PRE FEASIBILITY REPORT 1.0 EXECUTIVE SUMMARY AND INTRODUCTION OF THE PROJECT

Transcription

1 PRE FEASIBILITY REPORT 1.0 EXECUTIVE SUMMARY AND INTRODUCTION OF THE PROJECT Shri Dudhganga Vedganga Sahakari Sakhar Karkhana Limited, (SDVSSKL) located at Bidri (Mouninagar), Tal.: Kagal, Dist.: Kolhapur, Maharashtra State was registered vide Registration : G-279 dated The SDVSSKL have planned to go for expansion of Sugar Factory from 5000 TCD to TCD (expansion by 5000 TCD), & establishment of 75 KLPD Molasses based Distillery in its existing premises of its sugar factory (500TCD) and Co-gen plant (20 MW). As per the provision of EIA Notification S. O (E) dated ; and amendments thereto; the proposed projects comes under Category A for Item Nos. 5(j) and 5 (g). Sugar cane will be available with 10 to 15 Km radius area. Promoters of SDVSSKL are well experienced in relevant fields and have made a thorough study of the overall project planning and implementation with prime objective towards development of the area and its economy. Molasses is a very important by-product of the sugar industry. Profits earned by conversion of molasses into alcohol are much higher than that of resale of molasses alone. Moreover, there is a good demand for alcohol in the country as production and consumption of alcohol in India are quite balanced. Also, there is a good export potential, out of the country, for the alcohol. 1.1 Need of the Project The sugar industry in India is well maintained and growing at a steady pace, boasting of a consumer base of over billions of people. India is the second largest producer of sugar in the world. With more than 45 millions of sugarcane growers in the country, the bulk of rural population in India depends on this industry. One of the agro-based enterprises in India, sugar manufacturing is the second largest agricultural industry, after the textile sector. Sugar manufacturing in Maharashtra is one of the most notable sectors in the country. The pace of growth of this industry has been massive over the past few years. Most of the sugar units have by-product utilization plants, based on bagasse and molasses. Ethanol, power and paper projects have tremendous scope for development in India. In near future, about 10-15% ethanol may be allowed to be blended with petrol. Thus, alcohol production from molasses has the most promising prospects. Bagasse based power generation projects, installed in the premises of sugar factory, not only fulfill captive need of the industry but also make available surplus power which could be exported in the grid thereby providing value addition. Distillery business is gaining more importance with regards to production, usage, easy availability of raw material (grains as maize, sugarcane molasses). With the increase in business it has a considerable share in national income. Alcohol industry is the second largest source of revenue of the state. The industry is probably only one in which the inputs are decontrolled, but selling prices are determined by local state levies and excise duties. 1.2 Employment Generation Potential Main Products of economically importance & Secondary Products for value addition are manufactured that include; Sugar, Molasses, Bagasse, Alcohol, Power etc. The economy & 1

2 developments as a result of projects such as sugar factory, distillery, power, etc. The activities in proposed expansion industry would improve the socio-economic status of people in the study area in terms of local labor employment and contract basis jobs. The proposed and expansion activity might provide opportunities to the local populace, especially in business and other services. The improved employment potential & development of infrastructure are direct benefits resulting out of the projects. 2.0 PROJECT DESCRIPTION 2.1 Location Shri Dudhganga Vedganga Sahakari Sakhar Karkhana Ltd. is located at Bidri (Mouninagar), Tal.: Kagal, Dist.: Kolhapur, Maharashtra State. Project Co-ordinates of 4 corner of plot are as follows, i. Latitude '24.09"N Longitude '59.96"E ii. Latitude '53.29"N Longitude '59.08"E iii. Latitude '30.52"N Longitude '58.95"E iv. Latitude '30.67"N Longitude '59.77"E 2.2 Site Selection The expansion of Sugar factory and establishment of Distillery would be implemented in the existing factory premises of SDVSSKL. The favorable aspects of proposed project are- 1. Availability of excess cane for crushing in sugar factory from the operational area. 2. Availability of adequate quantity of water and electricity for the proposed project. 3. The nearest city is Kagal 25 km away from the project site which is very well connected with other parts of the country by roads. 4. No rehabilitation and resettlement shall be required. 2.3 Alternative Site Proposed expansion of sugar factory as well as establishment of distillery would be implemented in the existing factory premises; hence no any alternative sites were examined. 2.4 The Products & Raw Materials Different products to be manufactured under existing & expansion activity and their maximum production quantities are as under- Table 1 List of Product Sr. Quantity Name of Product Existing After Expansion 1. Sugar (MT/ M) Molasses (MT/ M) Bagasse (MT/ M) Press Mud (MT/ M)

