Form 1& Prefeasibility Report for Environmental Clearance Submitted …environmentclearance.nic.in/writereaddata/Online/TOR/3… · · 2017-05-31Form 1& Prefeasibility Report for

Form 1& Prefeasibility Report for Environmental Clearance

Submitted to Expert Appraisal Committee

Proposed Expansion of Sugar 6000 TCD to 13000 TCD, Co-generation Plant

21 MW to 90 MW & Proposed New Molasses based Distillery of 150 KLPD

For

M/s Shri Gurudatt Sugars Ltd.

Gut No. 61/A, Akiwat Takaliwadi Road, Takaliwadi,

Tal.-Shirol, Dist. - Kolhapur (MS)

Report Prepared by

sd engineering services pvt.ltd.,

14 Age Arcade, New Osmanpura,

Near Sant Eknath Rang Mandir, Aurnagabad-431005 (MS)

Tel: No. (Office) 91-240-2333622, 233064, (Cell) 91-9960634559

Email ID: [email protected]

May 2017

mailto:[email protected]

M/s Shri Gurudatt Sugars Ltd., Kolhapur (MS) Prefeasibility

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2017

1 sd engineering services pvt. ltd. Aurangabad

INDEX

1. EXECUTIVE SUMMERY

2. INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

Identification of the project and Project Proponent

Nature of the Project

Need of project with description for region and country

Demand and Supply gap

Imports vs. Indigenous production

Export Possibility

Domestic/ Export Markets

Employment Generation due to Project

3. PROJECT DESCRIPTION

Type of Project

Location of Project

Details of Alternate sites

Size of magnitude of Operation

Project Description

Raw material and Finished Products

Resources optimization

Availability of Resource (Water, Energy/ Power Requirement)

Quantity of Waste to be generated

4. SITE ANALYSIS

Connectivity

Land form, Land use, Land ownership

Topography

Existing land use pattern

Existing Infrastructure

Soil classification

Climatic data for secondary sources

Social Infrastructure available


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5. PLANNING BRIEF

Population Projection

Land use planning

Assessment of Infrastructure Demand

Amenities/ Facilities

6. PROPOSED INFRASTRUCTURE

Industrial area

Residential area

Green Belt

Social Infrastructure

Connectivity

Drinking Water Management

Sewerage System

Industrial Waste management

Air Pollution

Solid waste Management

Power Requirement & Supply/ Source

7. REHABILATION AND RESETTLEMENT (R & R PLAN)

Policy to be adopted

8. PROJECT SHEDULE & COST ESTIMATES

Time schedule for the Project

Estimated project cost (Economic viability of the project)

9. ANALYSIS OF PROPOSAL

Financial and Social benefit


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CHAPTER 1

EXECUTIVE SUMMARY

M/S SHRI GURUDATT SUGARS LTD is proposing an expansion of Sugar plant, Co-

Generation, Refinery & distillery. Shri Gurudatt Sugars is desirous to produce sugar &

energy in this Large Size Industrial (LSI) sector at Gut No.61/A, Akiwat, Takaliwadi Road,

Takaliwadi, Taluka-Shirol, Dist- Kolhapur Maharashtra. Capacity of the complex will be

Sugar manufacturing from 6000 TCD to 13000 TCD

Refining the sugar produced to refining sugar – 1755 TPD

Refining RAW SUGAR to refining sugar -1755 TPD

Co-generation from 21 MW to 90 MW

Proposed new molasses based Distillery- 150 KLPD

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

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

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

attached. The Land is already changed to Industrial Land use. Thus there is a no change

in the status. 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.

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

Acoustic Enclosure. There will not be crushing, pulverizing operations. Labor strength is

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

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


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List of Products

Sr.

No.

