For establishment of New Molasses Based Distillery from

Transcription

1 Pre-feasibility report as per MoEF &CC Guidelines for obtaining prior Environmental Clearance in terms of the provisions of EIA Notification,2006 For establishment of New Molasses Based Distillery from KLD (AA/ENA/RS) along with 5.0 MW Power Plant and Expansion of existing Sugar unit from 2500 TCD to 8000 TCD (cane crushing capacity) along with expansion of power plant from 6.0 MW to 30 MW. By: M/s N R INFRACON Private Limited (SUGAR UNIT) Formerly known as M/s Kamlapur Chini Mills Address: Village Kamlapur, Tehsil Sidhaouli, Distt. Sitapur, Uttar Pradesh

2 PRE-FEASIBILITY REPORT Introduction M/s N R Infracon Private Limited (Formerly known as M/s Kamlapur Chini Mills and M/s Magna Agro Industries Limited) is an existing sugar mill (the said sugar plant was last operated during season , since then said sugar plant was closed till date). It is an existing 2500 TCD capacity sugar mill. The company has also proposed to setup a distillery plant of 100 KLPD in the same premises of sugar plant. Project Proponent: M/s N R Infracon Private Limited has acquired the sugar unit in action in year 2017 from Honourable High Court of Calcultta. Type of Project: M/s N R Infracon Private Limited (Formerly known as M/s Kamlapur Chi ni Mills) is an agro based company focused on the manufacturer of sugar, power and allied by-products. The proposed plant units will be established in the same premises of the existing sugar industry. The raw materials, molasses and bagasse generated from the sugar plant will be utilized in the proposed distillery and co-gen power plants respectively. To be economically and environmentally sustainable, it is necessary for the sugar industry to convert these by-products into high value products and hence new 100 kld distillery is proposed, for which this EIA study is undertaken. Products of proposed unit are presented in Table 1. Table 1: Products of Unit Sl No. Feature Existing Proposed Total 1 SUGAR PLANT 1.1 Capacity of Sugar 2500 TCD 5500 TCD 8000 TCD Plant (TCD) 1.2 Co-gen Power (MW) 6.0 MW 24.0 MW 30.0 MW 2 Distillery plant 2.1 Molasses based KLD 100 KLD distillery 2.2 Co-Gen Power (MW) MW 5.0 MW The total land area of the project site is acres which is sufficient for existing and proposed activities. The proposed plants will be established in the same premises of the existing sugar industry. The raw materials molasses and bagasse generated from the sugar plant will be utilized in the proposed distillery and co-gen power plants.

3 Purpose of the Project: M/s N R Infracon Private Limited (Formerly known as M/s Kamlapur Chini Mills) has decided for expansion of sugar plant from 2500TCD to 8000 TCD and establishment of new distillery of 100 KLPD in the same premises of existing sugar unit. The Ministry of Environment, Forest and Climate Change (MoEFCC), Government of India has issued an EIA Notification No S.O promulgated on 14 th September, 2006 amended on 1 st December, 2009 vide S.O. No. 3067, under Environmental (Protection) Act, Prior Environmental Clearance (EC) from the EIA Authorities it is mandatory for the establishment of projects/activities listed in the scheduled of above Notification. Sugar industry 5000 TCD cane crushing capacity categorized under Category B of schedule 5(j) and 100 KLPD distillery on molasses based is categorized under Category A of schedule 5(g). Therefore, the Projects require prior Environmental Clearance from the Expert Appraisal Committee (EAC), New Delhi.

4 Site Location: This proposed project is of about acres has a connecting road and has approachability. This site appears to be environmentally best as also from the business angle and therefore this option was finally adopted, including infrastructure optimization. ENVIRONMENTAL SENSITIVITY AROUND 15 KM RADIUS OF THE PROPOSED PROJECT Sr. No. Attributes Details 1- Name of the project Location of the project Village Block Tehsil District State M/s N R Infratech Private Limited (Formerly known as M/s Kamlapur Chini Mills) Kamlapur Kamlapur Sidhaouli Sitapur U.P. Latitude 27 24'44.11"N Longitude 80 49'58.20"E 2- Protected Area No Any 3- Ecological sensitive area Protected area under No sensitive species of Flora/Fauna i. State/National boundaries No ii. Any tourism/pilgrim area No iii. Defense area No Any iv. National Park, Wild Life Sanctuary, Biosphere Reserve, Tiger / Elephant Reserve, Wildlife Corridors, Reserved Forests (RF) / Protected Forests (PF) etc. There is no National Park, Wild Life Sanctuary, Biosphere Reserve, Tiger / Elephant Reserve, Wildlife Corridors, / Protected Forests (PF) with in the 15 km radius of the project site. Protected forest is found in the 15 km radius of the

