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PRE-FEASIBILITY REPORT

For

Proposed 32 MW Power Plant and Expansion of Project of 2500 TCD to 10000

TCD Sugar Plant

By

M/s. Jarandeshwar Sugar Mills Pvt. Ltd., Post Chimangaon , Tal., Koregaon,

District Satara (MS).

Project Proponent

M/S. Jarandeshwar Sugar Mills Pvt. Ltd.

PREPARED BY

Mantras Green Resources Ltd., Hall No. 1, 1

st Floor, Nice Sankul, ITI Signal, Nasik-422007

ISO Certified and NABET/QCI Accredited Consultancy, ISO 9001:2008

(S.N. 100 -List of Accredited Consultant Organizations 8th

April 2016)

Email: [email protected]

[email protected]

MARCH 2017

i

CONTENTS

ITEM NO PARTICULARS PAGE NO 1.0 Introduction

1

1.1 Project Proponent 1

1.2 Management of JSMPL 1

1.3 The Consultant 1

1.4 Project Details 2

1.5 Purpose of the Project 3

1.6 Estimated project cost 3

1.7 Justification for the project 4

1.8 Screening Category as per EIA Notification 2006 & Subsequent

Amendments

6

1.9 Project Location and Environmental Settings 6

1.10 Geography 12

1.11 Climate 12

1.12 Rainfall 12

1.13 Temperature 12

1.14 Land details 12

1.15 Raw material 13

2.0 Manufacture of Sugar Process 13

2.1 Cogeneration of Electrical Power: Process 15

2.1.1 Fuel Handling System 16

2.12 Ash handling system 17

2.1.3 Electrostatic precipitator (ESP)_ 19

2.1.4 Demineralization plant (DM Plant) 20

2.2 Magnitude of Operations 21

2.3 Utilities and Consumables 23

2.3.1 Water 23

2.3.2 Steam 24

2.3.3 Power 24

2.3.4 Manpower 24

3.0 Environmental Management Plan (EMP)

24

3.1 Wastewater Management 25

3.2 Emission Control 27

3.3 Environmental Impact and Mitigation measures 27

3.3.1 Air pollution 27

3.3.2 Water Pollution 30

3.3.3 Noise pollution 32

3.3.4 Solid Waste Pollution 33

3.3.5 Flora and Fauna 33

3.3.6 Environmental Monitoring Program 34

3.3.7 Monitoring Facilities and Schedule 35

3.3.8 Environmental Records 35

3.3.9 Budget Allocation for EMP 36

ii

4.0 Project Benefits 36

5.0 CSR Activity 36

6.0 Conclusion 38

LIST OF FIGURES

FIGURE NO PARTICULARS PAGE NO 1. Google Imagery of the Project Location 8

2 Location of the project 9

3. Map of 10 km km Study Area Map 10

4. Plant layout map 11

5. Sugar Manufacturing Process 14

6. Refined Sugar Manufacturing Process 14

7. Cogen Power Plant Process Flow 15

8. Effluent Treatment Plant 26

LIST OF TABLES

ITEM NO PARTICULARS PAGE NO 1 Project Details 2

2 Environmental Setting within 10 km radius of the project site 7

3 Land Details 12

4 Typical Composition of Fuel: Bagasse 16

5 Technical Data of Boiler 17

6 Operating Parameter of Steam Generator 17

7 Raw Water Analysis 20

7 Parameters of Alternator 13

8 Magnitude of Operations 21

9 Utility Consumption Norms 23

10 Particulate emission from existing 32 TPH Boiler 27

11 Particulate emission from proposed 160 TPH Boiler 28

12 Ambient Noise Quality Standards w.r.t Noise 33

13 Budget allocation for EMP 36

14 CSR Activity 37

M/s. Jarandeshwar Sugar Mills Pvt. Ltd. Pre feasibility Report

Mantras Green Resources Ltd., Nasik 1

1.0 Introduction

1.1 Project Proponent

The Jarandeshwar Sugar Mills Pvt. Ltd. (JSMPL) formally known as

Jarandeshwar Sahakari Sakhar Karkhana was established in 1997-98 is a

private sugar factory situated at Chimangaon, Tal- Koregaon, District Satara,

Maharashtra State. JSMPL is registered under Companies Act, 1956

(Registration No. is U15421PN2010PLC13769) with an objective of setting of a

sugar mill for processing Sugarcane manufacturing of sugar & allied products.

