PREFEASIBILITY REPORT For

PROPOSED EXPANSION

1) In Distillery (Proposed 90 KLPD) 2) In Sugar Factory (2500 Existing + 5500 Proposed = 8000 TCD) 3) In Co-Gen plant (Proposed 35 MW)

By

M/s Athani Sugars Ltd. Unit III

At/Post Shewalewadi, Tal-Karad, Dist-Satara State: Maharashtra

INDEX

SR.NO. CONTENTS PAGE NO.

1 Introduction 3

2 Justification 3

3 Location 4

4 Resources 5

5 Process 6

6 Pollution Control 9

7 Background Study 11

8 Safety 12

9 Benefits 13

10 EIA Structure 13

11 Conclusion 13

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1. INTRODUCTION M/s Athani Sugars Ltd. (ASL) is desirous to expand its unit at Village Shewalewadi, Tehsil Karad, Dist. Satara, Maharashtra. thus-

# Production Unit No. Cat Unit Existing Additional Total 1 Distillery 5(g) A KLPD 0 90 90 2 Sugar 5(j) B TCD 2500 5500 8000 3 Co-Gen Power 1(d) B MW 0 35 35

The Notification no. S. O. 3067(E) amended on 1st December 2009 h as covered these types of industries under its entry shown above. With Screening it is necessary for M/s Athani Sugars Ltd. (ASL) to approach Ministry of Environment and Forests (MoEF), New Delhi for Environmental Clearance for all these three projects. This Pre- feasibility Report is prepared for forming a framework for EIA study, Scoping and finalizing the Terms of Reference.

Form I, as is prescribed by the said Notification is duly filled up and submitted. This Pre- feasibility Report is an accompaniment to the same. The Form I contains details regarding Justification of the project, Nearby Land Use, Resources, Process, Pollution Control, Aesthetics, Risk Involved, Consequent Developments and Environmental Sensitive Issues.

The working days in a year for sugar will be 180 days, for Co-gen 210 days and for distillery 330 days.

2. JUSTIFICATION Molasses is one of the waste products produced from sugar factory. Environmentally speaking it has very undesirable & risky properties. However, it is possible to put it to useful purpose by producing Alcohol. Molasses can be used as raw material for distillery. The resultant alcohol has various uses in chemical industry, pharmaceutical industry and as Ethanol. The liquid effluent however, is highly polluting though not poisonous or toxic. This effluent, (Spent Wash) is passes through Multi-effect Evaporator (MEE) for concentration. This concentrated spent wash is burned in the incinerator boiler along with coal. Ethanol is being used as automobile fuel in these days & hence new distillery unit is justifiable. Distillery unit needs the raw material as molasses & this can be fulfilled if we have a sugar factory of our own. This area has very good soil & availability of water. The people are enthusiastic about such crop & hence sugar factory is justifiable. Sugar factory will also produce baggasse, this baggasse has fuel value. We can convert this in power & steam. Power will be useful to our units & colony for captive consumption & surplus can be given to State, as this State has short in power supply. Thus, spent steam at its tail end can still be used for production of sugar & the alcohol. Thus, a power plant is justifiable.

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Old Method

New Method

Waste Exchange Oriented Unit (WEOU)

3. LOCATION The proposed location is in Village Shewalewadi, Tehsil Karad, Dist. S a t a r a , in State Maharashtra. This candidate site is in premises of Sugar mill, so that there is less transportation of Molasses and press mud. The land requirement for proposed industry unit is already in possession and is not prime Agricultural Land. This is flat Land whereby Cutting-filling will be nearly balanced and there will be No/Low Borrowing from Nature. Within 10 km Influence Zone, there is no Tropical Forest, Biosphere Reserve, National Park, Wild Life sanctuary and Coral Formation Reserve. The Yevati dam (1 Km), City Karad (25 Km), R a i l w a y station and Tehsil Place Karad (32 Km), District place Satara (78 Km), National Highway (18 Km) and State Highway ( 6 km) is at a sufficient, s a f e distance. The Clearance is obtained from Local Grampanchayat and hence will have public acceptability.

