02 pre - feasibility report r 2 - environmentclearance.nic.in

Mylar Sugars Ltd., 1

PREFEASIBILITY REPORT

for

MYLAR SUGARS LTD

FOR

THE EXPANSION OF 3500 TCD SUGAR AND 14 MW COGENERATION UNIT

TO 10,000 TCD SUGAR INDUSTRY AND 60 MW COGEENRATION ALONG

WITH INSTALLATION OF 120 KLPD DISTILLERY ALONG WITH

INCINERATION BOILER TO GENERATE 5 MW POWER

at

Sy No 241/C3, 158/2, 251/a, 257/1, 248/1, 267/B, 248/B/1b, 263/2a, 269/C, 240/A, 247/A, 241/B,

243/A,247/B, 247/D, 241/C1, 241/C2 of Birrabbi Village, 157/3, 157/1 of Kotihal village,

Hoovina Hadagali Taluk, Bellary District

PREPARED BY

ENVIRONMENTAL HEALTH & SAFETY CONSULTANTS PRIVATE LTD,

# 13/2, 1ST MAIN ROAD, NEAR FIRE STATION, INDUSTRIAL AREA,

RAJAJINAGAR, BANGALORE‐560 010,

Tele: 080‐23012100, Fax: 080 23012111

Email:[email protected]/[email protected] ;

www.ehsc.in


1. Executive Summary

M/s Mylar Sugars Ltd., have already obtained Consent for establishment for the

establishment of 3500 TCD sugar cane crushing, 14 MW cogeneration unit. Now

based on the demand, management has decided to expand the sugar and

cogeneration unit project to 10000 TCD sugar cane crushing and 60 MW

cogeneration unit and 120 KLPD distillery along with 5 MW power by the

installation of incineration boiler.

Sl.No Items Particulars

1 Objective of the Project Expansion to 10000 TCD of sugar plant with 60

MW Cogeneration unit, 120 KLPD distillery +

installation of incineration boiler to generate 5

MW power.

2 Promoters Mylar Sugars Ltd

3 Total Investment , Rs 545 Crores

4 Project location Sy No 241/C3, 158/2, 251/a, 257/1, 248/1, 267/B,

248/B/1b, 263/2a, 269/C, 240/A, 247/A, 241/B,

243/A,247/B, 247/D, 241/C1, 241/C2 of Birrabbi

Village, 157/3, 157/1 of Kotihal village, Hoovina

Hadagali Taluk, Bellary District

5 Extent of land 64 acres

6 Man Power 350

7 Water demand and

Source

for 10000 TCD sugar cane crushing and 60 MW

cogeneration

During season: 783 KLD

During off season: 3115 KLD

For 120 KLPD distillery:

2166 KLD


8 Power supply The total power required for the proposed

project will be 500 kwh – for construction

phase from KPTCL

During operation:

Power generation: 44 MW

Power consumption at cogen= 4.4 MW

Power consumption at Sugar unit= 10 MW

Power export = 29.6 MW

During Off season

Power consumption at cogen= 4.8 MW

Power consumption at Sugar unit= 0.5 MW

Power export = 54.7 MW

Power requirement in the distillery = 3.0 MW

9 Latitude 14 0 55’ 00.5 “ N

10 Longitude 75 0 47’ 40.1 “ E


2. Introduction of the Project/ Background Information

2.1 Identification of project and project proponent.

Sl no Names Designation

1 M.V. Gachinmath Managing Director

2 Ramakrishna Tarikoppada Director

3 Tarikoppada Narayana Reddy Whole time Director

4 Ravi Shashikant Kavatgimath Director

5 Shilpa Ramakrishna Tarikoppada Director

6 Shobha Mahadevayya Gachinamath Director

7 Mahantesh Rajasekharayya

Choukimath

Director

8 Puranikmath Udyakumar

Gangadharayya

Whole time Director

9 Anil Kumar Bhagyanaik Banjara Additional Director

Mylar Sugar Ltd. is a public limited company proposed to expand the sugar and

cogeneration unit to 10,000 TCD sugars, 60 MW capacity cogen power plant, 120

KLPD distillery along with installation of 5 MW incineration boiler. This integrated

project will be located at Sy No 241/C3, 158/2, 251/a, 257/1, 248/1, 267/B, 248/B/1b,

263/2a, 269/C, 240/A, 247/A, 241/B, 243/A,247/B, 247/D, 241/C1, 241/C2 of Birrabbi

Village, 157/3, 157/1 of Kotihal village, Hoovina Hadagali Taluk, Bellary District.

Total land area required is 64 acres of land has been purchased in the name of Mylar

Sugars Ltd.,. Total capital investment on the proposed project is Rs. 545 Crores.

The nearest town ship with residential area is Hirehadagali, which is at 4.25 kms

away from the proposed project site. The commercial & social infrastructure around


the proposed site is considered quite well for setting up the proposed integrated

project.

The integrated project comprises of a sugar factory for the manufacture of white

plantation sugar, thereby making available required bagasse for the cogen power

plant. Raw sugar for refinery will be imported. The command area of the proposed

sugar mill has excellent irrigation facilities from Tunga‐Bhadra River, availability

and potential for sustained cane supply & biomass materials like cane trash etc. And

imported coal for operating the Co‐Gen power plant during off‐season.

The aggregated capital investment for the integrated project has been estimated at

Rs.544.62 crore.

2.2. Brief description of nature of the project.

Mylar Sugars Ltd is located at Sy No 241/C3, 158/2, 251/a, 257/1, 248/1, 267/B,

248/B/1b, 263/2a, 269/C, 240/A, 247/A, 241/B, 243/A,247/B, 247/D, 241/C1, 241/C2 of

Birrabbi Village, 157/3, 157/1 of Kotihal village, Hoovina Hadagali Taluk, Bellary

District.

The propose sugar complex is to be developed on a land of about 64 acres. This is flat

land whereby cutting‐filling will be balanced and there will be no/low borrowing

from nature.

The area of operation and cane cultivation is mostly irrigated by lifts, wells, and

canals, & Tunga‐Bhadra river is at a distance of 6.5 kms from the site. The climate,

soil, rains are favorable for sugarcane growth and sugar cane yield.

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

The proposed factory is situated in the heartland of intensive sugar cane agricultural

area. The site is well situated with Tunga Bhadra river on the North‐West.


The promoter being an agriculturist and a businessman has felt the need for

establishment of a sugar factory and now venturing into this project. He also

visualized the need to provide employment to the local population and improve the

overall economy of the society in the area. After studying the necessity for such a

factory and the profitability of the project he decided to establish a sugar factory

with Co‐Generation and distillery.

The promoter being an agriculturist and a businessman has felt the need for

establishment of a sugar factory and now venturing into this expansion project. He

also visualized the need to provide employment to the local population and improve

the overall economy of the society in the area. After studying the necessity for such a

factory and the profitability of the project he decided to expand the Sugar factory

with Co‐Generation.

