Prefeasibility Report
12/12/2016
PRE-FEASIBILITY REPORT Expansion cum modernization of sugar factory capacity from 4800 to 8000 TCD, cogeneration power plant from 22 MW to 45 MW and distillery 30 KLPD to 95 KLPD capacities
Belawadi-Kalamma, Tal.Kagal, Dist. Kolhapur, Maharashtra.
By
Sar Senapati Santaji Ghorpade Sugar Factory Ltd.
Distillery Consultants
Business Brains
Royal Prestige, E-5, 1127, E Ward, Sykes Extension, Kolhapur 416 001, Maharashtra. Telephone No: +91 (0) 231+2529813 Cell No. : +91 (0) 9823139883 Email: [email protected]; [email protected] web site: www.ethanolindia.net
Environmental Consultant
SMS Envocare Limited
QCI-NABET Accredited Consultant Organization
301, Pentagon P3, Magarpatta city, Hadapsar, Pune 411028, Maharashtra. Tel: 020-66801112/3 Email: [email protected] Website: www.smsenvocare.co.in
Expansion cum modernization of sugar unit from 4800 TCD to 8000 TCD along with
cogeneration unit from 22 to 45 MW and distillery unit from 30 KLPD to 95 KLPD
at village Belewadi Kalamma, Tal. Kagal, Dist. Kolhapur, Maharashtra
Prefeasibility Report
Sar Senapati Santaji Ghorpade Sugar Factory Ltd.
1
Content
Sr. No. Items Page no.
1. Executive summary 3
2. Introduction 3
3. Project description 6
4. Site analysis 18
5. Planning in brief 19
6. Proposed infrastructure 20
7. Rehabilitation and resettlement plan 21
8. Project schedule and cost estimate 21
9. Analysis of the proposal 21
Expansion cum modernization of sugar unit from 4800 TCD to 8000 TCD along with
cogeneration unit from 22 to 45 MW and distillery unit from 30 KLPD to 95 KLPD
at village Belewadi Kalamma, Tal. Kagal, Dist. Kolhapur, Maharashtra
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1. Executive summary
Sar Senapati Santaji Ghorpade Sugar Factory Limited (SSSGSFL) is a sugar factory located at
village Belewadi Kalamma, Tal. Kagal, Dist. Kolhapur in Maharashtra State. The present
registered crushing capacity of SSSGSFL is 4800 TCD. In view of sufficient cane availability to
the extent of more than 9-10 lac MT with increased irrigation facilities in the area of
operation from season 2016- 17 and future trends for next five season, SSSGSFL has decided
to carry out modernization cum expansion of sugar plant from 4800 TCD to 8000 TCD along
with expansion of cogeneration from 22 MW to 45 MW and distillery from 30 KLPD to 95
KLPD. All proposed equipment’s of modernization cum expansion along with expansion of
cogeneration project will be commissioned in 2017-2018 season, and technical efficiency
figures considered in Modernization cum Expansion with expansion of cogeneration project
report.
2. Introduction
2.1 Project proponent
Sar Senapati Santaji Ghorpade Sugar Factory Ltd., was registered under the Maharashtra
State Cooperative Societies Act 1960 having registration No. U15421 PN.2011PLC 138600,
dated 04-10-2011. Sar Senapati Santaji Ghorpade Sugar Factory Ltd., is an integrated sugar
mill situated at village Belewadi Kalamma, Tal. Kagal, Dist. Kolhapur at a distance of 70 km
from Kolhapur. The site is about 50 km away from Kagal city towards east direction on
Kolhapur-Goa road in the State of Maharashtra. It is one of the progressive and modern
sugar mills in Maharashtra and was established in the year 2014.
2.2 Nature of the project
The present crushing capacity of SSSGSFL 4800 TCD along with 22 MW cogeneration plant
with 30 KLPD distillery and incineration boiler. Factory proposing modernization cum
expansion project from 4800 TCD to 8000 TCD along with expansion of cogeneration project
from 22 MW to 45 MW and distillery from 30 to 90 KLPD distillery.
2.3 Need of the project and its importance to the country and or region
India was the first to begin with the production of sugar following the process of sugarcane
to extract juice to boil and it to get crystals. India is well known as the original home of sugar
Expansion cum modernization of sugar unit from 4800 TCD to 8000 TCD along with
cogeneration unit from 22 to 45 MW and distillery unit from 30 KLPD to 95 KLPD
at village Belewadi Kalamma, Tal. Kagal, Dist. Kolhapur, Maharashtra
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and sugarcane. The government of India in 1950-51 made serious industrial development
plan and has set many targets for production and consumption of sugar. India is regarded
second after the textile Industry in India as per the agro-processing Industry in the country.
India is the largest sugar consumption and second largest producer of sugar in the world
according to the USDA foreign Agricultural services.
