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Executive Summary Proposal for Molasses Based Fuel Ethanol Plant of 45 KLD Executive Summary EXECUTIVE SUMMARY 1. Proposed Project: M/s Shree Durga Khandsari Sugar Mills (SDKSM) is operating Sugar plant with capacity of 2500 TCD alongwith 11 MW Co-gen power plant at Village- Mendrana, Tehsil- Pansemal Dist Barwani (MP). Keeping in view of the future requirements of fuel ethanol, M/s SDKSM are setting up a 45 KLD fuel ethanol plant (Molasses based) with 14 TPH Incineration Boiler in same premises with an estimated cost of Rs. 4682 Lacs. 2. Objective Of The Study: The Environmental Impact Assessment has been carried out to assess the existing base line environmental scenario of the area and probable impacts on various components of the proposed activities. Based on the activities of existing and proposed grain base distillery unit alongwith cogeneration plant, an environmental management plan has been suggested. The plan will identify and address the impacts and design mitigative measures to manage such impacts in a manner as to conserve environment and ecology of the area. The EMP has been prepared with a view to ultimately ensure that the adverse impacts can be minimized if these cannot be prevented altogether. The main objectives of the study are listed as below: To anticipate & avoid, minimize or offset biophysical, social, and other relevant adverse effects of project To ensure environmental consideration are explicitly addressed and incorporated in to the development decisions making process To protect the productivity and capacity of natural system and ecological processes which maintain their functions. To establish the present environmental scenario To anticipate the impacts of proposed operations on the environment. To suggest preventive and mitigating measures to minimize adverse impacts and to maximize beneficial impacts. To prepare a detailed action plan for implementation of mitigating measures. To suggest a monitoring program to evaluate the effectiveness of mitigating measures. To suggest the formation of a core group responsible for implementation of environmental control and protective measures and monitoring of such implementation. To suggest a feedback mechanism enabling to make mid course corrections. To prepare a capital cost estimate and annual recurring cost for Environmental Management Plan. M/s Shree Durga Khandsari Sugar Mills, ES- 1 Dist. Barwani (MP) M/s CES, Bhopal Proposal for Molasses Based Fuel Ethanol Plant of 45 KLD Executive Summary 3. Environmental Setting: The environmental setting of the proposed plant is given in Table. Table 1 S. No. Particulars Details 1. Locations A. Village Mendrana B. Tehsil Pansemal C. District Barwani D. State Madhya Pradesh Toposheet No. 46K/9, 46K/10, 46K/13 & 46K/14 2. General ground level 222-212 above MSL 3. Nearest National/ State Highway Sendhwa- Khetia State Highway-36 – 0.15km- S 4. Nearest Railway Station Dondaicha – 37.25km 5. Nearest Airport Shirpur – 48.00km 6. Nearest Tourist Place None within 10km radius 7. Archaeological Important Place None within 10km radius 8. Ecological Sensitive Areas (Wild None within 10km radius Life Sanctuaries) 9. Reserved / Protected Forest within RF - 1.50km - SE 10km radius RF - 9.50km - NE RF - 8.50 km - N 10. Nearest major city >50000 None population 11. Nearest Town/City within 10km Pansemal – 4.25 km radius 12. Other Industry within 10km radius 1. Sugar Plant, Khetia – 5.75km - W 2. Cooton Factory – 8.75km- W 13. Surrounding village within 1 km Bamrata – 0.75km – N area of the project. Mendrana – 1.0km- E 14. Nearest village Bamrata – 0.75km – N 15. Nearest River Gomai River –1.00 km – S Bandhara Buzurg Nadi – Adjacent Dhamni Nadi – 3.25km- E Umari River - 3.25km- W Sukali Nadi - 6.75km- E Bandhara Nadi – 6.75km- E Khapri Nadi - 3.50km - SW 16. Nearest Nalla/Lake/ Ponds No. of Seasonal nallas/gullies which flows rainy season M/s Shree Durga Khandsari Sugar Mills, ES- 2 Dist. Barwani (MP) M/s CES, Bhopal Proposal for Molasses Based Fuel Ethanol Plant of 45 KLD Executive Summary 17. Surrounding features within 500m N- Banddhara Buzurg Nadi radius S- SH-36 followed by agricultural land E- Agricultural land W- Agricultural land 4. Details About The Project Site The project is located at 1 km in west of the Mendarana village, which is 0.17km away from Khetia Sendhawa Road State Highway -36 and 3 km from Pansemal . The area is approachable by SH-27 through Indore- Khandwa Road. The area lies at the cross section of 21°39'19.07"N to 21°39'33.38"N and 74°39'5.35"E to 74°39'37.85"E and is covered under Toposheet no 46K/9, 46K/10, 46K/13 & 46K/14. 5. Salient Features Of The Project Proposed Project Sr. No. Particulate Description 1. Name of the proponent M/s Shree Durga Khandsari Surgar Mills 2. Project capacity 45 KLPD Molasses Based Ethanol Plant with 14 TPH Incineration Boiler. 