2.4. Demand‐Supply

The existing Sugar factories could not crush all available cane from the areas of

operation and hence, rest of the sugarcane is being taken to the sugar

factories in neighbouring districts of Karnataka and Maharashtra. Presently, the

cane grown by farmers are diverting to the sugar factories located in Maharashtra,

in this connection farmers are suffering like delay in disposal, less price, less

payment etc., Thus, the farmers are facing problems of disposal of sugarcane in 3‐4

seasons. This situation has demanded to need Sugar units at this area.

The demand for electrical power has been increasing at a faster pace after the

countryʹs economic development the pace speeded up, especially in Karnataka

which has been the hub of software services. The effective generation of power

has not been meeting the demand and the same trend is expected to continue,

especially during the peak hours and summer seasons. Hence, there is good scope

for exporting power to the third parties using the state grid through power traders /

purchasers.


2.5. Imports vs. Indigenous production

Not Applicable

2.6. Export possibility and Domestic / Export markets.

Not applicable. Will be used for domestic use

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

About 350 no of persons of all categories are working in the industry.

3. Project Description

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

Not applicable

3.2. Location (map showing general location, specific location, and project

boundary & project site layout) with coordinates.


Toposheet with 10 Kms demarcation showing location of the proposed project site

(Topo sheets No: 48 N/9, 48 N/13, 48 M/16)

10kms radius


Proposed Project Site Photographs


Aerial View of the proposed project site (showing salient features)

3.3. Details of alternative sites, considered and the basis of selecting the

proposed site particularly the environmental considerations gone into should be

highlighted.

Not applicable


3.4. Size & magnitude of operation

The company proposes to expand a sugar complex to 10,000 TCD cane crushing, 60

MW Co‐Gen, 120 KLPD distillery + 5 MW from incineration boiler.

3.5. Project description with process details (a schematic diagram/flow chart

showing the project layout, components of the project etc) should be given.

Sugar manufacturing process

Sugar cane is the raw material for manufacture of sugar. Juice is extracted from the

sugar cane, which is then processed to recover sugar. Bagasse, which is the left out

fibre material after extraction of juice from sugar cane, is used as fuel in boiler to

produce steam. Steam is used for generation of electric power and exhaust steam is

used for evaporation of water in the juice.

The flow diagram of sugar manufacturing process is given in figure below. A brief

description of the process is given below.

Crushing of Sugar cane

Sugar cane is harvested and dresses in the fields and then supplied to factories

through lorries, tractor‐trailers or bullock carts. Crushing takes place mainly in two

stages; first preparation and then milling. Preparation is done in leveller, cutter and

fibrizer. The prepared cane is then crushed by passing through mills. Hot water is

added in the course of crushing as imbibition water for better extraction of juice from

sugar cane. After crushing, the bagasse is sent to boiler as fuel and juice is sent for

purification & recovery of sugar.

Juice Clarification

The weighed quantity of juice is primarily heated to 70‐75oCin juice heaters and then

treated with sulphur and lime. Then the treated juice is again heated to 100‐1020 C in


another set of juice heaters. The hot juice is sent to clarifier. Clarified juice is

decanted out and sent for evaporation in a set of multiple effect evaporate bodies.

The juice of 15o Brix is concentrated in the evaporators to syrup of 60o Brix.

Crystallization

The syrup is sent to pan floor for further concentration in vacuum pans. The syrup

collected in supply tanks is taken to pans for boiling where the syrup concentrates

and attains super saturation stage. In such a condition sugar grains are formed in the

syrup. The syrup mass with sugar particles is called massecuite. The massecuite is

dropped in crystallizers and cooled to complete the crystallization.

Curing or Centrifuging

Massecuite is taken into the high speed centrifugal machine. Sugar crystals are

separated from mother liquor and sent to driers. Non crystallisable matter from the

massecuite called molasses, is drained out from the centrifuge. The molasses is

weighed and sent to storage tank.

Drying, Grading and Bagging

Sugar is dried in the vibrating hopper and graded by passing through standard

sieves. The graded sugar is bagged, weighed for 50/100 Kgs net, stitched, numbered

and stacked in sugar godown.


Process Flow diagram of Sugar industry


Co‐Generation Unit

Green field bagasse based power plant developing by availing CDM benefits.

Actual crushing capacity of sugar plant will be 455 TCH on 22 hr basis

Average production of bagasse will be 30 % on cane.

Bagasse used for vacuum filter will be 0.6 % on cane and reserved for start up

to stoppages and windage losses will be 0.2 % on cane. Thus the bagasse

available for the steam generation will be 28.27 %

The gross season will be of 180 days.

Captive power consumption for the sugar unit 22 kW/TCH

Existing 120 TPH boiler along with new Boiler of 150 TPH and 125 ata

pressure and matching TG set will be used

Surplus power will be exported during season (180 days) and during off

season (80days) to KPTCL grid of 110 KV level

GCV of mill wet bagasse : 2270 Kcal/kg

Thermal efficiency of boiler on GCV of bagasse : 71 %

Steam to bagasse ratio (120 TPH, 87 ata and 150 TPH, 125 ata boiler): 2.4

Technology Selection

1. Working pressure of boilers are 87 bara and 125 bar‐a with steam temperature

520‐ 545 +/‐5 0C. Such boilers are available and are easy to manage. At this

pressure, the targeted steam consumption and export of power is effectively

achieved.

2. Turbo generating set has been selected to work as double extraction cum

condensing system. The system is so designed to balance the steam demand.

At ultimate capacity a DEC TG set shall be installed.

3. At injection and cooling tower single entry condensers & cooling towers have

been suggested which consumes less water and hence less power and to be

more energy conservative. Power consumption at this station should be


around 1.5 KW/T cane by adopting automation of nozzle governing the

condenser.

Instrumentation

Steam flow‐meter (integrating, indicating & recording)

Raw water flow meter, DM water flow meter, blow down water flow

meter, return condensate water flow meter of integrating, indicating &

recording type.

Feed water flow‐meter (integrating, indicating & recording)

Drum water level (indicating & recording)

Superheated steam pressure (indicating & recording)

Multipoint temperature scanner with thermocouple. All points

indicating & recording. (all for steam, feed water, flue gas, air and

furnace temperatures in and out)

Many draft gauges. (all for fans, flue gas, air and furnace temperature in

and out )

Oxygen analyser and data logger.

Pressure gauges 250 to 150 mm dia & isolation valves (steam,

economizer, feed water pumps etc)

Microprocessor based 24‐channel data logger to many inputs like

current, mv, T/C and recording with 80‐column dot matrix printer.