3 Sr. Quantity Name of Product Existing After Expansion 5. Electricity (MW) Rectified Spirit (RS) (KLPD) Ethanol (KLPD) ENA (KLPD) 0 75 Sr. Name of Raw Material Table 2 List of Raw Material Existing Quantity MT/M Expansion Quantity MT/M Total Quantity MT/M 1. Sugarcane Lime Sulphur Lubricants Investment Table 3 Capital Investment Sr. Project Name Existing After Expansion 1. Sugar & Co-gen Distillery Total cost Size / Magnitude of Operation Based on availability of sugarcane in its area of operation, the management of SDVSSKL has planned to go for expansion of the existing sugar factory (5000 TCD) and establishment of 75 KLPD molasses based distillery. 2.7 Process Details Sugarcane, which is used as a raw material in sugar factory, is grown in the field and harvested according to the maturity survey and date of plantation after ensuring maximum sugar content in the cane. Harvesting may be done either manually or mechanically. Thereafter, the cane is transported to the factory. Sugarcane is unloaded mechanically on cane carrier and subjected to different units like crushing mills, raw juice extraction & its processing, weighment of the juice, juice heater, clarifier, evaporator, pan boiling, crystallizer and ultimately centrifuge to obtain final product. Manufacturing of Rectified Spirit (RS), Ethanol and Extra Neutral Alcohol (ENA) through molasses route comprises of a number of operations and processes involving various reactions of basic raw materials. Eventually, the desired products are formed which are refined and separated. 2.8 Resource Optimization/ Recycling and Reuse All the manufacturing units in SDVSSKL have been designed in versatile fashion by adopting latest process techniques as well as with state-of-the art machinery. 3

4 Effluent from existing as well as expansion activity of sugar factory & co-gen plant would be treated in ETP Duly upgraded after expansion. Entire treated effluent quantity shall be used for irrigation of own factory land as well as given to nearby farm lands. Under the proposed distillery, raw spentwash will be concentrated in Multiple Effective Evaporator (MEE). Conc. spent wash will be burnt in incineration boiler. Condensate from MEE, spent lees and other effluents such as - cooling blow down, boiler blow down, lab & washing effluent will be treat in proposed Condensate Polishing Unit (CPU). Treated water from CPU will be recycled back in process. 2.9 Input Requirements and Infrastructure Facilities including Power Sources Water Water requirement for existing 5000 TCD sugar factory & 20 MW co-gen plant of SDVSSKL is 3490 M 3 /D. After expansion total water requirement for TCD sugar factory and 20 MW Co-gen would be 2993 M 3 /D, out of which 2600 M 3 /D would be cane condensate, 344 M 3 /D would be fresh water taken from Dudhganga river and 49 M 3 /D would be treated water from sugar ETP which shall be used for Gardening. Table 4 Water Consumption in 10,000 TCD Sugar Factory & 20 MW Co-gen Plant Sr. Description Unit Existing After Expansion 1 Domestic M 3 /D 89 #89 2 Industrial i Process M 3 /D 1040 *1850 ii Cooling Makeup M 3 /D *720 iii Boiler Makeup M 3 /D #165 iv DM Backwash M 3 /D 2336 #90 v Washing M 3 /D *20 vi Ash Quenching M 3 /D *10 Total M 3 /D (* #255) 3 Gardning & Green Belt M 3 /D 25 $ 49 4 Grand Total M 3 /D (* #344 + $ 49 ) Note: - * - Sugar cane condensate, # - Fresh water taken from water source, $- Treated water from ETP For proposed 75 KLPD molasses based distillery total water requirement would be 819 M 3 /D. Out of which, 10 M 3 /D would be used for domestic purpose and 809 M 3 /D would be used for industrial purpose. Out of 809 M 3 /D, 565 M 3 /D would be MEE condensate water and 244 M 3 /D will be fresh water taken from Dudhganga River. Table 5 Water Consumption in 75 KLPD Distillery of SDVSSKL Sr. Description Unit Proposed Distillery 1 Domestic M 3 /D # 10 4

