no important hill system in the region. 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. Housing accommodation is provided for employs with drinking water & sanitation facilities. A well developed Hospital is established for the benefit of Employees, shareholder & nearby Villagers. Recreation facilities such as well developed Gardens, Fishpond, Temple and gymkhana are established. IT and Diploma college of engineering is established for the benefit of local people. Well developed Tar felted/ Concrete Roads are constructed in the entire campus area.

4.6. Soil Classification

The soil is mainly clay loam; consist of high N, P, and K. The soil is also in rich in nutrients like Ca, and Mg. The groundwater table is high and the water table is always maintaining around 10 meters as the Rives panchaganga flows in the command area.

4.7. Climatic data from stationary sources

Shirol is situated towards the east 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 normal temperatures in the region are between 180 C to 420 C in summer and 80C to 250 C in winter. 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. Here is no occurrence of frost in the area of operation of the factory. Hence, the climate of the region is well suited for sugarcane cultivation.

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 Kolhapur 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. c) Drinking Water: The villages in the study area are drawing water from mainly from the river,

according to the sources of drinking water used by the villages are a Water tank, Well, River, Hand Pump, Tap lake, etc

d) Transport and Communication: The Mumbai – Bangalore National Highway (N.H. 4) is 45 km from factory site.

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) g) In industrial premises - The cultural activities such as get-together of employs in various

occasions such as festivals and marriages are frequently arranged. Primary and Secondary schools


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are sponsored to the employees. Education loans are given to the employees. Farmers are supplied with agricultural seeds and security on bank Loans for seed capital for agricultural activities. As already mentioned a well developed Hospital is established in the campus for the wellfare of the employees.

5. PLANNING BRIEF

5.1. Planning Concept (a type of industries, facilities, transportation etc.) Town and country planning / Development authority Classification

SDSSSKL 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)

Table 11 Land use planning

Sr. No.

Description Existing in

hectares Proposed in

hectares Total Area in

hectares 1 Built up area (Sugar & Distillery plants

including storage facilities) 4.61 2.0 6.61

2 Parking Area 10.5 10.5 3 ETP (Sugar + Distillery) 13.0 13.0 4 Roads 2.48 2.48 5 Educational Institutes 2.50 2.50 6 Green Belt 29.64 29.64 7 Water Storage & Rainwater Harvesting 2.0 2.0 8 Domestic Colony 0.73 0.73 9 Cogeneration plant on BOOT principles 10.0 10.0

10 Vacant Land 10 -2.0 8.0 Total 85.46 0.0 85.46

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 expansion of the Sugar factory capacity, foundations etc.

5.5. Amenities / Facilities

Existing amenities would be adequate for the proposed expansion

6. PROPOSED INFRASTRUCTURE

6.1. Industrial Area (Processing Area)

Total of 2.0 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


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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 29.64 Hectares of land is reserved for greenbelt development; hence there should be minimum 44460 no. of trees. The industry has already planted about 30000 Trees, and remaining 14460 trees shall be planted within two years. 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

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 11.2 MW. Additional 7.5 MW of power will be required after the proposed expansion. Therefore the total power requirement after the proposed expansion will be 18.70 MW. The industry proposes to establish 21MW Co-generation Power Plant based on Bagasse and 5 MW from incineration boiler, to achieve the industrial requirement power required. Thus, the industry shall meet its own power requirement from the proposed Co-generation power plant. Excess power 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 outstees, land outstees and landless laborers (a brief outline to be given)

Not applicable as the project does not fall under project affected areas


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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 270.23 Crore rupees, EMP cost is estimated as Rs.35.0 Crore, recurring expenditures per annum is around Rs. 4.0 Crore and 0.75 % of the total project cost (Ref: Office Memorandum Dated 1st May 2018 F. No- 22-65/2017-IA.III) shall 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 SDSSSKL.


