pre- feasibility reportenvironmentclearance.nic.in/writereaddata/online/tor/09...taluk, burlatti...

PRE- FEASIBILITY REPORT

For

THE EXPANSION OF DISTILLERY FROM

120 KLPD TO 500 KLPD WITHIN EXISTING

UNIT

At

Survey R.S.No.367/1,

Munoli Village,

Saundatti. Taluk,

Belagavi District,

Karnataka State

Submitted to

MoEF & CC,

New Delhi

Renuka Sugars Distillery Expansion

1

CHAPTER-1

EXECUTIVE SUMMARY

1. Executive Summary

1.1 Introduction

M/s Shree Renuka Sugars Ltd., at Survey R.S.No.367/1 Manoli Village, Saundatti Taluk,

Belagavi District is operating since 1999, with valid consent from KSPCB & prior environmental

clearances. The land area is 104.18 acres. The consent for operation under The Water

(Prevention and Control of Pollution) Act 1974 and The Air (Prevention and Control of

Pollution) Act 1981 for the existing activity viz., manufacturing sugar of 900MT/day (Sugar

crushing capacity – 7500 TCD), co-gen power plant of capacity 35.5 MW and Distillery of

capacity 120 KLD from KSPCB and is valid up to 30.06.2021.

Now the industry proposes to expand the Distillery unit capacity from existing 120 KLPD to 500

KLPD of ethanol. The proposed expansion is planned within the existing infrastructure of the

industry. It is proposed to add some additional Machineries/equipments during expansion.

1.2 Project Details:

The industry proposed to expand the Distillery unit capacity from existing 120 KLPD to 500

KLPD to manufacture Ethanol.

Water and waste Management:

The water source for the industry is Malaprabha River. Water is used for process,

cooling tower make up, boiler feed & domestic utilities.

The process effluent (spentwash) generated from the process will be concentrated in

Multi effect evaporators and incinerated in Incineration Boilers. The vapor

condensate during spentwash evaporation and spentlees will be treated in Distillery

polishing condensate unit and reuse for process. The Domestic Sewage will be

disposed to septic tank followed by soak pit.

i. Air Pollution:

The source of emission is from existing boilers (i.e. 44 TPH, 100 TPH, 50 TPH & 26

TPH are provided with stacks of adequate height and Scrubber and ESP) and DG

Sets-1165 KVA X 1 No & 1010 KVA X 1 No. are provided with stacks of adequate

height and housed in the acoustic enclosure. APC measures are adequate to control

and disperse the pollutants.

The proposed incineration Boilers ( 2* 65 TPH) for treatment of Distillery

concentrated spentwash will be provided Bag filters as an APC and stacks of

adequate height


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ii. Solid waste Management:

The solid waste generated from the industry is boiler bottom ash, boiler fly ash, lime

grit, yeast sludge and ETP sludge. This has being disposed in eco-friendly manner

including domestic garbage.

iii. Hazardous Waste Management:

The hazardous waste generation from the industry is waste oil from DG set (i.e Used

oil (5.1)) will be stored in safe and scientific manner which will be disposed to

KSPCB authorized agencies only.


3

CHAPTER 2

INTRODUCTION OF THE PROJECT BACKGROUND INFORMATION

2. INTRODUCTION

Identification of project & project proponent

2.1 Identification of Project

Shree Renuka Sugars Ltd is a Public Limited Industry and is into the business of production

of Sugar, co-gen power and Alcohol. In Karnataka Shree Renuka Sugars Ltd., has their units

and the following location Manoli Village, Saundatti. Taluk, Burlatti village-Athani Taluk,

lease of Raibag SSK, Raibag Village-Chikodi taluk, Gokak Sugars Limited, Kolavi Village-

Gokak Taluk and Belagavi District, Avalga Village-Afzalpur Taluk, Gulbarga District.

Shree Renuka Sugars Ltd, Saundatti. Taluk, Belagavi District is operating since 1999, with

valid consent from KSPCB at Survey. R.S.No.367/1 Manoli Village. The land area is 104.18

acres. The consent for operation under The Water (Prevention and Control of Pollution) Act

1974 and The Air (Prevention and Control of Pollution) Act 1981 for the existing activity

viz., Sugar cane crushing capacity-7500 TCD, co-gen power plant of capacity 35.5 MW and

Distillery of capacity 120 KLD from KSPCB and is valid up to 30.06.2021. The company

has the Authorization under the Hazardous & Other Wastes (Management and

Transboundary Movement) Rules, 2016. Now the industry proposes to expand the Distillery

unit from existing 120 KLPD to 500 KLPD.

The activity is covered under EIA Notification 2006, Schedule 5(g) Category ‘A’. Hence the

Pre-feasibility report for seeking Terms of reference for carrying out EIA study and to

prepare report to seek Environmental Clearance.

2.2 About the Project Proponent

The Company is a public limited company. It is headed by a dynamic, progressive and

visionary Chairperson Mr. Atul Chaturvedi. He is a successful industrialist with wide

experience. The company is engaged by Executive Director, Shri Vijendra Singh and

President of the company Shri Ashok Kumar Sharma.

2.3 Brief description of the nature of the project

Shree Renuka sugars Ltd., Manoli Village, Savadatti Taluk, Belagavi District is a Large

Scale industry with an investment of Rs.400.6 crores. This is a Sugar, Co-generation and

Distillery complex. In view of surplus cane availability in the region and to improve the

economic performance of the industry, the Company has now proposed to expand the

Distillery unit capacity 120 KLPD to 500 KLPD to manufacture Ethanol. The details of the

existing and the proposed expansion is given in the table below;


4

Table 2.1: Details of existing & Proposed Expansion

Sl

#

Product Name Production Capacity

Existing Proposed

Expansion

Total (after expansion)

1 Distillery Unit

capacity

120 KLPD 380 KLPD 500 KLPD Ethanol

2 Sugar cane crushing

capacity

7500 TCD - 7500 TCD

3 Co-gen Power Plant 35.5 MWH - 35.5 MWH

In the proposed expansion. In the existing infrastructure industry propose to add some new

Machineries/equipments to meet the expansion capacity with some additional buildings.

2.4 Need for the project & its importance to region

The Government of India, in the National Policy on Bio-fuels is encouraging blending of bio-

fuel with diesel & petrol to ease the demand of petroleum import. The Government of India’s

policy is to encourage the farmers to take up plantation of bio-fuel based agriculture by fixing

statutory minimum price mechanism. The policy encompasses bio-ethanol, bio-diesel & others.

During 2008, the Government of India has allowed the increase of blending from 5% to 10%

ethanol with petrol & diesel. This blended fuel not only reduces the financial burden of India in

purchasing crude petroleum but also helps in reducing/controlling the emissions of pollutants &

transport vehicles.

The National Policy on bio-fuel enumerates that, Ethanol is mainly being produced in the

country at present from molasses, which is a by-product of the sugar industry. 5% blending of

ethanol with gasoline has already been taken up by the Oil Marketing Companies (OMCs) in 20

States and 4 Union Territories. 10% mandatory blending of ethanol with gasoline is to become

effective from October, 2008 in these States. In order to augment availability of ethanol and

reduce over supply of sugar, the sugar industry has been permitted to produce ethanol directly

from sugarcane juice. The sugar and distillery industry will be further encouraged to augment

production of ethanol to meet the blending requirements prescribed from time to time, while

ensuring that this does not in any way create supply constraints in production of sugar or

availability of ethanol for industrial use. Bio-ethanol already enjoys concessional excise duty of

16% and biodiesel is exempted from excise duty. No other Central taxes and duties are proposed

to be levied on bio-diesel and bio-ethanol. Custom and excise duty concessions would be

provided on plant and machinery for production of bio-diesel or bio-ethanol, as well as for

engines run on biofuels for transport, stationary and other applications, if these are not

manufactured indigenously.