Product Name Quantity Unit

Existing

1. Sugar Cane Crushing 6000 TCD

2. Power generation 21 MW

Capacity after Expansion

1. Sugar Cane Crushing 13000 TCD

2 Refining the raw

sugar to refining

sugar

1755 TPD

3 Refining the sugar

produced

1755 TPD

4 Power generation 90 MW

5. Molasses Based

Distillery

150 KLPD

Whereas, during production water input requires 892 M3/day. Fuel used will be

bagasse, coal & concentrated spent wash.

In Shri Gurudatt 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


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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 Gurudatt Sugars Ltd, acronymic (SGSL), 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 Gurudatt Sugars Ltd. factory will be promoted at Gut No. 61/A Village

Akiwat Takaliwadi Road, Takaliwadi 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/A village Akiwat, 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 Gurudatt Sugars Ltd. (SGSL) is proposing expansion Project with

capacity to manufacture sugar from 6000 TCD to 13000 TCD, Refinery Produced

Sugar 1755 TPD, Refining the raw sugar to Refining sugar 1755 TPD & Power 21

MW to 90 MW & Alcohol- 150 KLPD. This level of production will not be


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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.

Need of project with description for region and country

1. 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.

2. 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.

3. 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.

4. 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.

5. 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

6. 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.

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


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

9. 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 State Pollution Control Board can be easily obtained as a

matter of routine.

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.


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2.5 Imports vs. Indigenous

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

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.


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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.

2.5 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.

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 336 200 536

2. Unskilled 175 100 275


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CHAPTER 3

PROJECT DESCRIPTION

3.1 Type of Project

Shri Gurudatt Sugars Ltd is proposing an expansion of Sugar plant, Refinery

Sugar & Co-generation & distillery. Shri Gurudatt Sugars is desirous to

produce sugar, energy & alcohol in this Large Size Industrial (LSI) sector at Gut

No. 61/A Village Akiwat, Takaliwadi Road, Takaliwadi, Taluka:-Shirol, Dist:-

Kolhapur Maharashtra. Proposed capacity of the project Capacity of the

complex will be

Sugar manufacturing from 6000 TCD to 13000 TCD

Refining the sugar produced to refining sugar – 1755 TPD

Refining RAW SUGAR to refining sugar -1755 TPD

Cogeneration from 21 MW to 90 MW

Proposed new molasses based Distillery- 150 KLPD.

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

Ministry of Environment and Forest (MoEFCC), 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.


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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

74o

35’39.5 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.

So e i porta t air dista ces fro proposed site are as u der…..

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.

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.


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Proposed Layout Plan is given as (Annexure IV)

3.4 Size or Magnitude of Operation

Shri Gurudatt Sugars Limited (SGSL) is proposing expansion with capacity as, sugar

6000 TCD to 13000, Power 21 MW to 90 MW & Alcohol 150 KLPD. 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

Proposed Product Details

Sr.

No. Product name Quantity Unit

1. Sugar cane crushing 13000 TCD

2 Refining the sugar produced to

refining sugar

1755 TPD

3 Refining RAW SUGAR to refining

sugar

1755 TPD

4 Power Generation 90 MW

5. Alcohol 150 KLPD

The Plant will house the following equipments

Plant and Machinery

➢ Co-generation Unit

Machinery & Hardware

1. Turbo generating set based on Double Extraction cum condensing mode

and with generation capacity of total 90 MW.

➢ Ancillary machinery

1. Single entry condensers & Cooling Towers, for co-generation units, which


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360MT

11 MW

184MMT

154 MT

~ ~

High Pressure

Use Steam Turbine

Bank‐ 90 MW

340MT

0 MT 0 MT 323MTT

~ ~

High Pressure

Use Steam Turbine

Bank‐ 90 MW

consume less water and hence less power.

