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.
Crushing of Sugar cane
Sugar cane is harvested and dresses in the fields and then supplied to factories
through lorries, tractor‐trailers or bullock carts. Crushing takes place mainly in two
stages; first preparation and then milling. Preparation is done in leveller, cutter and fibrizer. The prepared cane is then crushed by passing through 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.
Juice Clarification
The weighed quantity of juice is primarily heated to 70‐75oCin juice heaters and then
treated with sulphur and lime. Then the treated juice is again heated to 100‐1020 C in
Mylar Sugars Ltd.,
11 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 evaporate bodies.
The juice of 15o Brix is concentrated in the evaporators to syrup of 60o Brix.
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.
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
massecuite called molasses, is drained out from the centrifuge. The molasses is
weighed and sent to storage tank.
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 50/100 Kgs net, stitched, numbered
and stacked in sugar godown.
Mylar Sugars Ltd.,
12
Process Flow diagram of Sugar industry Mylar Sugars Ltd.,
13 Co‐Generation Unit
Green field bagasse based power plant developing by availing CDM benefits.
Actual crushing capacity of sugar plant will be 455 TCH on 22 hr basis
Average production of bagasse will be 30 % on cane.
Bagasse used for vacuum filter will be 0.6 % on cane and reserved for start up
to stoppages and windage losses will be 0.2 % on cane. Thus the bagasse
available for the steam generation will be 28.27 %
The gross season will be of 180 days.
Captive power consumption for the sugar unit 22 kW/TCH
Existing 120 TPH boiler along with new Boiler of 150 TPH and 125 ata
pressure and matching TG set will be used
Surplus power will be exported during season (180 days) and during off
season (80days) to KPTCL grid of 110 KV level
GCV of mill wet bagasse : 2270 Kcal/kg
Thermal efficiency of boiler on GCV of bagasse : 71 %
Steam to bagasse ratio (120 TPH, 87 ata and 150 TPH, 125 ata boiler): 2.4
Technology Selection
1. Working pressure of boilers are 87 bara and 125 bar‐a with steam temperature
520‐ 545 +/‐5 0C. Such boilers are available and are easy to manage. At this
pressure, the targeted steam consumption and export of power is effectively
achieved.
2. Turbo generating set has been selected to work as double extraction cum
condensing system. The system is so designed to balance the steam demand.
At ultimate capacity a DEC TG set shall be installed.
3. At injection and cooling tower single entry condensers & cooling towers have
been suggested which consumes less water and hence less power and to be
more energy conservative. Power consumption at this station should be
Mylar Sugars Ltd.,
14 around 1.5 KW/T cane by adopting automation of nozzle governing the
condenser.
Instrumentation
. Steam flow‐meter (integrating, indicating & recording)
. Raw water flow meter, DM water flow meter, blow down water flow
meter, return condensate water flow meter of integrating, indicating &
recording type.
. Feed water flow‐meter (integrating, indicating & recording)
. Drum water level (indicating & recording)
. Superheated steam pressure (indicating & recording)
. Multipoint temperature scanner with thermocouple. All points
indicating & recording. (all for steam, feed water, flue gas, air and
furnace temperatures in and out)
. Many draft gauges. (all for fans, flue gas, air and furnace temperature in
and out )
. Oxygen analyser and data logger.
. Pressure gauges 250 to 150 mm dia & isolation valves (steam,
economizer, feed water pumps etc)
. Microprocessor 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)
. Micro‐processor based hooters for trips, low levels, high levels, high
temperatures.
. On line baggase weighing system
Mylar Sugars Ltd.,
15 60 MW/hr Power
Process flowchart of Cogeneration process DISTILLERY SECTION FERMENTATION Molasses, diluted with water to the desired concentration is metered continuously into a single tank fermenter. Additives like 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 Mylar Sugars Ltd.,
16 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 toʹ50% without affecting the fermentation.
Fermented wash passes through a series of hydrocyclones (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 hydrocyclone 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 hydrocyclone and the wash tank protect the separator from erosion damage by removing grit and similar hard particles.
Yeast Recycling: The yeast in the fermented wash is removed as 45 to 55 v/v slurry, and is returned to the fermenter. This feature ensures that a high yeast cell concentration is achieved and maintained in the fermenter. By recirculating grown, active yeast, sugar that would have otherwise been consumed in yeast growth, is made available for ethanol production, ensuring high process efficiency.
Distillation : Clarified or de‐yeasted wash flows by gravity to the propagation vessel No. III, which during continuous production, operates as an intermediate wash tank. From here, fermented wash is pumped to the wash preheater, which uses vapours from the rectifying column to preheat wash. Further heating is done in an exchange of heat with weak wash and spent wash (see flow sheet for primary distillation).
Preheated wash then enters the degassifying column of the distillation section.
Primary Distillation: The CO2 and the degassifying section help remove the
CO2 and other non‐condensables entrained in the wash. The wash column is first column in the distillation section. It is also called the analyser. Wash is boiled in this column with steam either supplied as live steam from the boiler (after pressure reduction and desuperheating ) or from a reboiler which Mylar Sugars Ltd.,
17 generates steam by evaporating effluent wash.
Alcohol in wash vapourises and is carried, along with water vapour, to the top of the wash column from where it goes to the rectification column. As wash travels down the analyser, it is progressively ʹstrippedʹ of its alcohol content. At a point in the column, where the alcohol concentration is 0.5 to 1.0 v/v, a portion of the wash is drawn off. This is called weak wash.