Assuming normal market conditions, ethanol imports will rise from 400 million liters in 2016 to

600 million liters through 2018. Almost 80 percent of imported ethanol (worth $173 million) in


5

2016 was sourced from the United States and was mostly classified as Undenatured, Fuel Use (at

port of origin). Incidentally, 2016 import volume was the largest since 2009 (278 million liters)

and almost double the import volume of 2015.

Therefore, in-order to make use of the above policy & to raise up to the occasion with the Policy

of Government of India, Shree Renuka Sugars Ltd., which is a sugar, co-gen & distillery

complex is now equipping to produce 500 KLD of ethanol.

2.5 EXPORT POSSIBILITY

Since the Government of India is encouraging production of bio-ethanol, the main aim of Shree

Renuka Sugars Ltd. is to ensure that ethanol is produced to meet the local market demand in the

country.

2.6 DEMANDS‐SUPPLY GAP

Alcohol has assumed a very important place in the economy of the country. 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. This is partly due

to high costs of products produced through petroleum route, consequent to the phenomenal

increase in petroleum price. Further, it is a potential fuel in the form of power alcohol when

blended with petrol. Alcohol is a substitute to the imported petroleum. Large demand is has

arisen for its use as fuel as GOI has allowed 20% blending of bio-fuel with petrol. Use of alcohol

as an ingredient in beverages is well known. It is a major source of revenue by way of excise

duty for the State Governments.

It follows that the supply of industrial alcohol to chemical and drugs units in the country will

remain below normal for some more time.

In order to maintain proper rate of growth of Industries, production of alcohol must increase.

India in 2016 achieved its highest ever ethanol market penetration, a gasoline blend rate of 3.3 percent on

average across the country. Nevertheless, tight ethanol supplies through 2018 will limit further gains or

even shrink that percentage of penetration. As a result, the ethanol blending program (EBP) is likely to

expand but at a slower pace as demand from industry is partly met by imports, which are projected to

grow from 500 million liters in 2017 to 600 million liters in 2018.

2.7 EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO PROJECT.

M/s. Shree Renuka Sugars company will give direct employment to local people based on

qualification and requirement. In addition to direct employment, indirect employment shall

generate ancillary business to some extent for the local population.


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CHAPTER 3

PROJECT DESCRIPTION

3.1 Type of Project Including Interlinked and Interdependent Projects, If Any.

The proposed project is expansion and modification of Molasses Based Distillery Plant from 120

KLPD to 500 KLPD through process modification in its existing Distillery Plant.

3.2 Location (Map Showing General Location, Specific Location, Project Boundary and

Project Site Layout with Coordinates)

The project site is located at Survey. R.S.No.367/1, Manoli Village, Saundatti Taluk, Belagavi

District of Karnataka State. The plant facilities are spread over 104.18 Acres. The location

details of the project is given below table.

Table 3.1: Location Details

Description Details

Location Survey.R.S.No.367/1, Munoli Village, Soundatti Taluk,

Belagavi District

Co-ordinates Points Latitude Longitude

A 15051’14.60” N 75

006’23.76” E

B 15051’17.63” N 75

006’16.61” E

C 15051’29.62” N 75

006’19.46” E

D 15051’29.66” N 75

005’51.11” E

E 15051’19.97” N 75

005’49.98” E

F 15051’01.73” N 75

006’10.12” E

G 15051’12.12” N 75

006’14.66” E

Total Area 104.18 Acres

Across road SH 103-Yaragatti – Manoli Road at 10Mtrs away

District Headquarters Belagavi – 50 Km towards W

Nearest Water body Renukasagar reservoirs nearest water spread location to industry

is 3.7 Kms towards South-west. Malapraba river downstream of

the reservoir is- 1.4 Kms from the nearest factory building.

Nearest Town Savadatti -10 Km towards SSE

Nearest Railway

Station

Belagavi railway Station-63 Km towards W

Nearest Airport Belagavi Airport- 51.52 Km towards W


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Figure 3.1: Location of project site on Google Map- 5Km radius

Figure 3.2: Location of the proposed plant on the district map


8


9

Figure3.3: Site Photos


10

Figure 3.4: Plant Layout Plan


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3.3 Details of alternate sites considered and the basis of selecting the proposed site,

particularly the environmental considerations gone into.

No alternative site is considered. The proposed expansion is in the existing factory.

3.4 Size or magnitude of operation

The existing capital cost of the industry is Rs. 400cr.

The list of existing, proposed and expansion product are given in below said table;

Table 3.2: Details of existing, proposed & Expansion products and capacity

Sl

#

Product Name Production Capacity

Existing Proposed

Expansion

Total (after expansion)

1 Distillery Unit

capacity

120 KLPD 380 KLPD 500 KLPD Ethanol

2 Sugar cane crushing

capacity

7500 TCD - 7500 TCD

3 Co-gen Power Plant 35.5 MWH - 35.5 MWH

3.5 Project descriptions with process details (a schematic diagram/flow chart showing the

project layout, components of the project etc.) By Products

3.6 PRODUCTS MANUFACTURED

3.6.1 MANUFACTURING PROCESS TECHNOLOGY

Rectified Spirit production is based on Fermentation Technology with yeast recycle using yeast

separators for production of ENA and RS. Yeast strain used has property to form flocks and

settle faster than sludge present in the medium. Thus separation and recycle of sludge is avoided

employing the special strain of yeast. The yeast cream obtained by settling is subjected to

centrifugal yeast separation, acidified and then reactivated in the dilute molasses medium. The

reactivation stage brings back the yeast to normal stage and performs better compared to

recycling yeast without reactivation stage. Yeast separation employing yeast separators ensures

separation of maximum yeast bio-mass and maintenance of required Yeast concentration in the

medium leading to higher fermentation efficiency, higher productivity and generation of less

quantity of spent wash.

Adequate space has been provided for foaming to minimize the requirement of antifoam

compound.

Effective wash cooling and monitoring of parameters viz fermentation temperatures, pH, YCS,

contamination level, residual sugars and alcohol concentration will ensure highest fermentation

efficiency and better yield per MT of molasses.


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3.6.2 PROCESS DESCRIPTION – 500 KLD Distillery

Rectified Spirit production in the plant is based on Fed Batch Fermentation Technology.

Production of Rectified spirit is mainly carried under the following three steps.

1. Dilution - Preparation of molasses for fermentation

2. Fermentation - Production of alcohol from fermentable sugars in molasses soln.

3. Distillation - Product Recovery

Each of the above steps of production are detailed below:

Dilution

Molasses available from sugar mills (Our parent company Shri Prabhulingeshwar Sugars &

Chemicals Ltd.) contains solid content between 76-90 % and sugar content varies between 45

and 50 %

The main dilution operation occurs in a diluter where the solid concentration is brought down to

20 – 25o Brix. The bulk of this diluted molasses is fed to the fermentation tank while a small

quantity is further diluted to 10 – 15o Brix and used for preparation of the final yeast inoculum.

Propagation of yeast for the final inoculation is done in successive stages in volumes of 10, 100,

1000 and 10,000 liters where in each stage 10 parts of diluted molasses is inoculated with 1 part

yeast culture.