I. MANUFACTURING PROCESS

Cogeneration Process (During Season)

A. Co-generation Unit

(180 + 180) TPH – 125 Kg/cm2

Pressure Boilers

77.4 MW

To Grid

195 MT

Exhaust

Steam for

Process

15 MW

for Use

Cogeneration Process (During Season)

A. Co-generation Unit:

180+ 180 TPH – 125 Kg/cm2

Pressure Boiler

323 MT

Exhaust

Steam for

Condensation

72.4 MW

To Grid

12.8MW

for Use


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B.Sugar Manufacturing Process


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Manufacturing Process of Alcohol

(A) Manufacturing Process of Alcohol:- (Molasses–based)

Molasses, a by-product of sugar industry is used as raw material by most of the distilleries

for production of alcohol by fermentation and distillation processes. The molasses contains

about 40-50% sugar, which is diluted to bring sugar contents to 10- 15% sugar, 20-250

Brix

for further fermentation process. The pH is adjusted by addition of sulphuric acid, if

necessary.

Yeast culture is done in the laboratory and propagated in a series of fermenters, each about

10 times larger than the previous one. The diluted molasses is inoculated with about 10%

by volume of yeast inoculums. In the fermenters the reducible sugars are broken down to

ethyl alcohol and carbon di oxide (CO2). The reaction is exothermic and cooling water is

sprayed on fermenter walls to maintain the temperature at 29-300

C. Sludge is produced

and discharged from the bottom, while the clear fermented beer from sent to degasifying

section of the analyser which is a bubble-Cap-fractionating column, the beer is heated by

live steam and fractionated to give a 40% alcohol stream from the top. This stream is

further fractionated in the rectifier column to obtain rectified spirit. Part of the rectified

spirit is sent back to the column, and the condensed water from this stage, known as spent

lees is usually pumped back to the analyzer column. The bottom discharge from the

analyzer column is known as the spent wash, which is drained off after heat exchange with

the incoming beer from the fermenters.

In general the layout of, most distilleries is similar and can be divided into two broad

sections. The first section houses laboratory; yeast propagation vessels, diluters, pre-

fermenters and fermentation vessels. The second section houses all the distillation columns

condensers and heat exchangers.

The yeast propagation vessels are generally closed reactors where strict temperature

control is maintained. The diluter in most of the distilleries is of continuous type where the

molasses and water streams are pumped into two coaxial tubes in a closed vessel. The two

streams get thoroughly mixed by the high turbulence before they flow into the fermenter.


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A single diluter with a diameter of about 300-400 m, an overall height of about 3,0000101

and a capacity of about 15,000 to 30,000 L of diluted molasses per hour is commonly used

for continuous dilution. Generally, the continuous diluter is cleaned once in a day with

water and steam. There is no process waste stream produced from yeast propagation

vessels, diluter and pre- fermenters except the wash waters used for cleaning after

processing cycles. Most of the distilleries have open top fermenters where CO2 is generally

not recovered.

Manufacturing process for Alcohol:

In India, Alcohol is manufactured by below mentioned processes:

Continuous Process

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

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

highly active yeast cell initiates the fermentation rapidly and the alcohol yield is also much

higher compared to the batch process.

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 waste water, spent

lees and yeast sludge. Spent lees are usually mixed with the spent wash. 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.

Raw Material for finished Product

List of Raw Materials:


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A. For sugar production

Sr. No. Raw Material Quantity/day

1. Sugarcane 13000 TCD

2. Lime 20.8 MT

3. Sulphur 7.8 MT

B. For power generation

Sr. no. Raw Material Quantity /day

1. Baggase 3648 MT

C. For Alcohol

Sr. no. Raw Material Quantity /day

1. Molasses 520 MT

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 90 MW/day. The power required

for the factory will be consumed from the in-house production and excess will be

sold to MSEB.


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Water: The water requirement is about 892 M3 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 will be about 300 Nos. workforces including staff

members will work in shifts.

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

Project Cost: 350 Cr.


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3.9 Quantity of waste

Water & wastewater

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

generated in the factory will be as follows:

Effluent Generations

Sr.

No.

