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Dhampur Sugar Mills Ltd. Rajpura

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Dhampur Sugar Mills Ltd. Rajpura Pre-Feasibility Report Dhampur Sugar Mills Ltd. Rajpura PRE-FEASIBILITY REPORT For PROPOSED 300 KLPD DISTILLERY PLANT (MOLASSES BASED)/200 KLPD MOLASSES AND 100 KLPD GRAIN ALONG WITH 12.0 MW COGENERATION POWER PLANT Project Proponent: DSM SUGAR RAJPURA (A unit of Dhampur Sugar Mills Limited) Rajpura, District-Sambhal (April, 2019) Environmental Consultant: ENVIRO INFRA SOLUTIONS PVT.LTD. Accredited by NABET (Quality Council of India) for EIA studies as ‘A’ Category Consultant (S. No. 48th, as on March, 2019) Address: - 301, 302 & 305, SRBC, Sec.-9, Vasundhara, GZB-201012 Ph.: 0120-4151183 Email: [email protected] Website: www.enviroinfrasolutions.com Proposed 300 KLPD molasses based/200 KLPD molasses based and 100 KLPD grain Based Distillery Unit Page 1 Pre-Feasibility Report Dhampur Sugar Mills Ltd. Rajpura SUMMARY 1 Dhampur Sugar Mills Ltd. (DHAMPUR) is a company registered under Indian Companies Act, 1956 (Now under the Companies Act, 2013) having its Registered Office at Dhampur Distt. Bijnor. The Company has a sugar Mill at Rajpura Distt. Sambhal. 2 The company is proposing a new distillery plant of 300 KLPD Molasses / Grain based with option of 300 KLPD molasses based or 200 KLPD Molasses based and 100 KLPD Grain based along with 12.0 MW Cogeneration Power at their existing Sugar Mill at Village & Block Rajpura, Tehsil Gunnaur , District Sambhal, Uttar Pradesh. The co- ordinates of site are 28°21'26.63"N and 78°22'50.11"E. 3 Total 45 acres (18.21 ha) land is required for proposed project and out of which 20 acres is existing industrial land in possession of promoters adjacent to existing sugar mill and rest 25 acres of agricultural land will be converted to industrial use after taking due permissions. The benefits of the location are as below; Required raw material is abundantly available in the nearby adjoining area. Good availability of groundwater Well connected by road/rail network Proximity to spirit and ethanol consuming market Manpower available for industrial purposes Availability of basic Infra Structure with the existing Sugar Mill 4 The molasses based distillery process will have process steps namely - molasses receiving and storage, fermentation, multi-pressure distillation, multi-effect evaporation, spirit storage. Grain based distillery process will have process steps namely - grains receiving and storage, grains handling and milling, slurry preparation/liquefaction, scarification and instantaneous fermentation, fermentation, multi-pressure distillation, decantation, multi-effect evaporation, spirit storage. 5 The industry will generate 12.0 MW power from incineration boiler based cogeneration power plant. Bagasse/coal/rice husk would be used as support fuel @ 30 % along with concentrated spent wash @ 70 % for the boiler furnace. 6. The industry would require utilities for 300 KLPD molasses based or 200 KLPD Molasses and 100 KLPD grain based with the capacity of water treatment plant (DM plant) @ 1125 m3/day and that of cooling towers @ 12000 m3/Hour. 7. The distillery will use molasses as basic raw material. Besides this, processing chemicals would be used for the production of ethanol and other Distillery products. The daily fuel requirements for the 90 TPH boiler furnaces would be around 2110 cum/ day conc. spent wash along with 500 MT/Day (bagasse) or 300 MT/Day (coal). Proposed 300 KLPD molasses based/200 KLPD molasses based and 100 KLPD grain Based Distillery Unit Page 2 Pre-Feasibility Report Dhampur Sugar Mills Ltd. Rajpura 8. The fresh water requirements of the industry would be around 2095 (max) m3/day. The source of fresh water will be ground water. 9. Waste water in the form of spent lees (360 m3/day), MEE condensate (1470 m3/day) would be generated. Besides this, misc. effluent such as floor/fermenter washing effluent @ 50 m3/day, cooling tower blow down @ 75 m3/day, DM plant Reject water @ 75 m3/day and boiler blow down @ 50 m3/day would be generated. 10. The industry will proposed two nos. of Multiple Effect Evaporators of 2200 m3/day capacity (1100 m3/ day X 2), which is sufficient for the treatment of spent wash, thereby maintaining the Distillery as ZERO EFFLUENT DISCHARGE INDUSTRY. The spent lees and MEE condensate would be reused in the process after treatment in CPU combined with Bio Composting of concentrated Spent Wash as per Norms./SOP prescribed by the MoEF&CC vide OM dated 04.09.2018 and dated 25.03.2019. 