5 falls within 15 km radius of the plant site. project site: 1.Daudpur Protected Forest 800 m (North South Direction) 4- Environmentally Sensitive Places i. Nearest River Gona River : 1.55 km in North west Direction Sarda Canal : 1.56 km in East direction ii. Nearest railway station Kamlapur Railway Station : 3.87 km south direction iii. Nearest Airport IAF Airstrip BKT : km South Direction Chaudhary Charan Singh International Airport: Km in South direction. iv. District headquarter Sitapur : kms v. Rehabilitation & No any resettlement (R & R) vi. Highway National Highway -24 in 1.80 Km in West direction

6 Location with coordinate: For EIA Study 5.0, 15.0 km radial study area is covered and the is shown on SOI Toposheets 63A/14, 63D/11, 63A/15 in the map below Fig: 1.1&1.2 respectively. Latitude and Longitude of the site at four corners and in the centre given below in Table 2.3 Table; 2: Latitude and longitude of the project site Coordinates Coordinate 1: Latitude: 27 24'49.58"N Longitude: 80 49'48.63"E Coordinate 2: Latitude: 27 24'43.40"N Longitude: 80 50'5.74"E Coordinate3: Latitude: 27 24'20.86"N Longitude: 80 49'58.97"E Coordinate 4: Latitude: 27 24'24.74"N Longitude:80 49'47.60"E Coordinate 5: Latitude: 27 24'44.60"N Longitude: 80 49'59.64"E Direction North West North East South East South West Centre There is no sensitive establishment in the vicinity such as health resort, hospitals, archeological monuments, sanctuaries, no critically/severely polluted areas, eco-sensitive area within 10 km radius of the project site.

7 Coordinate: Latitude: 27 24'49.58"N Longitude: 80 49'48.63"E Coordinate: Latitude: 27 24'43.40"N Longitude: 80 50'5.74"E Coordinate: Latitude: 27 24'24.74"N Longitude: 80 49'47.60"E Figure:1 Showing coordinates of proposed project NR Infracon Private Limited Vill Kamlapur Tehsil Sidhouli, Distt Sitapur. Coordinate: Latitude: 27 24'20.86"N Latitude: Longitude: 80 49'58.97"E 27 24'20.86"N Longitude:

8 Figure:2 Showing Google image of proposed project: NR Infracon Private Limited Vill Kamlapur Tehsil Sidhouli, Distt Sitapur

9 Gona Canal the Closest Distance from The Site Is 1.6 Km Location of Project Site Sarayan River is Located 3.21 Km From The Project Site Shardaa Canal is located 1.4 KM from the Project Site Figure:2 Showing Google image of proposed project: NR Infracon Private Limited Vill Kamlapur Tehsil Sidhouli, Distt Sitapur

10 Toposheet Map Showing 15 Km Radius around the proposed project site Unit Kamalapur Sugar Mill, DaudpurCharsi, Tehsil Sidhauli, Distt. Sitapur (UP). 63A/14 63A/11 63A/15 Picture Showing Topo-sheets involved In Study Area

11 Site Selection Criteria There is an existing sugar mill of 2500TCD capacity which generates molasses and press mud required for existing distillery. These by-products presently being used in existing and proposed distillery. Company intends to increase its profitability by adding more products generated from by-products. Company has enough land for installing manufacturing facilities along with composting facility to ensure a zero discharge project (in case of new distillery project). Project area is in reserve plot of existing sugar mill where raw material, fuel and power will be available Adequate land is available with units to installed manufacturing units using both raw materials and associated pollution control facilities to ensure a zero discharge project Infrastructure facilities like communication and electricity are also closely available. The site is away from the flood plain of major revering system The site is away from metropolitan cities, National parks, wildlife sanctuaries, ecological sensitive areas like tropical forest, biosphere reserve and coastal areas There is no defence installation close to the site The proposed project provides employment opportunities to a large number of rural populations in the region. Location in rural areas benefitting farmers as it is an agro based industry Alternative Sites: Alternative sites have not been considered as this is an expansion project to be executed at existing location based on above site selection criteria. Therefore, no alternative site has been proposed for this expansion of sugar and distillery units. Land Requirement: The project site is fully in possession over the years as the factory is working since long. There is no major river within 1 km radius. The details of factory area, built up area and the area reserved for green belt development is given below. M/s N R Infratech Private Limited (Formerly known as M/s Kamlapur Chini Mills) has about acres of land in its possession to conduct it s for manufacturing activities.

