PRE FEASIBILITY REPORT

Transcription

1 PRE FEASIBILITY REPORT 1.0 EXECUTIVE SUMMARY AND INTRODUCTION OF THE PROJECT Shivneri Sugars Ltd., A/p. - Ganesh tekadi, Nhavi (Bk.), Tal.: Koregaon, Dist.: Satara, Maharashtra State was registered vide Registration No. : U15400PN2016PLC dated As per the provision of EIA Notification No. S. O (E) dated ; amended on December 01, 2009; the proposed projects would come under Category A. Shivneri Sugars Limited (SSL) have planned to go for expansion of Sugar Factory from 800 TCD to TCD (expansion by 9200 TCD), establishment of 60 MW Co-gen plant (50 MW electricity generation from Co-gen plant while 10 MW from Distillery) & 200 KLPD Molasses based Distillery. Sugar cane will be available with 10 to 15 Km radius area. Co-gen plant will help to reduce /lower down the requirement of power in state of Maharashtra as well as other state. Promoters of SSL 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 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 & 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 Expansion of sugar factory from 800 TCD to TCD (expansion by 9200 TCD), establishment of 60 MW co-gen plant (50 MW electricity generation from Co-gen plant while 10 MW from Distillery) and 200 KLPD molasses based distillery project by Shivneri Sugars Ltd., would be implemented at A/p. - Ganesh tekadi, Nhavi (Bk.), Tal.: Koregaon, Dist.: Satara, Maharashtra State. Area is well connected by mettled and unmettled roads as well as rail networks. Satara railway station is situated around 22 Kms from the project site. Rahimatpur city is located at about 6 Km from the project site. Koregaon Taluka is located at about Km from the project site. 2.2 Site Selection The expansion of Sugar factory, establishment of Co-gen and Distillery activity would be implemented in the existing factory premises of SSL. 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 Rahimatpur 6 km away from the project site which is very well connected with other parts of the country by roads, rail. 4. No rehabilitation and resettlement shall be required. 2.3 Alternative Site Proposed expansion of sugar factory as well as establishment of co-gen plant and 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- 2

3 Table 1 List of Product Sr. Existing Expansion Total Name of Product No. Quantity Quantity Quantity 1. Sugar (MT/ M) Molasses (MT/ M) Bagasse (MT/ M) Press Mud (MT/ M) Electricity (MW) Rectified Spirit (RS) (KLPD) Ethanol (KLPD) ENA (KLPD) Sr. No. 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 Bagasse Molasses DAP Urea Investment Capital investment towards expansion and proposed establishment activities would be Rs. 520 Cr. and existing activity is Rs. 10 Cr. Hence total investment of the project is Rs. 530 Cr. 2.6 Size / Magnitude of Operation Based on availability of sugarcane in its area of operation, the management of SSL has planned to go for expansion of the existing sugar factory and establishment of co-gen plant and 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 3

4 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 SSL have been designed in versatile fashion by adopting latest process techniques as well as with state-of-the art machinery. Effluent from existing as well as proposed sugar factory & co-gen plant will be treated in proposed ETP. 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 800 TCD sugar factory of SSL is 427 M 3 /day. For additional 9200 TCD sugar factory & proposed 60 MW co-gen plant 4705 M 3 /day of water will be required for industrial purpose & 46 M 3 /day will be for domestic purpose. Total water required for industrial purpose of TCD sugar factory and 60 MW co-gen plant will be 5128 M 3 /day and 50 M 3 /day will be for domestic purpose. Table 3 Water Consumption in 10,000 TCD Sugar Factory & 60 MW Co-gen Plant Sr. Existing Water Expansion Water Total Water Description No. Requirement (m 3 /day) Requirement (m 3 /day) Requirement (m 3 /day) 1. Domestic 4 ( # 0.8+ $ 3.2 ) 46 ( # $ 36.8) 50 ( # 10 + $ 40) 2. Industrial a. Process *260 *2813 *3073 b. Cooling Makeup *104 *1196 *1300 c. Boiler Makeup 40 ( # 18+*22) 440 ( # 210+*230) 480 ( # 228+*252) d. Lab& Wash *4 *61 *65 e. DM Backwash *14 *186 *200 f. Ash Quenching *1 *9 *10 Industrial Use (a+b+c+d+e+f) 423 (#18 +*405) 4705 ( # 210+*4495) 5128 ( # 228+*4900) 3. Grand Total (1+2) 427 ( # 18.8+*405+ $ 3.2) 4751( # *4495+ $ 33.6) 5178 ( # 238+*4900+ $ 40) Note: # - Actual quantity of fresh water taken from Krishna River, * - Cane Condensate water $ - Treated water For proposed 200 KLPD molasses based distillery total industrial water requirement will be 2326 M 3 /day and for domestic purpose 27 M 3 /day. Out of the 2326 M 3 /day 1109 M 3 /day will be CPU treated water and 1217 M 3 /day will be fresh water taken from Krishna River. 4