(Flows, temperature, levels, pressure, oxygen‐all for steam, superheated

steam, economizer, drum, de‐aerator, feed water, flue gas, air and

furnace)

Micro‐processor based hooters for trips, low levels, high levels, high

temperatures.

On line baggase weighing system


Process flowchart of Cogeneration process

DISTILLERY SECTION

FERMENTATION

Molasses, diluted with water to the desired concentration is metered continuously

into a single tank fermenter. Additives like urea (in the form of pellets or prills) and

defoaming oil are also introduced in the fermenter as required. There is an automatic

foam level sensing and dosing system for defoaming oil.

Every Kilogram of alcohol produced, generates about 290 Kcal of heat. This excess

heat is removed by continuous circulation of fermenting wash through an external

plate heat exchanger called the Fermenter Cooler. The fermenter temperature is

always maintained between 32 and 35 deg. C, the range optimum for efficient

fermentation.

The yeast for the fermentation is initially (i.e. during start‐up of the plant) developed

60 MW/hr Power


in the Propagation Section described further on. Once propagated, a viable cell

population of about 500 million cells/ml is maintained by yeast recycling and

continuous aeration of the fermenter. Fluctuations in the yeast count of +/‐ 20 % have

little effect on the overall fermenter productivity. Yeast cell vitality which is usually

above 70% may, in times of stress. (such as prolonged shut‐downs) drop toʹ50%

without affecting the fermentation.

Fermented wash passes through a series of hydrocyclones (one to three or move in

number depending on plant capacity), which remove grit, iron filings and similar

heavy particulate matter. This rejected material along with some wash, is taken to

the bottom portion of the wash column for alcohol recovery.

The overflow from the first hydrocyclone is taken a wash tank, also provided with

an arrangement to facilitate removal of heavy settable particulate matter. Overflow

from the wash tank is taken to the yeast separator, which clarifies the wash. The

hydrocyclone and the wash tank protect the separator from erosion damage by

removing grit and similar hard particles.

Yeast Recycling: The yeast in the fermented 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. By

recirculating grown, active yeast, sugar that would have otherwise been

consumed in yeast growth, is made available for ethanol production,

ensuring high process efficiency.

Distillation : Clarified or de‐yeasted wash flows by gravity to the

propagation vessel No. III, which during continuous production, operates as

an intermediate wash tank. From here, fermented wash is pumped to the

wash preheater, which uses vapours from the rectifying column to preheat

wash. Further heating is done in an exchange of heat with weak wash and

spent wash (see flow sheet for primary distillation).

Preheated wash then enters the degassifying column of the distillation section.

Primary Distillation: The CO2 and the degassifying section help remove the

CO2 and other non‐condensables entrained in the wash. The wash column is

first column in the distillation section. It is also called the analyser. Wash is

boiled in this column with steam either supplied as live steam from the boiler

(after pressure reduction and desuperheating ) or from a reboiler which


generates steam by evaporating effluent wash.

Alcohol in wash vapourises and is carried, along with water vapour, to the

top of the wash column from where it goes to the rectification column. As

wash travels down the analyser, it is progressively ʹstrippedʹ of its alcohol

content. At a point in the column, where the alcohol concentration is 0.5 to 1.0

v/v, a portion of the wash is drawn off. This is called weak wash.

Weak Wash Recycling: Weak wash recycling of weak wash helps maintain

the desired level of dissolved solids in the fermenter, so that an adequately

high osmotic pressure is achieved. Osmotic pressure and the concentration

of alcohol in the fermenter, together keep off infection and minimize sugar

losses. Weak wash recycling also reduces the quantity of effluent spent

wash and reduces the process water requirement of the plant.

Spent wash is the wash from which all alcohol has been removed, this

emerges from the bottom of the wash column at about 105 deg C. Some of

the heat is recovered to preheat fermented wash entering the degassifying

column.

Spent wash may also be passed through a forced circulation reboiler to

generate vapours. This concentrates the effluent and reduces the volume

further.

Propagation: The propagation section is a feeder unit to the fermenter. Yeast,

either Saccharomyeescereviseae or Schizosaccharomyeespombe (the choice

being determined by other process parameters, mainly the downstream

effluent treatment system) is grown in 3 stages. The first two stages are

designed for aseptic growth. Propagation vessel III develops the inoculum

using pasteurized molasses solution as the medium. This vessel has a dual

function. During propagation, it serves for inoculum build‐ 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 shut‐downs during which

the fermenter is emptied.

CO2 Scrubbing and Recovery: The carbon‐di‐oxide produced during

fermentation is scrubbed with water in packed‐bed scrubber, to recover

alcohol. The water from the scrubber is returned to the fermenter. About


1.0 % of the total alcohol production is saved by scrubbing the fermenter off

gas. In plants where it is desired to recover carbon‐di‐oxide, a part of the

wash is drawn into a separate vessel and is aerated there. This external

aeration allows the recovery of CO2 uncontaminated with air.

Fermentation Parameters (Typical): The pH of the fermenter is maintained

between 4.0 & 4.8 usually without addition of any acid. The alcohol

concentration is maintained between 7.0 & 7.5 % v/v, unless a highly

concentrate effluent is to be produced. To reduce the effluent volume, the

fermenter is operated at a very high dissolved solids level by increasing the

proportion of weak wash recycle. Under these conditions, alcohol

concentration is reduced to between 5.5 to 6.0 % v/v.

Conversion of sugar to ethanol is instantaneous, and the residual sugar

concentration is maintained below 0.2 % w/w as glucose. This usually

corresponds to a residual reducing substances concentration of 2.0 to 2.5 w/w

in wash.

All the nutrient elements necessary for yeast growth exist in adequate

quantities as impurities in molasses. Occasionally, Nitrogen may have to be

supplemented. Defoaming oil (DFO), say Turkey Red Oil is added to the

fermenter by an automated DFO dosing system, to control foaming. Usually

no other additives are required.

Flexibility: This process accords tremendous flexibility to the operator.

Process conditions and plant design can be varied to suit individual

requirements of alcohol quality, effluent concentration and characteristics.

This unit can give spent wash suitable for use in any effluent treatment

process.

2. MULTI PRESSURE VACUUM DISTILLATION:

After fermentation the next stage in the manufacture of alcohol is to separate

alcohol from fermented wash and to concentrate it to 95% alcohol called as

rectified spirit. For this purpose, distillation process is employed.

Distillation step consumes a considerable amount of energy and is also a deciding

factor in the quality of ethanol produced. Hence, in line with the demand of the

industry, efforts have always been to minimize requirement of energy and to


improve the basic quality of alcohol produced. Ease of operation, reliability, lower

down time and flexibility of operations are other parameters considered during the

design.

