at village asurle-porle, tehsil panhala, district...

Proposed Capacity Enhancement in Existing Molasses Based Distillery from 60 KLPD to 75 KLPD, Sugar Mill from 7500 TCD to 9000 TCD & Co-Generation Power Plant from 30 MW to 32 MW within the existing plant premises by modernization & efficiency improvement

At Village Asurle-Porle, Tehsil Panhala, District Kolhapur, Maharashtra Pre- Feasibility Report

Shri Datta Sakhar Karkhana

(A Unit of Dalmia Bharat Sugar & Industries Limited) 1

PRE - FEASIBILITY REPORT

1.0 EXECUTIVE SUMMARY

(I) INTRODUCTION

Shri Datta Sakhar Karkhana (SDSK) is a unit of Dalmia Bharat Sugar & Industries Ltd

(DBSIL). The company has an existing 60 KLPD Molasses Based Distillery, 7500 TCD

Sugar Mill and 30 MW Co-generation Power Plant at Village Asurle-Porle, Tehsil

Panhala, District Kolhapur, Maharashtra. Now, the company is proposing capacity

enhancement in Existing Molasses Based Distillery from 60 KLPD to 75 KLPD, Sugar

Mill from 7500 TCD to 9000 TCD & Co-Generation Power Plant from 30 MW to 32

MW within the existing plant premises by modernization & efficiency improvement.

In line with the ambitious programme of honourable prime minister like “MAKE IN

INDIA” and to become self-dependent on fuel within the country, The Company has

planned for capacity expansion in distillery from 60 to 75 KLPD and Sugar Unit from

7500 to 9000 TCD by modernization & efficiency improvement. There is no proposal

to increase in power generation capacity. However only incidental power generation

due to treatment of spent wash in incineration route as recommended by

honourable Ministry will result into power generation in the tune of 2 MW, therefore

this capacity needs to be captured while issuing amendment of EC.

No additional land is required for the proposed enhancement project, as the same

will be done within the existing plant premises.

TABLE - 1 Salient Features of the Project

S. NO.

PARTICULARS DETAILS

A. Nature & Size of the Project Units Existing Capacity

Proposed Enhancement

Capacity

Total Capacity after

Enhancement

Distillery 60 KLPD 15 KLPD 75 KLPD

Sugar Mill 7500 TCD 1500 TCD 9000 TCD

Co-generation

Power Plant

30.0 MW 2.0 MW

(Incidental)

32.0 MW

(only capacity correction)

B. Category of the Project As per EIA Notification dated 14th September, 2006, as amended from time to time; the project falls under Category “A”, Project or Activity - 5(g) & 5 (j) (Distillery & Sugar Industry)





C. Location Details

Village Asurle - Porle

Tehsil Panhala

District Kolhapur

State Maharashtra

Latitude 16046’00.56’’ N

Longitude 74008’08.17’’ E

D. Area Details

Total Plant Area o Existing plant area: 34.9 hectares (86 acres).

o No additional land is required for the proposed capacity enhancement, as the same will be done within the existing plant premises by modernization & efficiency improvement.

Greenbelt / Plantation Area 11.53 hectare (28.5 acres) i.e. 33% of the total plant area has already been developed and the same will be maintained in future also.

E. Environmental Setting Details (with approximate aerial distance & direction from plant site)

1. Nearest Village Asurle - Porle

2. Nearest Town / City Kolhapur (13 km in SE direction)

3. Nearest National Highway NH-204 (2.5 km in NE direction)

4. Nearest Railway station Kolhapur (13 km in SE direction)

5. Nearest Airport Kolhapur (22 km in SE direction)

6. National Parks, Reserved Forests (RF) / Protected Forests (PF), Wildlife Sanctuaries, Biosphere Reserves, Tiger/ Elephant Reserves, Wildlife Corridors etc. within 10 km radius

No National Park, Wildlife Sanctuary, Biosphere Reserve, Tiger / Elephant Reserve, Wildlife Corridor within 10 km radius .

There are 9 Reserved / Protected forests.

S. No. Name Distance Direction

1. Porle RF Nearby West

2. Rakshi PF 3.0 km NNW

3. Waghave PF 6.0 km NW

4. Pohale PF 6.5 km ENE

5. Giroli PF 7.0 km NE

6. Sadake PF 8.5 km ENE

7. Jakhale PF 9.0 km NE

8. Kotoli PF 9.5 km WNW

9. Manpadali PF 9.5 km ENE

7. River / Water Body (within 10 km radius)

• Kasari River (2.5 km in South direction)

• Panchganga River (5.5 km in SE direction)

F. Cost Details

Total Cost of the Capacity Enhancement Project

Rs. 60 Crores

Cost for Environment Management Plan

o Capital Cost - Rs. 5 Crores (Existing facilities are adequate for proposed enhancement only modernisation is





considered)

o Recurring Cost - Rs. 1.0 Crores / annum

G. Basic Requirements for the project

Existing Additional for proposed capacity

enhancement

Total after proposed capacity

enhancement

Water Requirement (KLD) 1250 KLPD Nil 1250 KLPD

Source: Surface water (Kasari river)

Power Requirement (MW) 11 MW 1 MW 12 MW

Source: Cogeneration Power Plant & D.G Sets (for emergency).

Man Power Requirement 763 37 800

Source: Unskilled / Semi-Skilled - Local Area; Skilled-local/outside

H. Product Mix Ethanol, Rectified Spirit, Extra Neutral Alcohol, Country Liquor & IMFL, Sugar and Power

I. Working Days Distillery - 330 days per annum

Sugar Mill – 160 days per Annum

Co-generation Power Plant – 330 days per Annum

1.1 ENVIRONMENT MANAGEMENT PLAN

Particulars Details

Air Management

Emissions � All major sources of air pollution are/will be provided with ESPs to maintain

PM emissions below permissible limits (i.e. 50 mg/Nm3). No Additional Is

proposed.

� Boilers are equipped with RCC stack of suitable height for discharge of

pollutants as per CPCB standards.

