E.I.D. PARRY (INDIA) LIMITED

Transcription

1 PRE- FEASIBILITY REPORT For Proposed expansion of Sugar Plant from 4750 TCD to 7500 TCD Cogeneration power from 15 to 34 MW & Distillery of 60 KLPD along with 3 MW power plant E.I.D. PARRY (INDIA) LIMITED NAGARAL & NAINIGALI VILLAGE, BAGALKOT TALUK BAGALKOT DISTRICT, KARNATAKA

2 1.0 EXECUTIVE SUMMARY E.I.D. - Parry (India) Limited is an existing Sugar & Cogeneration Power plant at Nagaral & Nainigali Village, Bagalkot Taluk and District. The following is the capacity of the existing Plant Sr. No Unit Capacity 1. Sugar 4750 TCD 2. Co-gen Power plant 15 MW Total area already in possession of the management is acres. Now the company has proposed to enhance the Sugar Plant capacity along with Co-gen Power and put up a new 60 KLPD Molasses based Distillery. The proposed expansion will be taken up in the existing plant premises only. The following will be the capacities after proposed expansion Sr. No Unit Capacity Existing Expansion Total 1. Sugar 4750 TCD 2750 TCD 7500 TCD 2. Co-gen Power plant 15 MW 19 MW 34 MW 3. Distillery KLPD 60 KLPD 4. Power from -- 3 MW 3 MW incineration boiler The following is the summary of the proposed expansion project S. No. Parameters Description 1. Existing Plant capacity Sugar 4750 TCD Co-gen power 15 MW 2. Proposed expansion Capacity Sr. No Unit Existing Expansion Total 1. Sugar 4750 TCD 2750 TCD 7500 TCD 2. Co-gen 15 MW 19 MW 34 MW Power plant 3. Distillery KLPD 60 KLPD 4. Power from -- 3 MW 3 MW incineration boiler 3. Total area already in acres possession 4. Sy. No. of the land 29, 32/1, 32/2, 33/1/B and 33/1A, 36, 27/2, 27/3,28/1, 1

3 S. No. Parameters Description 28/2. 29/1, 30/6, 30/3, 30/4b, 30/4a, 30/4c, 30/5a, 30/5b, 33/2a, 35/2, 36/1b, 36/2, 48/1a, 48/1b/1. 39/1, 36/3, 62/1a, 3/3 + 4/1, 30/1+2, 39/2b, 43/1+2/c, 43/1, 135/1 5. Project cost Rs: 351 Crores 6. Water requirement a. Water requirement for 406 KLD existing plant b. Water requirement for the 1504 KLD proposed expansion c. Total water requirement 1910 KLD d. Source of water Krishna river 7. Total effluent generation a. Effluent generation from the 596 KLD existing plant b. Effluent generation from the 1083 KLD proposed expansion c. Total effluent generation 1679 KLD 8. Existing Effluent treatment Sugar Plant Effluent generated from the Sugar plant is being treated in specially designed ETP and treated effluent is being utilized for greenbelt development after ensuring quality of treated effluent with standards stipulated for onland for irrigation by CPCB / KSPCB. 9. Effluent treatment (proposed expansion) Power Plant Effluent from the power plant is being treated in Sugar Plant ETP and treated effluent is being utilized for greenbelt development in the plant premises after ensuring quality of treated effluent with standards stipulated for onland for irrigation by CPCB / KSPCB Sugar Plant Effluent generated from the Sugar plant will be treated in specially designed ETP and treated effluent will be utilized for greenbelt development after ensuring quality of treated effluent with standards stipulated for onland for irrigation by CPCB / KSPCB. Power Plant Effluent from the power plant will be treated in Sugar Plant ETP and treated effluent will be utilized for greenbelt development in the plant premises after ensuring quality of treated effluent with standards stipulated for onland for irrigation by CPCB / KSPCB 2

4 S. No. Parameters Description Distillery Plant Spent wash generated from the Process will be concentrated in Multiple Effective Evaporators up to 55% solids and will be incinerated in the Boiler mixing with other fuels like coal or biomass 10. Steam requirement (existing) Steam requirement existing sugar plant is being met from existing 85 TPH Cogeneration power plant Boiler 11. Steam requirement (expansion) Steam required sugar plant will be met from proposed 110 TPH Cogeneration power plant Boiler Steam required for the Distillery plant and Multiple Effective Boilers will be met from the 25 TPH Incineration Boiler 12. Air emissions (existing) Emissions from Project are Particulate matter, SO 2 and NOx ESP has been provided to Boiler to bring down the particulate matter to below 100 mg/nm 3. The exhaust gases from the boiler are being discharged into the atmosphere through a stack of 70 m height for effective dispersion of gases into the atmosphere. 13. Air emissions (expansion) Emissions from Project will be Particulate matter, SO 2 and NOx ESP will be provided to 110 TPH Boiler to bring down the particulate matter to below 50 mg/nm 3. The exhaust gases from the boiler will be discharged into the atmosphere through a stack of 67 m height for effective dispersion of gases into the atmosphere. 14. Noise levels Ambient Noise levels are within the standards prescribed by MOE&F Notification and its amendments and after proposed expansion also similar practice will be followed. 15. Solid waste generation (existing) Sugar Plant Press mud generated from the Sugar plant is being given to farmers as organic manure Bagasse generated from the Plant is being utilized for power generation in Co-gen Power plant boiler 16. Solid waste generation (expansion) Power Plant Ash generated form the power plant is being given to farmers as organic manure when bagasse / biomass is used as fuel and being to disposed off to brick manufacturers when coal is used as fuel. Sugar Plant Press mud generated from the Sugar plant will be given to farmers as organic manure Bagasse generated from the Plant will be utilized as fuel for power generation in Co-gen Power plant boiler 3

5 S. No. Parameters Description Power Plant Ash generated form the power plant will be given to farmers as organic manure when bagasse / biomass is used as fuel and will be disposed off to brick manufacturers when coal is used as fuel. 4

