Prefeasibility Report 1.0 Executive Summery And

PREFEASIBILITY REPORT

1.0 EXECUTIVE SUMMERY AND INTRODUCTION OF THE PROJECT

The proposed project is incorporated as a limited company under the name “Jaywant Sugars Limited” . The company is now proposing to commence business by setting up a distillery with main objective to manufacture Ethyl Alcohol (EA) and Extra Neutral Alcohol (ENA) and Absolute Alcohol through molasses with an installed capacity of 45 KLPD. The proposed project’s site is located Gat No 90,106,107,108,111,112,113,115, at post: Dhawarwadi, Tal.: Karad ,Dist.: Satara, Pin Code No.: 415109. As per the provision of “EIA Notification No. S. O. 1533 (E)” dated 14.09.2006 amended on 25.06.2014 it comes under Category ‘A’; Item 5(g). It is an entirely new project.

The proposed project shall be undertaken & implemented by the management team of industry. The promoters have sound experience in the field of Distillery and are well aware of the manufacturing processes of products to be undertaken for production. They have made thorough study of entire project planning as well as implementation schedule.

Table No. 1 Name and Designation of the Promoters

Sr. Name Designation No. 1. Shri Chandrakant Bhikaji Desai Chairman 2. Shri Charudatta Narhar Deshpande Director / President 3. Shri Dattatray Raghunath Patil Director 4. Shri Rahul Madhukar Patil Director

1.1 Need of the Project

Distillery business is gaining more importance with regards to production, usage, easy availability of raw material (grains as maize, sugarcane molasses). With the increase in business it has a considerable share in national income. Alcohol industry is the second largest source of revenue of the state. The industry is probably only one in which the inputs are de-controlled, but selling prices are determined by local state levies and excise duties.

Some salient features of the distillery sector in India are as under -

Overall production of alcohol in India is 2350 million liters per annum which is consumed as 600 million liters as fuel grade Ethanol to be mixed with petrol and about 500 million liters finds use as industrial grade alcohol, used in downstream chemical manufacturing such as Acetic Acid, Acetaldehyde, Ethyl acetate etc. and approx 50% of the total production is consumed by potable segment.

For potable purposes in India the alcohol is used to manufacture country liquor or Indian made foreign liquor. Extra Neutral Alcohol is vital ingredient in the making of an alcoholic beverage. It is most suited to produce potable liquor for which the demand is increasing both in domestic as well as international market.

The downstream liquor industry using ENA and rectified spirit is expanding rapidly requiring new and increased production capacities along with optimized utilizations to tread well on the growth trajectory.

1.2 Employment Generation Potential

The activities in proposed industry would improve the socio-economic status of people in the study area in terms of local labor employment and contract basis jobs. The proposed activity might provide employment opportunities to the local populace, especially in business and other services. Under proposed project about 38 skilled and 60 unskilled manpower would be required.

2.0 PROJECT DESCRIPTION

2.1 Location

The proposed project would be located at Post: Dhawarwadi, Tal.: Karad, Dist.: Satara, Maharashtra State. The area is located in a rural region and is about 27 Km from Karad . The Kolhapur airport is 91 Km and Tarali river is about 3.88 Km from proposed site.

2.2 Site Selection

The selection of project site at the above-mentioned location was done in light of following considerations-

Availability of all basic facilities like raw material, water, power, man power etc. and other allied facilities. The district has rail and road links to every destination so that procurement of raw material as well as marketing of finished product will be easier and economical. Good communication facilities are available No national park or wildlife habitats fall within 10 Km radial distance from proposed project site.

2.3 Alternative Site

No any alternative sites were examined as the proposed distillery would be undertaken in existing sugar factory premises. Site is located in Dhawarwadi and NOC for the same has been taken by Grampanchayat of Dhawarwadi.

2.4 The Products & Raw Materials

The products considered for manufacturing and their maximum production quantities are as under- Table No. - 2 List of Products and By-products

Sr. No. Name of Products Quantity 1 Rectified spirit 45 KLPD 2 Extra Neutral Alcohol 43 KLPD 3 Absolute Alcohol 41KLPD 4 Impure Spirit 2.5 KLPD Sr. No. Name of By -Products 1 Carban -dioxide 32 MT/Day

The details of raw material consumption under the proposed project are summarized as follows:

Table No. - 3 List of Raw Material

Sr. No. Name of The Raw Materials Quantity 1 Molasses 4950 MT / Month 2 Yeast 0.027 MT /Month 3 Urea 0.9 MT / Month 4 De - foaming Oil 2.7 MT / Month

2.5 Investment

The expected cost of the proposed project will be around Rs 64.81Crores.