� CO2 generated during the fermentation process is being/ will be collected by

utilizing CO2 scrubbers and sold to authorized vendors.

� All the roads are asphalted and concreted to control the fugitive dust

emissions.

� Greenbelt around the periphery and within premises is already in place and

same will be maintained.

Monitoring � Ambient air quality and stack emission is being/will be regularly monitored to

ensure that ambient air quality standards are being met all the time.





� Online Monitoring System for air is already in place.

Water Management

Management � The distillery project is based on “Zero Effluent Discharge” and same will be

maintained.

� Presently spent wash is treated through concentration in MEE and the

concentrated spent wash is mixed with auxiliary fuel and burnt in the

incinerator boiler. The entire process condensate is treated in state of art CPU

and reused in process and cooling tower makeup etc.

� A full-fledged ETP for sugar and co-gen is already in place. Improvement and

application of latest proven technology adoption is a regular practice to

modernise the operations.

� Effluent from Sugar Unit & Co-generation Power Plant is being treated in ETP

and treated water is recycled / reused in process, greenbelt development and

ferti-irrigation.

� A full-fledged STP for domestic sewage treatment is already in place.

Monitoring � Online monitoring System for water quality is already in place.

Noise Management

Management � Proper maintenance, oiling and greasing of machines at regular intervals is

being / will be done to reduce generation of noise.

� Personal Protective Equipments like earplugs and earmuffs is being / will be

provided to the workers exposed to high noise level.

� D.G sets are being /will be provided with acoustic to control the noise level

within the prescribed limit.

� Greenbelt inside the plant premises and at the plant boundary is already

developed and same will be maintained in future.

Monitoring Regular monitoring of noise level is being / will be carried out and corrective

measures in concerned machinery are being/will be adapted accordingly to the

possible extent.





Solid & Hazardous Waste Management

� Bagasse generated is being/will be used as fuel for power generation in Co-gen Power Plant.

� Molasses is dark colour viscous matter generated from Sugar industry. This is being/will be used as

raw material in distillery for fuel grade Alcohol production.

� The concentrated spent wash from molasses based distillery will be burnt in Incinerator boiler

along with baggasse/ coal as fuel.

� ETP Sludge generated after treating waste water generated in sugar unit is being/will be used as

manure.

� Ash is utilized in in-house brick manufacturing facility and balance given to brick manufacturers /

cement manufacturing.

� Press Mud generated is given to the farmers as manure.

Greenbelt Development / Plantation

� Out of the total plant area of 34.9 hectare (86 acres), 28.5 acres (~33%) has already been developed

under greenbelt / plantation. The same will be maintained.

� Greenbelt has been developed as per Central Pollution Control Board (CPCB) guidelines.

� Greenbelt development along with the road & plant boundary will be continued to attenuate noise

level, arrest dust and improve the environment in surrounding.

2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

(i) Identification of Project and Project Proponent

Existing Project –


(DBSIL). DBSIL has taken over Co-operative Sugar Company on 12th September,

2012.

The company is having an existing 60 KLPD Molasses Based Distillery, 7500 TCD

Sugar Mill and 30 MW Co-generation Power Plant at Village Asurle-Porle, Tehsil

Panhala, District Kolhapur, Maharashtra.





Environmental Clearance for the same has been obtained from MoEFCC, New Delhi

vide Letter No. J-11011/277/2013-IA II (I) dated 04th February, 2015 and later an

amended on dated 10th August, 2016.

Project Proponent –


(DBSIL). SDSK is operating a sugar plant complex at Village Asurle - Porle, Panhala

Taluka, Kolhapur District in Maharashtra. Earlier SDSK was a Cooperative Sugar

Company, registered under Maharashtra State Co-operative Societies Act and its

first crushing season was taken in the year of 1985-86 with initial capacity of 1230

TCD producing sugar in double sulphitation process. Dalmia Bharat Sugar &

Industries Ltd., New Delhi (DBSIL) has taken over the cooperative sugar company on

12th September, 2012. Dalmia Bharat Sugar and Industries Limited is a part of Dalmia

Bharat Group, which has interest in Cement, Sugar, Conventional Power, Renewable

Energy, Refractory, and Travel etc. The group turnover for the Financial Year 2015-

2016 was around Rs. 7600 Cr; Dalmia Bharat cogeneration plant of 109 MW, Distillery

of 180 KLPD. Company also has facilities for processing of raw sugar.

With the establishment of the proposed facilities SDSK could assure the cane

growers and offer competitive rate to their surplus cane by creating competition

among other sugar factories. SDSK could also generate employment for the local

labour, carters and transporters. SDSK / DBSIL are actively involved in social services

and social activities. They are continuously striving to promote and develop the

infrastructure and facilities to rural folk. The company has taken a number of

initiatives to drive sustainable growth, lasting competitive advantage & efficiencies

in all aspects of operations. The group has also taken on a proactive role at industry

level and has been instrumental in driving many policy & regulatory changes in the

sugar and renewable energy sector. Company continue contributing to income &

employment creation opportunities in the local economy, infrastructure

development, promotion of sustainable farming techniques, improvement of

sugarcane yields, propagation of higher recovery sugarcane varieties etc. For

improving service delivery to farmers company have leveraged technology - IVRS,

SMS based information dissemination systems, Handheld Terminals at cane

purchasing centres and GPS devices for cane survey being a few of these. SDSK





proposes to make additional investment with state of art equipment. Fully aware of

the advantages of High Pressure co-generation systems and surplus power export

to grid and production of ethanol, SDSK proposes to modernize the sugar factory

with energy efficiency and by upgrading the capacity of turbo generators.

Installation of high pressure co-generation projects and distillery will bring

additional revenue to the factory by supplying green power to the grid. The factory

proposes to operate the cogeneration plant and distillery during Cane crushing

season and off season.

(ii) Brief description of nature of the project

Shri Datta Sakhar Karkhana (A unit of Dalmia Bharat Sugar & Industries Ltd.) is

proposing capacity enhancement of Molasses Based Distillery from 60 KLPD to 75

KLPD, Sugar Mill from 7500 TCD to 9000 TCD & Co-Generation Power Plant from 30

MW to 32 MW at Village Asurle-Porle, Tehsil Panhala, District Kolhapur, Maharashtra.

