PRE - FEASIBILITY REPORT

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2 PRE - FEASIBILITY REPORT 1.0 EXECUTIVE SUMMARY (I) Introduction Gokul Sugar Industries Limited (GSIL) is engaged in manufacturing of sugar. GSIL is situated at Village Dhotri, Tehsil South Solapur, District Solapur (Maharashtra). GSIL has existing sugar factory with 3500 TCD sugar plant along with 14.5 MW Co-generation power plant. GSIL now proposes to set up a 35 KLPD capacity molasses based distillery plant to produce ethanol /ENA/ RS and 1.5 MW Co-generation Power Plant, adjacent to the existing sugar plant located at Village Dhotri, Tehsil South Solapur, District Solapur (Maharashtra). The company has its sugar complex in total ha (152 acres) area. Out of this ha (25 acres) has been earmarked for installing proposed distillery. For this proposed distillery project Molasses and Bagasse will be sourced from adjacent and nearby sugar mills. The proposed project will produce fuel ethanol from own molasses and also from procured molasses from nearby sugar factories as raw material. The company proposes to install 15 TPH boiler to generate 1.5 MW cogeneration power. As per EIA Notification dated 14 th Sep., 2006 and subsequent amendments; the project falls in Category A, Project or Activity - 5(g) Distilleries. TABLE 1 Salient Features of the Project S. NO. PARTICULARS DETAILS A. Nature & Size of the Project Proposed 35 KLPD Molasses Based Distillery B. Category of the Project As per EIA Notification dated 14 th Sep., 2006 and subsequent amendments; the project falls in Category A, Project or Activity - 5(g). C. Location Details Village Dhotri Tehsil/Block South Solapur District Solapur State Maharashtra Latitude to N Longitude to E Toposheet No. 56C2 and 56C1 D. Area Details Total Plant Area 25 acres (10.11 hectares) Gokul Sugar Industries Limited 1

3 Greenbelt & Plantation Area ~33% of the project area E. Environmental Setting Details (with approximate aerial distance & direction from plant site) 1. Nearest Village Dhotri Village (~1.5 km in West direction) 2. Nearest Town & City Solapur district headquarter (~20 km in West direction) 3. Nearest National Highway / State Highway NH-9 (~8.5 km in NW direction) 4. Nearest Railway station Solapur Railway Station (~23.0 km in West direction) 5. Nearest Airport Pune (~ 250 km in NW direction) 6. Reserved Forests (RF)/ Protected Forests (PF) 7. National Parks, Wildlife Sanctuaries, Biosphere Reserves, Tiger/ Elephant Reserves, Wildlife Corridors etc. within 10 km radius 8. Water Body (within 10 km radius) No Reserved Forests (RF)/ Protected Forests (PF) fall within 10 km radius of the project site. No National Park, Wildlife Sanctuary, Biosphere Reserve, Tiger / Elephant Reserve, Wildlife Corridors etc. falls within 10 km radius of the project site. Harni River (~3.5 km in NNE direction) Palas Odha (Nala)(~ 3.5 km in ENE direction) Rampur Talav (Pond) (~4.5 km in SW direction) F. Cost Details Total Cost of the Project Rs. 62 Crores Cost for Environment Capital Cost: Rs Crores Management Plan Recurring Cost: Rs. 1.0 Crore/annum G. Basic Requirements for the project Water Requirement 291 KLPD Source - Groundwater Power Requirement 1.5 MW Source 1.5 MW Co Generation Power Plant Manpower Requirement 100 persons (Source:- Unskilled / Semi-Skilled - Local Area; Skilled- Local & Outside) H. Product Ethanol/ENA/RS I. By Product CO2 J. Working Days 270 days/annum Gokul Sugar Industries Limited 2

4 1.1 ENVIRONMENT MANAGEMENT PLAN Air Management ESP/Bag Filter with proposed boiler will be provided to maintain the PM (Particulate Matter) emission level within the prescribed limit. Boiler will be equipped with stack of suitable height for discharge of pollutants as per CPCB standards. CO2 generated during the fermentation process will be collected by utilizing CO2 scrubbers and sold to authorized vendors. Roads within the plant will be concreted to control the fugitive emissions. Greenbelt around the periphery and within premises will be developed and same will be maintained. Online Stack Monitoring system will be installed. Ambient air quality will be regularly monitored to ensure that ambient air quality standards and suggested limits are maintained. Water Management The distillery will be based on ZERO EFFLUENT DISCHARGE. The spent wash from molasses will be first treated in Bio-digester and thus production of useful Biogas (used as fuel in boiler), which will be followed by concentration in Multi- effect Evaporator. Concentrated spent wash will be mixed with press mud generated from sugar unit for manufacturing of organic manure (bio-composting). Process condensate & other waste water will be treated in state of art Condensate Polishing Unit (CPU)/ RO and recycled in fermentation process and cooling tower makeup. Online Monitoring System for water quality monitoring will be installed. Sewage will be collected in a common septic tank and discharged as per accepted norms. Noise Management Proper maintenance, oiling and greasing of machines at regular intervals will be done to reduce generation of noise. Personal Protective Equipment like earplugs and earmuffs will be provided to the workers exposed to high noise level. D.G sets will be provided with acoustic to control the noise level within the prescribed limit. Greenbelt inside the plant premises and at the plant boundary will be developed. Regular monitoring of noise level will be carried out. Gokul Sugar Industries Limited 3

