John Distilleries Pvt.Ltd., A/P :-Chitali, 2014 Tal:- Rahata, Dist:- Ahmadnagar, (M.S.) Prefeasibility Report

INDEX

1. EXECUTIVE SUMMERY 2. INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION 2.1 Identification of the project and Project Proponent 2.2 Nature of the Project 2.3 Need of project with description for region and country 2.4 Demand and Supply gap 2.5 Imports vs. Indigenous production 2.6 Export Possibility 2.7 Domestic/ Export Markets 2.8 Employment Generation due to Project 3. PROJECT DESCRIPTION 3.1 Type of Project 3.2 Location of Project 3.3 Details of Alternate sites 3.4 Size of magnitude of Operation 3.5 Project Description 3.6 Raw material and Finished Products 3.7 Resources optimization 3.8 Availability of Resource (Water, Energy/ Power Requirement) 3.9 Quantity of Waste to be Generated 4. SITE ANALYSIS 4.1 Connectivity 4.2 Land form, Land use, Land ownership 4.3 Topography 4.4 Existing land use pattern 4.5 Existing Infrastructure 4.6 Soil classification 4.7 Climatic data for secondary sources

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4.8 Social Infrastructure available 5. PLANNING BRIEF 5.1 Planning concept 5.2 Population Projection 5.3 Land use planning 5.4 Assessment of Infrastructure Demand 5.5 Amenities/ Facilities 6. PROPOSED INFRASTRUCTURE 6.1 Industrial area 6.2 Residential area 6.3 Green Belt 6.4 Social Infrastructure 6.5 Connectivity 6.6 Drinking Water Management 6.7 Sewerage System 6.8 Industrial Waste management 6.9 Air Pollution 6.10 Solid waste Management 6.11 Power Requirement & Supply/ Source 7. REHABILATION AND RESETTLEMENT (R & R PLAN) 7.1 Policy to be adopted 8. PROJECT SHEDULE & COST ESTIMATES 8.1 Time schedule for the Project 8.2 Estimated project cost (Economic viability of the project) 9. ANALYSIS OF PROPOSAL 9.1 Financial and Social benefits

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CHAPTER 01

EXECUTIVE SUMMARY

M/S John Distilleries Pvt.Ltd. is proposing a expansion of existing distillery complex based on molasses. It is desirous to produce alcohol in this Large Size Industrial (LSI) sector at At-Po – Chitali Tal. Rahata Dist. Ahamadnagar . The existing capacity to manufacture Alcohol (ENA/ RS) is 50 KLPD and it is proposed to add additional 100 KLPD totally 150 KLPD.

The Notification no. S. O. 1533 promulgated on 14th September 2006 have covered these types of industries under its entry 5(g) stated distillery.

The proposed land is at Chitali Gut no.398, 399, 420, 423, and 424 admeasuring area of 226.34 acres. Proposed Layout Plan is attached. This is an expansion of existing project. The Land converted to Industrial purpose since 1960. Thus there is 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 from the Godavari Right bank canal, the internal road network, external approach road and networking. There is no sensitive establishment in the vicinity (study zone) such as health resort, hospital, archaeological monuments, sanctuaries etc. All villages are provided with drinking water from wells or Government Water Supply Schemes RWS. Hence we do not encroach upon their resource.

There will be no nuisance from noise. Machinery and Equipments will be provided with Acoustic Enclosure. There will not be crushing, pulverizing operations. Labour strength is also limited in this LSI unit. In this case input is odorless. No nuisance generation.

List of Products:

Sr. No. Product name Quantity Unit 1 Alcohol (ENA/ RS) 100 KLPD

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Whereas, during production water input requires 807 M3/Day. Fuel used for boiler will be, Coal 14 tons/day, biogas 14 tons/day and Bagasse 200 MT/day requirement shall be, and there will be chimney with adequate height.

In John Distilleries Pvt.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 will be 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 are 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 near Srirampur MIDC at-village-Chitalli, Tal.Rahata Dist. Ahmadnagr, Maharashtra. The Site is km from 16 km away from State highway Ahmadnagar - Kopargaon, and 10 k.m. away from Godavari River. The electricity and other is made available by local authority and the raw material is easily available. The Srirampur city has Railway station. State Highway is passing adjacent to the project site.

The industry is proposing to manufacture Alcohol for growing needs of . This will not disturb the present land use because our area occupied will be only small % of influence zone of 10 km.Trees are present at the proposed site , rehabilitation is not required. 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

John Distilleries Pvt.Ltd., private limited company is floated and promoted by reputed well-known Industrial families in Ahmadnagar in Maharashtra state.