The registered office of the company is located at Shop No. 105 & 106,

Atharva Fariyaz Plaza, Opp, Shankar Maharaj Math, Pune Satara Road,

Dhanakawadi Pune; Maharashtra Postal Code: 411043

The overall control and management of the Company is vested with the Board

of Directors. The Company is managed by experienced promoters-directors

with a long track record who will be instrumental in the growth of the

Company.

1.2 Management of JSMPL

The Jarandeshwar Sugar Mills Pvt. Limited (JSMPL) has a team of dynamic and

progressive members in the Management Board.

1. Mr. R.S. Ghadge Director.

2. Mr.P.D.Rakshe Managing Director.

3. Mr.P. D.Rakshe Plant head

Under their leadership, the sugar mill is functioning well and achieving its goals

consistently.

1.3 The Consultant

The project proponent is having sugar industry near Chimangaon, Karegoan,

Satara, Maharashtra with a capacity of 2500 TCD Sugar Plant. Now,

Jarandeshwar Sugar Mills Pvt. Ltd.’ Management is planning to expand the

sugar plant capacity 2500 TCD to 10000 TCD and proposing a New 32 MW

Cogen Power Plant. To seek the environment clearance, Jarandeshwar Sugar



Mills Pvt. Ltd. has appointed Mantras Green Resources Limited (MGRL) as

environment consultant.

Mantras Green Resources Limited (MGRL) is a group of professional associated

with the industries for past 30 years in highly diversified activities like

manufacturing, engineering and consultancy services, including import and

export etc. On 9th May 2013 the company having registered office at Nasik and

Branch Offices in India are at Kalyan, Pune, Hyderabad, Jaipur and Delhi.

MGRL is an ISO 9001-2008 certified company and QCI/NABET Accredited EIA

Consultant for the various sectors. They are exposed to various aspects to

environment and technology. The company is under leadership of CEO Dr. U. K.

Sharma whose visionary approach has made us one of the most prominent

consultants in the country.

1.4 Project Details

The company envisaged setting up of the following facilities in phase:

Byproducts of Existing and Proposed Expansion of Sugar and

Cogeneration Plants

Table 1: Project Details

Existing Activity

Proposed Activity

Total Capacity

After Expansion

2500 TCD

Sugar Mills

Commissioned 7500 TCD

Sugar Mill

Expansion 10,000 TCD

Sugar Mills

By Products

750 MTD

Bagasse

Useful as fuel 2250 MTD

Bagasse

Useful as

fuel

3000 MTD

Bagasse

130 TPD

Molasses

Sold to nearby

Distillery

390 TPD

Molasses

Sold to nearby distillery

520 TPD Molasses

23 TPD Press

Mud

Bio compost 70 TPD Press

Mud

Bio-compost 93 TPD Press Mud



Consent for operation of Exisitng 2500 TCD Sugar Mill :

The exiting 2500 TCD sugar mill has obtained Consent to Operate (Number

Format1.0/BO/CACCELL/uanno.0000009389/R/CAC1701000957,dated18/01/

2017) , under Section 26 of the Water (Prevention and Control of Pollution Act)

1974 & under Section 21 of Air (Prevention and Control of Pollution) Act and

Authorization under Rule 5 of the Hazardous Wastes (M, H & T M) Rules, 2008

which is valid for a period from 1/12/2014 to 31/07/2017. Copy attached as

Annexure II.

1.5 Purpose of the Project

JSMPL has decided for expansion of sugar plant from 2500 TCD to 10,000

TCD. Promoter is going for proposing to set a new 32 MW Cogeneration Power

Plant with 7500 TCD Sugar Plant.