5 Solid & Hazardous Waste Management Concentrated spent wash from MEE will be mixed with press mud from the sugar mill and utilized for bio-composting. Ash from the boiler will be used in bio-composting & also given to nearby brick manufacturers. The company will utilize the spent wash for manufacturing bio-compost within the premises, with proper labeling & marketing of finished compost, in sealed bags, bearing the name and seal of our industry & composition of the bio-compost. Used oil & grease generated from plant machinery/gear boxes as hazardous waste will be sold out to the CPCB authorized recyclers. Green Belt Development & Plantation Out of the total plant area of 25 acres (10.11 hectares), 8.3 acres i.e. 33% will be developed under greenbelt & plantation. Native plant species will be planted in consultation with local DFO. Greenbelt will be developed as per Central Pollution Control Board (CPCB) guidelines. Greenbelt development along with the road & plant boundary will attenuate noise level, arrest dust and improve the environment in surrounding. Greenbelt & plantation development will begin simultaneously with the initiation of construction activities of the proposed unit. Odour Management Adequate greenbelt all around the periphery of the plant. Efficient CO2 scrubbing to avoid carryover of alcohol vapours & other fumes. Better housekeeping will maintain good hygiene condition by regular steaming of all fermentation equipment. Longer storages of any product/by-products will be avoided & use of efficient biocides to control bacterial contamination. Regular use of bleaching powder in the drains to avoid generation of putrefying micro-organisms. 2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION (i) Identification of Project and Project Proponent Gokul Sugar Industries Limited was registered at Registrar of Companies Pune on 17 th April, 2008 and is categorised as Company limited by Shares and a Non-govt company. Gokul Sugar Industries Limited's Corporate Identification Number (CIN) is U15424PN2008PLC and Registration Number is The promoters have extensively and carefully analysed the present and future scenario of ethanol and sugar industry. They have also studied carefully the present irrigation facilities and surplus cane availability, as well as future potential of irrigation and additional cane availability. The command cane area has excellent irrigation facilities due Gokul Sugar Industries Limited 4

6 to the perennial water source. With this background, the promoters have finalized the said project. Most of the shareholders are from the sugar cane belt and having experience in sugar industry and sugarcane cultivation, have been able to foresee the cane potential in the command area. GSIL will generate about MT of molasses from expected / sustained cane crushing of 5.60 lakh MT / year. The total requirement of molasses for the 270 days operation of the proposed distillery plant at optimum level of operation will be around 37,800 MT and the balance MT of molasses procured will be sourced from near sugar factories. The fuel ethanol yield from cane molasses will be at 250 lit/ton. The daily requirement of molasses will be about 140 MT per day for 35 KLPD ethanol productions. The total requirement of molasses for the 270 days operation of the proposed ethanol plant will be about 37,800 MT (at maximum 100% utilization level). Molasses should be adequate to run the ethanol plant for at least 270 days. Apart from own Molasses of GSIL, available molasses from sugar factory & procured molasses will be sufficient to run the 35 KLPD of distillery plant for 270 days. The promoters also have acknowledged in depth, the socio-economic and environmental value addition of the captioned project to the local people, region, State and the Country, as well as its win-win situation to all the stakeholders involved. (ii) Brief description of nature of the project Gokul Sugar Industries Limited is proposing to set up a molasses based distillery with an installed capacity of 35 KLPD along with 1.5 MW Co-generation Power plant. For the purpose of setting up the plant, company has earmarked land adjacent own sugar mill at Village Dhotri, Tehsil South Solapur, District Solapur (Maharashtra). (iii) Need for the project and its importance to the country and/ or region Advancement in science and technology has created so many products that have enhanced the quality of human life in every passing year. The human race is largely dependent on industrialization for up gradation in quality of life. Progress of the nation is judged through its economic growth which is largely dependent on industrial productivity. In Indian economy (which is agro based) many industries are dependent over agricultural produce for production of luxury and need based commodities. Alcohol has assumed a very important place in the Country s economy. It is a vital raw material for a number of chemicals. It has been a source of revenue by way of excise duty levied by the State Government on alcohol liquors. It has a potential as fuel in the form of power alcohol for blending with petrol which is expected to achieve the ratio of 20:80. The use of alcohol for the purpose of potable liquor is as high as its use for industrial purposes. According to analysts, the Indian alcoholic beverages industry is expected to witness accelerating growth in coming years with the consumer base likely to expand amidst rising disposable income. The domestic alcoholic drinks market is estimated around $13 Gokul Sugar Industries Limited 5

7 billion and has been growing at a compounded annual growth rate in excess of 10% in the past few years. The growth rate is higher than other major Asian markets like China and South Korea, etc. In the path of company s growth and development this project will serve as yet another milestone. Presently, Govt. of India is pushing ethanol blending programme in a big way to achieve blending target of approximately 10% in near future and progressively increase to 20%. To achieve this target GOI is coming out major policy announcement to encourage setting up of molasses based distilleries. (iv) Demand- Supply Gap Presently, ethanol blending programme has achieved only 3-4% blending target which is way short of 10% limit. (v) Import vs. Indigenous Production With the increase of percentage of ethanol blending in petrol, dependence on crude import will decrease in the coming years. (vi) Export Possibility With the current scenario, possibility of export doesn t arise. (vii) Domestic / Export Markets Domestic market presently driven by ethanol blending programme. (viii)employment Generation (Direct and Indirect) due to the project For smooth functioning of the plant, the company needs a team of 100 persons. These persons are responsible towards their respective department such as Process Plant, Boiler Operating Plant and administrative block. 3.0 PROJECT DESCRIPTION (i) Type of Project including interlinked and independent projects, if any. There are no interlinked projects related to this proposed project. (ii) Location (map showing general location, specific location, and project boundary & project site layout) with coordinates Gokul Sugar Industries Limited 6

