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PREFEASIBILITY REPORT for MYLAR SUGARS LTD FOR THE EXPANSION OF 3500 TCD SUGAR AND 14 MW COGENERATION UNIT TO 10,000 TCD SUGAR INDUSTRY AND 60 MW COGEENRATION ALONG WITH INSTALLATION OF 120 KLPD DISTILLERY ALONG WITH INCINERATION BOILER TO GENERATE 5 MW POWER at Sy No 241/C3, 158/2, 251/a, 257/1, 248/1, 267/B, 248/B/1b, 263/2a, 269/C, 240/A, 247/A, 241/B, 243/A,247/B, 247/D, 241/C1, 241/C2 of Birrabbi Village, 157/3, 157/1 of Kotihal village, Hoovina Hadagali Taluk, Bellary District PREPARED BY ENVIRONMENTAL HEALTH & SAFETY CONSULTANTS PRIVATE LTD, # 13/2, 1ST MAIN ROAD, NEAR FIRE STATION, INDUSTRIAL AREA, RAJAJINAGAR, BANGALORE‐560 010, Tele: 080‐23012100, Fax: 080 23012111 Email:[email protected]/[email protected] ; www.ehsc.in Mylar Sugars Ltd., 1 1. Executive Summary M/s Mylar Sugars Ltd., have already obtained Consent for establishment for the establishment of 3500 TCD sugar cane crushing, 14 MW cogeneration unit. Now based on the demand, management has decided to expand the sugar and cogeneration unit project to 10000 TCD sugar cane crushing and 60 MW cogeneration unit and 120 KLPD distillery along with 5 MW power by the installation of incineration boiler. Sl.No Items Particulars 1 Objective of the Project Expansion to 10000 TCD of sugar plant with 60 MW Cogeneration unit, 120 KLPD distillery + installation of incineration boiler to generate 5 MW power. 2 Promoters Mylar Sugars Ltd 3 Total Investment , Rs 545 Crores 4 Project location Sy No 241/C3, 158/2, 251/a, 257/1, 248/1, 267/B, 248/B/1b, 263/2a, 269/C, 240/A, 247/A, 241/B, 243/A,247/B, 247/D, 241/C1, 241/C2 of Birrabbi Village, 157/3, 157/1 of Kotihal village, Hoovina Hadagali Taluk, Bellary District 5 Extent of land 64 acres 6 Man Power 350 7 Water demand and for 10000 TCD sugar cane crushing and 60 MW Source cogeneration During season: 783 KLD During off season: 3115 KLD For 120 KLPD distillery: 2166 KLD Mylar Sugars Ltd., 2 8 Power supply The total power required for the proposed project will be 500 kwh – for construction phase from KPTCL During operation: Power generation: 44 MW Power consumption at cogen= 4.4 MW Power consumption at Sugar unit= 10 MW Power export = 29.6 MW During Off season Power consumption at cogen= 4.8 MW Power consumption at Sugar unit= 0.5 MW Power export = 54.7 MW Power requirement in the distillery = 3.0 MW 9 Latitude 14 0 55’ 00.5 “ N 10 Longitude 75 0 47’ 40.1 “ E Mylar Sugars Ltd., 3 2. Introduction of the Project/ Background Information 2.1 Identification of project and project proponent. Sl no Names Designation 1 M.V. Gachinmath Managing Director 2 Ramakrishna Tarikoppada Director 3 Tarikoppada Narayana Reddy Whole time Director 4 Ravi Shashikant Kavatgimath Director 5 Shilpa Ramakrishna Tarikoppada Director 6 Shobha Mahadevayya Gachinamath Director 7 Mahantesh Rajasekharayya Director Choukimath 8 Puranikmath Udyakumar Whole time Director Gangadharayya 9 Anil Kumar Bhagyanaik Banjara Additional Director Mylar Sugar Ltd. is a public limited company proposed to expand the sugar and cogeneration unit to 10,000 TCD sugars, 60 MW capacity cogen power plant, 120 KLPD distillery along with installation of 5 MW incineration boiler. This integrated project will be located at Sy No 241/C3, 158/2, 251/a, 257/1, 248/1, 267/B, 248/B/1b, 263/2a, 269/C, 240/A, 247/A, 241/B, 243/A,247/B, 247/D, 241/C1, 241/C2 of Birrabbi Village, 157/3, 157/1 of Kotihal village, Hoovina Hadagali Taluk, Bellary District. Total land area required is 64 acres of land has been purchased in the name of Mylar Sugars Ltd.,. Total capital investment on the proposed project is Rs. 545 Crores. The nearest town ship with residential area is Hirehadagali, which is