Fermentation

Fermentation in the fermentation tank continues for about 15 to 20 hours after the final inoculum

is added to it. The basic reaction in the fermentation process is

C6H12O6 ----- 2 C2H5OH + 2 CO2 + 26 calories

Glucose Ethyl Alcohol + Carbon dioxide + Energy

Yeast seed material is prepared in water-cooled yeast vessels by inoculating molasses with yeast.

The contents of the yeast vessel are then transferred to the yeast activation vessel. The purpose of

aerated yeast activation vessel is to allow time for the yeast cell multiplication.

Fermentation:

The purpose of fermentation is to convert the fermentable sugars into alcohol. During

Fermentation, sugars are broken down into alcohol and Carbon dioxide. Significant heat release


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takes place during Fermentation. Fermentation temperature is maintained at optimum level by

forced recirculation heat exchangers.

Fermentation process on Fed batch mode which is very feasible for the molasses having higher

valve of volatile acids by using culture yeast .Which offers you the flexibility of running the

process in Fed batch. Inoculation of yeast culture is 20% filling of molasses is 13 hours ,total

fermentation period 24 -28 hours and residuals sugars is controlling at > 1.60% and achieved the

average Alcohol is 10-11% then finally total spirit yield will be 270-280 MT of molasses.

In this Fed batch fermentation to increase in the alcohol in wash. The plant capacity will be

increased by 10-15%. However the steam consumption will be remain same and the generation

of Spent wash will be reduced by 3-4% by this process optimum efficiency can be achieved.

Distillation:

Fermented wash is preheated in fermented wash preheater and fed to the analyzer column. The

dilute alcohol water vapors from the analyzer top are fed to the Pre-Rectification column. An

impure spirit draw of 3 % is drawn from this column. Bottom liquid from Pre-Rectified column

is fed to the IS purification column. Draw from IS purification column is fed to purified column.

The purification column is operated under atmospheric pressure and is heated by using steam.

The bottom of this column is maintained at 20%v/v alcohol and is fed to the rectification/

Exhaust column. A small draw from the top of the column is fed to the IS Purification column.

The purified rectified spirit is removed from the bottom of the purified column.

The Lees from the Exhaust column bottom is used to pre heat the heat from the purified bottom

to the Rectifier/ Dilution water.

Lower side draws streams are taken from Rectified column to avoid fusel oil build up in the

column. These streams are then taken to the IS Purification column.

The total spent wash generation from the process is estimated to be about 10 kl/ kl of RS

produced.

The total spentwash generation after concentration upto 60 brix will be from the plant is about

1100 m3/day.


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3.6.3 MANUFACTURING PROCESS FOR MOLASSES BASED ETHANOL

The manufacture of ethanol through molasses consists of following operations and process. A

typical flow chart for manufacture of ethanol based on molasses is given in Figure.

i. Substrate (Feed) Preparation

Molasses stored in a storage tank is first weighed in a tank with load cells so that accurate

quantity can be fed to the fermentation section. The weighed molasses then transferred from tank

to the diluter in fermentation section where it is diluted with water and fed to the Fermenter.

ii. Yeast Propagation and Fed Batch Fermentation

In this process the culture containing highly efficient yeast strain ( Hi firm XP ) from Praj ind

Pune is propagated in yeast culture vessel under aseptic conditions,

The ready yeast seed is then transferred from culture vessel number 2 and 3 transferred to

Fermenter. Because of fresh yeast culture and good retention time we will get average alcohol of

11% in 30 hr retention. The glucose in media gets converted to alcohol and CO2 The gas

liberated during reaction is contaminated with traces of alcohol vapors. It is sent to CO2 scrubber

for recovery of ethanol and vented to atmosphere.

After fermentation the sludge containing spent yeast is separated from the wash in a settler cum

decanter tank. Then passes through decanter and disposed as solid waste.

iii. Multi-Pressure Distillation

The fermentation wash containing Alcohol, non-fermentable solids and water is supplied to

distillation to separate the alcohol and other impurities, as a continuous flow. The distillation

system is designed for quality ethanol. The system details are as below.

The system consists of 8 columns, namely CO2 stripper, analyzer column, Pre-rectifier column,

Extraction column, Rectification Column, Refining Column, Fusel Oil column & HCC Column.

Wash is fed to de-gasifier cum analyzer column. CO2 and other non-condensable gases are

removed at the de-gasifier unit. Distillate containing 40 % alcohol from analyzer column along

with additional fresh water as lees water is sent to R.S. column. RS as distillate and spent lees as

bottoms are taken out from RS column. In case of ENA production, the RS along with lees or

dilution water is sent to extraction column. Most of the high boiling impurities are removed from

top of this column and from bottom aqueous alcohol is obtained. The latter is taken to

rectification column, and from where 95 % alcohol and spent lees water are obtained as distillate

and bottoms, respectively. 95 % alcohol is further distilled in refining column to remove low

boiling impurities (mainly methanol) Extra Neutral alcohol from is sent to storage tanks.


15

The impure spirit from top of RS column, extraction column, rectifier column and refining

column are taken to purification column. Impure spirit is recovered from purification column and

balance alcohol is recycled to RS column. The alcohol containing fusel oil from pre-rectifier and

rectifier column is fed to fusel oil column. The FOC column inputs are so adjusted to get 15 kl

/day RS with required concentration at the top.

The top vapors from analyzer column, extraction column and fusel oil column are condensed in

evaporator for spent wash concentration. The rectifier column, fusel oil column and pre-rectifier

column get heat from fresh stream at 3.5 kg/cm2.

Rectification column works under positive pressure. The top vapors from rectifier column are

condensed in analyzer column for giving heat to stripper re-boiler. Most of the other columns

work under vacuum.

IV. Dehydration of RS to Anhydrous/fuel grade ethanol

Rectified spirit at Azeotropic concentration is pumped by a feed pump to the dehydration plant.

The rectified spirit containing 95 % alcohol and 5 % water will first pass through feed

economizer, then through a vaporizer cum super heater which will convert the rectified spirit

feed to superheated vapors. The superheated vapor will pass through a sieve column, which is

already regenerated and pressurized to working pressure. All the water vapors present in vapor

mixture are adsorbed in the column. Along with alcohol traces of alcohol are also adsorbed in the

column. The Anhydrous alcohol vapors free from water vapors exhausted from the column are

duly condensed in the re-boiler at the recovery column and is further passed through feed

economizer to preheat the incoming feed and then to a final product cooler. After saturation of

sieve column with water, the flow will be shifted to the next sieve column, which is already

regenerated and pressurized. After completion of dehydration cycle, the sieve column saturated

with water is regenerated by evacuation of adsorbed water and alcohol. The evacuated vapors are

condensed. The condensed mixture of alcohol and water is then fed to a recovery column, which

enriches the stream back to azeotropic composition. This sequence of adsorption and

regeneration of sieve column continues.


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PROCESS FLOW CHART FOR DISTILLERY

Molasses Arrives

Molasses Weighed & Diluted

Yeast propagated with Molasses in Sterilized Separate vessels

Fermentation

Clarified Wash Tank

Analyzer column

Pre-Rectifier column if required

Rectifier Column

Exhaust column

Reboiler


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3.6.4 Brief description of Fed Batch Process

1. Fed Batch fermentation process is used for fermentation process, where 11% v/v alcohol

concentration in fermented wash is achieved and fresh yeast is used for every batch. It has

extra fermenters, they can increase capacity by 30% to the existing.

2. Yield and quality of product are of high standard.

3. To convert the existing “Continuous Fermentation System” into “Fed Batch System” to

increase Alcohol content in Fermented Wash from 10.5 % to 11% v/v

4. It consumes less quantity of steam and operates efficiently.

5. Yield and quality of product are of high standard.

6. High Brix fermentation & more Alcohol % in wash i.e 10% to 11% v/v, when compared to

Continuous Process 8% to 9% v/v.