8 Proposed 35 KLPD Molasses based Distillery Figure - 1: Location Map Gokul Sugar Industries Limited 7

9 Proposed 35 KLPD Molasses based Distillery (iii) Key Plan Figure - 2: Key Plan Gokul Sugar Industries Limited 8

10 (iv) Details of alternative sites consideration and basis of selecting the proposed site, particularly the environmental considerations gone into should be highlighted. No alternative site has been taken into consideration as the proposed site has been acquired by the company keeping in mind following mentioned factors: Land is adjacent to own Sugar Mill of the company. Proximity to existing sugar mill enabling easy movement of raw material like molasses and bagasse. Bagasse, molasses and press mud are the by-products of sugar industry. These products once thought to be waste are now being used as raw material in the production of valuable products such as alcohol, bio-manure and allied products. Proximity to NH-9 (~8.5 km in NW direction) makes it easier to transport raw materials & final product to market. There is no National Park, Biosphere Reserves and Tiger Reserves within 10 km radius of study area. (v) Size or magnitude of operation The total proposed capacity of Molasses Based Distillery is 35 KLPD & Co-generation Power Plant is 1.5 MW. The process includes basic raw material requirement, sizing of equipment, utilities & services, infrastructure facilities & sources of waste generation, their quantity, treatment & safe disposal of the waste. S. No. Units Capacity 1. Distillery 35 KLPD 2. Co-Generation Power Plant 1.5 MW (vi) Project Description with Process Details For Molasses Based Distillery Operation Molasses unloading and storage Molasses from tankers/pipe line will be unloaded at unloading point and transferred in to molasses storage tank. Alcohol is produced from carbohydrates by fermentation with yeast. Yeasts are unicellular, uninucleate fungi that can reproduce by budding, fission or both. They have been used for centuries to brew alcoholic beverages and are the most commonly used micro-organism in the industrial production of alcohol by fermentation. Ethanol production by fermentation comprises four steps: Yeast propagation from yeast slant from the laboratory. Fermentation to produce fermented wash containing alcohol. Gokul Sugar Industries Limited 9

11 Recovery, enrichment and purification of alcohol from fermented wash to produce 95.5 V/V alcohols. Production of absolute alcohol by dehydration of 95.5% V/V alcohol to produce absolute alcohol. A proper choice of appropriate technology in each of these steps governs the efficient and viable operation of fermentation alcohol plant. Yeast Propagation Yeast, for the production of alcohol is characterized by high selectivity of the yeast species, low production of by-products (side products), high ethanol yield, high fermentation rate, good tolerance towards both high ethanol concentration and high in organics in the fermenting substrate, high temperature tolerance, land high genetically stability. Although finding a strain that has all these characteristics is difficult, a proper selection and development of the best possible strain is needed. Saccharomyces cerevisiae is the commonly deployed yeast strains in alcohol fermentation of sugars. The purity and sterility of yeast culture used as inoculums have great influence on the alcohol yield and longevity of yeast in fermenter. Flocculating yeasts are deployed for continuous fermentation particularly with yeast recycle system. The selectivity of yeast is also essential to maintain the required metabolic reaction pathways specific to conversion of sugars to alcohol. The side products are higher alcohols, acids, etc. which naturally reduce the alcohol yields and final quality of alcohol. It is, therefore, customary to propagate yeast from laboratory strain in increasing volumes under sterile and aerobic conditions protecting the same from other wild yeasts and moulds during their growth. This is done in 3 or four stages starting from a 1 lit inoculum developed in laboratory from a wellpreserved yeast culture slant. Yeast will be developed in plant from fresh slant to laboratory flash culture and then in 3 stage S.S. yeast propagation vessels which operate in series but in batch mode. When enough bio mass strength is developed, it is pitched Into Fermenter. Fermentation The yeast propagation is only at the start and stabilization of the fermenter. When once the continuous fermentation is on, the yeast propagation is stopped and only a periodic continuous addition of small make up of fresh culture from yeast vessel is done to maintain the activity of yeast in the active yeast count in the fermenter. The yeast vessels are fitted with jacket for sterilizing and cooling the medium in situ. Sterile air is supplied to these vessels through compress or and the sterilization-system comprising a series of fine filters followed by HEPA filters. Molasses from the molasses tank in the yard are pumped to transfer pump into tipper type molasses weighing system W-01 and weighed molasses feed tank from where molasses feed pump it to yeast vessels (when necessary) or to fermenter through a static mixer type molasses diluter. Main fermenter could be one Gokul Sugar Industries Limited 10