2.6 Size / Magnitude of Operation

Jaywant Sugars Limited would be involved in manufacturing of Ethyl Alcohol (EA), Extra Neutral Alcohol (ENA) and Absolute Alcohol through molasses with an installed capacity of 45 KLPD. The proposed project shall be a large scale industry.

2.7 Process Details

The manufacturing of Ethyl Alcohol (EA), Extra Neutral Alcohol (ENA) and Absolute Alcohol through molasses route comprises of a number of operations and processes involving various reactions of basic raw materials. Eventually, the desired products are formed which are refined and separated.

2.8 Resource Optimization/ Recycling and Reuse

The company will be setting up an integrated evaporation system followed by stand alone evaporation system. The condensate from evaporation will be forwarded to Condensing Polishing Unit (CPU). The treated water from the CPU shall be then reused for industrial operations and the reject shall be forwarded to MEE thereby achieving ZERO DISCHARGE of process effluent. The concentrated spent wash after evaporation will be used as fuel in incineration for steam generation.

2.9 Input Requirements and Infrastructure Facilities including Power Sources

Water

The total water requirement for proposed activities would be 455 M3/day. Out of total water requirement, about 223 M3/day would be taken from Tarali River & remaining quantity of 232 M3/day would be utilized from ‘Condensate Water’. The same would be consumed for Fermentation dilution – 150 M3/day, fermenter cooling 5 M 3/day, boiler 10 M 3/day, Cooling - 60 M3/day, gardening-5 M3/day, scrubber-2 M3/day.

Fuel

In the proposed project, the steam for the distillery operation shall be taken from proposed incineration boiler of18 TPH

Table No. – 4 Fuel Consumption

Fuel Quantity Coal 40 MT/Day Spent wash 114 KL /Day

Power

The power required for distillery operation and construction work would be taken from independent incineration boiler and TG set. Exiting power generation of JSL is 10 MW through co-gen unit .JSL is going to install a 1.5 MW capacity turbine separately for distillery unit.

Manpower

Under the proposed project, about 98 no. of manpower would be appointed. While selecting manpower preference would be given to persons from local area thereby creating better employment opportunities.

2.10 Environmental Aspects under the Project

A) The Effluents

i) Domestic Effluent-

The domestic effluent of 4.5 M3/Day would be treated separately in proposed STP to be provide on site

ii) Industrial Effluent-

The effluent generated from proposed distillery activities would be mainly in the form of spent wash to the tune 337 M3/Day and same would be primary evaporated in integrated evaporation system followed by Concentration in stand alone evaporator. Further, the concentrated spent wash (114 M3/Day) shall be subjected to incineration in the 18 TPH incinerator boiler.

Moreover, the effluent generated in the form of spent lees, cooling blow down and from washing activities would be to the tune of 105 M3/Day and same would be treated in the proposed Condensate polishing unit (CPU) along with the condensate of MEE (226 M3/Day ) The treated water from the CPU shall be then reused for industrial operations and the reject shall be forwarded to MEE there by achieving ZERO DISCHARGE of process effluent.

The water usage and effluent generation details are as follows -

Table No. - 5 Water Consumption & Effluent Generation

Sr. Purpose Water Losses Effluent Disposal Method No. consumption M3/day generation M3/ day M3/ day 1. Industrial Process 360 -- Spent Spent wash shall be primary (#210+*150) wash 337 evaporated in integrated evaporation system followed by Concentration in stand alone evaporator. Further, the Concentrated Spent wash shall be subjected to incineration in the 18 TPH incinerator boiler. Other Effluents viz. spent lees, Spent lees fermenter cooling, condenser 90 cooling, Boiler blow down, lab & washing shall be forwarded Cooling *65 60 5 to condensate polishing unit Boiler *10 8 2 (CPU). The treated water from Scrubber *2 2 00 the CPU shall be then reused Washing and #7 2 5 for industrial operations and Laboratory the reject shall be forwarded to Total 444 72 439 MEE thereby achieving ZERO # of process ( 217+*227) DISCHARGE effluent. 2. Domestic #6 1.5 4.5 Treated in STP 3. Gardening *5 5 00 -- Total (1+2+3) 455 78.5 443.5 (#232+*223) Note : # - Water taken from Tarli River,* - Treated water from Distillery CPU

B) The Emissions

The steam required for the proposed distillery operation shall be taken from the incineration boiler of 18 TPH. The boiler shall be provided with Electrostatic Precipitator (ESP) as air pollution control equipment (APC) followed by adequate stack height of 82 M.