6 2.0 INTRODUCTION: 2.1 Identification of project and Project Proponent EID Parry (India) Limited is a distinguished and rapidly expanding sugar producer in India. Our sugar manufacturing facility is certified ISO 9001:2008, FSSC:22000:2005 and the distillery is certified "zero-effluent. We are deeply committed to a larger vision of our social responsibility, of looking after the needs and quality of life of the farmers and local communities. Through our effective farmer partnership model we provide assistance in farming practices and undertake various economic initiatives for the benefit of the local communities. The Promoters The following is the list of promoters of the group S.No Name Designation 1. Mr. A.Vellayan Chairman 2. Mr. V.Ravichandran Vice Chairman 3. Mr. Anand Narayan Bhatia Director 4. Mr. V.Manickam Director 5. Mr. M.B.N.Rao Director 6. Mr. Rca Godbole Director 7. Mr. V.Ramesh Managing Director 8. Mr. S.Suresh Dy. Managing Director 2.2 Brief Description of nature of Product: Sugar Sugar known as sucrose or saccharose is an anhydrous crystalline organic product of comparatively 99.96% purity. The physical properties of sucrose are defined as follows CRYSTALLINE NATURE: Sucrose crystals are hard and belong to the mono-clinic system, characterized by three axes of unequal length. Density of sucrose is equal to gm/cu.cm. The presence of impurities in sugar has a remarkable influence on the formation of the crystals. 5

7 SOLUBILITY: Sucrose is very soluble in water and in dilute ordinary alcohol. The solubility in water increases with the rise in temperature, such that for a 10% sucrose solution, the boiling point is Deg.C and for a 90% sucrose solution the boiling point is 130 Deg.C. It is insoluble in chloroform, in cold absolute alcohol, either and glycerine. SPECIFIC GRAVITY: The specific gravity of sucrose varies from to according to the concentration of the solution. The density of the sugar solution is determined in practice by brix and beaume spindles or balling saccharimeter. OPTICAL ROTATION: Sucrose and glucose rotate the plane polarised light in a `clockwise direction or to the right and are called dextro-rotatory. Fructose, rotate in a `counter clock wise direction or to the left and is known as levorotatory. The specific rotation of sucrose is 66.5 Deg. CHEMICAL PROPERTIES: Dry sugar (sucrose) melts at 160 Deg.C into a thick transparent liquid which on cooling again becomes crystalline. If heated for a long time at 160 Deg.C sucrose splits up into glucose and levulosane. At higher temperatures between 190 to 220 Deg.C the decomposition is more complete and caramel is produced. On further, heating, carbondioxide, carbon monoxide, acetic acid and acetone are produced. In the presence of moisture, sucrose decomposes at 100 Deg.C and becomes dark in colour liberating water. On prolonged heating of sucrose at the boiling point and at ordinary pressures, the dissolved sucrose combines with water and breaks up into glucose and fructose in equal parts and the phenomenon is called Hydrolysis of Inversion. APPLICATIONS: The principal use of sugar as explained is as the sweetening agent in foods. The consumption of sugar is distributed in the various sectors such as for daily human consumption in household sector for food processing industries, beverages, baking industry, confectioneries and miscellaneous users. Sucrose serves as raw materials for manufacture of glucose, fructose, invert sugar syrups etc. 6

8 Non food uses of sugar constitute a small amount of total sugar consumption. They include use of sugar as a scurose octacetate, a denaturant in ethyl alcohol, as sucrose diacetate, Hexaisobutyrate, octa benzoate, as mono and difatty acid esters for surfactants, as allyl sucrose, in plasticisers and as raw materials for manufacture of various chemicals like glycerol, mannitol etc. Dextran is a polysaccharide produced from sucrose by the biological process and is a very effective plasma volume expander. Sucrose when administered by intravenous infusion relieves shock and prevents loss of body fluids after excessive burns, wounds or infectious diseases. Other industries wherein sucrose is finding application include drying oil esters for surface coating industries and sugar derived detergents. PRODUCT SPECIFICATIONS: The specifications required for white sugar complying with Indian sugar standards are defined as follows: Characteristics Moisture (%) weight Pol Reducing sugars (%) by weight Conductivity x [10 6 ] Sulphur dioxide (ppm) Calcium oxide (CaO) (mg/100gm) Turbidity, (%) by weight Requirements 0.05% Max. 99.5% Min. 0.10% max. 100 max. 70 max. 30 max. 15 ax Power Power is generated by converting the mechanical energy i.e steam generated from Boiler into electrical energy through Turbine. The power generated will be utilized for meeting the power requirements for sugar, Distillery and other auxiliaries. Remaining power after meeting the power requirement for the project, will be exported to nearby grid DISTILLERY PRODUCTS Extra Neutral Alcohol ENA IS is an Extra Neutral Alcohol, Basic raw material for IMFL. Produced from Molasses, Sweet Swargam, Cane Juice and Grain etc. Rectified Spirit IS Quality is inferior to ENA. ENA is nothing but refined Rectified Spirit. ENA Process is a physical process in which Aldehydes, Esters and Fusel Oils impurities are separated by virtue of their difference in Boiling Points by steam Distillation. 7

9 ENA RS ETHANOL 01 Ethanol content percent by Volume at O C,Min 02 Acidity gms/100 ml 1 Max Residue on Evaporation gms/100 ml Max 04 Ester content gms/100 ml Max Aldehydes gms/100 ml 1 Max PP Times, Minutes 30 Nil Nil 2.3 Demand Supply Gap: The sugar industry today is facing fierce competitive situation due to fluctuations in sugar prices in the national & international markets, higher cane prices to be paid to the cane growers, rising input costs, etc. The survival and growth of this industry depends on energy efficiency, cost optimization and revenue generation from bi-products and down steam products including power, ethanol, chemicals, etc. The implementation of cogen power plant concurrently with the sugar modernization cum expansion project along with other by-products, right from the beginning goes a long way to integrate the operations and improve sustainability. Sugar Industry Overview, India & Karnataka The origin of Indian sugar industry dates back to 1930, when the first sugar factory was set up in the pre-independence era. Over the last 76 years, the sugar industry has steadily grown and has become the backbone of the agricultural and rural economy in India. Today, sugar is the second largest agro processing industry, next to the textile industry. India is one of the largest producers of sugar in the world, with a production of over 15 million tones. Sugar factories are located mostly in the rural India. They act as centers of development, provide largest direct employment in the rural areas and contribute substantially to the Central and State exchequers. The prospects of earning foreign exchange from export of sugar are also quite high. Sugar factories in India have capacities ranging from 1250 TCD to TCD. The Indian sugar industry has developed indigenous capabilities for design, manufacture, supply, operation and maintenance, R&D and cane development. The major stakeholders of this industry in India are Ministry of Agriculture, Govt. of India, Ministry of Consumer Affairs, Food and Public Distribution, federations of co-operative and private sector sugar factories at the national and the State levels, sugarcane growing farmers, equipment and technology suppliers, research institutions, consultants and service providers, financial institutions and Central / State Governments. A total of 619 sugar factories are in operation today, with additional few new sugar factories under implementation in different parts of the nation. The area under sugar cane cultivation, sugar cane 8