The distillery has put up the most modern technology for treatment of distillery

spent wash which ensures Zero discharge of distillery effluents. The distillery unit is

self-sufficient in terms of steam and power requirement. These steam and power is

generated in incineration boiler which in turn use spent wash as a fuel (hence, it is a

compliance of direction of honourable Ministry).

As per EIA Notification dated 14th September, 2006, as amended from time to time;

the project falls under Category “A”, Project or Activity - 5(g) & 5 (j) (Distillery &

Sugar Industry).

(iii) Need for the project and its importance to the country and or region

Sugar cane is one of the important cash crops of India. The industries based on

sugarcane and its allied by-products help farmers and provide employment to the

rural people. Bagasse, molasses and press mud are the waste 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.

Basis for Expansion in capacity of Sugar

The sugar is also food commodity required to be distributed to local marketing and

also has a potential to earn forging exchange by the export. The sugar mill is located

in the potential sugarcane belt of the state. Sugar recovery in the located area is





comparatively higher and there is further scope to increase the production of

sugarcane due to following reasons-

• Plenty of water availability due to nearby reservoirs.

• Soil & climatic condition are very conducive for cane cultivation

• Quality of sugar cane in the area is very good. High recovery expected from the

area.

• Yield of cane is very good

• The area is fully free from floods etc.

• The farmers are very keen to supply cane to mill due prompt payment by DBSIL.

• Presently the cane is being supplied to nearby sugar mills (and the existing plant)

• Plant has been suitably designed to reduce steam consumption and power

consumption and Bagasse shall be used for Co-generation of power.

Basis for expansion in capacity of Distillery

In line with the ambitious programme of honourable prime minister like “MAKE IN

INDIA” and to become self-dependence on fuel within the country. Hence Company

has planned for capacity expansion in distillery from 60 to 75 KLPD.

Alcohol is eco-friendly product which can be blended with petroleum and as a fuel in

automobiles. Hence, the distillery helps to reduce the dependency on petroleum and

has potential to save foreign exchange. Petroleum is a scarce, non-renewable and

non eco-friendly product. Alcohol being used in beverages is a potential source of

revenue to the government. The importance and utility of alcohol is well known as

an industrial raw material for manufacture of a variety of organic chemicals including

pharmaceuticals, cosmetics, potable alcohol etc. It is now being increasingly

appreciated all over the world. This is partly due to high costs of products produced

through petroleum route, consequent to the phenomenal increase in petroleum

price. Alcohol is also known as eco-friendly product as it is produced out of

renewable source.

Under the National Ethanol Programme, there is a mandate to blend 10 % ethanol, in

petrol in nine sugar producing states. This programme was started on 1st October

2003. This amounts to a demand of 360 million litres of ethanol per year. This

programme took the back seat in 2004 due to the draught like conditions and a bad





sugar cane crop. With good monsoons in 2004 and onwards, the country is set for a

reasonably good sugar cane crop in this season. In addition, the Government of

India has set a dead line for introduction of gasoline and diesel confirming to Euro-3

fuel standards in 11 cities of India. The Euro-3 standard specifies the presence of an

oxidant in the fuel, which minimizes the emissions due to the combustions of these

fuels. Ethanol being one of the most viable additives available, the oil companies has

to use ethanol for blending with petrol. The ethanol programme has already been

restarted. Government of India as all ready initiated to enhance blending of alcohol

with petrol up to 10% from November 2007. Once this programme is stabilized by

then the demand for ethanol would be more than double.

Following are the reasons for the capacity enhancement in distillery:

• Increase in ethanol yield from molasses from 24% to 26%

• Optimization of fermentation and distillation process.

• No additional fresh water is required for proposed increase in capacity

• No additional effluent generation

• Total concentrated spent wash generated is proposed to be consumed in

existing incinerator

(iv) Demand- Supply Gap

Based upon our recent study about cane availability in Kolhapur district which is

known to be highest cane producing district in Maharashtra state. Hence we will

safely increase the capacity from present level which will be beneficial to run own

distillery with in-house molasses production.

(v) Import vs. Indigenous Production

Indian market could not meet present alcohol demand. So they import alcohol 5-7%

of total demand. As far as ethanol production is concerned, Indian market play a

vital role at both domestic & international level. So they require producing more

alcohol to meet the demand.

(vi) Export Possibility

Export of ethanol & sugar is currently governed by Govt. policy.

(vii) Domestic Markets

Sales and Marketing division has always been a key focus area for our company.

Over the years we have reached a number of key customers through our initiatives.





We have a thrust on institutional Buyers which is a paradigm shift from the tradition

of selling to wholesale market.

Our Company is a preferred sugar supplier to brand-enhancing institutional giants

such as:-

Sugar Business

• Britannia

• Dabur India

• PepsiCo

• Bharti Wall mart

• Parle

Alcohol

• Oil marketing companies to fulfill 10% blending target

• Indian Glycol limited

• Allied Blenders & Distilleries Pvt. Ltd.

• United Breweries

• Jubilant

Apart from this we have a strong customer base of wholesale agents in state of U.P,

Delhi, Haryana, Bihar & West Bengal for regular supply of sugar.

(viii) Employment Generation (Direct and Indirect) due to the project

The total existing direct manpower is 763 persons and requirement after the

proposed capacity enhancement of the project will be 800 persons.

Indirectly associated people will be benefited with the increase in capacity.

3.0 PROJECT DESCRIPTION

(i) Type of Project including interlinked and independent projects, if any.

Existing plant is integrated production of Sugar, Distillery and Power. There are no

interlinked projects related to this capacity enhancement project.