Weak Wash Recycling: Weak wash recycling of weak wash helps maintain the desired level of dissolved solids in the fermenter, so that an adequately high osmotic pressure is achieved. Osmotic pressure and the concentration of alcohol in the fermenter, together keep off infection and minimize sugar losses. Weak wash recycling also reduces the quantity of effluent spent wash and reduces the process water requirement of the plant.
Spent wash is the wash from which all alcohol has been removed, this emerges from the bottom of the wash column at about 105 deg C. Some of the heat is recovered to preheat fermented wash entering the degassifying column.
Spent wash may also be passed through a forced circulation reboiler to generate vapours. This concentrates the effluent and reduces the volume further.
Propagation: The propagation section is a feeder unit to the fermenter. Yeast, either Saccharomyeescereviseae or Schizosaccharomyeespombe (the choice being determined by other process parameters, mainly the downstream effluent treatment system) is grown in 3 stages. The first two stages are designed for aseptic growth. Propagation vessel III develops the inoculum using pasteurized molasses solution as the medium. This vessel has a dual function. During propagation, it serves for inoculum build‐ up. When the fermenter enters the continuous production mode, Propagation Vessel III is used as an intermediate wash tank. Propagation is carried out only to start up the process initially or after very long shut‐downs during which the fermenter is emptied.
CO2 Scrubbing and Recovery: The carbon‐di‐oxide produced during fermentation is scrubbed with water in packed‐bed scrubber, to recover alcohol. The water from the scrubber is returned to the fermenter. About Mylar Sugars Ltd.,
18 1.0 % of the total alcohol production is saved by scrubbing the fermenter off gas. In plants where it is desired to recover carbon‐di‐oxide, a part of the wash is drawn into a separate vessel and is aerated there. This external
aeration allows the recovery of CO2 uncontaminated with air.
Fermentation Parameters (Typical): The pH of the fermenter is maintained between 4.0 & 4.8 usually without addition of any acid. The alcohol concentration is maintained between 7.0 & 7.5 % v/v, unless a highly concentrate effluent is to be produced. To reduce the effluent volume, the fermenter is operated at a very high dissolved solids level by increasing the proportion of weak wash recycle. Under these conditions, alcohol concentration is reduced to between 5.5 to 6.0 % v/v.
Conversion of sugar to ethanol is instantaneous, and the residual sugar concentration is maintained below 0.2 % w/w as glucose. This usually corresponds to a residual reducing substances concentration of 2.0 to 2.5 w/w in wash.
All the nutrient elements necessary for yeast growth exist in adequate quantities as impurities in molasses. Occasionally, Nitrogen may have to be supplemented. Defoaming oil (DFO), say Turkey Red Oil is added to the fermenter by an automated DFO dosing system, to control foaming. Usually no other additives are required.
Flexibility: This process accords tremendous flexibility to the operator. Process conditions and plant design can be varied to suit individual requirements of alcohol quality, effluent concentration and characteristics. This unit can give spent wash suitable for use in any effluent treatment process.
2. MULTI PRESSURE VACUUM DISTILLATION:
After fermentation 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, distillation process is employed.
Distillation step consumes a considerable amount of energy and is also a deciding factor in the quality of ethanol produced. Hence, in line with the demand of the industry, efforts have always been to minimize requirement of energy and to Mylar Sugars Ltd.,
19 improve the basic quality of alcohol produced. Ease of operation, reliability, lower down time and flexibility of operations are other parameters considered during the design.
Three basic types of plant are designed: a) One is to produce primary quality of alcohol, usually referred to as ʹRectified Spiritʹ (R.S.) from the fermented wash. Such plants are also referred to as ʹPrimary distillationʹ plants. b) Second is to produce fine quality of spirit usually referred to as ʹExtra Neutral Alcoholʹ (ENA) starting from R.S. Such plants are also referred to as ʹsecondary distillationʹ plants. c) Third is to directly produce fine quality alcohol (ENA) from fermented wash. Such plants are referred to as ʹwash (mash) to ENAʹ plants, where the two steps of primary and secondary distillation are combined. Such plants usually have lower consumption of energy than two separate plants.
Multi‐pressure vacuum distillation system for production of Rectified Spirit /ENA consists of following distillation columns namely 1. Degasifying cum analyzer column ‐ Operation under vacuum 2. Pre‐rectification column ‐ Operation under vacuum 3. Rectification cum Exhaust Column ‐ Operated under pressure 4. Recovery column ‐ Operated under atmospheric 5. Extractive distillation column ‐ Operated under vacuum 6. Simmering column ‐ Operated under atmospheric
Benefits of Pressure Vacuum Distillation: ‐ Following are the advantages of pressure vacuum distillation. Since the analyzer column operates under vacuum, the formation of by‐ products such as acetal may minimize there by improvement in quality of alcohol. Pre‐rectification column ensure removal of sulfur compounds/mercaptans and also reduces load of lower boiling volatile compounds passing on to Rectifier cum exhaust column. The chances of scaling due to invert solubility of certain precipitating inorganic salts are minimized in vacuum distillation. Vacuum distillation requires low steam consumption with reboiler
Mylar Sugars Ltd.,
20 Integrated Multi‐products Concept: ‐
It is now possible to install a distillation system, which can produce different products. In the proposed scheme; the production of fuel ethanol has been considered. This allows flexibility of operation and various products can be manufactured depending on the market demand. This integrated multi‐product system involves less capital investment as compared to independent system.
In this type of system, switching over from one product to another is quite easy and there is no chance of contamination of one product with another. The system can work under multi‐pressure principle with few columns operating under vacuum and few under pressure/atmospheric.
3. Dehydration of Alcohol
Molecular Sieve:
The feed (Rectified Spirit) ,pumped from the storage tanks, Is heated through the heat exchanger by the dehydrated alcohol ,then heated Rs of 93% to 96% is fed to the top of the distillation column.
