PRE-FEASIBILITY REPORT
Extension of validity of Environment Clearance letter no. J- 11011/453/2009-IA II (I) dated 24th Nov 2011 for Expansion of sugar capacity from 5,500 TCD to 11,000 TCD, Co-generation Capacity from 39 MW to 64 MW. Distillery Capacity from 35 KLPD to 100 KLPD, ENA Capacity from 20 KLPD to 75 KLPD and establishing 30 KLPD Ethanol and 2 Nos. of 1 MW D.G. sets.
AT BELLAD- BAGEWADI, HUKKERI (TAL), BELGAUM ( DIST) -591 305
BY VISHWARAJ SUGAR INDUSTRIES LIMITED. FORMERLY KNOWN AS VISHWANATH SUGAR AND STEEL INDUSTRIES LIMITED
Report Prepared By: DR. SUBBARAO’S ENVIRONMENT CENTER ‘ Arundhati’, Opp. Sahyognagar, MSEB Road, Vishrambag, Sangli-416415 Phone: 0233-2301857, (M) 9372109522, 9890992118 QCI-NABET Accredited EIA Consultant Organization Certificate No. NABET/EIA/1619/RA0057 NABL Quality Assurance Laboratory Accreditation Certificate No. TC-6121
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VISHWARAJ SUGAR INDUSTRIES LIMITED, BELLAD-BAGEWADI PRE FEASIBILITY REPORT
TABLE OF CONTENTS TABLE OF CONTENTS ...... i LIST OF TABLES ...... iv LIST OF FIGURES ...... v 1. EXECUTIVE SUMMARY...... 1 2. INTRODUCTION OF THE PROJECT / BACKGROUND INFORMATION ...... 4 2.1. Identification of Project and Project proponent ...... 4 2.1.1. Project Proponent ...... 4 2.1.2. Project Consultants ...... 5 2.2. Brief description of nature of the project ...... 6 2.2.1. Status of Previous Environmental Clearance of Sugar and Distillery Plants ...... 6 2.2.2. Consent to Operate of Existing Sugar and Distillery Plants ...... 7 2.3. Need for the project and its importance to the country and or region ...... 7 2.4. Demand-Supply gap ...... 7 2.5. Imports vs. Indigenous products ...... 7 2.6. Export possibility ...... 8 2.7. Domestic / Export markets ...... 8 2.8. Employment Generation (Direct and Indirect) due to the project ...... 8 3. PROJECT DESCRIPTION ...... 9 3.1. Type of project including interlinked and inter dependent projects, if any...... 9 3.2. Location with coordinates ...... 9 3.3. Details of alternate sites considered and the basis of selecting the proposed site (particularly the environmental considerations gone into should be highlighted) ...... 16 3.4. Size or magnitude of operation ...... 16 3.5. Project description with process details ...... 16 3.5.1. Process Details ...... 16 3.5.1.1. Sugar manufacturing process ...... 16 3.5.1.1.1. Crushing of sugar cane ...... 17 3.5.1.1.2. Juice clarification ...... 17 3.5.1.1.3. Crystallization ...... 17 3.5.1.1.4. Curing or centrifuging ...... 17 3.5.1.1.5. Drying, grading and bagging ...... 17 3.5.1.2. Co-generation Unit (25 + 5MW) ...... 18
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VISHWARAJ SUGAR INDUSTRIES LIMITED, BELLAD-BAGEWADI PRE FEASIBILITY REPORT 3.5.1.2.1. Technology Selection ...... 18 3.5.1.2.2. Instrumentation ...... 19 3.5.1.2.3. Expansion Plan of Co-generation Unit to 64 MW ...... 19 3.5.1.2.4. Boiler Specifications: ...... 20 3.5.1.3. Distillery manufacturing process ...... 22 3.5.1.3.1. Flow Sheet (Simplified) ...... 22 3.5.1.3.2. Process of alcohol production: ...... 24 3.5.1.3.3. Fermentation section: ...... 25 3.5.1.3.4. Distillation: ...... 26 Integrated distillation and evaporation section ...... 26 Analyzer column cum Degasifying Column: ...... 27 Aldehyde Column ...... 27 Rectifier Cum Exhaust Column ...... 27 3.5.1.4. Manufacture of Ethanol ...... 27 3.5.1.5. Process of manufacture of extra neutral alcohol ...... 30 3.6. Raw material required along with estimated quantity, likely source, marketing area of the final product, Mode of transport of raw material and finished product...... 31 3.7. Resource optimization / recycling and reuse envisaged in the project, should be briefly outlined. 32 3.8. Availability of water its source , Energy / Power requirement and source ...... 32 3.9. Quantity of waste to be generated (liquid and solid) and scheme for their Management/Disposal 32 4. SITE ANALYSIS ...... 33 4.1. Connectivity ...... 33 4.2. Land Form, Land use and Land ownership ...... 33 4.3. Topography ...... 33 4.4. Existing Infrastructure...... 33 4.5. Soil Classification ...... 33 4.6. Climatic data from stationary sources ...... 34 4.7. Social Infrastructure available ...... 34 5. PLANNING BRIEF ...... 34 5.1. Planning Concept (type of industries, facilities, transportation etc.) Town and country planning / Development authority Classification ...... 34 5.2. Population Projection ...... 35 5.3. Land use planning (breakup along with green belt etc) ...... 35 5.4. Assessment of Infrastructure Demand (Physical and Social) ...... 35 5.5. Amenities / Facilities ...... 35
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VISHWARAJ SUGAR INDUSTRIES LIMITED, BELLAD-BAGEWADI PRE FEASIBILITY REPORT 6. PROPOSED INFRASTRUCTURE ...... 35 6.1. Industrial Area (Processing Area) ...... 35 6.2. Residential Area (Non Processing Area) ...... 35 6.3. Green belt ...... 35 6.4. Social Infrastructure ...... 36 6.5. Connectivity (Traffic and Transportation Road/Rail/Metro/Water ways etc.) ...... 37 6.6. Drinking Water Management (Source and Supply of water) ...... 37 6.7. Sewerage System ...... 37 6.8. Industrial Waste Management ...... 37 6.9. Solid Waste Management ...... 37 6.10. Power requirement & Supply / Source ...... 37 7. REHABILITATION AND RESETTLEMENT (R&R) PLAN ...... 37 7.1. Policy to be adopted (Central/State) in respect of the project affected persons including home outstees, land outstees and landless laborers (a brief outline to be given) ...... 37 8. PROJECT SCHEDULE AND COST ESTIMATES ...... 37 8.1. Likely date of start of construction and likely date of completion (Time schedule for the project to be given) ...... 37 8.2. Estimated project cost along with analysis in terms of economic viability of the project ...... 37 9. ANALYSIS OF PROPOSAL (Final recommendations) ...... 38 9.1. Financial and social benefits with special emphasis on the benefit to the local people including tribal population, if any, in the area...... 38 ANNEXURE I ...... 39 Water Budget ...... 39 ANNEXURE II ...... 42 CONSENT TO OPERATE ...... 42 ANNEXURE III...... 54 PREVIOUS EC LETTER ...... 54
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VISHWARAJ SUGAR INDUSTRIES LIMITED, BELLAD-BAGEWADI PRE FEASIBILITY REPORT LIST OF TABLES Table 1 Consented quantities of Products of Existing Unit ...... 4 Table 2 List of Board of Directors ...... 5 Table 3 Change in the existing capacity after the Extension of Validity of Environmental Clearance ...... 6 Table 4Size of Operation (Existing and Proposed) ...... 16 Table 5 Specifications of Turbine ...... 19 Table 6 Specifications of Boiler...... 20 Table 7 Specifications of Superheater ...... 20 Table 8 Specifications of Economiser ...... 21 Table 9 Spcifications of Air Heater ...... 21 Table 10 Specifications of Chimney ...... 21 Table 11 Composition of Condensate ...... 28 Table 12 Mass Balance of Ethanol Production ...... 29 Table 13 Raw material requirement ...... 31 Table 14 Details of the Green belt development ...... 36 Table 15: Water Budget for Sugar Factory Unit ...... 39
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VISHWARAJ SUGAR INDUSTRIES LIMITED, BELLAD-BAGEWADI PRE FEASIBILITY REPORT LIST OF FIGURES Figure 1 Location Map ...... 10 Figure 2 Toposheet ...... 11 Figure 3 Land use Map ...... 12 Figure 4 Vishwaraj Sugar Industries Ltd, Google Earth Imagery...... 13 Figure 5 Plant Layout (Sugar Unit)...... 13 Figure 6 Plant Layout (Existing Distillery Unit)...... 14 Figure 7 Plant Layout ( Proposed Distillery Unit) ...... 15 Figure 8 Flow Sheet Diagram of Sugar Manufacturing Process ...... 18 Figure 9 Fermentation flow Sheet ...... 23 Figure 10 Azeotropic anhydrous flow sheet ...... 24
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VISHWARAJ SUGAR INDUSTRIES LIMITED, BELLAD-BAGEWADI PRE FEASIBILITY REPORT
