pre - feasibility reportenvironmentclearance.nic.in/.../online/tor/17_sep...new management has...

Proposed 30 KLPD Molasses based Distillery along with 2 MW Incidental power generation, Expansion of Sugar Mill (2500 TCD to 7500 TCD) & Co-Generation Power Plant (4.5 MW to 25 MW) within the Existing Plant Premises

At Village Arala-Karanguli, Tehsil Shirala, District Sangli, Maharashtra Pre- Feasibility Report

Ninaidevi Sakhar Karkhana

(A Unit of Dalmia Bharat Sugar and Industries Limited) 1

PRE - FEASIBILITY REPORT

1.0 EXECUTIVE SUMMARY

(I) INTRODUCTION

Ninaidevi Sakhar Karkhana (NDSK), a unit of Dalmia Bharat Sugar and Industries Ltd.

(DBSIL) at Gram Arala-Karanguli, Tehsil Shirala, District Sangli (Maharashtra) was first

established in 2002 as a co-operative sugar mill with initial cane crushing capacity of 1250

TCD. Later, in 2014, this factory was taken over by Dalmia Bharat Sugar Industries Limited

under open bidding from Maharashtra State Cooperative (MSC) Bank under SARFAESI act.

New management has successfully operated the factory for about 20 days during 2014-15

season on trial basis. In Season 2015-16 plant has run successfully with 1.20 Lac MT of cane.

During 2015-16 new management has obtained Consent to establish for the expansion of

the plant upto 4800 TCD Sugar mill & 14.5 MW Co-generation Power Plant. In leave of this

CTE company has expanded sugar plant capacity to 2500 TCD in 2016.

During the passing years company has made extensive survey in nearby area and

concluded there is a further scope of expansion.

In line with the ambitious programme of honourable prime minister like “MAKE IN INDIA”

and to become self-dependence on fuel within the country and extensive survey done by

the company. It is concluded that there is definite need of further capacity expansion in

the same plant premises.

Now, the company is proposing 30 KLPD Molasses based Distillery along with 2 MW

Incidental power generation, Expansion of Sugar Mill (2500 TCD to 7500 TCD) & Co-

Generation Power Plant (4.5 MW to 25 MW) within the Existing Plant Premises.

TABLE - 1

Salient Features of the Project

S. NO. PARTICULARS DETAILS

A. Nature & Size of the Project Units Existing

Capacity

Proposed

Expansion

Capacity

Total Capacity

after

Expansion

Distillery Nil 30 KLPD 30 KLPD

Incidental

power

- 2 MW 2 MW





generation

Sugar Mill 2500 TCD 5000 TCD 7500 TCD

Co-generation

Power Plant

4.5 MW for

Captive use

only

20.5 MW 25 MW

B. Category of the Project As per EIA Notification dated 14th September, 2006, as

amended from time to time; the project falls under Category

“A”, Project or Activity - 5(g) & 5 (j) (Distillery & Sugar

Industry)

C. Location Details

Village Arala-Karanguli

Tehsil Shirala

District Sangli

State Maharashtra

Latitude 17005’16.43’’ N

Longitude 73054’58.32’’ E

Topo-sheet No. 47G16 & 47K4

D. Area Details

Total Plant Area o Existing plant area: 28.0 ha.

o No additional land is required for the proposed expansion,

as the same will be done within the existing plant premises

Greenbelt / Plantation Area 9.24 hectare i.e. 33% of the total plant area is being / will be

developed.

E. Environmental Setting Details (with approximate aerial distance & direction from plant site)

1. Nearest Village Arala-Karanguli

2. Nearest Town Malkapur (18 km in South direction)

3. Nearest National Highway o SH 144 (9.0 km in SE Direction)

o NH-204 (15.5 km in South direction)

4. Nearest Railway station Karad (40 km in NE direction)

5. Nearest Airport Pune (165 km in North direction)





6. National Parks, Reserved

Forests (RF) / Protected

Forests (PF), Wildlife

Sanctuaries, Biosphere

Reserves, Tiger/ Elephant

Reserves, Wildlife Corridors

etc. within 10 km radius

o Chandoli National Park (Part of Sahyadri Tiger Reserve) 6

km in NW Direction (Outer boundaries).

o Some Reserve Forests - Unnamed

7. River / Water Body (within 10

km radius)

o Warana River (1.0 km in WSW direction)

o Chandoli Dam (8.0 km in NW direction)

o Warana Left Bank Irrigation Canal (Adjacent to the plant

site in North direction)

F. Cost Details

Total Cost of the Capacity

Enhancement Project

Rs. 265 Crores

o Sugar Plant – 105 Crores

o Co-gen – 110 Crores

o Distillery – 50 Crores

Cost for Environment

Management Plan

o Capital Cost - Rs. 50 Crores

o Recurring Cost - Rs. 2.5 Crores / annum

G. Basic Requirements for the

project

Existing Total after proposed capacity enhancement

Water Requirement (KLD) 565 KLPD Season – 1125 KLPD

Off season – 698 KLPD

Source: Surface water (Warana river)

Power Requirement (MW) 4.5 MW 11 MW

Source: Proposed Co-generation Power Plant & D.G Sets (for

emergency).

Man Power Requirement 320 450

Source: Unskilled / Semi-Skilled - Local Area; Skilled-

local/outside

H. Product Mix Ethanol, Rectified Spirit, Extra Neutral Alcohol, Sugar and





Power

I. Working Days o Distillery - 330 days per annum

o Sugar Mill – 160 days per Annum

o Co-generation Power Plant – 330 days per Annum

1.1 ENVIRONMENT MANAGEMENT PLAN

Particulars Details

Air Management

Emissions � All major sources of air pollution will be provided with ESP to maintain PM

emissions below permissible limits.

� Boilers will be equipped with RCC stack of suitable height for discharge of

pollutants as per CPCB standards.

� CO2 generated during the fermentation process will be collected by utilizing

CO2 scrubbers and sold to authorized vendors.

� Fly ash is being stored in silos & Ash storing Yard and the open areas are/will

be sprinkled with water to reduce dust/fugitive emissions.

� Fugitive dust emission control guidelines are being / will be followed.

� Green belt will be strengthened along the plant premises as dust preventive

barrier.

Monitoring � Regular air quality monitoring will be carried out as per CPCB / SPCB norms.

� Online Monitoring System for stack will be installed.

Water Management

Management � Plant will adopt “Zero Effluent Discharge”

� In Distillery - The spent wash will be treated through concentration in MEE

and the concentrated spent wash will be mixed with auxiliary fuel and burnt

in the incinerator boiler. The entire process condensate will be treated in state

of art CPU and reused in process and cooling tower makeup etc.

