Prepared by

MITCON Consultancy & Engineering Services Ltd. NABET accrediated consultant Environment Management and Engineering Division Behind DIC Office, Agri College Campus, Shivajinagar, Pune 411 005, Maharashtra (INDIA), Tel.: +91- 020-66289400 Website: http://www.mitconindia.com Email ID: eme@mitconindia.com

PREFEASIBILITY REPORT

for

Bidar Kissan Shakkar karkhana Ltd.

At village Mogdal, Tal &Dist- Bidar, Karnataka

Prefeasibility Report

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Contents

1.0 Executive summary ......................................................................................................... 3

2.0 Introduction .................................................................................................................... 3

3.0 Project Description ......................................................................................................... 5

4.0 Site analysis ..................................................................................................................... 9

5.0 Planning in Brief ............................................................................................................ 11

6.0 Proposed infrastructure ................................................................................................ 11

7.0 Rehabilitation & resettlement plan .............................................................................. 13

8.0 Project schedule and cost estimate .............................................................................. 13

9.0 Analysis of proposal ...................................................................................................... 13

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1.0Executive summary

2.0 Introduction

Bidar Kissan Shakhar Karkhana Limited (BKSKL) is a Company registered in the State of

Karnataka under the Companies Act, 1956 bearing certificate of incorporation number

U15429KA2000PLCO26372 dated -11-02-2000.

Bidar Kissan Shakhar Karkhana Limited (BKSKL) is a public limited Company, engaged in

manufacturing of sugar. BKSKL is situated at Mogdal village, Taluk& District: Bidar, Karnataka

with sugar plant of 3500 TCD licensed capacity & 15 MW bagasse based co-generation plant.

BKSKL started its trial season during July, 2016. BKSKL has projected to crush 5.6 Lakh MT of

cane in the crushing season 2016-17. Once the 3500 TCD capacity factory is commissioned,

Bidar Kissan Shakhar Karkhana Limited, now proposes to set up a 60 KLPD capacity distillery

to produce RS/ENA/Ethanol, adjacent to the existing sugar plant located at Mogdal village,

Taluk& District: Bidar, Karnataka.

2.1 Project proponent

Bidar Kissan Shakhar Karkhana Limited, was promoted by Late Shri Merajuddin Patel, who

was minister in the government of Karnataka. Due to his untimely death, there was delay in

implementation of the sugar cum cogen project. However, the new management of the

company has taken steps to revive the project with robust systems, company has always

relied on experienced professionals & board of directors to predict & plan business strategies

to create wealth for its stakeholders.

BKSKL is lead under the able leadership of the Board of Directors of the company. The list of

directors is shown as under:-

Shri K. A. Aziz (Age 74 Years) is Executive President of Bidar Kissan Shakhar Karkhana

Limited., (BKSKL), has interests in the field of sugar, power generation, alcoholic beverages,

etc. He holds degree of M.Sc. & H.D.C

Shri. Aziz retired as the Additional Registrar of Co-operative Societies from Government of

Karnataka. He worked as Managing Director for well-known co-operative sugar factories in

Karnataka including Shri. Malaprabha SSKN, Hiranyakeshi SSKL &the Nandi SSKN. He is

supported by a team of professionals in implementing the project.

The list of board of directors of BKSKL is as follows:-

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Names Designation

Shri. Kalmesh Sadashiv Sarwad Chairperson

Shri. Khaja Abdul Aziz Executive President

Shri. Syed Naimuddin Director

Shri. NaseemuddinNizamuddin Patel Director

Shri. Hanamanth Pandappa Sonnad Director

Shri. KallanagoudaTammanagoudaPatil Director

Shri. Krishna NarayanaParaddi Director

Smt. Naseem Banu Fatima Director

Shri. Rajshekhar Rudrappa Angadi Director

Shri. Sunil LaxmappaTalewad Director

Smt. AshaTalewad Director

BKSKL already has appointed a technical / managerial team of highly qualified engineers,

contract & arbitration experts, agricultural officers and managerial personnel for

implementation and operation of the captioned integrated project.