(ii) Location (map showing general location, specific location, and project boundary &

project site layout) with coordinates





Figure - 1: Location Map





Figure - 2: Plant Layout

Proposed Capacity Enhancement in Existing Molasses Based Distillery (60 to 75 KLPD), Sugar Mill from 7500 TCD to 9000 TCD & Co-Generation Power Plant from 30 MW to 36 MW by Modernization & Efficiency Improvement



(A Unit of Dalmia Bharat Sugar & Industries Limited 13

Figure - 3: Key Plan





(iii) Details of alternative sites consideration and basis of selecting the proposed site,

particularly the environmental considerations gone into should be highlighted.

Since the proposed capacity enhancement will be done within the existing plant

premises by modernization & efficiency improvement hence no additional land will

be required; therefore, no alternative site has been considered.

(iv) Size or magnitude of operation

Shri Datta Sakhar Karkhana (A unit of Dalmia Bharat Sugar & Industries Ltd.) is

proposing capacity enhancement in existing Molasses Based Distillery from 60 KLPD

to 75 KLPD, Sugar Mill from 7500 TCD to 9000 TCD & Co-Generation Power Plant

from 30 MW to 32 MW within the existing plant premises by modernization &

efficiency improvement at Village Asurle-Porle, Tehsil Panhala, District Kolhapur,

Maharashtra.

Table - 3

S. No Units Existing Capacity


Capacity

Total Capacity after

Enhancement

1 Distillery 60 KLPD 15 KLPD 75 KLPD

2 Sugar Mill 7500 TCD 1500 TCD 9000 TCD

3 Co-generation Power Plant

30.0 MW

2.0 MW

(Incidental generation)

32.0 MW

(only capacity correction)

(v) Project Description with Process Details

Project Description

Sugar Manufacturing Process

Sugar cane is the raw material for manufacture of sugar. Juice is extracted from

sugar cane, which is then processed to recover sugar. Bagasse, which is the left out

fiber material after extraction of juice from sugar cane, is used as fuel in boiler to

produce steam. Steam is used for concentration of sugar juice, production of alcohol

and for generation of electric power. The flow diagram of sugar manufacturing

process is given in Figure below. Brief description of the process is given below.

1) Crushing of Sugarcane

Sugarcane is harvested and dressed in the fields and then supplied to factories

through Lorries, tractor trailers or bullock carts. Crushing takes place mainly in

two stages; first the preparation and then milling. Preparation is done in

leveller, cutter and fibrizer. The prepared cane is then crushed by passing





through 4 sets of mills. Hot water is added in the course of crushing as

imbibitions water for better extraction of juice from sugarcane. After crushing,

the bagasse is sent to boiler as fuel and juice is sent for purification and

recovery of sugar

2) Juice Clarification & Filtration

The weighed quantity of juice is primarily heated 70-730C in juice heaters and

then treated with lime solution. The juice is heated again to 100-1130C in

another set of juice heaters. The hot juice is sent to clarifier. Clarified juice is

decanted out and sent for evaporation in a set of multiple effect evaporator

bodies. The juice at 15% is concentrated in the evaporators in to syrup of 60%

concentration.

3) Crystallization

The syrup is sent to pan floor for further concentration in vacuum pans. The

syrup collected in supply tanks is taken to pans for boiling where the syrup

concentrates and attains super saturation stage. In such a condition sugar

grains are formed in the syrup. The syrup mass with sugar particles is called

massecuite. The massecuite is dropped in crystallizers and cooled to complete

the crystallization.

4) Centrifugation

Massecuite is taken into the high-speed centrifugal machine. Sugar crystals are

separated from mother Liquor and sent to driers. Non crystallable matter from

the syrup, called molasses, is drained out from the centrifuge. The molasses is

weighed and sent to storage tank.

5) Drying, Grading & Bagging

Sugar is dried in the vibrating hopper and graded by passing though standard

sieves. The graded sugar is bagged, weighted for 30 and 100 Kg net, stitched,

numbered and stacked in sugar godown.





Figure 5: Sugar Manufacturing Process





FOR MOLASSES BASED OPERATION

i) Molasses Unloading and Storage

Molasses from tankers will be unloaded at unloading point and transfer in to molasses

storage tank.

ii) Hiferm-Nm Saccharification and Instantaneous Fermentation:

Yeast Activation:

Yeast seed material is prepared in water-cooled Yeast Activation Vessel by inoculating

sterilized mash with Active Dry Yeast. Optimum temperature is maintained by cooling

water. The contents of the Yeast Activation Vessel are then transferred to Fermenter.

Fermentation:

The Molasses from storage tank to be pumped to Dilutor installed in Fermentation

section and diluted with water. The diluted Molasses called Wort will be feed into Pre

Fermenter for activation of Yeast. The activated yeast from the Yeast activation vessel

transfer into pre fermenter.

Once the yeast activated in Pre fermenters it will be transfer in to fermenters and

diluted molasses to be add the process of fermentation is to convert the fermentable

substrate into alcohol. The pH of the wort is adjusted by the addition of acid. Yeast is

available in sufficient quantity to initiate fermentation rapidly and complete it within

the cycle time.

At the start of the cycle, the fermenter is charged with wort and contents of the Yeast

Activation Vessel. Significant heat release takes place during fermentation. This is

removed by passing cooling water through the Fermenter PHE’s to maintain an

optimum temperature. The recirculating pumps also serve to empty the fermenters

into Beer Well. After the fermenters are emptied, they are cleaned with water and

caustic solutions and sterilized for the next batch. The carbon dioxide evolved during

the process is vented to atmosphere (to be processed and stored for industrial use)

after recovery of alcohol in a scrubber.

iii) Ethanol Distillation:

Fermented wash from wash holding tank is pumped by wash feed pump to the top of

degassing column after preheating the same in beer heater and spent wash heat

exchanger. The vapours along with non-condensable gases from the top of degassing

column are rectified in Heads column, to expel the high volatiles, technically known 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 thick slop discharge pump through heat

exchanger where it preheats the fermented wash before it enters degassing column.

The slop from the analyser column will be feed in to decanter. The dilute alcohol

vapours 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 from is collected in Rectifier Feed

Tank. The vapours for stripping alcohol are generated from analyzer column bottom

liquid in the analyzer column re-boiler by using the rectified column top vapours, as

discussed subsequently.