5 Table 4 Water Consumption in 200 KLPD Distillery of SSL Sr. Total Water Requirement Description No. (M 3 /day) 1. Domestic 27 ( # 7 + $ 20) 2. Industrial a. Fermentation dilution 1587 ( # *555) b. Cooling tower replenishment *554 c. Boiler Blow down # 180 d. Lab & Wash # 5 e. Scrubber -- Industrial Use (a+b+c+d+e) 2326 ( # *1109) 3. Grand Total 2353 ( # *1109+ $ 20) Note: # -Actual quantity of fresh water taken from Krishna River, * -MEE Condensate Water $ - Treated water Fuel Bagasse to the tune of 2400 MT/D will be used for 200 TPH co-gen boiler. Under distillery project an incineration boiler of capacity 75 TPH will be installed. Concentrated spentwash to the tune of 906 MT/D blended with coal to the tune of 36 MT/D will be used as fuel for incineration boiler. Power Electricity required for manufacturing operations shall be met from proposed 60 MW cogeneration plant (50 MW from co-gen plant & 10 MW from distillery plant). Manpower Under expansion and proposed project, about 640 no.s of skilled and unskilled worker shall be 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 SSL project complex will be 67 M 3 /D (Domestic effluent from Sugar factory and Co-gen plant - 45 M 3 /D and from Distillery - of 27 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 & propose co-gen plant will be 997 M 3 /D. Same will be treated in proposed 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 5 Effluent generation from Sugar & Co-generation Plant Description Existing Effluent Expansion Effluent Total Effluent M 3 /day M 3 /day M 3 /day Domestic Industrial a. Process b. Cooling Blow down c. Boiler Blow down d. Lab & Wash e. DM Backwash Industrial Use (a+b+c+d+e) Grand Total Effluent generated from proposed distillery activities would be 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 1600 M 3 /D will be concentrated in MEE. Conc. spentwash to the tune of 640 M 3 /D will be burnt in incineration boiler along with coal. Spentlees to the tune of 400 M 3 /D, MEE condensate to the tune of 960 M 3 /D and other effluents to the tune of 162 M 3 /D will 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. Table 6 Effluent generation from proposed Distillery Description Expansion Effluent M 3 /day Remark Domestic 22 Treated in proposed STP Industrial Raw Spent wash Raw spent wash shall be a. Process Conc. Spent wash 640 (3.2 KL/KL) concentrated in MEE. Conc. Sp.wash shall be incinerated in MEE condensate 960 Spent lees b. Cooling Blow down 110 c. Boiler Blow down 18 d. Lab & Wash 34 Industrial Use Spent wash 640 (a+b+c+d) Other effluent 562 B) The Emissions incineration boiler. Other Effluents viz. spent lees, cooling blow down, boiler blow down, lab & washing, MEE condensate shall be forwarded to Distillery CPU. Steam required for sugar factory and co-gen plant will be met from 200 TPH Bagasse fired boiler. ESP will be provided as APC along with a stack of 94 M height. Under proposed distillery project an incineration boiler of capacity 75 TPH will be installed on site. For which concentrated spentwash blended with coal will be used as fuel. ESP will be installed as APC along with a stack of 91 M height. 6

7 Two new DG sets of capacity 1 MW each will be installed on site. HSD is used as fuel for the same. DG sets will be operated during power failure situations. C) Fugitive Emissions There would not be any generation of fugitive emissions from the proposed projects. 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 No. Type of Waste Quantity Disposal 1. Yeast Sludge MT/M 2. CPU Sludge 0.5 MT/M 3. ETP sludge 11 MT/M Used as manure 4. Boiler Ash- bagasse 720 MT/M 5. Boiler Ash- Sp. wash 4892 MT/M Sold to brick manufacturer 6. Boiler Ash- Coal 138 MT/M F) Hazardous Waste Table 8 Hazardous Wastes No. Description Quantity Mode of Disposal 1 Cat. No. 5.1 Spent Oil 0.5 MT/M Burnt with bagasse in Co-gen boiler 3.0 SITE ANALYSIS 3.1. Connectivity: Proposed expansion project would be implemented in the existing premises of SSL at Ganesh tekadi, Nhavi (Bk.), Tal.: Koregaon, Dist.: Satara. Site is located at a rural surrounding and its nearest railway station Koregaon is located at about 18 Km. and nearest airport is Pune, located at about 114 Km from the proposed site Land Form, Land Use and Ownership: 7

