PRE-FEASIBILITY REPORT Extension of validity of Environment Clearance letter no. J- 11011/453/2009-IA II (I) dated 24th Nov 2011 for Expansion of sugar capacity from 5,500 TCD to 11,000 TCD, Co-generation Capacity from 39 MW to 64 MW. Distillery Capacity from 35 KLPD to 100 KLPD, ENA Capacity from 20 KLPD to 75 KLPD and establishing 30 KLPD Ethanol and 2 Nos. of 1 MW D.G. sets. AT BELLAD- BAGEWADI, HUKKERI (TAL), BELGAUM ( DIST) -591 305 BY VISHWARAJ SUGAR INDUSTRIES LIMITED. FORMERLY KNOWN AS VISHWANATH SUGAR AND STEEL INDUSTRIES LIMITED Report Prepared By: DR. SUBBARAO’S ENVIRONMENT CENTER ‘ Arundhati’, Opp. Sahyognagar, MSEB Road, Vishrambag, Sangli-416415 Phone: 0233-2301857, (M) 9372109522, 9890992118 QCI-NABET Accredited EIA Consultant Organization Certificate No. NABET/EIA/1619/RA0057 NABL Quality Assurance Laboratory Accreditation Certificate No. TC-6121 i VISHWARAJ SUGAR INDUSTRIES LIMITED, BELLAD-BAGEWADI PRE FEASIBILITY REPORT TABLE OF CONTENTS TABLE OF CONTENTS ............................................................................................................................... i LIST OF TABLES ....................................................................................................................................... iv LIST OF FIGURES ...................................................................................................................................... v 1. EXECUTIVE SUMMARY................................................................................................................... 1 2. INTRODUCTION OF THE PROJECT / BACKGROUND INFORMATION .................................... 4 2.1. Identification of Project and Project proponent ................................................................................ 4 2.1.1. Project Proponent .......................................................................................................................... 4 2.1.2. Project Consultants ....................................................................................................................... 5 2.2. Brief description of nature of the project .......................................................................................... 6 2.2.1. Status of Previous Environmental Clearance of Sugar and Distillery Plants ................................ 6 2.2.2. Consent to Operate of Existing Sugar and Distillery Plants ......................................................... 7 2.3. Need for the project and its importance to the country and or region ............................................... 7 2.4. Demand-Supply gap .......................................................................................................................... 7 2.5. Imports vs. Indigenous products ....................................................................................................... 7 2.6. Export possibility .............................................................................................................................. 8 2.7. Domestic / Export markets ................................................................................................................ 8 2.8. Employment Generation (Direct and Indirect) due to the project ..................................................... 8 3. PROJECT DESCRIPTION ................................................................................................................... 9 3.1. Type of project including interlinked and inter dependent projects, if any. ..................................... 9 3.2. Location with coordinates ................................................................................................................. 9 3.3. Details of alternate sites considered and the basis of selecting the proposed site (particularly the environmental considerations gone into should be highlighted) ................................................................. 16 3.4. Size or magnitude of operation ....................................................................................................... 16 3.5. Project description with process details .......................................................................................... 16 3.5.1. Process Details ............................................................................................................................ 16 3.5.1.1. Sugar manufacturing process .................................................................................................. 16 3.5.1.1.1. Crushing of sugar cane ............................................................................................................ 17 3.5.1.1.2. Juice clarification .................................................................................................................... 17 3.5.1.1.3. Crystallization ......................................................................................................................... 17 3.5.1.1.4. Curing or centrifuging ............................................................................................................. 17 3.5.1.1.5. Drying, grading and bagging .................................................................................................. 17 3.5.1.2. Co-generation Unit (25 + 5MW) ............................................................................................ 18 Page | i VISHWARAJ SUGAR INDUSTRIES LIMITED, BELLAD-BAGEWADI PRE FEASIBILITY REPORT 3.5.1.2.1. Technology Selection .............................................................................................................. 18 3.5.1.2.2. Instrumentation ....................................................................................................................... 19 3.5.1.2.3. Expansion Plan of Co-generation Unit to 64 MW .................................................................. 19 3.5.1.2.4. Boiler Specifications: .............................................................................................................. 20 3.5.1.3. Distillery manufacturing process ............................................................................................ 22 3.5.1.3.1. Flow Sheet (Simplified) .......................................................................................................... 22 3.5.1.3.2. Process of alcohol production: ................................................................................................ 24 3.5.1.3.3. Fermentation section: .............................................................................................................. 25 3.5.1.3.4. Distillation: ............................................................................................................................. 26 Integrated distillation and evaporation section ........................................................................................... 26 Analyzer column cum Degasifying Column: .............................................................................................. 27 Aldehyde Column ....................................................................................................................................... 27 Rectifier Cum Exhaust Column .................................................................................................................. 27 3.5.1.4. Manufacture of Ethanol .......................................................................................................... 27 3.5.1.5. Process of manufacture of extra neutral alcohol ..................................................................... 30 3.6. Raw material required along with estimated quantity, likely source, marketing area of the final product, Mode of transport of raw material and finished product. ............................................................. 31 3.7. Resource optimization / recycling and reuse envisaged in the project, should be briefly outlined. 32 3.8. Availability of water its source , Energy / Power requirement and source ..................................... 32 3.9. Quantity of waste to be generated (liquid and solid) and scheme for their Management/Disposal 32 4. SITE ANALYSIS ............................................................................................................................... 33 4.1. Connectivity .................................................................................................................................... 33 4.2. Land Form, Land use and Land ownership ..................................................................................... 33 4.3. Topography ..................................................................................................................................... 33 4.4. Existing Infrastructure..................................................................................................................... 33 4.5. Soil Classification ........................................................................................................................... 33 4.6. Climatic data from stationary sources ............................................................................................. 34 4.7. Social Infrastructure available ........................................................................................................ 34 5. PLANNING BRIEF ............................................................................................................................ 34 5.1. Planning Concept (type of industries, facilities, transportation etc.) Town