Vapours 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 of

is also taken into Rectified feed tank.

Dilute alcohol water mixture from rectifier feed tank are pumped by rectifier feed

pump through rectifier feed pre-heater in to rectifying column. Rectifier and its

associated equipment work under pressure so that these vapours can supply the

necessary heat for generating the vapours.

The condensate from is then pumped as Reflux to rectifying column. Rich alcohol

vapors at a concentration of 95.5% v/v from top of rectifying column are condensed

first in Analyzer and then in Reflux Vent Condenser. The liquid from are collected in

Rectifier Reflux Tank. Part of the liquid 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 vapours 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 and are

mixed with water and allowed to separate out in fuel oil separator. 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 fuel oils in fuel

oil separator to recover alcohol from the fuel oil fractions. The absorber vent is





connected to vacuum pump which is used to create vacuum in the analyzer and

degasser.

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 vapours at kg/cm² g

pressure and 130° C temperature pass through PSA column, where the water vapours

are retained while water free alcohol is released as vapours. The vapours are

condensed and collected as Absolute Alcohol. When the molecular sieve bed is

saturated with water the alcohol vapours 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 vapours from the

tower in dehydration operation. The vapours are condensed and the vent vapours are

recovered through scrubber 2. Vacuum can be created. (Educator may also be

considered for this duty). Product is cooled and transferred to Absolute Alcohol

receiving tank and then on to storage tank.

iv) Alcohol Daily Receivers & Bulk Storage:

Alcohol is first taken to Daily receiver storage tanks, which is based on the State Excise

laws, storage for three days considering the weekly holidays of two days. Thereafter,

the alcohol is transferred to Bulk Storage Tanks after taking the daily receiver Dip. This

is transferred using flameproof pumps. Final dispatch of alcohol is metered and again

is carried out using special flameproof pumps. The Bulk Spirit Storage is proposed to

be set up for 30 days.

B) EFFLUENT HANDLING SECTION

i) Evaporation Section:

The spent wash coming from Distillation section will be fed in to first calendria of

the evaporator section. There will be five calendria will be installed as per design

to concentrate the dissolved solids .suggested treatment scheme is a four FF +

Finisher Evaporation Plant for spent wash Evaporation. The following points will

elucidate the basic working principle:

� Shell & Tube type Evaporators with highly efficient liquid distributor working

on the principle of Falling Film Evaporation have been used, with Plate type





Preheaters for preheating of FEED stream which serves the purpose of energy

conservation.

� Analyzer vapour is fed to the first effect evaporator shell side at the given

pressure and temperature as the heating medium.

� The Feed from the Feed balance tank is taken to make the best heat recovery.

� The Feed after getting heated to the predetermined temperature in preheater

is fed from the first effect evaporator which is Falling Film Evaporator -1

� Vapours generated in 1st effect VLS (Vapour Liquid Separator) are used as heat

source in the 2nd effect and from 2nd to third and so on.

� The product at the desired concentration of TS is obtained at the outlet from

the final effect.

� A Shell & tube type Multi-pass Surface condenser is employed for condensing

the shell side vapours.

� The Pure and the process condensate are collected in receiving vessels.

� Highly efficient operating pumps will be provided for pumping the required

fluid.

� The operation of the plant will be under vacuum. Vacuum is created with the

help of a water ring vacuum pump.

� The plant will have high level of automation to get consistent output at

required concentration.

� The system operates under vacuum. Water-ring vacuum pumps are used to

maintain a desired vacuum.

� Cooling water from cooling tower is used in the surface condensers for

condensing the vapours.

ii) Incinerator boiler:

The concentrated effluent is mixed with bagasse/coal and fired into specially

designed boiler to generate steam and power. A complete state of art Boiler +

Turbine + Balance of plant + Electrical distribution system in place and same will be

used for capacity enhancement.





Figure - 4: Process flow diagram of Molasses Based Distillery





Co-Generation Plant

The company has an existing 23 + 3 MW Co-generation Power plant and proposed to

increase up to 30 MW total as per existing EC.

The existing two boilers having capacity of 200 TPH (120 TPH & 40 TPH and to be

enhanced 80TPH) are based on bagasse as a fuel + coal as supplementary fuel in Sugar

Unit and will be sufficient for proposed increase in capacity.

One incinerator boiler having capacity of 22 TPH is based on Conc. Spent wash &

Coal/Bagasse in Distillery Plant has already been installed as per recommendation by

Hon’ble ministry & is sufficient for proposed capacity enhancement of distillery.

Now Company will be generating 2 MW additional powers through waste recovery

incineration boiler (22 TPH) as an additional source of incidental power. This is the only

power generation capacity addition to be done under this proposal.

vi) 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 raw material required for the sugar industry will be sugarcane. This

presently is being purchased from local growers. Also the same shall be

continued to reach the proposed 9000TCD of sugar.

The basic raw material used for the manufacturing of Ethanol, Rectified spirit,

ENA, Country liquor and IMFL is molasses. Presently the molasses is being

used from in-house sugar industry and nearby sugar mills.

TABLE – 4

Raw material requirement for sugar unit

Description Units Existing

Requirement


Capacity

Total Capacity after Enhancement

Sugar Mill – Cane

TPD 7500 1500 9000

Distillery Molasses

MTPD 284 16 300

(b) Fuel Requirement

There is no proposal to increase bagasse and coal requirement with respect

to earlier projection presented to the Ministry.





TABLE 6

Fuel requirement for cogeneration power plant

S. No Name of material

Unit Fuel Source of material

Mode of Transportation

1 Bagasse T/day 1560 In house -

2

Coal in Sugar Mill Boiler as per MNRE guidelines @ 15%

T/day 234 Authorized

dealer By road

Coal in incineration boiler along with conc. Spent wash

T/day 35 Authorized

dealer By road

(vii) Resources optimization/ recycling and reuse envisaged in the project, if any, should be

briefly outlined.

Water as a resource is being/will be recycled at each possible step of the process and

latest technology and methodology is being/will be adopted to conserve and reuse the

resources.