10 production, sugar cane crushing in sugar factories, average season days, sugar recovery and sugar production has increased steadily over the years. The crop yield per hectare and recovery has improved, particularly in the last decade. Sugar factories in India are spread over the entire country, however 92.73% of them are located in 9 States viz., Uttar Pradesh, Bihar, Punjab and Haryana in the north, Maharashtra and Gujarat in the west and Karnataka, Andhra Pradesh & Tamil Nadu in the south. More than 80% sugar factories are below 3500 TCD capacity and balance have higher capacities. About 61.23% of the Indian sugar factories are in the co-operative and Government / joint sectors / Public and balance 38.77% in the private sector. Following Table no 1.3 shows the distribution of sugar factories all over India. Status of Sugar Factories in India State Private Public Co-op Total Assam Orissa Bihar Uttar Pradesh Uttarakhand Punjab Haryana Andhra Pradesh Telangana Tamilnadu Maharashtra Gujarat Madhya Pradesh Kerala Rajasthan Karnataka Pondicherry Goa 1 1 Chattisgarh 1 1 Dadra Nagar & Haveli 1 1 West Bengal All India Total Source: Sugar India Year book,

11 The Ministry of Consumer Affairs, Food & Public Distribution, and Government of India revised the standard specifications for sugar plant & equipment, in the year The special committee finalized specifications for economical capacity of 2500 TCD, expandable to 3500 TCD, employing higher-pressure boiler and turbine configuration and efficient equipment, with a potential to export incidental surplus power to the grid. The Indian sugar industry was de licensed in the year 1998 vide press note No. 12 issued by the Government of India, Ministry of Industry, Department of Industrial Policy and Promotion, on August 31, The salient features of de licensing are as follows: The sugar industry stands deleted from the list of industries requiring compulsory licensing under the provisions of Industries Development and Regulation Act, However, in order to avoid unhealthy competition among sugar factories to procure sugarcane, a minimum distance of 15 km would continue to be observed between and existing sugar factory and a new factory, by exercise of powers under the Sugar Control Order, The entrepreneurs, who wish to de-license their sugar factory, would require filing an Industrial Entrepreneur Memoranda (IEM) with the secretariat of industrial assistance in the Ministry of Industry, as laid down for all de-licensed industries, in terms of the press note dated August 2, 1991, as amended from time to time. Entrepreneurs who have been issued Letter of Intent (LoI) for manufacture of sugar need not file an initial IEM. In such cases, the LoI holder shall only file Part B of the IEM at the time of commencement of commercial production against the LoI issued to them. It is however open to entrepreneurs to file an initial IEM (in lieu of LoI / industrial license held by them) if they so desire, whenever any variation from the conditions and parameters stipulated in the LoI / industrial license is contemplated. The statistics on economic and commercial performance for the industry is quite fluctuating. The changes in the agro climatic conditions and sugarcane crop production, as well as the sugar markets have been mainly responsible for these fluctuations. Efficiency, quality, and integration have become order of the day for this industry. The industry has grown till today over the last seven decades. The strength and capacity built so far will surely help meet these challenges. The following are major options to meet these challenges: a. Effecting substantial improvement in cane development and management, including cultivation practices, varietals and water management, so as to improve yield and recovery, without affecting the average fibre content. b. Effecting visible improvement in the operational efficiencies and reduction of sugar losses. c. Effecting and sustaining improvement in energy efficiency, both in steam and power, for saving of additional bagasse, for both sugar and by-products manufacture. 10

12 d. Expansion of capacities and diversification into absolute alcohol/ethanol and cogeneration power projects. e. Effecting adequate capacity building within and without. f. Maximizing sugar exports for value addition. g. Effective marketing in the national and international markets. h. Product quality and diversification. i. Commercializing the excess power capacity by exporting to utilities or to other bulk power consumers. Ministry of Consumer Affairs, Food & Public Distribution Department of Food & Public Distribution Government of India has issued a revised order dated November 10, 2006, amending Sugarcane (Control) Order, The key provisions of this order are outlined below: a. No new sugar factory shall be set up within a radius of 15 km of any existing sugar factory or another new sugar factory in a State or two or more States. b. Before filing the Industrial Entrepreneur Memorandum (IEM) with a Central Govt., a certificate from the Cane Commissioner or Director Sugar or specified authority of the concerned State Govt. shall be obtained regarding the distance criteria re-defined as above. c. Submission of performance guarantee of Rs. 1 crore to Chief Director, Sugar, Dept. of Food & Public Distribution, within 30 days of filing the IEM, as a surety for implementation of the IEM within the stipulated or extended time. d. The stipulated time for taking effective steps shall be 2 years and commercial production shall commence within 4 years from the date of filing of the IEM, failing which the IEM shall stand de-recognized and performance guarantee shall be forfeited. e. If an IEM remains un-implemented within the stipulated or extended time limits, the performance guarantee shall be forfeited after giving a reasonable opportunity of being heard. f. The above clauses will be applicable for IEM already acknowledged as on the date of this notification, but who have not taken effective steps for its implementation, duly defined, shall furnish a performance guarantee of Rs. 1 crore to the Chief Director, Sugar. Power Sector Review The maximum demand met by the state has increased from 7,815 MW in FY 2011 to 9,549 MW in FY 2015 showing a growth of 22% during the 4 year period, while energy requirement has increased by 29% during the same period. The maximum demand deficit has however reduced due to many DSM activities undertaken by DISCOMs and sourcing of power on short term basis to meet the need. 11