12 or two stages depending on the control system envisaged based on the final designs. The heat of fermentation is extracted by circulating the fermenter contents through wort coolers Temperature in the fermenter is to be maintained at C. Carbon dioxide evolved during fermentation is vented out through scrubber to recover entrained alcohol vapors. Dilute molasses are fed to the fermenter continuously. The final fermented wash is transferred by wash pump to yeast separation system comprising hydrocolones and centrifuge. The sludge and dead yeast are purged into sludge tank and yeast cream is returned to the fermenter while clear fermented wash is collected in wash tank. Sludge from sludge tank is fed to the bottom of Analyzer Column in the distillation section. Part of spent wash from a selected tray in the column is returned to fermenter after cooling the same to as near to ambient temperature as possible. Anti-foam oil is added from whenever necessary when the level in the fermenter rises beyond a limit due to foaming because of runaway fermentation rate. The operations in the fermenter can be controlled closely through automation. Process water is taken into scrubber water tank from where it is fed to scrubber and overhead water tank by water pump. All process water in the fermentation section is supplied by gravity from this overhead tank. ETHANOL/ENA/RS/AA Distillation Fermented wash from wash holding tank is pumped by wash feed pump P-01 to the top of degassing column after preheating the same in beer heater and spent wash heat exchanger. The vapors along with non-condensable gases from the top of degassing column are rectified in Heads column, to expel the high volatiles, technically know as heads. Bottom liquid from the degasser flows into analyzer column where alcohol is stripped from the liquid. The liquid from bottom of analyzer column is completely stripped of alcohol and is pumped out by spent wash discharge pump through heat exchanger where it preheats the fermented wash before it enters degassing column. Part of spent wash from a tray, few numbers above the bottom tray is cooled and returned to the fermenters as a measure of water saving and reduction of effluent discharge. The dilute alcohol vapors from near the top of analyzer column are condensed first in beer heater while exchanging heat with wash feed and then in analyzer condenser. Degasser and analyzer operate under vacuum. The condensate is collected in Rectifier Feed Tank. The vapors for stripping alcohol are generated from analyzer column bottom liquid in the analyzer column re-boiler by using the rectified column top vapors, as discussed subsequently. Vapors from the top of heads column are condensed in heads column condenser and then in head column vent condenser. Part of the condensate is returned to column as reflux while a small portion is taken out as an impure spirit cut. Liquid from bottom is also taken into Rectified feed tank. Dilute alcohol water mixture from rectifier feed tank are pumped by rectifier feed pump through rectifier feed pre-heater in to rectifying column. Rectifier and its associated Gokul Sugar Industries Limited 11

13 equipment work under pressure so that these vapors can supply the necessary heat for generating the vapors. The condensate is then pumped as Reflux to rectifying column. Rich alcohol vapors at a concentration of 95.5% v/v from top of rectifying column are condensed first in Analyzer and then in Reflux Vent Condenser. The liquid is collected in Rectifier Reflux Tank. Part of the liquid from E-05 may be drawn off as impure spirit. The impure spirit cut will be maintained as little as possible to maintain aldehyde levels to meet the required limits in Absolute Alcohol. Liquid from the reflux tank is pumped by Product Pump partly as product and partly as reflux to the top of the Rectifying Column. The necessary rectifying vapors are generated by boiling the bottom liquid in Rectifier Column Re-boiler using medium pressure steam. Some side streams are drawn from rectifier column as light and heavy fractions of higher alcohols called fusel oils and cooled in fusel oil coolers E-09 and E-10 and are mixed with water and allowed to separate out in fuel oil separator F-01. All vents are connected to Vent Gas Absorber where the vent gases are scrubbed with water to recover entrained alcohol. The scrubber water is used for washing the fusel oils in fusel oil separator to recover alcohol from the fusel oil fractions. The absorber vent is connected to vacuum pump which is used to create vacuum in the analyzer and degasser. The products Rectified Spirit and Impure Spirit, are cooled in product coolers and collected in the respective receiver tanks prior to pumping the same through respective transfer pumps into storage tanks in the excise godown. Impure spirit, is however, returned to Ethanol plant along with the rectified spirit feed, subject to maintaining, the Absolute Alcohol quality required for blending with petrol. Fuel Grade Ethanol Absolute alcohol is manufactured by dehydration of Rectified Spirit. The process adopted here is based on Pressure Swing Adsorption (PSA) system using Molecular Sieves. Rectified spirit, after preheating by waste hot streams, is vaporized and superheated by using medium pressure steam at 6 Kg/cm2g pressure. Hot vapors at kg/cm² g pressure and 130 C temperature pass through PSA column where the water vapors are retained while water free alcohol is released as vapors. The vapors are condensed and collected as Absolute Alcohol. When the molecular sieve bed is saturated with water the alcohol vapors are shifted to the other tower and the first tower is taken for regeneration. Regeneration is done first by pressure releasing and creating vacuum and then by elutriating with dehydrated alcohol vapors from the tower in dehydration operation. The vapors are condensed and the vent vapors are recovered through scrubber. (Eductor may also be considered for this duty). Product is cooled and transferred to Absolute Alcohol receiving tank and then on to storage tank. Gokul Sugar Industries Limited 12

14 Effluent Handling Section Effluent discharged from the distillation process, commonly known as Spent Wash, is one of the most polluting effluents with very high values of BOD and COD. It is first treated in a Bio-methanation System, which not only reduces the effluent load, but also produces methane rich biogas. Biogas is ahigh calorific value fuel and is used as fuel for boiler to produce power and steam to run distillery plant. The production of extra power from biogas improves the economics of the ethanol project. The effluent after Bio-methanation is being/will be concentrated in Multi-effect evaporator and then used for Bio-composting. 1) Bio-methanation Process Bio-methanation involves conversion of organic compounds present in the effluent, using a consortium of bacteria under anaerobic conditions. During their life cycle, the bacteria break down these organic compounds into methane and carbon dioxide. The bacteria, being living organisms, require specific conditions to prosper. This is achieved by controlling the following parameters: Temperature Acidity Organic Loading Nutrient Balance The existing bio-methanation system uses a specially designed CSTR, called bio-digester, to convert organic matter into useful energy in the form of biogas. The biological process of conversion takes place at mesophilic temperature in a controlled atmosphere, ensuring maximum conversion efficiency and production of biogas. Following are the salient features of the process: Pre - Settling Before entering the bio digester, the spent wash from the distillery unit is received into a spent wash pit to enable settling of suspended solids. The pre-settling system ensures consistent operation by reducing the solid build up in the bio digester. The settled solids are removed periodically from the pit for further disposal. ph Control Spent wash ph is adjusted to by recycling part of the treated effluent. Mixing in Bio digester Mixing is done by recirculation of biomass, using a specially designed mixing system and is further enhanced by gas propagation. Efficient mixing helps micro organisms to reach fresh nutrients in a favorable living condition and convert organic matter into methane and carbon dioxide. Various sample points are provided in the biodigester to measure the concentration of sludge. Drain points are provided to drain the sludge from the bio digester. The sludge is settled in the parallel plate clarifier, which is recycled to increase Gokul Sugar Industries Limited 13