Effluent Generation M3/day

1. Domestic 100

2. Sugar 1300

3. Co-gen 168

4. Distillery 2000

Water Balance

Water

Source

Qty

Available

(m3/day)

UTILIZATION

Qty

Required

(m3/day)

Condensat

e Qty Used

(m3/day)

Raw

Water

Requirem

ent

(m3/day)

Sugar, Co-Gen. And Distillery Operation

Sugar

Condensate 3120

1. Fermenter Makeup 1785 1785 -

2. Cooling Tower Makeup (Co-Gen) 864 864 -

3. Other Uses ( Sugar) 471 471 -

Distillery

Condensate 1500

1. Cooling Tower make-up (Dist.) 1080 1080 -

2. Vacuum pump sealing (Dist.) 120 120 -

3. Floor Washing 60 60 -

Raw Water

1. Advanced WTP (Co-Gen) 480 - 480

2. Distillation Column 240 - 240

3. Boiler makeup( Distillery) 72 - 72

4. Domestic 100 - 100

Net Raw Water Requirement 892


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Water Pollution Control

Domestic Wastewater

a) Constraint Conditions

pH : 7.0 – 7.5

C.O.D. : 450 – 500 mg/l

B.O.D. : 200 – 250 mg/l

The domestic effluent shall be treated in septic tank followed by soak pit. The

overflow of soak pit shall be mixed with co-gen and DM water plant.

Industrial Waste (Co-generation)

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 downstream 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.

Effluent from co-gen: The boiler blow down shall be allowed to settle in a

settling tank and over flow shall be mixed with other effluent from septic

tank & DM plant. The effluent from DM Plant shall be neutralized & mixed

with above effluent. The mixed effluent is used for green belt.


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Effluent from Sugar Plant

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

M/s Shri Gurudatt Sugars Ltd., Kolhapur (MS) Prefeasibility Report 2017


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

Domestic

Effluent

Septic Tank Anaerobic Filter

Boiler Blow Down

Settling Tank

Collection Tank

DMF

Disposal

on land

for

irrigation

DM Regeneration

Neutralization Tank

Schematic Process Flow Diagram for Effluent Treatment at

Shri Gurudatta Sugars Ltd.


Mill

House

Effluent

DSM

Screen

Boiling House

Effluent

O&G(Skimmer)

Equalization

Tank

Anaerobic Filter

Disposal on Land

Treated Sump Clarifier Aeration Tank

Clarifier

Aeration Tank



Effluent Treatment System for the Distillery:

In this process, the Spent wash from the distillation column is subjected to evaporation

and concentrated to about 65% solids. The concentrate is then incinerated. The

incineration system consists of specially designed burners and furnace in a boiler.

Secondary fuel is also used in small proportion. The system yields steam and ash, which is

rich in potash. The steam can be utilized advantageously in the ethanol plant unit and the

ash can be sold as fertilizer. The condensate is treated and reutilized for non process

applications like cooling tower make-up.

Typical Calculation for Mass Balance for Conc.-Incineration Process

Distillery Capacity = 150 KLPD

S.W. = 1723 m3/day (12% w/w)

= 1775 MT/day

Solids :- 1775 x 0.12 = 213 MT/d

With Evaporation to Solids Conc. 60% w/w

Volume = 213/0.6 = 355 cum

At 60 % Solids ,Water Evaporated= 1368 m3/d

355 cum with 60% Solids has Calorific Value of 1600 – 1750 Kcal/ Kg (Av.1675)

This will produce steam = 595 MT/day = 24.77 MT/hr

With 70:30 ratio, The Secondary Fuel used (Coal)used is 152.14 T/day

Which shall produce steam = 760.71 T/day = 31.70 MT/hr

Taken together – This shall produce = 56.47 TPH steam

Provide a boiler of 60 TPH



Details of Existing and proposed boiler

Parameter Existing Proposed Impact

I ii I ii

Capacity TPH 70 40 Ҳ Nil, Since No Change

Fuel Consumption TPH 47.8 152 Nil, Since No Change

Steam Temperature

(0c)

500 ---- Positive, As Power

Generation Shall

Improve For The Same

Steam Quantity

Co‐Ge eratio Capacity 20.5 MW 83.4 MW Positive, since increase

is without any

additional fuel

burning and emissions

Stack Attached (Dia. In M)

2.3 Ҳ 5.5 Nil, Since No Change

Height (M) 65 Ҳ 7 Nil, Since No Change

Control Equipment Wet Scrubber &

ESP

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.