13 The average daily consumption of registered rural domestic consumers has increased to 1.19 kwh in FY 2015 at CAGR of 4% during the last 6 years. On the other hand, the average daily consumption of registered domestic urban consumers has increased to 3.00 kwh in FY 2015 at CAGR of 3% during the same period. As per projections made in 18 th EPS of CEA, the projected energy demand and maximum demand for the state of Karnataka was 89,285 MU and 14,945 MW in FY 2019 as against the now calculated energy requirement of 87,626 MU and maximum demand of 14,710 MW in FY Ethanol Sector Overview, India and Karnataka The use of alcohol as a drink is an age-old story. It appears that in India the technique for fermentation and distillation was available even in the Vedic times. Alcohol is an integral part of the Ayurvedic system of medicine also. Carew & Co. Ltd. set up the first distillery in the country at Cownpore (Kanpur) in 1805 for manufacture of Rum for the British army. The technique of fermentation, distillation and blending of alcoholic beverages was developed in India on the lines of practices adopted overseas, particularly in Europe. The original use of alcoholic fermentation was of course for preserving fruit juices. Now the fermentation is adapted for the preparation of fermented grain beverages and then distilled beverages. The utilization of Ethanol, for industrial use is a recent phenomenon. It became important towards the end of the Second World War. When large-scale production of alcoholic beverages was taken up, various Governments found that alcohol was a good source for increasing government revenue through collection of tax. When synthetic organic chemistry advanced rapidly, about a century ago, alcohol became an indispensable chemical for this industry. However extensive manufacturing of alcohol for industrial use was hampered due to excessive taxes. The problem was to device a means for conserving government s interest in tax collection on potable alcohol and at the same time making alcohol for industrial use relatively free of tax. Thus different governments introduced the process of denaturation of alcohol for industrial use. During the Second World War, the demand for the industrial alcohol increased 4-5 times, above the prewar period, due to the production of smokeless powder for weapons. The imports of molasses were hampered due to war conditions. This leads to evolving the process of grain fermentation for meeting the requirement of Ethanol. 12

14 In India, after the protection granted to the sugar Industry in 1932, a large number of sugar factories were established in the country, particularly in Maharashtra and Uttar Pradesh where irrigation facilities existed for cultivation of sugarcane. Increase in sugar production resulted in accumulation of molasses, which resultantly, caused unmanageable environmental problems. At that time the demand for molasses was almost insignificant and the sugar mills had to incur considerable expenditure for disposal of molasses. For resolving these problems a joint committee of U.P. and Bihar was constituted in 1938 to explore the possibilities of using molasses for developing alcoholbased industries. The Committee recommended establishment of distilleries for production of alcohol, utilizing molasses as a substrate. The committee also recommended that alcohol produced by the distilleries should be admixed with petrol, to supplement motor fuel. This helped in solving the problems of disposal of molasses. It also filled up the gap in the demand and supply of motor spirit. As a result, after meeting alcohol requirement for manufacture of gasohol, substantial quantity of alcohol was diverted for production of alcohol based chemicals. Present Status Fossil fuels are declining. Transportation sector consumes more than 50% of the fuels. Environmental degradation from these fuels is a major problem all over the world. World oil production is expected to last till 2125 A.D., if consumption at the present level is maintained. On this background the use of Ethanol for fuel blending should be given a top priority. India requires ethanol for the following three major purposes:- For potable liquor For industrial use For fuel blending Today, the distillery industry of India uses only molasses for manufacturing alcohol. There are handful of grain distillery units (e.g. Seagram Manufacturing Ltd.) and the alcohol produced by them is used for captive use to make value added liquors. All other liquor (IMFL) manufacturers use alcohol produced from molasses. In advanced countries, liquor for human consumption is made only from grain alcohol. It is known that alcohol produced from molasses can have residues such as sulphates, sulphites, higher aldehydes, higher alcohols, higher acids and ketones etc., which are not present in alcohol from, grains. 13

15 However, no such above-mentioned distinction is made in India. Thus alcohol produced only from one source i.e. molasses is used for all 3 purposes (liquor, industrial use, fuel blending). There is an urgent need to bring in above quality consciousness in the IMFL industry and appropriate policy measures by the Govt. Today, Indian distillery industry broadly consists of two parts: One is alcohol production from molasses for industrial alcohol and two alcohol production from molasses for liquor purposes. Ethanol demand for fuel blending is a recent phenomenon. For this purpose, alcohol from molasses is used. The potable distillery producing Indian Made Foreign Liquor (IMFL) has a steady but limited demand. The alcohol produced is now being utilized in the ratio of approximately 52 per cent for potable purpose and the balance 48 percent for industrial purpose. Ethanol blending Ethanol blending is the practice of blending petrol with ethanol. Many countries, including India, have adopted ethanol blending in petrol in order to reduce vehicle exhaust emissions and also to reduce the import burden on account of crude petroleum from which petrol is produced. It is estimated that a 5% blending (105 crore litres) can result in replacement of around 1.8 million Barrels of crude oil. The renewable ethanol content, which is a byproduct of the sugar industry, is expected to result in a net reduction in the emission of carbon dioxide, carbon monoxide (CO) and hydrocarbons (HC). Ethanol itself burns cleaner and burns more completely than petrol it is blended into. In India, ethanol is mainly derived by sugarcane molasses, which is a by-product in the conversion of sugar cane juice to sugar. The practice of blending ethanol started in India in Government of India mandated blending of 5% ethanol with petrol in 9 States and 4 Union Territories in the year 2003 and subsequently mandated 5% blending of ethanol with petrol on an all-india basis in November 2006 (in 20 States and 8 Union Territories except a few North East states and Jammu & Kashmir). This was also an attempt to reduce the Under-recovery of Public Sector Oil Marketing Companies (OMCs). Ministry of Petroleum and Natural Gas, on 1 September, 2015, inter-alia has asked OMCs to target ten percent blending of ethanol in Petrol in as many States as possible. In countries like US, blending is allowed upto 10%. Subsequent to Brazil's bio-fuel programme, which began in 1976, close to 94% of cars sold in Brazil are flexible fuel cars that can handle ethanol blends from 18 per cent upward. Ethanol blending first found mention in the Auto fuel policy of It suggested developing technologies for producing ethanol/ bio fuels from renewable energy sources and introducing 14

