PREFEASIBILITY REPORT
Expansion of existing 30 KLPD to 60 KLPD distillery and Ethanol plant (Molasses/Sugarcane juice based) with Incineration Boiler At Sonarsiddhnagar, Tal. Atpadi, Dist. Sangli, Maharashtra
M/s Manganga Sahakari Sakhar Karkhana Ltd.
MITCON Consultancy & Engineering Services Ltd. Environment Management and Engineering Division Behind DIC Office, Agri College Campus, Shivajinagar, Pune – 411 005, Maharashtra (INDIA) Tel.: +91- 020-66289400/4/6/7
Prefeasibility
Report
Contents 1. Executive summary ...... 3
2. Introduction ...... 3
3.0 Project Description ...... 4
4. Site analysis ...... 8
5. Planning in Brief ...... 9
6.0 Proposed infrastructure ...... 10
7.0 Rehabilitation & resettlement plan ...... 11
8.0 Project schedule and cost estimate ...... 12
9.0 Analysis of proposal...... 12
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1.0 Executive summary
Manganga Sahakari Sakhar Karkhana Ltd. Is located at Sonarsiddhnagar, Tal. Atpadi, Dist. Sangli, Maharashtra. The existing sugar complex consists of Sugar unit (1250 TCD), Distillery Units 30 KLPD and proposes expansion of existing distillery unit up to 60 KLPD.
2.0 Introduction
2.1 Project proponent
Manganga Sahakari Sakhar Karkhana Ltd. is a registered under the Companies Act, 1956 with Identity Number- San/PRG/ (A)-5 dated 25.11.1981. Its mailing address is Sonarsiddhnagar, Tal. Atpadi, Dist. Sangli, Maharashtra. India.
Its Board of Directors is as follows-
Mr. Rajendra Babasaheb Deshmukh, Chairman Mr. Bhagvan Pralhad More, Vice Chairman Mr. N M Mote, Managing Director
Chairman of the Board of Director is a most experienced person. Factory has already appointed a technical / managerial team of highly qualified engineers, contract & arbitration experts, agricultural officers and managerial personnel, for implementation and operation of the captioned integrated project.
To make the venture commercially viable and financially profitable, the capacity of the Distillery plant expansion is decided.
The suitability of the soil, increased irrigation facilities, and previous experience of the farmers in cane growing will be helpful in developing the required area for cane plantation.
2.2 Need of the Project
Alcohol has assumed very important place in the country’s economy. It is vital raw material for a number of chemicals. It has been a source of large amount of revenue by way of Excise Duty levied by State Government. Ethanol has a potentiality as fuel in the Form of “power alcohol” for blending with petrol in the ratio of 20:80. This trend is continuing and will
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2.5 Employment generation due to project
The total direct employment potential of the proposed expansion is about 55 people. However, the Commencement of this industry will create direct and indirect employment opportunities to more than 500 persons in terms of factory employment, transportation, vehicle maintenance, petty shops etc.
3.0 Project Description
3.1 Type of the project
The proposed project mainly to expand the capacities of distillery from 30 KLPD to 60 KLPD along with incineration type boiler for achieving Zero Liquid Discharge (ZLD) for the entire complex.
3.2 Location of the project
The existing and proposed distillery will is in Gat. No. 106. 107 village, Tal. Atpadi, Dist. Sangli, Maharashtra. For the present study, an area covered in 10 Km radius from the project location has been considered and marked as per the guidelines. The study area lies between Latitude – 17.446160° N & Longitude – 74.956840° E Project site and the 10 km radius study area falls in the survey of India Toposheet no. 47 K/14, 47 K/15 , 47 O/2 and 47 O/3.
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Figure 1: Map showing general location of the proposed project
3.3 Details of the alternate sites
Proposed project will be located in existing sugar factory premises. Hence, no alternate sites have been examined.
3.4 Size and magnitude
Size and magnitude of the project is given in Table 1.