Three basic types of plant are designed:

a) One is to produce primary quality of alcohol, usually referred to as ʹRectified

Spiritʹ (R.S.) from the fermented wash. Such plants are also referred to as ʹPrimary

distillationʹ plants.

b) Second is to produce fine quality of spirit usually referred to as ʹExtra Neutral

Alcoholʹ (ENA) starting from R.S. Such plants are also referred to as ʹsecondary

distillationʹ plants.

c) Third is to directly produce fine quality alcohol (ENA) from fermented wash.

Such plants are referred to as ʹwash (mash) to ENAʹ plants, where the two steps

of primary and secondary distillation are combined. Such plants usually have

lower consumption of energy than two separate plants.

Multi‐pressure vacuum distillation system for production of Rectified Spirit

/ENA consists of following distillation columns namely

1. Degasifying cum analyzer column ‐ Operation under vacuum

2. Pre‐rectification column ‐ Operation under vacuum

3. Rectification cum Exhaust Column ‐ Operated under pressure

4. Recovery column ‐ Operated under atmospheric

5. Extractive distillation column ‐ Operated under vacuum

6. Simmering column ‐ Operated under atmospheric

Benefits of Pressure Vacuum Distillation: ‐

Following are the advantages of pressure vacuum distillation.

Since the analyzer column operates under vacuum, the formation of by‐

products such as acetal may minimize there by improvement in quality of

alcohol.

Pre‐rectification column ensure removal of sulfur compounds/mercaptans

and also reduces load of lower boiling volatile compounds passing on to

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 with reboiler


Integrated Multi‐products Concept: ‐

It is now possible to install a distillation system, which can produce different

products. In the proposed scheme; the production of fuel ethanol has been

considered. This allows flexibility of operation and various products can be

manufactured depending on the market demand. This integrated multi‐product

system involves less capital investment as compared to independent system.

In this type of system, switching over from one product to another is quite easy

and there is no chance of contamination of one product with another. The system

can work under multi‐pressure principle with few columns operating under

vacuum and few under pressure/atmospheric.

3. Dehydration of Alcohol

Molecular Sieve:

The feed (Rectified Spirit) ,pumped from the storage tanks, Is heated through

the heat exchanger by the dehydrated alcohol ,then heated Rs of 93% to 96% is

fed to the top of the distillation column.

The liquid passes through the distillation column where ethanol is stripped of.

The alcohol free liquid called spent lees is separated and discharged from the

bottom of the distillation column and the ethanol stream, with strength of about

96% by volume, is removed as vapor, at the top section of the distillation column

and feed to the molecular sieve unit after a super heating about 115°C by steam

in the heat exchanger.

Fuel oils are removed from an intermediate point of the column in order to avoid

any risk of flooding of the column and feed to the static settling device where are

separated from the weak water which are recycled to the column.

The distillation column has an operating pressure of about 160 kPa(A) and is

heated with low pressure steam by means of reboiler.

This solution shows following advantages:

Total recovery of steam condensate which is recycled to the steam boiler at

high temperature with consequent increasing of the efficiency of the

reboiler (higher production of steam per unit of fuel)


Lower cost for softening of demineralization of raw water to be fed to the

boiler as steam condensate does not need any treatment

Lower quantity of stillage, potential source of pollution

The super heated ethanol stream removed at the top of the distillation column

feeds one of the two sieve beds is now in regeneration mode.

The second sieve bed when in regeneration mode (under vacuum) and receives

a small amount of vapour from bed working in over pressure. As soon as

regeneration is finished (a regeneration cycle lasts about 5 minutes), an

automatic control system changes the operating conditions of the two sieve beds in

order to have the first sieve bed in regeneration and the second one in

dehydration mode.

The dehydration process releases a vapour ethanol stream with a very small

amount of water (500 p.p.m or less), which is condensed in the condensor

cooled in the heat exchangers and sent to the storage as dehydrated alcohol.

The regeneration process releases a certain amount of absorbed water and

ethanol, which are condensed in the condenser and recycled to the column.

Cooling media of the first cooling step of the dehydrated alcohol (condenser) is

the regeneration stream recycled to the distillation column and cooling media of

the second cooling step of the dehydrated alcohol (condenser) is the fed stock

coming from the storage tanks, which is preheated as herein above described.

Remaining vapors and liquid are condensed and cooled by cooling water in S & T

or P&F heat exchangers. The unit operation is fully automatic and all operations

are governed by logics executed by a PLC Control system.

Spent wash treatment ‐

Incineration:

The spent wash which is generated after recovery of alcohol from the distillery is a

highly pollutant liquid which will cause great pollution to receiving body like land

or water. Hence this needs to be taken care. The latest technology developed to

achieve the zero discharge is spent wash incineration boiler. This is a specially

designed boiler which will burn the concentrated spent wash along with the coal as

supporting fuel. The ratio of this spent wash to coal is 75 : 25.


In this specially designed boiler after burning the spent wash we can generate the

steam which is required to run the distillery. In turn, we can save bagasse or coal

upto some extent. The calorific value of the concentrated spent wash is 1705 K Cal.

Hence this special technology helps us in achieving zero discharge of spent wash.

The air pollution causing from this boiler is also very minimum and normal bag

house filters can be used as air pollution control equipment to achieve SPM

<100μgm/Nm3. The ash collected from the bag filters will be utilized as manure.

This technology helps us in generating steam, power and most important is

achieving zero discharge of spent wash.

Salient Features of Incineration boiler:

The proposed 32 TPH Boiler has the following features

Capacity Pressure Temperature Qty Type

32 TPH 45 kg/cm2 400 0C 1 70 %

concentrated

Spent wash

and 30 % Coal

fired CFBC

boiler

The construction of the boiler is such that the fouling potential is minimized

through multi‐ pass design.

The boiler is designed such that it is easily maintainable.

The convective section of the boiler (consisting of Economiser, Superheater

and Evaporator) are of vertical tubes.

A Steam Coil Air Preheater is provided to preheat combustion air. This is

required to Maintain the bed from quenching.

Deep Fluidised bed construction to improve combustion efficiency.

Fluidised bed combustor ensures complete combustion.

Special On‐line cleaning devices are provided.

The boiler will need off‐line cleaning once in 30 days of operation. The cleaning will

include the water wall, super‐heater, evaporator and economiser section. The total

time required will be 2‐3 days. The cleaning frequency and duration is an estimated

one, and will be decided based on the actual operating parameters condition.


Typical Boiler Schematic

Technical parameters considered for design

Sl. No. Description UOM Value

1. Spent wash concentration % solids 55

2. Spent wash quantity‐ concentrated TPD 370

3. Spent wash quantity‐ concentrated Kg/hr 15.4

4. GCV of spent wash for given

concentration Kcal/kg 2000

5. Approximate Quantity of Support

coal required Mt/hr 3.0 ‐ 4.0

6. GCV of Imported Coal Kcal/kg 5200

7. Minimum ash content in coal % wt / wt 7


8. Gross steam generation @ MSSV

outlet Kg/hr 32,000

9. Pressure at MSSV outlet Kg/cm2(g) 45

10. Temperature at MSSV outlet °C 400 +/‐ 5

11. Start‐up fuel ‐‐‐ Char Coal mixed

with diesel

3.6. Raw material required along with estimated quantity, likely source,

marketing area of final products, mode of transport of raw material and finished

products.