7. For every batch fresh culture is to be added. This will avoid bacterial contamination.

8. Changing process parameter for every batch depending on the Molasses characteristic.

Fused oil separated and Alcohol Returned

Rectified Spirit

Molecular Sieve Dehydration Bed

Absolute Alcohol / Ethanol


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9. Minimize the acid formation in Fermentation Media for getting good quality of Alcohol &

to increase the yield.

10. Due to increase in the Alcohol % in wash, the plant capacity will be increased by 15

to 20%. However the steam requirement remains same.

11. The generation of spent wash will be reduced by 3 to 4%.

12. The term fed signifies that fed is provided at a required rate to fermentation system

Without getting accumulated.

13. Simple to operate.

14. Proper control on operating parameters.

15. Optimum efficiency can be achieved.

3.6.5 Continuous Process

In this process yeast is recycled. Fermentation and distillation is coupled to get a continuous

supply of fermented mass for the distillation column. The advantage of the process is that a

highly active yeast cell initiates the fermentation rapidly but the quality of molasses affects

immediately.

Bio-still process is one of the continuous processes, which is a trade name in which molasses is

fed to the fermenter at a constant flow rate. The flow rate of molasses is controlled to maintain

the sugar and alcohol concentrations in the wash at 0.2% or lower and 6-7% respectively.

The waste streams comprise spent wash which is the main source of wastewater, spent lees and

yeast sludge. The yeast sludge is disposed separately after drying. In addition wastewater may be

generated from the bottling, fermentation tank cooling and washing and utility sections of the

plant, which is used as a diluents for the treated spent wash.

3.7 RAW MATERIALS: Existing and Proposed expansion:

Molasses and Cane Juice would be the main raw materials. A detail of the raw material

used in the plant is stated in below table. 3.3

3.7.1 Sugar and Distillery Plant:

Table -3.3 Raw Materials Requirement

Sr.N

o

Plant Raw

material

name

Raw material Quantity Remarks

Existing Proposed Total


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1 Sugar plant Sugar cane 7500

MT/Day

- 7500 MT/Day

2 Distillery

plant

Final

Molasses

‘C’

460

MT/day

1456

MT/day

1916

MT/day

OR

B-Heavy

Molasses

- 1500 MT/day 1500 MT/day

OR

Cane Juice

(60 Brix)

- 1630

Cum/day

1630 cum/day From

existing

Sugar Plant

3.7.2 Co-generation Unit:

Raw material (fuel) for existing Boilers

Table No. 3.4 : Raw material for Boilers

Sr. No Boiler/DG set capacity

in TPH

Fuel Qty in MT/day

1 100 Bagasse 1140

2 50 Bagasse 570

3 44 Bagasse 495

4 22 Bagasse 252

Total 216 TPH Bagasse 2457

3.7.3 Raw material for proposed incineration Boilers for Distillery Spentwash treatment.

Table No. 3.5 : Raw material for Boilers

Sr. No Boiler

incineration

Boiler

capacity in

TPH

Type of Fuel Qty in MT/day

1 65 (proposed) (Bagasse + Concentrated spent

wash) Or (Coal + Concentrated

spent wash)

(249.5 MT/day+550 MT/day)

or ( 550 MT/day+ 128.5

MT/day)

2 65 (Proposed) (Bagasse + Concentrated spent (249.5 MT/day+550 MT/day)


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wash) Or (Coal + Concentrated

spent wash)

or ( 550 MT/day+ 128.5

MT/day)

Total 130TPH Bagasse/coal/Conc/spentwash 499 MT/d & 1100 cum/D or

257MT/d & 1100 Cum/d

3.8 Operation details of the plant after expansion

3.8.1 Distillery Operation:

Table 3.6- Operation details of the plant after expansion

Sl. No Description Unit Quantity

1 Distillery Capacity KLPD 500

2 Production rate TPH 20.83

3 Duration of operation of plant Days 330

3.8.2 Proposed Incineration Boilers for existing and expansion for Distillery spentwash

treatment

Fuel Combination – Concentration spentwash & Bagasse (Option 1)

a. Concentration spentwash generated : 1100 cum/day with 60 Brix

b. Calorific value for concentrated spentwash : 1800 Kcal/Cum

c. Spentwash to Bagasse ratio : 65:35

d. Steam generation from spentwash : 82.5 TPH

e. Steam generation from Bagasse

Consider ratio of Spentwash & Bagasse : 43.7 TPH

f. Total steam generation : 126TPH Say 130 TPH

g. Each Boiler capacity : 65 TPH

h. No. of Boiler requirement : 2 No.s

i. Bagasse requirement for two Boilers : 20.8 MT/Hr, 499 MT/day

Fuel Combination – Concentration spentwash & Coal (Option 2)

j. Concentration spentwash generated : 1100 cum/day with 60 Brix

k. Calorific value for concentrated spentwash : 1800 Kcal/Cum

l. Spentwash to Bagasse ratio : 70:30

m. Steam generation from spentwash : 82.5 TPH

n. Steam generation from Bagasse

Consider ratio of Spentwash & Bagasse : 35.5 TPH

o. Total steam generation : 118 TPH Say 120 TPH

p. Each Boiler capacity : 60 TPH


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q. No. of Boiler requirement : 2 No.s

r. Bagasse requirement for two Boilers : 10.7 MT/Hr, 257 MT/day.

3.8.3. Sugar and Co-generation:

Sugar Plant- 7500 TCD and CO-generation: 35.5 MWH. These two units are also under

expansion form 7500 to 10,000TCD. The application is made to SEIAA Karnataka. Public

hearing is scheduled on 16th Nov 2018.

3.9Molasses Storage Capacity:

3.9.1 Existing

At Distillery location molasses is stored in three storage tanks each of capacity 6000 MT is

provided.

At Sugar Plant location molasses storage tanks of capacity of 1 X 4500 MT and 3 X 6000 MT is

provided. The storage tanks are well secured with tank forms with collection facility for spilled

molasses if any.

3.9.2 Proposed: Total 10 No.s each tank having 10000 MT molasses storage tank will be

provided. MOC of tank is Mild Steel.

3.10 Alcohol Storage capacity:

3.10.1Existing

Table 3.7 Details of Alcohol storage capacity

Sl. No. Vessel No. Material storage Storage Capacity in LTR.

1 RSS-1 ENA Storage 1 1161108



4 ENS-1 Ethanol Storage 1 1468670.94

5 ENS-2 Ethanol Storage 2 1470118





10 ISS-1 RS below 65 OP tank 150648.96

11 ISS-2 RS receiver 2 150648.96

12 ISS-3 ENA Receiver 3 150648.96

13 RSR-1 ENA Receiver 1 65579.41

14 RSR-2 ENA Receiver 2 65579.41

15 RSR-3 Ethanol Feed Tank 65579.41


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16 ISR-1 IS Receiver 1 8230.95



19 DSS-1 Ethanol Receiver 1 65731.35



22 F.O tank Fuel Oil Tank 15924.87

Total Storage Capacity 14853319 Lit

3.10.2 Proposed :

Total 15 No.s of each tank having 5000 KL will be provided for Ethanol storage.

3.11.Resource optimization/recycling and reuse envisaged in the project, if any, should be

briefly outlined.

Spent wash generated during the process of distillation will be fed to integrated evaporation to

concentrate spent wash. Concentrated spent wash will be burn in incineration boiler.

The process and steam condensate generated during the process will be treated in condensate

polishing unit and reused in the process thus decreasing the net water requirement.