16 vehicles to utilise these bio fuels. Later, as per National Policy on Bio-fuels, announced in December 2009, oil companies were required to sell petrol blended with at least 5% of ethanol. It proposed that the blending level be increased to 20% by Ethanol, being a by product of the sugar industry, was expected to be freely available. However, Oil marketing companies (OMCs) were not even able to get bids for more than 50% of the amount offered for purchase. Further, the Government decided on that procurement price of ethanol will henceforth be decided between Oil Marketing Companies (OMCs) and suppliers of ethanol. In addition, on , it was decided that ethanol would be procured only from domestic sources. This led to a rise in ethanol prices, which to a great extent reportedly eroded the economy of the blend. At present, government has permitted OMCs to implement the ethanol blending programme in notified 20 States and 4 Union Territories as per the availability of ethanol. There are reportedly significant transaction barriers which impede smooth supplies of ethanol for blending. In several States, State not only imposes levy on molasses but also regulates the movement of non-levy molasses. Inter-state movement of ethanol requires No-Objection- Certificates (NOCs) from the State Excise Authorities along with permits from dispatching and receiving States. Most States impose Export/Import duties on ethanol leaving and entering their boundaries. There are some instances where Octroi is levied on ethanol for entry into municipal limits. Hence States were requested by the Central Government to liberalise restrictions on the supply of ethanol so that its blending with petrol can be encouraged while improving the financial health of sugar sector and also liquidation of cane dues of farmers. As per the estimates given in Auto Fuel Vision and Policy 2025 issued in May 2014, blended petrol is available only in 13 states and the average blend is 2%. During the sugar year , OMCs have achieved a blending percentage of 2.3% as per the press release dated 25 April Hence, in order to improve the availability of ethanol, the Government, on December 10, 2014, fixed the price of Ethanol in the Range of Rs to Rs , depending upon the distance of distillery from the depot/installation of the OMCs. (The rates are inclusive of all central and statutory levies, transportation cost etc, which would be borne by the Ethanol suppliers). Fixation of ethanol price based on distance, has encouraged movement of ethanol to longer distances, including States having lack of distilleries. Further, ethanol produced from other non-food feedstocks besides molasses, like cellulosic and ligno cellulosic materials including petrochemical route, has also been allowed to be procured subject to meeting the relevant Bureau of Indian Standards (BIS) specifications. 15

17 2.4 Employment generation (Direct & Indirect): The man power required for the industry is 500 Nos. which is inclusive of 275 nos. on permanent basis and rest all will on Temporary or contract basis. S.No. Particulars No. Employees 1. Technical & Administrative Staff Skilled & Semi Skilled Unskilled & Helpers 75 Total

18 3.0 PROJECT DESCRIPTION: 3.1 Type of the Project: The proposed Project mainly involves Production of Sugar from Sugarcane Power generation using Bagasse / Coal as fuel Production of Rectified Spirit / ENA / Ethanol using Molasses as raw material 3.2 Location E.I.D. - Parry (India) Limited is an existing Sugar & Cogeneration Power plant at Nagaral & Nainigali Village, Bagalkot Taluk and District. Now the company has proposed to enhance the Sugar Plant capacity along with Co-gen Power and put up a new 60 KLPD Molasses based Distillery. The proposed expansion will be taken up in the existing plant premises only. 3.3 Details of the Alternate sites: No Alternate sites have been examined as existing premises has been given permission to set up Sugar Plant. 3.4 Size or Magnitude of Operation: The following will be the capacities after proposed expansion Sr. No Unit Capacity Existing Expansion Total 1. Sugar 4750 TCD 2750 TCD 7500 TCD 2. Co-gen Power plant 15 MW 19 MW 34 MW 3. Distillery KLPD 60 KLPD 4. Power from -- 3 MW 3 MW incineration boiler 3.5 Process details: Sugar Process Description Milling: Sugarcane from the fields are weighed and fed in cane carrier by means of cane unloaders. The cane is passed through kicker, leveler and Fibrizer. The Fibrizer improves the extraction of the mills by breaking the rigid ness of the cane and so facilitating its disintegration and extraction of its juice. The fibres are then crushed in mill house, consisting of the 4 mills. During crushing, juices present in 17

19 the cane cells are extracted by the mills. The juice obtained from milling is sent for process, fibre that comes out from 4 th mill is termed as bagasse and it is used as fuel in boilers. Boilers: In boilers condensate water is converted into steam by burning bagasse as fuel. Steam produced in boilers is used in the steam turbine to generate power and the exhaust steam coming out from the turbine is used in the process for sugar manufacturing. Power House: Power House consists of steam turbine and alternator. The alternator is driven by steam turbine and power is generated. The generated power is used to meet the in-house power requirement of the factory and the surplus power is exported to grid. The in-house LP steam from the steam turbine is used for sugar processing at the boiling house. Clarification: The extracted juice from mills is called as raw juice and it is heated to Deg. C. in juice heaters and treated simultaneously with the milk of lime and sulphur dioxide gas in order to separate the impurities. The sulphited juice is again heated to 102 Deg. C through juice heaters and allowed to settle in the clarifier. The purified juice, which comes out from clarifier, is called as clear juice and is sent to evaporator for concentration. The settled impurities are called mud. The mud contains small amount of juice, which is separated in vacuum filters. Evaporation: The clear juice after clarification is concentrated in evaporators by evaporating the 75% of the water present in it. Evaporators are huge vessels consist of calendria where the juice is made to flow through the tubes and around w3hich steam is passed. The clear juice of Brix is concentrated to 60 Brix. Concentrated juice is then called syrup. The syrup is again treated with sulphur dioxide (Bleaching agent). Crystallization: The sulphited syrup is concentrated further in the vessels called pans. During the above process, sugar crystals are developed by means of exhaustion. The formed crystals are then cooled in crystallisers. The crystals are surrounded by thin film liquid called as mother liquor. The crystal along with the mother liquor (Molasses) is called as massecuite. 18

20 Curing: The above massecuites are centrifuged in centrifugals, where crystals are separated from the mother liquor. Separated mother liquor of A & B massecuites are again used for boiling and maximum exhausted mother liquor is called as Final Molasses, which is stored in the steel tanks and sent to distillery for manufacture of Ethyl alcohol. The separated sugar crystals are dried in hopper, sieved in graders and bagged. 19

21 Bagging: Sugar is bagged in `A Twill Gunny bags and each bag contain 100 kg / 50 kg sugar nett. The bags are stacked in sugar godowns and are dispatched as per the directions given by the Directorate of Sugar, New Delhi Co-generation Power Plant Sugar plant will be installed with 2750 TCD in addition to existing 4750 KLD capacity. The cogeneration capacity is so designed that the plant will be able to feed steam and power requirements entire Sugar Complex. The capacity of the boiler will be 110 TPH at 108 ata and 540ºC. The turbine capacity would be 19 MW at 110 TPH at 108 ata and 540ºC steam parameters. The turbine will have 3 extractions and condensing mode. The two numbers of HP extractions will be uncontrolled and one no. of LP extraction controlled. The first HP extraction (higher pressure) will feed HP heater II and second HP extraction will feed HP heater I and process HP steam requirement of Sugar and Distillery. The controlled LP extraction will feed the requirements of LP steam of Sugar process Dearator and Distillery. For off-season operation, we have to utilize the purchased biomass fuel and imported coal. The season period will be 5 to 6 months and off-season will be 3 to 4 months depending on the availability of fuels at economical price Fuel Balance: Cane crushing per hr 315 TPH Bagasse % on cane is 30% Bagacillo consumption 1.0% on cane Net bagasse available for cogeneration 29% Steam fuel ratio for bagasse is 2.50 for new Boiler of ata Steam generation from mill bagasse is 110 TPH and Procured Bagasse. For off season we have to procure biomass fuels and imported coal to ensure 25% of the total fuel consumption is from coal and other biomass in a year Manufacturing Process (Rectified Spirit/Ethanol/ENA) Yeast propagation: Yeast seed material is prepared in water-cooled yeast vessels by inoculating molasses with yeast. The contents of the yeast vessel are then transferred to the Yeast activation vessel. The purpose of aerated yeast activation in the yeast activation vessel is to allow time for the yeast cell multiplication. 20