Mr. Paul P John, by Qualification and first generation entrepreneur started John Distilleries in 1996, a company manufacturing Indian Made Foreign and within a span of 16 years, our reach spread from to establish footprint in 11 States across India. We are the Sixth Largest Liquor Company in the country in terms of volume. Currently, we are present in 11 States & CSD business through multiple models like own, lease & tie- up facilities. We also export our premium products to developed countries and regular brands to Middle East & African Nations. Mr. Paul P John has also got his presence in Hospitality Industry and currently owns “Kumarakom Lake Resort” in and “The Paul” in Bangalore. Apart from Beverages & Hospitality segment, he has business interests in US, with a furnishing fabric trading house, real estate & construction business based in Tampa, Florida, that has a distribution network across the US and Canada. Promoted John Distilleries and has grown Original Choice into a 12 million case brand with distribution in 11 states & CSD Business. A visionary entrepreneur having interests in beverages and hospitality with the award winning Kumarakom Lake Resort Expanded into premium wines with Big Banyan Holds degrees in Commerce and Law At John Distilleries Pvt. Ltd. Going to carry a Business of Distillery Plant for the manufacture of Country Liquor and Foreign Liquor. The proposed expansion will have the flexibility to produce , Extra neutral alcohol and Anhydrous Alcohol based on the market requirement. The plant will incorporate multi-pressure distillation over conventional steam distillation for better energy efficiency and consistent good quality of the product. John Distilleries Pvt. Ltd. factory is situated at Chitali Gut no. 398, 399, 420, 423, 424 of

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Village- Chitalli, in Rahata tahesil of (MS) Ahmadnagar District. Application has been made to MPCB for the Consent to establish. The manufacturing site is located at Chitali Gut no.398, 399, 420, 423, 424 of Village-Chitalli, in Rahata tahesil of (MS) Ahmadnagar District (Maharashtra).

The plot admeasures about 226.34 acres. The company shall be engaged in manufacture of molasses based alcohol. 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

John Distilleries Pvt.Ltd. is proposing 100 KLPD of expansion with existing capacity as 50 KLPD Alcohol. This level of production will not be commenced from day one, but will be commissioned smoothly. This is an optimum site for us because it is manageable from production, pollution control and quality assurance point of view.

2.3 Need of project with description for region and country 1. The molasses has very high level BODs & CODs. If the same is not in use properly shall cause more damage to environment. 2. The molasses can be converted in valuable products like alcohol and the risk of more pollution can be diluted. 3. The latest technology is adopted with a better productivity and Quality of alcohol. 4. The molasses based distilleries are linked with sugar factory and sugar producing farmers will be benefit by it. 5. These also involved in several developmental activities to help farmers.

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Justification: -

1) ENA will be available for the IMFL unit 2) Revenue will be generated for state government. 3) Ethanol will be used for mixing in fuel like petrol. It will reduce the valve of petrol in the country. 4) Foreign Currency will be saved 5) Import of Foreign Liquor will reduce 6) Employment will be provided to the nearby region which will reduce poverty 7) Development of Local region 8) Increase in Local Business 9) Standard of Living of people will increase. Worker will be skilled • 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 and • 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 alcohol always prevail. As far as the products like the molasses is by product of sugar mill. It is concerned to alcohol are there is a huge gap in our country in demand and supply. There are three main uses of ethanol in India. Of the total available ethanol, the maximum – about 45 per cent – is used to produce potable liquor, about 40 per cent is used in the alcohol-based chemical industry (as a solvent in synthesis of other organic chemicals) and the rest is used for blending with petrol and other purposes. The demand for ethanol has been continually increasing on account of the growth of user industries

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and use of ethanol as a fuel in the country. However, the production and availability of ethanol has largely lagged behind. India is the fourth largest producer of ethanol. In the world after Brazil, the United States of America (USA) and China, producing approximately 2000 million litres of ethanol, mainly by fermentation of sugarcane molasses. Ethanol is made by fermentation of sugars: enzymes from yeast change simple sugars into ethanol and carbon dioxide. Potable ethanol and more than half of industrial ethanol is made by this process.

Table 1: Ethanol production and consumption in India (million liters)

Ethanol Production 2004 2005 2006 2007 2008 2009 ISMA (in sugar year) 1240 1925 2950 2715 1560 – ICC (in alcohol year) 980 1590 2100 2200 1300 1680 USDA FAS 1199 1300 1,898 2,398 2,150 1073 Ethanol Consumption ISMA (in sugar year) 1410 1550 1700 1840 2010 – ICC (in alcohol year) 1470 1740 2120 2280 1650 2870 USDA FAS 1430 1479 1639 1750 1940 1780 Surplus Ethanol ISMA (in sugar year) (–170) (375) (1250) (875) (–450) – ICC (in alcohol year) (–490) (–150) (–20) (–80) (–350) (–1190) USDA FAS –231 –179 259 648 210 (–707) Imports ICC (in alcohol year) 490 150 20 80 350 – USDA FAS – – 29 15 70 280

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.