1. EXECUTIVE SUMMARY 1. Vishwanath Sugar and Steel Industries Ltd., (VSSIL) (Formerly Known as Vishwanath Sugars Ltd.) is situated at Bellad-Bagewadi, Tal. Hukkeri, Dist. Belgaum, registered under the Companies Act, 1956 vide Registration no 08/17730 on 02nd May 1995. 2. VSSIL has its registered office at Bellad-Bagewadi, Taluka Hukkeri, Belgaum, District, Karnataka State. 3. This proposal is for the Extension of validity of Environment Clearance Vide F.No. J- 11011/453/2009-IA II (I) dated 24th Nov 2011 for Expansion of sugar capacity from 5,500 TCD to 11,000 TCD, Co-generation Capacity from 39 MW to 64 MW. Distillery Capacity from 35 KLPD to 100 KLPD, ENA Capacity from 20 KLPD to 75 KLPD and establishing 30 KLPD Ethanol and 2 Nos. of 1 MW D.G. sets. 4. Subsequent amendment was made in the EC granted for the installation of 150 TPH boiler instead of 100 TPH boiler in order to get additional 5 MW Power without increasing the Fuel Consumption, Vide F.No. J-11011/453/2009-IA II (I) dated 10th September 2013. 5. The Project Proponent could not expand its capacities as per the EC due to the Financial Constraints. Therefore now it is proposed to extent the validity of the Earlier Environmental Clearance Vide F.No. J-11011/453/2009-IA II (I) dated 24th Nov 2011 for another 5 years, so that the project proponent can expand its production capacities as approved in the Environmental Clearance. 6. The industry treats the sugar factory effluent on two stage aeration principles. The Co-generation effluent is neutralized and settled. The existing ETP facilities would be adequate for the proposed expansion. 7. The treated sugar & Co-generation effluent are used for irrigation. Wet Scrubber and ESP are installed to existing boilers and propose to install ESP for the proposed expansion of the Co- generation Unit. 8. There are no reserved forests, Historical places, Wild life Sanctuaries, Heritages etc within 10 Km radius of the factory site. 9. The industry has its own land of 53.14 hectares which is sufficient for the existing and the proposed expansion. No forest area or displacement of habitation or acquisition of private land is required. 10. The proposed expansion of sugar factory shall provide additional bagasse to meet the requirement of fuel of Co-generation plant during the sugarcane crushing season. Imported coal shall be used during the off season. The quantity of Coal used is 288 MT/day for the existing 39 MW Unit and for the proposed expansion of Co-generation capacity additional 288 MT/day shall be used during the off season. 11. The stack height and the ash disposal facilities are calculated based on bagasse and coal consumption whichever is higher for the proposed expansion of 25 + 5 MW. The power generated will be used by Sugar mill and other ancillary units and the surplus of power shall be exported to Karnataka Power Grid. 12. The Ghatprabha River is the main source of water in the area. Sufficient sugarcane is available and Commissioner of Sugar, Karnataka has given the permission for the proposed expansion of the Sugar Unit from 5,500 to 11,000 MT/day. Approximately 42 T/hr of bagasse with 50% moisture will be used as fuel for power generation during the Sugarcane crushing season for the proposed expansion. 13. Water requirement for this project is estimated as 720 KLD even after expansion. To minimize water consumption and wastewater generation recycling arrangement of condensates, cooling waters are
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adopted. The industry has permission to withdraw 1.241 million KLD of water per annum which is adequate even for the proposed expansion. 14. It has an existing Distillery of 35 KLD and adopted “Biomethanation” as primary treatment and “Composting” as secondary treatment. It is proposed to expand the distillery capacity from 35 KLPD to 100 KLPD. The spent wash treatment shall be based on anaerobic digestion followed by Evaporation and Composting for the total distillery capacity of 100 KLPD. 15. The effluent quantity shall be 1028 KLD and it would be reduced to 350 KLD by installing multiple effect evaporators. The concentrated bio-methanated effluent shall be composted as per the CPCB guidelines. 16. The Ethanol and ENA processes do not generate any effluent. The spent lees from ENA process shall be reused as dilution water in the process. 17. The existing Sugar & Co-generation Plants have 70 TPH and 80 TPH Boilers at 67 Kg/cm2 pressure. Venturi Scrubber and ESP are installed as APC equipment. There is a common stack of 73 meter height for these boilers. 18. For the proposed expansion of Sugar & Co-generation 150 TPH Boiler at 87 Kg/cm2 pressure shall be installed and ESP as APC equipment with stack height of 73 meters. There are two Boilers of 10 TPH and 12 TPH for the existing distillery and ENA plant and bag filter as APC equipment. It is proposed install additional boiler of 13 TPH for the proposed expansion of the Distillery. The stack height shall be 43 meters and bag filter shall be installed as APC equipment. There will be two DG sets of 1 MW each. The stack height shall be 7 meters above the roof level. 19. The Co-generation unit shall be operated for maximum 300 days in a year. Incase of Distillery, the number of operation shall be 270 days and Sugar Unit 200 – 220 days. Fly ash will be sold to brick manufacturers and also mixed in composting process. 20. The daily quantity of Sugar factory effluent will be around 510 KLD even after expansion. A full- fledged existing ETP is already provided to treat the liquid waste arising from the expansion. 21. The Cogeneration effluent is mainly the regeneration effluent from the DM Plant, Boiler blow down and the cooling tower / spray pond blow down. The BOD concentration is not more than 20 mg/lit. The effluent quantity shall be 280 KLD for the 69 MW Co-generation Unit. The treated effluent of sugar factory and cogeneration effluent amounting to 790 KLD shall be used on land for irrigation for which eight hectares of land is earmarked. 22. It is proposed to collect storm water from the office buildings, colony and the factory area and recharge in the existing bore wells situated in the factory premises. 23. There will not be any separate colony and the existing facilities shall be used. Domestic waste shall be treated based on septic tank followed by anaerobic filter. The treated effluent is being used for gardening / irrigation. 24. The industry has 53.14 hectares of land and the break up of the land utilization is Built up area - 6.59 hectares, Compost Yard – 5.05 hectares, Storage of fuel and finishing product – 6.5 hectares, Parking of vehicles – 6.38 hectares, Vacant Land – 8.08 hectares, Greenbelt – 17.54 hectares, ETP, internal roads – 3.0 hectares. 25. The daily quantity of fly ash generated after expansion will be 33 MT/day when bagasse is used as fuel and it would be 57.6 MT/day when coal is used as fuel. Fly ash would be used for composting process during sugarcane crushing and during the off season it would be sold to brick manufacturers. 26. Cost of the project is 30 Crore rupees, EMP cost is estimated as Rs. 3 Crore, recurring expenditures per annum is around Rs. 0.5 Crore and 1.5 % of the total project cost (Ref: Office Memorandum
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Dated 1st May 2018 F. No- 22-65/2017-IA.III) will be spent on Corporate Social Responsibilities (CSR) over a period of 5 years. 27. According to CPCB guidelines, 1500 trees should be available per hectare of land for Greenbelt development. Total 17.54 Hectares of land is reserved for greenbelt development; hence there should be minimum 26310 no. of trees. At present the industry has planted 12184 trees in the plant area. The details of the trees planted till date given in table no 14. The remaining 14126 trees shall be planted within 2 years. 28. The industry has taken the forest land on lease basis for green belt development, which is 5 km away from the factory site. It is proposes develop the green belt in the entire forest land of 40 hectares of area.
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VISHWARAJ SUGAR INDUSTRIES LIMITED, BELLAD-BAGEWADI PRE FEASIBILITY REPORT
2. INTRODUCTION OF THE PROJECT / BACKGROUND INFORMATION 2.1. Identification of Project and Project proponent Vishwanath Sugar Industries Ltd., (VSIL) (Formerly Known as Vishwanath Sugar and Steel Industries Ltd.) is situated at Bellad-Bagewadi, Tal. Hukkeri, Dist. Belgaum, registered under the Companies Act, 1956 vide Registration no 08/17730 on 02nd May 1995. VSIL has its registered office at Bellad- Bagewadi, Taluka Hukkeri, Belgaum, District, Karnataka State.
VSIL is an integrated sugar and other allied products manufacturing company operating from Belgaum District in the State of Karnataka which is designated as one of the “High Recovery zones” for sugar production by Government of India. VSIL operate a single location sugar unit having licensed crushing capacity of 11,000 TCD. In addition to sugar it is engaged in manufacture other allied products like
Rectified Spirits, Extra-Neutral Spirits, Indian Made Liquor, Vinegar, Compost, Carbon dioxide (CO2), etc. and are further engaged in the generation of Power for captive consumption as well as external sale. VSIL business can hence be broken up into five main segments namely Sugar, Co-Generation, Distillery, Indian Made Liquor (IML) and Vinegar.