The industry currently has more than 550 operating sugar mill in different part of the
country. Indian sugar industry has always been a focal point for socioeconomic development
in the rural areas. Today nearly 550 million sugarcane farmers and large number of
agricultural labors are involved in sugarcane cultivation and ancillary activities contributing
to 7.5% of the rural population.
Indian Sugar Industry generates power to its own requirement and even gets surplus power
to the grid based on byproduct bagasse. There is even production of ethanol, an ecology
friendly and renewable energy for blending with petrol.
The existing licensed crushing capacity of SSSGSFL is 4800 TCD, which is effected from the
year 2014. Last two years performance of SSSGSFL is tabulated in Table 1.
Table 1: Last two years performance of SSSGSFL
Sr. No. Particulars Seasons
2014-15
1. Cane Crushed (Lac MT) 4.76
2. Sugar Produced (Lac Qtls.) 6.16
3. Recovery % Cane 12.92
4. Molasses Produced (MT) 19585
5. Press-mud produced (MT) 19060
Based on proposed expansion cum modernization programme of the SSSGSFL, the expected
performance in the coming five years is indicated in Table 2. Cane molasses is produced by
SSSGSFL @ 4.50 % on cane crushed based on last two years molasses production. Hence,
future molasses production is also calculated based on previous data.
Table 2: Predicted future five years performance of SSSGSFL
# Particulars
Seasons
2016-17 2017-18 2018-19 2019-20 2020-21
1 Cane to be Crushed (Lac MT) 6.50 12.00 12.00 12.00 12.00
2 Sugar to be Produced (Lac Qtls.)
8.26
15.24
15.24
15.24
15.24
3 Recovery % Cane 12.75 12.70 12.70 12.70 12.70
Expansion cum modernization of sugar unit from 4800 TCD to 8000 TCD along with
cogeneration unit from 22 to 45 MW and distillery unit from 30 KLPD to 95 KLPD
at village Belewadi Kalamma, Tal. Kagal, Dist. Kolhapur, Maharashtra
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# Particulars
Seasons
2016-17 2017-18 2018-19 2019-20 2020-21
4 Molasses to be Produced (MT) 29250 54000 54000 54000 54000
5 Press-mud to be produced (MT)
26000
48000
48000
48000
48000
As per cane availability potential and considering the present sugarcane productivity and
existing area of 24000 hectares under sugarcane; with enrollment of new sugarcane
members and nonmembers will be available for crushing.
In view of the above, modernization cum expansion project from 4800 TCD to 8000 TCD for
SSSGSFL has been considered.
Distillery
The policy of Central Government is to increase percentage of ethanol blending with petrol
from the present 10% to 20% by the year 2017. Therefore, it is important to all distilleries in
the country to increase its ethanol production to meet the demand & supply.
The performance of SSSGSFL is expected to improve in coming few years. To exploit more
benefit from this industrial complex, the management of the SSSGSFL has decided to
modernize and expand its distillery capacity from 30 KLPD to 95 KLPD. For proper and
complete treatment of spent wash after proposed expansion of distillery SSSGSFL
management has also decided to install integrated evaporation followed by multiple effect
evaporation plant followed by incineration system, TG set and process condensate polishing
unit to achieve “Zero Spent Wash Discharge”.
2.5 Demand- Supply Gap and Import V/s Indigenous generation
Indian domestic sugar market is one of the largest markets in the world; in volume terms. It
remains a key growth driver for world sugar, growing above the Asian and world
consumption growth average. Sugar is one of the most important cash crops in the world
and hence there is always a wrestle to control its imports/export.
India, sugar is an essential item of mass consumption and the cheapest source of energy,
supplying around 10 percent of the daily calorie intake. India is the second largest producer
of sugar (16.3 million ton production in 2008 ‐ 09).It, however, ranks 15th in export rankings
(0.23 million ton exports in 2008 ‐ 09) as India is the largest consumer of sugar in the world.
Expansion cum modernization of sugar unit from 4800 TCD to 8000 TCD along with
cogeneration unit from 22 to 45 MW and distillery unit from 30 KLPD to 95 KLPD
at village Belewadi Kalamma, Tal. Kagal, Dist. Kolhapur, Maharashtra
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Raw as well as refined sugar prices plunged this year on expectation that output in Brazil
and India, the second‐biggest producer, will increase.
The world's largest consumers of sugar are India, China, Brazil, USA, Russia, Mexico,
Pakistan, Indonesia, Germany and Egypt. Brazil & India are the largest sugar producing
countries followed by China, USA, Thailand, Australia, Mexico, Pakistan, France and
Germany.
The world consumption is projected to grow to 160.7 MMT in 2010 and 176.1 MMT by
2015. India is predominantly an agro based economy. Sugarcane plays a very vital role in
this agro based economy by providing sugar, the main sweetener used in India. With the
growing demand for sugar, the emphasis has been on increasing sugar production.
In India the annual per capita consumption of white crystal sugar and that of non-centrifugal
sugar is 15 kg per annum and 23 kg per annum respectively. The annual overall consumption
of the centrifugal and non- centrifugal sugar in the country comes to more than 25 million
tons. Thus, there is vast untapped potential for growth in the area of sugar production.