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4. RESOURCES ASL proposes to expand to 8000TCD Sugar Plant and install new molasses based 90 KLPD distillery, & 35MW Cogeneration Plant. (A) The capacity of the proposed distillery totally shall be 90 KLPD. For this the main and

sole raw material is molasses. The yeast brings about the change. Some chemicals in small quantity are used for supporting propagation of the yeast and help in fermentation. Thus,

# Raw Material Quantity/day Unit

1. Molasses 336 T

2. Sulfuric acid 180 lit

3. Nutrients N, P 90 Kg

4. Turkey Red Oil (TRO) 180 Kg

(B) The capacity of the proposed sugar mill t o ta l l y shall be 8 0 00 TCD. For this the main

and sole raw material is sugarcane. Some chemicals in small quantity are used for supporting. Thus,

# Raw Material Quantity/day Unit

Existing Additional Total

1. Sugarcane 2500 5500 8000 T

2. Sulphur 0.92 2.01 2.93 T

(C) Athani Sugars Ltd. proposes to install a Bagasse based 35 MW Co-gen power plant, which

requires following resources. For this the main raw materials are baggasse and high quality water. Some chemicals in small quantity are used for supporting. Thus,

# Raw Material Quantity/day Unit

1. Baggasse 1900 T

In addition to the raw material, utilities are also required. These are: Power: Need 2500 KW. Available through Govt. Electricity Board and own

generation. Man Power: Staff, skilled and unskilled totally 640 persons will be required, and

will be available. For essential people from Safety, Environment and production point of view, a small colony will be provided in vicinity,

Water Need is a b o u t 1480 cum/d and shall be met partly from Yevati dam (1 Km away)and partly by recycle.

Molasses Storage Tanks (2 + 2 = 4) of 4500 MT capacities each. Alcohol will be stored in steel tanks with dyke walls. Sugar will be stored in separate sugar godowns and for other materials, warehouses

provided. Building materials: This is not a heavy construction, and majority is in fabrication

from Mild steel structural. The orientation is so kept as to balance nearly the cutting and filling. The small requirement is available systematically. The construction -erection time will be small and will be done in daytime. Labor camp

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is not necessary. Total Cost for project presently is Rs. 49 Crores and proposed is 378 Crores.

Thus all the resources are available and will be used economically and judiciously.

5. PROCESS

(A) Distillery – This is a simple three step process namely molasses preparation, fermentation and distillation. The standard flow sheet as will be adopted can be given as -------

For the sake of eco-friendly considerations continuous fermentation and multi- pressure

distillation will be practiced. The CO2 will be scrubbed in water and the water that entraps escaping alcohol fumes will be recycled for molasses preparation.

(B) Sugar Unit –

ASL has existing 2500 TCD cane crushing capacity. Now they propose to expand by 5500 TCD capacity, thus total cane crushing capacity of the sugar factory after expansion will be 2500 + 5500 = 8000 TCD. The peculiarities of manufacturing process are as follows, This is a simple three step process namely Cane milling, Evaporation and Crystallization. The standard flow sheet as will be adopted can be given as

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Most of the sugar factories in India follow double sulphitation process and produce plantation white sugar.

The major unit operations are shown in figure these are 1. Extraction of juice 2. Clarification 3. Evaporation 4. Crystallization 5. Centrifugation

1. Extraction of Juice The sugarcane is passed through devices like knives for cutting the stalks in to chips before being subjected to crushing in a milling tandem comprising 4 to 6 three roller mills. Fine preparation with its impact on final extraction, is receiving special attention & shredders & particularly the fibrizers are gaining popularity. The mills are of modern design, being equipped with turbine drive, special feeding devices, efficient compound imbibitions system etc. In the best milling practice, more than 95% of the sugar in the cane goes into the juice, this percentage being called the sucrose extraction or more simply the extraction. A fibrous residue called Bagasse; with a low sucrose content is produced about 25 to 30 % of cane, which contains 45 to 55% moisture.