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2.6 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. Manpower required as follows.

Sr.no. Particulars No. of employees

1. Officers & supervisors 25

2. Skilled 40

3. Semiskilled 08

4. Labour 13

Total 86

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CHAPTER 03 PROJECT DESCRIPTION

3.1 Type of Project:

John Distilleries Pvt.Ltd. is proposing an expansion of existing distillery complex consisting of Distillery. John Distilleries Pvt.Ltd. is desirous to produce alcohol in this Large Size Industrial (LSI) sector at Chitalli Gut no. 398, 399, 420, 423, 424 Village. Chitali Tal. Rahata Dist. Ahamadnagar Maharashtra. The proposed Expansion capacity of the complex shall be Alcohol 100 KLPD.

With Screening it is necessary for John Distilleries Pvt.Ltd. to approach Delegated Authority from Ministry of Environment and Forest (MoEF), New for Environment Clearance 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 Chitalli. In order to have a sustainable development, the pollution generation from this industry is finally made insignificant having taken all the precautions right from raw material selection up to low or no waste generation and conversion.

3.2 Location of Project:

The proposed expansion of distillery complex at Chitalli Gut no. 398, 399, 420, 423, 424 of Village- Chitalli In taluka - Rahata of Dist.Ahamadnagar in Maharashtra state. Area is around 226.34 acres. The Geographical Location of this Industry is N 19041’13.0” Latitude and E 740 37’06.2” Longitude with an elevation of 532 m. (1745.41 ft) above mean sea level (MSL). Local Authority has assured to provide all infrastructure like assured Electrical power, continuous water supply from the nira right bank canal, the internal road network, external approach road are already available.

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

1. Nearest Airport at Aurangabad 81km towards East direction. 2. Nearest State High way 16 km away from Ahmadnagar - Kopargaon towards East direction. 3. Nearest Railway station at Chitalli 0.5km towards North Direction. 4. Nearest Habitat is Chitalli village towards South direction. 5. Nearest river is” Godavari River” at 10 km towards North direction. GPS Location and Google Imagery of the proposed site are attached as (Annexure I).

3.3 Conclusion of the report Considering merits and demerits of the sites in question, a marking system that is Followed for ranking the considering following aspects is as under: a) Source of water and land availability for Industrial (factory) use. b) Topography, soil condition, land cost. c) Environmental impact. With all this consideration, this site was ranked first and adopted. 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. In addition to this plant, attendant waste minimization, sophisticated R & D laboratory is required and shall be provided. 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 II). 3.4 Size or Magnitude of Operation

John Distilleries Pvt.Ltd.is proposing Expansion of existing distillery complex with capacity from 50 to proposed 100 KLPD Alcohols. This level of production will not be commenced from day one, but will be commissioned smoothly. This will not disturb the present land use because our area occupied will be only small % of influence zone of 10 km. Landscape and greenery will be developed in 33% area and only native species will be promoted No Rehabilitation is required.

3.5 Project Description with Processes Details:

Product Details:

Sr. No. Product name Quantity Unit 1. Alcohol(ENA/ RS ) 100 KLPD/Day

Manufacturing Process:

(A) Manufacturing Process of Alcohol:-(Molasses–based) FERMENTATION In Hi Ferm Fermentation process for molasses based operation, culture yeast is used. Hi Ferm Fermentation is Fermentation system which offers running the process in fed batch mode. Hi Ferm Fermentation Plant has following sections, Molasses Handling and Distribution Screened molasses from Day Molasses Tank is fed to molasses receiving tank and molasses is weighed. Weighed molasses is distributed to cell mass propagation, Fermentation and yeast.

Yeast Propagation Culture yeast is grown in laboratory during plant start-up. Yeast propagation section comprises molasses diluter and hygienically engineered yeast vessels equipped with heating, cooling and air Sparing facility.

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Pre Fermentation In Pre-Fermented vessel, molasses, process water, nutrients and additive are added for activation/growth of cell mass. Filtered air is spared as required for repairing of cell membranes and other cell components. Activated cell mass is transferred to Fermented to maintain desired cell mass concentration in Fermented. • Dilute molasses media is prepared in yeast vessel by re-circulating media through molasses diluter. Laboratory propagated cell mass is scaled up in series of yeast vessels. Sterile air is spared in pasteurized and cooled dilute molasses medium for optimum growth of yeast. Temperature is maintained at 30-32 degree by recirculation cooling water through jacket of yeast vessels. Cell mass from Yeast vessel is transferred to Pre fermented to build up cell mass required for Fermentation by cell mass transfer pump.