Alcohol/Ethanol
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 on Alcoholic liquors. It has a potentiality as fuel in the
form of fuel ethanol for blending with petrol in the ratio of maximum 26:74.
The world total ethanol production in the year 2015-16 was 117.52 billion liters and major
consumption of alcohol was for fuel purpose. Many countries, including Brazil, USA, Canada,
Sweden and China have already started using anhydrous ethanol for blending with petrol. In
our country, the Central Government has taken a policy decision to start using anhydrous
alcohol (fuel ethanol) for blending with petrol as explained above. Thus, it is expected that
the demand of alcohol for fuel purpose is going to increase in coming years.
Domestic / Export Markets
A huge demand of sugar and huge demand of alcohol is in the national and international
market. Indians by nature have a sweet tooth and sugar is a prime requirement in every
household. Almost 75% of the sugar available in the open market is consumed by bulk
consumers like bakeries, candy makers, sweet makers and soft drink manufacturers.
Expansion cum modernization of sugar unit from 4800 TCD to 8000 TCD along with
cogeneration unit from 22 to 45 MW and distillery unit from 30 KLPD to 95 KLPD
at village Belewadi Kalamma, Tal. Kagal, Dist. Kolhapur, Maharashtra
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Khandsari sugar is less refined and is typically consumed by sweet makers. Gur, an unrefined
form of lumpy brown sugar, is mostly consumed in rural areas, with some quantities illegally
diverted for alcohol production. Greater urbanization & rising standard of living have
sparked of a rising trend in usage of Sugar. Industrial consumption for sugar is also growing
rapidly particularly from the food processing sector & sugar based bulk consumers such as
soft drink and ice cream manufacturers.
Alcohol
Export Possibility
Export possibility for sugar is totally dependent on government’s policies.
2.6 Employment generation (Direct & Indirect)
The total man power required for sugar, cogeneration 80-100 and for proposed distillery
100 Skilled and unskilled.
3. Project description
3.1 Type of the Project
Proposed project is of expansion and modernization of existing sugar & cogeneration power
plant by 4800 TCD to 8000 TCD for sugar, 22 MW to 45 MW cogeneration power plants and
distillery capacity from 30 KLPD to 95 KLPD.
As per EIA Notification dated 14th September, 2006 and its amendment thereof, the Sugar
expansion project comes under category “B”, activity - 5(j) (≥5000 TCD cane crushing
capacity); cogeneration plant expansion is under category “B”, Activity-1(d) (Thermal power
plants) and distillery expansion from 30 KLPD to 95 KLPD is falls under Category “A” activity
5(g) (All molasses based distillery)
Hence, we are putting our combine / integrated expansion cum modernization proposal of
Sugar, cogeneration and distillery to Expert Appraisal Committee (EAC) Ind-II of MoEF&CC
for the grant of ToR.
Expansion cum modernization of sugar unit from 4800 TCD to 8000 TCD along with
cogeneration unit from 22 to 45 MW and distillery unit from 30 KLPD to 95 KLPD
at village Belewadi Kalamma, Tal. Kagal, Dist. Kolhapur, Maharashtra
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3.2 Location of the project
The project site is located at village Belewadi Kalamma, Taluka. Kagal, Dist. Kolhapur at a
distance of 70 km from Kolhapur. Site is geographically located at Long:16°16' 55.00" N, Lon:
74°14' 48.56" E and 685 m above MSL. Location map of the project is given in Figure 1.
Figure 1: Proposed project location map
Figure 1: General location of the project
Sar Senapati Santaji Ghorpade Sugar Factory Ltd.
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Figure 2: Project Layout
Expansion cum modernization of sugar unit from 4800 to 8000 TCD along with
cogeneration unit from 22 to 45 MW and distillery unit from 30 KLPD to 95 KLPD
at village Belewadi Kalamma, Tal. Kagal, Dist. Kolhapur, Maharashtra
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Sar Senapati Santaji Ghorpade Sugar Factory Ltd.
8
3.3 Details of the alternate sites
No alternate sites have been examined, as proposed project will be located in existing factory
premises.
3.4 Size or magnitude of operation
Size and magnitude of proposed expansion is briefed in Table 3.
Table 3: Project information in brief
Sr. No.