5 2 Industrial i Fermentation dilution M 3 /D 596 ( # ) ii Cooling Tower Make up M 3 /D # 160 iii Water for vacuum pump, pump M 3 /D # 10 sealing, air blower & others iv Boiler Makeup M 3 /D # 41 v Ash quenching M 3 /D # 2 Total M 3 /D 809 ( # ) 3 Gardening & Green Belt M 3 /D 0 4 Grand Total M 3 /D 819 ( # ) Fuel Under existing project activities, bagasse to the tune of MT/D is used as fuel for 120 TPH boiler and diesel to the tune of 100 Lit./Hr. is used for 1500 KVA DG set. Under proposed distillery project a new incineration boiler of 30 TPH shall be installed. Concentrated spentwash 120 MT/D blended with coal 70 MT/D would be used as fuel for same. Power Electricity required for manufacturing operations shall be met from existing 20 MW cogeneration plant and DG set in case of power failure. Manpower Under existing sugar factory and co-gen plant, about 569 number of skilled and unskilled worker are appointed. Under proposed establishment project, about 84 number of skilled and unskilled worker are appointed. Preference is given to persons from local area thereby creating better employment opportunities Environmental Aspects under the Project A) Effluents i) Domestic Effluent- Total domestic effluent generated from SDVSSKL project complex would be 80 M 3 /D (Domestic effluent from Sugar factory and Co-gen plant - 72 M 3 /D and from Distillery - of 8 M 3 /D) same will be treated in proposed Sewage Treatment Plant (STP). ii) Industrial Effluent- Total industrial effluent generated from expansion of sugar factory & co-gen plant would be 878 M 3 /D. same will be treated in Effluent Treatment Plant (ETP). Treated water from ETP will be used for gardening on own land as well as for irrigation in nearby farmlands. Details of wastewater generation under existing and proposed operations are as follows- 5

6 Table 6 Effluent generation from Sugar factory & Co-gen plant Sr. Source Unit Quantity Disposal Method 1 Domestic M 3 /D Industrial iprocess M 3 /D iicooling Blowdown M 3 /D 50 iiiboiler Blowdown M 3 /D ivwashing M 3 /D 20 3 Total M 3 /D Grand Total M 3 /D Effluent generated from proposed distillery activities would be in the form of spent wash, spentlees & other effluents namely boiler & cooling blow downs, effluents from washings etc. Raw spentwash to the tune of 600 M 3 /D would be concentrated in MEE. Conc. spentwash to the tune of 120 M 3 /D will be burnt in incineration boiler along with coal. Spentlees to the tune of 107 M 3 /D, MEE condensate to the tune of 600 M 3 /D and other effluents to the tune of 40 M 3 /D would be treat in proposed CPU. Treated water from the CPU shall be then reused for industrial operations. Thereby achieving Zero Liquid Discharge (ZLD) of process effluent. Sr. Industrial 1 Process Table 7 Effluent generation from proposed Distillery Source Unit Quantity Disposal Method M 3 /D 600 Raw Spent wash 120 Conc. Sp. wash MEE Incineration 107 Spent Leese 2 Boiler Blow Down M 3 /D 14 3 Cooling Tower Blow M 3 /D 16 Proposed CPU 4 Washing M 3 /D 10 Domestic 1 Domestic M 3 /D 8 Proposed STP B) The Emissions Steam required for sugar factory and co-gen plant would be met from existing 120 TPH Bagasse fired boiler. ESP would be provided as APC along with a stack of 80 M height. No new boiler shall be installed under sugar factoy expansion. Moreover, under proposed distillery an incineration boiler of capacity 30 TPH would be installed on site. For which concentrated spentwash (120 MT/D) blended with coal (70 MT/D) would be used as fuel. ESP would be installed as APC along with a stack of 71 M height. A DG set of capacity 1500 KVA is installed on site. HSD to the tune of 100 Lit./H. is used as fuel for the same. DG sets will be operated only during power failure situations. No new DG set will be installed under expansion. 6