Raw Material and Product (For Sugar Plant and cogeneration plant)

Sl. No. Particulars Quantity

01 Sugar cane (MT/d) 10000

02 Bagasse as fuel (MT/d) at 85% of heat

input

2550

03 Coal as fuel (MT/d) at 15% of heat input 180

04 Sulphur (MT per month) 150

05 Lime (MT per month) 600

06 Caustic Soda flakes (MT/month) 30

07 Lubricants (KL/month) (Wheel bearing

greases, lubricating oils etc.)

15

08 OP acid, MT/month 18

Raw material requirement – Distillery Sl. No Raw Material Quantity/120 KLPD Source

1 Molasses 500 MT Own production plus other sugar factories


2 Sulphuric Acid 240 to 260 lit Mumbai Market

3 Nutrients N, P 72 Kg Mumbai Market

4 Turkey Red Oil (TRO) 240 to 260 Kg Mumbai Market

3.7. Resource optimization/recycling and reuse envisaged in the project, if any,

should be briefly outlined.

The cane sugar factory has unique characteristics for the application of cogeneration

technology. The principal advantages lie in the good fuel characteristics of bagasse

and in the high uses of low‐pressure steam within the plant. In conventional power

plants, most of the heat that is obtained by burning fuel is thrown away in the form

of low‐pressure steam as the steam condenses and heats cooling water. In the sugar

factory, the heat in low‐pressure steam is used to perform such work as juice

heating, evaporation and sugar boiling. During the process steam condenses.

A well‐known option for sugar mills to increase their profitability is bagasse

cogeneration. At present, bagasse is burnt inefficiently in low‐pressure boilers to

raise steam. Cogeneration has long been a standard practice in the cane sugar

industry. With the application of efficient processing and energy management

systems, energy from the bagasse, well above the factory needs, is available and can

be exported conveniently in the form of electric power. Application of sugar

cogeneration will displace a part of fossil‐based electricity generation leading to a

more sustainable mix in power generation.

3.8. Availability of water its source, Energy/power requirement and sources

should be given.

Water requirement :

During season: 782 KLD

During off‐season: 3115 KLD


Distillery: 2166 KLD

Power Requirement

For sugar unit: 9.2 MW

For cogeneration ‐ during season: 4.8 MW

during off season: 7.2 MW

The power requirement will be met through cogeneration unit. DG sets are also

provided as a backup

3.9. Quantity of wastes to be generated (liquid and solid) and scheme for their

Management/disposal.

Water and effluent

Sugar cane

crushing

10000

Cogen 60

Condensate 6500

Sl No Description Water

consumption

Condensate Freshwater Recycle/losses Effluent

1 Domestic 16 16 13

2 Process 3600 3600 3096 504

Cooling 1872 1872 1685 187

Boiler feed 1152 461 691 1037 115

DM water 70 70 70

Lab and

washing

5 5 5

Total 6715 5933 782 5818 894

During off season

Sugar cane crushing 0

Cogen 60

Condensate 0

Sl No Description Water

consumption

Recycle/losses Effluent


1 Domestic 16 13

2 Process 0 0 0

Cooling 1872 1685 187

Boiler feed 1152 1037 115

DM water 70 70

Lab and washing 5 5

Total 3115 2722 390

894 KLD Effluent generated will be treated in the ETP of capacity 1000 KLD and the

domestic sewage is disposed to septic tank and soak pit.

Water requirement for distillery

Sl No Purpose Requirement, KLD

1 Yeast propagation 156

2 Preparation of molasses 660

3 Water (as steam) for distillation 270

4 Cooling water for fermentor 180

5 Condenser 900

Total 2166

About 960 KLD of spentwash and 120 KLD of spentlees will be generated. Spent

wash will be stored in the impervious storage tank and will be concentrated and

used as fuel in the slop fired boiler.

Spentlees will be neutalised and recycled back in the process.

Effluent treatment ‐ Sugar

Design Data and Performance Projections

The characteristics of the raw effluent considered for designing the plant

having UASB followed by Extended Aeration are as follows;

Sl No Parameters Design value

1 Flow 1000 m3/day

2 COD 5000 mg/l

3 BOD 2000 mg/l

4 TSS 800 mg/l

5 Oil and grease 100 mg/l


It is assumed that the effluent does not contain any inhibitory substance for

the biological process. It is also assumed that all other parameters are within

acceptable limits.

Outlet Parameters

Upon reaching the steady state, the system will produce the following

results when operated at 38 ± 2OC under optimum design conditions;

Sl No Parameters Design value

1 COD <250 mg/l

2 BOD <30 mg/l

3 TSS <100 mg/l

4 Oil and grease <10 mg/l

5 pH ~7.0

Process Description:

Screen Channel & O&G Trap

The raw effluent from process will comes to screen channel of effluent

treatment plant by pumping . The separation of floating matter from effluent

takes place in screen channel. Further on downstream of screen separation of

floating oil from effluent will takes place in O&G Trap. The oil collected on

top is removed by belt skimmer.

Equalisation Tank (EQT)

Effluent will be received under gravity in the Equalisation Tank from O&G

Trap. Static mixer is provided in this tank for mixing purpose and equalizing

the flow & characteristics variation coming in the raw effluent. Effluent

transfer pumps are provided for this tank to transfer effluent to downstream

buffer tank.

Buffer Tank


Effluent comes to buffer tank by transfer pumps at EQT. Part of the treated

effluent from UASBR is recycled back in this tank. Hydrolysis of complex

organic matter present in the effluent takes place in this tank. The

homogenized effluent from Buffer Tank shall then pump into downstream

UASBR for anaerobic treatment of effluent.

Upflow Anaerobic Sludge Blanket Reactor (UASB R)

UASB reactor consists of M.S. fabricated tank consist of feed distribution

network at t he bottom, Sludge blanket at approx. mid height of reactor and

the gas, liquid, solid separator (GLSS structure) at the top of the reactor. In

UASB process the bacteria responsible for digestion of organics are present in

the form of sludge blanket. The bacterial population grows and reside a s

bacterial flocs suspended in the Upflow effluent stream. The bacteria take

upon organic content of wastewater to metabolize it and produce bio gas and

new biomass. UASB reactor operates in the mesophilic range of temperature,

i.e. 36O – 40OC. The pH inside the reactor is usually kept around near neutral

while proper ratio of volatile acid and alkalinity is maintained.