Fermentation The Fermentation process is engineered to operate in batch mode depending upon the quality of molasses. The purpose of Fermentation is to convert the fermentable sugars into alcohol. During Fermentation, sugars are broken down into alcohol and carbon - di - oxide. Significant heat release takes place during Fermentation. The fermented temperature is maintained at around 30 -320C by forced recirculation flow through plate heat exchangers 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

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cooling water is sprayed on fermenter walls to maintain the temperature at 29-300C. Sludge is produced and discharged from the bottom, while the clear fermented beer from top is sent to degasifying section of the analyzer 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 first section generally has two floors with equipment like diluter, pre-fermenters, etc., and laboratory placed on the first. Fermentation vessels are laid on the ground floor with their top extending about 1.5 m. into the first floor. The ground floor of the fermenters is usually wet because of the cooling water sprayed on the outer walls of the fermenters. This water splashes on the floor and flows out through open channels on the floor along with fermenter sludge and washes water.

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. 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.

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Manufacturing process for Alcohol:

In India, Alcohol is manufactured by two processes:

• Batch Process • Continuous Process a) Batch Process

The molasses obtained from the sugar industry is first diluted to bring down the concentration of sugar from 40-45% to 10-15%. Using a portion of the diluted molasses a yeast culture is developed from inoculums. After 4-6 hours, when the culture has developed fully, the remaining molasses is mixed and allowed to ferment for 30-40 hours. The pH is maintained around 4-4.5 by addition of Sulphuric acid. As the reaction is exothermic, the contents of the fermentation tank are kept at 35-370C by constantly sprinkling cold water on the outer surface of the fermentation tank. After fermentation is complete the yeast sludge is removed from the bottom and the fermenter wash is pumped to the analyzer column for distillation using steam. The free mixture of alcohol vapors and steam is collected at the top of the column and alcohol free spent wash is discharged from the bottom,

The alcohol and the steam are fed to rectification column where water and alcohol vapors condense at different levels and rectified spirit is withdrawn. The condensed water from this stage is called spent lees and forms another waste stream.

b) 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.

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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.

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Flow Sheet:

Manufacturing Process Flow Diagram for Distillery unit

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Material Balance Findings: Controlling Equations:

1. C12H22O11 + H2O 2C6H12O6 Sucrose + Water Reducing Sugar 342 + 18 360 1 + 0.05263 1.05263

2. C6H22O6 2C2H5OH + 2CO2 Reducing Sugar Ethyl Alcohol + Carbon Dioxide 180 92 + 88 1 0.5111 + 0.4889 1.05263 0.53978 + 0.51462

DISTILLATION - WASH TO RS MODE Wash to RS Mode: - Following Columns will be under operation 1. Analyser Column 2. Degasifying Column 3. Rectifier cum Exhaust Column 4. Recovery Column 5. Purifier Column Pre-heated Fermented wash will be fed to Degasifying Column. Fermented wash is stripped off alcohol by ascending vapors in Analyser Column. Vapors of Degasifying Column are condensed and appropriate TA cut is taken out from this Column. The DG Condensate is fed to Recovery Column. Analyser vapors are condensed in Analyser Condensers and taken to Rectifier Feed Tank (which acts as Pre-Rectifier Column Feed Tank in Wash to ENA mode). Rectifier Column, which operates under pressure, concentrates the condensate of Analyser Column to 95% v/v concentration. Fuel Oil Draws are taken from appropriate trays and fed to Recovery Column. Recovery Column concentrates the fuel oil streams.

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A suitable Impure Spirit cut is taken out from this Column. Rectified Spirit draw of 95% v/v is taken out from the upper trays of Rectifier Column and taken to storage after passing it through a cooler.

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DISTILLATION - WASH TO ENA MODE

Following Columns will be under operation 1. Analyser Column 2. Degasifying Column 3. Pre-Rectifier Column 4. Extractive Distillation Column 5. Rectifier cum Exhaust Column 6. Recovery Column 7. Simmering Column Pre-heated Fermented wash will be fed to Degasifying Column. Fermented wash is stripped off alcohol by ascending vapors in Analyser Column. Rectifier vapors provide energy to Analyser Column through a Thermo-siphon re-boiler. Vapors of Degasifying Column are condensed and taken to Recovery Feed Tank. Analyser vapors are condensed in Analyser Condensers and are taken to Pre-Rectifier Feed Tank. Analyser Condensate is concentrated in Pre-Rectifier Column, which operates under pressure. Condensing steam provides energy to Pre-Rectifier Column through a vertical Thermosyphon reboiler. A Technical Alcohol cut of about 1-2% of Total Spirit is taken from the Pre-Rectifier column. Concentrated alcohol draw from Pre-Rectifier Column is fed to Extractive Distillation Column for purification. Dilution water is added in this column for concentrating higher alcohol at the top. Top of this Column is condensed in its condensers and fed to Recovery Feed Tank while bottoms are fed to Rectifier cum Exhaust Column for concentration. Rectifier Column operates under Pressure and condensing steam provides energy to this column through a vertical Thermosyphon Reboiler. Technical Alcohol cut is taken out from the top of this Column while ENA draw is taken out from appropriate upper trays and fed to Simmering Column after cooling. Fuel Oil build up is avoided by taking fusel oil draws from appropriate trays. These Fusel oils along with the condensate of Degasifying & Extractive Distillation columns are fed to Recovery Column for concentration. A Technical Alcohol cut is taken out from the top of