22 Fermentation: The fermentation technology adopted in the industry is of continuous fermentation with yeast recycle with this technology the total spent wash generation will be restricted to a max. of 10 kl/kl of R.S. (As per latest CPCB recommendation). The purpose of fermentation is to convert the fermentable sugars into alcohol. During fermentation, sugars are broken down into alcohol and carbon-di-oxide. Significant heat release takes place during fermentation. However the fermentation temperature is maintained at C by forced recirculation heat exchangers. At the end of fermentation, the wash is fed through a yeast separator where the yeast cream is separated, acidified in the yeast treatment tank and returned to the yeast activation vessel for activation. Sludge is separated in a sludge decanter. The clear wash from both the yeast separator and sludge separator flows to the clarified wash tank. The wash is then pumped to distillation. Distillation: Fermented Wash about 8% v/v alcohol is preheated in two stages i.e. in the beer heater using the Rectifier vapours and then in the Fermented wash PHE using the effluent. The preheated wash is then fed the Degasifying Column to remove residual CO 2 and volatiles. The wash then flows down to Analyser Column, which acts as a total stripper. The alcohol water vapour mixture which rises upward in this column is fed to the Rectifier Column. The spent wash, which is devoid of alcohol, flows down the Analyser Column for suitable treatment. The lower boiling impurities are concentrated in the Aldehyde Column where about 5% spirit is drawn off as impure spirit with a minimum strength of 66 0 OP. The alcohol vapours are concentrated in the Rectifier Column to produce Rectified Spirit of 95% v/v strength. Higher boiling impurities, which are formed during fermentation, are removed by taking side draw purges to a decanter from the Rectifier Column. A trace stream of spirit is drawn off as impure spirit (about 2% of plant capacity) to remove the concentrated volatile compounds. The high grade Rectified Spirit is taken as a draw from the upper trays of the Rectifier Column. The Rectified spirit is fed to the purification column. Dilution water is fed on the top most tray of the column with a dilution ratio of 1: 9. This column serves to remove the impurities based on the principle of HYDROEXTRACTION. The water is fed to the column in such a way that it selects the higher alcohols and other impurities to move upwards and extracts ethanol down. The purifier bottom alcohol composition is maintained at 12 % v/v. At this composition there is an inversion in 21

23 relative volatiles of higher alcohols as compared to ethanol and these alcohols get separated in the top distillate. Top draw for volatiles is fed to the Fusel oil concentration column. The purified dilute ethanol is removed from the bottom of the purification column and fed to the rectification column, which concentrates the ethanol to 96% v/v. The high grade spirit is drawn from one of the upper trays of the rectification column. A small heads cut is removed from the overhead stream as technical alcohol (T.A.) cut to with draw impurities and is fed to the heads concentration column. The lees from the exhaust column is recycled as dilution water after a part of it is purged. The purged spentlees is used to preheat the make-up dilution water. Lower side draw streams are taken from rectification column to avoid fusel oil build up in the column. These streams are then taken to the fusel oil column. This column concentrates the dilute streams of ethanol containing esters and fusel oils to approximately 95% v/v of ethanol. The concentrated ethanol is removed as T.A. cut from the top of the column. T.A. cut is removed out of the system in order to remove propanol and remaining is fed to the heads concentration column where the heads from the purification column and rectification are fed to the static mixer. Soft water, which has been preheated, is used for diluting the high proof ethanol. An impure spirit cut of about 5% of the rectified spirit feed is drawn from the top of the column. The dilute ethanol solution at the bottom of this column is pumped back to the purification column for repurification. Carbon Dioxide Recovery System (By Product): Carbon dioxide produced during fermentation will be recovered by means of scrubbing arrangement, chemical treatment drying process and finally liquefaction. The water utilized for scrubbing will be recycled back into the fermentor. CO 2 gas will pass through scrubbing tower, where the gas is scrubbed with water. From the scrubber after washing the gas will pass through air compressor and then the gas will pass through a tower containing sodium dichromate to eliminate the impurities, if any and then to drying arrangement with sulphuric acid. Subsequently it passes through a tower containing coke coated with washing soda to eliminate odour. Finally it goes to the chilling unit to cool the gas before passing through different cylinders, where the cooled gas will be filled into the cylinders under pressure. The scrubber blowdown will be recycled into the fermenters. Total CO 2 production : 45.6 T/day This carbon dioxide in cylinders will be sold to industries like soft drink manufacturing units, etc. 22

24 Ethanol Production: This plant is filled with imported 3A grade Molecular Sieve. It is operated with vaporized Alcohol and removes water completely. Then Molecular sieves are regenerated under vacuum of 710 mm Hg. Feed Alcohol comes to this Plant in a Day Tank continuously from bulk storage tank. From this tank alcohol is pumped to a steam vaporizer at 4 Kg/cm2 pressure. This is vaporized in a steam heater and then vapor is super heated to 160 o C in a super heater and taken to Molecular Sieve Unit. This super heated vapor now pressure through one Molecular Sieve column for moisture removal. There are 2 Molecular Sieve columns. At a time one column remain in drying cycle while other columns under goes vacuum regeneration. Each column remains in cycle for 6 minutes. Here drying process takes place at 3.0 Kg/cm2 pressure and dry alcohol vapor of 99.8% purity comes out as final product. This alcohol vapor is condensed in a water cooler and then collected in another day tank. From this tank dry alcohol is continuously pumped to bulk day storage tank through a level controller and a control valve. In the regeneration process some left over alcohol also comes out which is condensed in regeneration condenser. This alcohol is around 95% strength and is recycled in to rectifier column continuously. The other Molecular Sieves column under goes regeneration by a vacuum pump. In this column vacuum pumps pulls and creates vacuum of 710 mm Hg. At this vacuum the moisture from Molecular Sieve pores comes out and along with 30% pure alcohol from on line Mole Sieve bed is sprayed. Thereafter during vacuum process, some left over alcohol and water from Molecular Sieves comes out and is condensed. Concentration of this lean alcohol is around 70% alcohol, which can be recycled to the Rectifying Column. From Rectifier the pure water will be sent out automatically. 23