� No water is extracted from ground.

� The distillery is Zero Effluent Discharge so does not pose any threat to ground or

surface water quality.

� Incorporation of advanced technique i.e. Multi Effect Evaporator and Incineration

boiler is enabling substantial reduction of final effluent.

� Centralized lubrication system is used in Milling Tandem in place of equipment specific

lubrication. This will result in reduction in quantity of cleaning water and oil and

grease.

� Waste water generated in operations like Floor washing, Boiler blow down will be

used in green belt after treatment.

� Presently waste water generated from Sugar Mill is used in farm irrigation and

recycled after treatment in ETP due to its high nutrients value. The same will be

followed after expansion.





� Water is conserved at every stage of process. Large quantity of water is re-used &

recycled.

� In power generation Air Cooled Condensor is used in place of cooling towers.

� Uses of water in power plant is reduced drastically by installing Air Cooled Condenser

(Although with a higher capital expenditure) instead of water intensive cooling tower

operation hence reduction in demand of fresh water.

� Company has chosen state of art best available boiler configuration of high pressure

i.e. 125 Kg/Cm2. This resulted in reduction of water top up for the same amount of

energy generation as compared to low pressure boiler.

� Rainwater from rooftop is collected and stored in water tanks and reused.

(viii) Availability of water it’s source, energy /power requirement and source should be given.

(a) Water Requirement and Source

The water required will be same as existing. This is mentioned in table below

TABLE – 7

Water requirement for the entire plant

S. No Plant Facility Units

Season

fresh Water

Requirement

Off Season

fresh Water

Requirement

Remark

1 Domestic KLPD 100 100 -

2 Sugar Unit KLPD 600 --- Working days 160 days

3 Distillery KLPD 150 595

Condensate from Sugar

mill 445 KLPD

Net Fresh water

requirement 150 KLPD

Working Days

(330days/annum)

4 Co-generation

Power Plant

KLPD 400 329 Working Days : 330 days

5

Total Fresh

Water

Requirement

KLPD 1250 1024 Surface water





Water Balance:-

TABLE – 7(A)

Total water input

S. No.

Section Water Quantity (KLD)

1. Process Water in fermentation 638

2. DM water for RS dilution 585

3. DM Water for Boiler Feed 528

4. Soft Water for AnalyserFlash Tank 117

5. Soft Water for Vacuum Pumps & Others 30

6. Soft Water for Makeup for Cooling Tower 350

7. Water in Molasses 90

8. Other Domestic Usage 10

9. Miscellaneous Washings 10

TOTAL WATER INPUT 2358

TABLE - 7(B)

Total Water Output

S. No.

Section Water Quantity (KLD)

1. Steam Condensate 422

2. Water in Spent Wash 748

3. Spent Lees ( Rectifier) 638

4. Spent Lees ( Pre-Rectifier) 83

5. CT Evaporation & Drift Looses 388

6. Domestic consumption 10

7. Boiler Drift & Blow Down 30

8. Vaccum Pump & Sealing 30

9. Miscellanous Washing 10

TOTAL WATER OUTPUT 2358





TABLE - 7 (C)

Recycle & Utilization Streams

S. No.

Section Water Quantity

(KLD)

1 Lees Recycle For RS Dilution 497

2 Steam Condensate Recycle For BOILER 422

3 Spent Lees (Rect) Cooling Tower Make up 230

4 Process Condensate Recycle to Process 583

5 Process Condensate for Cooling Tower Make-up 30

TOTAL RECYCLING /RE -UTILISATIONS OF WATER PER DAY 1762

TOTAL FRESH WATER INPUT 595

(b) Power Requirement and Source

Existing power requirement is 11 MW and additional 1 MW power will be

required for proposed capacity enhancement project. Thus, the total power

requirements after proposed capacity enhancement will 12 MW.

Source: Co-generation Power Plant & D.G Sets (for emergency).

(c) Steam Requirement

Existing total steam requirement is 194 TPH. After proposed capacity

enhancement the total steam requirement will be same.

Source: 3 number of Boilers of capacity 120TPH, 80 TPH and 22 TPH

(incineration Boiler)

TABLE - 8

Steam requirement

S. No. Description Unit Total Proposed

1. LP steam for sugar mill TPH 130

2. LP steam for Distillery TPH 18

3. Steam required for Boiler HP heater TPH 30

4. Steam to condenser TPH 16

5. Capacity of the Boiler required TPH 194

6. MCR Design Capacity of the boiler TPH 222

Boiler details

The existing boilers are sufficient to carter the needs of existing and proposed plant. Other





details regarding boilers are given below:

TABLE – 9

Details of boiler

S.

No Details Units

Type of

fuel

Height of

stack 100% MCR

Remarks

1 Boiler 1 TPH Bagasse /

coal

76 120 Existing

2 Boiler 2 TPH 70 80 40 TPH Existing and to

be increased to 80 TPH

3 Boiler 3 TPH Slop & Coal 65 22 Existing

Pollution control equipment – ESP installed (existing)

Details regarding DG sets

TABLE – 10

Details of DG sets

S. No Details Remarks

1 Capacity 2 x 1000 KVA, 500 KVA, 125 KVA

All are Existing

2 Type of fuel HSD

3 Stack height As per CPCB guidelines

4 Pollution control

equipment Adequate stack height/ Acoustic

(ix) Quantity of waste to be generated (liquid and solid) and scheme for their

management/disposal

• The proposed capacity enhancement project is being/will be based on “ZERO

EFFLUENT DISCHARGE”.

• The spent wash from molasses based distillery is being/will be sent to MEE for

concentration and the concentrated spent wash will be mixed with fuel and will be

burnt in the incinerator boiler.

• A full-fledged ETP for sugar and co-gen is already in place.

• Water is being/will be conserved at every stage of process. Condensate water will

be re-used & recycled.

• Rainwater is being/will be used to recharge the underground water source

through scientifically designed rain water harvesting system.





• Bagasse generated is being/will be used as fuel for Power generation in Co-gen

Power Plant.