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this column. Simmering Column is operated under high reflux for better separation of methanol and di-acetyls. Final ENA product draw is taken from the bottom of this column. Technology selection:

1. The process used is based on Raw materials that are available, without any bottleneck. 2. Thus it is not necessary to store any one of it in excess. Excess storage also means wastage. Here we can follow easily the principle of JIT (Just in Time) procurement. Basic raw material i.e. sugar cane is available in the surrounding area abundantly. Rest of the raw material is the byproduct of the prevailing process e.g. Bagasse and Molasses. 3. The process used is developed and streamlined by team and hence are aware about the sensitive points that need careful attention in advance. 4. The process is cost effective, safe and environment friendly. 5. There is no highly elevated pressure condition in processing. 6. Working pressure of furnaces is reasonably low. Such furnaces are available and are easy to manage. 7. No hazardous material is involved in process. 8. We can recover alcohol and generate power from molasses and Bagasse. After recovery the remains can be used in brick making and as manure thus following the principal of “at source reduction of waste”.

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3.6 Raw Material for finished Product: List of Raw Materials:

List of Raw Materials and their Requirements on monthly basis

Name of Raw Required Description Mode of Source Storage at Material Quantity Transport site

Molasses 28000 M.T Minimum 50% By Road Nearer sugar 12000 M.T T.RS and 88° with tanker factories Brix

List of Products and production on monthly basis:

Name of the Description (Physical Storage at site Mode of Transport Product and Chemical Nature)

Extra Neutral Clear Appearance 12 Laks B. L. By Road Alcohol Soluble in water

Rectified Sprit Clear Appearance 19 Laks B.L. By Road Soluble in water

3.7 Source for Raw Material Procurement:

Raw Material is easily available in the local. Market and in the surrounding

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

Storage at the site: Raw materials will be stored in Storage Yard at the project site as per the norms. Location of Storage Yard is demarcated in Layout Plan.

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

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John Distilleries Pvt.Ltd., A/P :-Chitali, 2014 Tal:- Rahata, Dist:- Ahmadnagar, (M.S.) Prefeasibility Report

Power: The total power generation here will be 1000 kw/hr. The power required for the factory will be consumed from the in-house production and excess will be sold to MSEB.

Water: The water requirement is about 807 M3/Day for domestic, greenery, process, and part cooling purposes. The source of water is already available from existing dam and the same is adequate and satisfactory. The source is dependable and reliable.

Manpower: The manpower required for administration and production purposes will be recruited locally without any difficulty. The requirement will be variable as per phase of working but shall be about workforces including staff members shall work in shifts. The list of workers & staff as shown in table below

Sr. Particulars No. of employees No.

1. Officers & supervisors 25

2. Skilled 40

3. Semiskilled 08

4. Labour 13

Total 86

List of staff & workers

Fuel for Furnace: Fuel used will be as below.

a) Coal – 14 Tons/day.

b) Biogas- 14 Tons/day.

c) Bagasse – 200 MT/day

DG Set: proposed DG set capacity shall be of 1010 KVA.

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Land: Approximately 226.34 acres of land is already in the possession of proponent.

Project Cost: 40 Cr. (Fourty Core) for this unit.

EMP Cost: 6.35 Cr.

3.9 Quantity of waste to be generated:

Water & wastewater: The water supply will be through the Nira river right bank canal located near village. This source is from Nira River and hence extremely dependable source. Local Authority has provided full water works including filtration. The water & wastewater generated in the factory will be as follows:

A) Water requirement for various purpose:

Sr. Purpose Fresh Water Recycled Water No.

1. Boiler 70 cum/day 353 cum/day

2. Process (Fermentation) 425 cum/day 495 cum/day

3. Floor Washing ------20 cum/day

4. Cooling Tower make up ------400 cum/day

5. Domestic 12 cum/day

6. Green Belt ------80 cum/day

7. Distillation 300 cum/day 400 cum/day

Total 807 cum/day 1748 cum/day

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B) Effluent Generation Blow Down (Boiler/CT/WTP) 95 cum/day

Process Effluent (Lean stream) 267 cum/day (spent lees)

Process Effluent (Spent Wash) 800 cum/day

Floor Washings 15 cum/day

Domestic 9 cum/day

Waste water generation and Characteristics. Table lists the major wastewater streams generated at different stages in the alcohol manufacturing process summarizes the typical characteristics of spent wash generated in Indian distilleries using sugarcane molasses. Values for beet molasses-based effluent are given for comparison. The main source of wastewater generation is the distillation step wherein large volumes of dark brown effluent (termed as spent wash, stillage, slop or vinasse) is generated in the temperature range of 71–81 1C The characteristics of the spent wash depend on the raw material used also, it is estimated that 88% of the molasses constituents end up as waste. Sample quantities and characteristics of wastewater streams generated in an Indian distillery

Characteristics of spent wash generated from various feedstock.