In the year 2001, VSIL commenced operations of manufacture of Distillery products such as Ethanol, Rectified Spirit and Extra Neutral Spirit. In the year 2006, VSIL implemented backward integration and began commercial operations for Sugar manufacture from sugarcane, along with Co-Generation capabilities. During the year 2008, the unit began bottling of Indian Made Liquor. Currently the industry’s integrated unit processes sugarcanes to produce sugar and the by-products which are used to generate electricity for captive use and commercial sale, manufacture rectified spirit, ENA, IML, Vinegar, Press-mud and Compost. Over the years, VSIL have expanded the production / manufacturing capacities of all our products. The present licensed manufacturing capacity for our various products is given below
Table 1 Consented quantities of Products of Existing Unit
Sr. No. Products/ By-Products Quantity 1 Whiter crystal Sugar 8500 TCD 2 Co-generation 39 MW 3 Rectified Spirit or Ethanol 35 KLPD 4 IML Bottling 5000 Boxes/day 5 ENA 30 KLPD 6 Natural Alcohol vinegar (with 10 % acidic Content) 75 KLPD 7 Liquid Carbon-di-oxide 15 MTPD 2.1.1. Project Proponent Name of the Industry: Vishwaraj Sugar Industries Limited. (Formerly known as Vishwanath Sugar and Steel Industries Limited) Address: Bellad- Bagewadi -591 305 Hukkeri (Tal), Belgaum (Dist), 591305 Phone: (08333) 251251 Fax: (08333) 251322 This enterprise is a legal Private Limited entity. The project proponents are known for their track records of honest and transparent businesses. The company is well aware of energy crises and takes various steps for conservations of energy. This industry is committed to prevent pollution,
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VISHWARAJ SUGAR INDUSTRIES LIMITED, BELLAD-BAGEWADI PRE FEASIBILITY REPORT continually improve environmental performance, comply with environmental legislation and regulations, health care etc. reducing the spillages and fugitive pollution emissions, conserving energy and other resources with waste minimizations. List of Board of Directors is detailed below: Table 2 List of Board of Directors
Sr. Date of Name Designation Full Address No Appointment 341, Town/village: Bellad- 1 Umesh Vishwanath Katti Director 02/05/1995 Bagewadi Taluka: Hukkeri, Belgaum 591305, Karnataka, India No. 828, Vaccine Depot Road, Managing 2 Nikhil Umesh Katti 16/01/2009 Tilakwadi, Belgaum 590006, Director Karnataka, India Sheh. Bellad-Bagewadi Taluka: 3 Lava Ramesh Katti Director 30/06/2013 Hukkeri, Belgaum 591305, Karnataka, India Sheh. Bellad-Bagewadi Taluka: 4 Kush Ramesh Katti Director 30/06/2013 Hukkeri, Belgaum 591305, Karnataka, India 458, Bellad-Bagewadi Taluka: Whole Time 5 Mallikarjun Pujar 30/06/2007 Hukkeri, Belgaum 591305, Director Karnataka, India 116, Ramtirth Nagar, Belgaum- 6 Surendra Shnataveer Khot Director 20/03/2011 590015 At Post Bellad-Bagewadi Taluka: Pratibha Pramod 7 Director 30/09/2017 Hukkeri, Belgaum 591305, Munnolli Karnataka, India H No. 1460/42, Pragati Housing Basavaraj Veerappa Colony, Bellad-Bagewadi Taluka: 8 Director 30/09/2017 Hagaragi Hukkeri, Belgaum 591305, Karnataka, India Shivanand Basavanneppa Anugraha, Plot no. 278, 2nd Sector 9 Director 30/09/2017 tubachi Shivabasav Nagar, Belgaum 590010 7-2-1760/a/104, Akruti Avenue, St. Venkata Radhakrishna 10 Director 18/12/2017 No. 4, Czech Colony, Sanathnagar, Racharla Hyderabad 500018
2.1.2. Project Consultants To seek the Extension of validity of Environmental clearance, VSIL has appointed Dr. Subbarao‟s Environment Center (SEC), Sangli, Maharashtra (formerly known as Water and Wastewater research center). SEC is a QCI-NABET accredited consulting organization, for conducting EIA studies, encompassing baseline scenario with respect to different components of environment viz. air, noise, water, land, biological and socio-economic etc. SEC is serving for more than 45 years in the field of Environmental Services. The company was established by an entrepreneur Dr. B. Subbarao in the year 1972.
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VISHWARAJ SUGAR INDUSTRIES LIMITED, BELLAD-BAGEWADI PRE FEASIBILITY REPORT
2.2. Brief description of nature of the project VSIL is an agro-based company focused on the manufacturing of sugar and allied by-products. The proposed plant units will be established in the existing premises of VSIL. 53.14 hectares of land is available with the industry which is sufficient for the proposed expansion. Bagasse and Molasses to be generated will be utilized in co-generation and distillery respectively. VSIL has already expanded its sugarcane crushing capacity from 5500 TCD to 11000 TCD in the year 2015-16 as per the Environment Clearance vide F. No. J-11011/453/2009-1A 11(1) dated 24th November 2011. Subsequent amendment was made in the year 2013 for the installation of 150 TPH boiler instead of 100 TPH Boiler in order to get additional power of 5 MW without increase in the fuel consumption. Vide F. No. J-11011/453/2009-1A 11 (1) Dated 10th September 2013. VSIL could not expand its Distillery capacity from 35 KLPD to 100 KLPD, ENA 20 KLPD to 75 KLPD, Cogeneration Capacity from 39 MW to 64 MW, establishment of 30 KLPD Ethanol plant and DG Sets (2 x 1 MW) due to the financial issues for which Environmental Clearance was granted (vide F. No. J-11011/453/2009-1A 11(1) dated 24th November 2011). VSIL is now intend to expand its Distillery capacity from 35 KLPD to 100 KLPD and also Co-generation capacity from 39 MW to 64 MW in order to increase productivity and profitability in addition to abating pollution. Along with the expansion of Sugarcane crushing and Co-generation Power Plant, it is economically and environmentally sustainable to expand distillery capacity and to generate power plant so as to utilize molasses and bagasse which otherwise are harmful to Environment. Products and By-products of existing and proposed units are presented as follows.
Table 3 Change in the existing capacity after the Extension of Validity of Environmental Clearance
Proposed Sr No. Product Existing Capacity Total Capacity 1 Whiter crystal Sugar 8500 TCD 2500 TCD 11000 TCD 2 Co-generation 39 MW 25 + 5MW 69 MW 3 Rectified Spirit or Ethanol 35 KLPD 65 KLPD 100 KLPD 4 IML Bottling 5000 Boxes/day -- 5000 Boxes/day 5 ENA 20 KLPD 55 KLPD 75 KLPD Natural Alcohol vinegar (with 6 75 KLPD -- 75 KLPD 10 % acidic Content) 7 Liquid Carbon-di-oxide 15 MTPD 8 Ethanol -- 30 KLPD 30 KLPD
2.2.1. Status of Previous Environmental Clearance of Sugar and Distillery Plants VSIL has obtained an Environmental Clearance in the year 2011 for the expansion of Sugarcane crushing capacity from 5500 to 11000 TCD, Molasses based Distillery unit (35 KLPD to 100 KLPD), EN Plant (20 KLPD to 75 KLPD), and Co-generation power plant (39 MW to 64 MW), establishment of 30 KLPD Ethanol plant and D.G. Sets (2 x 1 MW) from Government of India, MoEF, (I.A. Division) Vide F. No. J- 11011/453/2009-1A 11 (1) Dated 20th November 2011. Subsequent amendment was made in the year 2013 for the installation of 150 TPH boiler instead of 100 TPH Boiler in order to get additional power of 5 MW without increase in the fuel consumption. Vide F. No. J-11011/453/2009-1A 11 (1) Dated 10th September 2013.
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2.2.2. Consent to Operate of Existing Sugar and Distillery Plants VSIL has valid Consent to Operate issued from Karnataka State Pollution Control Board; Combined Consent order no. PCB/157/HPI/2017-18/OB/1140 Dated 20th February 2018 valid till 30th June 2021.
2.3. Need for the project and its importance to the country and or region The sugar industry is one of the major agro-based manufacturer industries. India being the largest Sugarcane producer country after Brazil, it is inevitable and unavoidable for India to grow as the largest sugar and allied products manufacturing country. The major shareholder of this sector is the farmer, producer of raw material sugarcane and it is estimated that around 45 millions of people in India are sugarcane growers. Sugarcane Potential, agro-climatic conditions and the cost of conversion and overheads etc. are the major deciding factors for fixing the crushing capacity of a sugar plant. It has been established that wages and other overhead costs per ton of sugar get reduced substantially with higher plant sizes. As there is excess cane available in the command area, industry shall have to make arrangement for the timely crushing of sugarcane of not only its shareholders but also entire farmer‟s community in the command area. Incidentally, the economic viability would also improve not only by producing sugar more but also to generate power which can be exported to the state grid and additional money can be distributed to farmers as cane price. Besides the direct benefit, the expansion would help to crush sugarcane in time so that the high recovery due to timely crushing would further improve the economy of the farmers. Apart from this, the establishment of such institutions brings employment and other developmental opportunities for the entire region. In the case of VSIL, the proposed expansion in sugarcane crushing, distillery capacity and co-generation of power would greatly increase the productivity and profitability of the industry. By the means of newly proposed cogeneration and expanded distillery capacity, bagasse and molasses to be generated (due to additional crushing) will be utilized in co- generation and distillery expansion, respectively. Production of alcohol from molasses based distilleries is not only helpful in abating pollution by utilizing molasses but also helpful in partly fulfilling the need for petrol by blending ethanol in the petrol. The co-generation power plant produces power, which helps in reducing the load on state electricity grids and fulfilling the necessity of electricity for society. Thus, the proposed project would immensely benefit not only it shareholders but also to the people of the entire region around VSIL. To implement the above program, the management of VSIL has appointed consultants with the objective of expansion & capacity optimization of sugar plant, with emphasis on reduction in the cost of production through improvement in milling efficiency and reduction in process steam/energy consumption.
2.4. Demand-Supply gap Sugarcane availability in the command area of VSIL surpasses the existing crushing capacity due to the availability of an adequate amount of water by the courtesy of River Ghatprabha. Also, Sugar, Alcohol, and Power are having high demand and monetary value as well. Hence, the efforts to supplement to the demands of society are necessary in order to achieve profitability.
2.5. Imports vs. Indigenous products Major products to be manufactured in this sugar complex are Sugar, Alcohol, and Power. Sugar and Alcohol from this industry are qualitatively better and competitive against imported products. Hence, the benefit of foreign exchange saving could be achieved.
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2.6. Export possibility Sugar is mostly sold in the local market. Depending on the international market conditions and prices, sugar could be exported. Alcohol produced is mainly utilized in blending with petrol (additives).
2.7. Domestic / Export markets Domestic markets are found to be more suitable, by the observations made over the years. Convenience and profitability are always preferred by the management of VSIL.
2.8. Employment Generation (Direct and Indirect) due to the project After the proposed expansion project, direct employment of about 50 people will be generated and indirect employment of around 100 people is possible. Also, around 20 % increase in indirect employment is expected due to the additional transportation required after the proposed expansion.