SGSL has in place the following mitigation policy future



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 - Compost Own garden Organic

2. Garden Trash 500 Compost Land filling ----

3. Office waste 200 Collection Sales For Recycle

4. ETP Sludge 250 --- --- Used as

manure

5. Boiler Ash 365 MT/day ----- --- Sold to

brick

manufactur

ers

(b) Hazardous Waste:

Sr.

No.

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

1. 5.1/5.2 Used/ Spent oil 600 kg/lit. 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.



CHAPTER 04

SITE ANALYSIS

4.1 Connectivity

The proposed expansion will be at Gut No. 61/A of Village Akiwat,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.

So e i porta t air dista ces fro proposed site are as u der…..

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 1.20 Km towards NE direction.

4. Nearest River is Krishna 4.19 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.

4.2 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.

4.2 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. 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 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.

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.

4.3 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 habit is at the distance-1.20 Km in North West Direction

Krishna River 4.19Km towards South East Direction.



CHAPTER 5

PLANNING BRIEF

5.1Planning 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

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.

5.3 Land use planning

The present land has been already 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 SGSL proposed new project will be having only Expansion of sugar and cogeneration &

alcohol. 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.



CHAPTER 6

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. SGSL proposes Expansion for existing producing

cane crushing from 6000 to 13000 TCD, power generation from 21MW to 90 MW & Alcohol-150

KLPD. SGSL will be developing infrastructure as per requirement for proposed expansion of

production.

6.2 Residential Area

In SGSL 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 will be

proposed for tree plantation. The selection of trees is based upon the climatologically

conditions of the Study area.

In and around the SGSL 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 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 SGSL 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 & Alcohol 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 892 M3/ 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.



6.8 Industrial Waste Management

SGSL proposed Expansion for producing cane crushing, power generation and Alcohol. As there

are only 3 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

1. Gas flow rate will be corresponding to MCR of boiler.

2. Temp of gas at ESP inlet will be 150oC.

3. Inlet dust concentration will be 5 g/cum.

4. Outlet emission at ESP exit will be < 150 mg/Nm3.

5. Pressure drop across ESP for condition gas side will be < 25 mm water column.

6. 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:

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

speed travel, avoiding vibrations en-route.

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

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

4. 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

Ash generation will be about 36.5 MT/day.

This will be disposed of using the Ash handling system.

The ash will be sold out to brick manufacturers.

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.

(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: 0.6 MW SELF generations

Proposed power requirement: 4.8 MW



DG set only in emergency backup

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

Existing

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

2. 500 KVA 135 lit./hr. 30 m

Proposed

1 1000 KVA 135 30 m



CHAPTER 7

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 her



CHAPTER 8

PROJECT SCHEDULE & COST ESTIMATES

8.1 Time schedule of the Project

SGSL 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 350 Cr. (including cost for land, building, plant and machinery).



CHAPTER 9

ANALYSIS OF PROPOSAL

9.1 Financial and Social Benefits

M/s Gurudatt Sugars Ltd has proposed expansion for Sugar, Power and Alcohol manufacturing

products which will be used in the market by different industries at National as well as

International levels.

Approximate percentage of 30-40 % manufactured goods will be exported in the national

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

revenue.

By doing so, SGSL can participate towards the development of nation by generating the foreign

exchange, and also serve the social community



Annexure I: Google Image



Annexure II: - Toposheet



Annexure III: Location in Map



Annexure III: Master Lay-Out

Documents

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