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2. Clarification The dark-green juice from the mills is acidic (pH 4.5) & turbid, called raw juice or mixed juice. The mixed juice after being heated to 65 to 75 0 C is treated with phosphoric acid, sulphur dioxide & milk of lime for removal of impurities in suspension in a continuously working apparatus. The treated juice on boiling fed to continuous clarifier from which the clear juice is decanted while the settled impurities known as mud is sent to the field as fertilizer. The clear juice goes to the evaporators without further treatment. 3. Evaporation The clarified juice contains about 85 % water. About 75% of this water is evaporated in vacuum multiple effects consisting of a succeeding (generally four) of vacuum boiling cells arranged in series so that each succeeding body has higher vacuum. The vapours from the final body go to condenser. The syrup leaves the last body continuously with about 60% solids & 40% water 4. Crystallization The syrup is again treated with sulphur dioxide before being sent to the pan station for crystallization of sugar. Crystallization takes place in single-effect vacuum pans, where the sysrup is evaporated until saturated with sugar. AT this point ‘seed grain’ is added to serve as a nucleus for the sugar crystals & more syrup is added as water evaporates. The growth of the crystals continues until the pan is full. Given a skilled sugar boiler (or adequate instrumentation) the original crystals can be grown without the formation of additional crystals, so that when the pan is just full, the crystals are all of desired size & the crystal & syrup form a dense mass known as ‘massecuite’. The ‘strike’ is then discharged through a foot valve into a crystallizer. 5. Centrifugation The massecuite from crystallizer is drawn in to revolving machines called centrifuges. The perforated lining retains the sugar crystals, which may be washed with water if desired. The mother liquor ‘molasses’ passes through the lining because of the centrifugal force exerted & after the sugar is ‘Purged’ it is cut down leaving the centrifuge ready for another charge of massecuite . Continuous centrifuges may purge low grades. The mother liquor separated from commercial sugar is again sent to pan for boiling and re-crystallization. Three stages of re-crystallization are adopted to ensure maximum recovery of sugar in crystal form. The final molasses is sent out the factory as waste being unsuitable for recovery of sugar under commercial condition from economical point of view.

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(C) Co-Gen Power Plant- –

ASL proposes to establish Co-gen Power 35 MW capacity. The peculiarities of manufacturing process are as follows,

This is a simple three step process namely Water preparation, Steam Generation and Power Generation. The standard flow sheet as will be adopted can be given as

Power generation and Distribution

6. POLLUTION CONTROL

Effluent Treatment Plant:

Stream (A): Sober effluent: The Sober wastewater stream comes from boiler blow down, pump cooling and cooling purging water. Except temperature, it has little other objectionable characteristic. This is can be treated by physico-chemical treatment, lowering the temperature to ambient, giving detention for some time and recycle either for industrial purpose or gardening or using as diluent to moderately polluted waste water before treatment.

Bagasse Cold Air Chimney Feed Water

Boilers Economizer Forced Draft Flue Gas

Induced Draft Air Pre heater

High Pressure Steam

Preparatory Devices

Power Turbine

Exhaust

To Process

Sulphur melting & Centrifugal station

Process Export to Grid

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Stream (B): Industrial moderately polluted wastewater: The Moderately polluted wastewater is the spent lees stream, floor vessel washing which has low PH however no low organic matter. We shall use ETP with UASB technology for this treatment. Treated water can be disposed on land for irrigation or recycled in process. This will also take care of the condensate water post-MEE for treatment and disposal. Stream (C): Industrial highly polluted wastewater: Zero Pollution by Distillery Effluent - Technical Approach

The Industrial wastewater (720 m3) is acidic in pH, has deep color, and has high BOD, COD and TDS. However, it is neither poisonous, nor toxic, nor hazardous, is highly biodegradable, and has good calorific value. It is proposed to treat the effluent employing Evaporation (MEE) and concentration, as fuel & incineration in boiler. Working for 330 days. DISPOSAL Disposal is of predominant importance in total environmental management. Stream (A) The stream of utility water (cooling purging) after cooling is fit for joining stream (B) & can serve as diluents. Stream (B) The stream of industrial effluent of only moderately polluted after full treatment in ETP with UASB technology it is fit for disposal on land for irrigation or for recycle after tertiary. This will also include the condensate from MEE. Stream (C) The stream of industrial effluent of highly polluted type coming after Distillation, Re-boiler and M.E.E. treatment is then converted in concentrated Spent Wash. The Spent wash will be used as fuel in incinerator boiler after mixing it with coal.