Parameter Mg / lit.

COD (mg/l) 65,000–130, 000

BOD (mg/l) 30,000–70,000

COD/BOD ratio 2.49

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Total solids (mg/l) 30,000–100,000

Total suspended solids (mg/l) 350

Total dissolved solids (mg/l) 80,000

Total nitrogen (mg/l) 1000–2000

Total phosphorus (mg/l) 800–1200

Potassium (mg/l) 8000–12,000

Sulfur as SO4 (mg/l) 2000–6000

pH 3–5.4

Molasses spent wash has very high levels of BOD, COD, COD/BOD ratio as well as high potassium, phosphorus and sulfate content (Table 3). In addition, cane molasses spent wash contains low molecular weight compounds such as lactic acid, glycerol, ethanol and acetic acid (Wilkie et al., 2000). Cane molasses also contains around 2% of a dark brown pigment called melanoidins that impart color to the spent wash (Kalavathi et al., 2001). Melanoidins are low and high molecular weight polymers formed as one of the final products of Maillard reaction, which is a no enzymatic browning reaction resulting from the reaction of reducing sugars and amino compounds (Martins and van Boekel, 2004). This reaction proceeds effectively at temperatures above 50 1C and pH 4–7. The structure of melanoidins is still not well known (Rivero-Pe´ rez et al., 2002). Only 6–7% degradation of the melanoidins is achieved in the conventional anaerobic–aerobic effluent treatment process (Gonzalez et al., 2000). Due to their antioxidant properties, melanoidins are toxic to many microorganisms involved in wastewater treatment

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(Sirianuntapiboon et al., 2004a). Apart from melanoidins, spent wash contains other colorants such as phenolics, caramel and melanin. Phenolics are more pronounced in cane molasses wastewater whereas melanin is significant in beet molasses.

Effluent Treatment: The molasses based distillery shall generate two types of waste water. a) Concentrated stream – call as spent wash b) Learn stream – consisting of spent leese, boiler and cooling tower blow down, DM water, softener regeneration and process condensate. The treatment shall be as under: 1) Spent Wash- the spent wash generated from factory shall be collected in a 30 days storage lagoon and shall be forward to bio-digester. The bio-gas from biodigester shall be used as fuel in boiler. The treated effluent from biodigester shall be forward to MEE. The concentrated spent wash shall be further incinerated in boiler. The press mud from sister concern unit and boiler ash shall be used as filler material. The bio compost shall be sold as fertilizer. 2) Lean Steam – all lean stream from various sources like boiler blow down, cooling tower blow down, spent leese, MEE condensate, process condensate, floor washing shall be collected together and subjected to primary and two stage biological treatment followed by UF and RO to recycle the treated effluent. i) Solid Waste

The main solid waste from this factory will be of non-hazardous from office, garden and Effluent Treatment Plant. Non hazardous waste will be segregated as compostable and saleable. This will be so done.

M/S John Distilleries Pvt. Ltd. has in place the following mitigation policy future:

• Waste minimization at all levels of operations.

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• 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 20 Compost Own garden Organic 2. Garden Trash 114 Compost Land filling -- 3. Office waste 70 Collection Sales For paper recycle

(b) Generation of hazardous solid waste:

Sr. List of Processes Generating Waste stream Quantity No. Hazardous Waste

5 Every action relating to and 5.1 Spent oil every use of lubricating and system oil 5.2 Wastes/residues 230 lit /year containing oil

Aesthetics: Boiler Turbine, Centrifuges etc. shall be source of noise and vibrations. Sturdy foundations and anti vibration arrangements shall be provided to reduce the effect. Acoustic enclosures and enclosures shall be done to reduce noise level. Tree plantation will be carried out. PPF’s will be provided to the workers in this area.

There will be no nuisance from noise as the machinery and equipments are acoustically enclosed. DG sets will run occasionally. No nuisance will go to surrounding area.

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CHAPTER 04 SITE ANALYSIS

4.1 Connectivity:

The proposed production shall be at Gut no. 398, 399, 420, 423, 424 Village- Chitalli, in Taluka – Rahata of Dist. Ahmadnagar in Maharashtra state. Total area is around 226.34 acres.