The cane sugar factory has unique characteristics for the application of cogeneration technology.

The principal advantages lie in the good fuel characteristics of bagasse and in the high uses of

low-pressure steam within the plant. In conventional power plants, most of the heat that is

obtained by burning fuel is thrown away in the form of low-pressure steam as the steam

condenses and heats cooling water. In sugar factory, the heat in low- pressure steam is used to

perform such work as juice heating, evaporation and sugar boiling. During the process steam

condenses.

A will know option for sugar mills to increase their profitability is bagasse cogeneration. At

present, bagasse is burnt inefficiently in low-pressure boilers to raise steam. Cogeneration has

long been a standard practise in the cane sugar industry. With the application of efficient

processing and energy management systems, energy from the bagasse, well above the factory

needs, is available and can be exported conveniently in the form of electric power. Application

of sugar cogeneration will displace a port of fossil based electricity generation leading to a more

sustainable mix in power generation.


23

3.12 Availability of water its source, energy/power requirement and source.

Resource requirement:

3.12.1 Energy Requirement

Steam requirement for existing and proposed expansion projects

Existing:

Table No. 3.8: Steam requirement in existing plant.:

Sr. No Steam

generation

TPH

Utilization

Sugar

and

process

Distillery

process

Boiler

utilized

for power

generation

Total Remark

1 100 110

20 86 216 Steam

condensate

recycle to

Boiler

2 50

3 44

4 22

After proposed Distillery expansion

Table No. 3.9 : Steam requirement after proposed

Sr. No Steam

generation

TPH

Utilization

Sugar

and

process

Distillery

process

Boiler

Bleed

Total Remark

1 100 110

Nil 86 216 Steam

condensate

recycle to

Boiler

2 50

3 44

4 22

5 65

(proposed)

Nil 80 50 130 Steam

condensate

recycle to

Boiler

65 Proposed

Total 346 110 80 136 346


24

3.12.2 Electrical power generation, captive consumptions and export

Existing

Power Generation : 34 MW (3 turbines of 15 + 10.3 + 9.7 MW)

Power consumption at Co-Gen unit

Power consumption for Sugar Unit

Distillery consumption 12.5 MW

Export to KPTCL : 22.5 MW

After proposed Distillery expansion

From proposed incineration Boilers for Distillery spentwash treatment

Power Generation : 18 MW ( turbines of 09 + 09 MW)

Power consumption at incineration Boiler unit

Power consumption for Distillery Unit 9.0 MW

Export to KPTCL : 9.0 MW

3.12.2 :Water Requirement

The source of water for the industry is Malaprabha River.The sugar cane has about 60 to 70 %

water content of which about 35 to 45 % of surplus condensate is available and could be utilized.

This water is recovered during the process at various stages as condensates and reused for boiler,

cooling, imbibition etc. The condensate and spentlees generated from Distillery will be treated in

Distillery condensate polishing unit and resue to process and cooling tower makeup. This CPU

consists of Anaerobic process followed by Aerobic system with tertiary treatment., therefore the

fresh water requirement is very less.

3.12.1 Water available from Sugar cane: Table No. 3.10: Water available from Sugar cane:

Sl

No

Water In Qty

cum/

D

Water Out Qty

Cum/D

1 Water

available

from Sugar

cane 68% of

Sugar Plant

5100 Loss of Water through Bagasse 15 % on cane 1125

Loss of Water through Press mud 2.8 % on cane 210

Loss of Water through F.M. 0.4% on cane 30

Loss of Water through Lime Grit 0.24% on cane 18

Loss of Water through vapour vent of Evap.& Pans 0.5% 41


25

7500 TCD Loss of Water through Clarifier flash vapour 0.75% on cane 56

Loss of Water through Cooling tower evaporation 24% on

cane

1800

Surplus condensate water 1820

Total 5100 5100

3.12.2Existing: Table. 3.10: Water Balance

Sr. Plant

name

Input

Qty in

cum/d

Out put

Qty in

cum/d

A.

1

Sugar

Plant

Reuse water from

Sugar plant excess

condensate polishing

Unit

90 Effluent generation from Sugar

and CO-generation Plant is

treated in ETP and disposal for

on land.

Vent and stream traps loss in

Boilers, sugar and Distillery

process

Evaporation loss from cooling

tower .

486

28

710

2

Co-

generatio

n

Reuse water from

Sugar plant excess


Unit for Boiler &

Cooling tower

Makeup

1128

Total 1224 1224

B Distillery Fresh water for

molasses dilution

223 Ethanol/ENA production 120

Molasses (Volume) 317 Scrubbed CO2 60

Reuse water from

Distillery CPU &

sugar CPU to

molasses dilution

840 Concentrated Spentwash to

Compost

360

Process condensate & spent lees 840

Spentwash for

molasses dilution

225 Spentwash recycle 225

Cooling tower make

up from reuse from

Sugar plant

502 Evaporation and drip loss 502

Total 2102 2102

C Domestic Domestic

consumption

50 Domestic effluent 45

Consumption 05

Note :Total fresh water Consumption is 273 cum/daY


26

3.12.3 After Expansion:

Table 3.11: Water balance proposed

Sr. Plant

name

Input

Qty in

cum/d

Out put

Qty in

cum/d

A.

1

Sugar

Plant

Reuse water from

Sugar plant excess


Unit

90 Effluent generation from Sugar

and CO-generation Plant is

treated in existing 800

cum/day ETP and disposal for

on land

Vent and stream traps loss in

Boilers, sugar and Distillery

process

CBD,IBD, Strem trap from

Boilers and Evaporation loss

from cooling tower .

486

28

710

2

Co-

generatio

n

Reuse water from

Sugar plant excess


Unit for Boiler &

Cooling tower

Makeup

1128

Total 1224 1224

B Distillery Fresh water for

molasses dilution

430 Ethanol/ENA production 500

Molasses (Volume) 1320 Scrubbed CO2 250

Reuse water from

Distillery CPU &

sugar CPU to

molasses dilution

3610 Concentrated Spentwash will

be incinerated in Boilers

1100

Process condensate & spent

lees

3510

Spentwash for

molasses dilution

950 Spentwash recycle 950

Cooling tower make

up

Nil Evaporation and drip loss Nil

Fresh water for

Incineration Boiler

makeup water

300 CBD, IBD, stream trap loss

and vent loss

200

Purge water would be taken

into Distillery CPU

100

Total 6510 6510

C Domestic Domestic

consumption

60 Domestic effluent 54

Consumption 06


27

NOTE: Air cooled cooling tower would be provided for existing and proposed expansion

Distillery. Proposed Incineration Boilers no required because of Boilers would be back

pressure boilers.

Total fresh water requirement is 790 cum/day


28

BLOCK DIAGRAM FOR PROPOSED 500 KLPD DISTILLERY PLANT WATER/MASS BALANCE

(All figures are in M³/day)

Fresh water- 430

Reuse water - 3610

Spentwash recycle -950

To Incineration Boiler To Bio-composting

Condensate-2025 Fresh water-300

CBD, IBD, stream

trap loss and vent

loss -200

Process Condensate-925

Purge water-100

Fermentation I

6310

Water

(932)

Distillation I

(6060)

Raw Spentwash

(4050) Raw Spentwash

Nil

Nil

Alcohol (500

KLD)

Conc. Spent wash to

Incineration Boiler (1100)

MEE (2025)

Dist CPU

3610

Spent lees

(560)

Water-

(2434)

Molasses

1916 MT/D

1320 M³/D

Water-

(4040)

Input Molasses : 1320

Fresh water : 430

Reuse water : 3610

SW recycle : 950

Total : 6310

Output

Alcohol : 500

CO2 : 250

PC & SL : 3510

SW Recycle : 950

SW disposal to Boiler : 1100

Total : 6310

Total : 3786

CO2 after

Scrubber-

(250)

FEE (4050) Water Treatment

Plant

Incineration Boiler


29

3.12.3 Quantity of wastes to be generated (liquid and solid) and scheme for their

management/ disposal.

i. Water Environment & Management:

The water consumption for industry is process, cooling tower, boiler feed & domestic

purpose. Industrial effluent will be treated in ETP and domestic sewage will be disposed

to septic tank followed by soak pit.

ii. Air Environment & Management:

Existing:

The major source of emission is from boiler & DG stack. The industry is presently

operating 4 boilers each of capacity 100 TPH, 50 TPH, 44 TPH & 26 TPH respectively.