15 solid retention time in the bio digester. Supernatant liquid from the clarifier is sent for further treatment. Excess biomass and sludge is removed from the bottom of the bio digester regularly and sent to sludge drying beds for disposal. Gas Collection & Handling Biogas produced in the bio digester is collected from the top of the digester and flows to the gas holder. The gas holder acts as an intermediate gas storage and pressure control device. Biogas is transferred to a biogas power plant to produce power. A flare unit is provided for excess gas burning. Safety Systems For safe operation, flame arresters are provided on gas lines to protect the bio digester from backfire& pressure relief valves are provided on bio digester to protect from excess pressure or vacuum. Control Systems Controlling ph ensures the smooth and safe operation of the system. Temperature, volatile acidity and alkalinity are also controlled, using various control features provided. Type of Bacteria Anaerobic digestion of organic compounds is carried out, using different bacteria. Three main groups of bacteria, used in the process are indicated below: Hydrolyzing bacteria (Solubilizing bacteria) Acetogenic bacteria (Acetate forming bacteria) Methanogenic bacteria (Methane forming bacteria) 2) Multi-Effect Evaporation Direct spent wash will be concentrated in a multistage vacuum evaporator from 5-7% to 30-35% solids. The total process is under vacuum and the vapours generated in the system are compressed in a TVR to economize steam consumption. Condensate water generated from the evaporation system will be recycled back in the process. The concentrated effluent is used in Bio-composting 3) Bio Compost Plant The composting process consists of converting the spent wash into useful manure. This is done with the help of specialized microbial culture or using fresh compost as seed for the micro-organisms. The raw materials required for composting are concentrated spent wash from multi effect evaporator, bacterial culture, Press mud from the sugar factory, ash from boiler Composting is a biological oxidation process for decomposing organic material by a mixed microbial population in a suitably warm and moist environment under aerobic conditions. The degradation converts the material to a stable organic fertilizer which is also a soil improver. The aerobic composting process involves arranging the press mud (filler material) in 300 to 400 m long windrows of triangular section of about 1.5 m height Gokul Sugar Industries Limited 14

16 by 3.0 m. width on impervious ground usually with the help of front end loaders. The windrows are sprayed with a measured quantity of spent wash, in the ratio of 2.5:1 (spent wash to press mud). The ratio will vary depending on the moisture content of the filler materials. The spraying of spent wash is done when the moisture content of the press mud drops to 50%. The moisture content is not allowed to exceed 65% as at that moisture anaerobic condition start prevailing which is detrimental to the composting process. The windrows are inoculated with the seed material after the first spray. About 1 Kg. of bio culture is required per ton of press mud. From ambient temperature at start up the temperature rises to 65 Deg. C. by the second week and continues up to the 4th week. The total duration for completion of the reactions is about 6 weeks by which time the temperature returns to ambient. A further 2 weeks is allowed for curing. Carbon to nitrogen ratio is the deciding factor to determine the completion of the bio composting process. Specialized mixing machines called aero-tillers, traveling along the length of the windrows are used to mix and aerate the decomposing mass, about once in three days. This results in increased spent wash absorption, oxygen supply for proper growth of micro-organisms and dissipation of heat, which is liberated due to metabolic activity of micro-organisms. The moisture content during composting is maintained at 50-60% by periodic spraying of the spent wash. Adequate holding capacity (min. 30 days) is to be provided for the spent wash in lined lagoons to cater to any demand mismatch. The lagoons should be duly lined and pitched by stone/bricks with cement mortar to prevent leachate. Composting is to be carried out on a raised impervious floor protected by bunds with provision for leachate collection and surface runoff and it s pumping to the holding lagoon. Pipe network is laid for automatic spraying of spent wash. Gokul Sugar Industries Limited 15