The Characteristics of this effluent stream are expected to be:

Characteristics of Effluents

# Parameter (C) Spent wash (A +B) Sober and Moderate 1 pH 4.0 – 4.5 5.5 – 6.5 2 Temperature 90-95o C 45-850 C 3 Color Dark brown Faint 4 Total Solids 125000-137000 1300-1500 5 BOD 50000-55000 500-700 6 COD 120000-130000 1200-2000 7 Quantity CMD 720 139 (82 + 57)

(All Values from serial No. 4-6 are in mg/l)

Domestic effluent: The domestic effluent shall be treated in STP or septic tank and then shall be used for gardening.

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Solid Waste: This is not a big problem. The solid in process generate only as yeast spent residue. This is highly biodegradable.

Waste Treatment Disposal

Canteen Vermi composting Own Garden

ETP Sludge --- Sales

Sweepings Segregation Sales

Garden trash Collection Mulching

Ash Collection Brick kiln

Hazardous waste like empty containers, lube oil etc. will be re-used or sent to authorized re-processor. Air Pollution details

# Source Pollutant In-plant Measures Control Equipment

1 Boiler SPM, CO Dry Baggasse boiler feed ESP & tall stack

2 D. G. Set SO2 As per CPCB norms Stack

3 Fermentation CO2 Tank Covered Scrubbed in Water

4 Anaerobic Digester H2S Closed Roof. No foul smell. --

5 ETP CO2 Closed conduit Fully Aerobic. No cess-pool.

7. BACKGROUND STUDY: This is important part of study. (A) Natural Environment :- We shall conduct this study with sampling as –

# Media Stations Parameters Frequency 1 Ground Water 6 21 1

2 Surface Water 6 23 1

2 Ambient Air 9 5 3 months

3 Ambient Noise 9 2 1

4 Soil 9 15 1

The stations will be selected in all the eight directions from the factory and in 10 km radius. The 10 km study area is shown in Google Image.

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Fig.: Google Image of 10 Km Radius

(B) Manmade environment :- This will include existing land-use, demography, employment, s o c i o - economic

aspects and community development needed and proposed. This will be for entire area both rural and urban in this study zone.

Socio-Economic Status in Influence Zone will include the study of Non- Workers percentage whether high, from the percentage employed population on Agricultural, how far is the scope for other avenues of livelihood like Livestock, Forestry, Fishing, Hunting, Orchards, Mining, Trade Commerce.

Further Out of Total Land what percentage is already under Cultivation and Out of Total Land what percentage is already under Irrigation.

If the land is not likely to support more people, then whether Industrialization is necessary to improve the situation. All this will be studied as cost benefit ratio.

8. SAFETY

Safety and Occupational Health will be dealt carefully. A disciplined approach is natural to this industry. Safety policy will be in place. The unit will be registered under Factory Act and are bound by State Factory Rules. Thus, First aid trained and Fire-fighting trained person will be available in every shift. Safety Officer will be appointed, as also the competent person retained. Where necessary, provisions of other Acts, where required like Petroleum act, Explosive Act, etc. will be obeyed. Fire fighting system is kept as per norms of Insurance Company and CIF.

DMP (Disaster Management Plan) and off-site emergency plan will be in place. Accordingly, Personal protection equipment will be given and use will be insisted. Consulting Physician is retained to attain the factory.

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9. BENEFITS The industry will produce Ethanol which is a vital commodity in the national as well as international market, and which will save foreign exchange. This will not disturb the present land use because our area occupied will be only small % of Influence zone 10 km. Compatible Architecture will be adopted and No Prime Agriculture Land will be put to this industrial use. Trees will be maintained and not razed down. No Rehabilitation is involved. People will get jobs here and some incidental small employment like eatery, canteen, tyre repairs, and garage too will become available to genuine people. This will be beneficial to the society. Due to this project, farmers will get more prices for sugar cane.

10. EIA Study Report The Terms of Reference (ToR) is proposed to be kept identical to what MoEF & CC has recently published (April 2015) for these type of industries.

11. CONCLUSION This project is very necessary in view of producing Ethanol, a useful foreign

exchange saver product which the nation requires as a useful resource for development. This will be accompanied by Sugar and Co-generation power.

The local people have already accepted this industry and further up- gradation for their benefit will be welcome in their area.

The candidate site is suitable from general MoEF expectations. Water, power, raw material, Filler Material and Market is assured and found

available with ease. Full precautions will be taken for Pollution Control, Resource Conservation

and Environmental Protection. This is cost effective and Sustainable Development.

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