� A full-fledged ETP for sugar and co-gen is already in place and will be





augmented.

� Effluent from Sugar Unit & Co-generation Power Plant is being /will be treated

in ETP and treated water will be recycled / reused in process, greenbelt

development and ferti-irrigation.

� Water is conserved at every stage of process. Condensate water will be re-

used & recycled.

� A full-fledged STP for domestic sewage treatment will be proposed.

Monitoring � Online monitoring System for ETP water quality will be installed.

Noise Management

Management � Proper maintenance, oiling and greasing of machines at regular intervals is

being / will be done to reduce generation of noise.

� Personal Protective Equipments like earplugs and earmuffs is being / will be

provided to the workers exposed to high noise level.

� D.G sets are being /will be provided with acoustic to control the noise level

within the prescribed limit.

� Greenbelt inside the plant premises and at the plant boundary will be

developed.

Monitoring Regular monitoring of noise level is being / will be carried out.

Solid & Hazardous Waste Management

� Bagasse generated is being/will be used as fuel for power generation in Co-gen Power Plant.

� Molasses is dark colour viscous matter generated from Sugar industry. This will be used as raw

material in distillery for fuel grade Alcohol production.

� The concentrated spent wash from molasses based distillery will be burnt in Incinerator boiler

along with bagasse/ coal as fuel.

� ETP Sludge generated after treating waste water generated in sugar unit is being/will be used as

manure.

� Ash is being/will be given to brick manufacturers / cement manufacturing.

� Press Mud generated is given to the farmers as manure.

Greenbelt Development / Plantation





� Out of the total plant area of 28 hectare, 33% will be developed under greenbelt / plantation.

� Greenbelt will be developed as per Central Pollution Control Board (CPCB) guidelines.

� Greenbelt development along with the road & plant boundary will be continued to attenuate noise

level, arrest dust and improve the environment in surrounding.

2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

(i) Identification of Project and Project Proponent

Dalmia Bharat Sugar and Industries Limited is a part of Dalmia Bharat Group, which has

interest in Cement, Sugar, Conventional Power, Renewable Energy, Refractory, and Travel

etc. The group turnover for the Financial Year 2015-2016 was around Rs. 7600 Cr; Dalmia

Bharat cogeneration plant of 109 MW, Distillery of 180 KLPD. Company also has facilities

for processing of raw sugar.

M/s. Vivek Ganna Ltd., which possessed a license for manufacture of sugar, was

amalgamated with DBSIL (Dalmia Bharat Sugar and Industries Limited) as per the orders

of the High Courts of Calcutta and Madras. In December 1994, The company has set up a

state-of-the-art 2500 TCD plant at Ramgarh in Sitapur district of Uttar Pradesh under the

name and style of ‘Ramgarh Chini Mills’. During FY 2000, The company expanded the

capacity of its sugar plant to 5000 tons crushing capacity per day. The capacity was further

extended in phases and the present capacity stands at 6800 TCD.

During 2006-07, company embarked on a major growth path by setting up two Greenfield

plants at Jawaharpur (Dist. Sitapur, U.P.) and Nigohi (Dist. Shahjahanpur, U.P.) and

expanding existing facilities at Ramgarh unit. The total cane crushing capacity of the

company is now 22500 TCD which makes it one of the leading sugar producers in the

country. Company is now a fully integrated player with 79 MW of cogeneration capacity &

a distillery of 80 KLPD. Company also has facilities for processing of raw sugar.

These state-of-the-art facilities serve as a role model for the industry and have achieved

excellence in plant operational metrics and also have a technological leadership position in

the industry. Company has robust quality systems and has also embarked upon 5S & TPM

initiatives to create world-class systems & processes.

Due to this emphasis on world class systems, company produce sugar of high quality

which has found wide acceptance in markets in U.P. & eastern India and institutional





buyers such as Pepsi, Coke, Britannia, Bharati Wal-Mart, Parle, Heinzh, Reliance etc. who

have stringent quality norms.

The company has taken a number of initiatives to drive sustainable growth, lasting

competitive advantage & efficiencies in all aspects of operations. It has also taken on a

proactive role at industry level and has been instrumental in driving many policy &

regulatory changes in the sugar and renewable energy sector.

Company continue contributing to income & employment creation opportunities in the

local economy, infrastructure development, promotion of sustainable farming techniques,

improvement of sugarcane yields, propagation of higher recovery sugarcane varieties etc.

For improving service delivery to farmers company have leveraged technology - IVRS, SMS

based information dissemination systems, Hand-held Terminals at cane purchasing centers

and GPS devices for cane survey being a few of these.

Company is also credited with pioneering achievements in registration of our

cogeneration projects under CDM (Clean Development Mechanism). All cogen plants are

registered under this mechanism and are helping in global efforts to mitigate impact of

greenhouse gas emissions. Company produces ethanol which is a green fuel from the

sustainable molasses route. From the distillery waste, company produces bio-compost

which is organic manure.

At Kolhapur distillery plant state of art and latest technology for the treatment of spent

wash is installed. Spent wash is used in slop fired boiler and generating steam and power

which is self-sufficient for distillery operations.

Ninaidevi Sakhar Karkhana (NDSK), a unit of Dalmia Bharat Sugar and Industries Ltd.

(DBSIL) at Gram Arala-Karanguli, Tehsil Shirala, District Sangli (Maharashtra) was first

established in 2002 as a co-operative sugar mill with initial cane crushing capacity of 1250

TCD. Later, in 2014, this factory was taken over by Dalmia Bharat Sugar Industries Limited

under open bidding from Maharashtra State Cooperative (MSC) Bank under SARFAESI act.

New management has successfully operated the factory for about 20 days during 2014-15

season on trial basis. In Season 2015-16 plant has run successfully with 1.20 Lac MT of cane.

During 2015-16 new management has obtained Consent to establish for the expansion of

the plant upto 4800 TCD Sugar mill & 14.5 MW Co-generation Power Plant. In leave of this

CTE company has expanded sugar plant capacity to 2500 TCD in 2016.