at 4.25 kms away from the proposed project site. The commercial & social infrastructure around Mylar Sugars Ltd., 4 the proposed site is considered quite well for setting up the proposed integrated project. The integrated project comprises of a sugar factory for the manufacture of white plantation sugar, thereby making available required bagasse for the cogen power plant. Raw sugar for refinery will be imported. The command area of the proposed sugar mill has excellent irrigation facilities from Tunga‐Bhadra River, availability and potential for sustained cane supply & biomass materials like cane trash etc. And imported coal for operating the Co‐Gen power plant during off‐season. The aggregated capital investment for the integrated project has been estimated at Rs.544.62 crore. 2.2. Brief description of nature of the project. Mylar Sugars Ltd is located at Sy No 241/C3, 158/2, 251/a, 257/1, 248/1, 267/B, 248/B/1b, 263/2a, 269/C, 240/A, 247/A, 241/B, 243/A,247/B, 247/D, 241/C1, 241/C2 of Birrabbi Village, 157/3, 157/1 of Kotihal village, Hoovina Hadagali Taluk, Bellary District. The propose sugar complex is to be developed on a land of about 64 acres. This is flat land whereby cutting‐filling will be balanced and there will be no/low borrowing from nature. The area of operation and cane cultivation is mostly irrigated by lifts, wells, and canals, & Tunga‐Bhadra river is at a distance of 6.5 kms from the site. The climate, soil, rains are favorable for sugarcane growth and sugar cane yield. 2.3. Need for the project and its importance to the country and / or region. The proposed factory is situated in the heartland of intensive sugar cane agricultural area. The site is well situated with Tunga Bhadra river on the North‐West. Mylar Sugars Ltd., 5 The promoter being an agriculturist and a businessman has felt the need for establishment of a sugar factory and now venturing into this project. He also visualized the need to provide employment to the local population and improve the overall economy of the society in the area. After studying the necessity for such a factory and the profitability of the project he decided to establish a sugar factory with Co‐Generation and distillery. The promoter being an agriculturist and a businessman has felt the need for establishment of a sugar factory and now venturing into this expansion project. He also visualized the need to provide employment to the local population and improve the overall economy of the society in the area. After studying the necessity for such a factory and the profitability of the project he decided to expand the Sugar factory with Co‐Generation. 2.4. Demand‐Supply The existing Sugar factories could not crush all available cane from the areas of operation and hence, rest of the sugarcane is being taken to the sugar factories in neighbouring districts of Karnataka and Maharashtra. Presently, the cane grown by farmers are diverting to the sugar factories located in Maharashtra, in this connection farmers are suffering like delay in disposal, less price, less payment etc., Thus, the farmers are facing problems of disposal of sugarcane in 3‐4 seasons. This situation has demanded to need Sugar units at this area. The demand for electrical power has been increasing at a faster pace after the countryʹs economic development the pace speeded up, especially in Karnataka which has been the hub of software services. The effective generation of power has not been meeting the demand and the same trend is expected to continue, especially during the peak hours and summer seasons. Hence, there is good scope for exporting power to the third parties using the state grid through power traders / purchasers. Mylar Sugars Ltd., 6 2.5. Imports vs. Indigenous production Not Applicable 2.6. Export possibility and Domestic / Export markets. Not applicable. Will be used for domestic use 2.7. Employment Generation (Direct and Indirect) due to the project. About 350 no of persons of all categories are working in the industry. 