25 3.6 Raw Materials The following will be the raw material requirement for the for the existing and proposed expansion project S.NO RAW MATERIAL SOURCE QUANTITY ( TPD) Existing Expansion Total METHOD OF TRANSPORT Sugar plant : 1 Sugar Cane From Bagalkot By trucks 2 Lime Local area Through covered trucks by Road 3 Sulphur Local area Through covered trucks by Road 4 Phosphoric Acid Local area Through covered trucks by Road Co-gen power plant : 1 Fuel Bagasse From Sugar plant Conveyor (or) Coal Imported By Sea/ Rail/Road Covered trucks Distillery : 1 Molasses From Sugar plant & Through Pipeline/Tanker External 2. FUEL For 25 TPH Boiler Concentrated Spent wash From Distillery Unit Through Pipeline Coal (100%) Karnataka Through covered trucks by Road 24

26 3.7 Resource Optimization / recycling and reuse: Sugar Plant Condensate from the Sugar Plant will be utilized for Cooling tower make up Power Plant The effluent generated from the Plant will be treated in Neutralization pits and will be utilized for dust suppression, ash conditioning and Greenbelt development after ensuring compliance with stipulation for on land irrigation by MoEF / CPCB Distillery Spent wash generated during the process of Fermentation, will be treated in Multiple Effective Evaporators to concentrate the solids content up to 55% and concentrated spent wash will be incinerated in the Boiler along with Coal. The condensate generated during the process of Multiple Effective Evaporators will be reused in the Process thus decreasing the net water requirement. 3.8 Availability of Water: Water requirement for the existing Plant is being met form the Krishna River. For the proposed expansion also, water required will be met from the Krishna River. Water requirement for the existing plant 406 KLD and for proposed expansion will be 1504 KLD. Hence after proposed expansion the total water requirement will be 1910 KLD. Prior permission from Irrigation Department will be for enhanced water requirement in due course. Section WATER CONSUMPTION (in KLD) Sugar Co-gen Expansion Existing (2750 TCD) (15 MW) Existing (4750 TCD) Expansion (19 MW) Total after expansion a)domestic b)industrial purpose 1. Process water Boiler feed DM plant regeneration Cooling water make up Service water Total

27 WATER REQUIREMENT FOR 60 KLPD DISTILLERY PLANT & 3 MW CO-GEN. POWER PLANT SECTION Water requirement Process water 560 Make up water for Boiler 40 DM water for RS dilution 190 Cooling tower make up 220 DM plant regeneration 30 Domestic water 10 Net water Requirement 1050 Water requirement for Sugar (Existing) : Water requirement for Sugar (Expansion) : Water requirement for Co-gen power (existing) : Water requirement for Co-gen power (expansion) : Water requirement for Distillery : Total water requirement for after proposed expansion will be : 1910 cum/day 3.9 Power Requirement: The power required for the existing and expansion project will be met from the Co-generation Power plant and proposed 3 MW Captive power plants Quantity of wastes generated: Waste water generation Waste water generation from the existing Plant 596 KLD. Waste water generation from the proposed expansion will be 1083 KLD. Hence total waste water generation after proposed expansion will be 1679 KLD SUGAR CO-GEN Total after SECTION Existing (4750 TCD) Expansion (2750 TCD) Existing (15 MW) Expansion (19 MW) proposed expansion a)domestic b)industrial purpose 1. Process & Washings Boiler Blow down Tube cleaning DM plant regeneration Cooling tower blow down Service water Total

28 WASTE WATER GENERATION FROM 60 KLPD DISTILLERY PLANT & 3 MW CO-GEN. POWER PLANT SECTION Water requirement Spent wash 600 Cooling tower blow down 23 Boiler blow down 9 DM water regeneration 30 Domestic water 8 Total 670 Waste water generation from Sugar (Existing) Waste water generation from Sugar (Expansion) Waste water generation from Co-gen power (existing) Waste water generation from Co-gen power (expansion) Waste water generation from Distillery : KLD : KLD : KLD : KLD : KLD Total waste water generation for after proposed expansion will be : 1679 KLD Waste water Treatment: Sugar Plant Total wastewater generation will be 750 cum/day. Effluent generation per ton of cane crushed will be below 100 lit/ton of cane crushed as per CREP recommendations. Capacity of the existing ETP is 1000 KLD. Hence existing ETP is adequate for proposed expansion also.. The following is the ETP description. Design Data & Performance Projections This Wastewater Treatment plant is designed for following parameters & shall perform as under upon reaching steady state of its operation: PARAMETER RAW WASTEWATER TREATED WASTEWATER Flow (KLD) ph (S U) BOD (mg/l) 3000 < 30 COD (mg/l) 6000 < 250 TDS mg/l 2000 < 2100 TSS mg/l 500 < 100 Oil & Grease mg/l 100 < 10 Note: The Sugar ETP has been designed for 1000 KLD, to treat 750 KLD of trade effluent from Sugar plant with a cushion of 25% in order to treat the non process effluent like cooling tower blow down and tube cleaning. However necessary provision shall be made to operate the ETP with a minimum flow of 750 KLD of trade effluent in the Digester and Aeration tank. 27

29 PROCESS DESCRIPTION The proposed wastewater treatment plant shall consist of following treatment units. PRIMARY TREATMENT Screen Oil & Grease trap ph adjustment Equalization Tank SECONDARY TREATMENT UASB Anaerobic reactor Aeration Tank Secondary Clarifier Sludge Drying Beds Screen Chamber: Screen chamber constructed in RCC shall be provided with SS 304 fabricated bar screen for removal of free and floating material. The screen shall be inclined at 45 Deg with horizontal. Oil & Grease Trap: Oil and grease trap constructed in RCC shall be provided for removal of free and floating oil from the Wastewater. The oil trap shall of gravity type and shall be provided with Belt type oil Skimmer. Lime Preparation Tank: A lime preparation tank constructed in RCC. In this tank is used for lime solution preparation and continuous mixing of lime. Lime solution is then feed to equalization tank for ph correction in a required proportion. 1 HP agitator shall be provided for mixing in the tank content. Equalization: Wastewater emanating from sugar has fluctuations in wastewater quality and quantity. Equalization tank shall be provided for dampening these fluctuations. In equalization tank the raw effluent is collected and equalized for adequate time. An equalization tank shall be provided with an agitator to mix the tank content thoroughly. The equalized effluent from equalization tank shall then be pumped to buffer tank. A stand by floating mixer shall also be provided for equalization tank 28