(ii) Brief description of nature of the project

Ninaidevi Sakhar Karkhana (NDSK) is proposing 30 KLPD Molasses based Distillery along

with 2 MW Incidental power generation, Expansion of Sugar Mill (2500 TCD to 7500 TCD)

& Co-Generation Power Plant (4.5 MW to 25 MW) within the Existing Plant Premises at

Village Arala-Karanguli, Tehsil Shirala, District Sangli (Maharashtra). Raw material for the

sugar industry will be sugarcane. Sugar industry will be operated for season, depending

upon availability of sugar cane. Molasses, a by-product of sugar production process will be

used as raw material for proposed 30 KLPD Molasses based distillery. Distillery will be

operational throughout the year. Distillery is proposed to produce rectified spirit/ENA and

then fuel grade absolute alcohol from it. Bagasse, produced as waste from sugar

manufacturing operation will be the source of fuel for power generation.

A state of art concentration and incineration route is proposed for spent wash treatment.

A slop fired boiler cum power turbine is proposed to generate incidental power of 2 MW.

As per EIA Notification dated 14th September, 2006, as amended from time to time; the

project falls under Category “A”, Project or Activity - 5(g) & 5 (j) (Distillery & Sugar

Industry).

(iii) Need for the project and its importance to the country and or region

Sugar cane is one of the important cash crops of India. The industries based on sugarcane

and its allied by-products help farmers and provide employment to the rural people.

Bagasse, molasses and press mud are the waste by-products of sugar industry. These

products once thought to be waste are now being used as raw material in the production

of valuable products such as alcohol, bio-manure and allied products.

Basis for Expansion in capacity of Sugar

The sugar is also food commodity required to be distributed to local marketing and also

has a potential to earn forging exchange by the export. The sugar mill is located in the

potential sugarcane belt of the state. Sugar recovery in the located area is comparatively

higher and there is further scope to increase the production of sugarcane due to following

reasons-

• Plenty of water availability due to nearby reservoirs.

• Soil & climatic condition are very conducive for cane cultivation

• Quality of sugar cane in the area is very good. High recovery expected from the area.

• Yield of cane is very good

• The area is fully free from floods etc.





• The farmers are very keen to supply cane to mill due prompt payment by DBSIL.

• Presently the cane is being supplied to nearby sugar mills (and the existing plant)

• Plant has been suitably designed to reduce steam consumption and power

consumption and Bagasse shall be used for Co-generation of power.

Basis for expansion in capacity of Distillery

In line with the ambitious programme of honourable prime minister like “MAKE IN INDIA”

and to become self-dependence on fuel within the country. Hence Company has planned

for 30 KLPD Distillery.

Alcohol is eco-friendly product which can be blended with petroleum and as a fuel in

automobiles. Hence, the distillery helps to reduce the dependency on petroleum and has

potential to save foreign exchange. Petroleum is a scarce, non-renewable and non eco-

friendly product. Alcohol being used in beverages is a potential source of revenue to the

government. The importance and utility of alcohol is well known as an industrial raw

material for manufacture of a variety of organic chemicals including pharmaceuticals,

cosmetics, potable alcohol etc. It is now being increasingly appreciated all over the world.

This is partly due to high costs of products produced through petroleum route,

consequent to the phenomenal increase in petroleum price. Alcohol is also known as eco-

friendly product as it is produced out of renewable source.

Under the National Ethanol Programme, there is a mandate to blend 10 % ethanol, in petrol

in nine sugar producing states. This programme was started on 1st October 2003. This

amounts to a demand of 360 million litres of ethanol per year. This programme took the

back seat in 2004 due to the draught like conditions and a bad sugar cane crop. With good

monsoons in 2004 and onwards, the country is set for a reasonably good sugar cane crop

in this season. In addition, the Government of India has set a dead line for introduction of

gasoline and diesel confirming to Euro-3 fuel standards in 11 cities of India. The Euro-3

standard specifies the presence of an oxidant in the fuel, which minimizes the emissions

due to the combustions of these fuels. Ethanol being one of the most viable additives

available, the oil companies has to use ethanol for blending with petrol. The ethanol

programme has already been restarted. Government of India as all ready initiated to

enhance blending of alcohol with petrol up to 10% from November 2007. Once this

programme is stabilized by then the demand for ethanol would be more than double.

Following are the reasons for the capacity enhancement in distillery:

• Increase in ethanol yield from molasses from 24% to 26%





• Optimization of fermentation and distillation process.

• No additional fresh water is required for proposed increase in capacity

• No additional effluent generation

• Total concentrated spent wash generated is proposed to be consumed in existing

incinerator

(iv) Demand- Supply Gap

India is a leading producer of sugar in the world. It contributes 16% out of total world

sugar production. The country has been indulged in the production of cane sugar rather

than beet sugar as India’s tropical weather conditions support sugarcane production.

Maharashtra holds the lead in the production of cane and sugar in the country. The

consumption level of sugar in India reaches up to 18.5 million tons annually making India

the largest consumer of sugar in the world. India is successfully able to meet its domestic

demand as well as earns valuable foreign exchange by exporting it to other parts of the

world. India is a developing country with the growing population at high rate. To continue

meeting its domestic demand as well as for exporting sugar, India needs to increase its

sugar production. Already a large area is under sugarcane cultivation and also there is

crisis of land because of such a large population. Thus adopting best cultivation practices,

high yielding varieties can serve the above purpose. NDSK in this context has planned a

sugar cane development plan. It includes training of farmers by providing them

demonstration on adopting and practicing best agricultural methodologies.

The Indian Alcohol Industry is mostly dependent on sugar factories for molasses as raw

material. One tone of molasses generates about 220 liters of alcohol. Fuel based alcohol is

basically required for blending with petrol as substitute fuel to reduce the petrol demand.

Total demand of petroleum in India is 1 crore Kilo liters. Thus alcohol required (for 5%

blending) is 300 million liters.

(v) Import vs. Indigenous Production

Indian market could not meet present alcohol demand. So they import alcohol 5-7% of

total demand. As far as ethanol production is concerned, Indian market play a vital role at

both domestic & international level. So they require producing more alcohol to meet the

demand.

(vi) Export Possibility

Export of ethanol & sugar is currently governed by Govt. policy.





(vii) Domestic Markets

Sales and Marketing division has always been a key focus area for our company. Over the

years we have reached a number of key customers through our initiatives. We have a

thrust on institutional Buyers which is a paradigm shift from the tradition of selling to

wholesale market.

Our Company is a preferred sugar supplier to brand-enhancing institutional giants such as:-

Sugar Business

• Britannia

• Dabur India

• PepsiCo

• Bharti Wall mart

• Parle

Alcohol

• Oil marketing companies to fulfill 10% blending target

• Indian Glycol limited

• Allied Blenders & Distilleries Pvt. Ltd.

• United Breweries

• Jubilant

Apart from this we have a strong customer base of wholesale agents in state of U.P, Delhi,

Haryana, Bihar & West Bengal for regular supply of sugar.