12 100 KLD DISTILLERY UNIT: NEW PROJECT DETAILS M/s N R Infracon Private Limited (Formerly known as M/s Kamlapur Chini Mills)

13 (A) Distillery Industry Augmenting Ethanol Supply Currently, due to very high cost of imported ethanol, the government does not wish to use imported ethanol for the ethanol blending program, hence the focus is on developing domestic production capacities. To augment supply, the government of India has permitted ethanol production directly from sugarcane juice while ensuring that the move does not constrain production of sugar or ethanol for industrial use. The Government of India offering subsidized loans (through sugarcane development funds) to sugar mills for building ethanol production units. The loans would cover a maximum of 40% of the project cost to sugar mills for development of ethanol production unit. Oil companies have stated that during the year 2014, the distilleries could not fulfill their requirement of fuel ethanol for blending and they could get only 50% fuel ethanol for their blending purposes. Recently, for implementing 10% Ethanol. THE ALCOHOL INDUSTRY Ethyl Alcohol, Alcohol, Spirit, Denatured Spirit, there are myriad descriptions for this agriculture-based product. A globally traded commodity, Ethanol fires combustible engines in Brazil, slakes the thirst of many in Europe and finds its way in pharmaceutical and chemical industries, across the world. Ethanol is made by two routes: either by synthetic one from petroleum substances or by fermentation from sugar-bearing or starchy substrates using yeast. Market Potential: Uses of Alcohol Alcohol finds its use in diverse applications ranging from potable liquor to life- saving drugs to paints & perfumery to renewable source of energy. Industrial Alcohol / Solvents Ethyl Alcohol is an important feedstock for the manufacture of various chemicals. These chemicals are primarily the basic carbon based products like Acetic Acid, Butanol, Butadine, Acetic Anhydride, PVC, etc. Ethylenes, Ethylene oxide are also produced from a petrochemical route; however this requires plants of huge scales and thus requires substantially high investments. The drug industry also uses alcohol as a raw material for production of Insulin, Antibiotics, tonics and several other essential bulk drugs & formulations. The following table shows the projected demand for Alcohol for production of chemical in India:

14 Alcohol-based chemical industry Overview The alcohol-based chemical industry began in India in the early 1950s mainly with ethyl alcohol as feedstock in the absence of sufficient petroleum feed stocks. Ethyl alcohol is produced from molasses, which is a byproduct in sugar production. Molasses is a severe pollution hazard, which resulted in the evolution of downstream alcohol-based chemical units. The alcohol-based chemical industry saw rapid growth as the products were not only import substitutes but also available at economical and competitive prices in the country. Growth and present status of the industry The size of the alcohol-based chemical industry is estimated to be in the region of Rs 50 bn. Through licensing and price controls on feedstock, Central and State governments encouraged the alcohol-based chemicals industry. In June 1993, the Union government decontrolled molasses/alcohol to encourage this industry. Presently, there are over 200 alcohol-based products manufactured in India, the single largest alcohol-based chemical being acetic acid. Acetic acid itself is the raw material for the manufacture of several other alcohol-chemicals like ethyl acetate (EA), butyl acetate (BA) acetic anhydride, etc. Ethyl alcohol is also used to produce acetaldehyde and ethylene.

15 Major end use of alcohol-based chemical industries The following are the major end uses of alcohol- based chemical industries in the country: Synthetic fibres and synthetic yarn Drugs and pharmaceuticals Agrochemicals Personal care products Dyestuffs, pigments, flavours and fragrances Textile processing Toiletries and perfumeries Paints and surface coatings Electroplating Synthetic adhesives Plastics and polymers Solvents for inks and lacquer finishes Food preservatives Oilfield chemicals Leather chemicals

16 SUMMARY DISTILLERY: 100 KLD Sr. No. Attributes New Distillery Details 1 Name New 100 KLPD distillery (Rectified Spirit/Extra Neutral alcohol/ethanol) & Power Generation: 5.0 MW. 2 Raw Material Molasses : 320KLD Requirement 3 Product 100 KLPD (Rectified Spirit/Extra Neutral alcohol/ethanol) 4 No. of working days Distillery unit: 360 days /annum 5 Product (power) Power Generation: 5.0 MW. 6 Power Requirement 2.2 MW for 100 KLD Distillery Plant. Additional power will be exported to power grid. 7 By Product No Any 8 Boiler Proposed new: 01 no. of 40.0 TPH (Slop Fired Boiler) 9 Fuel Requirement (For Boiler) Slop : 172 KLD, Bagasse: 20 Tonn/day 10 Steam Requirement 23.0 TPH for 100 KLD Distillery Plant 11 Air Pollution Control System 12 Fresh Water Requirement 13 Source of fresh water 14 Waste Water Generation ESP will be installed with 40.0 TPH slop Fired Boiler along with stack of 65.0 meter height (particulate emission from the stack will be within the permissible limit mg/nm 3.) Water Requirement for distillery unit: KLD (@ 7.0KL/KL of product) ( Net fresh water requirement after recycling) Domestic Water Requirement:20.0 KLD Total water Requirement: 720 KLD Ground water via bore well Distillery unit: Spent Wash KL/KL of Product Other Effluents: 900 KLD (Condensates) 1. For Spent wash treatment : MEE + Incineration (Slop fired Boiler) 2. For Other effluent : Process Condensate Polishing Plant will be