Particulate Description
1. Project Expansion cum modernization of sugar from 4800 to 8000 TCD along with cogeneration expansion from 22 MW to 45 MW and distillery from 30 KLPD to 95 KLPD
2. Available land Total plot area : 85 acres Sugar and cogeneration: 33 acres Distillery area: 15 acres Other Misc: 10 acres Green belt area: 27 acres
3. Product Products Existing Total Proposed
Cane crushing 4800 TCD 8000 TCD
Sugar 600 TPD (12.05% on cane)
1000
Bagasse 1368 TPD 2280 TPD
Molasses 192 TPD 307 TPD
Press mud 192 TPD 320 TPD
Power generation 22 MW 45 MW
Pure Rectified Spirit/ Impure Spirit/ENA
30.0 KLPD 95 KLPD
4. Operation days Sugar factory season: 160 day Cogeneration : 330 (Seasonal operational days 160 and off season operational days 170) Distillery: 330 days
5. Sugarcane required 8000 TPD
6. Molasses requirement 562.5 TPD
7. Water requirement Sugar and cogeneration
Existing sugar and cogeneration fresh water requirement: 482 CMD
For expansion Sugar 188 CMD
For expansion cogeneration 1186 CMD (Initial startup)
Distillery
Existing 260 CMD
Expansion 563 CMD for proposed expansion
Expansion cum modernization of sugar unit from 4800 TCD to 8000 TCD along with
cogeneration unit from 22 to 45 MW and distillery unit from 30 KLPD to 95 KLPD
at village Belewadi Kalamma, Tal. Kagal, Dist. Kolhapur, Maharashtra
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9
8. Source of water Chikotra river. Permission is available from Executive Engineer, Kolhapur Irrigation department, Kolhapur
9. Boiler Exiting boiler: 120 TPH X 1 Proposed: 120 TPH X 1 Distillery existing incineration boiler 10 TPH Proposed incineration boiler 20 TPH (2.2 MW TG)
10. TG Exiting TG : 22 MW Proposed TG: 23 MW Distillery incineration boiler 2.2 MW TG
11. Electricity # Particulate Quantity
Season
1 Total power generation 43.070 MW
2 Sugar plant including boiler(New + Old)
8.184 MW
3 Cogeneration plant (New + Old) 3.61 MW
4 Office /Colony / other 0.20 MW
5 Existing distillery and spent wash boiler
0.80 MW
6 Total captive power consumption 12.794 MW
7 Surplus exportable power 30.276 MW
8 Power requirement for distillery 2.2 MW
Off season
1. Power Generation form TG set 22 MW
2. Cogeneration plant 1.96 MW
3. Office /Colony / other 0.20 MW
4. Distillery and spent wash boiler 0.80 MW
5. Total captive power consumption 2.96 MW
6. Surplus exportable power 20.04 MW
12. Fuel- Bagasse
Total (Exiting + proposed) Bagasse balance
1. Bagasse production(28.5% on cane) 97.185 TPH
2. bagasse available for the steam generation 27.5% on cane
93.775 TPH
3. Bagasse used for 120 TPH existing boiler
44.98 TPH
4. Bagasse used for 120 TPH new boiler 42.81 TPH
5. Total bagasse required as fuel for boiler
87.79 TPH
6. Saved bagasse (1.75% on cane) during season
5.985 TPH i.e. 21000 T
Off season
1. Total bagasse saved during the season 21000 T
2. Bagasse used for 120 TPH x 01 nos boiler having 88.25 TPH load (steam to bagasse ratio 2.65)
33.30 TPH
Expansion cum modernization of sugar unit from 4800 TCD to 8000 TCD along with
cogeneration unit from 22 to 45 MW and distillery unit from 30 KLPD to 95 KLPD
at village Belewadi Kalamma, Tal. Kagal, Dist. Kolhapur, Maharashtra
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13. Coal Existing 30 KLPD distillery Coal: 1.25 TPH Proposed 65 KLPD distillery Coal : 2.75 TPH
14. Steam S. No
Particulate Quantity
1. Steam from existing boiler 120 TPH
119.23 TPH
2. Steam from proposed 120 TPH
113.45 TPH
3. Existing and proposed Steam requirement
20 TPH (New 20 TPH and old 10 TPH incineration boilers.
15. Total effluent generation Sugar + Cogeneration Factory Existing effluent generation: 500 CMD Proposed generated effluent: 300 CMD ETP capacity: 800 CMD Distillery Existing effluent generation 288 CMD Existing CPU : 288 CMD Proposed effluent generation 640 CMD Proposed CPU capacity: 640 CMD (Process condensate, blow down, excess condensate Misc.)
16. Effluent treatment system Existing 500 CMD ETP from sugar unit & co-generation power plant is being treated in proposed ETP capacity 800 CMD and treated water is recycled/reused in greenbelt development and ferti-irrigation. Effluent from distillery spent wash generation will be ~ 950 CMD. Generated spent wash will be concentrated in integrated evaporation and burn in spent wash fired boiler.