Biogas is collected at the top of the reactor in GLSS structure an d burnt in

flare stack. If biogas utilization is aimed for, biogas‐hand ling units such as

gash older, blower and burners etc. will have to be additionally provided. The

anaerobically treated effluent is collected from the network of gutters and

launder and sent to aerobic treatment units.

Extended Aeration Tank (EAT)

Anaerobically treated effluent from UASB enters into downstream Extended

Aeration Tank. In EAT, microorganisms degrades soluble organics

aerobically. In order to ensure required population of bacteria in EAT, a

requisite Mixed Liquor Suspended Solids (MLSS) is maintained in EAT. To


maintain requisite MLSS and Food to Microorganism s ratio (F/M ), the settled

sludge from Clarifier is part of recirculated back to aeration tank. An aeration

consists of surface aerators for providing oxy gen to bio mass and system

mixing of tank content

Secondary Clarifier The mixed liquor from EAT enters in downstream feed

well of secondary clarifier for separation of solids and liquid. The clarifier is a

hopper bottom circular tank equipped with rotating scrapper mechanism. In

clarifier tank, solids get settled & accumulate in bottom hopper by rotation of

scrapper mechanism . The supernatant from the clarifier overflows uniformly

over the peripheral weir and passes through launder for further downstream

treatment. A part of excess sludge from the clarifier is re‐circulated back to

aeration tank while balanced is wasted to sludge drying beds for dewatering

& drying.

MGF Feed Tank�&�MGF (Multigrade Filter)

The overflow from Secondary Clarifier get collects into MGF Feed Tank. From

MGF feed tank treated effluent feds into Multigrade Filter (MGF) under

pressure. The separation of fine suspended particles takes place into MGF and

outlet gets collects into treated water tank for further storage and disposal.

Sludge Drying Beds

In aerobic digestion the sludge is sufficiently mineralized and does not need

any further

treatment before dewatering and disposal. Sludge Drying Beds are provided

for dewatering of sludge on sand & gravel beds and drying of sludge cake by

solar radiation. Sludge Drying Beds are constructed in brick masonry with

gravel bed supporting sand media on them. Beds are also provided with

suitable under drain arrangement to collect filtrate from sludge. T he collected

filtrate is again recycle d back into process.


Basic Design Criterion:

Screen Channel

Design Par meter Design Value Unit of Measurement

Design Flow 42 m3/hr

Channel Size 2.0 X 1.45 X 1.1 S WD m

O&G Trap



Tank Size 16.0 X 3.0 X 1.0 S WD m

Detention Time (Minimum) app. 30 mins

Equalisation Tank



Detention Time app. 12 hrs

Volume required 504 m3

Tank Size 13.0 X 13 X 3.0 SWD m

Buffer Tank



Detention Time app. 6.0 hrs


Volume required 252 m3

Tank Size 9.5 X 9 . 0 X 3.0 SWD m

UASB (Upflow Anaerobic Sludge Blanket Reactor)



Organic Load 5000

Kg COD /day

Organic Loading Rate 6.0

Kg COD /day

/ m3

Volume provided 840 m3

Detention Time app. 20

hrs

Size of Reactor

13.5 Ø X 6.0 SWD m

Extended Aeration Tank (EAT)



Design BOD Concentration 300 mg/l

Design BOD Load 300 Kg BOD / day

MLSS in Tank 3500 mg/l

F/M 0.1 ‐


Oxygen Requirement 2 Kg O2/ Kg BOD

BOD Reduction 90 %


Outlet BOD Concentration 30 mg/l

Secondary Clarifier



Surface Overflow Rate

(SOR) 12 m3/day/m2

Surface Area provided 83.3 say 85.0 m2

Size of Tank 10.4 Ø X 3.0 SWD m


MGFFeed Tank



Detention Time app. 0.5 hrs


Tank Size 3.5 X 3 .0 X 2.0 SWD m

Multi Grade Filter



Filtration Rate 10.0 m3/hr/m2

Filter dia. 2.5 m

Filter Height (HOS ) 2.0 m

4. Estimated Outlet Characteristics from ETP:


Tentative percent wise reduction across each stage of treatment

Details Flow

(m3/d)

COD

(mg/l)

BOD

(mg/l)

TSS (mg/l)

O & G

(mg/l)

Inlet Raw Effluent 1000 5000 2000 800 100

% Reduction in

O&G

‐ 0 0 0 85

At the outlet of

O&G

1000 5000 2000 800 15

% Reduction in

UASB R

‐ 75 85 15 25

Effluent Outflow

from UASBR

1000 1250 300 680 11

% Reduction in

EAT

‐ 82.5 90 20 20

Effluent Outflow

from EAT /

clarifier

1000 219 30 544 9

% Reduction in

MGF

‐ 0 5 82 5

Outlet Treated

Effluent MGF

1000 219 29 98 9

Final Treated

Effluent

1000 <250 <30 <100 <10

Flow meter

Weir and float type of flow measuring device with dial type flow indicator is

provided to indicate the flow rate of treated effluent in the gutter

Sampler

A rotating cup type sampler device is provided to collect the composite sample from

the gutter carrying effluent.

Cleaning day sump

The tank is constructed of RCC or SSM work. The tank interior is plastered with

cement mortar


Capacity 400 m3

Tank size 12.0 mts X 10.0 mts X 3.6 mts

Free Board 0.6 mts

Laboratory house

It shall have two parts with internal partition walls and independent entry doors,

one for laboratory cum electrical panel (8m X 5 m) and other for storage of chemicals

(4 m X 5 m). Laboratory is to be provided with glazed tiled platforms, two numbers

wash basins, shelves for chemicals, electrification, water and drainage piping and

1000 ltsover head water tank. The laboratory is to be constructed with RCC roof,

polished granite flooring and complete with painting

Floor area of the laboratory house : 12 m X 5m

Sludge pits

Sludge pits are constructed of stone masonry or RCC

Capacity 8 m3

Size of the tank 2 m X 2 m X 3 m

Free board 0.6 m

Hot water cooling tank

The cooling water tank is constructed of stone masonry and is provided with

support pillars for piping and spray nozzles. The cooling tank is provided with

piping and spray nozzle and the same is connected to cooling water pump

Size of the tank 10 m X 10 m X 3.6 m

Sprayers and piping Sprayer nozzles and piping for the cooling tank

Cooling tank size 20 m X 12 m

Capacity of each nozzle 10 m3/hr


Cooling water circulation 100 m3/h

Cooling water rate 50 m3/h

Solid waste generated from different operations

Sl No Solid waste Method of collection Mode of disposal

1 Boiler‐ Bottom

Ash

Mechanical conveyor into

common silo for further

disposal

Mixed in required

proportions and

used as manure.