A diesel generator of 1165 KVA- 1 No. and 1 No. of 1010 KVA DG Set are also present

in the industry. APC measures are adequate to disperse the pollutant. Adequate green

belt will be developed to mitigate the pollution arising due to movement of vehicles. The

air pollution source and control measures are given below;

Proposed: Two 65 TPH incineration Boilers will be proposed for Distillery spentwash

treatment. The mainly concentrated spentwash with Bagasse/Coal will be used as fuel.

The ratio would be 65:35 Spentwash to Bagasse or 70:30 Spentwash to Coal. The APC

would be provided as Bag filter/ESP with adequate height stack.

Table 3.11- Air Pollution Sources and control measures

Stack

No

Stack attached to Stack height Emission Limits Air pollution

control measures Existing Proposed

1 100 TPH

Boiler

No change Common

chimney of

65m AGL

SPM

150

mg/cum

ESP

2 50 TPH

Boiler

No change ESP

3 44 TPH

Boiler

No change Common

chimney

of 58m AGL

Wet Scrubber

4 26 TPH

Boiler

No change Wet Scrubber

5 - 65 TPH

incineration

Boiler

As Suitable SPM 150

mg/cum

Bag filter/ESP

6 - 65 TPH

incineration

Boiler

As Suitable SPM 150

mg/cum

Bag filter/ESP

7 1165 KVA

DG

No change 30m AGL No2 &

PM

710 &

100

Acoustic

Enclosures


30

8 1010 KVA

DG

No change 30m AGL Acoustic

Enclosures

The standards prescribed under EP rules for emission from sugar plant, boiler sources is

particulate not to exceed 150 mg/Nm3

(G.S.R 35 (E) date 14th

January 2016). The consent

issued by KSPCB is also as per the EP rules. The emissions standards are meet with the

existing APC equipments.

iii. Solid waste Management:

The solid wastes or by-products produced in sugar industry such as bagasse, press mud

and molasses are made use as valuable resources. Other solid wastes in the industry are

boiler ash, lime sludge and ETP sludge. The solid waste generated from different

operations are given below said Table;

Table 3.12- Solid waste management

Sl. # Solid Waste Mode of collection Mode of disposal

1 Boiler ash

from

existing and

proposed

Boiler fly

ash

Mechanical conveyor into

common silo or further

disposal

Ash collected from ash silo . The

existing Boiler ash is missed with

proposed Boilers and will be supply

as a potash rich source for cane

farmers

3 Lime grit Mechanical screw

conveyor

Collected in trailers used for land

filling

4 Press mud Mechanical conveyor Supply as a manure to cane farmers

5 Sludge from

ETP

Sludge drying beds Sludge collected from ETP is used

as manure for plantations inside the

factory.

Domestic solid waste (garbage trash/ garden litters) will be stored in garbage

collection pits and disposed to nearby municipality.

Any other solid waste generated from the facility will be disposed of by using

proper disposal mechanism.

iv. Hazardous waste Management:

There is no Hazardous Waste generation from the process, only waste oil from the D G

Sets is the hazardous waste generation from the industry. The hazardous waste is being

disposed to KSPCB Authorized agencies. The quantity and disposal details are given

below;

Table 3.13: Hazardous waste management

Waste Hazardous Quantity Method of handling


31

category waste

generated

Existing After

Expansion

5.1 Used Oil 0.4

KLPA

0.5 KLPA Stored in secure manner and

dispose to KSPCB authorized

incinerator.


32

(x) Schematic representations of the feasibility drawing which give information of EIA purpose.

ACTIVITIES OVERVIEW OF SOURCE OF INFORMATION E.I.A STUDIES

RECONNAISANCE SURVEY OF

EXISTING PLANT

MONITORING OF AIR, WATER &

SOIL QUALITY NOISE LEVELS

DATA ON METEOROLOGY

SOCIO-ECONOMIC STATUS &

BASIC ANIMITIES SITES VISITS

BY AN INTERVIEWS WITH

LOCALS

CONSEQUENCE ANALYSIS

PREPARASTION OF DISASTER

MANAGEMENT PLAN

DESCRIPTION OF EFFLUENT

TREATMEN PLAN, AIR

POLLUTION CONTROL,

HAZARDOUS WASTE

MANAGEMENT, GREEN BELT

DEVELOPMENT MONITORING

PROGRAM

SAFTEY, HEALTH & ENVIRONMENTAL

POLICY, GUIDELINES BY DIRECTOR

GENERAL OF FACTORY SAFTEY,

MINISTRY OF LABOUR

IDENTIFICATION &

ASSESSMENT OF IMPACTS

EVALUATION OF IMPACTS BY

MATRIX METHOD

FACILITY DESCRIPTION

ENVIRONMENTAL INFORMATION CENTER

CENTRAL GROUND WATER BOARD

KARNATAKA STATE POLLUTION CONTROL BOARD

AGRICULTURE DEPARTMENT

IRRIGATION DEPARTMENT

CENSUS FROM SECANDARY SOURCE

INDIAN METHADOLOGICAL DEPARTMENT

ANNUAL REPORT

MARKET ASSESSMENT

FINANCIAL REPORT

PROJECT REPORT

ENVIRONMENTAL

MANAGEMENT PLAN

IMPACTS

METHODOLOGY OF

IMPACT ASSESSMENT

PROPOSED PLANT

SOCIO ECONOMIC

STATUS &

INFRASTRUCTURE

BASELINE

ENVIRONMENTAL

STATUS

INTRODUCTION

RISK ANALYSIS

STUDIES &DISASTER

MANAGEMENT PLAN


33

CHAPTER 4

SITE ANALYSIS

4. SITE ANALYSIS

4(i) Connectivity

The unit is located at Sy.No 376/1, Manoli Village, Savadatti Taluk, Belagavi District Karnataka

State. The proposed expansion is within the existing industry. The unit is well connected by all

modes of transportation as the project is located on SH 103 Gokak Main Road.

Road Connectivity

The road connected from the industry of 10 mts from the Gokak Main road SH 103 from

the site.

Rail connectivity

The nearest railway station is Belagavi Railway station which is located at distance of 63

Kms in W direction from the project site.

Airport connectivity

The nearest Airport is Belagavi Airport at approximately 51.52 Kms from the site

towards W direction from the project site.

Communication

The site has access of telephone, internet and mobile connectivity.

4(ii) Land Form, Land Use and Land Ownership

Land is owned by M/s Shree Renuka Sugars Ltd. The present land use is industrial activity,

before it is agricultural land and it is converted to industrial activity is carried out for

manufacturing of sugar. The surrounding area of the project site is agricultural land. The plant

facilities are spread over 104.18 acres which is completely fortified and protected on all four

sides by boundary walls.