The liquid passes through the distillation column where ethanol is stripped of. The alcohol free liquid called spent lees is separated and discharged from the bottom of the distillation column and the ethanol stream, with strength of about 96% by volume, is removed as vapor, at the top section of the distillation column and feed to the molecular sieve unit after a super heating about 115°C by steam in the heat exchanger.
Fuel oils are removed from an intermediate point of the column in order to avoid any risk of flooding of the column and feed to the static settling device where are separated from the weak water which are recycled to the column.
The distillation column has an operating pressure of about 160 kPa(A) and is heated with low pressure steam by means of reboiler.
This solution shows following advantages:
Total recovery of steam condensate which is recycled to the steam boiler at high temperature with consequent increasing of the efficiency of the reboiler (higher production of steam per unit of fuel) Mylar Sugars Ltd.,
21 Lower cost for softening of demineralization of raw water to be fed to the boiler as steam condensate does not need any treatment Lower quantity of stillage, potential source of pollution
The super heated ethanol stream removed at the top of the distillation column feeds one of the two sieve beds is now in regeneration mode.
The second sieve bed when in regeneration mode (under vacuum) and receives a small amount of vapour from bed working in over pressure. As soon as regeneration is finished (a regeneration cycle lasts about 5 minutes), an automatic control system changes the operating conditions of the two sieve beds in order to have the first sieve bed in regeneration and the second one in dehydration mode.
The dehydration process releases a vapour ethanol stream with a very small amount of water (500 p.p.m or less), which is condensed in the condensor cooled in the heat exchangers and sent to the storage as dehydrated alcohol. The regeneration process releases a certain amount of absorbed water and ethanol, which are condensed in the condenser and recycled to the column.
Cooling media of the first cooling step of the dehydrated alcohol (condenser) is the regeneration stream recycled to the distillation column and cooling media of the second cooling step of the dehydrated alcohol (condenser) is the fed stock coming from the storage tanks, which is preheated as herein above described. Remaining vapors and liquid are condensed and cooled by cooling water in S & T or P&F heat exchangers. The unit operation is fully automatic and all operations are governed by logics executed by a PLC Control system.
Spent wash treatment ‐
Incineration:
The spent wash which is generated after recovery of alcohol from the distillery is a highly pollutant liquid which will cause great pollution to receiving body like land or water. Hence this needs to be taken care. The latest technology developed to achieve the zero discharge is spent wash incineration boiler. This is a specially designed boiler which will burn the concentrated spent wash along with the coal as supporting fuel. The ratio of this spent wash to coal is 75 : 25.
Mylar Sugars Ltd.,
22 In this specially designed boiler after burning the spent wash we can generate the steam which is required to run the distillery. In turn, we can save bagasse or coal upto some extent. The calorific value of the concentrated spent wash is 1705 K Cal. Hence this special technology helps us in achieving zero discharge of spent wash. The air pollution causing from this boiler is also very minimum and normal bag house filters can be used as air pollution control equipment to achieve SPM <100μgm/Nm3. The ash collected from the bag filters will be utilized as manure.
This technology helps us in generating steam, power and most important is achieving zero discharge of spent wash.
Salient Features of Incineration boiler:
The proposed 32 TPH Boiler has the following features
Capacity Pressure Temperature Qty Type
32 TPH 45 kg/cm2 400 0C 1 70 % concentrated Spent wash and 30 % Coal fired CFBC boiler
The construction of the boiler is such that the fouling potential is minimized through multi‐ pass design. The boiler is designed such that it is easily maintainable. The convective section of the boiler (consisting of Economiser, Superheater and Evaporator) are of vertical tubes. A Steam Coil Air Preheater is provided to preheat combustion air. This is required to Maintain the bed from quenching. Deep Fluidised bed construction to improve combustion efficiency. Fluidised bed combustor ensures complete combustion. Special On‐line cleaning devices are provided.
The boiler will need off‐line cleaning once in 30 days of operation. The cleaning will include the water wall, super‐heater, evaporator and economiser section. The total time required will be 2‐3 days. The cleaning frequency and duration is an estimated one, and will be decided based on the actual operating parameters condition. Mylar Sugars Ltd.,
23
Typical Boiler Schematic
Technical parameters considered for design Sl. No. Description UOM Value
1. Spent wash concentration % solids 55
2. Spent wash quantity‐ concentrated TPD 370
3. Spent wash quantity‐ concentrated Kg/hr 15.4 GCV of spent wash for given 4. Kcal/kg 2000 concentration Approximate Quantity of Support 5. Mt/hr 3.0 ‐ 4.0 coal required 6. GCV of Imported Coal Kcal/kg 5200
7. Minimum ash content in coal % wt / wt 7
Mylar Sugars Ltd.,
24 Gross steam generation @ MSSV 8. Kg/hr 32,000 outlet 9. Pressure at MSSV outlet Kg/cm2(g) 45
10. Temperature at MSSV outlet °C 400 +/‐ 5 Char Coal mixed 11. Start‐up fuel ‐‐‐ with diesel
3.6. Raw material required along with estimated quantity, likely source,
marketing area of final products, mode of transport of raw material and finished products.
Raw Material and Product (For Sugar Plant and cogeneration plant)
Sl. No. Particulars Quantity
01 Sugar cane (MT/d) 10000
02 Bagasse as fuel (MT/d) at 85% of heat 2550
input
03 Coal as fuel (MT/d) at 15% of heat input 180
04 Sulphur (MT per month) 150
05 Lime (MT per month) 600
06 Caustic Soda flakes (MT/month) 30
07 Lubricants (KL/month) (Wheel bearing 15
greases, lubricating oils etc.)