The Ministry of Environment, Forests and Climate Change (MoEF&CC),

Government of India has issued an EIA Notification, S.O. 1533 dated 14th

September 2006 amended on 1st December 2009 vide No. 3067, under

Environmental (Protection) Act, 1986. Prior Environmental Clearance (EC) from

the EIA Authorities is mandatory for the establishment of projects/activities

listed in the schedule of above Notification Sugar Industry > 5000 TCD cane

crushing capacity. Therefore, the said Project categorized under 5 (j) of

schedule of activities Category “B1’ require prior environmental clearance from

the State Expert Appraisal Committee (SEIAA/SEAC). Similarly, Cogeneration

Power Projects of 32MW based on Biomass (Bagasse) and using auxiliary fuel

such as coal/lignite/petroleum products 15% are categorized under 1(d) of

schedule of activities, category ‘B1’.

1.6 Estimated Project cost:

The estimated project cost of Expansion of Sugar Mill and Cogeneration plant

is: - Rs. 24685.30 lac.



1.7 Justification for the project:

Power is the most essential input for industrialization and it is indeed the

fulcrum on which the future pace of growth & development of our country

rests. Demand for energy is rising exponentially all over the India. With

increased demand for energy, the existing infrastructure is unable to supply

the required quantum & quality of electricity. Various government & private

agencies are struggling to increase power supply capacities to meet these

demands. Most of power supply requirement in India is met through the fossil

fuel based thermal power stations. Again the sinking fossil reserves will not be

able to meet the future power demands. However these electric utilities

contribute greatly to emission of the green house gases (GHG) to the

atmosphere.

In India, nearly 70 % of installed power generation capacity is based on coal

and hence is one of the largest contributors of GHG emission. This aspect of

GHG emission in India is highly relevant as India is the sixth largest emitter of

GHGs, contributing to 2% global emission. More worrisome is that the rate of

growth in the GHG emission in India is more than double the world arrange at

46% annually. It is obvious that greater pressure will be brought will be

brought on India, form the word community, to take every possible step to

reduce the emission of GHGs. The Indian Society, the world community and

the future generation have the right to cleaner environment and even a small

effort in reducing the emission of the GHGs is positive step to towards better

future.

Therefore, the use of Non-conventional energy source has become the ultimate

option for sustainable development. From the various Non conventional energy

options, Cogeneration in Sugar Factories found to be the most viable

proposition to meet the existing power shortfall to some extent. The bagasse

based cogeneration projects fit very well into our objective of containing the

GHG emission to the atmosphere to achieve a clean sustainable development

without damage to the environment.

India is the second largest producer of sugar in the world having over 500

sugar mills. It is estimated that the potential for the surplus exportable power

from these Sugar Mills is around 5000 MW The Sugar Industry in Maharashtra

state having about one third share in the total sugar production of India has

potential of about 1250 MW of exportable surplus power.

The power situation in Maharashtra state indicates that there is a shortage

during the peak demand. The existing power shortage demands the necessicity



for the state to tap every possible alternate source of energy from biomass. This

is in view of the projections for requirement of power for sustained economic

development of the state and shortages of funds in implementing conventional

power projects. The government of Maharashtra has already acknowledged the

importance of power from renewable energy sources and has decided to

promote bagasse based cogeneration projects.

Bagasse based cogeneration in sugar mills eminently fits in as a desirable source of augmenting the power generation as it has following merits:

• It is environment friendly as it does not add to the existing pollution level of the environment due to carbon recycling.

• It is a renewable source of energy resulting into reduced dependence on fossil fuels.

• There is no need to transport the fuel to the generating stations as the sugarcane in any case is transported to the factories.

• It helps in bridging the gap between the demand and supply in the power sector to some extent.

• It has lower gestation period and lower installation & operating cost compared to the conventional utility thermal plants.

• The transmission and distribution losses are minimized as the plants are located invariably in the rural areas due to which the quality of power is also improved.

• It facilitates the sugar factories with increased viability and profitability to pay remunerative cane price to their cane grower members.