1. President of the company Mr. Ashok Kumar Sharma.

2. The Chairperson of the Company is Mr. Atul Chaturvedi a successful industrialist with

wide experience.

3. The company is managed by Executive Director, Sri Vijendra Singh the guidance of

Board of Directors.


34

4(iii) Topography (Along with Map)

The terrain is almost flat, no hills in the surroundings. The geographical coordinates of the area

are the proposed site is 620 m above the men sea level.

4(iv) Existing Land Use Pattern (Agriculture, Non-Agriculture, Forest, Water Bodies

(Including Area Under CRZ)), Shortest Distance From The Periphery Of The Project To

Periphery Of The Forests, National Park, Wildlife 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.

The existing plot is converted industrial land. Industrial activity is carried out for manufacturing

of sugar. There are no eco sensitive areas such as forest International Park, wildlife sanctuary,

biosphere reserves and wildlife corridors etc. located within 15 Kms radius of project area.

4(v) Existing Infrastructure

Total area of the project site is 4007 Sq mt (0.99 Acre), the existing unit has raw material storage

facility, production area & forced evaporation system.

4(vi) Soil Classification

The soil of Belgaum district can broadly be classified into red soil and black soil. These soils

vary in depth and texture, depending on the parent rock type, physiographic settings and climatic

conditions. By and large, black soils predominated the Deccan trap terrain and the red soils are

found in the southwestern and southern part of the district in gneissic terrain. These soils in turn

can be grouped into seven categories as given below, out of which the first five cover large

tracks of land while the last two are local in nature.

1. Shallow black soil

2. Medium black soil

3. Deep to very deep black soil

4. Mixed red and black soil

5. Red loamy soil

6. Lateritic soil

7. Alluvial soil


35

4(vii) Climatic data from secondary sources

The climate of the district as a whole can be termed as semi-arid. The variation in the maximum

temperature during the year ranges from 340C to 43°C and minimum from 8

0C to 16

0C. The

district experiences pleasant winters and hot dry summers. The hot season extends from March

to May, during which the daily maximum temperature often shoots up to 430C.

Agro-climatologically the district can be divided into three zone i.e., high rainfall “Hilly zone”,

”Northern transitional zone” and “Northern dry zone” from southwest to northeast respectively.

The average rain fall of the district is mmm.

The classification of months according to the seasons is given in the following table;

Season Period

Summer March to May

Monsoon June to September

Post monsoon October to November

Winter December to February

The driest month is January, with 0 mm of rain. Most precipitation falls in July, with an average

of 207 mm.

April is the warmest month of the year. The temperature in April averages 43°C. In January, the

average temperature is 8°C. It is the lowest average temperature of the whole year.

The yearly average temperature graph and average precipitation graph are given below said table.

Climate Table between JAN 2016-DEC 2016

Min.

Temperature(°C

)

Max.

Temperature

(°C)

Humidity

%

Precipitation

/Rainfall

(mm)

Wind

Speed

Km/hr

January 7 34 50 0 7

February 9 37 44 1 7

March 10 39 45 6 8

April 13 43 52 48 9

May 16 40 63 72 13

June 14 39 81 165 15

July 12 35 87 207 15

August 11 36 88 181 13

September 8 38 83 123 9

October 11 34 74 63 7

November 9 39 61 27 44

December 8 39 54 6 8

Source: myweather2.com


36

Figure 4.2-Annual Temperature Graph of Belagavi

Figure 4.3-Annual Precipitation Graph of Belagavi


37

4(viii) Social infrastructure available

Social infrastructure facilities such as schools, hospitals, community halls, markets, collages,

railway station and religious building are located with 10 Km radius from the site. Due to the

existence of the industry the social infrastructure is well developed.


38

CHAPTER-5

PLANNING BRIEF

5. PLANNING BRIEF

5(i) Planning concept (Types of industries, facilities, transportation etc.,) town & country

planning/ development authority classification.

The proposed expansion project is within the existing operating factory. All the infrastructure

facilities are well developed. The pollution control systems are also well planned and

established. The proposed Distillery expansion we will be provided multi effect evaporators with

incineration Boilers for treatment of entire Spentwash. The generated condensate and spentlees

will be treated in upgraded CPU and reuse for molasses dilution.

The existing sugar factory and Co-gen effluent is being treated in ETP having capacity 800

KLD. Over the years since inception lot of water conservation measures practiced in the plant

has resulted in reduction in effluent generation. Therefore, the existing effluent generation is

restricted to 486 KLD. The treated effluent will be utilized for green belt development, gardening

and irrigation. The existing boilers have got APC equipment as prescriber by the KSPCB and

emissions are within the prescribed standards. The proposed incineration Boilers will be

provided Bag filter/ESP as an APC.

Within in the vicinity of the industry there is no forest and Eco sensitive zones. The project site

is well accessed by SH 103, the nearest airport is situated at 51.52 kms from the factory at

Belagavi. The nearest township with residential areas is Munoli at 0.8 kms away from the factory

5(ii) Population Projection

An official Census 2011 detail of Belagavi, it had population of 4,779,661 of which male and

female were 2,423,063 and 2,356,598 respectively.

Table 5.1: Census details of Belagavi

Description 2011

Actual Population 4,779,661

Male 2,423,063

Female 2,356,598

Population Growth 13.41%

Average Literacy 73.48

Male Literacy 82.20

Female Literacy 64.58

Total Child Population (0-6 Age) 626,269

Male Population (0-6 Age) 323,761


39

Female Population (0-6 Age) 302,508

Literates 3,052,032

Male Literates 1,725,548

Female Literates 1,326,484

Child Proportion (0-6 Age) 13.10%

Boys Proportion (0-6 Age) 13.36%

Girls Proportion (0-6 Age) 12.84%

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

The plant is located at Survey No. 376/1, Manoli Village, Savadatti Taluk, Belgaum District and

Karnataka State. The land use pattern is as shown in the table.

Table 5.2- Land use planning

Sl. No. Particulars Area (m2) In %

1 Ground coverage area (total built up area)

including paved and roads

54.9 52.68

2 Vacant Area 4.22 13.31

3 Landscape Area (Green belt area

(minimum 34.01% of total plot area))

35.44 34.01

Total Plot Area 104.18 100

5(iv) Assessment of infrastructure demand (physical & social)

The infrastructure facility is already available along with this additional new machineries/

equipments will be installed for the proposed expansion activity.

1. Equipment lists .

Sr

No EQUIPEMENT LISTS

Proposed Incineration Boiler- 2 * 65 TPH

1 Boiler pressure parts (Furnace water wall, steam drum, super-heater coil, Economizer

tube )

2 Boiler auxiliaries (ID, FD, SA &PA fans )

3 EVAPORATOR


40

4 SCAPH

5 FEED WATER SYSTEM (Feed tank ,transfer pump, Dearator tank &Feed Pump )

6 Soot Blowing (LRSV &Rotary )

7 Chemical Dosing System (HP & LP )

8 Air compressor

9 AIR POLLUTION CONTROL EQUIPMENT ESP OR Bag Filter (Collecting

&Emitting Electrode &Rapping system

10 Ash handling System (belt conveyor, screw conveyor, RAVS)

11 Coal handling system (Coal conveyer, Coal vibrator, coal crusher, Coal screen, coal

tipper coal bunker, coal drag chain &Coal spreader )

12 Bagasse handling system (belt conveyor, MBC)

13 Furnace Grate (Traveling Grate )

Instrumentation

1 Boiler Automation (DCS )

2 Turbine automation (DCS )

3 water system automation

4 Flue gas automation

5 Control valve

6 PRDS Automation

7 Bagasse & Coal handling system automation

Electrical

1 Electrical Equipment (TG Generator 11KV ,MCC, PCC ,Distribution transformer

HT&LT breakers ,HT&LT cables, Lighting ,bus -ducts )

Turbine


41

1 Turbine

2 Gear box

3 Generator

4 Surface Condenser

5 TG auxiliaries (AOP, Turning Gear, COP, EOP, CEP, ACW, MCW &CT Fan )

6 Cooling tower

7 Steam Line

5(v) Amenities/Facilities

Basic amenities/facilities is available as road, power supply, communication, water supply,

medical and health checkup of workers and staff of the facility will be provided with the

necessary Personal Protective Equipments and periodical medical checkups will be provided.


