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Shri Gurudatt sugars ltd, Gut No.61, Akiwat Takliwadi Road, Tq. Sirol, Dist. Kolhapur (Maharashtra) Prefeasibility Report

2014

CONSULTANT: sd engineering services private limited, Aurangabad (MS) Pg. 1

INDEX

1. EXECUTIVE SUMMERY

2. INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

2.1 Identification of the project and Project Proponent

2.2 Nature of the Project

2.3 Need of project with description for region and country

2.4 Demand and Supply gap

2.5 Imports vs. Indigenous production

2.6 Export Possibility

2.7 Domestic/ Export Markets

2.8 Employment Generation due to Project

3. PROJECT DESCRIPTION

3.1 Type of Project

3.2 Location of Project

3.3 Details of Alternate sites

3.4 Size of magnitude of Operation

3.5 Project Description

3.6 Raw material and Finished Products

3.7 Resources optimization

3.8 Availability of Resource (Water, Energy/ Power Requirement)

3.9 Quantity of Waste to be Generated

4. SITE ANALYSIS

4.1 Connectivity

4.2 Land form, Land use, Land ownership

4.3 Topography

4.4 Existing land use pattern

4.5 Existing Infrastructure

4.6 Soil classification

4.7 Climatic data for secondary sources

4.8 Social Infrastructure available

5. PLANNING BRIEF

5.1 Planning concept


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5.2 Population Projection

5.3 Land use planning

5.4 Assessment of Infrastructure Demand

5.5 Amenities/ Facilities

6. PROPOSED INFRASTRUCTURE

6.1 Industrial area

6.2 Residential area

6.3 Green Belt

6.4 Social Infrastructure

6.5 Connectivity

6.6 Drinking Water Management

6.7 Sewerage System

6.8 Industrial Waste management

6.9 Air Pollution

6.10 Solid waste Management

6.11 Power Requirement & Supply/ Source

7. REHABILATION AND RESETTLEMENT (R & R PLAN)

7.1 Policy to be adopted

8. PROJECT SHEDULE & COST ESTIMATES

8.1 Time schedule for the Project

8.2 Estimated project cost (Economic viability of the project)

9. ANALYSIS OF PROPOSAL

9.1 Financial and Social benefits


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CHAPTER 01

EXECUTIVE SUMMARY

M/S SHRI GURUDATTA SUGARS LTD is proposing an expansion of Sugar plant & Co-

Generation. Shri Gurudatta Sugars is desirous to produce sugar & energy in this Large Size

Industrial (LSI) sector at Gut no.61, Akiwat, Takaliwadi Road, Takaliwadi, Taluka-Shirol, Dist-

Kolhapur Maharashtra. Capacity of the complex shall be Sugar manufacturing from 4900TCD to

6000 TCD, & Co-generation capacity from 15 MW to 21 MW.

The Notification no S. O. 1533 promulgated on 14th September 2006 have covered these types of

industries under its entry 5(j) & 1(d).

The land is on Gut no. 61 admeasuring area of 36.72 Hectare. Proposed Layout Plan is attached.

This is an Agricultural Land. The Land shall be changed to Industrial Land use. Thus there is a

change in the status. This project is an expansion industrial Unit. The main river, city, Railway

line, National Highway is sufficiently at a safe distance. Local Authority has provided all

infrastructures like assured Electrical Power, Continuous water supply, the internal road network,

external approach road and networking. There is no sensitive establishment in the vicinity (study

zone) such as health resort, hospital, archaeological monuments, sanctuaries etc. All villages are

provided with drinking water from wells or Government Water Supply Schemes RWS. Hence we

do not encroach upon their resource.

There will be no nuisance from noise. Machinery and Equipments will be provided with Acoustic

Enclosure. There will not be crushing, pulverizing operations. Labour strength is also limited in

this LSI unit. In this case input is odorless. No nuisance generation.

Shri Gurudatta Sugars Ltd is desirous to produce the products like sugars and Power.

List of Products:

Sr. No. Product name Quantity Unit

1. Sugar cane crushing 6000 TCD/ Day 2. Power Generation 21 MW/ Day


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Whereas, during production water input requires 418 M3/day. Fuel used will be bagasse.

In Shri Gurudatta Sugars Ltd Safety and occupationally Health will be dealt carefully. A

disciplined approach is natural to this industry. Safety policy will be in place. This unit is

registered under Factories Act and is bounded by State Factory Rules. Thus, first aid trained and

Fire– fighting trained person will be available in every shift. Safety Officer will be appointed.

Wherever necessary, provisions of other Acts, like petroleum Act, Explosive Act etc. will be

obeyed. Firefighting system is kept as per norms of Insurance Company and CIF.

DMP (Disaster Management Plan) and off-site emergency plan will be in place. Accordingly,

Personal protection equipment will be given and use will be insisted. Consulting physician will be

retained to attain the factory.

This proposed project is located at village Akiwat, Takaliwadi Road, Takaliwadi, Tal:-Shirol,

Dist. Kolhapur, Maharashtra. The infrastructure like road transmission lines is made available by

local authority and the raw material is easily available. The Kolhapur city has Railway station and

Air port. State Highway is passing adjacent to the project site.

The industry is manufacturing Sugar and power for growing needs of India. This will not disturb

the present land use because our area occupied will be only small % of influence zone of 10 km.

There will be no problematic waste materials as all will be disposed as per CPCB norms.

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CHAPTER 02

INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

2.1 Identification of the project and Project Proponent

Shri Gurudatta Sugars Ltd, acronymic (GSL), a limited company is floated and promoted by a

reputed well-known Industrial family in Kolhapur District in Maharashtra state.