17. Ash Sugar
Existing bagasse ash generation: 19 TPD (2% on total bagasse consumption)
Proposed bagasse ash generation: 18-19 TPD Distillery
Coal ash from existing distillery: 7.5 TPD (Max 25 % of coal consumption)
Coal ash from proposed distillery: 16.5 TPD
Spent wash ash from existing distillery: 9-10 TPD (Max 15% of spent wash consumption)
Spent wash ash from proposed distillery: 20 TPD
Bagasse and spent wash ash collected from the furnace bottom hoppers can be used as landfill or the high potash
Expansion cum modernization of sugar unit from 4800 TCD to 8000 TCD along with
cogeneration unit from 22 to 45 MW and distillery unit from 30 KLPD to 95 KLPD
at village Belewadi Kalamma, Tal. Kagal, Dist. Kolhapur, Maharashtra
Prefeasibility Report
Sar Senapati Santaji Ghorpade Sugar Factory Ltd.
11
content in the bagasse ash is good manure. Coal ash will be sold to the brick manufacturer.
18. ETP sludge The sludge from primary clarifies, settling tank and secondary clarifier will be sent to sludge drying beds. Sludge will be dried in natural heat of sunlight. The dried cakes will be scrapped off periodically and can be utilized for as manure.
19. Air pollution control measures
Proposed: Electrostatic precipitators Existing: Electrostatic precipitator Proposed Stack height: 85 m Existing stack height: 85 m
20. Man-power For Sugar and cogeneration 80-100 Skilled and unskilled For proposed distillery 100 Skilled and unskilled
21. Total project cost Sugar expansion: 3810.40 lacs Cogeneration expansion: 871.43 lacs Project cost of the distillery : 84.2546 cr.
22. Total EMP cost Sugar proposed: 1.78 Cr. Distillery : 2.05 Cr.
Environment Sensitivity
23. Nearest Village Belewadi Kalamma
24. Nearest Town / City Gargoti 12.0 km Gadhinglaj 12.2 km
25. Nearest National Highway NH-4 (Mumbai- Chennai) 17.31 km towards north east
26. Nearest Railway station Chhatrapati Shahu Maharaj Terminus railway station 46.15 km
27. Nearest Airport Belgavi airport: 62 km Kolhapur airport: 42.67 km
28. National Parks, Reserved Forests (RF) / Protected Forests (PF), Wildlife Sanctuaries, Biosphere Reserves, Tiger/ Elephant Reserves, Wildlife Corridors etc. within 10 km radius
Higher Elevation of Village Murukate 8.30 km is at the end of Eco-sensitive area declared in MoEFCC notification S.O. 2435(E).–4th September, 2015 Latitudes and Longitudes of prominent points on the outer boundary of Eco-sensitive area point number 94, Lat. 74.1853 Long. 16.2414.
29. River / Water Body (within 10 km radius)
Chikotra river : 1.16 km
Expansion cum modernization of sugar unit from 4800 TCD to 8000 TCD along with
cogeneration unit from 22 to 45 MW and distillery unit from 30 KLPD to 95 KLPD
at village Belewadi Kalamma, Tal. Kagal, Dist. Kolhapur, Maharashtra
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12
3.5 Manufacturing process details
A: Sugar and cogenration power plant
B: Distillery manufacturing process details
Fermentation
Weighed & prepared sugarcane
Milling/ crushing
Juice
Juice Clarification
Juice Sulphitation
Syrup boiling
Centrifugation
Crystallizer
Drying
Sugar
Molasses
Bagasse Power
To grid
To factory
Press mud
Mix with boiler ash and use as manure
Distillery
Boiler
Turb
ine
Alternator
Condenser To Feed water
heater/ Cooling Tower
Steam to
Effluent
Alcohol (Rectified Spirit /
Extra Neutral Alcohol)
Dehydration using Molecular Sieve
RS/ENA/TA Used as Boiler Fuel
Concentrated Spent wash
Evaporation in Multi-Effect
Spent Wash Multi-pressure Distillation
Fermented Wash
Molasses, Yeast, water
Expansion cum modernization of sugar unit from 4800 TCD to 8000 TCD along with
cogeneration unit from 22 to 45 MW and distillery unit from 30 KLPD to 95 KLPD
at village Belewadi Kalamma, Tal. Kagal, Dist. Kolhapur, Maharashtra
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13
3.6 Raw material requirement
The raw material requirement is given below,
Table 2: Raw materials
Sr. No. Raw material Existing Proposed
1. Sugarcane 4800 TCD 8000 TCD
2. Lime 6.72 TPD 11.2T
3. Sulphur 1.92TPD 3.2 TPD
4. Molasses 192 TPD 320 TPD
5. Coal 1.25 TPH 2.75 TPH
3.7 Resource Optimization / recycling and reuse
Required water source is Chikotra River. There is no ground water extraction. Waste water
generated in sugar and cogeneration power plant will be treated in aerobic ETP and the
treated effluent will be used for irrigation purpose. Water will be recycle and reuse at each
possible. Effluent generation from distillery will be treated in condensate polishing unit;
treated waste water will be recycled in process. Spent wash will be concentrated in
integrated evaporation and burned in spent wash fired boiler.
3.8 Project requirement
3.8.1 Availability of Water
Existing water requirement of sugar and cogeneration plant is water requirements for the
proposed project will be met from Chikotra River. Water extraction permission for the same
is available. A water storage tank is at the place to ensure adequate water supply. Efforts
will be taken to minimize & conserve water.