Table 1: Project in brief
Sr. Particulate Description No. 1. Name of the proponent Manganga Sahakari Sakhar Karkhana Ltd. 2. Project Expansion existing 30 KLPD to 60 KLPD distillery and Ethanol plant (Molasses/Sugarcane juice based) with incineration Boiler
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Sr. Particulate Description No. 3. Location of the project Sonarsidhnagar, Tal- Atpadi, Sangli, Maharashtra State 4. Land requirement For proposed expansion 10 -12 Ha Total industrial activity area is 40 Ha 5. Proposed Product Molasses based distillery / Ethanol Plant (60 KLPD) - R S & IS / Fuel Ethanol :60 KLPD - Fusel oil: 0.18 KLPD 6. Operation days Molasses/Sugarcane juice based distillery / ethanol : 330 days/ annum 7. Raw materials # Raw Material Unit Qty For total expanded Molasses based distillery / Ethanol Plant (60 KLPD) capacity 1 Molasses (FS- 42%) TPD 240 2 Nutrient kg/D 60 3 TRO Kg/D 120 4 Sulphuric acid Kg/D 90 8. Total water requirement Total fresh water requirement for proposed expansion i.e. expanded 30 KLPD distillery is 300 m3/d. from Nimbode irrigation Tank 9 km 9. Electricity requirement 2 MW (including auxiliary steam requirement for (Operational) incineration boiler based cogen plant of 2.5 MW capacity) 10. Steam Total steam requirement for integrated project, 18-20 TPH 11. Fuel Concentrated spent wash : 240 Cu. M/day Imported Coal : 67 TPD 12. Boiler Incineration Boiler – 23 TPH – For 60 KLPD Molasses based Distillery / Ethanol Plant 13. DG D.G. Set (250 KVA) 14. Effluent treatment Distillery units: Spent wash concentration in multiple system (capacity) effect evaporator system and then mixing with support fuel as coal or Bagasse or combination and utilization as fuel in the boiler, for achieving Zero Liquid Discharge (ZLD). 15. Man power During Construction: 50-80 Nos. During Operation : 55 Nos. 16. Total project cost Rs. 80.36 Cr. 17. Total cost for EMP Rs.~ 40 Cr.
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3.5 Process description
Molasses/Cane Juice Based Distillery (60KLPD)
3.7 Resource Optimization / recycling and reuse
Excess condensate from sugar factory will recycled back in the process. Spent wash generated during the process of distillation will be concentrated in multiple effective evaporators and then it will be incinerated in spent wash fired boiler. The condensate generated during the process of Multiple Effective Evaporators will be reused in the process consequently decreasing the net water requirement.
3.8 Availability of Water
The total water required for the expanded 30 KLPD distillery is 300 CMD and it will be taken from Nimbode irrigation Tank 9 km. Permission from the same is available with factory.
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3.9 Quantity of waste generated
Wastes generated during whole process are
Process condensate- recycled back in process and cooling tower makeup Spent lees- recycled back in process and cooling tower makeup Boiler and cooling tower blow down- Sugar ETP/Gardening Concentrated spent wash – Incineration boiler
3.10 Schematic representation of the feasibility drawing which give information of EIA purpose Molasses/sugarcane juice based distillery 60 KLPD)
Molasses based Distillery: 5(g) Cat. A (All molasses based distillery)
ToR application (Form I) & Pre- feasibility study To MOEFCC 4. Site analysis
4.1 Site connectivity
Details of connectivity towards proposed site is given below
Road SH- 136 Atpadi- Pandharpur- Top state highway in W Railway Railway Station: Sangola 25 km in E Air Airport Solapur Airport 105 km & Kolhapur Airport 115 km Nearest town/city Atpadi 2.2 km I W 4.2 Land form, land use and land ownership
The proposed project will be located in existing sugar factory premises and land is for industrial use. The total 84.46 Ha. Land is in possession with management. Total Area under industrial activity – 40.0 Ha. For Proposed expansion 10-12 ha.
4.3 Topography
The topography of the land is flat with some undulations. Topo-sheet is attached separately with ToR application.
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4.4 Existing land use pattern
Existing land is vacant plot and it is under for industrial purpose. There is no forest land, wild life sanctuary and an eco-sensitive area comes in 10 km radius of the proposed project location.
4.5 Existing Infra structure
Proposed plant will be located in the existing sugar factory premises. Hence the maximum resources like water, power and road connectivity are available.
4.6 Soil classification
The soils of the region are derived from the Deccan trap. The soil of the area is fertile black.
4.7 Climatic condition
The climate of Sangli is characterized with hot summers and dry winters. The cold season which last to February, the air is dry and invigorating. It is too hot in summer. Summer highest day temperature is 40 0C.The Mean Maximum and Minimum temperature of Atpadi Taluka is 38.00C & 22.50C respectively.
4.8 Social infrastructure available
Social infrastructure like community center, hospital, and electricity is available in the area.
5. Planning in Brief
5.1 Planning Concept
The proposed project is an integrated sugar industrial complex with facilities to manufacture white sugar, power, and alcohol/ethanol.