7 C) Fugitive Emissions Fugitive emission under existing and expansion activities of sugar factory shall be mainly the dust emissions. Sources of same are mill house, sugar bagging, bagasse yard, pressmud yard, internal kuccha roads, bagasse conveyor; feeding section and ash storage yard in co-gen plant, improper function of APC equipment etc. An action plan has been prepared in the industry that includes proper exhaust and ventilation arrangements, monitoring of proper working of pollution control equipment, proper handling; storage and disposal of dust collected, use of PPEs for staff and workers, augmentation of existing green belt with adequate density and type to control and attenuate dust transfer in the premises, provision of properly surfaced internal roads and work premises (tarred and concrete). D) Noise Pollution Aspect The source of noise generation would be cane carrier, mills, pumps, compressors, boiler house distillation assembly etc. Trucks will be used for transportation of sugarcane and raw material as well as finished product. Noise generated from transportation is a fleeting source. All preventive measures such as regular operation & maintenance of pumps, motors, and compressors will be carried out and enclosures will be provided to abate noise levels at source. Workers would be provided with earmuffs and other Personal Protective Equipments (PPE) which would give the reduction of 30 db (A). E) Solid Wastes Solid wastes generated from the proposed project are categorized as Hazardous and Non- Hazardous Wastes. Table 7 Non-Hazardous Wastes Sr. Type of Waste Quantity Disposal 1. Ash 74.7 MT/D. Sell to brick manufacture 2. Yeast Sludge 12.5 KL/D. 3. CPU Sludge 31.4 MT/ D. Incinerate 4. ETP sludge 5 MT/M Used as manure 5. Discarded Containers 200 s/ Y Reprocessed through Authorized Dealer F) Hazardous Waste Table 8 Hazardous Wastes Sr. Description Quantity Mode of Disposal 1. Cat. 5.1 Spent Oil 1 MT/Y Burnt with bagasse in Co-gen boiler 3.0 SITE ANALYSIS 3.1. Connectivity: 7

8 Proposed expansion project would be implemented in the existing premises of SDVSSKL at Bidri (Mouninagar), Tal.: Kagal, Dist.: Kolhapur. Site is located at a rural surrounding and its nearest railway station & airport is Kolhapur, located at about 32 Km. 30 Km from the proposed site Land Form, Land Use and Ownership: The terrain of the study area varies (from 540Mtr. to 930Mtr.) due to presence of Western Ghat ranges and no prime agricultural land is sacrificed since it is expansion of sugar factory & establishment of distillery project. The entire premise is owned by SDVSSKL Topography General topography of the area is undulating. River Dudhganga (North West) and Vedganga (South East) are the major source of water in the study area Existing Land Use Pattern: Existing land use pattern of the study area is taken from Census Book of 2011 which is mentioned as below, Name Of Taluka Table 9 Land Use / Land Cover Categories of Study Area Geographic al Area (Ha) Forest (Ha) Land under Cultivation (Ha) Irrigated Non irrigated Culturable Waste land (Ha) Area Not available for Cultivation Kagal Total Percentage of total area (%) Existing Infrastructure: Total land acquired by SDVSSKL is Hectors. Out of this, built up area of project is 6.65 Ha. For expansion and proposed establishment activities, construction of new buildings and allied infrastructure installation shall be done. After procurement of Environmental Clearance (EC), developmental activities would be undertaken Soil Classification: Mostly the black soil is found in the Kagal District Climate: Climate in Kagal Taluka is classified as tropical. With an average of 305 mm, the most precipitation falls in July. With an average of 29.2 C, April is the warmest month. December has the lowest average temperature of the year. It is 22.6 C. Average annual temperature of district is 25.2 C. Average annual rainfall in the district is 955 mm. 8

9 3.8. Social Infrastructure Available: Area is well served with social infrastructural facilities such as school, colleges, hospitals, public transportation and telecommunications. 4.0 PLANNING BRIEF 4.1 Planning Concept: Expansion of sugar factory would be undertaken in existing manufacturing set-up. Infrastructure needed for expansion of project will be done on site. In the proposed 75 KLPD molasses based distillery products like Ethyl Alcohol, Extra Neutral Alcohol and Rectified Spirit would be manufactured by using continuous fermentation process. 4.2 Population Projection According to Census 2011, the Taluka Kagal has a total population of 2,75,372. Kagal has a sex ratio of 948 females for every 1000 males, and a literacy rate of 78.65%. 5.0 PROPOSED INFRASTRUCTURE 5.1. Industrial Area Total land acquired by SDVSSKL is Ha. Out of this, built up area of project will be 7.21 Ha. Unit wise area breakup in the SDVSSKL is as shown in following table Table 10 Area Break-up Sr. Description Area(Sq. M) 1. Total Plot Area Built up Area: i. Existing ii. Proposed Green Belt Area: i. Existing ii. Proposed Open Space Greenbelt: Sq. M. (13.3% of total plot area) is developed under green belt, 4815 number of trees are planted. While under the proposed project, additional 2000 trees would be developed as Green Belt on Sq. M. (10 % of total plot area) Social Infrastructure: Amenities like education, medical, water supply, communication, road network, electricity etc. are available in the project area. 9