08 OP acid, MT/month 18
Raw material requirement – Distillery Sl. No Raw Material Quantity/120 KLPD Source
1 Molasses 500 MT Own production plus other sugar factories
Mylar Sugars Ltd.,
25 2 Sulphuric Acid 240 to 260 lit Mumbai Market
3 Nutrients N, P 72 Kg Mumbai Market
4 Turkey Red Oil (TRO) 240 to 260 Kg Mumbai Market
3.7. Resource optimization/recycling and reuse envisaged in the project, if any, should be briefly outlined.
The cane sugar factory has unique characteristics for the application of cogeneration
technology. The principal advantages lie in the good fuel characteristics of bagasse
and in the high uses of low‐pressure steam within the plant. In conventional power
plants, most of the heat that is obtained by burning fuel is thrown away in the form
of low‐pressure steam as the steam condenses and heats cooling water. In the sugar
factory, the heat in low‐pressure steam is used to perform such work as juice
heating, evaporation and sugar boiling. During the process steam condenses.
A well‐known option for sugar mills to increase their profitability is bagasse
cogeneration. At present, bagasse is burnt inefficiently in low‐pressure boilers to
raise steam. Cogeneration has long been a standard practice in the cane sugar
industry. With the application of efficient processing and energy management systems, energy from the bagasse, well above the factory needs, is available and can
be exported conveniently in the form of electric power. Application of sugar
cogeneration will displace a part of fossil‐based electricity generation leading to a
more sustainable mix in power generation.
3.8. Availability of water its source, Energy/power requirement and sources
should be given.
Water requirement :
During season: 782 KLD
During off‐season: 3115 KLD Mylar Sugars Ltd.,
26 Distillery: 2166 KLD
Power Requirement
For sugar unit: 9.2 MW
For cogeneration ‐ during season: 4.8 MW
during off season: 7.2 MW
The power requirement will be met through cogeneration unit. DG sets are also provided as a backup
3.9. Quantity of wastes to be generated (liquid and solid) and scheme for their
Management/disposal.
Water and effluent
Sugar cane 10000 crushing Cogen 60 Condensate 6500 Sl No Description Water Condensate Freshwater Recycle/losses Effluent consumption 1 Domestic 16 16 13 2 Process 3600 3600 3096 504 Cooling 1872 1872 1685 187 Boiler feed 1152 461 691 1037 115 DM water 70 70 70 Lab and 5 5 5 washing Total 6715 5933 782 5818 894
During off season
Sugar cane crushing 0 Cogen 60 Condensate 0 Sl No Description Water Recycle/losses Effluent consumption Mylar Sugars Ltd.,
27 1 Domestic 16 13 2 Process 0 0 0 Cooling 1872 1685 187 Boiler feed 1152 1037 115 DM water 70 70 Lab and washing 5 5 Total 3115 2722 390 894 KLD Effluent generated will be treated in the ETP of capacity 1000 KLD and the domestic sewage is disposed to septic tank and soak pit.
Water requirement for distillery
Sl No Purpose Requirement, KLD 1 Yeast propagation 156 2 Preparation of molasses 660 3 Water (as steam) for distillation 270 4 Cooling water for fermentor 180 5 Condenser 900 Total 2166
About 960 KLD of spentwash and 120 KLD of spentlees will be generated. Spent wash will be stored in the impervious storage tank and will be concentrated and used as fuel in the slop fired boiler.
Spentlees will be neutalised and recycled back in the process.
Effluent treatment ‐ Sugar
Design Data and Performance Projections The characteristics of the raw effluent considered for designing the plant having UASB followed by Extended Aeration are as follows; Sl No Parameters Design value 1 Flow 1000 m3/day 2 COD 5000 mg/l 3 BOD 2000 mg/l 4 TSS 800 mg/l 5 Oil and grease 100 mg/l Mylar Sugars Ltd.,
28
It is assumed that the effluent does not contain any inhibitory substance for the biological process. It is also assumed that all other parameters are within acceptable limits.
Outlet Parameters Upon reaching the steady state, the system will produce the following results when operated at 38 ± 2OC under optimum design conditions; Sl No Parameters Design value 1 COD <250 mg/l 2 BOD <30 mg/l 3 TSS <100 mg/l 4 Oil and grease <10 mg/l 5 pH ~7.0
Process Description:
Screen Channel & O&G Trap
The raw effluent from process will comes to screen channel of effluent
treatment plant by pumping . The separation of floating matter from effluent
takes place in screen channel. Further on downstream of screen separation of
floating oil from effluent will takes place in O&G Trap. The oil collected on
top is removed by belt skimmer.
Equalisation Tank (EQT)
Effluent will be received under gravity in the Equalisation Tank from O&G
Trap. Static mixer is provided in this tank for mixing purpose and equalizing
the flow & characteristics variation coming in the raw effluent. Effluent
transfer pumps are provided for this tank to transfer effluent to downstream
buffer tank.
Buffer Tank
Mylar Sugars Ltd.,
29 Effluent comes to buffer tank by transfer pumps at EQT. Part of the treated
effluent from UASBR is recycled back in this tank. Hydrolysis of complex
organic matter present in the effluent takes place in this tank. The
homogenized effluent from Buffer Tank shall then pump into downstream
UASBR for anaerobic treatment of effluent.