2 Boiler flyash

3 Lime Grit Mechanical screw

conveyor

4 Press mud Mechanical conveyor

5 Sludge from ETP Sludge drying beds

6 Used oil from DG

sets

Stored in leakproof sealed

barrels

Used as

lubricants within

the industry 7 Waste oil residue

from ETP

• Domestic Solid waste (Garbage/ Trash/ garden litters) will be stored in

Garbage collection pits and disposed off by using proper disposal mechanism

• Used Oil generated from the industry will be collected and stored in

barrels/drums and later used as lubricants within the industry.

• Any other solid waste generated from the facility will be disposed off by

using proper disposal mechanism.

3.10. Schematic representations of the feasibility drawing which give


information of EIA purpose

As per EIA notification, 2006 and further amendments the proposal is 5(g)‐ 120

KLPD Distillery, 5 (j)‐ 10000 TCD sugar cane crushing, 1 (d)‐ 60 MW cogeneration

unit based on biomass (such as bagasse)

4. Site Analysis

4.1. Connectivity

The proposed sugar factory will be located at Sy No 241/C3, 158/2, 251/a, 257/1,

248/1, 267/B, 248/B/1b, 263/2a, 269/C, 240/A, 247/A, 241/B, 243/A,247/B, 247/D,

241/C1, 241/C2 of Birrabbi Village, 157/3, 157/1 of Kotihal village, Hoovina Hadagali

Taluk, Bellary District.

The proposed site is well accessed by SH – 40, a road from Haveri to

Hoovinahadagali. The nearest airport is situated at 90.3 kms from the factory at

Hubli city. The nearest port is situated at 179 kms from the factory at Karwar. The

nearest townships with residential areas are Hirehadagali, Hoovinahadagali,

&Holalu which are 3.6, 17.5 and 18.5 kms away from the plant respectively.

Tumbinakeri Reserved Forest is located opposite to the project site &Herada Block C

Reserved Forest is located at 7.5 Km distance from the project site. The river

Tungabhadra flows at a distance 6.5 Kms away from the proposed site and the

reservoir is at a distance of 52 Km from the proposed site.

There are no protected monuments within a distance of 25.0 Km.

4.2. Land form, land use and land ownership.

The site is situated at Sy No 241/C3, 158/2, 251/a, 257/1, 248/1, 267/B, 248/B/1b, 263/2a,

269/C, 240/A, 247/A, 241/B, 243/A,247/B, 247/D, 241/C1, 241/C2 of Birrabbi Village,

157/3, 157/1 of Kotihal village, Hoovina Hadagali Taluk, Bellary District


4.3. Topography (along with map)

Map of the proposed project site

Project site


Aerial View of the Proposed Project Site Showing 10 Kms Radius Demarcation


Toposheet with 10 Kms demarcation showing location of the proposed project site

(Topo sheets No: 48 N/9, 48 N/13, 48 M/16)

4.4. Existing land use pattern (agriculture, non agriculture, forest, water bodies

(including area under CRZ), shortest distances from the periphery of the project to

periphery of the forest, national parks, wild life sanctuary, eco sensitive areas,

water bodies (distance from, the HFL of the river)). In case of notified industrial

area a copy of the Gazette notification should be given.


As per 2001 census, 84.74% of land holdings are having less than 4ha, which cover

53.04% of the total area. The major crops grown are the cereals with an area 234771ha

where jowar (37.89%), paddy (28%), maize (22.90%, and Bajra (7.9%) are the major

cereals. This follows the cash crops in an area 220646 ha in which other cash crops

and cotton are the major crops. Then follows oil seeds with an area of 174943ha in

which sunflower as the major crops. Lastly pulses with an area of 33426ha in which

other pulses and gram are the major crops. The net sown area comprises 56.47% of

the total geographical area, in which 15.80% of the area is being sown more than

once. As per the records about 20.40% of the net sown area is irrigated through

surface water source, and about 13.15 of the area is irrigated through ground water.

The surface water irrigation practices is through canals with the total length of 456

kms from T.B. major irrigation project and two medium irrigation projects

(Hagaribommanahalli and Naarihalla) with the other surface water sources like

tanks and lift irrigation. As per the census records, the district has 24055 minor

irrigation schemes, of which 2860 pertains to dug wells, 17768 tube wells, 104 surface

water flow schemes and 3322 lift irrigation schemes.

Land utilization pattern of the Bellary District

Sl.No Land classification Area (in Sqkms)

1. Forest 27017

2. Net area sown 459250

4.5. Existing Infrastructure





nearest townships with residential areas are Hirehadagali, Hoovinahadagali, &

Holalu which are 3.6, 17.5 and 18.5 kms away from the plant respectively.

Tumbinakeri Reserved Forest is located opposite to the project site & Herada Block C




4.6. Soil Classification

The soils of the district are derived from Granites, Gneisses and Schistose rocks. The

Sandy loam soil mixed with black and grey soil occurs along the stream beds. These

are originated from gneisses and granites. They are permeable and mildly alkaline in

nature. The thickness of the soil varies from 0.2 to 1.00m. The Red soil are the major

type of soil in the district, found mainly at elevated places especially at fringes of

hills due to decomposition of rocks and surrounding granitic and gneissic hills.

These soils are with high permeability and neutral PH. Black soil with high initial

infiltration rate when dry and cracked. On getting wet cracks will close and

infiltration rate will be very low. These are derived from schistose rocks. The Black

soil is found in the prolonged submerged areas and canal command areas having

low Permeability. It is calcareous and mildly alkaline in nature.

Mineral Resources

This district is endowed with rich mineral resources. The minerals include

Limestone, Dolomite Limestone, Gray Limestone, Siliceous Limestone & Thinly

bedded soil / black cotton soil.

4.7. Climatic and Rainfall data from secondary sources

The climate of Bellary district is quite moderate shows dryness in major part of the

year and a hot summer from March to May months where mean maximum


temperatures ranges from 23.2°C to 40.4°C. June to September is the southwest

monsoon period where the temperature 19.7°C to 35.1°C, October and November is

the post monsoon retreating monsoon season with clear bright weather with the

mean daily temperature ranges from 14.4°C to 31.1°C. During December to February

weather remains dry and comparatively cool season. The skies clouded or overcast

during southwest monsoon. During October and November some of the depressions

and cyclonic storms originates in Bay of Bengal moving in a westerly to north

westerly direction which passes through the district causing wide spread heavy

rains and high winds. The mean maximum temperature in the district is 40.4°C. and

the mean minimum temperature is 14.3°C (January month). Relative humidity

ranges from 48 to 74% in the morning and in the evening it ranges from 27% to 61%.

The winds are light to moderate with some strengthening in the south west

monsoon.

During October to April, the winds blow from directions between north east and

southeast and are calm in morning. Winds blow southwest and northwest direction

during May to September with an average velocity of 12 kmph. These high winds

combined with higher temperature result in high degree of evaporation to the tune

of 12.5 mm/day in May against a minimum of 5.4 mm/day in the month of

December.