2.2 Need of the Project

The proposed project will produce fuel ethanol from own molasses and optimum quantity of

diverted B-heavy molasses, as well as procured molasses from nearby sugar factories as raw

material. The steam and power requirement for the proposed plant will be made available

from the new slop fired incineration boiler & condensing turbine.

The ethanol production and consumption in India has been increasing over the years as

predicted by Indian Sugar Mills Association (ISMA), Alcohol has assumed very important

place in the country’s economy. It is vital raw material for a number of chemicals. It has been

a source of large amount of revenue by way of Excise Duty levied by State Government.

Ethanol has a potentiality as fuel in the Form of “power alcohol” for blending with petrol in

the ratio of 20:80. This trend is continuing and will continue in view of the fact that potable

liquor has larger revenue generating potential for the Governments. The demand for alcohol

will always be there for industrial purposes. Further the use of alcohol in automobile fuel will

enhance the demand for alcohol. Other than the above mentioned major requirement,

alcohol is also being used in the production of many downstream chemicals including drugs,

polymers, plastic, etc.

2.5 Employment generation due to project

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The total direct employment potential of the proposed distillery is about 80-85 people.

However, the commencement of this industry will create direct and indirect employment

opportunities to more than 500persons in terms of factory employment, transportation,

vehicle maintenance, petty shops etc.

3.0 Project Description

3.1 Type of the project

The proposed project is new 60 KLPD molasses/B- heavy/ Sugarcane juice based distillery in

the existing sugar factory premises.

3.2 Location of the project

The proposed distillery will be located at sr. no. 92, 93, 94, 337/1/2, village Mogdal, Tal.&

Dist. Bidar, Karnataka. For the present study, an area covered in 10 Km radius from the

project location has been considered. Present Sugar unit is geographically located

at17.710335° N & Longitude 77.395826° E project site and the 10 km radius study area falls

in the survey of India Toposheet no. 56 G / 5 and 56 G / 6.

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Figure 1: Map showing general location of the proposed project

3.3 Details of the alternate sites

Proposed project will be located in existing sugar factory premises. Hence, no alternate sites

have been examined.

3.4 Size and magnitude

Size and magnitude of the project is given in Table 1.

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Table 1: Project in brief

Sr. No.

Particulate Description

1. Name of the proponent

Bidar Kissan Shakhar Karkhana Limited

2. Project New 60 KLPD molasses/B- heavy/ Sugarcane juice based distillery

3. Location of the project At sr. no. 92, 93, 94, 337/1/2, village Mogdal, Tal &Dist- Bidar, Karnataka

4. Land requirement For proposed distillery 18 acres

5. Proposed Product RS / Ethanol/ENA :60 KLPD

6. Operation days Sugar plant : 180 days/ annum Molasses based distillery / ethanol : 300-330 days/ annum

7. Raw materials For total expanded capacity

# Raw Material Unit Qty

Molasses based distillery / Ethanol Plant (65 KLPD)

1 Molasses (FS- 42%) TPD 262

2 Nutrient kg/D 60-65

3 TRO Kg/D 600

4 Sulphuric acid Kg/D 97.5

8. Total water requirement

Total fresh water requirement for proposed distillery will be 600 CMD. It will be sourced from Karanja River.

9. Electricity requirement (Operational)

2.5 - 3.0 MW

10. Steam Total steam requirement for integrated project 22-24 TPH

11. Fuel Concentrated spent wash : 188 Cu. M/day Coal: 47 TPD (Slop: 75 %, Coal: 25 %

12. Boiler Incineration Boiler 25 TPH ,for 60 KLPD Molasses based Distillery

13. TG 2.5 - 3.0 MW

14. DG -

15. Effluent treatment system (capacity)

Distillery units: Spent wash concentration in multiple effect evaporator system and then mixing with support fuel as coal in the boiler, for achieving Zero Liquid Discharge (ZLD). Evaporated process condensate and distillery spent lees shall be treated in Condensate Polishing unit and polished condensate shall be recycled back to process, which helps to reduce fresh water requirement.