Upflow Anaerobic Sludge Blanket Reactor (UASB R)
UASB reactor consists of M.S. fabricated tank consist of feed distribution
network at t he bottom, Sludge blanket at approx. mid height of reactor and
the gas, liquid, solid separator (GLSS structure) at the top of the reactor. In
UASB process the bacteria responsible for digestion of organics are present in
the form of sludge blanket. The bacterial population grows and reside a s
bacterial flocs suspended in the Upflow effluent stream. The bacteria take
upon organic content of wastewater to metabolize it and produce bio gas and
new biomass. UASB reactor operates in the mesophilic range of temperature,
i.e. 36O – 40OC. The pH inside the reactor is usually kept around near neutral
while proper ratio of volatile acid and alkalinity is maintained.
Biogas is collected at the top of the reactor in GLSS structure an d burnt in
flare stack. If biogas utilization is aimed for, biogas‐hand ling units such as
gash older, blower and burners etc. will have to be additionally provided. The
anaerobically treated effluent is collected from the network of gutters and
launder and sent to aerobic treatment units.
Extended Aeration Tank (EAT)
Anaerobically treated effluent from UASB enters into downstream Extended
Aeration Tank. In EAT, microorganisms degrades soluble organics
aerobically. In order to ensure required population of bacteria in EAT, a
requisite Mixed Liquor Suspended Solids (MLSS) is maintained in EAT. To
Mylar Sugars Ltd.,
30 maintain requisite MLSS and Food to Microorganism s ratio (F/M ), the settled
sludge from Clarifier is part of recirculated back to aeration tank. An aeration
consists of surface aerators for providing oxy gen to bio mass and system
mixing of tank content
Secondary Clarifier The mixed liquor from EAT enters in downstream feed
well of secondary clarifier for separation of solids and liquid. The clarifier is a
hopper bottom circular tank equipped with rotating scrapper mechanism. In
clarifier tank, solids get settled & accumulate in bottom hopper by rotation of
scrapper mechanism . The supernatant from the clarifier overflows uniformly
over the peripheral weir and passes through launder for further downstream
treatment. A part of excess sludge from the clarifier is re‐circulated back to
aeration tank while balanced is wasted to sludge drying beds for dewatering
& drying.
MGF Feed Tank & MGF (Multigrade Filter)
The overflow from Secondary Clarifier get collects into MGF Feed Tank. From
MGF feed tank treated effluent feds into Multigrade Filter (MGF) under
pressure. The separation of fine suspended particles takes place into MGF and
outlet gets collects into treated water tank for further storage and disposal.
Sludge Drying Beds
In aerobic digestion the sludge is sufficiently mineralized and does not need any further
treatment before dewatering and disposal. Sludge Drying Beds are provided
for dewatering of sludge on sand & gravel beds and drying of sludge cake by
solar radiation. Sludge Drying Beds are constructed in brick masonry with
gravel bed supporting sand media on them. Beds are also provided with
suitable under drain arrangement to collect filtrate from sludge. T he collected
filtrate is again recycle d back into process.
Mylar Sugars Ltd.,
31
Basic Design Criterion:
Screen Channel
Design Par meter Design Value Unit of Measurement
Design Flow 42 m3/hr Channel Size 2.0 X 1.45 X 1.1 S WD m
O&G Trap
Design Par meter Design Value Unit of Measurement
Design Flow 42 m3/hr Tank Size 16.0 X 3.0 X 1.0 S WD m
Detention Time (Minimum) app. 30 mins
Equalisation Tank
Design Par meter Design Value Unit of Measurement
Design Flow 42 m3/hr Detention Time app. 12 hrs
Volume required 504 m3 Tank Size 13.0 X 13 X 3.0 SWD m
Buffer Tank
Design Par meter Design Value Unit of Measurement
Design Flow 42 m3/hr Detention Time app. 6.0 hrs Mylar Sugars Ltd.,
32
Volume required 252 m3 Tank Size 9.5 X 9 . 0 X 3.0 SWD m
UASB (Upflow Anaerobic Sludge Blanket Reactor)
Design Par meter Design Value Unit of Measurement
Design Flow 42 m3/hr Organic Load 5000 Kg COD /day Kg COD /day Organic Loading Rate 6.0 / m3 Volume provided 840 m3 Detention Time app. 20 hrs
Size of Reactor 13.5 Ø X 6.0 SWD m
Extended Aeration Tank (EAT)
Design Par meter Design Value Unit of Measurement
Design Flow 42 m3/hr Design BOD Concentration 300 mg/l
Design BOD Load 300 Kg BOD / day
MLSS in Tank 3500 mg/l
F/M 0.1 ‐
Volume provided 840 m3
Oxygen Requirement 2 Kg O2/ Kg BOD
BOD Reduction 90 %
Mylar Sugars Ltd.,
33 Outlet BOD Concentration 30 mg/l
Secondary Clarifier
Design Par meter Design Value Unit of Measurement
Design Flow 42 m3/hr Surface Overflow Rate (SOR) 12 m3/day/m2 Surface Area provided 83.3 say 85.0 m2 Size of Tank 10.4 Ø X 3.0 SWD m
Volume provided 260 m3
MGFFeed Tank
Design Par meter Design Value Unit of Measurement
Design Flow 42 m3/hr Detention Time app. 0.5 hrs
Volume provided 21 m3 Tank Size 3.5 X 3 .0 X 2.0 SWD m
Multi Grade Filter
Design Par meter Design Value Unit of Measurement
Design Flow 42 m3/hr Filtration Rate 10.0 m3/hr/m2 Filter dia. 2.5 m
Filter Height (HOS ) 2.0 m
4. Estimated Outlet Characteristics from ETP: Mylar Sugars Ltd.,
34
Tentative percent wise reduction across each stage of treatment
Details Flow COD BOD TSS (mg/l) O & G (m3/d) (mg/l) (mg/l) (mg/l)
Inlet Raw Effluent 1000 5000 2000 800 100 % Reduction in ‐ 0 0 0 85 O&G At the outlet of 1000 5000 2000 800 15 O&G % Reduction in ‐ 75 85 15 25 UASB R Effluent Outflow 1000 1250 300 680 11 from UASBR % Reduction in ‐ 82.5 90 20 20 EAT Effluent Outflow 1000 219 30 544 9 from EAT / clarifier % Reduction in ‐ 0 5 82 5 MGF Outlet Treated 1000 219 29 98 9 Effluent MGF Final Treated 1000 <250 <30 <100 <10 Effluent
Flow meter
Weir and float type of flow measuring device with dial type flow indicator is provided to indicate the flow rate of treated effluent in the gutter
Sampler
A rotating cup type sampler device is provided to collect the composite sample from the gutter carrying effluent.