10 5.4. Connectivity: National Highway (NH-4) is about 23.8 Km & State Highway (SH-179) is about 100 Mtr. from the project site. The site is 6 km from the Murgud town. Kolhapur railway station is located at about 32 Km. Nearest airport is Kolhapur, located at about 30 Km from project site Drinking Water Management: Total fresh water requirement will be met from Dudhganga River. Adequate quantity of water is present round the year as the source of supply Sewerage System: The domestic effluent generated from SDVSSKL complex would be treated in proposed STP Industrial Waste Management: Industrial Effluent Total industrial effluent generated from TCD sugar factory & 20 MW co-gen plant would be 878 M 3 /D. Same is treated in ETP. ETP comprises of Primary, Secondary and Tertiary treatment units. Treated water from ETP would be used for gardening in own premises as well as for irrigation purpose on nearby farm land. Effluent generated from proposed distillery activities would be mainly in the form of spent wash, spentlees & other effluents namely boiler & cooling blow downs, effluents from lab & washings etc. Raw spentwash to the tune of 600 M 3 /D would be concentrated in MEE. Conc. spentwash to the tune of 120 M 3 /D would be burnt in incineration boiler. Spentlees to the tune of 107 M 3 /D, MEE condensate to the tune of 600 M 3 /D and other effluents to the tune of 40 M 3 /D would be treat in proposed CPU. Treated water from the CPU shall be then reused for industrial operations. Thereby achieving Zero Liquid Discharge (ZLD) of process effluent. Emissions Emissions would be generated from 120 TPH bagasse fired boiler as well as 30 TPH incineration boiler (fuel-coal + conc. spent wash). ESP will be installed for same as APC equipment. Hazardous Waste Hazardous Waste generated in the form of spent oil to the tune of 1 MT/Y. and same shall be burnt in boiler. Solid Waste Generation & Management Details of solid waste is presented at following table Table 11 Details of Solid Waste Type of Waste Quantity Disposal 1. Ash 74.7 MT/D. Sell to brick manufacture 2. Yeast Sludge 12.5 KL/D. 3. CPU Sludge 31.4 MT/ D. Incinerate 4. ETP sludge 5 MT/M Used as manure 10

11 5. Discarded Containers 200 s/ Y Reprocessed through Authorized Dealer 5.8. Power Requirement & Supply / Source: Power requirement of project complex will be met from own co-gen plant. 6.0 REHABILITATION & RESETTLEMENT (R& R) PLAN There are no rehabilitation & resettlement issues involved. 7.0 PROJECT SCHEDULE & COST ESTIMATES 7.1 Date of Start: Construction work would be initiated after Grant of Environmental Clearance. 7.2 Estimated Project Cost: Capital investment towards expansion of sugar factory and proposed establishment molasses based distillery would be Rs Cr. Hence total investment of the project is Rs Cr. 8.0 ANALYSIS OF PROPOSAL Additional proposed activity would be implemented in the existing premises which support adequate equipments, allied infrastructure, water and electricity. Fresh water use will be minimized, as the condensate water will be available from cane juice evaporation from sugar factory unit. Primary, Secondary and Tertiary treatment units should be provided in the ETP. There is no any air pollution due to proposed distillery unit as Bagasse is source of fuel. Also, Air Pollution Control (APC) equipment shall be provided. Captive use of hazardous and solid waste generated. Provision of fire fighting system and fire hydrant system. Direct and indirect employment opportunities would be extended to the nearby resident. Fire protection and safety measures would be provided to take care of fire and explosion hazard. The proposed project would be implemented by adopting latest technologies and equipments thereby minimizing the pollution load in Environment. 11