The group is managing sugar factories has been the recipient of many prestigious awards from

government and Sugar Institutes for efficient management and attaining excellent results and

efficiencies.

M/s Shri Gurudatta Sugars Ltd. factory will be promoted at Gut no. 61 Village Akiwat near

Takliwadi, in Shirol tahesil of Kolhapur District (MS).

Application has been made to MPCB for the Consent to establish. The manufacturing site is

located on Gut No. : - 61, village Akiwat, Near Takaliwadi Road, Takaliwadi in Shirol tahsil of

Dist.:- Kolhapur in Maharashtra. The plot admeasures about 36.72 hectares. The company shall

manufacture sugar and power.

Form I, as is prescribed by the EIA Notification, 2006 amendment 2009 is duly filled up and

submitted. This Pre-feasibility Report is an accompaniment to the same.

The Form I & Prefeasibility report generally covering Justification, Nearby Land Use, Resources,

Process, Pollution Control, Aesthetics, Risk Involved, Consequent Developments and

Environmental Sensitive Issues.

2.2 Nature of the Project M/s Shri Gurudatta Sugars Ltd. (GSL) is proposing expansion Project with capacity to

manufacture sugar from 4900 TCD to 6000 TCD & Power from 15 MW to 21 MW. This level of

production will not be commenced from day one, but will be commissioned smoothly. This is an

optimum site for us because it is manageable from production, pollution control and quality

assurance point of view.

2.3 Need of project with description for region and country

1. India has been known as the original home of sugar cane and sugar. India is the second

largest producer of sugar in the world after Brazil and produces more of cane sugar and


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not beet sugar. It produces approximately 22 million tons of sugar annually with

Maharashtra contributing over one-third of it.

2. In India sugar is a prime requirement in every house hold. Almost 75 % of the sugar

available in the open market is consumed by bulk consumers like bakeries, candy makers,

sweet makers, & soft drink manufactures.

3. The crushing season in the country starts from October and reaches its peak in January

before finally ending in March or April of the next year. But based on cane availability,

the start of crushing season may postponed by one to one and half months in different

states of the country.

4. The period of November to March, 150 days is an ideal one for sugar recovery in general,

more particularly in Bihar & Uttar Pradesh. From April onwards, sugar recovery shows a

down ward trend and in June the percentage of sugar recovery comes to lowest levels.

5. Sugar cane and sugar production in India typically follows a cyclic pattern, wherein 2 to 3

years of higher production are followed by 3 to 4 years of lower production.

6. The production of sugar cane in India has increased during the last ten years and is still on

an increasing trend. The productivity of cane in the northern areas of the country is lower

than the productivity in southern areas. In India, sugar is grown over 4 million hectares of

land

7. After two consecutive years of decline in sugar production i.e. MY 2008/09 & MY

2009/10 (Marketing Year), production has started to resurge in MY 2010/11 & is gained

in 2011/12. The gap between demand & supply is narrow and depends mainly on climatic

conditions and cane sugar price, Fair and Remunerative Price (FRP) declared by the

government.

8. Maharashtra has huge deficit in power generation & requirement.

9. The power generation from biomass is eco- friendly compared to other sources.

10. Investment for power generation is minimum as compared to other sources of power.

Justification: -

1. In the industry, effluent produced is only water. Therefore, problems of pollution hazard

are nil.

2. Consent from Environmental Department and Pollution Control Board can be easily

obtained as a matter of routine.


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3. Cane growing needs a longer time to get the crop. The management of sugar factory is

implementing lift irrigation schemes for sugar cane growers under the cane development

program.

4. They have decided to implement drip irrigation scheme to irrigate more land in minimum

water quantity. Thus large water is conserved.

5. It is proposed to use water from cane for power generation thus reducing water

requirement practically.

• How this project is economically strong.

• How the wastage and scrap arising out of one development activity can serve as raw

material for us, in turn again to be useful to serve further national development in

building, bridges, factories etc.

• How the pollution generated from this unit can be successfully managed through EMP

implementation.

• How the residual pollution can be successfully managed through common facilities like,

though it is hardly needed in this instant case.

2.4 Demand and Supply gap

As per the increase in population demand in the Market for sugar always prevail. As far as the

products like sugar, powers are concerned; there is a huge gap in our country in demand and

supply.

2.5 Imports vs. Indigenous production

Sugar Statistics (All India)

Year � 2006/07 2007/08 2008/09 2009/10 2010/11 2011/12 Total sugar production* (000, tones)

28361 26356 14538 18912 24394 25500

Sugar import/export Export and Import depends up on Production, Supply & Demand

*includes Khandsari Sugar 2006/07-500, 2007/08-425, 2008/09-435, 2009/10-343, 20010/11-420 World Scenario:-


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1. Over 3/4ths of the total sugar produced is consumed domestically in the countries in which it is produced, and the rest is treaded around the globe which is often termed as World Sugar.

2. The world exports of sugar however around 40 million tons and the leading sugar exporting country is Brazil exporting to around 55 % of its total produce.

3. Contribution of sugar production (%) of India in total world sugar production

European Union 10.42 % Brazil 22.66 % India 14.49 % China 8.23 % USA 4.53 % Australia 2.74 % Thailand 4.59 % Mexico 3.3 % Pakistan 2.39 % Russia 2.20 % Rest World 24.44 %

As per the increase in demand of products, need of Imports may get increased. But if production

is done in self sufficient manner at the national level (indigenously), there is no need of

dependency on the other resources for the Import of goods. Power generation with bagasse helps

to reduce solid waste quantity as also will be the best use of bio-waste to energy generation

concept.

Export Possibility

1. Marketing will be done at national level as well as international level. Requirement of

alcohol and Sugar globally is always be there.