17 15 Solid waste generation and its management installed for treatment of various other effluents (Condensate, Lees, Floor washing, Blow downs). Domestic effluent shall be disposed in Soak pit and Septic tank. Distillery unit : Ash generation: 50 MT/Day: Will be used as manure. Fermenter Sludge: 70.0 MT/Day: Will be used as manure. 16 Total project cost lacks (Estimated) (150 Crores) 17 Cost towards Environmental protection measures (Capital cost) Rs Lakhs 18 Recurring cost towards Environmental control measures. 19 Cost towards Corporate Environmental Responsibility (CER) Rs Lakhs The proposed CER Cost is Rs Crores (1.5% of capital investment), as per office memorandum no. F.No /2017-IA.III dated 1 st May 2018 as project is green field (new distillery project). 20. Employment 150 Persons (For distillery project)

18 Technology and Process Description (a) Molasses Based Operation Technology and Process Description Alcohol production mainly involves three main Processes; A. Fermentation B. Distillation C. Dehydration The process of alcohol manufacturing involve various sections are; Molasses Storage and Handling Section Fermentation Section Distillation for Production of rectified spirit and extra neutral alcohol molecular sieve for production of absolute alcohol. RS/ENA /AA receiver and Storage Section Effluent treatment plant comprising Evaporation plant and incineration for Spent wash treatment and other effluent (Condensates, Spent lees etc) will be treated in Condensate Polishing Unit. Alcohol is produced from carbohydrates by fermentation with yeast. Yeasts are unicellular, uninucleate fungi that can reproduce by budding, fission or both. They have been used for centuries to brew alcoholic beverages and are the most commonly used micro organism in the industrial production of alcohol by fermentation. Ethanol production by fermentation comprises four steps: Yeast propagation from yeast slant from the laboratory. Fermentation to produce fermented wash containing alcohol. Recovery, enrichment and purification of alcohol from fermented wash to produce 95.5 V/V alcohol. Production of absolute alcohol by dehydration of 95.5% V/V alcohol to produce absolute alcohol. A proper choice of appropriate technology in each of these steps governs the efficient and viable operation of fermentation alcohol plant.

19 Yeast Propagation: Yeast, for the production of alcohol is characterized by high selectivity of the yeast species, low production of by-products (side products), high ethanol yield, high fermentation rate, good tolerance towards both high ethanol concentration and high in organics in the fermenting substrate, high temperature tolerance, land high genetically stability. Although finding a strain that has all these characteristics is difficult, a proper selection and development of the best possible strain is needed. Saccharomyces Cerevisiae and Sacharomycetes pombe are the commonly deployed yeast strains in alcohol fermentation of sugars. The purity and sterility of yeast culture used as inoculums have great influence on the alcohol yield and longevity of yeast in fermenter. Flocculating yeasts are deployed for continuous fermentation particularly with yeast recycle system. The selectivity of yeast is also essential to maintain the required metabolic reaction pathways specific to conversion of sugars to alcohol. The side products are higher alcohols, acids, etc. which naturally reduce the alcohol yields and final quality of alcohol. It is, therefore, customary to propagate yeast from laboratory strain in increasing volumes under sterile and aerobic conditions protecting the same from other wild yeasts and moulds during their growth. This is done in 3 or four stages starting from a 1lit inoculums developed in laboratory from a well preserved yeast culture slant. Yeast will be developed in plant from fresh slant to laboratory flash culture and then in 3 stage S.S. yeast propagation vessels which operate in series but in batch mode. When enough bio mass strength is developed, it is pitched Into Fermenter. B) Fermentation The yeast propagation is only at the start and stabilization of the fermenter. When once the continuous fermentation is on, the yeast propagation is stopped and only a periodic continuous addition of small make up of fresh culture from yeast vessel is done to maintain the activity of yeast in the active yeast count in the fermenter. The yeast vessels are fitted with jacket for sterilizing and cooling the medium in situ. Sterile air is supplied to these vessels through compressor and the sterilization-system comprising a series of fine filters followed by HEPA filters. Molasses from the molasses tank in the yard are pumped to transfer pump into tipper type molasses weighing system and weighed molasses feed tank from where molasses feed pump it to yeast vessels (when necessary) or to fermenter through a static mixer type molasses diluter. Main fermenter could be one or two stages depending on the control system envisaged based on