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VISHWARAJ SUGAR INDUSTRIES LIMITED, BELLAD-BAGEWADI PRE FEASIBILITY REPORT
3. PROJECT DESCRIPTION 3.1. Type of project including interlinked and inter dependent projects, if any. It is an Extension of Validity of Environment Clearance vide F.No. J-11011/453/2009-IA II (I) dated 24th Nov 2011 for the expansion in existing sugarcane crushing capacity from 5500 TCD to 11000 TCD, Molasses based Distillery capacity from 35 KLPD to 100 KLPD, ENS Plant (20 KLPD to 75 KLPD), Co- generation capacity from 39 MW to 64 MW, establishment of Ethanol Plant (30 KLPD) and D.G.Sets (2 X 1 MW). Subsequent amendment was made in the year 2013 for the installation of 150 TPH boiler instead of 100 TPH Boiler in order to get additional power of 5 MW without increase in the fuel consumption F.No. J-11011/453/2009-IA II (I) dated 10th September 2013. Expansion of existing sugarcane crushing would contribute to additional molasses and bagasse generation. Hence, to utilize these by-products, it is advisable and essential to expand Distillery and Cogeneration capacities. VSIL is expanding distillery and Co-generation power plant capacities to scope up with the increased production of Bagasse and Molasses.
3.2. Location with coordinates There are no sensitive, historical, forest reserves and wildlife sanctuaries etc within 10 Km radius of the factory site The location is at Bellad-Bagewadi, Tal: Hukkeri, Dist: Belagaum, Karnataka State, at longitude 740 42’ 34.16” E and latitude 160 16’ 38.01” N. The MSL is 605.43 meters. The site is surrounded by the sugar cane growing area so that there is less transportation of raw material and lower loss of recoverable sugar.
The Project Site is conveniently located for development of the Project. 66 km away from Belguam, which is a District place Other important towns nearby are Bellad-Bagewadi, at a distance of 2 km in NE Direction Hukkeri, at a distance of 13 km in SWW Direction Ghatprabha is nearest Railway station 9.2 km away from the factory site Belagavi is nearest airport 49 kms away from the factory site in SSW Direction. Environmental Setting- Location – 160 16’ 38.01” N and 740 42’ 34.16” E Nearest Village –Bellad-Bagewadi- 3 km in NNE Direction Nearest town – Bellad-Bagewadi- 3 km in NNE Direction Nearest City – Hukkeri- 13 km in SWW Direction Nearest National Highway NH4 – 23 km in SWW Direction Nearest Railway Station – Ghatprabha 6.6 km in SE Direction Nearest Airport – Belagavi – 49 Km in SSW direction Nearest River – Ghatprabha River – 3 Km in SE Direction from plot boundary Seismicity – Seismic Zone III
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Figure 1 Location Map
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Figure 2 Toposheet
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Figure 3 Land use Map
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Figure 4 Vishwaraj Sugar Industries Ltd, Google Earth Imagery
Figure 5 Plant Layout (Sugar Unit)
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Figure 6 Plant Layout (Existing Distillery Unit)
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Figure 7 Plant Layout ( Proposed Distillery Unit)
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The available land is 132.85 acres (53.14 hectare) out of which 8.0 hectares for expansion including process, ETP and for other purposes like storage of Bagasse, Coal etc. and 17.54 hectares of land for development of Green Belt. This Land is flat whereby Cutting – filling is being balanced.
3.3. Details of alternate sites considered and the basis of selecting the proposed site (particularly the environmental considerations gone into should be highlighted) It is an existing industry which was established in the year 2001-02 considering the following features:
The site is well connected by Road Proximity to Raw Material (Sugar Cane) Availability of sufficient land Availability of power evacuation facilities Availability of water for industrial use
Modern infrastructure support and amenities at par with industry including: Efficient transport facilities. Environment-friendly zone as the habitation is remote and surrounded by Agricultural activities. Uninterrupted power supply from Own Co-generation Power Plant 3.4. Size or magnitude of operation Table 4Size of Operation (Existing and Proposed)
Existing Proposed Sr No Description Total Quanity Addition 1 Sugarcane Crushing Capacity (TCD) 8500 2500 11000 2 Cogeneration (MW) 39 25+5 69 3 Rectified Spirit (KLPD) 35 65 100 4 IML Bottling (Boxes/day) 5000 5000 5 ENA (KLPD) 20 55 75 6 Ethanol (KLPD) -- 30 30 7 DG Set (MW) -- 2 2
3.5. Project description with process details VSIL intends to expand its sugarcane crushing capacity from 5500 TCD to 11000 TCD, Distillery capacity from 35 KLPD to 100 KLPD, ENA Plant capacity from 20 KLPD to 75 KLPD and Co- generation power plant capacity from 39 MW to 69 MW, establishment of ethanol plant of 30 KLPD and 2 X1 MW D.G. Sets.
3.5.1. Process Details 3.5.1.1. Sugar manufacturing process Sugar cane is the raw material for manufacture of sugar. Juice is extracted from the sugar cane, which is then processed to recover sugar. Bagasse, which is the left out fiber material after extraction of juice from
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sugar cane, is used as fuel in boiler to produce steam. Steam is used for evaporation of water in the juice and for generation of electric power. The flow diagram of sugar manufacturing process is given in Figure – 8. A brief description of the process is given below.
3.5.1.1.1. Crushing of sugar cane Sugar cane is harvested and dressed in the fields and then supplied to factories through lorries, tractor trailers or bullock carts. Crushing takes place mainly in two stages; first the preparation and then milling. Preparation is done in leveler, cutter and Fibrizer. The prepared cane is then crushed by passing through 4 sets of mills. Hot water is added in the course of crushing as imbibition water for better extraction of juice from sugar cane. After crushing, the bagasse is sent to boiler as fuel and juice is sent for purification & recovery of sugar.
3.5.1.1.2. Juice clarification The weighed quantity of juice is primarily heated to 70 - 75oC in juice heaters and then treated with Sulphur and Lime. Then the treated juice is again heated to 100 - 115oC in another set of juice heaters. The hot juice is sent to clarifier. Clarified juice is decanted out and sent for evaporation in a set of multiple effect evaporator bodies. The juice of 15o Brix is concentrated in the evaporators to syrup of 60o Brix.
3.5.1.1.3. Crystallization The syrup is sent to pan floor for further concentration in vacuum pans. The syrup collected in supply tanks is taken to pans for boiling where the syrup concentrates and attains super saturation stage. In such a condition sugar grains are formed in the syrup. The syrup mass with sugar particles is called massecuite. The massecuite is dropped in crystallizers and cooled to complete the crystallization.
3.5.1.1.4. Curing or centrifuging Massecuite is taken into the high speed centrifugal machine. Sugar crystals are separated from mother liquor and sent to driers. Non crystallisable matter from the syrup, called molasses, is drained out from the centrifuge. The molasses is weighed and sent to storage tank.
3.5.1.1.5. Drying, grading and bagging Sugar is dried in the vibrating hopper and graded by passing through standard sieves. The graded sugar is bagged, weighed for 100 Kg net, stitched, numbered and stacked in sugar godown.
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Figure 8 Flow Sheet Diagram of Sugar Manufacturing Process
3.5.1.2. Co-generation Unit (25 + 5MW) 3.5.1.2.1. Technology Selection i. Working pressure of Boilers is 87 Kg/Cm2 (g) with steam temperature 505 – 510 0C. Such Boilers are available and are easy to manage. At this pressure, the targeted steam consumption and export of power is effectively achieved. ii. Turbo generating set has been selected to work as Back Pressure cum bleeding mode. The system is so designed to balance the steam demand. At ultimate capacity a SEC TG set shall be installed. iii. At injection and cooling tower single entry condensers & Cooling tower have been suggested which consumes less water and hence less power and to be more energy conservative. Power consumption at this station should be around 1.5 KW/T cane by adopting automation of nozzle governing the condenser.
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3.5.1.2.2. Instrumentation A DCS SYSTEM INTEGRATING THE BOILER, TURBINE AND SUGAR MILL SHALL BE INSTALLED.