• Molasses is dark colour viscous matter generated from Sugar industry. This is

being/will be used as raw material in distillery for alcohol production.

• ETP Sludge generated after treating waste water generated in Sugar Unit is

being/will be used as manure.

• Ash is utilized in in-house brick manufacturing facility and balance given to brick

manufacturers / cement manufacturing.

• Press mud is given to farmers for soil enrichment due to higher nutrients value.

4.0 SITE ANALYSIS

(i) Connectivity

The plant site is located about at Village Asurle-Porle, Tehsil Panala, District Kolhapur

(Maharashtra). NH-204, approx. 2.5 km in NE direction from the plant site and

nearest Kolhapur Railway Station, approx. 13 km in SE direction from the plant site.

It has an easy access to raw material availability and other infrastructural facilities

e.g. land, power, water, transport and communication, approach through road &

access distances from the nearest highway, railway station etc. The site is well

connected with communication facilities like telephone, fax, wireless and telex and

as such, no constraints are envisaged in this aspect also.

(ii) Land from Land use and Land ownership

Total plant area is 34.9 hectares (86 acres). Since, the proposed capacity

enhancement will be done within the existing plant premises by modernization &

efficiency improvement, thus, no additional land is required for the same.

(iii) Topography

The topography of the area 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 Asurle – Porle

2. Nearest Town / City Kolhapur (~ 13 km in SE direction)

3. Nearest National

Highway

NH-204 (~ 2.5 km in NE direction)

4. Nearest Railway station Kolhapur (~ 13 km in SE direction)

5. Nearest Airport Kolhapur (~ 22 km in SE direction)

6. National Parks/ Wildlife

Sanctuaries/ Biosphere

Reserves /Reserved /

Protected Forest within

10 km radius (Boundary

to boundary distance)

No National Park, WildLife Sanctuary, Biosphere

Reserve, Tiger / Elephant Reserve, Wildlife Corridor

within 10 km radius. There are 9 reserved forests.

S. No. Name Distance Direction

1. Porle RF Nearby West

2. Rakshi PF 3.0 km NNW

3. Waghave PF 6.0 km NW

4. Pohale PF 6.5 km ENE

5. Giroli PF 7.0 km NE

6. Sadake PF 8.5 km ENE

7. Jakhale PF 9.0 km NE

8. Kotoli PF 9.5 km WNW

9. Manpadali PF 9.5 km ENE

7. Nearest Water Bodies Kasari River (~2.5 km in South direction)

Panchganga River (~5.5 km in SE direction)

8. Soil type Silty loam, blackish brown

9. Seismic Zone Zone-III [as per IS 1893 (Part-I): 2002]

(v) Existing Infrastructure

Total plant area is 34.9 hectares (86 acres). Presently 60 KLPD Molasses Based

Distillery, 7500 TCD Sugar Mill and 30 MW Co-generation Power Plant already exists.

Proposed capacity enhancement will be done within the existing plant premises by

modernization & efficiency improvement.

(vi) Soil classification

Kolhapur city is known as Karveer Nagari. Kolhapur is located on the Sahayadri

mountain range and south western part of the Maharashtra state. The city is close

to the Konkan coast which is connected by 12 Ghats going through Western Ghats

like Anuskura, Amba, Phonda, Amboli, Bawada, Shivgarh, etc. Kolhapur city is

situated on the bank of Perennial River Panchaganga on the adjoining hill named as

Bramhapuri. The general elevation with respect to mean sea level is 574 m.





Soil

The soils in the region are originated mainly from Deccan Trap. The soils in the

valleys are mixed in character, varying in colors from brownish to radish. The eastern

portion, due to its undulating nature, dipper soils are formed in the low lying parts

while ridges are covered by shallow soils.

Physio-graphically, Kolhapur district can be divided into three broad soil zones: (a)

the western part, with heavy rainfall (is mountainous and woody and is covered with

lateritic soils); (b) the fertile central part, with brownish well-drained soils of neutral

reaction; and (c) the dry eastern zone, with precarious rainfall and covered with

medium black soil of varying depth.

Lateritic soils (Tambad mati) occur mainly in the western hilly tracts of heavy rainfall,

on the hill tops and in the ridges which are not covered by forest, They are found in

the western parts of Karvir, Bhudhargad and Ajra and the whole of Shahuwadi,

Panhala, Radhanagari and Bavadatalukas. They are red to brownish-red in colour,

mostly eroded and shallow with good drainage. The soils are acidic with low

phosphoric contents and liming has been found to be beneficial. They are not

retentive of moisture and hill millets are predominantly taken from them. When

terraced, applications of nitrogen and phosphorus are found quite useful and in such

cases paddy crop can also be taken from the soil.

In the valleys, lateritic soils are mixed with trap soils. They vary in colour from brown

to black, are fairly deep retentive of moisture. Paddy is the main crop of this area

and in the rabi season vol is also grown wherever possible.

(vii) Climatic data from secondary sources

Kolhapur's climate is a blend of coastal and inland elements common to

Maharashtra. The temperature has a relatively narrow range between 10°C to 35°C.

Summer in Kolhapur is comparatively cooler, but much more humid, than

neighbouring inland cities. Maximum temperatures rarely exceed 38 °C and typically

range between 33°C and 35°C. Lows during this season are around 24°C to 26°C.

The city receives abundant rainfall from June to September due to its proximity to

the Western Ghats. The heavy rains often lead to severe flooding during these

months. 2005 and 2006 were years when floods occurred. Temperatures are low in

the rainy season and range between 19 °C and 30 °C.

Kolhapur experiences winter from November to February. Lows range from 9°C to





16°C while highs are in the range of 26°C to 32°C due to its high elevation and being

adjacent to the Western Ghats. Humidity is low in this season making the weather

much more pleasant.

(viii) Social Infrastructure available

Nearest habitation are at Asurle - Porle village. The nearest City is Kolhapur, which is

approx. 13 km distance from the plant site.

At Kolhapur City schools, Hospital, dispensaries, colleges, places of worship, Railway

station, Markets & other facility etc are available. Electrical power supply in most of

surrounding villages is available.