• It presents good business opportunities and benefits to the sugar factories through Clean Development Mechanism (CDM) for reduction in the emission levels of the GHGs. There are several financial institutes like Indian Renewable Energy Development Agency (IRSEDA), PTC Financial services Pvt. Ltd., Power Finance Corporation and Sugar development Fund (SDF) who are providing financial assistance for cogeneration power projects. Most of them provide Term Loan up to 70% total project cost except SDF. The Ministry of New and Reliable Energy (MNRE) giving back ended subsidy up to 50% for sugar factories developing co-generation power projects in co-operative sectors/public sectors/Government undertaking/SPV company after issuance of purchase order for large equipments like boiler, turbine etc. The remaining 50% subsidy could be availed after commissioning of the project. The benefits of switching over to combine heat and power system will be huge and rewarding.

.



1.8 Screening Category as per EIA Notification 2006 & Subsequent Amendments The Ministry of Environment, Forests and Climate Change (MoEF&CC),

Government of India has issued EIA Notification, S .O. 1533 dated 14th

September 2006. As per the EIA notification and its subsequent amendments,

Sugar & Cogen project projects are categorized under 5(j) & 1 (d) of schedule of

activities, respectively. As the proposed expansion project of Sugar & Proposed

Cogen Project is Bagasse based, it comes under category ‘B’ under Schedule

5(j) &1 (d). Therefore, the Projects require prior Environmental Clearance from

the State Expert Appraisal Committee / Authority (SEAC), Maharashtra.

However, at present there is no SEIAA or SEAC Committee existing in the

Maharashtra State. Therefore, as per EIA Notification dated 14th September,

2006, in the absence of a duly constituted SEIAA or SEAC in Maharashtra, this

Project may be treated as a Category ‘A’ Project.

1.9 Project Location and Environmental Settings

M/s Jarandeshar Sugar Mills Pvt. Ltd. is proposing for expansion of Sugar

Plant and setting up of Cogen Power Plant with the following facilities at Gut

No. 30, at post Chimangaon, Taluka- Koregaon, District-Satara (Maharashtra).

• About 25,855.81 m2 area of land is already available with Proponent.

• Koregaonand Chiamgaon cities are respectively 12 km and 2 km away

from the Project’ Site. The site is well connected with National Highway No. 4

and State Highways, Railway Station and Airport.

• The average rainfall of the District is 935.7 mm/year.

• Maximum temperature in summer is 340C and minimum temperature in

winter is less than 140 C.

• Water is available at a depth of 160-165 feet.

• Environmental conditions dusty and non-corrosive.

• Seismic zone III.



Table 2 : Environmental Setting within 10 km radius of the project site

Particulars Details

Project Location At-Cimangaon,Tal-Koregaon,

District-Satara, Maharashtra State

Latitude & Longitude Latitude: 170 24’ 20.49” N

Longitude: 74013’48.25” E

Survey of India Toposheet No. E4302 Scale: 1: 50,000

Estimated Project Cost Rs. 24685.30 Lacs

Nearest Highway State Highway: Satara- Pandharpur

: 2 Km

Nearest Village Bhatamwadi 0.2 km, (south)

Khirkhandi -- 1.7 km in South

Nearest Town Koregaon: 12 km

Nearest Railway station Koregaon : 12 km

Nearest Airport Pune : 146 km

Other Historical / Religious

places

None

Defense installations No

Ecologically sensitive areas

(National Parks / Wild life

sanctuaries / bio-sphere reserves,

migratory routes within).

None

Reserved / Protected Forest 2.3 km in North-East direction

Dhamanyachar Dongar RF : 5.5km

in NE direction

Nearest Water Bodies Ner talav : 8.4km in NE direction

Dhom Left bank canal : 5.9 km in

SW direction

The location of project site is depicted in Google Imaginary (Fig. 1), project site

(Fig. 2), map of study area (Fig.3) and Plant Layout map shown in (Fig. 4).