11. The estimated cost of proposed distillery project and cogeneration of 12 MW of power would be around Rs. 325.87 Cr. Proposed 300 KLPD molasses based/200 KLPD molasses based and 100 KLPD grain Based Distillery Unit Page 3 Pre-Feasibility Report Dhampur Sugar Mills Ltd. Rajpura CHAPTER – 1 INTRODUCTION Dhampur Sugar Mills Ltd. (DHAMPUR) is an agro based industry having started their operations in the year 1933 with a 300 TCD sugar mill located at Dhampur, Uttar Pradesh in North India. The company has a successful track record of about seven decades of efficient operation. During this period, it has grown into one of the largest sugar manufacturing groups in India, owning at present five sugar mills in the State of Uttar Pradesh with a combined cane crushing capacity of more than 45,500 TCD with Bagasse based power cogeneration Units in all five Sugar Units. With the passage of time, Dhampur Sugar Mills Ltd. (DHAMPUR) has diversified into molasses based chemicals manufacturing, by setting up a distillery facility for alcohol & alcohol based chemicals, such as Ethyl acetate. The company is proposing distillery plant of 300 KLPD molasses based/200 KLPD molasses based and 100 grain based along with 12.0 MW Cogeneration Power Plant at Village & Block Rajpura, & District Sambhal, Uttar Pradesh. The distillery will be based on most modern technologies and the state of art features. Project will result in higher efficiencies, energy conservation and Zero Effluent Discharge. Raw materials i.e. molasses and bagasse will be sourced from the sugar mill located within the plant, other sugar plants of the group and from other sugar mills located nearby. The estimated cost of proposed project would be around Rs 325.87 Crores. The project would be installed and commissioned within 8 to 12 months from the date of receipt of Environmental Clearance from the Ministry of Environment, Forests & Climate Change, New Delhi. The industry would operate for 365 days in a year. The distillery plant would require a power input of around 12 MW which would be available from their in-house co-generation power plant. Table1: Salient Features of the Project S. No. Particulars Details 1. Nature & Size of the Project Proposed New 300 KLPD molasses based/200 KLPD molasses based and 100 grain based along with 12.0 MW Cogeneration Power Plant at Village & Block Rajpura, & District Sambhal, Uttar Pradesh. 2. Category of the Project Sr. No. 5(g); Category ‘A’ 3. Location Details Village Rajpura Block Rajpura Tehsil Gunnaur District Sambhal Proposed 300 KLPD molasses based/200 KLPD molasses based and 100 KLPD grain Based Distillery Unit Page 4 Pre-Feasibility Report Dhampur Sugar Mills Ltd. Rajpura State Uttar Pradesh Latitude 28°21'26.63"N Longitude 78°22'50.11"E Toposheet No. H44S7 4. Total Plant Area Total 45 acres (18.21 ha) land is required for proposed project and out of which 20 acres is existing industrial land and rest 25 acres of agricultural land will converted to industrial use. 5. Greenbelt / Plantation Area 14.85 Acres, i.e. ~33% of the project area will be covered under greenbelt/ plantation 6. Environmental Setting Details Nearest Village Rajpura Nearest Town & City Anupshahar (10.5 km in west direction) Nearest National Highway / NH 93 (10 km) State Highway Nearest Railway station Babrala Railway Station (10.3 km, aerial) Indira Gandhi International Airport, New Delhi Nearest Airport (Approx. 126.0 Km, aerial) National Parks, Wildlife No National Parks, Wildlife Sanctuaries, Sanctuaries, Conservation Conservation Reserves, Tiger / Elephant Reserves, Tiger/Elephant Reserves fall within 10 km radius from the plant Reserves site River / Water Body (within 10 km Ganga River – 10 km radius) 7. Products to be manufactured Ethanol/RS/ENA – 300 KLPD Cogeneration of power – 12 MW 8. By Products Conc. spent wash – 600 m3/day KLD, DDGS – 60 MT/day 9. Raw Material Consumption Molasses – upto 1350 MT/day Chemicals - enzymes (@28 kg/day), Sulphuric Acid (@8050 kg/day), Urea (@395 kg/day), anti- foam agent (@1400 kg/day), yeast (@700 kg/day and DPA @ 130 kg/day) 10. Fuel Consumption Conc. Spent Wash 34.5 MT/hour and Bagasse- 20.8 MT/hour or Coal – 12.5 MT/hour 11. Water Requirement & Source Fresh water requirement is 2095 KLD will be met through bore well after taking necessary permission from CGWA. 12. Quantity of Effluent generation Spent Wash @ 2070 m3/day 13. Disposal of treated effluent Concentrated Spent Wash will be used as fuel in Boiler & condensates to be reused for dilution of molasses and cooling tower make-up after treating in CPU. Proposed 300 KLPD molasses based/200 KLPD molasses based and 100 KLPD grain Based Distillery Unit Page 5 Pre-Feasibility Report Dhampur Sugar Mills Ltd. Rajpura 14. Details of process emissions Process emissions from boiler furnace of 90 TPH capacities 15. Proposed air pollution control Bag Filter, Stack height – 80 meters device along with stack height 16. Cost of the Project: Rs (in 325.87 Crores) 17. Working Days 365 days / annum Proposed 300 KLPD molasses based/200 KLPD molasses based and 100 KLPD grain Based Distillery Unit Page 6 Pre-Feasibility Report Dhampur Sugar Mills Ltd. Rajpura CHAPTER – 2 PROJECT LOCATION Dhampur Sugar Mills Ltd. are 300 KLPD molasses based/200 KLPD molasses based and 100 grain based along with 12.0 MW Cogeneration Power Plant at Village & Block Rajpura, & District Sambhal, Uttar Pradesh.
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