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Pre - Feasibility Report PRE - FEASIBILITY REPORT FOR PROPOSED 35 KLPD MOLASSES BASED DISTILLERY PLANT BY M/S. SHREE MAROLI VIBHAG KHAND UDYOG SAHAKARI MANDLI LTD. SURVEY NO.: 71, 72 & 80 AT-KOLASARA (KALYAN NAGAR) P.O- MAROLI BAZAR, TALUKA JALALPORE, DISTRICT NAVSARI-396436 GUJARAT SUMMARY M/s. Shree Maroli Vibhag Khand Udyog Sahakari Mandli Ltd is an existing sugar mill located, at Survey No. 71, 72 & 80 At-Kolasara (Kalyan Nagar) P.O- Maroli Bazar, Taluka Jalalpore, District Navsari, Gujarat. Capacity of the existing Sugar Industry is 3000 TCD producing 11200 MT/Month of White Crystal Sugar. Now Shree Maroli Vibhag Khand Udyog Sahakari Mandli Ltd has proposed 35 KLPD Molasses based distillery unit within existing company premises. PROJECT COST The total cost of the project will be around Rs. 30.0 crores. Total capital cost of pollution control measures will be Rs. 3.0 crores & recurring cost per annum will be 1.0 crores. DETAILS OF PRODUCTS Details of existing and proposed products are given in following table. LIST OF EXISTING AND PROPOSED PRODUCTS AND PRODUCTION CAPACITY SR. EXISTING ADDITIONAL NAME OF THE PRODUCTS TOTAL NO. QUANTITY QUANTITY (A) PRODUCTS 1 White Crystal Sugar 11200 MT/Month -- 11200 MT/Month Captive Power Plant (In 2 5.85 Mw/Hr. -- 5.85 Mw/Hr. House During Crushing Season) Rectified Spirit/Anhydrous 3 -- 35 KLPD 35 KLPD Alcohol (B) BY PRODUCTS 4 Molasses 5,200 MT/Month -- 5,200 MT/Month 5 Bagasse 33,500 MT/Month -- 33,500 MT/Month 6 Press Mud 4,200 MT/Month -- 4,200 MT/Month 7 Bio Compost 4,200 MT/Month -- 4,200 MT/Month REQUIREMENTS FOR THE PROJECT LAND No new land will be acquired for the proposed project. Out of total land area (i.e. 1,53,262 m2) around 8,000 m 2 open land area will be utilized for the proposed distillery unit. WATER For the proposed project additional 506 m3/Day water will be required. Existing water required of the sugar plant is 428.7m3/Day, after proposed project total water required will be 934.7m3/Day. Source of water for existing unit is Borewell/ Canal and for the proposed distillery unit surface water (i.e canal water) will be utilized. ELECTRICAL ENERGY For proposed project additional power requirement will be 400 KW/Hr. Existing connected Power load is 299.10 KWH/MT. Power supply shall be full-filled by Dakshin Gujarat Vij Company Limited. MANPOWER At present, 237 personnel are working in the sugar industry. For proposed project additional 24 personnel will be employed who will come from local area. Total manpower after proposed project will be 261 personnel. FUEL For the proposed project, energy requirement will be met from existing boiler (2 Nos.) having capacity of 50 and 30 TPH, for the proposed project Baggase (1.9 MT/Hr) will be used as fuel in existing boiler. SOURCES OF AIR POLLUTION AND CONTROL MEASURES EMISSIONS FROM COMBUSTION OF FOSSIL FUELS FROM STATIONARY OR MOBILE SOURCES Sr. Stack Height Air Pollution Control Stack Attached To Parameter No. In Meter Devices EXISTING PM < 150 Mg/Nm3 Boiler No. 1 Ventury Type Wet 1. SO < 100 ppm (Bidrum Water Tube 50t/Hr) Scrubber 2 45.0 (common NO 2 < 50 ppm stack) PM < 150 Mg/Nm3 Boiler No. 2 Ventury Type Wet 2. SO < 100 ppm (Bidrum Water Tube 30t/Hr) Scrubber 2 NO 2 < 50 ppm PM < 150 Mg/Nm3 D. G. Set 3. 11.0 -- SO 2 < 100 ppm (500 KVA – Stand By) NO 2 < 50 ppm PROPOSED: No any additional utilities are required for the proposed project. WASTE WATER GENERATION AND IT’S TREATMENT: Wastewater generated from the sugar factory is being treated in existing ETP unit and treated water is being used in bio-composting. Waste water generated from the proposed distillery unit in the form of spent wash will be concentrating in multi effective evaporator and then sent for bio-composting. Condensate from MEE will be recycled back to the process, while spent less and other waste water will be treated in ETP units and treated water will be used for the bio-composting. Thus achieve the’ Zero Liquid Discharge’. NOISE POLLUTION AND CONTROL MEASURES: From the existing and proposed manufacturing unit noise pollution will generate which will be controlled by adopting different types of noise pollution control measures. Main sources of the noise pollution are machineries, Electric motors, etc. Following noise control measures to be adopted in the existing and proposed project, Encasement of noise generating equipment. Greenbelt all around the plant boundary. In addition personnel, working near high noise level generating sources, will be provided with ear muffs. Proper and suitable acoustic barrier will also be provided around, areas generating high noise. Effective preventive maintenance and vibration measurement of all rotating equipment will help in the improvement of plant life and also noise reduction. SOLID WASTE