20 the final designs. The heat of fermentation is extracted by circulating the fermenter contents through wort coolers. Temperature in the fermenter is to be maintained at C. Carbon dioxide evolved during fermentation is vented out through scrubber to recover entrained alcohol vapors. Dilute molasses are fed to the fermenter continuously. The final fermented wash is transferred by wash pump to yeast separation system comprising hydrocolones and centrifuge. The sludge and dead yeast are purged into sludge tank and yeast cream is returned to the fermenter while clear fermented wash is collected in wash tank. Sludge from sludge tank is fed to the bottom of Analyzer Column in the distillation section. Part of spent wash from a selected tray in the column C-01 is returned to fermenter after cooling the same to as near to ambient temperature as possible. Anti-foam oil is added from whenever necessary when the level in the fermenter rises beyond a limit due to foaming because of runaway fermentation rate. The operations in the fermenter can be controlled closely through automation. Process water is taken into scrubber water tank from where it is fed to scrubber and overhead water tank by water pump. All process water in the fermentation section is supplied by gravity from this overhead tank. C) Rectified /ENA Spirit 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 vapors along with non-condensable gases from the top of degassing column are rectified in Heads column, to expel the high volatiles, technically know 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 spent wash discharge pump through heat exchanger where it preheats the fermented wash before it enters degassing column. Part of spent wash from a tray, few numbers above the bottom tray is cooled and returned to the fermenters as a measure of water saving and reduction of effluent discharge. The dilute alcohol vapors 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 is collected in Rectifier Feed Tank. The vapors for stripping alcohol are generated from analyzer column bottom liquid in the analyzer column re-boiler by using the rectified column top vapors, as discussed subsequently. Vapors from the top of heads column are condensed in heads column condenser and then in head column vent

21 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 column 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 vapors can supply the necessary heat for generating the vapors. The condensate from Analyzer 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 analyzer and reflux vent condenser are collected in Rectifier Reflux Tank. Part of the liquid from reflux vent condenser 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 vapors to Rectifying column are generated by boiling the bottom liquid in Rectifier Column Reboiler 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 from High column vent condenser, analyzer condenser, rectified feed tank and reflux vent condenser 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 fusel oils in fusel oil separator to recover alcohol from the fusel oil fractions. The absorber vent is connected to vacuum pump which is used to create vacuum in the analyzer and degasser. The products Rectified Spirit and Impure Spirit, are cooled in product coolers and collected in the respective receiver tanks prior to pumping the same through respective transfer pumps into storage tanks in the excise godown. Impure spirit, is however, returned to Ethanol plant along with the rectified spirit feed, subject to maintaining, the Absolute Alcohol quality required for blending with petrol.

22 D) Fuel Grade Ethanol Absolute alcohol is manufactured by dehydration of Rectified Spirit. The process adopted here is based on Pressure Swing Adsorption (PSA) system using Molecular Sieves. The flow scheme is shown in above referred flow diagram. Rectified spirit, after preheating by waste hot streams, is vaporized and superheated in analyser condenser and analyser by using medium pressure steam at 6 Kg/cm 2 g pressure. Hot vapors at kg/cm² g pressure and 130 C temperature pass through PSA column, where the water vapors are retained while water free alcohol is released as vapors. The vapors are condensed in high column vent condenser and Rectified column reboiler and collected as Absolute Alcohol. When the molecular sieve bed is saturated with water the alcohol vapors 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 vapors from the tower in dehydration operation. The vapors are condensed in Head column condenser and reflux vent condenser and the vent vapors are recovered through scrubber degassing column. Vacuum can be created vacuum by rectified feed pump. (Eductor may also be considered for this duty). Product is cooled in fusel oil cooler and transferred to Absolute Alcohol receiving tank and then on to storage tank.

23 Water Requirement: (100 KLD Distillery) Fresh Water Requirement Fresh Water Requirement (=720 KLPD) 700KLD 7.0 KL/KL of Purposes Product Domestic 20 KLD Purposes Source Ground water (from Tube well) Waste water generation and treatment strategy: Waste Water Spent Wash 6.0 KL/KL of Product Generation Other Effluents: KLD (Condensates) Effluent Treatment For Spent wash : MEE + Incineration Technology (Slop fired Boiler) (ZLD BASED) For Other effluent : Process Condensate Polishing Plant will be installed for treatment of various other effluents (Condensate, Lees, Floor washing, Blow downs). Domestic effluent shall be disposed in Soak pit and Septic tank.

24 WATER BALANCE FOR 100 KLD DISTILLERY UNIT

25 SUGAR UNIT: EXPANSION PROJECT DETAILS M/s N R Infracon Private Limited (Formerly known as M/s Kamlapur Chini Mills) has proposed modernization/expansion of sugar plant from 2500 TCD to 8000 TCD Along with expansion of power plant from 6.0 MW to 30 MW.