3.8.2 Power requirement
Total power requirement for the existing and proposed plant will be 12.794 MW (sugar,
cogeneration, existing distillery boiler and other colony etc.).Total power generation from
existing and proposed cogeneration power plant will be 43.070 MW. Thus the cogeneration
plant will export 30.276 MW power. Total power requirement for distillery will be 2.2 MW
Expansion cum modernization of sugar unit from 4800 TCD to 8000 TCD along with
cogeneration unit from 22 to 45 MW and distillery unit from 30 KLPD to 95 KLPD
at village Belewadi Kalamma, Tal. Kagal, Dist. Kolhapur, Maharashtra
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3.8.3 Steam balance
S. No Particulate Quantity
Steam Generation
1. Steam generation from existing boiler 120 TPH 119.23 TPH
2. Steam generation from proposed 120 TPH 113.45 TPH
Steam Consumption proposed
1. H.P. heater II 10.20 TPH
2. H.P. heater I 9.00 TPH
3. Sugar plant process 88.00 TPH
4. De-aerator 06.10 TPH
5. Total 113.3
Steam Consumption existing
1. H.P. heater II 10.71 TPH
2. H.P. heater I 8.73 TPH
3. distillery operation 8.00 TPH
4. Sugar plant process (34.5% on cane) 64.72 TPH
5. De-aerator 6.49 TPH
6. Extracted steam 20.52 TPH
7. Total 119.17 TPH
3.8.4 Boiler details
S. No.
Boiler Capacity TG set capacity Fuel type Stack height (m)
1. Existing sugar & Cogeneration boiler
120 TPH 22 MW(Condensing)
Bagasse 85
2. Proposed boiler for expansion of sugar & cogeneration
120 TPH 23 MW (Back pressure)
Bagasse 85
3. Existing distillery spent wash fired boiler
10 TPH -- Concentrated spent wash and coal
-
4. Proposed new spent wash fired boiler
20 TPH 2.2 MW Concentrated spent wash and coal
-
3.9 Quantity of wastes generation
3.9.1 Liquid Waste Generation
The existing crushing capacity of factory is 4800 TCD and generation of effluent is about
500 CMD. The existing effluent treatment plant is suitable for treatment of waste water
Expansion cum modernization of sugar unit from 4800 TCD to 8000 TCD along with
cogeneration unit from 22 to 45 MW and distillery unit from 30 KLPD to 95 KLPD
at village Belewadi Kalamma, Tal. Kagal, Dist. Kolhapur, Maharashtra
Prefeasibility Report
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15
of 800 CMD. After segregation of cooling water & condensate water, the quantity of
sugar factory effluent to be treated during the sugar factory season is about 800 CMD.
Considering proposed quantity of effluent, it is proposed to treat through existing
aerobic treatment. The treated effluent will be useful for irrigation purpose.
Molasses is effluent generated from Sugar industry. This is being/will be used as raw
material in distillery for alcohol production.
Aqueous discharges arise from cogeneration sources includes cooling tower blow down,
sluice water from the bottom ash handling system, boiler chemical cleaning solutions, ion
exchange regeneration solutions from the dematerializing water plants, boiler blow
down, sewerage system discharges from buildings and plant floor drains.
Blow down will be put into excess condensate. The condensate does not normally
contain any pollutant. It is used as boiler feed water and for the washing operations or
water can directly be used for irrigation, after cooling it to ambient temperature.
Effluent from water treatment plant
RO + DM Plant: Hydrochloric acid and sodium hydroxide will be used as regenerates in
the proposed demineralizing water plant. The acid and alkali effluents generated during
the regeneration process of the ion-exchangers would be drained into an epoxy lined
underground neutralizing pit. Generally these effluents are self-neutralizing. However
provisions will be made such that the effluents will be neutralized by addition of either
acid or alkali to achieve the required pH of about 7.0. Quantity of effluent will be 50
CMD. The effluent will then be pumped into the effluent treatment plant which form part
of the sugar plant's effluent disposal system.
Sewage from various buildings in the power plant area will be conveyed through separate
drains to the septic tank. The effluent from the septic tank will be disposed in soil by
providing disposing trenches. There will be no ground pollution because of leaching due
to this. Sludge will be removed occasionally and disposed of as land fill at suitable places.
The existing system in the plant will be used and there will be no new addition.
Distillery
The low strength effluent generated i.e. process condensate will be treated through
condensate polishing unit and recycled back to process and non-process applications. DM
water requirement for boiler and steam condensate water recycle back to boiler.
Expansion cum modernization of sugar unit from 4800 TCD to 8000 TCD along with
cogeneration unit from 22 to 45 MW and distillery unit from 30 KLPD to 95 KLPD
at village Belewadi Kalamma, Tal. Kagal, Dist. Kolhapur, Maharashtra
Prefeasibility Report
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Spent wash will be concentrated in integrated evaporation and concentrated spent wash
will be incinerated in spent wash fired boiler.