8 The terrain of the project is plain and no prime agricultural land is sacrificed since it is expansion of sugar factory & establishment of co-gen plant & distillery project. The entire premise is owned by SSL Topography General topography of the area is flat. This area has little vegetation. There is Krishna river on West side which is the major source of water. This area has moderate rainfall. Vegetative growth is near water sources as well as pockets 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, Table 9 Land Use / Land Cover Categories of Study Area Name Of Taluka Geographical Area (Ha) Forest (Ha) Land under Cultivation (Ha) Culturable Waste Irrigated Non irrigated land (Ha) Koregaon Total Percentage of total area (%) 3.5. Existing Infrastructure: Area Not available for Cultivation Total land acquired by SSL is Hectors. Out of this, built up area of project is 6.79 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 Satara district Climate: Climate in Satara District is classified as tropical. When compared with winter, the summers have much more rainfall. Average annual temperature of district is 24.6 C. Average annual rainfall in the district is 783 mm. In July, the precipitation reaches its peak, with an average of 226 mm Social Infrastructure Available: Area is well served with infrastructural facilities such as road, rail, power station, and telecommunications. 4.0 PLANNING BRIEF 8

9 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. Proposed 60 MW co-gen (50 MW from co-gen plant & 10 MW from Distillery) electricity will be generated. In the proposed 200 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 district Satara has a total population of 3,003,741 Satara has a sex ratio of 988 females for every 1000 males, and a literacy rate of 82.87%. In the 2011 India census, the town of Koregaon had a population of 23,539 individuals. 5.0 PROPOSED INFRASTRUCTURE 5.1. Industrial Area Total land acquired by SSL is Ha Out of this, built up area of project will be 6.79 Ha. Unit wise area breakup in the SSL is as shown in following Table 6. Table 10 Area Break-up Sr. No. Description Built Up Area (Sq. M) A Total Plot area B Sugar Factory & Co-gen C Distillery D Colony Total built up area (B+C+D) Open Space Greenbelt: Under the proposed Green Belt Development Plan in the factory premises, 68,796.6 Sq. M. (33% of total plot area) will be developed as green belt Social Infrastructure: Amenities like education, medical, water supply, communication, road network, electricity etc. are available in the project area Connectivity: National Highway (NH-4) is about 29 Km & State Highway (SH-129) is about 1 Km from the project site. The site is 6 km from the Rahimatpur city. Rahimatpur & Satara railway station is located at about 6 Km & 22 Km respectively. Nearest airport is Pune, located at about 114 Km from project site. 9

10 5.5. Drinking Water Management: Total fresh water requirement will be met from Krishna River. Adequate quantity of water is present round the year as the source of supply Sewerage System: The domestic effluent generated from SSL complex will be treated in proposed STP Industrial Waste Management: Industrial Effluent Total industrial effluent generated from TCD sugar factory & 60 MW co-gen plant will be 997 M 3 /day. Same is treated in proposed ETP. ETP comprises of Primary, Secondary and Tertiary treatment units. Treated water from ETP will 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 1600 CMD will be concentrated in MEE. Conc. spentwash to the tune of 640 CMD will be burnt in incineration boiler. Spentlees to the tune of 400 CMD, MEE condensate to the tune of 960 CMD and other effluents to the tune of 162 CMD will 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 will be generated from 200 TPH bagasse fired boiler as well as 75 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 0.5 MT/M. 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 Generated from Sugar & Co-gen Sr. No. Type of Waste Quantity Disposal 1. Boiler Ash- bagasse 720 MT/M Used as manure 2. Boiler Ash- Coal 138 MT/M Sale To Brick Manufacture 3. Boiler Ash- Sp. wash 4892 MT/M 4. ETP sludge 11 MT/M Used as manure Table 12 Details of Solid Waste Generated from Proposed Distillery Sr. No. Type of Waste Quantity Disposal 1. Yeast Sludge KL/M Used as manure 2. CPU Sludge 0.5 MT/M 10

11 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 and proposed establishment activities would be Rs. 520 Cr. and existing activity is Rs. 10 Cr. Hence total investment of the project is Rs. 530 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 proposed 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