17 Figure 3: Process flow diagram of Molasses based Distillery Gokul Sugar Industries Limited 16

18 RO based Process condensate Treatment Plant The process condensate treatment plant will be based on the process of Reverse Osmosis technology. The system will comprise of following unit process & equipment. Equalization tank Neutralization tank Filtration section Pressure sand filter Dual media filter Feed RO system Permeate RO system Reject RO system RO CIP system Neutralization process: The stored process condensate will be transferred to the downstream neutralization tank. Process condensate will be neutralized in this tank with dosing of alkali solution. The neutralization process will be automated &will be controlled through the controller. Neutralized condensate will be then collected in filter feed tank for further processing through the filtration system. Filtration Process: Neutralized condensate from the filter feed tank will be passed through two stage media filters. First condensate will be filtered by pressure sand filter in order to remove suspended matters & turbidity present in it. The primary sand filter outlet will be filtered in Dual media filter to remove the fine suspended solids. Feed RO system: The neutralized & filtered water will be treated through Feed RO system. The feed water will be dosed with anti-scalant & SMBS solutions to condition the feed water prior to passing it through Feed RO system. The feed RO skid will be two stage systems comprising of two pressure vessels containing six elements each configured in series. As the feed water flows through the first pressure membrane from feed to reject end, the pure water permeates through membrane and will be collected in the permeate header. The concentrated water will be collected in Reject header& then passed through the second pressure vessel. The permeate generated from the Feed RO system will be collected in the permeate RO feed tank & Reject generated will be collected in the Reject RO feed tank. Permeate RO system: The permeate generated from the feed RO skid will be passed through the permeate RO system for further removal of dissolve solid. The system comprises of two pressure vessels containing four elements each configured in series. As the feed water flows through the first membrane from feed to reject end the pure water permeates through the membranes & will be collected in the permeate header. The concentrated water will be collected in Reject header & then passes through the second Gokul Sugar Industries Limited 17

19 pressure vessel. The permeate generated from the system will be collected on the permeate RO product tank & Reject generated will be collected in reject RO feed tank. Reject RO system: The reject generated from the feed RO skid & permeate skid will be passed through the Reject RO system for further recovery of low TDS water. The system will comprise of two pressure vessels containing four elements each configured in series. As the feed water flows through the first membranes from feed to reject end the pure water permeates through the membranes & will be collected in the permeate header. The concentrated water will be collected in Reject header & then passed through the second pressure vessel. The permeate generated from the Reject RO system will be collected in the reject RO product tank & reject generated will be collected in the final reject collection tank. The permeate from Permeate RO system & permeate from Reject RO system will be used in cooling towers & fermentation for makeup water & molasses dilution. The final reject will be fed to evaporation again. Table - 2 Characteristics of Untreated and treated effluent S. Parameters Untreated Effluent Treated No. Evaporation process Cooling tower effluent condensate blow down 1. TDS 200 mg/l 2000 mg/l <10 mg/l 2. ph BOD 2500 mg/l 60 mg/l <10 mg/l 4. COD 3500 mg/l 200 mg/l <100 mg/l Power Co-generation 1.5 MW OPERATIONS The unit proposes to set-up 15 TPH boiler and power turbine. Boiler of 15 TPH will be installed based on Bagasse as available fuel options. The Boiler will operate mainly to feed steam to Molasses based operations and 1.5 MW power generations from turbine. Proposed 1.5 MW Co-Generation plant consists of a high pressure water tube steam boiler extraction cum condensing steam turbine. Fuel in the steam boiler will be burnt with the help of air in the Incineration boiler furnace. Water will be circulated in the Incineration boiler drum and tubes thus getting heated by the flame burning in the Incineration boiler furnace. Water comes out of the Incineration boiler drum located at the top of the Incineration boiler as steam. Flue gases rise in the Incineration boiler furnace and come in contact with the steam coming out of Incineration boiler drum. Steam after coming in contact with flue gases gets heated up further thus getting superheated. Super heated steam leaves the incineration boiler in a pipe. Flue gases after Gokul Sugar Industries Limited 18

20 super heating the steam pass through economizer where they pre-heat the incineration boiler feed water before it enters the incineration boiler drum. After economizer, flue gases pass through air pre-heaters where they heat the air which is fed to the incineration boiler furnace for burning the fuel. After air pre heaters flue gases pass through Bag Filter / ESP where the dust particles are collected. The dust is collected in closed system with dense phase technology for final disposal. High pressure superheated steam from incineration boiler is passed through a steam turbine, which is used for distillery process operations. While passing through the turbine, the high pressure and temperature steam rotates the turbine rotor and an electric alternator mounted on the same shaft. Electric power is generated by the alternator. This electric power generated is consumed in house i.e. for running the distillery and utilities like incineration boiler s auxiliaries etc. Figure 4: Process Flow Chart for Co-Generation Power Plant (vii)raw material required along with estimated quantity, likely source, marketing area of final products, mode of transport of raw material and finished product. (a) Raw Material Requirement The basic raw material for the manufacturing of (Ethanol) will be Molasses. In the present scenario, Molasses is easily available in the nearby own & others sugar mills and will be procured from the same. Gokul Sugar Industries Limited 19

21 TABLE 3 Raw Material Requirement for Molasses Based Distillery S. No. Particulars Total Requirement Storage Source & mode of transportation 1 Molasses 140 MT/day Tanks From own/ nearby sugar mills via road & pipelines 2 Chemicals Sodium Hydroxide 350 kg/ day Packed in 50 kg Bags Near-by Markets via road (Caustic) & stored in Godown Nutrients 280 kg / day Packed in 50 kg Bags & stored in Godown Enzyme 1.75 kg / day Packed in Cans & stored in Godowns Antifoam Agent 350 Kg/day Packed in Cans & stored in Godowns Yeast (Active Dry Yeast/Distiller s Yeast) Own Propagation (b) Fuel Requirement Bagasse will be used for the proposed boiler of 15 TPH. Details regarding fuel requirements are given below. TABLE 4 Fuel Requirement Name of Material Requirement Source of Material Biogas m3/day Methane gas generated from Bio-Methanation plant Bagasse 80 TPD Own sugar mills via conveyor belt Note: - 15% Coal will be used as Axillary fuel (viii) Resources optimization/ recycling and reuse envisaged in the project, if any, should be briefly outlined. Water as a resource will be recycled at each possible step of the process and latest technology and methodology will be adopted to conserve and reuse the resources. Gokul Sugar Industries Limited 20