2. There is a huge potential for these products in global market. Around 30-40 % finished

goods can be exported to the Regulated and non regulated international Market.

2.6 Domestic / Export Markets:

Marketing will be done at the local level as well as finished goods will be exported to the

Regulated and non- regulated International Market. Power will be consumed locally.


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2.7 Employment Generation due to Project:

Employments generated for administration and production purposes will be recruited locally

without any difficulty. Indirect employment is done through road-side business & allied activities.

Sr.

No.

Types Of Worker

No. Of Workers

Existing

No. Of Workers

Proposed

Total

1. Skilled

326 10 336

2. Unskilled 165

10 175

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CHAPTER 03

PROJECT DESCRIPTION

3.1 Type of Project:

Shri Gurudatta Sugars Ltd is proposing an expansion of Sugar plant & Co-Generation. Shri Gurudatta

Sugars is desirous to produce sugar and energy in this Large Size Industrial (LSI) sector at Gut no. 61,

Village Akiwat, Near Takaliwadi, Takaliwadi, Taluka:-Shirol, Dist:-Kolhapur Maharashtra. Proposed

capacity of the project Sugar manufacturing from 4900TCD to 6000 TCD, & Power from 15 MW to

21 MW.

With Screening it is necessary for GSL to approach Delegated Authority from Ministry of

Environment and Forest (MoEF), New Delhi for Environment Clearance for guidance for this unit.

This Pre-feasibility report however, is prepared for forming a framework for EIA study, Scoping and

finalizing the Terms of Reference, as may be required.

The Local Authority has a desire to improve status of this District and has encouraged Industrial

establishments at Takaliwadi. In order to have a sustainable development, the pollution generation

from this industry is finally made insignificant having taken all the precautions right from raw

material selection up to low or no waste generation and conversion.

3.2 Location of Project:

The proposed production shall be at Gut no. 61 of Village Akiwat, Near Takaliwadi Road Takaliwadi

Taluka: - Shirol of Dist.:- Kolhapur in Maharashtra state. Area is around 36.72 hectares.

The Geographical Location of this Industry is 16037’15.5”N latitude and 74035’39.5”E Longitude with

an elevation of 540m. Local Authority has assured to provide all infrastructures like assured Electrical

power, continuous water supply, the internal road network, external approach road etc.

Some important air distances from proposed site are as under…..

1. Nearest air port Kolhapur – 35.50 km towards West direction

2. Nearest Railway Jaysingpur – 15 km towards North West direction.

3. Nearest Habitat is village Takaliwadi at 01.20 km towards NE direction.

4. Nearest River is Krishna 04.19 km towards South East direction.

GPS Location and Google Imagery of the proposed site are attached (Annexure I)

Site Analysis:-

As this is an expansion project hence there is no new site selection.


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Lay-Out

Layout is designed properly. It is proposed to make construction to house storage yards for Raw

Material and finished products, ware houses, utility building, Canteen and administrative offices etc.

The Layout of facility is prepared based on following:

1. There will be sufficient space for the movement of vehicles especially fire tender.

2. Shortest route for transfer of Raw material & Products from one department to other.

3. Consideration of prevalent Wind speed & direction for dispersion of Pollutants.

4. Optimum Utilization of utilities.

5. Use of Natural gradient to transport waste water.

Proposed Layout Plan is given as (Annexure IV)

3.4 Size or Magnitude of Operation:

Shri Gurudatt Sugars Limited (GSL) is proposing expansion with capacity as, sugar 4900 TCD to

6000, Power 15 MW to 21 MW. This level of production will not be commenced from day one, but

will be commissioned smoothly. This will not disturb the present land use because our area occupied

will be only small % of influence zone of 10 km. Landscape and greenery will be developed in 33%

area and only native species will be promoted. No Rehabilitation is required.

3.5 Project Description with Processes Details:

Product Details:

Sr. No. Product name Quantity Unit

1. Sugar cane crushing 6000 TCD/ Day 2. Power Generation 21 MW/ Day

The Plant will house the following equipments:

Plant and Machinery: Co-generation Unit

• Machinery & Hardware 1. ( 70+40)=110 TPH steam generation and working pressure and steam temperature of 45

kg/cm2g and 520 degree C respectively. 2. Turbo generating set based on Double Extraction cum condensing mode and with

generation capacity of total 21MW. Ancillary machinery


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1. Single entry condensers & Cooling Towers, for co-generation units, which consume less water and hence less power.

I. MANUFACTURING PROCESS A. Co-generation Unit

Cogeneration Process (During Season)

B. Co-generation Unit:

Cogeneration Process (During Off – Season

~ ~

(70+40 = 110) TPH – 45 Kg/cm2 Pressure Boilers

6 MT

High Pressure

Use Steam Turbine Bank‐ 21MW

90 MT Exhaust Steam for Process

84MT 20 MT

5.5 MW for Use

15.0 MW

To Grid

110MT

~ ~

70 TPH – 45 Kg/cm2 Pressure Boiler

0 MT

High Pressure

Use Steam Turbine Bank‐ 21MW

0 MT 70 MT

2.5 MW for Use

13.0 MW

To Grid

70 MT

69 MT Exhaust Steam for

Condensation


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B.Sugar Manufacturing Process


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3.6 Raw Material for finished Product:

List of Raw Materials:

A. For sugar production

Sr. No. Raw Material Quantity/day Quantity/month

1. Sugarcane 6000 MT 1,80,000 MT

2 Lime 13.2 MT 396 MT

3. Sulphur 4.32 MT 129.6 MT

B. For power generation

Sr. no. Raw Material Quantity /day

1 Baggase 2100 MT/day

3.7 Source for Raw Material Procurement: Raw Material is easily available in area around the

sugar factory.