i. Steam flow-meter (integrating, indicating & recording ) ii. Feed water flow-meter (integrating, indicating & recording iii. Drum water level (indicating & recording ) iv. Superheated steam pressure (indicating & recording ) v. Multipoint temperature scanner with thermocouple. All points indicating & recording. (all for steam, feed water, flue gas, air and furnace temperatures in and out.) vi. Many draft gauges. (all for fans, flue gas, air and furnace temperatures in and out) vii. Oxygen analyzer and data logger viii. Pressure gauges 250 to 150 mm dia. & isolation valves ( steam, economizer, feed water pumps etc ix. Micro-processor based 24 channel data logger to many inputs like current, mv, T/C and recording with 80 column dot matrix printer. (Flows, temperature, levels, pressure, oxygen – all for steam, superheated steam, economizer, drum, de-aerator, feed water, flue gas, air and furnace) x. Micro-processor based hooters for trips, low levels, high levels, high temperatures xi. For Co-generation Unit following infrastructure is needed- xii. Land: No new land is required. xiii. Total built-up area : 6.0 hectares xiv. Plant and machinery: Boiler of 100 TPH, Gen-sets, Transformers, Ducts, Electrostatic Precipitator, Stack, Fans etc. xv. Water requirement : 2000 KLD on normal days xvi. Facilities: Water storage Tank, Fire protection gadget, etc. 3.5.1.2.3. Expansion Plan of Co-generation Unit to 64 MW It is being established through steam turbines of single extraction cum condensing route (SEC) by installing 87 bar steam pressure Boiler at 510oC steam temperature and using steam turbines for T.G. Sets. It is proposed to install following machinery and equipment in the Co-generation Unit. Table 5 Specifications of Turbine
Horizontal, impulse, multi-stage Multi-valve, axial flow, Type of Steam Turbine condensing, Extraction &, geared. (DOWN EXHAUST TYPE) Output Rated output at generator terminal - 25 MW Operating Conditions:
Speed (turbine/generator) 7800/1500 rpm Inlet steam pressure 87 kg/cm². Inlet steam temperature 510 deg C Exhaust steam pressure 00.10 kg/cm². A
st Min.9 Kg/ cm². A (at 80% inlet flow) 1 Extraction pressure Un-Controlled Extraction at turbine nozzle
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2nd Extraction pressure 2.5 kg/cm2 A Un-Controlled Extraction at turbine nozzle Max. Inlet flow 100,000 Kg/hr
Max. I st Extraction flow 0 & 3000 to 9790 Kg/hr Max. II nd Extraction flow 0&7940 to 71320 Kg/hr Exhaust steam flow 97480 Kg/hr at 00.10 kg/cm². A M.C.R. (Max. Continuous Rating) 100 MT/Hr. Peak Generation 110 % of MCR for half an hour Pressure at outlet of MSSV 86 ata Steam Temperature at outlet of MSSV 515 + 5 Deg.C. at MCR
Steam Temperature Control range 60-100 % (bagasse)75-100 % (coal)
Feed water temp at economizer inlet 110 Deg.C Main fuel Bagasse with 50% moisture
Design Ambient Temperature for 28 to 40 Deg C DesignPerformance Relative Humidity Test for 60 % Dust emissionperformance at the outlet test of ESP Less than 150 mg/NM³
Type of Construction Bi drum, top supported, balanced draft, natural circulation,
Code of design & construction of as per Indian Boilermembrane Regulations(IBR) pressure 3.5.1.2.4. Boiler Specifications:
STEAM AND POWER PLANT Table 6 Specifications of Boiler
Boiler 70 TPH 80 TPH Make IJT IJT Type Water tube, Bi-drum Water tube, Bi-drum Working pressure 67 kg/cm2 67 kg/cm2 Designed pressure 80 Kg/cm2 83.5 Kg/cm2 Capacity 70 TPH 80 TPH Temperature 485 ± 5ºC 515 ± 5ºC Heating surface 3295.24 M2 5200 M2 Grate H.S. 150 mg/NM3 150 mg/NM3
SUPER HEATERS:- Table 7 Specifications of Superheater
Type Vertical Vertical Primary super heater, size 38 x4 mm thick 45.5 x 4.5 mm thick Secondary super heater, size 38 x4 mm thick 45.5 x 4.5 mm thick
ECONOMISER:-
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Table 8 Specifications of Economiser
Type Vertical Horizontal Size 38 x 4 mm thick 38 x 4 mm thick No of Blocks 1 No. 2 Nos. No of coils 36 +34 36 +45
AIR HEATERS:- Table 9 Spcifications of Air Heater
Type Plane & stay tubes Plane & stay tubes Size 63.5 x 3.25 mm thick 63.5 x 3.25 mm thick No. of Blocks 4 4 No of tubes 6552 Nos. 2184 +408 Nos.
BOILER CHIMNEY:- Table 10 Specifications of Chimney
1 Nos. Common for both boilers Made RCC height 73 meters Diameter 3.6 meters
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3.5.1.3. Distillery manufacturing process 3.5.1.3.1. Flow Sheet (Simplified) This is a simple three step process namely molasses preparation, fermentation and distillation. The standard flow sheet as will be adopted can be given as Molasses Arrives
Molasses Weighed & Diluted
Yeast Propagated with Molasses in Sterilized Separate Vessel
Fermentation
Clarified Wash Tank
Analyser Column
Pre-Rectifier Column if required
Rectifier Column RECTIFIED SPIRIT
Exhaust Column
Re-boiler
Fusel Oil Separated and Alcohol Returned
ENA
Azeotropic Dehydration Column
Absolute Alcohol
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Figure 9 Fermentation flow Sheet
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Figure 10 Azeotropic anhydrous flow sheet
3.5.1.3.2. Process of alcohol production: Molasses is the chief raw material used in India for production of Alcohol. Molasses contain about 50% total sugars, of which, 30 to 33% are cane sugar and the rest are reducing sugar. During the fermentation, yeast strains of the species saccharomyces cerevisiae, a living microorganism belonging to class fungi converts sugar present in the molasses, such as sucrose or glucose to alcohol. Chemically this transformation for sucrose to alcohol can be approximated by the equation.
I) C12H22O11 + H2O = 2C6H12O6 Cane Sugar Glucose
II) C6H12O6 = 2C2H5OH + 2CO2 180 = 2x46 + 2x44
Glucose Ethyl Alcohol Carbon dioxide
The 180 gm of sugars on reaction gives 92 gm of alcohol. Therefore, 1 tonne of sugar gives 511 kgs of alcohol. The sp. gravity of alcohol is 0.7934, therefore, 511 kg of alcohol is equivalent to 511/0.7934 = 644 litres of Alcohol. During fermentation other by-products like glycerin, succinine acid etc. are also formed from sugars. Therefore, actually 94.5% total fermentable sugars are available for alcohol, under ideal
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condition theoretically. Normally only 80 to 82% efficiencies are realized on plant. One tonne of molasses containing 45% fermentable sugars given alcoholic yield 255 - 265 litres per tonne of molasses.
For bringing out above biochemical reaction, we require proper and careful handling of yeast, optimum parameters like pH and temperature control and substrate concentration, which results into effective conversion of sugars to alcohol. For manufacture of yeast, separate equipment known, as pure yeast culture apparatus is required. Initially, yeast is developed in the laboratory from the single cell yeast culture. In the laboratory, yeast is propagated in a test tube 10ml. Then it is transferred to a bigger flask of 500 ml flask, and transferred to 5-litre flask containing the sterilized molasses solution. It is necessary to adjust the pH of the molasses solution in the range. Each stage of development of yeast propagation, namely 100 litres, 500 litres and 5000 litres. All these equipment’s are designed so as to facilitate boiling molasses solution in order to sterilize it and also cooing to bring it to the proper temperature of 33oC and letting in culture and taking out culture. Boiling, cooling introducing culture, etc is done in aseptic manner, i.e. keeping the fermentation medium free from any kind of infection. Further, stages of yeast propagation are done in open tanks i.e. pre-fermenter requires about 8 hours in order to build up necessary concentration of yeast in them. Finally, pre-fermenter is emptied in an empty fermenter, which is previously cleaned and kept ready. Dilute molasses solution is allowed to flow in this fermenter so as to fill it to its working capacity, say about one lakh litre.
The average efficiency of conversion of sugars in molasses to alcohol is 80 to 85% of theoretical value. All the sugars are not converted to alcohol during the process of fermentation because chemicals like glycerin; succinine acid, etc. are also produced by yeast during their metabolic process. Therefore, it is not possible to have 100% efficiency of conversion of sugars to alcohol. The average yield of alcohol from molasses is about 250 litres from 1 MT of molasses.
Recently, attractive developments have taken place in the field of fermentation and distillation whereby one can get high yield of 270 to 285 litres per tonne of molasses.
3.5.1.3.3. Fermentation section: HIFERM-GR fermentation technology uses Granulating Yeast, which settles under gravity. Section-wise description is as below: Molasses free from suspended particles is transferred to molasses receiving taken and is weighed. Weighed molasses is distributed to cell mass propagation, fermentation and yeast activation section. GR yeast is grown in laboratory during pant start up. Yeast propagation section comprises of molasses diluter and hygienically engineered yeast vessels equipped with heating, cooling and air sparging facility. Dilute molasses media is prepared in yeast vessel by re-circulation of media through molasses diluter. Laboratory propagated cell mass is scaled up in series of yeast vessels. Air is sparged in pasteurized and cooled dilute molasses medium for optimum growth of GR yeast. The Temperature is maintained at 32oC by re-circulating cooling water through jacket of yeast vessels. Cell mass from Yeast vessel is transferred to yeast activation vessel to built up cell mass required for fermentation (during start up only) by cell mass transfer pump.
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At steady stage, activated cellmass from yeast activation vessel is transferred continuously to fermenter-I. Molasses, process water and vinasse recycle stream from distillation is added to fermenter. Fermented wash from Fermenter-I overflows continuously to fermenter-II & then to yeast settling tank. As ethanol fermentation is exothermic process, optimum temperature required for yeast activity is maintained by forced re-circulation through fermenter wash coolers. Efficient mixers are provided in both fermenters. Fermented wash from Fermenter-II is sent to yeast setting tank for separation of yeast under gravity. Vinasse stream from distillation is recycled to fermenter depending on solids concentration in fermented wash and molasses composition. GR yeast having granulation property, settles in yeast settling tank under gravity, while fermented wash overflows to wash holding tank. Settled yeast is transferred at rated flow to yeast activation vessel with screw pump. In yeast activation vessel, molasses, process water, nutrients and additive are added for activation of recycled cell mass. Filtered air is sparged as required for re-activation of cell membranes and other cell components. Mixer is provided for better mass transfer in yeast activation vessel. Activated cell mass is transferred to fermenter-I to maintain desired cell mass concentration in fermenter. Carbon dioxide generated in fermentation is entrained with alcohol vapours. Alcohol from Carbon dioxide is scrubbed with water in gas scrubber. The scrubber water is transferred to wash charger. Fermented wash from wash charger is fed to Analyzer column. 3.5.1.3.4. Distillation: The next stage in the manufacture of alcohol is to separate alcohol from fermented wash and to concentrate it to 95% alcohol called as rectified spirit. For this purpose, method of distillation is employed. The distillation columns consists number of SIEVE plates where wash is boiled and alcoholic vapours are separated and concentrated on each plate stage by stage.
Integrated distillation and evaporation section Technology offered (multi-Pressure)
This technology is based on heat recovery principle.
The system comprises of 3 columns operating at different pressures and is designed to produce Rectified Spirit.