26 Importance to the Country and Region: (A) Sugar Industry The Indian sugar industry is passing through a difficult period. The sugar price in the Indian/World market is low. On the other hand, the cost of the raw material the sugarcane keeps increasing every year and so is the production cost. The sugar industry can hope to come out of these situations only by cutting down the cost of production and by adopting energy efficient processing and this justifies going in for higher and more efficient system are as follows: India needs sugar, alcohol and power on regular basis. Alcohol saves petrol (additives) and also foreign exchange saver-earner. Condensate water can be used for boiler and process. Consume bagasse and molasses, which otherwise is an environmental risk. The world s largest consumers of sugar are India, China, Brazil, USA, Russia to Mexico, Pakistan, Indonesia, Germany and Egypt. Brazil and India are the largest sugar producing countries followed by China, USA, Thailand, Australia, Mexico, Pakistan, France and Germany. The world consumption was projected to grow to 160 MMT in 2010 and 172 MMT by India is predominant an agro based economy. Sugarcane plays a very vital role in this agro based economy by providing sugar, the main sweeter used in India. With the growing demand for sugar, the emphasis has been on increasing sugar production. Due to the switching over from other sweetening agents to sugar, the effect of population growth and increase in per capital consumption, the sugar consumption is likely to increase. Hence, there is a lot of scope for increasing the sugar manufacturing infrastructure, hence further addition of sugar manufacturing infrastructure is envisaged in India. The economical size of the sugar plants is shifting from 2500 TCD to 8000 TCD considering mainly the cost of production and economical self sufficient own stream industries. The ever growing energy demand and the steep depletion of fossil fuels directed us to explore the possibility of developing other sources of energy particularly from non-conventional renewable energy sources, which is also environmental friendly. Further, it is an undisputed fact that the present level of generation of power from Hydel, Thermal and Nuclear sources could not meet the increasing demand due to various problems. Power interruption leads to unplanned shut down and consequences are excess consumptions of utilities, compromise in quality of sugar and overall increasing in manufacturing costs. Hence, it was decided to utilize bagasse produced in this sugar mill for cogeneration of power. The sugar industry generates large quantities of by-products viz. bagasse, molasses and press mud. To be economically and environmentally sustainable it is necessary for the sugar industries to convert these by-products into high value products. Thus, the proposed plant will be established in the same premises of the existing sugar mill. The raw materials molasses and

27 bagasse generated from the sugar mill will be utilized in the proposed distillery and co-gen power plant, respectively. In order to reduce the green house gas emission, the non-conventional energy is to be utilized for the generation of electricity. One of the non-conventional renewable energy sources is bagasse. So the ministry of non-conventional energy, Government of India encourages sugar mills for bagasse based co-generation by increasing the various subsidies. Bagasse based cogeneration in sugar mills eminently fits in as a desirable source of augmenting the power generation as it has following merits: Bagasse based cogeneration is environment friendly as it does not add to the existing pollution level of the environment due to carbon recycling It is a renewable source of energy resulting into reduced dependence on fossil fuels There is no need to transport the fuel to the generating stations as the sugarcane in any case is transported to the factories It helps in bridging the gap between the demand and supply in the power sector to some extent It has lower gestation period and lower installation and operating cost compared to the conventional utility thermal plants The project land is in possession of promoters and there are no rehabilitation resettlement issues. There is no litigation pending against the proposed project.

28 SUGAR MANUFACTURING PROCESS TECHNOLOGY Indian sugar industry is engaged mainly in the production of direct consumption commercial plantation white sugar (99.8 % pure) sugar is produced in vacuum pan factories. Sugar production process mainly comprises of following five operations. 1. Extraction of juice (Crushing) 2. Clarification of juice 3. Concentration of juice (Juice to syrup) by evaporation 4. Boiling of Syrup to grain (Crystallization) 5. Separation of crystals from mother liquor (Centrifuging) Cane receiving: The sugar cane in the field is examined for its quality before harvesting and harvesting permits are given after its quality and maturity is found satisfactory. The sugar cane is then manually harvested and transported to factory by tractor trailers, trucks and bullock carts. The farmers are supplied with steel wire rope slings to be placed below the cane in the vehicles to enable unloading by cranes. The vehicles bringing sugar cane are received at the factory cane yard. Sugarcane Weighment: The vehicles carrying the sugar cane are weighed on the platform type electronic weighbridges and released for unloading. The gross weight is recorded and printed. After unloading the vehicles are once again weighed for the tare weight. These weights are printed on the weighment slips, which also carry the details of the farmer, cane etc. Sugarcane Unloading: The cart cane is manually unloaded directly to the cane carrier. The cane from the trucks and tractor- trailers are unloaded with the help of cane un-loader crane. The cane is unloaded on to the feeder table. Sugarcane Conveying: The cane from the feeder table is then dumped to the main cane carrier, which conveys the cane to the cane preparatory devices. Electronic devices, depending on the cane-crushing rate control the speed of the cane carrier, and level in the cane carrier etc. Sugarcane preparation:

29 The sugar cane is passed through the cane preparatory devices called leveler, cutter and fibriser where in the cane is cut into small pieces to expose the juice cells for extraction. The preparatory index is about %. Milling: The prepared cane then passes through the milling tandem having 4 mills of three roller & necessary feeding device. The mills run at about 4.5 to 6.0 RPM driven through hydraulic motors or DC variable speed drives. The mills loaded hydraulically extract juice from the cane and is subjected for the extraction of juice aided by maceration water and compound imbibition. The cane is conveyed between mills with the help of rake type mechanical conveyors. Screens then filter the extracted juice and filtered juice is pumped for further processing. The fibrous residue after juice extraction known as bagasse is withdrawn from the last mill and conveyed through drag type steel conveyors to boiler for steam generation. Surplus bagasse is withdrawn from the conveyor and stored for reuse when necessary. The bagasse conveyor also has return conveyor to feed the stored bagasse. Juice clarification: The mixed juice received from milling after filtration is weighed in a juice weighing scale or by a mass flow meter to know the quantity of juice flowing. The juice contains certain undesirable impurities, which are removed before it is taken for concentration in evaporators. The juice is first heated to a temperature of 70 C in a tubular type vertical heater by using heat of vapours from the third effect of a quintuple effect evaporator. The use of third effect vapours resulted in steam economy. The hot juice is then mixed with lime and sulphur dioxide gas maintaining a ph of 7.0. This process is carried out in a reaction vessel known as juice sulphiter. Any SO 2 gas coming out of the vessel is again scrubbed though juice and no gas is allowed to atmosphere. The treated juice is again heated to a temperature of 105 C in a similar tubular type heater using vapours from second and first effect of evaporators. The heated sulfated juice is then sent to a gravity settler known as clarifier wherein the mud flocs and settles. Chemical settling aids like Magnafloc, Sedipur or Separan may be added to improve settling rate.

30 The mud settled at bottom of each of the four compartments in the clarifier is withdrawn continuously and is filtered in a rotary vacuum filter. The filtered mud after washing and removing residual juice in the filter is scraped from the filter drum and sent out. Fine bagasse is mixed with muddy juice as filter aid. The filtrate juice is returned to the raw juice tank and recirculated. The mud is used as manure in fields because of its nutrient value. Evaporation: The clarified clear juice is withdrawn from the clarifier continuously & sent to evaporators after heating the juice further to 115 C in a plate type heater. The evaporators consist of five evaporator bodies arranged to work in series as a quintuple effect. The exhaust steam or the bled steam from steam turbines at powerhouse is supplied to the first body of the evaporator for heating. The vapours from second body are bled to pans for boiling. The raw juice heating is done with the vapours bled from 3rd effect, sulfated juice with vapours from 2 nd and 1st effects of the evaporators. This type of quintuple effect evaporation and vapour bleeding achieves good steam economy. The exhaust steam condensate from the first body is withdrawn & sent to boiler condensate storage tank for use as boiler feed water. The condensate from all other evaporators is withdrawn individually and sent to hot water storage tank for use in various processes. The clear juice gets concentrated from a brix of 15 to 60 % and is withdrawn continuously from 5th body of the evaporators. The syrup thus, obtained from evaporators is passed through a continuous syrup sulphiter wherein SO2 gas is bubbled through syrup for bleaching purpose. The spurted syrup is then sent to pan floor storage tanks for further boiling. Pan boiling: A three stage boiling scheme is adopted to produce quality sugar with minimum sugar loss. The first massecuite (A -massecuite, sugar plus mother liquor) is boiled on hopper seed footing, syrup, melt, and A-light molasses. A-heavy molasses is used for boiling B- massecuite& A-light molasses is taken for A-massecuite boiling. C- Massecuite is boiled using true seed along with B-heavy molasses and C-light molasses for complete exhaustion. B-massecuite is boiled using double cured C -sugar magma. This sugar is taken as seed for A- boiling and surplus is melted and used along with A-light molasses and syrup to boil A-

31 massecuite. The pans used for A-boiling are low head calandria type batch pans and for B and C boiling are fully automated continuous pans. Cooling and curing: The process of crystallization initiated in the pan is completed in the crystallizer (storage tank with mechanical stirring arrangement and air or water cooling arrangement). Aircooled crystallizers are used for A-massecuite and water- cooled continuous type vertical crystallizers are used for B and C massecuites. A- massecuite is centrifuged in a fully automated high-speed batch type centrifugal machine to separate sugar and molasses. The sugar is washed with super heated water in the machine to get good quality white crystal sugar. The sugar is then discharged by a plough in the machine and dropped to a grasshopper conveyor. The hopper is provided with facility to dry and cool the sugar before graining. The heavy and light molasses separated in the centrifugal are sent back for reprocessing at pans. Continuous centrifugal machines are used for centrifuging B and C massecuites. The B- massecuite is cured in continuous centrifugal machines to separate B- heavy molasses and B- sugar. B-sugar thus obtained (B-fore sugar) is again made into magma with water and cured in a continuous centrifugal machine to separate B-light molasses and B- after sugar. Similarly C-massecuite is double cured in continuous centrifugal machines. The fore-worker molasses is the final molasses, which is sent to steel storage tanks. C-double cured sugar is melted and used for boiling B-massecuite. The sugar discharged from A- centrifugal machines is conveyed through grasshopper conveyors wherein drying and cooling arrangements are provided. Sugar then passes through mechanical graders where the sugar is graded as per their sizes to confirm to the IS standard. The graded sugar is then sent to sugar storage bins with the help of bucket elevators.