Cleaning day sump
The tank is constructed of RCC or SSM work. The tank interior is plastered with cement mortar Mylar Sugars Ltd.,
35 Capacity 400 m3
Tank size 12.0 mts X 10.0 mts X 3.6 mts
Free Board 0.6 mts
Laboratory house
It shall have two parts with internal partition walls and independent entry doors,
one for laboratory cum electrical panel (8m X 5 m) and other for storage of chemicals
(4 m X 5 m). Laboratory is to be provided with glazed tiled platforms, two numbers
wash basins, shelves for chemicals, electrification, water and drainage piping and
1000 ltsover head water tank. The laboratory is to be constructed with RCC roof,
polished granite flooring and complete with painting
Floor area of the laboratory house : 12 m X 5m
Sludge pits
Sludge pits are constructed of stone masonry or RCC
Capacity 8 m3
Size of the tank 2 m X 2 m X 3 m
Free board 0.6 m
Hot water cooling tank
The cooling water tank is constructed of stone masonry and is provided with
support pillars for piping and spray nozzles. The cooling tank is provided with
piping and spray nozzle and the same is connected to cooling water pump
Size of the tank 10 m X 10 m X 3.6 m
Sprayers and piping Sprayer nozzles and piping for the cooling tank
Cooling tank size 20 m X 12 m
Capacity of each nozzle 10 m3/hr
Mylar Sugars Ltd.,
36 Cooling water circulation 100 m3/h
Cooling water rate 50 m3/h
Solid waste generated from different operations
Sl No Solid waste Method of collection Mode of disposal
1 Boiler‐ Bottom Mechanical conveyor into
Ash common silo for further
disposal 2 Boiler flyash Mixed in required
3 Lime Grit Mechanical screw proportions and
conveyor used as manure.
4 Press mud Mechanical conveyor
5 Sludge from ETP Sludge drying beds
6 Used oil from DG Stored in leakproof sealed Used as
sets barrels lubricants within
the industry 7 Waste oil residue
from ETP
• Domestic Solid waste (Garbage/ Trash/ garden litters) will be stored in
Garbage collection pits and disposed off by using proper disposal mechanism
• Used Oil generated from the industry will be collected and stored in
barrels/drums and later used as lubricants within the industry.
• Any other solid waste generated from the facility will be disposed off by
using proper disposal mechanism.
3.10. Schematic representations of the feasibility drawing which give
Mylar Sugars Ltd.,
37 information of EIA purpose
As per EIA notification, 2006 and further amendments the proposal is 5(g)‐ 120
KLPD Distillery, 5 (j)‐ 10000 TCD sugar cane crushing, 1 (d)‐ 60 MW cogeneration unit based on biomass (such as bagasse)
4. Site Analysis
4.1. Connectivity
The proposed sugar factory 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.
The proposed site is well accessed by SH – 40, a road from Haveri to
Hoovinahadagali. The nearest airport is situated at 90.3 kms from the factory at
Hubli city. The nearest port is situated at 179 kms from the factory at Karwar. The nearest townships with residential areas are Hirehadagali, Hoovinahadagali,
&Holalu which are 3.6, 17.5 and 18.5 kms away from the plant respectively.
Tumbinakeri Reserved Forest is located opposite to the project site &Herada Block C
Reserved Forest is located at 7.5 Km distance from the project site. The river
Tungabhadra flows at a distance 6.5 Kms away from the proposed site and the reservoir is at a distance of 52 Km from the proposed site.
There are no protected monuments within a distance of 25.0 Km.
4.2. Land form, land use and land ownership.
The site is situated 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
Mylar Sugars Ltd.,
38 4.3. Topography (along with map)
Project site
Map of the proposed project site
Mylar Sugars Ltd.,
39
Aerial View of the Proposed Project Site Showing 10 Kms Radius Demarcation
Mylar Sugars Ltd.,
40
Toposheet with 10 Kms demarcation showing location of the proposed project site (Topo sheets No: 48 N/9, 48 N/13, 48 M/16)
4.4. Existing land use pattern (agriculture, non agriculture, forest, water bodies
(including area under CRZ), shortest distances from the periphery of the project to periphery of the forest, national parks, wild life sanctuary, eco sensitive areas,
water bodies (distance from, the HFL of the river)). In case of notified industrial area a copy of the Gazette notification should be given.
Mylar Sugars Ltd.,
41 As per 2001 census, 84.74% of land holdings are having less than 4ha, which cover
53.04% of the total area. The major crops grown are the cereals with an area 234771ha
where jowar (37.89%), paddy (28%), maize (22.90%, and Bajra (7.9%) are the major
cereals. This follows the cash crops in an area 220646 ha in which other cash crops and cotton are the major crops. Then follows oil seeds with an area of 174943ha in which sunflower as the major crops. Lastly pulses with an area of 33426ha in which
other pulses and gram are the major crops. The net sown area comprises 56.47% of
the total geographical area, in which 15.80% of the area is being sown more than
once. As per the records about 20.40% of the net sown area is irrigated through
surface water source, and about 13.15 of the area is irrigated through ground water.