The columns in order of flow are as follows:
1. Analyzer cum Degasifying Column (operating under vacuum) 2. Aldehyde Column (operating under Vacuum) 3. Rectifier cum Exhaust Column (Operative under Pressure) Fermented wash from the clarified wash tank is pumped to the fermented wash pre-heater and preheated to about 68-70oC by circulating hot spent wash on other side. Incoming spent wash temperature is 80 -
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82oC and after exchanging heat with fermented wash outlet temp of spent wash remains at 35-40oC. This hot fermented wash is then fed at the top of Degasifying column. Analyzer column cum Degasifying Column: Analyzer column strips the fermented wash before discharging the rest of the material as spent wash. Metered flow of fermented wash is feed to the top of the analyzer column. Vapours of Rectifier column provide energy to Analyzer column through an evaporator. Rectifier top vapours are condensed on the shell side of the evaporator and spent wash is getting re-circulated on tube side. Vapours generated from the re-boiler are used in the analyzer column now consist approximately 50% alcohol and 50% water with impurities such as higher alcohols, aldehydes, acids, sulphur dioxide, etc. Spent wash from the analyzer column bottom is sent for treatment to the Effluent Treatment Plant. The level in the column bottom is controlled to ensure proper distillation and correct concentration of the spent wash. The vapour draw from top of the Analyzer is condensed in forth stage of evaporator system and pumped to Rectifier column for concentration. Analyzer column is operating under vacuum. Using water ring vacuum pump creates vacuum and the vacuum in the column is maintained by manual valve, which bleeds extra air in the system. Aldehyde Column Aldehyde column is principally used for removal of low boiling impurities. Vapours from degasifying column are fed to Aldehyde column. The vapours coming out of the top of the Aldehyde column are fed to the condenser-I where they are partially condensed by passing cooling water on the tube side. Balance alcohol vapours are condensed in the condenser-II. Water is used for the Condensation. From aldehyde column top Technical Alcohol cut of 2% of total plant capacity is taken out. Aldehyde column works under vacuum. Rectifier Cum Exhaust Column Analyzer column top vapours condensed in forth stage of evaporator and fed to Rectified column for further concentration. Rectifier column designed in sieve trays construction and operates under pressure for obtaining desired strength of alcohol. Condensing steam provides heat to Rectifier column. Fusel Oil draws are taken from Rectifier column and are sent to fusel oil decanter. The fusel oil stream is diluted with water for separation of fusel oils. The aqueous layer send back to Rectifier column and fusel oil are sent to storage. Technical Alcohol cut of 3% of total plant capacity is taken out from top of Rectifier Column. Rectified Spirit of 95% v/v concentration is drawn from one of the upper trays of Rectifier Column and sent to storage after cooling. 3.5.1.4. Manufacture of Ethanol Absolute alcohol is an important product used for blending with petrol. As per IS Specification it is 100% water free alcohol. Rectified spirit is 94.68% (v/v) ethyl alcohol, and rest is water. It is not possible to remove water from rectified spirit by straight distillation as ethyl alcohol forms a constant boiling mixture with water at this concentration and is known as azeotrope. Therefore, special process for removal of water is required to manufacture Absolute Alcohol.
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In order to extract water it is necessary to use some dehydrant or entrainer, which is capable of separating water. Simple dehydrant is un slacked lime. Industrial alcohol is taken in a Reactor and quick lime is added and the mixture is kept over night for complete reaction. It is then distilled in fractionating column to separate Absolute Alcohol. Water is retained by quick lime. This process is used for small-scale production of absolute alcohol by batch process. The various processes used for dehydration of alcohol are as follows. I) Azeotropic Distillation. II) Molecular Sieves. III) Pervaporation / Vapour permeation system. The salient features of each of the processes are given herewith:-
I) Dehydration with entrainer process (Azeotropic distillation):- To manufacture Absolute Alcohol on large scale, Cyclohexane is used as entrainer. When 94.68 % (v/v) alcohol is mixed with Cyclohexane and distilled, ternary azeotrope is formed. e.g. if a mixture of ethanol, water and cyclohexane as given below is distilled and condensed then the condensate forms two layers with following composition. Table 11 Composition of Condensate
Azeotrope Composition (%) Decanter Upper Layer (%) Lower Layer (%) Alcohol 18.50 14.50 53 Cyclohexane 74.10 84.50 11 Water 7.40 1.00 36
The system consists of two to three columns. First is a dehydration column followed by recovery column. The Rectified Spirit is fed into the dehydration column Cyclohexane is introduced in this column. Vapour of ethanol, water & cyclohexane close to its azeotropic concentration is collected from the top where absolute alcohol is collected from the bottom of the column. Ternary mixture of ethanol, water, and cyclohexane is condensed and sent for decantation where it forms two layers. Top one is cyclohexane rich layer whereas bottom one is water rich layer. Top layer is refluxed back and bottom layer is sent to recovery column. Water is collected from the bottom of the recovery column whereas ternary mixture of cyclohexane, water and ethanol comes out of the top, which is condensed and partially sent to dehydration column.
Any cyclohexane lost in the system is taken care by adding make-up cyclohexane in the system.
One thousand litres of industrial alcohol of 94% v/v contains 940 litres of Absolute Alcohol and 60 litres of water. For a capacity of One KLPD absolute alcohol plant make-up cyclohexane required shall be three kg/day. The cyclohexane is continuously recovered in the process and recycled as entrainer. The process is rather simple and well established.
In another method, Glycerin is used as dehydrant. Glycerin is fed counter current wise to the rising alcohol vapours in a column. Glycerin absorbs all the water and leaves from the bottom of the column, which consists of Glycerin, water and some amount of alcohol. Distillate at the top is absolute alcohol. Glycerin water mixture is sent first to alcohol recovery column and then to vacuum evaporator for
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recovery of Glycerin and removal of water. Glycerin is recycled. This process is also effective giving good quality of absolute alcohol.
The steam requirement in the above two processes is around 1.8 to 2.0 kg. per litre of Absolute Alcohol produced. The chemistry behind this with controlling equations can be presented as
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
Thus,
Table 12 Mass Balance of Ethanol Production
Sr. No Input Output Alcohol 1. 1 kg Reducing Sugar 0.511 kg by Equation 2. 463.68 kg Reducing Sugar 298.23 Lit. by Equation 3. 463.68 kg Reducing Sugar 259.46 Lit. Actually (87% )
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3.5.1.5. Process of manufacture of extra neutral alcohol Conventionally, Extra Neutral Alcohol is manufactured from Rectified Spirit. The impurities in Rectified Spirit are reduced to considerable extent by properly diluting and redistilling the spirit. The impurities like aldehydes, acids, esters, higher alcohols are minimized by controlled condition and tapping impurities at appropriate points during distillation. The main stages in the manufacture of Extra Neutral Alcohol are as under. i. Dilution of Rectified Spirit with filtered soft water in the ratio 1:3 to 1:4. ii. The diluted spirit is treated with potassium permanganate. iii. Separation of low boiling impurities in purifying column. iv. Separation of esters and other volatile impurities in rectifying column and concentration of alcohol. v. Removal of excess water in exhaust column. vi. Concentration of fusel oil & their removal in the fusel oil concentration column. vii. Concentration of low boiling impurities & their removal in the heads concentration column. The material of construction used for entire distillation column and condensers is deoxidized red copper. Copper has special properties to react with some impurities and prevent their distillation with top product.
The distillation columns requiring steam for heating are provided with re-boilers so that direct mixing of steam is avoided. In some cases direct steam is also employed by sparging the steam in the bottom section. It depends upon quality of steam as regards its odour. For dilution of alcohol soft water is used in order to take special care regarding the quality of final product. Small quantity of potassium permanganate and sodium hydroxide are added to the mixture. The whole mixture is properly stirred and left to stand for 3 to 4 hours. The diluted and treated Rectified Spirit is pumped to overhead tank from where it is fed through a rotameter to the purifying column.
The distillation set up can work with indirect steam heating employing a re-boiler system for a three- column system or five-column system. In the system employing re-boiler and three column system, the hydrated rectified spirit is fed to the purification column where most of the low boiling components are removed as the top product. The bottom of the purification column is heated indirectly by steam through a thermosyphon re-boiler. From the bottom of the exhaust column spent lees is removed which preheat alcohol water mixture in a plate type heat exchanger before being discharged. The vapours from the exhaust column rise to the top of the rectification column, which are condensed and refluxed. Extra Neutral Alcohol is drawn near the top of the rectification column (3 to 4 trays below top). The ENA is cooled in a cooler and taken to storage. Fusel oil is drawn near the bottom of the rectification column, decanted, cooled and sent to storage.
In another modification of the above system an additional refining column and heated indirectly through a thermosyphon reboiler. Extra Neutral Alcohol is removed from two to three plates above refining column. In this system the quality of ENA obtained is of high grade. In the five-column system apart from purification, rectifying and exhaust columns two additional columns are employed. The fusel oil concentration column is heated directly with steam and fusel oil is tapped near the middle of the column. Fusel oil is separated and the alcohol containing water mixture is feed back to the column. The low boiling impurities from the purifying and rectification column are collected and after proper dilution with water are fed to the heads concentration column for final
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separation of Impure Spirit. The advantage of five columns is the reduction in percentage cut of Impure Spirit to 5 percent as compared to 25 percent cut in three column system. The quality of spirit produced in five-column system will be also superior to spirit produced in three-column system as it achieves better separation of impurities. However, the requirement of steam in five columns system is higher than the three-column system.
The design of the re-distillation plant is made in such a way that the Extra Neutral Alcohol Quality and the production do not get disturbed due to varying quality of rectified spirit. The plant may be preferably in copper. As the plant deals with rectified spirit, there is no risk of corrosion and the quality of spirit produced will be superior.
In the proposed project, EQENA will be produced directly from wash. The concentrated vapours from the rectification/ exhaust column will be fed directly to the EQENA section of multi-pressure distillation columns. The EQENA-distillation columns will work on multi-pressure principle so that maximum heat economy can be achieved with improved quality of EQENA.