The Geographical Location of this Industry is N 18001’54.5”latitude and E 740 20’33.2”Longitude with an elevation of 539 m. (1768.37 ft) mean sea level (MSL). Local Authority has assured to provide all infrastructures like assured Electrical power, continuous water supply, the internal road network, external approach road etc.

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

1. Nearest Airport at Aurangabad 81km towards East direction. 2. Nearest State High way 16 km away from Ahmadnagar - Kopargaon towards East direction. 3. Nearest Railway station at Chitalli 0.5km towards North Direction. 4. Nearest Habitat is Chitalli village towards South direction. 5. Nearest river is” Godavari River” at 10 km towards North 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 226.34 acres 91.596 (ha) only.

Existing Land use Pattern: This agricultural land already converted to industrial land. Now it is used for the industrial purpose. Hence there is no change in land use pattern.

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Existing Infrastructure:

Presently this area is existing with capacity 50 KLPD. 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 expansion 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.

Site 1. Open land, with no encroachment involved.

2. Climatic condition suitable for finer adjustment of control, making it fit for process condition.

3. Well connected road network with ease of transportation.

4. Almost leveled ground and load bearing soil.

4.6 Soil Classification:

Ahmednagar is the biggest district of Maharashtra in terms of area and population. The total geographical area of the district is 17.41 lakh ha. The net cropped area is 12, 56, 500 ha, out of which an area of 3,30,000 ha. (26.27 %) is under canal (84,000 ha) and well irrigation. About 9, 26, 500 ha. (73.73 %) area is rain fed. The area under Kharif crops is 4, 60,000 ha. (36.6 per cent) while 7, 58,000 ha (60.32 per cent) area is under Rabi crops. A multiple cropping system is followed on 1, 10, 500 ha. area. A total of 8.73 per cent area of the district is under forest. The soil types of the district are broadly divided into four categories namely coarse shallow soil; medium black soil; deep black soil and reddish soil occupying about 38, 41,13 and 8 percent of the cultivated area respectively. In the first two categories, soil moisture is the predominant limiting factor affecting productivity of crops particularly under rainfed condition. CONSULTANT: sd engineering services private limited, Aurangabad (MS) Pg. 30

John Distilleries Pvt.Ltd., A/P :-Chitali, 2014 Tal:- Rahata, Dist:- Ahmadnagar, (M.S.) Prefeasibility Report

4.7 Climate data from secondary sources:

Climate Classification: Project site features a semiarid climate under the Koppen climate Classification.

Temperature:

Annual temperature has a relatively high range between the weather and climate influence on our day to day life. Analysis of any weather data is most important. They are gives and identified appropriate condition of the given station. To using the various data man has aclimization to particular climatic position. Many methods are helps to declaration of the weather conditions. With the help of the climatic data we are able to find out climatic classification. With the help of koppen's classification we are able to understand that the climate of Ahmednagar city is semi arid, hot and dry climate is found. The concentration of ppt. in Summer / warmer six month is more than70% Precipitation that is 88.23% in summer / warmer six month at the Ahmednagar city therefore the dry climate is present. Rainfall is less than upper limit for B but more than half that amount that's why semi arid climate is present. And Average annual Temperature is over 180c therefore hot climate is present. In an all criteria fulfilled therefore in Ahmednagar city having dry arid hot type climate according to koppen classification.

Rainfall: The climate of the district is hot and dry, on whole extremely genial and is characterized by a hot summer and general dryness during major part of the year except during south-west monsoon season. receives average 566 mm. rainfall. The major rainfall received during month of June to September.

4.8 Social Infrastructure available:

Infrastructures like Airport is at the distance of 81 Km East and Railway Station is at 0.5 km in North direction and nearest habitat is at the distance of 2 Km in East direction; in north direction Godavari right bank canal are located in the study area.

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CHAPTER 05 PLANNING BRIEF

5.1 Planning Concept:

The area covered under study zone comprises of medium to heavy soil quality. Profuse availability of stored water has encouraged villagers to grow cash crops.

Facilities:

This site appeared to be environmentally best as also from the business angle and therefore this option was finally adopted. This site is inside the campus of the Village-Chitalli 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:

Total population of the district is 40.88 lakhs of which 32.84 lakhs is living in the rural area whereas 8.04 lakhs lives in urban area. The literacy of the district is 75.82 percent. The female to male ratio of the district is 941. In the district, there are 6.8 lakh farming families, out of these 32.45 per cent farmers are having less than 2 ha land holding, 57.89 per cent farmers are having land holding between 2-10 ha. and 9.66 per cent farmers have a land holding with more than 10 ha. Total 3.8 lakhs are agriculture laborer, 7.88 lakhs are SC/ST population, 2.11 lakh are dairy and sheep owners and total working population is 14.32 lakh.