3. Project Description 3.1. Type of project including interlinked and interdependent project, if any. Not applicable 3.2. Location (map showing general location, specific location, and project boundary & project site layout) with coordinates. Mylar Sugars Ltd., 7 10kms radius Toposheet with 10 Kms demarcation showing location of the proposed project site (Topo sheets No: 48 N/9, 48 N/13, 48 M/16) Mylar Sugars Ltd., 8 Proposed Project Site Photographs Mylar Sugars Ltd., 9 Aerial View of the proposed project site (showing salient features) 3.3. Details of alternative sites, considered and the basis of selecting the proposed site particularly the environmental considerations gone into should be highlighted. Not applicable Mylar Sugars Ltd., 10 3.4. Size & magnitude of operation The company proposes to expand a sugar complex to 10,000 TCD cane crushing, 60 MW Co‐Gen, 120 KLPD distillery + 5 MW from incineration boiler. 3.5. Project description with process details (a schematic diagram/flow chart showing the project layout, components of the project etc) should be given. 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 fibre material after extraction of juice from sugar cane, is used as fuel in boiler to produce steam. Steam is used for generation of electric power and exhaust steam is used for evaporation of water in the juice. The flow diagram of sugar manufacturing process is given in figure below. A brief description of the process is given below.
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    TO TO PUNE (PA) LATUR TO Eó®Ò¨ÉxÉMÉ® TO NANDED ROHA 0.000, 191.590(CST) DAUND JN.(DD) PARBHANI JN. ÊxÉVÉɨÉɤÉÉn 267.180(CST) KARIMNAGAR TO ENLARGEMENT AT A C NIZAMABAD MUMBAI ENLARGEMENT AT =º¨ÉÉxÉɤÉÉn HOSAPETE JN. (HPT) 143.261, 0.000(AVC) TORANAGALLU JN. (TNGL) NH 7 BAYALU VODDIGERI OSMANABAD 141.798 (BYO)161.530 175.700, 0.000(RNJP) MARMAGAO HARBOUR TO TO PAPINAYAKANAHALLI (MRH) 111.870 BALLARI CANTT. KURDUWADI JN. (KWV) MIRAJ HUBBALLI JN. (PKL)156.510 DAROJI (BYC) 202.940 376.28(CST) GADIGANURU (DAJ) 181.270 KONKAN RAILWAY MUNIRABAD (MRB) 137.290 (GNR)168.470 BELLARY CANTONMENT (H) VASCO-DA-GAMA 204.100 BARAMATI TO HOSAPETE BYE PASS LINE INDIA (VSG) 108.458 2.510 310.880(CST) KAZIPET JN. BALLARI JN. (BAY) TUNGA BHADRA DAM (TBDM) 5.020 KUDATINI 208.060, 0.000(RDG) KARIGANURU (KDN)188.230 DABOLIM (H) SWR LIMIT XX VERNA (KGW)149.605 174.105 KHED (DBM) 103.384 VYASANAKERI (VYS) 10.300 ºÉiÉÉ®É BIDAR (BIDR) TORANAGALLU 1.658 212.000 SOLAPUR (SUR) ¨ÉänE SWR LIMIT VYASA COLONY JN(VC) NH 9 ¤ÉÒn® 90.780 92.500 BYE PASS LINE TO BHIMA 454.970, 299.440(GDG) 16.218,0.000(SMLI) BALLARI SATARA SANKAVAL GUNTAKAL JN. XX RIVER MEDAK SWR LIMIT MAJORDA JN. (MJO) GUNJI (GNJ) MARIYAMMANAHALLI (H) (MMI) 21.930 BANNIHATTI BYE PASS LINE BIDAR XX (SKVL) 100.391 572.990 ¶ÉÉä±ÉÉ{ÉÖ® XX 109.110 (BNHT) 9.020 HOTGI JN. (HG) 435.730(ROHA/KRCL) HAMPAPATNAM (H) RAMGAD HADDINAGUNDU XX NH 9 470.040, 284.090(GDG) 91.500(LD) (HPM) 33.170 (RMGD) 13.122 (HDD) 214.680 SOLAPUR CANSAULIM TINAIGHAT TO OBALAPURAM CHIPLUN SWR LIMIT SANJUJE- DA- AREYAL (H) 0 (CSM) 95.873 (TGT) 11.640 HUBBALLI YESHWANTH NAGAR (OBM) 15.40 281.900 HUMNABAD XX (SJDA)79.655 SULERJAVALGE (H) (SLGE) 271.520 CASTLEROCK (YTG) 23.992 TPURA XX VALI (H) (SRVX) RANJI RAM (HMBD) 37.207 SURA (CLR) 24.500 HAGARIBOMMANAHALLI SOMALAPU 439.020, 88.210(LD) (RNJP) 23.020 30.860 TADWAL (TVL) 264.180 (HBI) 43.470 (SLM) SOUTH WESTERN RAILWAY Eó±É¤ÉÙ®MÉÒ SECUNDERABAD JN.