C) Noise Pollution Aspect

Noise would be generated in the proposed project from industrial activities. The probable sources shall be incineration Boiler, distillation assembly etc. Proper acoustic treatments wherever required would be provided to keep the ambient noise levels below the permissible limits as per CPCB standards. Expected noise levels in the section will be about 72 dB (A). All preventive measures such as regular operation & maintenance of pumps, motors, and compressors will be carried out and enclosures will be provided to abate noise levels at source. The workers would be provided with earmuffs and other Personal Protective Equipments (PPE) which would give the reduction of 30 dB (A).

3.0 SITE ANALYSIS

3.1 Connectivity:

The proposed activity is scheduled to commence at a site A/p: Dhawarwadi Tal.: Karad, Dist.: Satara, Maharashtra. The site is located at a rural surrounding and its nearest railway station is Karad, located at about 20 Km and nearest airport is Kolhapur, located at about 91 Km from the proposed site.

3.2 Land Form, Land Use and Ownership:

The premises have a gentle terrain and no prime agricultural land is sacrificed. The project proponent has taken No Objection Certificate (NOC) from the Grampanchayat Dhawarwadi. The land for proposed project is solely owned by the project proponents.

3.3 Topography

The Satara district falls under the western plateau with protruded hills, micro level division of the Deccan plateau. The district as a whole is a elevated land which has been incised by Krishna river and its tributaries and Nira and Man rivers, the tributaries of Bhima river. The district can be divided into two broad types of land forms. (i) The hill ranges of the Sahyadri and Mahadeo hills and (ii) The river basin of Krishna, Nira, Man and Yerla.

3.4 Existing Land Use Pattern:

The existing land use pattern of the Karad area is taken from Census Book of 2001; it has total area about 23,274.

Geographi Culturable Area Not Name Of Forest Land under Cultivation (Ha) cal Area Waste land available for Taluka (Ha) (Ha) (Ha) Cultivation Irrigated Non irrigated Karad 110659.13 10697.84 45965.93 34457.78 3763.06 6327.64 Total 110659.13 10697.84 45965.93 34457.78 3763.06 6327.64 Percentage of total 100 10 41.5 31.2 3.4 5.7 area (%)

3.5 Existing Infrastructure:

No any existing infrastructure is available on the land for the proposed distillery unit. After procurement of Environmental Clearance, the developmental activities would be undertaken.

3.6 Soil Classification:

Soils in the study area are essentially derived from the trap rocks and fall under the following three main categories.

a) Medium black to deep black soil on the plain lands b) Lighter soils on slopes and in the eastern parts of the district c) Laterite soils in the hilly region in the western parts and on the small hillocks in the east

3.7 Climate:

The climate of Satara district is on the whole pleasant. Within the district the seasons show local variations. In the western part the climate is cool and healthy as compared to eastern part. The year may be divided into four seasons. The cold season is from December to about the middle of February. This is followed by the hot season which lasts till the end of May, June to September is the south-west monsoon season while October and November constitute the post-monsoon or the retreating monsoon season.

The average daily annual maximum temperature for the district is 35 0C & minimum temperature is14 0C. The average rainfall in the district is 1371 mm.

3.8 Social Infrastructure Available:

The area is served with infrastructural facilities such as road, water and electricity supply, and telecommunication facilities.

4.0 PLANNING BRIEF

4.1 Planning Concept:

In the proposed 45 KLPD molasses based distillery unit products like Ethyl Alcohol, Extra Neutral Alcohol and Absolute Alcohol would be manufactured by using continuous fermentation process.