3. Khasara No. & Location of the Khasara No. 76/1 & 76/2, Village- Mendrana, Tahsil project Pansemal, Dist. Barwani, MP. 4. Geographic Location 21°39'24.56" N and 74°39'14.41" E 217 m MSL 5. Land requirement Total land 8.0048 acres for proposed Distillery Unit 1.989 acre built up area 2.64 acre green belt area 6. Product Product: Fuel Ethanol :45 KLPD With 14 TPH Incineration Boiler. 7. Operation days 270 days 8. Molasses required Molasses 158 TPD ( Fermentable sugar 42% w/w) 9. Total water 351 KLD (After recycling) 10. Source of water Borewell 11. Electricity Operational: 847 kWh Connected load: 1185 kWh 12. Turbine generator 1.20 MW 13. Steam 9.92 TPH 14. Fuel Concentrated spent wash: 117 TPD Bagasse – 115 TPD 15. Source Captive & Nearby Market 16. Boiler 14 TPH Incineration Boiler 17. DG Existing : One DG sets of capacity 1010 KVA M/s Shree Durga Khandsari Sugar Mills, ES- 3 Dist. Barwani (MP) M/s CES, Bhopal Proposal for Molasses Based Fuel Ethanol Plant of 45 KLD Executive Summary Proposed : One DG set of 250 KVA 18. Effluent treatment Condensate Polishing Unit (CPU) will treat spent System lees, cooling tower blow down, boiler blow down and process condensate. Spent wash will be treated by multi effect evaporator followed by slope fired boiler. 19. Man-power 70 skilled and unskilled 20. Total project cost 4682 Lakhs 21 Land acquired 24.19 acres 22 Land required for proposed 1.989 acres plant 23 Proposed area for plantation 8.50 acres ( inclusive of sugar unit) 24 Existing area of plantation 2 acres 25 Capital Cost for Environmental 1292 Lacs measures (proposed ) 26 Recurring cost for environmental monitoring etc 46.40 Lacs (Proposed) 6. Manufacturing Process M/s Shree Durga Khandsari Sugar Mills, ES- 4 Dist. Barwani (MP) M/s CES, Bhopal Proposal for Molasses Based Fuel Ethanol Plant of 45 KLD Executive Summary Fermentation Molasses, diluted with water to the desired concentration is metered continuously into a single tank fermenter. Additives likes urea (in the form of pellets or prills) and defoaming oil are also introduced in the fermenter as required. There is an automatic foam level sensing and dosing system for defoaming oil. Every Kilogram of alcohol produced, generates about 290 Kcal of heat. This excess heat is removed by continuous circulation of fermenting wash through an external plate heat exchanger called the Fermenter Cooler. The fermenter temperature is always maintained between 32 and 35 deg. C, the range optimum for efficient fermentation. The yeast for the fermentation is initially (i.e. during start-up of the plant) developed in the Propagation Section described further on. Once propagated, a viable cell population of about 500 million cells/ml is maintained by yeast recycling and continuous aeration of the fermenter. Fluctuations in the yeast count of +/- 20% have little effect on the overall fermenter productivity. Yeast cell vitality which is usually above 70% may, in times of stress (such as prolonged shut-downs) drop to 50% without affecting the fermentation. Fermented wash passes through a series of hydro cyclones (one to three or move in number depending on plant capacity), which remove grit, iron filings and similar heavy particulate matter. This rejected material along with some wash, is taken to the bottom portion of the wash column for alcohol recovery. The overflow from the first hydro cyclone is taken a wash tank, also provided with an arrangement to facilitate removal of heavy settable particulate matter. Overflow from the wash tank is taken to the yeast separator, which clarifies the wash. The hydro cyclone and the wash tank protect the separator from erosion damage by removing grit and similar hard particles. Wash Preparation For the plant mash, molasses is diluted with water to give a sugar concentration of 14 to 18% and pumped directly into the fermenter. This mash is usually not sterilized, although in certain cases it has been pasteurised with a resultant slight increase in efficiency. The fermenter is issued when it is one eighth to one fourth full with a large volume of active yeast. 2 to 4% of the final volume to allow development of the yeast during the entire filling period, which may amount to 8 hours and to avoid growth of contaminating organisms during this period. Nutrients Blackstrap molasses usually contains enough yeast nutrients to give a fast, efficient fermentation. In some cases, however, it is desirable to add small quantities of ammonium salts, such as ammonium sulphate, to the mash to increase the rate and efficiency of the fermentation. In such cases, the amount of ammonium sulphate added varies between 0.5 liters and M/s Shree Durga Khandsari Sugar Mills, ES- 5 Dist. Barwani (MP) M/s CES, Bhopal Proposal for Molasses Based Fuel Ethanol Plant of 45 KLD Executive Summary 3 liters per 10,000 liters of mash, depending on the molasses used, the optimum amount being determined by laboratory in a blackstrap molasses fermentation.
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