Mode of Transport of Raw Materials: The raw materials will be transported locally by way of road.

Storage at the site: The raw material which is cane shall be crushed as early as possible to have

maximum sugar recovery. A terminus is provided to hold vehicles bringing in sugar cane.

3.8 Availability of Resources (Water, Energy/Power Requirement):

Power: The total power generation here will be 21 MW/day. The power required for the factory will

be consumed from the in-house production and excess will be sold to MSEB.

Water: The water requirement is about 418 cum/ day for domestic, greenery, process, and part

cooling purposes. The source of water is already available from Krishna River and the same is

adequate and satisfactory. The source is dependable and reliable.

Manpower: The manpower required for administration and production purposes will be recruited

locally without any difficulty. The requirement will be variable as per phase of working but shall be

about 511 Nos. workforces including staff members shall work in shifts.


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Land: Approximately 36.72 hectare of land is already in the possession of proponent.

Cost: 86.34 Cr. for this unit.

EMP Cost: 11.50 Cr. for this unit.

3.9 Quantity of waste to be generated:

Water & wastewater

The water supply will be through the Krishna River. The water & wastewater generated in the factory

will be as follows:

Sr. No.

Water Consumed

Water consumption

(m3/d)

Losses

(m3/d)

Effluent (m3/d)

Remark

1. Domestic

• Industrial (Toilet, Canteen etc.)

• Residential quarters

130

32

98

Easily Bio- Degradable.

2. Cooling

• Bearing cooling • Pump gland cooling • Ejector condenser

3300

480

----

Recycled after cooling.

3. Industrial Processes like washing, cleaning

600 ‐ 600 Subjected to ETP

4.

Boiler feed (Make up) 288 260 28

5. DM regeneration 20 ---- 20

Effluent Generations:-

Sr. No. Effluent Generation Qty. (m3/d)

1. Domestic 98

2. Industrial Sugar 600


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3. Co-Gen 48

Water Pollution Control:

Domestic Wastewater

a) CONSTRAINT CONDITIONS Flow : 98 cum/d

pH : 7.0 – 7.5

C.O.D. : 250 – 300 mg/l

B.O.D. : 100 – 200 mg/l

Industrial Waste (CoGeneration)

a) Constraint Conditions Flow : 48 cum/d

pH : 6.5 – 7.5

C.O.D. : 100 mg/l

B.O.D. : 20 – 40 mg/l

Treatment Approach for Effluent Treatment:

All the effluent streams contain inorganic matter in suspended solids or in dissolved form and there is no organic matter concentration. The boiler blow down stream contains suspended solids to large extent besides having temperature. Settling tank is therefore proposed before the stream is connected to collection tank.

All the other streams contain inorganic matter in dissolved form, besides having variable pH.

The stream of domestic effluent after septic tank and anaerobic filter, the stream of boiler blow down after settling tank and all other streams are joined to 12 hour retention collection tank, where most of the variations in pH shall be absorbed. However arrangement shall be made for correction of pH to bring the same in the desired range if required. Treated effluent thereafter shall be passed to Dual media filter and then shall be disposed on land for irrigation.

UPGRADATION OF EFFLUENT TREATMENT PLANT

CONSTRAINT CONDITIONS


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Sr. No. Parameter Unit Design Value Performance Parameters

1 Flow m3/hr 600 600

2 pH -- 5-6.5 7 – 7.5

3 C.O.D. mg/L 2000-3500 < 150

4 B.O.D mg/L 1000-1600 <50

5 O& G Mg/L 10-20 <1

=================

SCHEMATIC PROCESS FLOW DIAGRAM FOR

EFFLUENT TREATMENT AT SHRI GURUDATTA SUGARS LTD.

SETTLING TANK

Boiler Blow

Down

Domestic Effluent

SEPTIC TANK ANAEROBIC FILTER

DMF COLLECTION TANK

NEUTRALIZATION TANK

Disposal on land for irrigation

DM Regeneration


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SALIENT TECHNICAL DETAILS OF THE SCHEME PROPOSED.

Component

1. Screens Existing DSM screen to be used.

2. Oil Skimmer New Horizontal Oil Skimmer to be installed.

3. Equalization tank Existing Tank of 300 cum capacity to be used.

4. Anaerobic filter Existing tanks to be utilized by addition of Anaerobic PVC structured media of 670 cum.

5. Aeration tank I Existing 900 cum tank to be used.

6. Aeration mechanism 25 HP equivalent Diffused Air aeration with microbubble diffusers

7. Clarifier I Existing 7 m dia clarifier to be used.

8. Aeration tank II Existing 900 cum tank to be used.

9. Aeration mechanism 5 HP equivalent Diffused Air aeration with micro bubble diffusers

10. Clarifier II New 7 m dia x 2.5 m SWD clarifier proposed.

11. Sludge Recycle Pumps of 7.5 cum/hr proposed for Primary and Secondary.

12. S.D.B. Existing SDB of 50 SQM to be used..

13. Dual Media Filter with Dosing Systems

New system with 25 cum/hr capacity proposed.