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5.3 Land use planning: The proposed expansion is a prime industrial 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. Topography Map of the proposed site is attached.

Proposed expansion 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 Project proponent expansion will be having which does not require any addition in existing Physical Infrastructure; so there will not be any demand of expansion of physical infrastructure and social infrastructure. As manpower requirement is very less for the proposed expansion which will not lead to any additional load on the existing social infrastructure.

5.5 Amenities/ Facilities:

Project proponent is proposing Manufacturing of Rectified spirit ENA & Ethanol from

Sugarcane molasses, compost & CO2 gas are byproducts in existing Industrial area. Local body provides many basic facilities like uninterrupted water supply, power and Road Network & solids disposal facility. This site is near the campus of the industrial area and means safe transportation, less need of Utilities, less constructing buildings and roads, less fuel, less water with optimization of infrastructure.

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CHAPTER 06 PROPOSED INFRASTRUCTURE

6.1 Industrial area:

This is new facility to manufacture Alcohol from molasses. Project proponent will develop infrastructure as per requirement for proposed project of production.

6.2 Residential Area:

Residential already exist.

6.3 Green Belt:

About 33% of the total Plot area i.e. 226.34 acre is demarcated and additional along the boundaries shall be proposed for tree plantation. The selection of trees is based upon the Climatological conditions of the Study area.

In and around the 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

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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:

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 Alcohol manufacturing facility is located at Village - Chitalli Shivar in Ahamadnagr district, Maharashtra. The Site is 16 km from Srirampur town and 0.5 km from Chitalli railway Station and 81 km from Aurangabad Air port. The land and infrastructure is made available by Local Authority and the raw material is easily available through the easy

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transport via road connectivity and via Sea route and Air route. The Kopargaon Road State Highway is passing adjacent to the project boundary.

6.6 Water Management:

The water requirement is about 807 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 Septic tank and will be used for green belt after treatment.

6.8 Air Pollution:

Process Emissions:

The air pollution caused by this industry is mainly from boiler. The boiler shall be provided with bag filter followed by stack of 40 m height.

Fugitive Emissions:

A number of mitigation measures are taken to control fugitive emissions, the presence of which will be noticeable by plain vision if not controlled. The measures are thus taken seriously and continuously such as: • Rubber wheel carts / trucks to bring in Raw Materials, not filled high, sides cladded, slow speed travel, avoiding vibrations en-route. • Collection of fugitive emissions by suitable suction system at the time of casting etc. • Engineering the plant layout in such a way so as to virtually Eliminate need of using heavy equipment for material handling in the main plant • Internal roads paved, scrap area paved, leveled, no undulations, no sharp curves, slow speed. No open storage of materials on barren unlined land to the maximum extent possible.

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6.9 Solid Waste Management:

The main solid waste from this factory will be (a) non-hazardous from office, garden and sewage ETP. Non hazardous will be segregated as recyclable/ saleable and Compostable. This will be so done.

JDPL has in place the following mitigation policy future:

• Waste minimization at all levels for discarded products, packing surplus, unloading spillages and fugitives. • 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 contents will not be stored in the factory for more than a fortnight. • The non-hazardous waste will be disposed by scientifically designed composting plant. (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. 6.10 Power Requirement & Supply/ Source

John Distilleries Pvt.Ltd.Power requirement 1000 kw/hr for unit connected load available through Govt. Electricity i.e. MSEDCL. Source of Power-from own Turbine & State Grid DG set only in emergency backup of capacity 1010 KVA for proposed product. Quantity of fuel shall be 283 Liters /hr of HSD.

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CHAPTER 07 REHABILITATION AND RESETTLEMENT (R & R PLAN)

7.1 Policy to be adopted

This project does not require acquisition of Land and the Infrastructure so there is no any kind of activity of Rehabilitation and Resettlement to be carried out over here.

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CHAPTER 08 PROJECT SCHEDULE & COST ESTIMATES

8.1 Time schedule of the Project

John Distilleries Pvt.Ltd. 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)

1) Estimated project cost is 40 Cr. (Fourty core) for the proposed project.

2) Estimated Environmental Management Plan cost is 6.35 Cr.

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CHAPTER 09 ANALYSIS OF PROPOSAL

9.1 Financial and Social Benefits

John Distilleries Pvt. Ltd. has proposed to develop Alcohol manufacturing products which will be used for Machinery manufactured by local manufacturer in the market.

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

By doing so, John Distilleries Pvt. Ltd. can participate towards the development of nation by generating the foreign exchange, and also serve the social community.

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Annexure I

GPS Location and Google Imagery of Proposed Site.

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Annexure II

Toposheet.

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Annexure III

Project Location in Maharashtra:

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Annexure IV

Lay-Out Plan with Proposed expansion:

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