3.9.2 Solid waste generation and management
The sludge from primary clarifies, settling tank and secondary clarifier will be sent to
sludge drying beds. Sludge will be dried in natural heat of sunlight. The dried cakes will be
scrapped off periodically and can be utilized for as manure.
Fly ash collected from the ESP hoppers and the air heater hoppers and the ash collected
from the furnace bottom hoppers can be used as landfill. The ash content in bagasse is
less than two percent (2%). The total fly ash collected could be used as a landfill or the
high potash content in the bagasse ash makes it good manure also.
Sugar
Existing bagasse ash generation: 19 TPD (2% on total bagasse consumption)
Proposed bagasse ash generation: 18-19 TPD
Distillery
Coal ash from existing distillery: 7.5 TPD (Max 25 % of coal consumption)
Coal ash from proposed distillery: 16.5 TPD
Spent wash ash from existing distillery: 9-10 TPD (Max 15% of spent wash
consumption)
Spent wash ash from proposed distillery: 20 TPD
Bagasse and spent wash ash collected from the furnace bottom hoppers can be used as
landfill or the high potash content in the bagasse ash is good manure. Coal ash will be sold
to the brick manufacturer.
3.9.3 Air pollution
Bagasse based co-gen project is environmental friendly as bagasse being a biomass
renewable fuel does not add any net carbon-di-oxide to the atmosphere, because of
the carbon recycling during the growth of cane.
The air pollutant that are discharged from the proposed unit are;
- Dust particulate from fly ash in flue gas
- Nitrogen oxide in flue gas
Expansion cum modernization of sugar unit from 4800 TCD to 8000 TCD along with
cogeneration unit from 22 to 45 MW and distillery unit from 30 KLPD to 95 KLPD
at village Belewadi Kalamma, Tal. Kagal, Dist. Kolhapur, Maharashtra
Prefeasibility Report
Sar Senapati Santaji Ghorpade Sugar Factory Ltd.
17
- Sulphur-di-Oxide in the flue gas
The proposed plant operates during cane crushing season and off-season by using
bagasse generated by the factory during season. Electrostatic precipitators are
proposed for the plant steam generator, to contain the dust emission from plant to a
level less than 150 Mg/Ncum during bagasse firing.
Bagasse contains very less sulphur and hence the criteria for fixing stack height based
on sulphur-di-oxide emissions are not applicable here for bagasse firing. The
temperatures encountered in the steam generator while burning high moisture bagasse
are low enough to minimize the nitrogen-oxides production. Moreover, the tender
specification for steam generator will stipulate over fire air system with staged
combustion which will also ensure reduction in nitrogen-oxide emission. Hence, no
separate measures are taken to contain the nitrogen oxide pollutants.
3.10 Schematic representation of the feasibility drawing which give information of EIA
purpose
Sugar Expansion from 4800 TCD to 8000 TCD
Category “B” Activity - 5(j) (≥5000 TCD cane crushing capacity)
Integrated proposal to EAC-II for grant for ToR
Expansion of cogeneration from 22 MW to 45 MW
Category “B”, Activity-1(d) >15 MW plants based on
biomass fuel
Screening category for combine project Cat A
Scoping by EAC Ind-II Committee, MoEFCC
ToR application: Form I & Pre- Feasibility study to MOEFCC
for grant of ToR
Expansion distillery from 30 KLPD to 95 KLPD
Category “A”, Activity-5(g) All molasses based on
distillery
Expansion cum modernization of sugar unit from 4800 TCD to 8000 TCD along with
cogeneration unit from 22 to 45 MW and distillery unit from 30 KLPD to 95 KLPD
at village Belewadi Kalamma, Tal. Kagal, Dist. Kolhapur, Maharashtra
Prefeasibility Report
Sar Senapati Santaji Ghorpade Sugar Factory Ltd.
18
4.0 Site analysis
4.1 Connectivity
Details of connectivity towards proposed site is given below,
Road NH-4 (Mumbai- Chennai) 17.31 km towards north east
Belewadi Kalamma- Dhamne road adjacent to the factory
Gadhinglaj-Gargoti road 1.64 km
Nipani- Ajara Link road 4.45 km
Railway Chhatrapati Shahu Maharaj Terminus railway station 46.15 km
Air Belgavi airport: 62 km
Kolhapur airport: 42.67 km
Nearest town/city Nipani: 20 km
Kagal : 35 km
4.2 Land form, land use and land ownership
The total land is in possession with management. Land is with undulating topography.
Proposed expansion will be in the exiting factory premises only.
4.3 Topography
The topography of the land is with undulating patches.
4.4 Existing land use pattern
The existing land is used for industry purpose.
4.5 Existing Infra structure
Maximum resources like water, power etc. is available with the existing factory.
4.6 Soil classification
Medium and Deep Black Soils (madhyam or bhari kali mati) are found in the area.