Bellary district receives rainfall from southwest monsoon from June to September

and northeast monsoon from October to December. Overall on an average, there are

43 normal rainy days (1901‐1970), where minimum in Bellary taluk with 32.4 rainy

days, maximum in Sandur taluk with 56.4 rainy days. Actual rainy days recorded

during the year 2005 ranged from 41 to 67 wherein Kudlugi taluk is the minimum

with 41 rainy days and maximum is in Sandur taluk again with 67 rainy days. As per

the 1951 to 1970 rainfall data analysis, the precipitation during southwest monsoon

accounts for 60% of the total amount of rainfall and during northeast monsoon it is

24% the remaining 11.62% is sporadic in summer.


September is the wettest month in the year. The analysis of the last ten years rainfall

data (1996‐2005) shows that the highest rainfall occurred in Sandur taluk with

752.1mm and the lowest at Bellary with 452mm and over all annual normal rain fall

in the district is 611mm. Again it is proved that south west monsoon contributes 63%

of the total rainfall in the district and north east monsoon with 25.36%. Deficiency in

rainfall is observed in the four taluks for the last ten years in the range of 2.40%

(Kudlugi taluk) to 26.02% (Bellary taluk). The excess rainfall in the range of 15.41%

(Siruguppa taluk) to 23% (Sandur taluk) was observed.

4.8. Social Infrastructure available

The district is well connected by high ways and other main roads. Fairly good

network of roads exists connecting taluk head quarters with the district head

quarters and hoblis to various taluk head quarter. Total there are 288.60kms of NH,

631.93kms of SH, 1323.30 kms of major district roads and village road length of

1200.65 kms serves as communication system. Added to this the South Central

railway line (Hubli‐Guntakal) passes through Hospet and Bellary. Overall 310 kms

length of railway roads falling in all the taluks except in Hadagali and Siruguppa

taluks adds the communication network.


5. Planning

5.1. Planning concept (type of industries, facilities, transportation, etc.,) Town

and Country Planning Development authority classification.

Sy No 241/C3, 158/2, 251/a, 257/1, 248/1, 267/B, 248/B/1b, 263/2a, 269/C, 240/A, 247/A,

241/B, 243/A,247/B, 247/D, 241/C1, 241/C2 of Birrabbi Village, 157/3, 157/1 of Kotihal

village, Hoovina Hadagali Taluk, Bellary District.






Tumbinakeri Reserved Forest is located opposite to the project site & Herada Block C




5.2. Population Projection:

As of 2011 Census of India, with regards to Sex Ratio in Bellary, it stood at 983 per

1000 male compared to 2001 census figure of 969. The average national sex ratio in

India is 940 as per latest reports of Census 2011 Directorate. In 2011 census, child sex

ratio is 960 girls per 1000 boys compared to figure of 947 girls per 1000 boys of 2001

census data..Average literacy rate of Bellary in 2011 were 67.43 compared to 57.40 of

2001. If things are looked out at gender wise, male and female literacy were 76.64

and 58.09 respectively. For 2001 census, same figures stood at 69.20 and 45.28 in


Bellary District. Total literate in Bellary District were 1,421,621 of which male and

female were 813,440 and 608,181 respectively. In 2001, Bellary District had 980,483 in

its district. Kannada is the major language spoken here

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

Sl No Land Description Area (acres)

1 Factory

Raw material storage yard 5.50

Sugar Unit 10.50

Distillery 8.50

Power plant 9.0

Admin, repair shop, lab 3.0

Internal Road 3.0

2 Landscape, garden 21.50

3 Officers and workers Colony 3.0

Total 64 A

5.4. Assessment of infrastructure Demand (Physical & Social).

There will not be any negative effect on the living conditions of people. Due to

project activities, the surrounding areas are expected to improve by way of socio‐

economic development due to direct and indirect employment and the project will

also lead to supporting utilities by improving business opportunities in the locality.

5.5. Amenities/facilities

Basic amenities and facilities will be provided for all workers working at site.

6. Proposed Infrastructure

6.1. Industrial Area (Processing area)

Sl No Land Description Area (acres)

1 Factory

Raw material storage yard 5.50


Sugar Unit 10.50

Distillery 8.50

Power plant 9.0

Admin, repair shop, lab 3.0

Internal Road 3.0

2 Landscape, garden 21.50

3 Officers and workers Colony 3.0

Total 64 A

6.2. Residential Area (non processing area)

Housing will be provided for the working staff.

6.3. Green Belt

33% of total area, 21.50 Acres is provided for green belt development

6.4. Social Infrastructure

Good infrastructure facilities seen around Bellary district.

6.5. Connectivity Traffic and Transportation Road/Rail/Metro/Water ways etc

Sy No 241/C3, 158/2, 251/a, 257/1, 248/1, 267/B, 248/B/1b, 263/2a, 269/C, 240/A, 247/A,

241/B, 243/A,247/B, 247/D, 241/C1, 241/C2 of Birrabbi Village, 157/3, 157/1 of Kotihal

village, Hoovina Hadagali Taluk, Bellary District.







Tumbinakeri Reserved Forest is located opposite to the project site &Herada Block C




6.6. Drinking Water Management (Source & Supply of water)

Drinking water is met through Tungabhadra river located at 6.5 kms from the site

followed by treatment in the water treatment plant at the site.

6.7. Sewerage System

Domestic sewage is treated in septic tank and soak pit. Industrial effluent will be

treated in the ETP through internal sewer network

6.8. Industrial Waste Management

Effluent generated will be treated in the ETP of 1000 KLD and treated water will be

used within the plant premises.

6.9. Solid Waste Management

Solid waste generated from the industry include Pressmud, ash from sugar industry

which is used mixed in the required proportions and sold as manure. Bagasse

generated will be used as fuel in the cogeneration boiler.

6.10. Power Requirement & Supply/Source

Power requirement will be met through cogeneration


7. Rehabilitation and Resettlement (R&R) Plan

7.1. Policy to be adopted (Central/State) in respect of the project affected

persons including home oustees, land oustees, and landless labourers (a brief

outline to be given).

Not applicable.

8. Project Schedule & Cost Estimation

8.1. Project Schedule

Expansion of a sugar complex to 10000 TCD sugar cane, 60 MW cogeneration unit

based on biomass (such as bagasse), 120 KLPD Distillery + 5 MW power from

incineration boiler

8.2. Cost Estimates

Rs. 545 Crores as estimated

9. Analysis of proposal (Final recommendation)

9.1. Financial and social benefits with special emphasis on the benefit to the

local people including tribal population, if any, in the area

350 nos, the company provides all necessary basic amenities to the workers of the

industry.

02 pre - feasibility report r 2 - environmentclearance.nic.in

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