Table 13 Raw material requirement
Sr. Raw Material 35 KLPD 65 KLPD Total No. (Semi-continuous (Semi continuous 100 KLPD process) process ) 1. Molasses MT/day 130 240 370 2. Alcohol yield (liters/MT) 270 270 -- 3. Water requirement (KLD) 380 620 1000 4. Steam Consumption (Process) (MT/day) 85 130 215 Multiple Effect Evaporation Plant (MT/day) -- 90 5. Power Consumption for process (Kwh) 8983 15,042 24,025 Multiple Effect Evaporation Plant -- 6153
For Multiple Effect Evaporator Plant, to reduce spent wash quantity the steam and power consumption are high. 3.6. Raw material required along with estimated quantity, likely source, marketing area of the final product, Mode of transport of raw material and finished product. Raw material, sugarcane is purchased from farmers. Sugarcane is available in the command area around VSIL in plenty of amount as this region is having water availability due to River Ghatprabha. Approximately 1980000 Tons of sugarcane shall be required after the proposed expansion, which is available in the command area of VSIL. Also, lime and sulphur are purchased from the open market and transported by road.
Final products sugar, alcohol, and power etc. are having their market available locally. Finished products are transported in closed containers, whereas sugarcane is brought to the industry from farms by the means of trucks, tractors and bullock carts etc. In the case of Distillery, molasses formed in the sugarcane crushing will be utilized as a raw material. Bagasse shall be utilized in Cogeneration power plant.
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Transport of both bagasse and molasses would be by internal means. Power is transferred to state/central electricity grids, Distillery products shall be transported using closed containers. The estimated quantity of molasses to be utilized after the proposed expansion is around 13860 MT/Month. Bagasse quantity to be utilized in Co-generation after expansion of 39 MW to 69 MW Co-generation power plant would be around 94380 MT/Month.
3.7. Resource optimization / recycling and reuse envisaged in the project, should be briefly outlined. It is proposed to expand existing 39 MW co-generation power plant to 69 MW capacity with high- pressure boilers in order to save raw material bagasse. The industry will recycle all excess condensates which shall be further improved to recycle excess condensate and use it as a boiler feed and process water. It is also proposed to adopt high-pressure water jet cleaning for evaporator bodies, process equipment so that the water requirement can be minimized.
3.8. Availability of water its source , Energy / Power requirement and source Ghatprabha River is the main source of raw water. There shall not be any water requirement after the proposed expansion of Sugar and Cogeneration Unit as entire sugar condensates are recycled into the process. Net water requirement for after the proposed expansion of the Distillery shall be 720 KLD (i.e. 660 KLD for Distillery processes and 60 KLD for Domestic use). The detailed water budget of the Sugar unit, Cogeneration Power Plant and Distillery unit is given as an Annexure-I in this report. Power requirements shall be fulfilled by the means of existing Co-generation power plant. At present 39 MW cogeneration power plant and 1000 KVA, DG set is utilized to fulfill power requirements.
3.9. Quantity of waste to be generated (liquid and solid) and scheme for their Management/Disposal Sr. No. Waste to be generated Quantity Scheme for Management/ Disposal Industrial Wastewater a. Sugar Sugar ETP consists of Preliminary treatment (Oil & Grease trap, screen, “V” notch), anaerobic lagoon, Aeration Tank, Clarifier, 510 KLD Monthly Washing Holding Tank, Sludge Drying Bed and Treated Sump. Treated effluent shall be used for irrigation on land owned by the Industry. 1 b. Cogeneration plant and Shall be treated along with Sugar Factory IML Bottling 280 KLD effluent and shall be used for irrigation on land owned by the Industry. c. Distillery Division Distillery ETP for existing 35 KLPD consists of Bio-methanation followed by composting. 1028 KLD The raw spent wash generated due to the proposed 65 KLPD distillery shall be treated based on the Same Principle. Domestic Waste STP is already constructed based on root zone 2 46 KLD (Combined) technology. Hazardous waste 3 5.1 Spent oil 1.01 MT/A Mixed with bagasse and burnt in the boiler
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Non-Hazardous Waste/ Solid waste 4 a. Fly/Boiler Ash 453 MT/M Disposed in Composting b.ETP Sludge 400 MT/M Disposed in Composting 4. SITE ANALYSIS 4.1. Connectivity The site is conveniently located in many aspects. There are no reserved forests, Historical places, Wild life Sanctuaries, Heritages etc within 10 Km radius of the factory site. The industry has its own land of 53.14 hectares having a connecting roads and approachability, which is sufficient for the existing and the proposed expansion. No forest area or displacement of habitation or acquisition of private land is required.
The Project Site is conveniently located for development of the Project. o 66 km away from Belguam, which is a Distric place Other important towns nearby are o Bellad-Bagewadi, at a distance of 4 km o Hukkeri, at a distance of 16 km o Ghatprabha is nearest Railway station 9.2 km away from the factory site o Belagavi is nearest airport 65 kms away from the factory site 4.2. Land Form, Land use and Land ownership Total land of 53.14 Ha in the existing premise is owned by the industry. The detailed land breakup along with the provision for Green Belt Development is given in Chapter 5.
4.3. Topography Belgaum District has an average height of topography between 450 and 900 meters above sea level. Its total geographical area is 13,415 sq. kms, which is 6.99% of the total geographical area of the Karnataka state, ranking second in area among the twenty sevens district. It has a rolling topography sloping to the east and there are isolated hills in the hill ranges extending from the Western Ghats out of which the North malaprabha and the North Ghataprabha ranges are important.
4.4. Existing Infrastructure The expansion can be accommodated in the Existing infrastructure facilities to the maximum possible extent. Additional land is available adjacent to the existing infrastructure to facilitate the use of utilities without much additional cost.
4.5. Soil Classification The Hukkeri taluka consists of different types of soil such as light black, reddish and the black cotton soil (BCS) which contains high alumina and carbonates of Ca and Mg. A typical characteristic of the soil is that it swells when wet and dries up with cracks on losing moisture. The thickness of the soil cover shows a large variation and ranges from a few centimeters to 5 meters. The soil is mostly no retentive in nature.
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4.6. Climatic data from stationary sources The district shows semi-arid climatic conditions. There is a distinct climatic pattern defining there climatic seasons. They are summer season, Rainy season and winter season.
Summer season- The Summer season prevail between February to June months. The rise in temperature varying from 360 -390C. Is recorded by the Meteorological department. The Northern part of the district shows hot climatic conditions during this period, and the temperature reduces west wise, with 280 -20 9 C. Few odd season monsoon showers with lightening and thunders are received in the month of February and May, must for the pre preparations of actual sowing.
Rainy Season- The SouthWest monsoon the district with heavy showers, during the month of June, and continue up to October. Highest rainfall 2134.6 mm is recorded in Khanapur taluka, the lowest 514 mm in Raibag taluka. The rainfall goes on reducing from SW part to NE part. Many seasonal springs strat to flow water up to September,October months. All reservoirs receive water, and water is let out in the canals. The NE monsoon rains are received in the northern parts of the district. Rainy season is the period of ground water recharge. The rivers, nallas, ponds, reservoirs etc. Get their water through the rainfall.
Winter Season- The winter cold strart just after the rainy season, i.e from October to February. Temperature recorded in the Malenadu region is 80 -140C in the Gadinaadu area 250 - 320C and up to 410C in Bayalunaadu area.
4.7. Social Infrastructure available Availability of infrastructure and facilities denote the level of overall development in the study area. The availability of facilities with regard to education, health, transport and communication, water supply and availability of electricity are dealt with in the following. a) Education Facilities: Good educational infrastructure in Belgaum district. It includes not only school and colleges but also engineering, medical pharmacy, and dentistry colleges. b) Health Services: There are excellent hospitals, nursing homes and dispensaries available. c) Drinking Water: The villages in the study area are drawing water from mainly from river, according to the sources of drinking water used by the villages are Water tank, Well, River, Hand Pump, Tap lake, etc d) Transport and Communication: Mumbai to Chennai (N.H. – 4) Highway 31 Km away from Industry. Belgaum district has a well-developed transportation network consisting of railway network, road network, and airline station. e) Post & Telegraph: Most of the villages are well connected by post and telegraph facilities. f) Electricity: All villages have a power supply from Karnataka Power Transmission Corporation Limited (KPTCL). 5. PLANNING BRIEF 5.1. Planning Concept (type of industries, facilities, transportation etc.) Town and country planning / Development authority Classification VSIL is a Private limited industry. Existing facilities, transportation, and infrastructure etc. are adequate. Hence, no additional planning is required.
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5.2. Population Projection Not Applicable.
5.3. Land use planning (breakup along with green belt etc) Detailed land use planning along with green belt is given as below
Description Existing Proposed Total Built up area 5.59 1.0 6.59 Storage of fuel and 6.5 -- 6.5 finishing product Compost Yard 5.05 -- 5.05 Parking of vehicles 6.38 -- 6.38 Vacant Land 9.08 -1.0 8.08 Greenbelt 17.54 -- 17.54 ETP, internal roads 3.0 -- 3.0 Total 53.14 00 53.14
5.4. Assessment of Infrastructure Demand (Physical and Social) The civil structures supporting Distillation Column, fermenter, anaerobic digesters and MEE for spent wash treatment for the proposed Distillery, the housing of the equipment required for the expansion of cogeneration power plant, and establishment of the new 30 KLPD Ethanol Plant.
5.5. Amenities / Facilities Existing amenities would be adequate for the proposed expansion.
6. PROPOSED INFRASTRUCTURE 6.1. Industrial Area (Processing Area) Total of 1 hectare would be utilized for the processing area of the proposed project.
6.2. Residential Area (Non Processing Area) Residential area available is adequate for the proposed expansion.
6.3. Green belt Greenbelt development is undertaken in the area provided separately. According to CPCB guidelines, 1500 trees should be available per hectare of land for Greenbelt development. Total 17.54 Hectares of land is reserved for greenbelt development; hence there should be minimum 26310 no. of trees. At present the industry has planted 12184 trees in the plant area. The details of the trees planted till date given in table no 14. The remaining 14126 trees shall be planted within 2 years.