16. Man power During Construction: 50 Nos. During Operation : 80-85 Nos.

17. Total project cost 98 Cr.

18. Total cost for EMP 1.8 Cr.

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3.5 Process description

3.7 Resource Optimization / recycling and reuse

Spent wash generated during the process of distillation will be concentrated in multiple

effective evaporators and then it will be incinerated in spent wash fired boiler. The

condensate generated during the process of Multiple Effective Evaporators will be reused in

the process consequently decreasing the net water requirement.

3.8 Availability of Water

The total water required for the 60 KLPD distillery is 600 CMD and it will be taken from the

water is drawn from Karanja River flowing at a distance of 1.8 km in north. Permission from

the same is available with factory.

3.9 Quantity of waste generated

Wastes generated during whole process are

Spent lees recycled in process/cooling

tower

Steam

RS/ENA/FO/AA/Ethanol

Storage

Spent wash treatment through

MEE & Incineration boiler

Molasses Dilution

Fermentation

Spent wash and Spent

lees

Multi-Pressure Distillation

Activated Yeast

Condensate

Condensate Polishing Unit (CPU)

Recycle to fermentation

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Process condensate recycled back in process and cooling tower makeup after

treatment in CPU.

Spent lees-recycled back in process and cooling tower makeup

Boiler and cooling tower blow down- Gardening

Concentrated spent wash – Fuel for incineration boiler

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

purpose

4.0 Site analysis

4.1 Site connectivity

Details of connectivity towards proposed site is given below

Road National Highway 65 adjacent to the sugar factory

Railway Railway Station: Bidar 25 km

Air Hyderabad Airport 143 km

Nearest town/city Town/city : Bidar 25 km

4.2 Land form, land use and land ownership

The proposed project will be located in existing sugar factory premises and land is for

industrial use.Total area required for proposed distillery 18 acres.

4.3 Topography

The topography of the land is flat with some undulations. Topo-sheet is attached separately

with ToR application.

Molasses based distillery 60 KLPD)

Molasses based Distillery: 5(g) Cat. A (All molasses based distillery)

ToR application (Form I) & Pre- feasibility study To MOEFCC

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4.4 Existing land use pattern

Existing land is vacant plot and it is under for industrial purpose. There is no any national

park, wild life sanctuary and an eco-sensitive area comes in 10 km radius of the proposed

project location.

4.5 Existing Infra structure

Proposed plant will be located in the existing sugar factory premises. Hence the maximum

resources like water, power and road connectivity are available.

4.6 Soil classification

The two important types of soils are in the district are black soils and lateritic soils. These are

deep black in color and their texture varies from loam to clay. Lime concentration in this soil

is high resulting in poor infiltration capacities. A lateritic soil is confined to the central portion

of the district. Lateritic soils are pale to bright red in colour and clay to clayey loam in nature.

This soil has moderate to good infiltration characteristics.

4.7 Climatic condition

The district experiences semi-arid climate with extreme summer. The dust storms and severe

heat waves are common in the district between April and May. Coldest months are

December and January. The temperature varies in the district between 20 °C and 42 °C The

summer season in Bidar starts in the first week of March and lasts until mid-June. This is

followed by southwest monsoon which continues till late September, and from September

to end of January is winter. May is the hottest month with average daily maximum

temperature of 38.8 °C while December is the coldest with average daily minimum of 16.4 °C,

The highest temperature recorded at Bidar was 43.3 °C on 8 May 1931, and the lowest 3.9 °C

on 5 January 1901. The average annual precipitation at Bidar is 847 mm with most of the

rainfall received during the monsoon season. The variation in rainfall from year to year is

large and the district is prone to drought.

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4.8 Social infrastructure available

Social infrastructure like community center, hospital, and electricity is available in the area.

5.0 Planning in Brief

5.1 Planning Concept

The proposed project is integrated with existing sugar industrial complex with facilities to

manufacture white sugar and power

5.2 Population projection

Factory will require additional 80-85 people for operation of proposed distillery. Manpower

requirement during construction will be 50. Skilled and unskilled labors and supervisory staff

are available within the vicinity of the industry. The company has a policy of providing

residential accommodation on-site for the essential employees.