32 Manufacturing process Flow Chart

33 M/s N R INFRACON Private Limited (SUGAR UNIT) Formerly known as M/s Kamlapur Chini Mills Address: Village Kamlapur, Tehsil Sidhaouli, Distt. Sitapur, Uttar Pradesh Sr. No. Attributes Project Details 1. Name of the project 2. Location of the project 3. Project Justification M/s N R Infracon Private Limited (Formerly known as M/s Kamlapur Chini Mills) has proposed modernization/expansion of sugar plant from 2500 TCD to 8000 TCD. Along with expansion of power plant from 6.0 MW to 30 MW. Village Kamlapur, Tehsil Sidhaouli, Distt. Sitapur, Uttar Pradesh Revenue will be generated for the state government. Employment will be provided to eligible people of the state. Increase in Local Business Standard of Living of people will increase. Lead to growth in income. 4. Project Area Unit has allotted acre land area 5. Total project cost Total Project Cost : Lacs (for Sugar expansion) 6. No. of working days 7. Green belt development 170 Days/Annum 33 % of Total Project area (24.46 acre)

34 Project Details Sr. No. Attributes Sugar Expansion Details 1 Name Unit has proposed modernization/ expansion of sugar plant from 2500 TCD to 8000 TCD. along with expansion of power plant from 6.0 MW to 30.0 MW 2 Raw Material Sugar cane : 8000 TCD Requirement 3 Product White Crystal Sugar 928 MT/Day 4 No. of working days Sugar unit: 180 days/annum 5 Product (power) Expansion of power plant from 6.0 MW to 30.0 MW 6 Power Requirement 12.5 MW for 8000 TCD Sugar Plant Additional power will be exported to power grid. 7 By Product Molasses : 380 MT/Day Bagasse:2304 TPD Pressmud:280 TPD 8 Boiler 75.0 TPH Boiler (existing) TPH Boiler (new) 9 Fuel Requirement (For Boiler) Bagasse: 28.0 TPH will be used as fuel for existing 75.0 TPH boiler. Bagasse: 50.0 TPH will be used as fuel for new 100 TPH Boiler 10 Steam Requirement 146 TPH for 8000 TCD Sugar plant 11 Air Pollution Control System 12 Fresh Water Requirement 13 Source of fresh water 14 Waste Water Generation ESP will be installed with Stack of height 65.0 meters in order to control dust emissions from TPH Boiler. Wet scrubber is installed with existing Stack of 55.0 meters height with existing 75.0 TPH Boiler. Water Requirement for sugar unit:(for 8000 TCD) KLD (@ 0.20 KL/KL of product) ( Net fresh water requirement after recycling) Domestic Water Requirement:50.0 KLD Total water Requirement: 1650 KLD Ground water via bore well Sugar Unit : For industrial effluents: 1180 KLD For proper treatment of effluent ETP up-to tertiary level will be modified.

35 580 KLD treated water will be discharged. 600 KLD will be recycled in process and in various other sections. NOTE: 50% treated water will be recycled back in process and As per GSR35(E) dated i.e. Environmental Standards for Sugar Industry. We will discharge 50% of treated effluent of B.O.D less than30 milligram per liter in surface water. For Domestic waste: Unit will install new 40 KLD sewage treatment plant (STP). 15 Solid waste generation and its management Sugar unit: Parti cular Quan tity Ash 19.0 gener MT/ ation Day Management Ash generated will be utilized as manure due to high organic and potash content. 16 Total project cost Total Project Cost : Lacs (for Sugar expansion) 17 Cost towards Environmental protection measures (Capital cost) Rs Lakhs 18 Recurring cost towards Environmental control measures. 19 Cost towards Corporate Environmental Responsibility (CER) Rs Lakhs 20. Employment 500 Persons (For sugar unit) The proposed CER Cost is Rs Crores (1.5% of capital investment), as per office memorandum no. F.No /2017-IA.III dated 1 st May 2018 as project is green field (new distillery project).

36 WATER BALANCE: SUGAR UNIT 8000 TCD

37 Waste water treatment scheme: For industrial effluents: For proper treatment of effluent ETP up-to tertiary level is will be modified. 580 KLD treated water will be discharged. 600 KLD will be recycled in process and in various other sections. NOTE: 50% treated water will be recycled back in process and As per GSR35(E) dated i.e. Environmental Standards for Sugar Industry. We will discharge 50% of treated effluent of B.O.D less than30 milligram per liter in surface water. For Domestic waste: Unit will install new 40 KLD sewage treatment plant (STP).