The surface water irrigation practices is through canals with the total length of 456 kms from T.B. major irrigation project and two medium irrigation projects
(Hagaribommanahalli and Naarihalla) with the other surface water sources like
tanks and lift irrigation. As per the census records, the district has 24055 minor irrigation schemes, of which 2860 pertains to dug wells, 17768 tube wells, 104 surface
water flow schemes and 3322 lift irrigation schemes.
Land utilization pattern of the Bellary District
Sl.No Land classification Area (in Sqkms)
1. Forest 27017
2. Net area sown 459250
4.5. Existing Infrastructure
The proposed site is well accessed by SH – 40, a road from Haveri to
Hoovinahadagali. The nearest airport is situated at 90.3 kms from the factory at
Hubli city. The nearest port is situated at 179 kms from the factory at Karwar. The
Mylar Sugars Ltd.,
42 nearest townships with residential areas are Hirehadagali, Hoovinahadagali, &
Holalu which are 3.6, 17.5 and 18.5 kms away from the plant respectively.
Tumbinakeri Reserved Forest is located opposite to the project site & Herada Block C
Reserved Forest is located at 7.5 Km distance from the project site. The river
Tungabhadra flows at a distance 6.5 Kms away from the proposed site and the reservoir is at a distance of 52 Km from the proposed site.
4.6. Soil Classification
The soils of the district are derived from Granites, Gneisses and Schistose rocks. The
Sandy loam soil mixed with black and grey soil occurs along the stream beds. These
are originated from gneisses and granites. They are permeable and mildly alkaline in
nature. The thickness of the soil varies from 0.2 to 1.00m. The Red soil are the major
type of soil in the district, found mainly at elevated places especially at fringes of
hills due to decomposition of rocks and surrounding granitic and gneissic hills.
These soils are with high permeability and neutral PH. Black soil with high initial
infiltration rate when dry and cracked. On getting wet cracks will close and
infiltration rate will be very low. These are derived from schistose rocks. The Black
soil is found in the prolonged submerged areas and canal command areas having
low Permeability. It is calcareous and mildly alkaline in nature.
Mineral Resources
This district is endowed with rich mineral resources. The minerals include
Limestone, Dolomite Limestone, Gray Limestone, Siliceous Limestone & Thinly
bedded soil / black cotton soil.
4.7. Climatic and Rainfall data from secondary sources
The climate of Bellary district is quite moderate shows dryness in major part of the
year and a hot summer from March to May months where mean maximum
Mylar Sugars Ltd.,
43 temperatures ranges from 23.2°C to 40.4°C. June to September is the southwest
monsoon period where the temperature 19.7°C to 35.1°C, October and November is
the post monsoon retreating monsoon season with clear bright weather with the
mean daily temperature ranges from 14.4°C to 31.1°C. During December to February
weather remains dry and comparatively cool season. The skies clouded or overcast
during southwest monsoon. During October and November some of the depressions
and cyclonic storms originates in Bay of Bengal moving in a westerly to north
westerly direction which passes through the district causing wide spread heavy
rains and high winds. The mean maximum temperature in the district is 40.4°C. and
the mean minimum temperature is 14.3°C (January month). Relative humidity
ranges from 48 to 74% in the morning and in the evening it ranges from 27% to 61%.
The winds are light to moderate with some strengthening in the south west
monsoon.
During October to April, the winds blow from directions between north east and
southeast and are calm in morning. Winds blow southwest and northwest direction
during May to September with an average velocity of 12 kmph. These high winds
combined with higher temperature result in high degree of evaporation to the tune
of 12.5 mm/day in May against a minimum of 5.4 mm/day in the month of
December.
Bellary district receives rainfall from southwest monsoon from June to September
and northeast monsoon from October to December. Overall on an average, there are
43 normal rainy days (1901‐1970), where minimum in Bellary taluk with 32.4 rainy
days, maximum in Sandur taluk with 56.4 rainy days. Actual rainy days recorded
during the year 2005 ranged from 41 to 67 wherein Kudlugi taluk is the minimum with 41 rainy days and maximum is in Sandur taluk again with 67 rainy days. As per
the 1951 to 1970 rainfall data analysis, the precipitation during southwest monsoon
accounts for 60% of the total amount of rainfall and during northeast monsoon it is
24% the remaining 11.62% is sporadic in summer.
Mylar Sugars Ltd.,
44 September is the wettest month in the year. The analysis of the last ten years rainfall
data (1996‐2005) shows that the highest rainfall occurred in Sandur taluk with
752.1mm and the lowest at Bellary with 452mm and over all annual normal rain fall
in the district is 611mm. Again it is proved that south west monsoon contributes 63% of the total rainfall in the district and north east monsoon with 25.36%. Deficiency in rainfall is observed in the four taluks for the last ten years in the range of 2.40%
(Kudlugi taluk) to 26.02% (Bellary taluk). The excess rainfall in the range of 15.41%
(Siruguppa taluk) to 23% (Sandur taluk) was observed.
4.8. Social Infrastructure available
The district is well connected by high ways and other main roads. Fairly good
network of roads exists connecting taluk head quarters with the district head
quarters and hoblis to various taluk head quarter. Total there are 288.60kms of NH,
631.93kms of SH, 1323.30 kms of major district roads and village road length of
1200.65 kms serves as communication system. Added to this the South Central railway line (Hubli‐Guntakal) passes through Hospet and Bellary. Overall 310 kms length of railway roads falling in all the taluks except in Hadagali and Siruguppa
taluks adds the communication network.