22 (ix) Availability of water it s source, energy /power requirement and source should be given. (a) Water Requirement and Source Total water requirement for the proposed project will be 291 KLPD. Source: Ground water TABLE - 5 Water requirement TOTAL WATER INPUTS (KL) Process water in fermentation 288 DM water for boiler feed 182 Soft water for analyser flash tank 63 Soft water for vacuum pump & others 58 Soft water makeup for cooling tower 157 Water in molasses 30 Other domestic usage (provisional) 10 Miscellaneous washings (provisional) 10 Total 798 RECYCLE & UTILIZATION STREAMS(KL) Lees recycle for fermentation 53 Steam condensate recycle for boiler 163 Vacuum pump water recirculation 58 Process condensate recycle to process 233 Total recycling/reutilization of water per day 507 Total fresh water input = 291 (b) Power Requirement and Source The power requirement is 1.5 MW, which will be sourced from proposed 1.5 MW Co- Generation Power Plant. (c) Steam Requirement Steam generated from the boiler will be utilized in the generation of 1.5 MW Power which will be for the own consumption and also for boiler feed water heating and distillery. Total steam requirement for distillery is 9.15 TPH. Source: 15 TPH Boiler. Gokul Sugar Industries Limited 21

23 Section Distillation Section Evaporation Section TABLE 6 Steam Details Requirement (TPH) 3.65 TPH 3.50 TPH De-aerator and boiler auxiliaries Total 2.0 TPH 9.15 TPH Boiler Details A boiler of 15 TPH capacity with ESP/Bag filter as Air Pollution Control Equipment will be installed. Details regarding proposed boiler are mentioned in the table given below: TABLE 7 PROPOSED BOILER DETAILS S. No. Details 1. Type of Fuel Bio-gas and Bagasse 2. Capacity of Boiler 15 TPH (45kg/cm 2 Pressure) 3. Stack Height As per CPCB/SPCB norms 4. Pollution Control Equipment Measures ESP/Bag filter Details regarding the D.G. Sets One Number of D.G. set of 500 KVA will be installed for the power backup. Details regarding the D.G. Sets are mentioned in the table given below: TABLE 8 Details Regarding the D.G. Sets S. No. Details 1. Type of Fuel HSD 2. Capacity 500 KVA 3. Stack Height (above roof level) As per CPCB/SPCB norms 4. Pollution Control Equipment Measures Adequate stack height/ Acoustic (x) Quantity of waste to be generated (liquid and solid) and scheme for their management/disposal: The proposed project is based on ZERO EFFLUENT DISCHARGE. Concentrated spent wash from MEE will be mixed with press mud from the sugar mill and utilized for bio-composting. Process condensate from MEE will be recycled back to the process. Gokul Sugar Industries Limited 22

24 Ash from the boiler will be used in bio-composting & also given to nearby brick manufacturers. Filtered sludge will be mixed with Press Mud for manufacturing Organic Manure. 4.0 SITE ANALYSIS (i) Connectivity The project site is well connected to Highway NH-9 (~8.5 Km in NW direction). The nearest railway station is Solapur Railway Station (~23.0 km in West direction) and nearest airport is Pune (~ 250 km in NW direction). The site is suitably located with respect to availability of raw material, water, road network, skilled/semi skilled/unskilled and professional manpower etc. All communication facilities such as telephone, telefax & internet are available in the vicinity of the project site. (ii) Land from Land use and Land ownership Total area required for the proposed project is 25 acres (10.11 hectares) and the same has been already acquired by the company. (iii) Topography Topography of the core zone of the proposed project is almost flat. (iv) Existing land use pattern (agriculture, non-agriculture, forest, water bodies (including area under CRZ), shortest distances from the periphery of the project to periphery of the forests, national park, wild life sanctuary, eco sensitive areas, water bodies (distance from the HFL of the river), CRZ. In case of notified industrial area, a copy of the Gazette notification should be given Environmental Settings of the Area S. NO. PARTICULARS DETAILS 1. Nearest Village Dhotri Village (~1.5 km in West direction) 2. Nearest Town & City Solapur district headquarter (~20 km in West direction) 3. Nearest National Highway / State Highway NH-9 (~8.5 km in NW direction) 4. Nearest Railway station Solapur Railway Station (~23.0 km in West direction) 5. Nearest Airport Pune (~ 250 km in NW direction) 6. Reserved Forests (RF)/ Protected Forests (PF) 7. National Parks, Wildlife Sanctuaries, Biosphere Reserves, Tiger/ Elephant Reserves, Wildlife No Reserved Forests (RF)/ Protected Forests (PF) fall within 10 km radius of the project site. No National Park, Wildlife Sanctuary, Biosphere Reserve, Tiger / Elephant Reserve, Wildlife Corridors etc. falls within 10 km radius of the project site. Gokul Sugar Industries Limited 23