5.2 Population projection
The skilled manpower required for operation of sugar and co-gen power plants will be easily available from surrounding areas. Factor will require additional 55 people for operation of proposed expansion. Manpower requirement during construction will be 50. Skilled and
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5.3 Land use planning
Land use planning of the proposed project is given below,
Total Plot Area – 84.46 Ha Total Industrial activity are-40 Ha Proposed 30 KLPD expansion area 12 Ha. Proposed green belt area is 4 Ha.
5.4 Amenities/Facilities
Facilities like canteen, rest rooms, and recreation facilities will be provided for the proposed project.
6.0 Proposed infrastructure
6.1 Industrial area
The major plant & machineries required for the proposed project are Fermentation section, Distillation section, Steam condensers, Air compressor, Incineration Boiler, Storage section, Multiple Effect Evaporation Section, Raw water treatment plant, Fire protection equipment’s, Laboratory instruments, Condensate polishing unit, Electrostatic precipitator, etc.
6.2 Residential area
Facilities like canteen and rest room will be provided in the proposed project. Local labor from nearby villages will be hired in project activity.
6.3 Green belt
Proposed greenbelt area is around 4 Ha. (33% of total proposed distillery area) of green belt will be developed in proposed project premises.
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6.4 Social Infrastructure
Factory will identify the need of the villagers and execute the CSR activity.
6.5 Drinking water management
Drinking water will be supplied through with proper water treatment system.
6.6 Sewerage system
Existing domestic waste water (sewage effluent) is treated through septic tank through soak pit. This is best done traditionally by providing a sewage treatment plant.
6.7 Industrial waste management
The spent wash generated from distillery unit will be concentrated in Multiple Effect Evaporator system to concentrate effluent up to 55 to 60 percent solids. Then concentrated Spent wash and it will be incinerated in Boiler using coal as supplementary fuel to generate power simultaneously achieving achieve zero discharge. It is proposed to store concentrated spent wash during emergency and repair & maintenance of boiler unit. The spent wash storage capacity will be maximum 15 days. It will be made impervious Pucca lagoon.
6.8 Solid waste management
Spent oil and grease mixed with bagasse & burnt in boiler Yeast sludge mixed with spent wash and incinerated in the boiler or used as manure. Ash generated will be given to brick manufacturers.
6.9 Power requirement
Total power required of proposed expansion will be 2.0 MW.
7.0 Rehabilitation & resettlement plan
No rehabilitation or resettlement plan is required as proposed plant will be located in the existing sugar factory premises.
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8.0 Project schedule and cost estimate
The total cost of the project is estimated about Rs. 80.36 Cr. The project cost estimates include all expenses to be incurred towards the entire project for Land &land development, civil, building / structure, plant & machinery, preliminary & pre-operative and other expenses, contingencies, plant & machinery, margin money of working capital. Environment management cost for the proposed project will be around 40 cr.
9.0 Analysis of proposal Strength
Raw materials (Sugarcane, grains) are available in Tahsil/District. Surrounding areas good Agro –climatic zone.
Area comes under traditional Cane & cereals growing area.
Good Market potential in State in general and in India particular.
Treated as priority sector project
Government appreciates this venture which is in rural backward area/region Weakness
Medium sugar recovery compared to western Maharashtra
Occasionally may not be able to pay optimum price to the farmers in the initial years as compared to existing well established units in Kolhapur region. Opportunities Bringing an Integrated Sugar Complex project for the benefit of farmers of the surrounding area Use of waste residuals for downstream benefits Benefits Proposed project will help to increase the socio-economic status of the local people as well as provide the stability to the existing sugar factory. Further it helps to uplift the rural mass. The industry will be located in the rural backward region of the state and has a good scope for development of sugarcane with suitable climatic conditions and assured source of underground and surface water. At present there are few sugar industries in the region. Sugarcane cultivated in the region is presently transported through 30 to 60 km. As compared to other crops sugarcane cultivation gives higher economical returns to the farmers. There is good potential to develop more than 20,000 hectares of sugarcane
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Report cultivable land in about 20 km distance from the proposed site. Hence, with the proposed industry more agricultural land would be brought under sugarcane cultivation and it benefits the farmers in the local region. The establishment of the integrated sugar industry will thus meet the national interest of economic power and food through sustainable development. The beneficial impact of proposed factory plant on the civic amenities will be substantial after the commencement of the project activities. The basic requirement of the community needs will be strengthened by extending educational facilities, health care, building, and strengthening of existing roads. The living standards of the nearby villages will be improved. The construction of new roads and improvement in existing roads in the influential area will enhance the transportation facilities. With improved transportation facilities, there is always scope for development.
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