42

CHAPTER 6

PROPOSED INFRASTRUCTURE

6. PROPOSED INFRASTRUCTURE

6(i) Industrial area (processing area)

Existing infrastructure (Plant machinery, building, security shed, toilet etc) is being utilized for

proposed expansion activity.

6(ii) Residential area (Non- processing area)

No residential area is proposed.

6(iii) Green Belt

34.01% of total area, 35.44 acres will be provided for green belt development. The number of

trees are planted (approximately) within the premises id 20482 nos. Green belt will be developed

according to CPCB guidelines. Plants of the various species predominant in the district will be

developed in the plant and peripheral areas. The list of tree species used for the Green Belt

Development are given below said Table:

Table 6.1: List of tree species used for the Green Belt Development

Sl.

No

Species Name English Name As per

Inspectio

n report

Heigh

t in m

Age of

the tree

Canopy /Area

occupied acre

1 Salix triandra Almond 574 5.5 10 1.50

2 Azadirachta idica Neem 1770 6 12 2.00

3 Achras sapota Ckikoo 202 4.5 8 0.15

4 Mangifera indica Mango 190 5 10 0.25

5 Ficus Benghalensis Banayan 1454 8 10 4.00

6 Cocus Nucifera Coconut 270 6 10 3.00

7 Polyalthia Longifolia Ashoka 606 6 8 0.80

8 Caesalpinia

pulcherrima

Shankasur 1116 8 6 0.50

9 Ficus religiosa Peepal 2028 7.5 10 3.00

10 Leucaena

leucocephala

Ipil ipil 3545 6 12 2.00

11 Ficus infectoria Ficus

infectoria)

76 6 3 0.10


43

12 Pthyllanthus embica Gooseberry 36 3 12 0.01

13 Syzygium cumini Jamun 52 4 8 0.04

14 Psidium guajava Guava 72 4 4 0.25

15 Thespesia populnea portia tree 34 3 2 0.12

16 Casuarina equisitifolia Casurina 595 7 5 2.00

17 Moringa oleifera Drumstick 16 4 4 0.02

18 Acacia mangium Acacia 334 4 8 1.40

19 Zizipus mauritiana Bor 14 5 12 0.01

20 Pithecolobium dulce Manila

tamarind

18 3 4 0.05

21 Eantulum album (Shrigandha) 16 4 5 0.05

22 Pongemia pinnata Karanja 1335 3 5 1.80

23 Pomagrante Pomagrante

(Dhalimbe)

112 2.5 8 0.86

24 Cerry leaves (kari bevu) 162 2 8 0.01

25 Salix triandra Umbar 44 4 10 0.10

26 Citrus medica Lemon 44 2 5 0.01

27 Phyllanthus emblica Indian

gooseberry

154 2 4 0.10

28 Albizia lebbeck Rain trees 250 5 10 1.50

29 Eucalyptus globubus Eucalyptus 2667 8 12 2.20

30 Carica papaya Papay 48 4 2 0.01

31 Tamarindus indica Tamrind 64 3 6 0.88

32 Artocarpus

heterphyllus

Jackfruit 12 4 4 0.10

33 Mangolia champca Champak 10 4 6 0.01

34 Melia dubia Meliadubia

(Hebbevu)

122 5 6 0.90

35 Grevillea robusta Silver oak 80 5 10 1.30

36 Thevetia peruviana Yellow

oleander

1970 3.5 6 0.80

37 Roystonea regia Royal Palm 414 3.5 6 1.40

38 Ficus elastica Rubber tree 6 5 10 0.60

39 Delonix regia Gulmohar 120 6 10 1.50

40 Anacardium Cashew 20 2 2 0.10


44

occidentale

41 Bougainvillea glabra bougainville 30 3 3 0.01

Total 20482 Area in

acre

35.44

6(vi) Drinking water management (source and supply of water)

Drinking water will be sourced from the Malapraba River downstream of the reservoir is 1.4

Kms from the nearest factory building

6(vii) Sewerage Management.

The domestic sewage is being treated in septic tanks and discharged through soak pits.

6(viii) Industrial Waste Management

The entire spentwash generated for existing and proposed Distillery will be concentrated in

MEE and incinerated in proposed incineration Boilers and condensate & spent lees will be

treated in upgraded CPU and reuse to achieve Zero liquid discharge.

The existing trade effluent generated from the Sugar and Co-gen plants is being treated in ETP

of capacity 800 KLD and treated water will be used within the factory premises garden and

irrigation purpose.

6(ix) Solid Waste Management

Existing solid waste generated from the industry include press mud is used manure for cane

framres, Bagasse is used as fuel to Boilers, ash from proposed and existing boilers would be

supplied as potash rich manure to farmers..

6(x) Power requirement & supply/source

Power requirement will be met through Co-generation plant. In case of power failure D.G. Set

(1165 KVA -1 No and 1010 KVA- 1 No. of capacity) will be used as back up.


45

CHAPTER 7

REHABILITATION & RESETTLEMENT PLAN(R&R)

7. REHABILITATION & RESETTLEMENT PLAN (R&R)

7(i) Policy to adopted (central/state) in respect of the project affected person including

home oustees, Land oustee and landless labour (a brief outline to be given).

Rehabilitation and Resettlement (R & R) Plan is not applicable.


46

CHAPTER 8

PROJECT SCHEDULE & COST ESTIMATES

8(i) Likely date to start of construction and likely date of completion (Time schedule for the

project to be given)

As soon as the EC is accorded the KSPCB will be approach to CFE and take up the erection of

new additional machineries to meet the expansion. The project is planned for commencement

during the 2018-19 crushing season.

8(ii) Estimated project cost along with analysis on terms of Economic Viability of the

Project

Table 8.1- Project Cost

Sl

No.

Description Existing Amount

in Crores

Proposed Amount

in Crores

1 Land and Development 5.7 -

2 Building 49.07 30.0

3 Plant and Machinery 317.3 350.0

4 Other Assets 9.75 -

TOTAL 381.82 380.0


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CHAPTER 9

ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)

9(i) Financial and Social benefits with special emphases on the benefit to the local people

including tribal population, if any, in the area.

By 2022, the Government of India (GOI) proposes to reduce its dependence on crude oil imports

by ten percentage points in several ways: increasing domestic output; promoting energy

efficiency and conservation; and encouraging greater use of alternative fuels. Growth in the

biofuel market will partly reduce import dependence on crude oils and encourage optimal use of

other renewable energy resources, particularly when strong economic growth prospects drive

higher demand for gasoline and petroleum products.

This policy of Government of India has direct bearing on the farming community as the farmers

will be encouraged to raise sugarcane plantation to meet the demand of the industry. They will

be supported by “Statutory Minimum Price” mechanism of Government of India & Karnataka.

pre- feasibility reportenvironmentclearance.nic.in/writereaddata/online/tor/09...taluk, burlatti...

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