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Mill House Effluent

Boiling House Effluent

DSM Screen

(Existing)

500 m3/d

Equalization Tank

(Existing)

Anaerobic Filter

(Existing Tank to be converted by inclusion of Media)

Aeration Tank

(Existing tank to be used)

Addition of New Diffused Aeration System

Clarifier

(Existing)

Treated Sump

(Existing)Disposal on Land for

Irrigation

Clarifier

(Existing)

Aeration Tank

(Existing tank to be used)

Addition of New Diffused Aeration

System

O& G Skimmer

(New)


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AIR POLLUTION CONTROL Capacity Increase in Co‐Generation without Additional Fuel Burning/Emission:

PARAMETER PRESENT

CONSENTED

IMPROVEMENT

PROPOSED

IMPACT

BOILER I II I II

CAPACITY TPH 70 40 70 40 NIL,SINCE NO CHANGE

FUEL CONSUMPTION TPH 47.8 47.8 NIL,SINCE NO CHANGE

STEAM TEMPERATURE

(0C)

500 500 POSITIVE,AS POWER

GENERATION SHALL

IMPROVE FOR THE SAME

STEAM QUANTITY

CO‐GENERATION CAPACITY 15 MW 20.5 MW POSITIVE,SINCE INCREASE

IS WITHOUT ANY

ADDITIONAL FUEL

BURNING,AND

EMISSIONS

STACK ATTACHED

(Dia. In M)

2.3 2.3 NIL,SINCE NO CHANGE

HEIGHT (M) 65 65 NIL,SINCE NO CHANGE

CONTROL EQUIPMENT WET SCRUBBER WET SCRUBBER &

ESP

POSITIVE SINCE BETTER

EFFICIENCY CONTROL

EQUIPMENTS ARE

PROVIDED

i. Solid Waste: - The main solid waste from this factory will be of non-hazardous from

office, garden and Sewage Treatment Plant. Non hazardous waste will be segregated as

compostable and saleable. This will be so done.

GSL has in place the following mitigation policy future:


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• Waste minimization at all levels of operations.

• The plant will produce very less amount of scrap material. All these will however be

stored carefully on raised platform, with dwarf toe-walls all around and an overhead roof.

• The main solid waste from sugar unit will be in form of bagasse which is utilized

completely for power generation.

• The hazardous waste will be disposed scientifically as per the norms.

(a) Non Hazardous Solid Waste:

Based on above working, the summery is:

Sr. No.

Waste Quantity kg/day Treatment Disposal Remark

1. Canteen 21 Compost Own garden Organic 2. Garden Trash 110 Compost Land filling ---- 3. Office waste 30 Collection Sales For Recycle 4. ETP Sludge 15MT/Y Used as

manure

(b) Hazardous Waste:

Sr. No.

Sch.- I / II Type of Waste Quantity Treatment / Disposal

1. 5.1/5.2 Used/ Spent oil 200 Kg/A Reuse in own boiler as fuel

Aesthetics: Boiler Turbine, Cane Crusher, Centrifuges etc. shall be source of noise and

vibrations. Sturdy foundations and anti vibration arrangements shall be provided to reduce the

effect. Acoustic enclosures and enclosures shall be done to reduce noise level. Tree plantation

will be carried out. . PPF’s will be provided to the workers in this area. There will be no nuisance

from noise as the machinery and equipments are acoustically enclosed. DG sets will run

occasionally. No nuisance will go to surrounding area.

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CHAPTER 04

SITE ANALYSIS

4.1 Connectivity:

The proposed production shall be at Gut no. 61 of Village Akiwat, Near Takaliwadi Road

Takaliwadi in Taluka – Shirol of Dist.:- Kolhapur in Maharashtra state. Total area is around 36.72

acres.

The Geographical Location of this Industry is 16037’15.5”N latitude and 74035’39.5”E Longitude

with an elevation of 540m. Local Authority has assured to provide all infrastructures like assured

Electrical power, continuous water supply, the internal road network, external approach road etc.

Some important air distances from proposed site are as under…..

1. Nearest air port Kolhapur – 35.50 Km towards West direction.

2. Nearest Railway station Jaysingpur – 15 Km towards North West direction.

3. Nearest Habitat is village Takaliwadi at 01.20 km towards NE direction.

4. Nearest River is Krishna 04.19 km towards South East direction.

GPS Location and Google Imagery of the proposed site are attached.

4.2 Land form, Land use and Land ownership:

Land Form: Although land is on the upper elevation compared to the surrounding area, the said

Land has a large portion with plain contour. Slope is gentle to moderate type.

Land Ownership: Land ownership is with project proponents. Total area is about 36.72 hectare.

Existing Land use Pattern: The Land is agricultural and is barren with no cultivation. This

agricultural land will be now used for the industrial purpose. This being expansion project on

same land there is a no change in land use pattern. This Project will participate in improvement of

the physical infrastructure of this area by incorporating Roof rain water harvesting, Storm water

management and green belt development.

4.3 Topography:

Proposed site is located on the topographically flat terrain with very less undulations. There is no

river or stream or natural drainage line is passing through the area.


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4.4 Soil Classification:

The dry eastern zone with precarious rainfall is covered with medium to deep black fertile soils

of varying depths. This zone consists of Gandhinglaj, Kagal, Karveer, Hatkanangale and Shirol

taluka. In this zone the crops like jawar and groundnut are cultivated on a large scale as well as

the crops like paddy, sugarcane and vegetables are grown with the help of irrigation water.

4.5 Climate data from secondary sources:

The climate of the Kolhapur plain is temperate and similar to the other district of Bombay Deccan

adjoining the ghats. In the western part of Kolhapur near the Sahyadris, it is always cooler than

that in the eastern part which is liable to hot winds during April and May. The nights over the

whole district are generally cool due to the influence of the sea breezes which set in during the

afternoons and continue till late in the evening.

The whole year climate of Kolhapur district may be divided into three periods as follows: - (i) hot

weather period from March to May; (ii) rainy period from June to October and (iii) cold weather

period from November to February.

Temperature: The climate of the Kolhapur plain is temperate and similar to the other districts

of Bombay Deccan adjoining the ghats. In the western part of Kolhapur near the Sahyadris it is

always cooler than that in the eastern part which is liable to hot winds during April and May.