25 Corridors etc. within 10 km radius 8. Water Body (within 10 km radius) Harni River (~3.5 km in NNE direction) Palas Odha (Nala)(~ 3.5 km in ENE direction) Rampur Talav (Pond)(~4.5 km in SW direction) 9. Seismic Zone Seismic Zone - III as per IS: 1893 (Part-I): 2002 (v) Existing Infrastructure Proposed project is new project. There are no existing infrastructures within the project site TCD sugar unit with 14.5 MW cogeneration power plant lies adjacent to the proposed distillery unit. (vi) Soil classification The soil prevailing in Solapur district is mainly derived forms Deccan basalts. The soil of the district is underlain by partially decomposed basaltic rock locally known as Murum which overlies parent rock. Due to more of less complete absence of leaching, the soils are base-saturated. The lime reserve in the soil is fairly high (3.5 to10%). The soils exhibit varying degrees of erosion and truncated profile is a common occurrence. The soils can be broadly classified in the four main categories on the basis of depth and structure. Vary shallow with depth less than 7.5cm. Shallow soils between 7.5-to22.5cm depths. Medium deep soils between 22.5 and 90cm depths. Deep soils with depth more than 90cm (vii) Climatic data from secondary sources Solapur falls under the category of dry (arid and semiarid) climate according to the Koppen climate classification. Climate of the district is characterized by high humidity throughout the year, an oppressive summer followed by well distributed and heavy rainfall during the southwest monsoon season. The cold season starts from December to February followed by summer from March to May. The mean daily maximum temperature is 40 C and means daily minimum temperature is 13 C. The highest temperature ever recorded is 48 C in April The southwest monsoon season is from June to September while October and November constitute the post monsoon season. Broadly speaking, the district can be divided into three natural zones. The eastern zone, comprising Barshi, North Sholapur, South Sholapur and Akkalkot talukas, has assured rainfall; the central or the traditional zone, comprising Mohol, Mangalwedha, eastern part of Pandharpur and Madha talukas has uncertain rainfall and the western zone which comprises the scarcity areas of Karmala, Sangola and Malshiras talukas and the western parts of the Madha and Pandharpur talukas has also uncertain rainfall. Gokul Sugar Industries Limited 24

26 Rainfall all over the district is uncertain and scanty with an annual average of 625 mm. Only in Barshi taluka which is nearer to Balaghat range it averages to 725 mm. The district gets rain from south-west as well as from north-east monsoon. The main precipitation during June to August is rather precarious. The normal rainfall for the monsoon period, i.e.. June-September is mm. which is 73.6 per cent of the total annual rainfall. The farming practices are adjusted according to the normal character of the rainy season. It is the minimum in the North Western part of the district around Malsiras (524mm). It increases towards southeast and attains a maximum around Akkalkot (707 mm). The coefficient of variation of the annual rainfall from the normal ranges from 30% at Barshi to 42% at Malsiras. This suggests a high fluctuation in annual rainfall over the district. The percentage probability of receiving excess rainfall (that is 25% or more in excess of the normal) varies from 19% to 23%. It is the minimum around Malsiras, Pandharpur and Solapur (19%) and maximum around Akkalkot (23%). the probabilities of occurrence of moderate drought ranges from 15% at Karmala to 22% at Madha and Akkalkot (Table 1). Severe drought conditions were experienced at all station for 1% to 11% of the years. Acute drought condition was experienced for 1% of the years only at Pardharpur, Malsiras and Madha. As every station of the district experienced moderate, severe and acute drought condition for more than 20% of the years, the entire district can be classified as Drought Area. (viii) Social Infrastructure available There are primary schools, dispensaries, small hospitals, places of worship in nearby area of the project site. 5.0 PLANNING BRIEF (i) Planning Concept (type of industries, facilities, transportation etc.) Town and country Planning/ Development authority classification. The proposed project is molasses based distillery. Facilities required for the proposed project will be provided as per requirement. Transportation of raw material and final product will be done via existing road network and cement concrete road will be developed within the proposed project area. (ii) Population Projection Temporary influx of people will be there as the managerial and supervisory staff will generally be outsider. A projection may be made by a governmental organization, or by those unaffiliated with a government. (iii) Assessment of infrastructure demand (Physical& Social) The Company will assess the demand of infrastructure (Physical & Social) in nearby area of the proposed site and will be developed in under corporate social responsibilities programs. Gokul Sugar Industries Limited 25

27 (iv) Amenities/Facilities The Company will develop the Amenities/Facilities in nearby area of the proposed project site as per requirement of local people under corporate social responsibilities programs. 6.0 PROPOSED INFRASTRUCTURE (i) Industrial Area (Processing Area) 25 acres (10.11 hectares) area will be required for proposed distillery plant & Cogeneration power plant. The company has total ha (152 acres) area. Out of this ha (25 acres) will be utilized for installing proposed distillery. (ii) Residential area (Non-Processing area) Residential colony is not proposed for proposed project. The local labour will be preferred to provide employment opportunities. (iii) Greenbelt Greenbelt will be developed in 33% of the total area of the proposed project. (iv) Social Infrastructure Proposed project will result in growth of the surrounding areas by increased direct and indirect employment opportunities in the region including ancillary development and supporting infrastructure. (v) Connectivity The proposed project is well connected with rail and road. (vi) Industrial Waste management The proposed Molasses based distillery would be based on ZERO EFFLUENT DISCHARGE. (vii) Solid Waste Management Concentrated spent wash from MEE will be mixed with press mud from the sugar mill and utilized for bio-composting. Ash from the boiler will be used in bio-composting & also given to nearby brick manufacturers. The company will utilize the spent wash for manufacturing bio-compost within the premises, with proper labelling & marketing of finished compost, in sealed bags, bearing the name and seal of our industry & composition of the bio-compost. Used oil & grease generated from plant machinery/gear boxes as hazardous waste will be sold out to the CPCB authorized recyclers. (viii) Power requirement and source The total power requirement for the proposed project will be 1.5 MW, which will be sourced from Co generation power plant of 1.5 MW & grid power (for emergency). Gokul Sugar Industries Limited 26