(viii) Employment Generation (Direct and Indirect) due to the project

The total existing direct manpower is 320 persons and requirement after the proposed

capacity enhancement of the project will be 450 persons.

Indirectly associated people will be benefited with the increase in capacity.

3.0 PROJECT DESCRIPTION

(i) Type of Project including interlinked and independent projects, if any.

There are no interlinked projects related to this proposed project.

Proposed project is integrated production of sugar, distillery and Power.

(ii) Location (map showing general location, specific location, and project boundary &

project site layout) with coordinates





Figure - 1: Location Map




(A Unit of Dalmia Bharat Sugar and Industries Limited 13

Figure - 2: Key Plan





(iii) Details of alternative sites consideration and basis of selecting the proposed site,

particularly the environmental considerations gone into should be highlighted.

Since the proposed capacity expansion & new installation will be done within the

existing sugar mills and no additional land will be required; therefore, no alternative

site has been considered.

(iv) Size or magnitude of operation

Ninaidevi Sakhar Karkhana (A unit of Dalmia Bharat Sugar and Industries Ltd.) is

proposing 30 KLPD Molasses based Distillery along with 2 MW Incidental power

generation, Expansion of Sugar Mill (2500 TCD to 7500 TCD) & Co-Generation Power

Plant (4.5 MW to 25 MW) within the Existing Plant Premises at Village Arala -

Karanguli, Tehsil Shirala, District Sangli (Maharashtra)

S. No Units Existing

Capacity

Proposed

Expansion Capacity

Total Capacity

after Expansion

1 Distillery Nil 30 KLPD 30 KLPD

2 Incidental power

generation

Nil 2 MW 2 MW

3 Sugar Mill 2500 TCD 5000 TCD 7500 TCD

4 Co-generation Power

Plant

4.5 MW for

Captive use

20.5 MW 25 MW

(v) Project Description with Process Details

Project Description

A. Sugar Manufacturing Process

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

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

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

produce steam. Steam is used for concentration of sugar juice, production of alcohol

and for generation of electric power. The flow diagram of sugar manufacturing

process is given in Figure below. Brief description of the process is given below.

1) Crushing of Sugarcane

Sugarcane is harvested and dressed in the fields and then supplied to factories

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





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

and fibrizer. The prepared cane is then crushed by passing through 4 sets of mills.

Hot water is added in the course of crushing as imbibitions water for better

extraction of juice from sugarcane. After crushing, the bagasse is sent to boiler as

fuel and juice is sent for purification and recovery of sugar

2) Juice Clarification & Filtration

The weighed quantity of juice is primarily heated 70-730C in juice heaters and then

treated with lime solution. The juice is heated again to 100-1130C 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 evaporator bodies. The juice at 15% is

concentrated in the evaporators in to syrup of 60% concentration.

3) 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.

4) Centrifugation

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

separated from mother Liquor and sent to driers. Non crystallable matter from the

syrup, called molasses, is drained out from the centrifuge. The molasses is weighed

and sent to storage tank.

5) Drying, Grading & Bagging

Sugar is dried in the vibrating hopper and graded by passing though standard sieves.

The graded sugar is bagged, weighted for 30 and 100 Kg net, stitched, numbered

and stacked in sugar godown.





Figure 3: Sugar Manufacturing Process





B. FOR MOLASSES BASED OPERATION

i) Molasses Unloading and Storage

Molasses from tankers will be unloaded at unloading point and transfer in to molasses

storage tank.

ii) Hiferm-Nm Saccharification and Instantaneous Fermentation:

Yeast Activation:

Yeast seed material is prepared in water-cooled Yeast Activation Vessel by inoculating

sterilized mash with Active Dry Yeast. Optimum temperature is maintained by cooling

water. The contents of the Yeast Activation Vessel are then transferred to Fermenter.

Fermentation:

The Molasses from storage tank to be pumped to Dilutor installed in Fermentation section

and diluted with water. The diluted Molasses called Wort will be feed into Pre Fermenter

for activation of Yeast. The activated yeast from the Yeast activation vessel transfer into

pre fermenter.

Once the yeast activated in Pre fermenters it will be transfer in to fermenters and diluted

molasses to be add the process of fermentation is to convert the fermentable substrate

into alcohol. The pH of the wort is adjusted by the addition of acid. Yeast is available in

sufficient quantity to initiate fermentation rapidly and complete it within the cycle time.

At the start of the cycle, the fermenter is charged with wort and contents of the Yeast

Activation Vessel. Significant heat release takes place during fermentation. This is

removed by passing cooling water through the Fermenter PHE’s to maintain an optimum

temperature. The recirculating pumps also serve to empty the fermenters into Beer Well.

After the fermenters are emptied, they are cleaned with water and caustic solutions and

sterilized for the next batch. The carbon dioxide evolved during the process is vented to

atmosphere (to be processed and stored for industrial use) after recovery of alcohol in a

scrubber.

iii) Ethanol Distillation:

Fermented wash from wash holding tank is pumped by wash feed pump to the top of

degassing column after preheating the same in beer heater and spent wash heat

exchanger. The vapours along with non-condensable gases from the top of degassing

column are rectified in Heads column, to expel the high volatiles, technically known as

heads. Bottom liquid from the degasser flows into analyzer column where alcohol is

stripped from the liquid. The liquid from bottom of analyzer column is completely stripped





of alcohol and is pumped out by thick slop discharge pump through heat exchanger where

it preheats the fermented wash before it enters degassing column. The slop from the

analyser column will be feed in to decanter. The dilute alcohol vapours from near the top

of analyzer column are condensed first in beer heater while exchanging heat with wash

feed and then in analyzer condenser. Degasser and analyzer operate under vacuum. The

condensate from is collected in Rectifier Feed Tank. The vapours for stripping alcohol are

generated from analyzer column bottom liquid in the analyzer column re-boiler by using

the rectified column top vapours, as discussed subsequently.

Vapours from the top of heads column are condensed in heads column condenser and

then in head column vent condenser. Part of the condensate is returned to column as

reflux while a small portion is taken out as an impure spirit cut. Liquid from bottom of is

also taken into Rectified feed tank.

Dilute alcohol water mixture from rectifier feed tank are pumped by rectifier feed pump

through rectifier feed pre-heater in to rectifying column. Rectifier and its associated

equipment work under pressure so that these vapours can supply the necessary heat for

generating the vapours.

