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(Sugar 5000 TCD, Co-Generation 29.5 MW, Grain Based Distillery 45KLPD

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(Sugar 5000 TCD, Co-Generation 29.5 MW, Grain Based Distillery 45KLPD 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 2 Prefeasibility Report 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 3 Prefeasibility Report continue in view of the fact that potable liquor has larger revenue generating potential for the Governments. The demand for alcohol will always be there for industrial purposes. Further the use of alcohol in automobile fuel will enhance the demand for alcohol. Other than the above mentioned major requirement, alcohol is also being used in the production of many downstream chemicals including drugs, polymers, plastic, etc. 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. 4 Prefeasibility Report 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 5 Prefeasibility Report 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. 6 Prefeasibility Report 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. 7 Prefeasibility Report 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. 8 Prefeasibility Report 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
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