4.7 Climate
The temperature has a relatively narrow range between 10 °C to 35 °C. Maximum
temperatures rarely exceed 38 °C and typically range between 33 and 35 °C. Lows during
this season are around 24 °C to 26 °C.
The city receives abundant rainfall from June to September due to its proximity to the
Western Ghats. Winter from November to February. Lows range from 9 °C to 16 °C while
Expansion cum modernization of sugar unit from 4800 TCD to 8000 TCD along with
cogeneration unit from 22 to 45 MW and distillery unit from 30 KLPD to 95 KLPD
at village Belewadi Kalamma, Tal. Kagal, Dist. Kolhapur, Maharashtra
Prefeasibility Report
Sar Senapati Santaji Ghorpade Sugar Factory Ltd.
19
highs are in the range of 26 °C to 32 °C due to its high elevation and being adjacent to the
Western Ghats. Humidity is low in this season making the weather much more pleasant.
Average yearly rainfall is about 764.00 mm.
4.8 Social infrastructure available
Social infrastructures like community center, hospital and electricity are available in the
area.
5.0 Planning Brief
5.1 Planning Concept
The existing unit is Sugar factory along with cogeneration power plant, distillery industry.
Proposed expansion of sugar, cogeneration and distillery will be done within the existing
plant premises by modernization & efficiency improvement. Facilities required for the
proposed capacity enhancement project will be provided as per requirement.
5.2 Population projection
The proposed activity will generate total 80 - 100 for sugar-cogeneration and ~100 for
distillery, skilled and unskilled employee opportunities. No influx, migration of population is
expected as labor shall be deployed from the local villages.
5.3 Land use planning
Total land in possession is 82 acres.
Sugar factory: 20 acres
Cogeneration: 10 acres
Distillery: 15 acres
Colony misc. : 10 acres
Green belt area will be: 27 acres
5.4 Amenities/Facilities
Facilities like canteen, rest rooms and recreation facilities are available with existing unit.
Expansion cum modernization of sugar unit from 4800 TCD to 8000 TCD along with
cogeneration unit from 22 to 45 MW and distillery unit from 30 KLPD to 95 KLPD
at village Belewadi Kalamma, Tal. Kagal, Dist. Kolhapur, Maharashtra
Prefeasibility Report
Sar Senapati Santaji Ghorpade Sugar Factory Ltd.
20
6. Proposed infrastructure
6.1 Industrial area
No additional infrastructure will be required for the proposed capacity enhancement project
as the same will be done within the existing plant premises by modernization & efficiency
improvement.
6.2 Residential area
No residential area is envisaged. Facilities like canteen, rest room etc., and facilities are
provided in the existing units.
6.3 Green belt
Total 27 acres of Green belt will be developed in proposed project premises.
6.4 Social Infrastructure
Proposed capacity enhancement plant will result in growth of the surrounding areas by
ancillary development and supporting infrastructure in the region. Factory will identify the
need of the villagers and accordingly execute the CSR activity.
6.5 Connectivity
The site is well connected with communication facilities like telephone, fax, and wireless as
such, no constraints are envisaged in this aspect as the tehsil and district headquarters are
near to the site.
6.6 Drinking water management
Total 5-10 CMD water will be required for drinking propos.
6.7 Sewerage system
Domestic waste water generated will be sent to septic tank via soak pit.
6.8 Industrial waste management
Details of waste management are described in point 3.9.
6.9 Solid waste management
Solid waste generation detains described earlier in 3.9.2.
Expansion cum modernization of sugar unit from 4800 TCD to 8000 TCD along with
cogeneration unit from 22 to 45 MW and distillery unit from 30 KLPD to 95 KLPD
at village Belewadi Kalamma, Tal. Kagal, Dist. Kolhapur, Maharashtra
Prefeasibility Report
Sar Senapati Santaji Ghorpade Sugar Factory Ltd.
21
6.10 Power requirement & Supply / Source
Details of power requirement is described 3.8.2
7.0 Rehabilitation & resettlement plan
No rehabilitation or resettlement will occur. Hence no rehabilitation or resettlement plans.
8.0 Project schedule and cost estimate
The cost of project has been estimated for sugar Rs. 3.810 cr., and for cogeneration Rs.
871.43 lacs which comprises of land, civil construction, plant & machineries, misc. fixed
assets, pre-operative expenses & margin money for working capital. Estimated project cost
for distillery 84.2546 cr. A provision for contingency has been made to take care of inflation
and changes due to delays if any. Cost for environment management has been estimated to
Rs. 1.78 cr. for sugar-cogeneration expansion and for distillery expansion estimated EMP
cost will be 2.05 Cr.
9.0 Analysis of proposal
A financial and social benefit has been considered while analyzing the proposal. The
proposal is environmental compatible and will helps to people improving their financial
status of the local people. Corporate Social Responsible (CSR) program shall be executed on
need base.