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ANNEXURE-I

WATER BUDGET FOR SUGAR, CO-GENERATION POWER PLANT, AND DISTILLERY UNIT

Table 12 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 9000 TCD

Expansion of 6000 TCD & Establishing 26 MW

Total 15000 TCD & 26 MW

Present 9000 TCD



Present 9000 TCD



Present 9000 TCD



1 Boiler 120 TPH

-- 2400 2400

200 200

2190 2190 -- 10 10

2 For Cooling of Mill Bearing

200 100 300 20 10 30 180 90 270 -- -- --

3 Washing of equipment

50 25 75 -- -- -- -- -- -- 50 25 75

4 Air compressors & pumps

70 60 130 05 05 10 65 55 120 -- -- --

5 Spray pond blowdown

250 150 400 100 75 175 -- -- -- 150 75 225

6 Cooling tower blowdown

250 -- 250 100 -- 100 -- -- -- 150 -- 150

7 Domestic 100 -- 100 20 -- 20 -- -- -- 80 -- 80

8 Recycling of Excess Condensate

-- -- -- -- -- -- 1500 1000 2500 50 25 75

Total 920 2735 3655 245 290 535 1745 3335 5080 480 135 615 Net water requirement: 3655 – 5080 = -1425 m3/day (Due to excess condensate available from Sugar unit, there is no requirement of water for sugar unit. In fact, an excess amount of 1425 m3/day is saved and is being utilized for Distillery and other usages) Net fresh water required for boiler make up shall be 200m3/day and for the domestic purpose shall be 100m3/day

Effluent Generation: 615m3/day (Sugar effluent- 375 m3/day, Cogeneration power plant effluent-160m3/day and Domestic effluent 80m3/day)


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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

Table 13 Water Budget - Distillery

Sr. No.

Details Water Requirement (m3/day) Consumption/Losses (m3/day) Reuse / Recovery (m3/day) Waste Generation (m3/day)

Present 60 KLPD

Proposed 30 KLPD

Total 90 KLPD

Present 60 KLPD

Proposed 30 KLPD

Total 90 KLPD

Present 60 KLPD

Proposed 30 KLPD

Total 90 KLPD

Present 60 KLPD

Proposed 30 KLPD

Total 90 KLPD

1. Process Water 600 300 900 -- -- -- 440 220 660 160 80 240

2. Cooling Tower Make-up Water

460 230 690 110 50 160 330 160 490 25 15 40

3 Fermenter Washing

15 05 20 -- -- -- -- -- -- 15 05 20

4

Miscellaneous such as pump and gland cooling etc.

15 05 20 -- -- -- 15 05 20 -- --- --

5 Evaporator Condensate

-- -- -- -- -- -- 440 220 660 -- -- --

6. Condensate from Storage tank

-- -- -- -- -- -- 0 400 400 -- -- --

7. Domestic 06 -- 06 02 -- 02 -- -- -- 04 -- 04 Total 1096 540 1636 112 50 162 1225 1005 1570 204 100 304

Net water requirement: 1636 – 1570 = 66 m3/day. However for process water 30 to 40 % fresh water may be use to improve the quality of RS thus the net water requirement is taken as 360 m3/day Effluent Generation: 304 m3/day (Spentwash = 260 m3/day, Cooling make-up effluent = 40 m3/day and Domestic effluent = 4 m3/day) Remarks: Present 175 m3/day of effluent shall be treated based on Concentration and Incineration principle. The effluent from the proposed 30 KLPD distilleries (85m3/day) shall be treated based on composting principle


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ANNEXURE II

ENVIRONMENTAL CLEARANCE- SUGAR AND DISTILLERY ENVIRONMENTAL CLEARANCE- SUGAR (5000 TCD to 7500 TCD, 2000)


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ENVIRONMENTAL CLEARANCE- SUGAR (7500 TCD to 9000 TCD, 2018)


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ENVIRONMENTAL CLEARANCE- DSTILLERY (30 KLPD to 60 KLPD, 2001)


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ANNEXURE III

CONSENT TO OPERATE: SUGAR


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CONSENT TO OPERATE: DISTILLERY DIVISION


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Documents

PRE-FEASIBILITY REPORT · 2018-10-22 · PRE-FEASIBILITY REPORT “Proposed Expansion of Sugarcane Crushing Capacity from 9000 TCD to 15000 TCD, Distillery Capacity from 60 KLPD to