The nights over the whole district are generally cool due to the influence of the sea breezes

which set in during the afternoons and continue till late in the evening.

The year in respect of Kolhapur district may be divided into three periods as follows:-hot

weather period from March to May; rainy period from June to October; and cold weather

period from November to February. There is only one observatory in the district located at

Kolhapur, which maintains temperature and related meteorological records.

The data available in another observatory in the neighborhood at Miraj have also been utilized

in describing the climate of the district. The mean daily maximum and minimum temperatures

and relative humidity for the city of Kolhapur based on available data (1949-58).

There is a rapid rise in temperature in March, reaching the maximum in May. May is the

hottest month of the year, with a mean maximum temperature of 99°F. The corresponding

figures for March and May are 96 °F. and 95 °F. respectively. Daily maximum temperatures

exceeding 100°F. are fairly frequent in May. On an average there are 12 such days. The

highest temperature recorded at Kolhapur during the last decade is 107°F. Temperatures


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exceeding 110°.F. are unlikely in this district. The mean daily maximum: temperature varies

from 66 °F to 72 °F the diurnal variation of temperature is large and the mean value ranges

from 30.7°F. in March to 22.7°F in May.

On individual days a range of 35°F. in March is not uncommon. The mean relative humidity in

(March to May) this period is 65 per cent, in the morning and 35 to 40 per cent, in the evening.

Low values of humidity of the order of 15 to 20 percent occur in these months in the

afternoon. The prevailing wind direction is mainly westerly though in the afternoons of March,

and April, easterly winds occur on about 50 per cent, of the days.

This is also a season of thunderstorm. At Kolhapur, one day in every three or four days in

April and May, is a day of thunder. The rainfall in this season is accompanied by

thunderstorms and it is about 1" in April and 1½" in May. This period accounts for about 10

per cent, of the total annual rainfall.

The normal period of the onset of the South-West monsoon in the district is the first week of

June. With the onset of the monsoon there is a rapid fall in the day temperatures and

conditions of near uniformity over wide areas are reached in the months of July and August.

The mean daily maximum temperature for July and August is 79 °F. Towards the end of

September temperatures again begin to rise. The moisture content of the atmosphere in this

season is very high and the air is nearly saturated on several days. The mean relative humidity

for June to September is 87 per cent, in the morning and 77 per cent, in the evening. The

direction of winds during this period is mainly westerly. There is a complete changeover in

October when the winds are mainly from North-East to East. The annual rainfall varies widely

in the district from 20" in the North-East to 250" in the west. This is the main rainy-season. A

fuller account of rainfall.

Although day temperature remains higher than in the monsoon, the mean minimum

temperature is the lowest and it ranges from 58° to 61 °F. December and January are the

coldest months of the year. The district lies in an area where the lowest temperature on

individual days may go down to 450 F. Dry wind blasts during the period and the daily range

of temperature is rather large. The mean daily range of temperature in December and January

is 28°F. On individual days it may be even 35°F. The mean relative humidity for the season at

Kolhapur is 63 per cent, in the morning and 33 per cent, in the evening. Low humidity less

than 20 per-cents, are not infrequent. Rainfall in November is about 1½ to 2". The rest of the

period is practically dry.


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Rainfall:

The district receives rain from the South-West as well as North-East monsoons. The proportion of

rainfall decreases very sharply from the west to east ranging between the maximum of 6000 mm

in the west to the minimum of 600 mm in the east. Hence we can have three broad divisions as far

as rainfall is concerned i) the western zone receiving heavy and assured rainfall. ii) The central

zone receiving moderate rainfall and iii) the eastern zone receiving low, irregular and uncertain

rainfall. The southwest mansoon commences by the first week of June and lasts till the end of

September. The north-east mansoon beginning in the eastern and central part of the district which

is helpful for the rabbi crops and for the standing sugarcane. As the district receives rainfall from

both the south-west and north-east monsoon and receives sufficient water from the various

irrigation projects throughout the year, the vegetable cultivation is done on a large scale in the

district.

4.6 Social Infrastructure available:

• Airport is at the distance of Kolhapur – 35.50 Km towards West direction.

• Railway Station is at Jaysingpur – 15 Km towards North West direction.

• Nearest habitat is at the distance 01.20 Km in North West direction.

• Krishna River 04.19 km towards South East direction.

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CHAPTER 05

PLANNING BRIEF

5.1 Planning Concept:

The area covered under study zone comprises of medium to heavy soil quality. Profuse

availability of stored water has encouraged villagers to grow cash crops.

Facilities:

This site appeared to be environmentally best as also from the business angle and therefore this

option was finally adopted. This site is inside the campus of the village Takaliwadi Shivar and

means safe transportation, less need of Utilities, less constructing buildings and roads, less fuel,

less water with optimization of infrastructure.

Local Authority has provided all infrastructures like assured Electrical power, continuous water

supply, the internal road network, external approach road.

All surrounding villages are provided with drinking water from wells or Government Water

Supply Schemes RWS. Hence we do not encroach upon their supply.