5.3 Land use planning

Proposed distillery will be located in 18 acre. The Land is situated adjacent to the National

Highway 65.

Land use planning of the proposed project is given below,

Total Plot Area – 18 acres.

Proposed 60 KLPD Distillery 10-12 acres.

Proposed green belt area is 5 acres.

5.4 Amenities/Facilities

Facilities like canteen, rest rooms, and recreation facilities will be provided for the proposed

project.

6.0 Proposed infrastructure

6.1 Industrial area

The major plant & machineries required for the proposed project are Fermentation section,

Distillation section, Steam condensers, Air compressor, Incineration Boiler, Storage section,

Multiple Effect Evaporation Section, Raw water treatment plant, Fire protection

equipment’s, Laboratory instruments, Condensate polishing unit, Electrostatic precipitator,

etc.

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6.2 Residential area

Facilities like canteen and rest room will be provided in the proposed project. Local labor

from nearby villages will be hired in project activity.

6.3 Green belt

Proposed greenbelt area is around 5 acres(33% of total proposed distillery area). Greenbelt

will be developed in proposed project premises.

6.4 Social Infrastructure

Factory will identify the need of the villagers and execute the CSR activity.

6.5 Drinking water management

Drinking water will be supplied through with proper water treatment system.

6.6Sewerage system

Existing domestic waste water (sewage effluent) is treated inexisting ETP.

6.7Industrial waste management

The spent wash generated from distillery unit will be concentrated in Multiple Effect

Evaporator system to concentrate effluent up to 55 to 60 percent solids. Then concentrated

Spent wash and it will be incinerated in Boiler using coal as supplementary fuel to generate

power simultaneously achieving achieve zero discharge. It is proposed to store concentrated

spent wash during emergency and repair & maintenance of boiler unit.

6.8 Solid waste management

Spent oil and grease mixed with bagasse & burnt in boiler

Yeast sludge mixed with spent wash and incinerated in the boiler or used as manure.

Ash generated will be given to brick manufacturers.

6.9 Power requirement

Total power required of proposed project will be 2.5 - 3.0 MW.

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7.0 Rehabilitation & resettlement plan

No rehabilitation or resettlement plan is required as proposed plant will be located in the

existing sugar factory premises.

8.0 Project schedule and cost estimate

The total cost of the project is estimated about Rs. 98 Cr. The project cost estimates include

all expenses to be incurred towards the entire project for Land &land development, civil,

building / structure, plant & machinery, preliminary & pre-operative and other expenses,

contingencies, plant & machinery, margin money of working capital. Environment

management cost for the proposed project will be around 1.8cr.

9.0 Analysis of proposal

Raw materials (Sugarcane, grains) are available in Tahsil/District. Surrounding areas good

Agro –climatic zone. Area comes under traditional Cane & cereals growing area. Good

Market potential in State in general and in India particular. Treated as priority sector project

Government appreciates this venture which is in rural backward area/region.

Proposed project will help to increase the socio-economic status of the local people as well

as provide the stability to the existing sugar factory. Further it helps to uplift the rural mass.

The industry will be located in the rural backward region of the state and has a good scope

for development of sugarcane with suitable climatic conditions and assured source of

underground and surface water. At present there are few sugar industries in the region.

Sugarcane cultivated in the region is presently transported through 30 to 60 km. As

compared to other crops sugarcane cultivation gives higher economical returns to the

farmers. There is good potential to develop more than 20,000 hectares of sugarcane

cultivable land in about 20 km distance from the proposed site. Hence, with the proposed

industry more agricultural land would be brought under sugarcane cultivation and it benefits

the farmers in the local region. The establishment of the integrated sugar industry will thus

meet the national interest of economic power and food through sustainable development.

The beneficial impact of proposed factory plant on the civic amenities will be substantial

after the commencement of the project activities. The basic requirement of the community

needs will be strengthened by extending educational facilities, health care, building, and

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strengthening of existing roads. The living standards of the nearby villages will be improved.

The construction of new roads and improvement in existing roads in the influential area will

enhance the transportation facilities. With improved transportation facilities, there is always

scope for development.