Mobile, Medical facilities are available in the nearby towns. Almost all the villages in

the buffer zone are electrified. L.T. power is being supplied for drawing water from

a large number of tube wells sunk around the important village of the buffer zone,

for irrigation purpose. Most of the tanks and ponds as well as the river water are

being utilized for irrigation.

5.0 PLANNING BRIEF

(i) Planning Concept (type of industries, facilities, transportation etc.) Town and

country Planning/ Development authority classification.

The existing unit is Sugar Mill complex along with Distillery industry and proposed

capacity enhancement will be done within the existing plant premises by

modernization & efficiency improvement. Facilities required for the proposed

capacity enhancement project will be provided as per requirement. Transportation

of raw material and final product is being / will be done by road.

(ii) Population Projection

No influx of people will be there as the proposed capacity enhancement will be

done by modernization & efficiency improvement by adopting improvement in

Fermentation & Distillation Technology.

(iii) Land use planning (breakup along with green belt etc)

Total Plant area is 34.9 hectares (86 acres). Proposed capacity enhancement

project will be set up in the existing plant premises. No additional land will be

required. About 33 % of the total plant area is already covered under greenbelt &

plantation in order to reduce dust & noise pollution levels & to increase aesthetic

beauty of the area.





(iv) Assessment of infrastructure demand (Physical & Social)

Shri Datta Sakhar Karkhana (A unit of Dalmia Bharat Sugar & Industries Ltd.) has

assessed the demand of infrastructure (Physical & Social) in nearby area of the

plant site and development activities are being undertaken under corporate social

responsibilities program for rural development initiatives for the upliftment of the

nearby communities from time to time.

(v) Amenities/Facilities

Shri Datta Sakhar Karkhana (A unit of Dalmia Bharat Sugar & Industries Ltd.) has

developed and will further develop the Amenities/Facilities in nearby area of the

proposed capacity enhancement plant site as per requirement of local people of

the nearby area under corporate social responsibilities programs.

6.0 PROPOSED INFRASTRUCTURE

(i) Industrial Area (Processing Area)

No additional infrastructure will be required for the proposed capacity enhancement

project as the same will be done within the existing plant premises by modernization

& efficiency improvement.

(ii) Residential area (Non Processing area)

No residential area is envisaged.

(iii) Greenbelt

Out of the total plant area of 34.9 hectares (86 acres), 11.53 hectares (28.5 acres)

almost 33% has been proposed to be developed under greenbelt / plantation. The

same will be maintained for proposed capacity enhancement project, in order to

reduce dust & noise pollution levels & to increase aesthetic beauty of the area.

(iv) Social Infrastructure

Proposed capacity enhancement plant will result in growth of the surrounding areas

by ancillary development and supporting infrastructure in the region.

(v) Connectivity

The site is well connected with communication facilities like telephone, fax, and

wireless as such, no constraints are envisaged in this aspect as the Tehsil and District

headquarters are near to the site.

(vi) Drinking Water

15 m3/ day water will be required for drinking purpose after proposed capacity

enhancement project.





(vii) Sewage Treatment System

A Full-fledged STP for domestic sewage is already in place.

(viii) Industrial Waste management

The present Molasses based distillery project is commissioned on “ZERO EFFLUENT

DISCHARGE”.

(ix) Solid Waste Management

• In Molasses based operation complete spent wash is being/will be concentrated

& incinerated and no spent wash is being/will be discharged.

• Bagasse generated is being/will be used as fuel for Power generation in Co-gen

Power Plant.

• Molasses is dark color viscous matter generated from Sugar industry. This is

being/will be used as raw material in Distillery for Alcohol production.

• ETP Sludge generated after treating waste water generated in Sugar Unit is

being/will be used as manure.

• Ash is utilized in in-house brick manufacturing facility and balance given to brick

manufacturers / cement manufacturing.

• Press mud is given to farmers for soil enrichment due to higher nutrients value.

(x) Power requirement and source

Existing power requirement is 11 MW and additional 1 MW power will be required for

proposed capacity enhancement project. Thus, the total power requirements after

proposed capacity enhancement project will 12 MW.

Source: Co-generation Power Plant & D.G Sets (for emergency).

7.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN

(i) Policy to be adopted (Central/State) in respect of the project affected persons

including home oustees, land oustees and landless labourers (a brief outline to be

given).

Proposed capacity enhancement will be done within the existing plant premises. No

additional land is required for proposed capacity enhancement project. Therefore

there will not be displacement of people and hence Rehabilitation & Resettlement is

not applicable.





8.0 PROJECT SCHEDULE AND COST ESTIMATES

(i) Likely date of start of construction and likely date of completion (time schedule for

the project to be given).

The project will start only after obtaining Environmental Clearance and other

statutory permissions. Project will be completed in 12 months period after getting all

the regulatory approvals.

(ii) Estimated project cost along with analysis in term of economic viability of the

project.

� Total cost of the Project: Rs. 60 Crores

� Cost for Environment Protection Measues:

� Capital Cost: Rs. 5 Crores

� Recurring Cost/annum: Rs. 1.0 Crores/annum

9.0 ANALYSIS OF PROPOSAL

(i) Financial and social benefits with special emphasis on the benefit to the local

people including tribal population, if any, in the area.

Proposed capacity enhancement project will result in growth of the surrounding

areas by increasing direct and indirect employment opportunities in the region

including ancillary development and supporting infrastructure. Special emphasis on

Financial and Social benefits will be given to the local people including tribal

population, if any, in the area.

Development of social amenities will be in the form of medical facilities, education

to underprivileged and creation of self help groups.

Maharashtra state will get revenues in terms of taxes and local people will get direct

& indirect employment. Sugar Cane is one of the important cash crop of India. The

industry is based on sugar cane & its allied by-products help farmers and

employment to the rural people.

Business opportunities for local community will be available like transport of cane,

alcohol, fly ash. In addition to above local people will be benefited with maintenance

& house-keeping contract work etc.

at village asurle-porle, tehsil panhala, district...

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