The condensate from is then pumped as Reflux to rectifying column. Rich alcohol vapors

at a concentration of 95.5% v/v from top of rectifying column are condensed first in

Analyzer and then in Reflux Vent Condenser. The liquid from are collected in Rectifier

Reflux Tank. Part of the liquid may be drawn off as impure spirit. The impure spirit cut will

be maintained as little as possible to maintain aldehyde levels to meet the required limits

in Absolute Alcohol.

Liquid from the reflux tank is pumped by Product Pump partly as product and partly as

reflux to the top of the Rectifying Column. The necessary rectifying vapours are generated

by boiling the bottom liquid in Rectifier Column Re-boiler using medium pressure steam.

Some side streams are drawn from rectifier column as light and heavy fractions of higher

alcohols called fusel oils and cooled in fusel oil coolers and are mixed with water and

allowed to separate out in fuel oil separator. All vents are connected to Vent Gas Absorber

where the vent gases are scrubbed with water to recover entrained alcohol. The scrubber

water is used for washing the fuel oils in fuel oil separator to recover alcohol from the fuel

oil fractions. The absorber vent is connected to vacuum pump which is used to create

vacuum in the analyzer and degasser.





Absolute alcohol is manufactured by dehydration of Rectified Spirit. The process adopted

here is based on Pressure Swing Adsorption (PSA) system using Molecular Sieves.

Rectified spirit, after preheating by waste hot streams, is vaporized and superheated by

using medium pressure steam at 6 Kg/cm2g pressure. Hot vapours at kg/cm² g pressure

and 130° C temperature pass through PSA column, where the water vapours are retained

while water free alcohol is released as vapours. The vapours are condensed and collected

as Absolute Alcohol. When the molecular sieve bed is saturated with water the alcohol

vapours are shifted to the other tower and the first tower is taken for regeneration.

Regeneration is done first by pressure releasing and creating vacuum and then by

elutriating with dehydrated alcohol vapours from the tower in dehydration operation. The

vapours are condensed and the vent vapours are recovered through scrubber 2. Vacuum

can be created. (Educator may also be considered for this duty). Product is cooled and

transferred to Absolute Alcohol receiving tank and then on to storage tank.

iv) Alcohol Daily Receivers & Bulk Storage:

Alcohol is first taken to Daily receiver storage tanks, which is based on the State Excise

laws, storage for three days considering the weekly holidays of two days. Thereafter, the

alcohol is transferred to Bulk Storage Tanks after taking the daily receiver Dip. This is

transferred using flameproof pumps. Final dispatch of alcohol is metered and again is

carried out using special flameproof pumps. The Bulk Spirit Storage is proposed to be set

up for 30 days.

EFFLUENT HANDLING SECTION

i) Evaporation Section:

The spent wash coming from Distillation section will be fed in to first calendria of the

evaporator section. There will be five calendria will be installed as per design to

concentrate the dissolved solids .suggested treatment scheme is a four FF + Finisher

Evaporation Plant for spent wash Evaporation. The following points will elucidate the

basic working principle:

� Shell & Tube type Evaporators with highly efficient liquid distributor working on

the principle of Falling Film Evaporation have been used, with Plate type

Preheaters for preheating of FEED stream which serves the purpose of energy

conservation.

� Analyzer vapour is fed to the first effect evaporator shell side at the given

pressure and temperature as the heating medium.





� The Feed from the Feed balance tank is taken to make the best heat recovery.

� The Feed after getting heated to the predetermined temperature in preheater is

fed from the first effect evaporator which is Falling Film Evaporator -1

� Vapours generated in 1st effect VLS (Vapour Liquid Separator) are used as heat

source in the 2nd effect and from 2nd to third and so on.

� The product at the desired concentration of TS is obtained at the outlet from the

final effect.

� A Shell & tube type Multi-pass Surface condenser is employed for condensing the

shell side vapours.

� The Pure and the process condensate are collected in receiving vessels.

� Highly efficient operating pumps will be provided for pumping the required fluid.

� The operation of the plant will be under vacuum. Vacuum is created with the help

of a water ring vacuum pump.

� The plant will have high level of automation to get consistent output at required

concentration.

� The system operates under vacuum. Water-ring vacuum pumps are used to

maintain a desired vacuum.

� Cooling water from cooling tower is used in the surface condensers for

condensing the vapours.

ii) Incinerator boiler:

The concentrated effluent is fired in Incinerator boiler of 18 TPH with bagasse/coal and to

generate steam and power.





Figure - 4: Process flow diagram of Molasses Based Distillery





C. Production of steam & Electricity

The steam is required for power generation, alcohol production and sugar plants

Co-Generation Plant

In the mid-eighties it was realized that by making maximum use of potential for co

generating steam and electricity from bagasse, generation of electricity could be

increased not only to fully meet the captive requirements but also to have exportable

surplus.

Thermodynamically, energy recovery from the Rankine Cycle is more dependent on the

steam inlet temperature than the pressure and the higher the inlet steam temperature,

higher the cycle efficiency. However, because of the nature of the working medium,

which is steam, the pressure also plays a major role in ensuring the optimum extraction of

the useful energy from the working medium and hence, the increase in the steam

temperature should be accompanied by the matching increase in the pressure.

Temperatures up to 400°C require the use of ordinary carbon steel and beyond 400°C, low

grade alloy steels are employed. Above 500°C, the requirements become stringent. Later,

87 ATA 510°C boilers with 84 ATA thermal cycle and HP heaters were introduced in the

sugar industry cogeneration plants.

Hence, many sugar plants in India have gone in for 110 ATA 540°C boiler outlet parameters

for the superheated steam with steam inlet parameters at turbine inlet as 105 ATA 535°C.

There are about 20 units which are operating and another 12 units are under installation in

India with 110 ATA thermal cycle. Presently the sugar plant is going with still higher

pressure boilers of 125 ATA cycle and few cogeneration plants along with one in NDSK

with 125 ATA cycle have been already commissioned & in operation.

In order to integrate the sugar plant expansion with power production, NDSK proposes to

implement an additional high pressure cogeneration power project. The cogeneration

project envisages installation of a suitable capacity, high pressure boiler, matching with 25

MW Turbo-generator, auxiliary equipment and all required grid paralleling / interfacing

equipment. The cogeneration project with energy efficient sugar plant will make

optimum use of available bagasse during the season operation.

The new additional high pressure Cogeneration plant will operate using the bagasse

generated in the sugar mill during the cane crushing season and with saved bagasse and

imported coal (As per MNRE guideline) as fuels for off-season operation. The sugar





factory proposes to modify the inefficient steam drives of the sugar mills, cane

preparatory system etc., and convert them to ACVFD drives which are very much efficient.