5.2 Population Projection:

An official Census 2011 detail of Kolhapur, a district of Maharashtra has been released by

Directorate of Census Operations in Maharashtra. Enumeration of key persons was also done by

census officials in Kolhapur District of Maharashtra. In 2011, Kolhapur had population of

3,876,001 of which male and female were 1,980,658 and 1,895,343 respectively. In 2001 census,

Kolhapur had a population of 3,523,162 of which males were 1,807,470 and remaining 1,715,692

were females. Kolhapur District population constituted 3.45 percent of total Maharashtra

population. In 2001 census, this figure for Kolhapur District was at 3.64 percent of Maharashtra

population. There was change of 10.01 percent in the population compared to population as per

2001. In the previous census of India 2001, Kolhapur District recorded increase of 17.85 percent

to its population compared to 1991. The initial provisional data released by census India 2011,

shows that density of Kolhapur district for 2011 is 504 people per sq. km. In 2001, Kolhapur

district density was at 458 people per sq. km. Kolhapur district administers 7,685 square

kilometers of areas. Average literacy rate of Kolhapur in 2011 were 81.51 compared to 76.93 of

2001. If things are looked out at gender wise, male and female literacy were 88.57 and 74.22

respectively. For 2001 census, same figures stood at 87.47 and 66.02 in Kolhapur District. Total


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literate in Kolhapur District were 2,825,845 of which male and female were 1,559,760 and

1,266,085 respectively. In 2001, Kolhapur District had 2,364,307 in its district.

With regards to Sex Ratio in Kolhapur, it stood at 957 per 1000 male compared to 2001 census

figure of 949. The average national sex ratio in India is 940 as per latest reports of Census 2011

Directorate. In 2011 census, child sex ratio is 863 girls per 1000 boys compared to figure of 839

girls per 1000 boys of 2001 census data. Out of the total Kolhapur population for 2011 census,

31.73 percent lives in urban regions of district. In total 1,230,009 people lives in urban areas of

which males are 631,843 and females are 598,166. Sex Ratio in urban region of Kolhapur district

is 947 as per 2011 census data. Similarly child sex ratio in Kolhapur district was 865 in 2011

census. Child population (0-6) in urban region was 128,986 of which males and females were

69,159 and 59,827. This child population figure of Kolhapur district is 10.95 % of total urban

population. Average literacy rate in Kolhapur district as per census 2011 is 88.28 % of which

males and females are 92.42 % and 83.95 % literates respectively. In actual number 971,976

people are literate in urban region of which males and females are 520,045 and 451,931

respectively.

As per 2011 census, 68.27 % population of Kolhapur districts lives in rural areas of villages. The

total Kolhapur district population living in rural areas is 2,645,992 of which males and females

are 1,348,815 and 1,297,177 respectively. In rural areas of Kolhapur district, sex ratio is 962

females per 1000 males. If child sex ratio data of Kolhapur district is considered, figure is 862

girls per 1000 boys. Child population in the age 0-6 is 279,956 in rural areas of which males were

150,362 and females were 129,594. The child population comprises 11.15 % of total rural

population of Kolhapur district. Literacy rate in rural areas of Kolhapur district is 78.35 % as per

census data 2011. Gender wise, male and female literacy stood at 86.75 and 69.73 percent

respectively. In total, 1,853,869 people were literate of which males and females were 1,039,715

and 814,154 respectively.

All details regarding Kolhapur District have been processed by us after receiving from Govt. of

India. We are not responsible for errors to population census details of Kolhapur District.


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5.3 Land use planning:

The present land has been converted to industrial purpose from agriculture. The expansion is

going to take place on same land.

Thus there is no change in the status. This is flat land whereby Cutting-filling balances and there

will be No/Low Borrowing from nature.

Proposed site will house the facilities, some part will remain untouched for the Future Expansion

and 33% area will be demarcated for Green belt development.

5.4 Assessment of Infrastructure Demand (Physical and Social):

In GSL proposed new project will be having only Expansion of sugar and cogeneration. As

manpower requirement is very less for the proposed project which will not lead to any additional

load on the existing social infrastructure.

5.5 Amenities/ Facilities:

GSL is proposing manufacturing products in existing area. Local body provides many basic

facilities like uninterrupted water supply, power and Road Network & solids disposal facility.

This site is having good road means safe transportation, less need of Utilities, less constructing

buildings and roads, less fuel, less water with optimization of infrastructure.

--0--


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CHAPTER 06

PROPOSED INFRASTRUCTURE

6.1 Industrial area:

There will be only expansion of Products capacity in this proposed project. GSL proposes to use this past

construction in expansion proposal. GSL proposes Expansion for existing producing cane crushing from

4900 to 6000 TCD and power generation from 15MW to 21MW. We will develop infrastructure as per

requirement for proposed expansion of production.

6.2 Residential Area:

In GSL has already have a having colony for its key staff & their families.

6.3 Green Belt:

About 33% of the total Plot area is demarcated and additional along the boundaries shall be proposed for

tree plantation. The selection of trees is based upon the climatologically conditions of the Study area.

In and around the GSL project plantation is carried out to develop green belt. The treated sewage water is

used for green belt development within the factory premises. Following are the status of green belt

development.

List of Species for landscape development:

Sr. No. Name of Plant Common Name For Dry Region 1 Ailanthus excelsa Maharuhk 2 Albizia lebbeck Siris 3 Azadiracta indica Neem 4 Casuarina equisetifolia Beef- wood/ Saru 5 Dalbergia sissoo Sisham 6 Eugenia jambolana Jamun 7 Grevillea robusta Silver oak 8 Peltophorum ferrugineum Copper pod 9 Tamarindus indica Imli 10 Pongamia glabra Indian beech 11 Tamarix articulate Tamarisk 12 Mangifera indica Mango 13 Ficus glomerata Umbar 14 Ficus bengalensis Vad 15 Dandrocalamus strictus Cane Bamboo 16 Cassia tora Tarwat 17 Bauhinia varigeta Kanchan 18 Psydium guava Peru


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19 Plumbago zeylania Plumbago 20 Santalum album Chandan 21 Acalypha spp. Acalypha 22 Alastonia scolarasis Saptaparni 23 Embelica officinalis Amla 24 Hibiscus spp. Jaswand 25 Jatropha curcus Mogli errand/ Ratanjyot 26 Symbopogon martini Lamon grass 27 Lantana camara Lantana 28 Vinca rosea Sadafuli 29 Jasmine grandiflorum Jasmine 30 Calotropis procera Aak 31 Ipomea purpurea Beshram 32 Dhatura mental Dhatura 33 Vitex nurgundo Nirgudi 34 Ixora parviflora Ixora

6.4 Social Infrastructure:

In GLS there is no need of providing any Social infrastructure as the proposed expansion project is

involving only very small number of man power. Existing infrastructure will be sufficient to

accommodate the increasing load from the proposed project.