The industry has taken the forest land on lease basis for green belt development, which is 5 km away from the factory site. It is proposes develop the green belt in the entire forest land of 40 hectares of area.
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Table 14 Details of the Green belt development
Sr .No Name of th e plant Number of plants Sr .No Name of th e plant Number of plants 1 silver Oak 205 42 Sambige 209 2 Casuarina 626 43 Takoma 40 3 Cashew nut 220 44 Peru 109 4 Coconut 1315 45 Rubber tree 8 5 Almond 514 46 Sisal pinia 36 6 Tamarind 156 47 Thabiba rosa 41 7 Tapasi 233 48 Hibiscus 123 8 Neem 517 49 Pongamia 223 9 Peacock flower 30 50 Picus Benchmia 10 10 sapota (Chikku) 293 51 Bamboo 100 11 Ashok 980 52 Koliyas 35 12 Lemon 271 53 Hebbat 45 13 Mango 713 54 Sivani 22 14 Custard 348 55 Honni 52 15 Teak 575 56 Sisavi 41 16 Cherry 228 57 Jakrapa 25 17 eucalyptus 290 58 Sacred Fig 104 18 Umbrella palm 200 59 Banyan 43 19 Bottle brush 320 60 Pentacarp 270 20 Bougan villa 261 61 Egjora 52 21 Akeshi 218 62 Green Palm 60 22 Dasawala 67 63 Desert Paim 12 23 Kanagale 62 64 Pathadouai 60 24 Duranta 80 65 Champak 10 25 Amelia 128 66 Drum stick 50 26 Jacaranda 49 67 Boatel bresh 25 27 Spethodea 29 68 Powder pupp 10 28 Simarouba 59 69 Aromatic flower 65 29 Mahogani 5 70 Arailea 10 30 Aricanut 26 71 Akkaliep 60 31 Amla 100 72 Cottrouns 50 32 Tapashi 24 73 Palm 50 33 sagwan 105 74 Pomegranate fruit 10 34 Sankeswar 173 75 Coastarred apple 10 35 Forest trees 415 76 pindlantus 10 36 Hulagal 128 77 Blood teak 5 37 Jack fruit 30 78 Sandal wood 10 38 Jamun 51 79 Java palm 10 39 Goose berry 0 80 Gous tree 10 40 Balor 0 81 Pongame oil tree 10 41 Patri 0 82 cashew tree 15 Total 12184 6.4. Social Infrastructure At present, several basic amenities are adequately available at the site. Hence, there is no need for the additional social infrastructure facilities.
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6.5. Connectivity (Traffic and Transportation Road/Rail/Metro/Water ways etc.) The present site is adequate in terms of connectivity. Transportation and traffic management facilities are sufficiently present at the existing site.
6.6. Drinking Water Management (Source and Supply of water) Drinking water facilities are already provided for the employees as well as for the people residing in the nearby area. There shall not be any additional demand for drinking water after the proposed expansion.
6.7. Sewerage System Existing sewerage system shall also be adequate after expansion.
6.8. Industrial Waste Management Industrial waste management facilities are adequate even for the expansion capacities.
6.9. Solid Waste Management Solid waste management and disposal facilities are not required additionally after expansion.
6.10. Power requirement & Supply / Source At present, the power requirement by the industry is 12 MW. Additional 4 MW of power will be required after the proposed expansion. Therefore the total power requirement after the proposed expansion will be 16 MW. The industry intends to expand its cogeneration capacity to 69 MW. The power required by the industry is met from its owned cogeneration power plant. Excess electricity produced will be supplied to the state electricity grids.
7. REHABILITATION AND RESETTLEMENT (R&R) PLAN 7.1. Policy to be adopted (Central/State) in respect of the project affected persons including home outstees, land outstees and landless laborers (a brief outline to be given) Not applicable as the project does not fall under project affected areas.
8. PROJECT SCHEDULE AND COST ESTIMATES 8.1. Likely date of start of construction and likely date of completion (Time schedule for the project to be given) Project activities will be initiated as soon as Environmental clearance is obtained. And it would take around two years for the completion of the project.
8.2. Estimated project cost along with analysis in terms of economic viability of the project Cost of the project is 30 Crore rupees, EMP cost is estimated as Rs. 3 Crore, recurring expenditures per annum is around Rs. 0.5 Crore and 1.5 % of the total project cost (Ref: Office Memorandum Dated 1st May 2018 F. No- 22-65/2017-IA.III) will be spent on Corporate Social Responsibilities (CSR) over a period of 5 years.
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9. ANALYSIS OF PROPOSAL (Final recommendations) 9.1. Financial and social benefits with special emphasis on the benefit to the local people including tribal population, if any, in the area. Due to the expansion, productivity and the profitability of the industry are going to be affected in a positive manner. The financial benefits are diverted directly to the farmers, by the higher cane prices due to timely crushing and high recovery. Hence, this project would immensely help farmers. Along with that, direct employment opportunities are generated for the local people due to this expansion project. Due to the increased transportation and other activities inside the industry premises, indirect employment generation is also possible. Hence, this project is beneficial to the entire region around the VSIL.
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ANNEXURE I Water Budget Table 15: Water Budget for Sugar Factory Unit
Consumption & Losses Generated Effluent Net Dischargeable Water Intake (Cum) Recycle and reuse (Cum)
(Cum) (Cum) Effluent (Cum)
TCD TCD TCD TCD TCD
Total Total Total Total Total
11,000 TCD 11,000 TCD 11,000 TCD 11,000 TCD 11,000 TCD
Expansion Expansion to Expansion to Expansion to Expansion to Expansion to
Existing 5500 Existing 5500 Existing 5500 Existing 5500 Existing 5500
i) Domestic 30 20 50 05 05 10 25 15 40 Nil Nil Nil 25 15 40 ii) Industrial 1) Boiler 200 200 400 Nil Nil Nil 190 190 380 190 190 380 10 10 20 2) Cooling 200 200 400 100 100 200 100 100 200 80 80 160 20 20 40 iii) Industrial process including washings 125 125 250 Nil Nil Nil 125 125 250 Nil Nil Nil 125 125 250 generating Bio- degradable effluent iv) Other usages such as 50 50 100 50 50 100 Nil Nil Nil Nil Nil Nil Nil Nil Nil Gardening, fire fighting etc.
Recycling of Excess Nil Nil Nil Nil Nil Nil Nil Nil Nil 1000 1000 2000 100 100 200 Condensates (v) Total A) Domestic 30 20 50 05 05 10 25 15 40 Nil Nil Nil 25 15 40
B) Industrial 575 575 1150 150 150 300 415 415 830 1270 1270 2540 255 255 510 Net Water Requirement= 1150-2540= -1390 KLD
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Table 2 : Water Budget for Co-generation Unit.
Recycle & Reuse Consumption & losses Generated effluent Net Discharged effluent Water Intake (Cum) (Cum) (Cum) (Cum) (Cum)
MW
Total Total Total Total
Total
25 MW 25 MW 25 MW 25 MW
Existing 39 MW Existing 39 MW Existing 39 MW
Existing 39 MW Existing 39 MW
Proposed expansion Proposed expansion Proposed expansion Proposed expansion Proposed expansion25 i) Domestic 05 -- 05 02 -- 02 03 -- 03 ------03 -- 03 ii) Industrial 1. Boiler 50 50 100 Nil Nil Nil 50 50 100 ------50 50 100 2. Cooling 630 300 930 530 260 790 100 40 140 ------100 40 140 iii) Industrial process generating Bio-Degradable 45 25 70 20 10 30 25 15 40 ------25 15 40 effluent Recycling of excess condensates from Sugar Unit 1390 iv) Total i) Domestic 05 -- 05 02 -- 02 03 -- 03 ------03 -- 03 ii) Industrial 725 375 1100 550 270 820 180 100 280 -- -- 1390 180 100 280 Net Water Requirement= 1100-1390= -290KLD
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Table 3: Water Budget for Distillery Unit
Consumption & Generated Effluent Recycle & Reuse Net Dischargeable Water Intake (Cum) Losses (Cum) (Cum) Effluent (Cum)
(Cum)
Total Total Total
KLPD KLPD KLPD KLPD KLPD
Total Total
KLPD
Existing 35 Existing 35
Expansion65
Expansionto 65
Expansionto 65
Expansionto 65
Existing 35 KLPD Existing 35 KLPD Existing 35 KLPD i) Domestic 05 -- 05 02 --Expansion65 KLPD 02 03 -- 03 Nil Nil Nil 03 -- 03 ii) Industrial
1. Boiler 20 40 60 16 36 52 4 4 8 100 200 4 4 8 300 2. Cooling ------60 160 220 40 40 80 -- -- 40 40 80 iii) Industrial process including washings generating Bio- 360 580 940 Nil Nil Nil 360 580 940 Nil Nil Nil 360 580 940 degradable effluent ENA Plant 50 100 150 50 100 150 Nil Nil Nil Nil Nil Nil Nil Nil Nil IMFL Bottling Plant 100 Nil 100 100 Nil 100 Nil Nil Nil Nil Nil Nil Nil Nil Nil Recycling of excess Condensates Nil Nil 290 Nil Nil Nil Total i) Domestic 05 -- 05 02 -- 02 03 -- 03 ------03 -- 03 ii) Industrial 530 720 1250 226 296 522 404 624 1028 100 200 590 404 624 1028 Net Water Requirement= 1250-590= 660 KLD Note: Boiler blow down and domestic effluent shall be used for plantation in distillery premises.
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ANNEXURE II CONSENT TO OPERATE
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ANNEXURE III PREVIOUS EC LETTER
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AMENDMENT IN ENVIRONMENTAL CLEARANCE
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