The proposed co-generation power plant will consist of one boiler of 160 TPH capacity

with steam outlet parameters of 125 ATA, 5480C and one 25 MW Turbo Generator along

with air cooled condenser to save the water. This boiler turbine plant will provide steam to

feed water heaters, de-aerator and the sugar process. The proposed system is capable of

operating during the sugar off-season with saved/bought out bagasse / coal (As per MNRE

guideline) etc.

In addition to this one slop fired boiler of 18 TPH of steam and 2 MW of power turbine is

proposed in Distillery plant to utilize concentration spent wash along with Coal/Bagasse as

a supporting fuel.

Figure 5: Co-gen Power Plant

vi) Raw material required along with estimated quantity, likely source, marketing area

of final products, mode of transport of raw material and finished product.

(a) Raw Material Requirement

Sugar Mill

The main raw material required for manufacture of sugar is sugarcane, which

is obtained from agricultural source existing in the region of the factory.

Chemicals such as lime, phosphoric acid etc. are used in the process for

purification of sugarcane juice. Common salt, hydrochloric acid and caustic

soda are used in water treatment plant. Lubricating oil and grease are also





used as consumable in the industry. The raw material sugar cane is available in

adequate quantities in the vicinity of the industry. Chemicals and consumables

are locally available in the country.

Distillery

Molasses is used as raw material for manufacture ethanol and other products.

The distillery as mentioned earlier is to operate round the year for 330 days.

Molasses requirement for a production capacity of 30 KLPD of fuel grade

alcohol shall be generated from both within the sugar mill and from market.

Chemicals consumed are mainly for production of rectified spirit. These are

broadly as below:

• Nutrients such as ammonium sulphate, urea and phosphoric acid in the

fermentation and yeast development.

• Chemicals and antibiotics required to eliminate contamination in the

fermenters and maintain activity of yeast.

• Antifoam oil in the continuous fermentation to suppress the foam

generated due to the evolution of carbon di-oxide gas.

• Various laboratory grade chemicals consumed in the quality control

laboratory and the bio-chemicals laboratory, and bio-compositing

operations.

• Alkali and other surfactants required to maintain the hygienic

conditions in the fermentation house and to clean the distillation

equipment, evaporators etc.

• Consumables required in the anhydrous alcohol production in the case

of molecular sieve distillation method as adopted in the present cane,

is mostly replacement of molecular sieves probably once in 10 years.

TABLE – 2

Raw material requirement for sugar unit & Distillery

Raw Material Quantity Source Distance Mode of

transportation

Sugar Mill Sugar

Cane

7500

TPD Cane Fields < 100 km Trucks

Distillery

Unit Molasses 142 TPD

Own and other Sugar

mills < 100 km Tankers





(b) Fuel Requirement

TABLE - 3

Fuel requirement for cogeneration power plant

Raw Material Quantity Source Mode of

transportation

Co-Generation Power

Plant

Bagasse 1360

TPD

In-house/

Bought out In-house/Trucks

Coal (@15%) As per

MNRE guideline 240 TPD Open Market Covered Trucks

Incineration Boiler in

Distillery

Spent wash 80 TPD In-house from

Distillery In-house

Coal (Supporting fuel) 50 TPD Open Market Covered Trucks

(c) Steam Requirement

Total Steam required at sugar plant will be 115 TPH. Steam demand of sugar &

power generation will be met from 160 TPH Boiler/Co-generation plant and

steam requirement for distillery shall be met from 18 TPH incineration boilers

cum power generation plant.

Steam required for both units at project site is given in table below:

Table No. 4

Steam Balance for Sugar & Power Plant

S. No. Description Unit Proposed

1 Quantity of LP steam in process TPH 115

2 Steam required for Boiler HP

heater

TPH 25

3 Steam to condenser TPH 20

4 Capacity of the Boiler MCR TPH 160





(vii) Resources optimization/ recycling and reuse envisaged in the project, if any, should be

briefly outlined.

Water as a resource is being/will be recycled at each possible step of the process and

latest technology and methodology is being/will be adopted to conserve and reuse the

resources.

� No water is extracted from ground.

� The distillery will be Zero Effluent Discharge so does not pose any threat to ground or

surface water quality.

� Incorporation of advanced technique i.e. Multi Effect Evaporator and Incineration

boiler will be enabling substantial reduction of final effluent.

� Centralized lubrication system will be used in Milling Tandem in place of equipment

specific lubrication. This will result in reduction in quantity of cleaning water and oil

and grease.

� Waste water generated in operations like Floor washing, Boiler blow down will be

used in green belt after treatment.

� Presently waste water generated from Sugar Mill is used in farm irrigation and

recycled after treatment in ETP due to its high nutrients value. The same will be

followed after expansion.

� Water will be conserved at every stage of process. Large quantity of water will be re-

used & recycled.

� In power generation Air Cooled Condensor will be used in place of cooling towers.

� Uses of water in power plant will be reduced drastically by installing Air Cooled

Condenser (Although with a higher capital expenditure) instead of water intensive

cooling tower operation hence reduction in demand of fresh water.

� Company has chosen state of art best available boiler configuration of high pressure

i.e. 125 Kg/Cm2. This is running satisfactory in other unit of company. This resulted in

reduction of water top up for the same amount of energy generation as compared to

low pressure boiler.

� Rainwater from rooftop will be collected and stored in water tanks and reused.





(viii) Availability of water it’s source, energy /power requirement and source should be given.

(a) Water Requirement and Source

The water required will be same as existing. This is mentioned in table below

TABLE – 5

Water requirement for the entire plant

S.