6.5 Connectivity:

This proposed cane crushing & Power generation facility is located at Village Akiwat, Near Takaliwadi

Road, Takaliwadi Tal. Shirol in Kolhapur district, Maharashtra. The Site is 12 km from Shirol town and

15 km from Jaisingpur railway Station and Air port 35.50 km towards west direction at Kolhapur. The

land and infrastructure is made available by Local Authority and the raw material is easily available

through the easy transport via road connectivity and via Sea route and Air route. The Shirol –Takaliwadi

Road State Highway is passing adjacent to the project boundary.

6.6 Water Management: The water requirement is about 418 cum/ day for Domestic, Greenery and

Processes. The source of water is already availability from existing water works of local authority and the

same is adequate and satisfactory. We are not encroaching on anybody’s water source.

6.7 Sewage System:

The Domestic Effluent will be treated in Effluent Treatment Plant and will be used for green belt after

treatment.


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6.8 Industrial Waste Management:

GSL proposed Expansion for producing cane crushing and power generation. As there are only 02

products, pollution control work can be much streamlined than a heterogeneous mixed stream. The details

regarding pollution control of water, waste water, air and solid wastes.

6.9 Air Pollution:

The air pollution due to bagasse and coal based high-pressure boiler will be taken care scientifically by installing highly efficient Electro Static Precipitator.

Electro Static Precipitator Specification

• Gas flow rate will be corresponding to MCR of boiler. • Temp of gas at ESP inlet will be 150oC. • Inlet dust concentration will be 5 g/cum. • Outlet emission at ESP exit will be < 150 mg/Nm3. • Pressure drop across ESP for condition gas side will be < 25 mm water column. • ESP shall be installed on suction side of ID fan, has rotary air lock valve. Suitable platform,

staging, ladders, railing, inspection holes. Fugitive Emissions:

A number of mitigation measures are taken to control fugitive emissions, the presence of which will be

noticeable by plain vision if not controlled. The measures are thus taken seriously and continuously such as:

• Rubber wheel carts / trucks to bring in Raw Materials not filled high, sides laded, slow speed

travel, avoiding vibrations en-route.

• Collection of fugitive emissions by suitable suction system at the time of casting etc.

• Engineering the plant layout in such a way so as to virtually

Eliminate need of using heavy equipment for material handling in the main plant

• Internal roads paved, scrap area paved, leveled, no undulations, no sharp curves, slow speed. No

open storage of materials on barren unlined land to the maximum extent possible.

6.10 Solid Waste Management:

• Co-generation unit:- • The main solid waste generated during the process is Ash. This will be disposed of using the Ash

handling system. The ash is used for brick making.


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• Ash from furnace shall be handled by water impounded submerged belt conveyor passing to main belt conveyor with cooling spray arrangement. Other ash points are pre-heating hoppers and ESP hoppers. Here water is sprinkled on screw conveyors to reduce temp and dust.

• All ash is taken to silo and handling system is complete with mono rails, lifting tackles, support structure, platform, gallery, ladder, and cladding. The ash shall be sold out to brick manufacturers.

(a) Non Hazardous Solid Waste:

Based on above working, the expansion uses existing canteen facilities and STP. The canteen waste

goes as manure in landscaping after treatment.

Consented quantities of Solid waste generation are:

i) From Process Manufacture:

The quantity of generation of non-hazardous solid waste from the process of manufacture is Nil.

ii) From the waste treatment:

Domestic Bio waste (dry leaves, roots & hey) & composting will be carried out for producing bio-

compost & will be used for Green Belt Development.

Power Requirement & Supply/ Source:

Power supply:

• Existing power requirement: 0.5 MW-Self Generation.

• Proposed power requirement: 0.6 MW-Self Generation.

DG set only in emergency backup:

Sr. No. D.G. Capacity Fuel Consumption Stack Height

1. 500 KVA 135 lit./hr. 30 meter

2. 125 KVA 35 lit. /hr.

30 meter


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CHAPTER 07

REHABILITATION AND RESETTLEMENT (R & R PLAN)

7.1 Policy to be adopted

This project does not require acquisition of Land and the Infrastructure so there is no any kind of activity

of Rehabilitation and Resettlement to be carried out over here.

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CHAPTER 08

PROJECT SCHEDULE & COST ESTIMATES

8.1 Time schedule of the Project

GSL has ability to complete their construction within 12 to 15 Months after getting all relevant

permissions and clearances.

8.2 Estimated project cost (Economic Viability of the Project)

Estimated project cost is 86.34crores (including cost for land, building, plant and machinery).

--0--

CHAPTER 09


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ANALYSIS OF PROPOSAL

9.1 Financial and Social Benefits

GSL has proposed to develop manufacturing products which will be used for Machinery manufactured by

local manufacturer in the market.

This will be financial benefit to the industry as well as nation for a generation of foreign revenue.

By doing so, Gurudatt Sugars Ltd. can participate towards the development of nation by generating the

foreign exchange, and also serve the social community.

--0--


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Annexure I: Google Image


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Annexure II :- Toposheet


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Annexure III: Location in Map


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Annexure III: Master Lay-Out

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