30 Buffer Tank: Buffer tank constructed in RCC shall be provided for preconditioning / pre-acidification of the raw effluent. In buffer tank the Raw Effluent is mixed with treated effluent form UASB Reactor. The nutrient required for the process will also be added to the effluent in Buffer tank. The content of buffer tank shall be mixed hydraulically using UASB Reactor feed pumps. The tank content will then be pumped to UASB Reactor for first stage biological treatment. UASB Reactor: Upflow Anaerobic Sludge Blanket reactor is provided for anaerobic treatment of dairy effluent. The UASB reactor shall be constructed in RCC M-25. The reactor consists of three zones viz. Influent distribution zone, Reaction zone, Gas solid liquid separation zone. Influent Distribution zone: The raw wastewater enters into the at the bottom through influent distribution zone. A sophisticatedly designed piping net work is provided for uniform distribution of the effluent in the tank. The effluent then travels upward in the reactor. Reaction Zone: In the reaction zone the anaerobic bacteria are maintained in the form of sludge blanket. The organic matter in the wastewater comes in contact with the bacterial population and is degraded anaerobically to methane rich biogas, the end product of anaerobic digestion. The process of conversion of organic matter in to the biogas is a two-stage process. In the first stage the organic matter in the raw effluent is converted in to the volatile acids by acid forming bacteria. In the second stage the acid produced in the first stage are converted in to methane by another group of bacteria i.e. methane formers. In UASB process both the stages are completed in single reactor. The biogas so produced is bubbled through the effluent and is separated out in the third section i.e. Gas-Solid-Liquid separation zone. The suspended solids are also separated to prevent escape of solids from the reactor. Gas-Solid Liquid Separation: In gas solid liquid separation a hood fabricated in M S and duly painted with corrosion resistant paint is provided. The hood separates the solid from the overflowing reactor content. Gas collectors are provided for collection and conveyance of gas. The treated effluent overflows through a launder and will take to a secondary treatment. Aeration tank: The partially treated effluent from UASB shall then be subject to activated sludge process for further reduction of organic matter. Aeration tanks are provided for degradation of organic matter through biological process. Microorganism in the controlled environment carries out the biodegradation process. The container i.e aeration tank of requisite capacity is provided for this purpose. The tank shall be provided with an aeration mechanism to transfer the oxygen from air to tank content for survival for microorganisms. Slow speed fixed type surface aerators shall be provided for this 29

31 purpose. The content in the aeration tank is kept under constant aeration and mixing. The aeration thank shall be constructed in RCC. Secondary Clarifier: A secondary Clarifier in the form of circular tank shall be provided for settlement of fully aerated Effluent from the aeration tank. The tank shall be provided with centrally driven fixed bridge type clarifier mechanism. Part of the settled sludge at the bottom of the settling tank will be pumped to the aeration tank and part of it will be discharged on sludge drying beds as per operational requirement. This sludge being fully mineralized is suitable for sun drying on sand drying beds. Sludge Drying Beds: In aeration system the sludge is sufficiently mineralized and does not need any further treatment before dewatering and disposal. Sand filtration drying beds will be provided, where sludge will be dewatered by filtration through sand bed and sun drying of the dewatered sludge is scraped & may be used as manure after composting. Note: All the civil structures in the ETP except sludge drying beds will be constructed with RCC M20 grade to make them impervious. Sludge drying beds will be constructed with brick masonry. Sugar ETP diagram shown below 30

32 B) Cogeneration Power Plant Total wastewater generation from power plant will be 227 Cum/day. The effluent generated from power plant will be sent to Sugar plant ETP. The treated effluent will be utilized for Greenbelt development, Dust suppression and ash conditioning. Sanitary waste water will be treated in septic tank followed by soak pit. Hence there will not be any adverse impact on environment due to the proposed activities. ETP diagram shown in below. C) Distillery Plant: With Molasses: As per CPCB recommendations the spent wash quantity will be restricted to a maximum of 10 kl/kl of R.S. for Molasses by adopting continuous fermentation technology with yeast recycle. The Maximum Spent wash generation from the proposed Ethanol plant with Molasses as raw material will be 600 KL/day. The spent wash will be concentrated to 60% solids in Multiple Effect Evaporators and then will be incinerated in exclusive 25 TPH Boiler. This is a ZERO discharge system already approved by Central Pollution Control Board. EVAPORATION SYSTEM The objective of Evaporation is to concentrate a solution consisting of a volatile solute and a volatile solvent. Evaporation is conducted by vaporizing a portion of the solvent to produce a concentrated solution of thick liquor with 60% solids and 40 % moisture content. The evaporation system consists of 5 evaporators, which are connected, in series. The spent wash will be pumped from distillation section, which will be fed to the evaporator by using feed pump. Gas Liquid separator (5 Nos.) will be used to separate the vapor and liquid. Both Vapor & Spent wash will be fed to the next evaporation effect so it is called as feed forward effect evaporation. The vapor from last evaporator will be condensed in condenser and transferred to the dryer while the condensate from the evaporators is first utilized for heat recovery. While vacuum pump maintains vacuum in the entire system. Product final thick spent wash with 60% solids will be used in boiler for incineration. INCINERATION OF CONCENTRATED SPENT WASH The final concentrate from the Evaporators (60% solids w/w) will be incinerated in the Boiler by mixing with coal. The condensate from the Evaporation system will be reused in the plant operation. Zero discharge will be implemented as per CREP recommendations. ETP diagram shown below 31

33 Non Process Effluent Treatment & Disposal: The boiler blow down & DM Plant & Softener regeneration water will be treated in a neutralization tank and after treatment it will be mixed with CT Blow down. All these treated effluent streams will be stored in a Central Monitoring Basin (CMB). The treated effluent will be used for dust suppression / ash conditioning and onland for irrigation within the premises after ensuring compliance with CPCB / KSPCB standards. The scrubbed water from CO 2 Scrubber will be consumed in the Fermentation section. The effluent will be used for greenbelt development within the plant premises after ensuring the compliance with CPCB / KSPCB standards. Storage Lagoon: A Spent wash storage lagoon of storage capacity of 5 days which is less than 30 days will be provided as per CPCB protocol. Closed storage tank will be provided. 32