No Plant Facility Units

Season

fresh Water

Requirement

Off Season

fresh Water

Requirement

Remark

1 Domestic KLPD 100 100 -

2 Sugar Unit KLPD 600 --- Working days 160

days

3 Distillery KLPD 75 298

Condensate from

Sugar mill 223 KLPD

Net Fresh water

requirement 75 KLPD

Working Days (330

days/annum)

4 Co-generation

Power Plant KLPD 350 300

Working Days : 330

days

5 Total Fresh Water

Requirement KLPD 1125 698 Surface water

Water Balance:-

1. Water Breakup with flow chart – 30 KLPD Distillery

Input and output of water for various process operations is given below:-

Table No. 5 (A)

Total Water Input

S. No. Section Water Quantity (m3/day)

1. Process Water in fermentation 256

2. DM water for RS dilution 234

3. DM Water for Boiler Feed 240

4. Soft Water for Vacuum Pumps & Others 24

5. Soft Water for Makeup for Cooling Tower 160

6. Water in Molasses 32

7. Other Domestic Usage 8

8. Miscellaneous Washings 6





TOTAL WATER INPUT 959

Table No. 5 (B)

Total Water Output

S. No. Section Water Quantity (m3/day)

1. Steam Condensate 204

2. Water in Spent Wash 248

3. Spent Lees ( Rectifier) 234

4. Spent Lees ( Pre-Rectifier) 39

5. CT Evaporation & Drift Looses 160

6. Domestic consumption 8

7. Boiler Drift & Blow Down 36

8. Vaccum Pump & Sealing 24

9. Miscellanous Washing 6

TOTAL WATER OUTPUT 959

Table No. 5 (C)

Recycle & Utilization Streams

S. No. Section Water Quantity

(m3/day)

1 Lees Recycle For RS Dilution 199

2 Steam Condensate Recycle For BOILER 184

3 Spent Lees (Rect) Cooling Tower Make up 39

4 Process Condensate Recycle to Process & CT 240

TOTAL RECYCLING /RE -UTILISATIONS OF WATER PER

DAY 662

TOTAL FRESH WATER INPUT 298





(b) Power Requirement and Source

The total power requirement for the Project is estimated to be 11 MW. The Company

proposal 25 MW Co-generation power plants which will be met the requirement.

Excess Power will be sold to the State Electricity Board.

Source: Co-generation Power Plant & D.G Sets (for emergency).

Table No. 6

Power Balance

Description Unit Proposed

Turbo generators (2 numbers) Capacity MW 27 (25+2)

Sugar Plant Power consumption MW 7.6

Distillery Consumption MW 0.7

Power Plant Consumption MW 2.7

Total internal power consumption MW 11

Balance Power to Grid - Season MW 16

Off season sugar consumption MW 0.5

Off season Power Export to Grid MW 23.8

(c) Boiler details

The proposed boilers will be sufficient to carter the needs of existing and

proposed plant. Other details regarding boilers are given below:

TABLE – 7

Details of boiler

S. No Details Units Type of fuel Height of stack 100% MCR

1 Boiler 1 TPH Bagasse / coal 76 160

2 Boiler 2 TPH Slop & Coal 65 18

Pollution control equipment – ESP





• Details regarding DG sets

TABLE – 8

Details of DG sets

S. No Details

1 Capacity Proposed -2 x 1000 KVA

Existing - 125 KVA

2 Type of fuel HSD

3 Stack height As per CPCB guidelines

4 Pollution control equipment Adequate stack height/ Acoustic

(ix) Quantity of waste to be generated (liquid and solid) and scheme for their

management/disposal

o The proposed project will be based on “ZERO EFFLUENT DISCHARGE”.

o The spent wash from molasses based distillery will be sent to MEE for concentration

and the concentrated spent wash will be mixed with fuel and will be burnt in the

incinerator boiler.

o Water will be conserved at every stage of process. Condensate water will be re-used

& recycled.

o A full-fledged ETP for sugar and co-gen is already in place and will be augmented.

o Rainwater will be used to recharge the underground water source through

scientifically designed rain water harvesting system.

o Bagasse generated will be used as fuel for Power generation in Co-gen Power Plant.

o Molasses is dark colour viscous matter generated from Sugar industry. This will be

used as raw material in distillery for alcohol production.

o ETP Sludge generated after treating waste water generated in Sugar Unit will be

used as manure.

o Ash will be given to brick manufacturers / cement manufacturing.

o Press mud is given to farmers for soil enrichment due to higher nutrients value.

4.0 SITE ANALYSIS

(i) Connectivity

The plant site is located about at Village Arala-Karanguli, Tehsil Shirala, District Sangli

(Maharashtra). NH-204, approx. 16 km in South direction from the plant site, nearest





railway station Karad 40 km in NE direction and nearest Airport Kolhapur, approx. 55 km in

SE direction from the plant site.

It has an easy access to raw material availability and other infrastructural facilities e.g.

land, power, water, transport and communication, approach through road & access

distances from the nearest highway, railway station etc. The site is well connected with

communication facilities like telephone, fax, wireless and telex and as such, no constraints

are envisaged in this aspect also.

(ii) Land from Land use and Land ownership

Total plant area is 28.0 hectares. Since, the proposed expansion and new installation will

be done within the existing plant premises, thus, no additional land is required for the

same.

(iii) Topography

The topography of the area is almost flat.

(iv) 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 forests, national park, wild life sanctuary, eco sensitive areas,

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

area, a copy of the Gazette notification should be given

TABLE – 9

Environmental Settings of the Area

S. NO. PARTICULARS DETAILS

1. Nearest Village Arala-Karanguli

2. Nearest Town Malkapur (18 km in South direction)

3. Nearest National Highway o SH 144 (9.0 km in SE Direction)

o NH-204 (15.5 km in South direction)

4. Nearest Railway station Karad (40 km in NE direction)

5. Nearest Airport Pune (165 km in North direction)

6. National Parks, Reserved

Forests (RF) / Protected

Forests (PF), Wildlife

Sanctuaries, Biosphere

Reserves, Tiger/ Elephant

o Chandoli National Park (Part of Sahyadri Tiger

Reserve) 6.0 km in NW Direction

o Some Reserve Forests – Unnamed





Reserves, Wildlife Corridors

etc. within 10 km radius

7. River / Water Body (within 10

km radius)

o Warana River (1.0 km in WSW direction)

o Chandoli Dam (8.0 km in NW direction)

o Warana Left Bank Irrigation Canal (Adjacent

to the plant site in North direction)

8. Soil type Silty loam, blackish brown

9. Seismic Zone Zone-III [as per IS 1893 (Part-I): 2002]

(v) Existing Infrastructure

Total plant area is 28.0 hectares. Presently 2500 TCD Sugar Mill Plant already exists.

Proposed capacity Expansion & new installation will be done within the existing plant

premises.

(vi) Soil classification

The soil in the area is mainly red coarse sandy soil and black cotton soil. Soil pH ranges

from 6.5 – 8.5. The physio-chemical soil characteristics in the area are found to be suitable

for sugarcane cultivation.

(vii) Climatic data from secondary sources

The sugarcane is a tropical/sub-tropical crop requiring warm growing season & dry, cool

& frost-free ripening & harvesting season. The agro-climatic conditions of the area are

well suited for sugarcane cultivation.