Mylar Sugars Ltd.,
45
5. Planning
5.1. Planning concept (type of industries, facilities, transportation, etc.,) Town and Country Planning Development authority classification.
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 proposed site is well accessed by SH – 40, a road from Haveri to
Hoovinahadagali. The nearest airport is situated at 90.3 kms from the factory at
Hubli city. The nearest port is situated at 179 kms from the factory at Karwar. The nearest townships with residential areas are Hirehadagali, Hoovinahadagali,
&Holalu which are 3.6, 17.5 and 18.5 kms away from the plant respectively.
Tumbinakeri Reserved Forest is located opposite to the project site & Herada Block C
Reserved Forest is located at 7.5 Km distance from the project site. The river
Tungabhadra flows at a distance 6.5 Kms away from the proposed site and the reservoir is at a distance of 52 Km from the proposed site.
5.2. Population Projection:
As of 2011 Census of India, with regards to Sex Ratio in Bellary, it stood at 983 per
1000 male compared to 2001 census figure of 969. The average national sex ratio in
India is 940 as per latest reports of Census 2011 Directorate. In 2011 census, child sex ratio is 960 girls per 1000 boys compared to figure of 947 girls per 1000 boys of 2001 census data..Average literacy rate of Bellary in 2011 were 67.43 compared to 57.40 of
2001. If things are looked out at gender wise, male and female literacy were 76.64 and 58.09 respectively. For 2001 census, same figures stood at 69.20 and 45.28 in
Mylar Sugars Ltd.,
46 Bellary District. Total literate in Bellary District were 1,421,621 of which male and
female were 813,440 and 608,181 respectively. In 2001, Bellary District had 980,483 in
its district. Kannada is the major language spoken here
5.3. Land use planning (breakup along with green belt etc.)
Sl No Land Description Area (acres) 1 Factory Raw material storage yard 5.50 Sugar Unit 10.50 Distillery 8.50 Power plant 9.0 Admin, repair shop, lab 3.0 Internal Road 3.0 2 Landscape, garden 21.50 3 Officers and workers Colony 3.0 Total 64 A 5.4. Assessment of infrastructure Demand (Physical & Social).
There will not be any negative effect on the living conditions of people. Due to project activities, the surrounding areas are expected to improve by way of socio‐ economic development due to direct and indirect employment and the project will also lead to supporting utilities by improving business opportunities in the locality.
5.5. Amenities/facilities
Basic amenities and facilities will be provided for all workers working at site.
6. Proposed Infrastructure
6.1. Industrial Area (Processing area)
Sl No Land Description Area (acres)
1 Factory Raw material storage yard 5.50
Mylar Sugars Ltd.,
47 Sugar Unit 10.50 Distillery 8.50
Power plant 9.0
Admin, repair shop, lab 3.0
Internal Road 3.0
2 Landscape, garden 21.50
3 Officers and workers Colony 3.0
Total 64 A
6.2. Residential Area (non processing area)
Housing will be provided for the working staff.
6.3. Green Belt
33% of total area, 21.50 Acres is provided for green belt development
6.4. Social Infrastructure
Good infrastructure facilities seen around Bellary district.
6.5. Connectivity Traffic and Transportation Road/Rail/Metro/Water ways etc
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 proposed site is well accessed by SH – 40, a road from Haveri to
Hoovinahadagali. The nearest airport is situated at 90.3 kms from the factory at
Hubli city. The nearest port is situated at 179 kms from the factory at Karwar. The
Mylar Sugars Ltd.,
48 nearest townships with residential areas are Hirehadagali, Hoovinahadagali,
&Holalu which are 3.6, 17.5 and 18.5 kms away from the plant respectively.
Tumbinakeri Reserved Forest is located opposite to the project site &Herada Block C
Reserved Forest is located at 7.5 Km distance from the project site. The river
Tungabhadra flows at a distance 6.5 Kms away from the proposed site and the reservoir is at a distance of 52 Km from the proposed site.
6.6. Drinking Water Management (Source & Supply of water)
Drinking water is met through Tungabhadra river located at 6.5 kms from the site followed by treatment in the water treatment plant at the site.
6.7. Sewerage System
Domestic sewage is treated in septic tank and soak pit. Industrial effluent will be
treated in the ETP through internal sewer network
6.8. Industrial Waste Management
Effluent generated will be treated in the ETP of 1000 KLD and treated water will be
used within the plant premises.
6.9. Solid Waste Management
Solid waste generated from the industry include Pressmud, ash from sugar industry
which is used mixed in the required proportions and sold as manure. Bagasse
generated will be used as fuel in the cogeneration boiler.
6.10. Power Requirement & Supply/Source
Power requirement will be met through cogeneration
Mylar Sugars Ltd.,
49
7. Rehabilitation and Resettlement (R&R) Plan
7.1. Policy to be adopted (Central/State) in respect of the project affected persons including home oustees, land oustees, and landless labourers (a brief outline to be given).
Not applicable.
8. Project Schedule & Cost Estimation
8.1. Project Schedule
Expansion of a sugar complex to 10000 TCD sugar cane, 60 MW cogeneration unit based on biomass (such as bagasse), 120 KLPD Distillery + 5 MW power from incineration boiler
8.2. Cost Estimates
Rs. 545 Crores as estimated
9. Analysis of proposal (Final recommendation)
9.1. Financial and social benefits with special emphasis on the benefit to the
local people including tribal population, if any, in the area
350 nos, the company provides all necessary basic amenities to the workers of the
industry.
Mylar Sugars Ltd.,
50