GENERATION AND ITS DISPOSAL METHOD The details of solid/Hazardous waste generation and its management are given in the following table. Sr. Name of the Cat Existing Additional Total Method of Storage & Disposal No. Waste No. (MT/Year) (MT/Year) (MT/Year) 58 58 Collection, Storage and used as 1. ETP Waste 34.3 -- (MT/Year) (MT/Year) Manure. Collection, Storage, transportation 1.45 0.55 2.0 and disposal by selling to GPCB 2. Used Oil 5.1 (MT/Year) MT/Year (MT/Year) approved registered recyclers / reuse. Discarded Collection, Storage and disposal by 150 150 3. Container/Barrel 33.3 -- selling to GPCB approved Nos./Year Nos./Year s/ Linear registered recyclers. GREEN BELT DEVELOPMENT Company is having total 1,53,262 m2 land area is available. The company has green belt area with Lawn, plants and flowers spread across about 33% of the total area. Further it will be developed at plant boundary. INDEX CHAPTER CONTENT NO. 1 Introduction of the Project 2 Project Description 3 Site Analysis 4 Planning Brief 5 Proposed Infrastructure 6 Rehabilitation and Resettlement (R & R) Plan 7 Project Schedule & Cost Estimates 8 Analysis of Proposal CHAPTER-1 INTRODUCTION OF THE PROJECT 1.1 IDENTIFICATION OF PROJECT M/s. Shree Maroli Vibhag Khand Udyog Sahakari Mandli Ltd. is a sugar industry located at Survey No. 71, 72 & 80 At-Kolasara (Kalyan Nagar) P.O-Maroli Bazar, Taluka Jalalpore, District Navsari, Gujarat. Molasses is produced as a by-product during manufacturing of sugar. Maroli sugar industry is planning to set up 35 KLPD distillery plant within existing premises using molasses as a basic raw material. 1.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT M/s. Shree Maroli Vibhag Khand Udyog Sahakari Mandli Ltd is planning for installation of the molasses based distillery unit at Survey No. 71, 72 & 80 At-Kolasara (Kalyan Nagar) P.O-Maroli Bazar, Taluka Jalalpore, District Navsari, Gujarat. LIST OF PRODUCTS AND PRODUCTION CAPACITY Sr. Existing Additional Name of the Products Total No. Quantity Quantity (a) Products 1 White Crystal Sugar 11,200 MT/Month -- 11,200 MT/Month Captive Power Plant (In House 2 5.85 Mw/Hr. -- 5.85 Mw/Hr. During Crushing Season) Rectified Spirit / Anhydrous 3 -- 35 KLPD 35 KLPD Ethanol (b) By Products 4 Molasses 5,200 MT/Month -- 5,200 MT/Month 5 Bagasse 33,500 MT/Month -- 33,500 MT/Month 6 Press Mud 4,200 MT/Month -- 4,200 MT/Month 7 Bio Compost 4,200 MT/Month -- 4,200 MT/Month 1.3 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY AND OR REGION. In India economy many industries are dependent over agriculture produce for production of luxury and need based committees. Alcohol is used in chemical industry as well as for preparation of beverages. The use of alcohol for the purpose of potable liquor is as high as its use for industrial purpose. As a source of income to the government, the potable liquor units get assured quota of alcohol. This trend is continuing and will continue in view of the fact that potable liquor has larger revenue generating potential. Denatured sprits are Rectified Sprit made unfit for drinking by addition of chemicals which have strong disagreeable odor and which cannot be easily separated from sprit. Ethyl alcohol is important feedstock for manufacture for basic carbon base products like Acetic Acid, Butanol, Butadiene, Acetic anhydride, Vinyl acetate, PVC etc. which are needed in pharmaceuticals, paints and other important industries as they are value added products. Ethyl alcohol has been a source of large amount of revenue by way of excise duty levied by Government on alcoholic liquor. Fermented ethyl alcohol has also great demand in countries like Japan, United state, Canada, Sri Lanka etc. as synthetic alcohol produced by these countries from Naphtha of Petroleum Crude is not suitable for beverages. Ethylene, Ethylene oxide and mono-ethylene glycol can be manufactured from petrochemical route. However, latest technological development and taking into account increasing cost of petrochemical raw material the above mentioned chemicals can be easily manufactured from ethyl alcohol. 1.4 DEMANDS-SUPPLY GAP The gap between the availability of alcohol and the requirement by the industry has been widening. The existing requirement of alcohol by the industries is around 600 million liters annually. In 1992-93, alcohol consumed for industrial purpose was 450 million liters and utilization for potable purpose was 434 million liters. The trend is expected to continue over last 9-10 years. 1.5 EMPLOYMENT GENERATION: For the proposed project additional 24 nos. of personnel (existing 237 nos.) will be employed. 1 CHAPTER-2 PROJECT DESCRIPTION 2.1 TYPE OF PROJECT M/s. Shree Maroli Vibhag Khand Udyog Sahakari Mandli Ltd is an existing sugar mill located, at Survey No.
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