Kolhapur's climate is a blend of coastal and inland climate of Maharashtra. The

temperature has a relatively narrow range between 10°C to 35°C. Maximum temperatures

rarely exceed 38°C and typically range between 30 to 35°C. Lows during this season are

around 24°C to 26°C. The area receives abundant rainfall from June to September due to

its proximity to the Western Ghats. Temperatures are low in the rainy season and range

between 19°C to 30°C. Kolhapur experiences winter from November to February. Lows

range from 9°C to 16°C while highs are in the range of 26°C to 32°C due to its high

elevation and being adjacent to the Western Ghats

These climatic conditions are highly conducive for cane growth in the presence of

adequate soil moisture. In fact the sugar recovery in the area is highest in India.





(viii) Social Infrastructure available

Nearest habitation are at Arala-Karanguli village. The nearest town is Malkapur which is

approx. 18 km distance in South direction from the plant site.

At Kolhapur City schools, Hospital, dispensaries, colleges, places of worship, Railway

station, Markets & other facility etc are available. Electrical power supply in most of

surrounding villages is available.

Mobile, Medical facilities are available in the nearby towns. Almost all the villages in the

buffer zone are electrified. L.T. power is being supplied for drawing water from a large

number of tube wells sunk around the important village of the buffer zone, for irrigation

purpose. Most of the tanks and ponds as well as the river water are being utilized for

irrigation.

5.0 PLANNING BRIEF

(i) Planning Concept (type of industries, facilities, transportation etc.) Town and

country Planning/ Development authority classification.

The existing unit is Sugar Mill complex and proposed expansion & installation will be

done within the existing plant premises. Facilities required for the proposed project will

be provided as per requirement. Transportation of raw material and final product is being

/ will be done by road.

(ii) Population Projection

Dalmia Bharat Sugar and Industries Ltd. has been / will plan awareness programs in

nearby area of the proposed project site for control the population under corporate

social responsibilities programs.

(iii) Land use planning (breakup along with green belt etc)

Total Plant area is 28.0 hectares. Proposed project will be set up in the existing plant

premises. No additional land will be required. About 33 % of the total plant area will be

developed under greenbelt / plantation.

(iv) Assessment of infrastructure demand (Physical & Social)

Ninaidevi Sakhar Karkhana (A unit of Dalmia Bharat Sugar and Industries Ltd.) has

assessed the demand of infrastructure (Physical & Social) in nearby area of the plant site

and development activities are being undertaken under corporate social responsibilities

program for rural development initiatives for the upliftment of the nearby communities

from time to time.





(v) Amenities/Facilities

Ninaidevi Sakhar Karkhana (A unit of Dalmia Bharat Sugar and Industries Ltd.) has

developed and will further develop the Amenities/Facilities in nearby area of the

proposed capacity enhancement plant site as per requirement of local people of the

nearby area under corporate social responsibilities programs.

6.0 PROPOSED INFRASTRUCTURE

(i) Industrial Area (Processing Area)

No additional land will be required for the proposed project as the same will be done

within the existing plant premises.

(ii) Residential area (Non Processing area)

No residential area is envisaged.

(iii) Greenbelt

Out of the total plant area of 28 hectare, 33% will be developed under greenbelt /

plantation. Greenbelt will be developed as per Central Pollution Control Board (CPCB)

guidelines. Greenbelt development along with the road & plant boundary will be

continued to attenuate noise level, arrest dust and improve the environment in

surrounding.

(iv) Social Infrastructure

Proposed plant will result in growth of the surrounding areas by ancillary development

and supporting infrastructure in the region.

(v) Connectivity

The site is well connected with communication facilities like telephone, fax, and wireless

as such, no constraints are envisaged in this aspect as the Tehsil and District headquarters

are near to the site.

(vi) Drinking Water

10 m3/ day water will be required for drinking purpose after proposed capacity

enhancement project.

(vii) Sewage Treatment System

A full-fledged STP for domestic sewage treatment will be proposed.

(viii) Industrial Waste management

Plant will adopt “Zero Effluent Discharge”

(ix) Solid Waste Management





o In Molasses based operation complete spent wash will be concentrated &

incinerated and no spent wash will be discharged.

o Bagasse generated will be used as fuel for Power generation in Co-gen Power Plant.

o Molasses is dark color viscous matter generated from Sugar industry. This will be

used as raw material in Distillery for Alcohol production.

o ETP Sludge generated after treating waste water generated in Sugar Unit is

being/will be used as manure.

o Ash will be given to brick manufacturers / cement manufacturing.

o Press mud will be given to farmers for soil enrichment due to higher nutrients value.

(x) Power requirement and source

During Construction

Grid connection: - The existing plant is having power connection with state distribution

utility from where electricity can be drawn or generated through DG sets.

During Operation

Power will be generated in Cogeneration power plant of capacity 27 MW (25+2MW).

Bagasse, Con. Spent wash & Permitted quantity of coal will be used as fuel in the sugar

season. Power Requirements for Sugar Unit, Co-gen Unit & Colony are met by the own Co-

generation Power Plant. The total power requirement for the Project is estimated to be 11

MW.

7.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN

(i) 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).

Proposed capacity expansion & installation will be done within the existing plant

premises. No additional land is required for proposed project. Therefore there will not be

displacement of people and hence Rehabilitation & Resettlement is not applicable.

8.0 PROJECT SCHEDULE AND COST ESTIMATES

(i) Likely date of start of construction and likely date of completion (time schedule for

the project to be given).

The project will start only after obtaining Environmental Clearance and other statutory

permissions. Project will be completed in 24 months period after getting all the regulatory

approvals.





(ii) Estimated project cost along with analysis in term of economic viability of the

project.

� Total cost of the Project: Rs. 265 Crores

� Cost for Environment Protection Measues:

� Capital Cost: Rs. 50 Crores

� Recurring Cost/annum: Rs. 2.5 Crores/annum

9.0 ANALYSIS OF PROPOSAL

(i) Financial and social benefits with special emphasis on the benefit to the local

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

Proposed project will result in growth of the surrounding areas by increasing direct and

indirect employment opportunities in the region including ancillary development and

supporting infrastructure. Special emphasis on Financial and Social benefits will be given

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

Development of social amenities will be in the form of medical facilities, education to

underprivileged and creation of self help groups.

Maharashtra state will get revenues in terms of taxes and local people will get direct &

indirect employment. Sugar Cane is one of the important cash crops of India. The industry

is based on sugar cane & its allied by-products help farmers and employment to the rural

people.

Business opportunities for local community will be available like transport of cane, alcohol,

fly ash. In addition to above local people will be benefited with maintenance & house-

keeping contract work etc.

pre - feasibility reportenvironmentclearance.nic.in/.../online/tor/17_sep...new management has...

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