The total trade effluent generated from proposed distillery activities would be in the form spent wash, spent lees as well as effluent generated from cooling blow down, boiler blow down, and washing activities. The spent wash would be primary evaporated in integrated evaporation system followed by Concentration in stand alone evaporator. Further, the Conc. Spent wash shall be subjected to incineration in the 18 TPH incinerator boiler.

The remaining effluent generated in the form of spent lees, cooling blow down and from washing treated in the proposed condensate polishing unit (CPU) along with the condensate of MEE thereby achieving ZERO DISCHARGE of process effluent.

While the domestic effluent generated would be treated in the Sewage Treatment Plant.

The solid waste generated in the form of Yeast Sludge would be incineration in incinerator boiler and boiler ash generated would be sold to the brick manufacturer.

No any hazardous waste shall be generated from the proposed distillery unit.

4.2 Population Projection:

The proposed project comes under Tal.: Karad, Dist.: Satara. Within 10 Km circle 70 nos. of villages are present According to Census 2011, Satara had population of 3,003,741 of which male and female were 1,510,842 and 1,492,899 respectively.

5.0 PROPOSED INFRASTRUCTURE

5.1 Industrial Area:

The area of total plot acquired by the project proponent for is 233200 Sq.M (23.3 ha) out of which 18738.42 Sq.M (1.87 ha) shall be utilized for installation of proposed distillery project.

5.2 Greenbelt

Total land acquired by the industry for Sugar, Co-gen and Distillery unit is about 233200 Sq. M. (23.3 ha) Out of this total land, an area about 18738.42 Sq. M. (1.87 ha) has been ear marked for the proposed 45 KLPD distillery unit. Further, as per norm, 33 % of Total area would be brought under green belt development plan which would be about 76,956.88 Sq. M. (7.6 ha)

5.3 Social Infrastructure:

The proposed area is provided with roads, water and power supply facilities.

5.4 Connectivity:

The proposed project area is well connected by roads, rail and airport facilities. The Karad railway station and airport is about 20 Km and 23 Km away from the proposed site.

5.5 Drinking Water Management:

For the proposed distillery unit water for processing as well as domestic purpose would be sourced from Tarali River.

5.6 Sewerage System:

The domestic effluent would be treated separately in proposed sewage treatment plant.

5.7 Industrial Waste Management:

Industrial Effluent – The effluent generated in the form of spent wash shall be primarily treated in an integrated evaporation system followed by Concentration in stand alone evaporator. Further, the Conc. Spent wash shall be subjected to incineration in the 18 TPH incinerator boiler.

While the effluent generated in the form of spent lees, cooling blow down and from washing activities would be treated in the proposed condensing polishing unit (CPU) along with the condensate from MEE.

Emissions - The unit proposes to install Electrostatic Precipitator (ESP) as Air Pollution Control Equipment for boiler in sugar factory.

Hazardous Waste – No any Hazardous waste would be generated

Solid Waste - Solid waste generated would be in the form of Yeast sludge is to the tune of 10 KL / Day and Boiler ash generated 36 MT /Day would be sold to the brick manufacturers.

5.8 Solid Waste Management

The solid waste would be generated in the form of Process Yeast Sludge to the tune of 10 KL / Day. The same shall be utilized in incineration boiler. And boiler ash generated 36 MT/ Day would be sold to brick manufactures.

5.9 Power Requirement & Supply / Source:

6.0 REHABILITATION & RESETTLEMENT (R& R) PLAN

6.1 Policy to Be Adopted:

There are no rehabilitation & resettlement issues involved.

7.0 PROJECT SCHEDULE & COST ESTIMATES

7.1 Date of Start: The construction work w.r.t. proposed project would be initiated after Grant of Environmental Clearance.

7.2 Estimated Project Cost:

The expected cost of the proposed project will be around Rs. 64.81 Crores.

8.0 ANALYSIS OF PROPOSAL

The proposed molasses based distillery unit has low pollution potential.

Water use will be minimized to improve the process.

The air pollution potential of the project will be mitigated by providing Electrostatic Precipitator as air pollution control system.

Fire protection and safety measures would be provided to take care of fire and explosion hazard.

Direct and indirect employment opportunities would be extended to the nearby resident.

Energy consumption of the unit is expected to be lowest in the industry compared to other similar technology supplier.

The proposed project would be implemented by adopting latest technologies and equipments thereby minimizing the pollution load in Environment.