Fig. 1: Google Imagery of the Project Location



Fig. 2: Location of the Project

Project Site



Fig. 3: Map of 10 km Radius Study Area



Fig. 4: Plant Layout Map

Proposed Cogeneration Unit



1.10 Geography

Chimangaon is a village in Taluka Koregaon, Satara district of Maharashtra State. The entire area of the district is covered by basaltic lava, flows of upper cretaceous of lower Eocene age. The basalt is capped by laterite of younger age which is bound in the plateau above 900 MSL. Alluvium occurs in patches along banks of rivers Krishna, Venna, Kudali and Koyana with average thickness of 10 m and contains pebbles, boulders of trap and beds of sand. 1.11 Climate

The climate of the district on the whole is moderate. It does not show extremities. However, three distinct seasons are experienced. These are monsoons from June to September while in October and November are the post-monsoon months with warmer climate, winters from end of November up to middle of February followed by a warm to hot summer from mid February up to first or second week of June. 1.12 Rainfall The South-West monsoon, the main source of rainfall, begins about the middle of June and lasts till the end of September. Nearly 85 % of the rainfall occurs during these months only. These rains do not cross beyond 40 km east of Satara. 1.13 Temperature The winters start by about end of November and continue till middle of February, December being the coldest month. In this season the mean daily maximum temperature in the plains is 28.40 C, while the mean daily minimum temperature is 13.20C.

1.14 Land Details Table 3 : Land Details

S. No. Land Utilization

Existing Area (m2) Proposed Area

Proposed (m2)

1 Main factory building 8900

Mill house building 750

2 Sugar godowns {1&2} 6465.26

boiling house building 2000

3 Store building 1317.05 Molasses Tank 750

4 Main Gate & Alide structure 110 Boiler 1500

5 Weigh Bridge cabin 120 Power House 2250

6 Auxiliary Building 1550 Cane carrier 3000

7 Laboratory 180 - -



Building

8 Turbine Building 450 - -

9 Molasses Tank 1730 Internal Rods 90000

10 Chimney 13.5 Open Area 30500

11 Cantin Building 120 Green Belt 572561

12 E.T.P. 3900 Parking area 20000

13 DM Plant 1000 - -

Sub-Total 25,855.81 7,23,311

Total

749166.81 Please give an overall description as follows:

Total Plant Area: 7, 49,166.81m2

Area occupied by the Existing Sugar mill and cogen units: 25,855.81 m2

Area Proposed for the Expansion units: 7, 23,311 m2

Green belt description and percentage of green belt proposing: 572561 m2

Rainwater Harvesting Facility area will be provided

Area for ETP Expansion: 3900m2

1.15 Raw Material

� Total requirement of sugarcane is 15 lac MT for existing 2500 TCD and

proposed 7500 TCD sugar mills expansion.

� About 1632 bagasse will be required for 32 MW Co-gen Power plant.

2.0 Manufacture of Sugar Process

Sugarcane is weighed, washed, cut, shredded and fed to series of mills.

Sugarcane juice is extracted and bagasses are separated. Juice is heated and

clarified. Mud is separated out and clarified juice is subjected to multiple

effects evaporators. Concentrated syrup is fed to vacuum pan where syrup gets

super saturated and fine crystals and mother liquor are separated in

centrifuges. Raw sugar is dumped on moving belt where it gets dried before

moving to storage. In normal courses main sugar plant boiler will function and

fulfill steam requirement of distillery also.

Manufacturing Process is given below:

• Extraction of juice by pressing sugarcane and bagasse is separated

M/s. Jarandeshwar Sugar M

Mantras Green Resources Ltd.

• Boiling the juice to

separation

• Creating raw sugar b

• Raw sugar to a refine

remaining non-sugar elem

• Crystallizations and d

• Packaging the ready s

The process flow diag

Fig.

Fig. 6: R

Mills Pvt. Ltd. Pre feas

td., Nasik

to obtained crystals and clarification

r by spinning crystals in extractor

inery for the process of filtering and wash

ements and hue

d drying sugar

y sugar

iagram is given in Fig.6 and Fig. 7.

Fig. 5: Sugar Manufacturing Process

: Refined Sugar Manufacturing Process

easibility Report

14

tion with mud

shing to discard

ess



2.1Cogeneration of Electrical Power: Process

• When a properly coiled wheel is rotated within magnetic field electricity is

generated

• To rotate the wheel mechanical, water or steam may be used

• Steam generated in a boiler is fed to a turbine coupled to an alternator

• Steam is produced in a boiler by burning of bagasse and coal as fuel

• Steam at high pressure moves the turbine which rotates alternator and

electricity is produced

• Part of steam is ejected at low pressure is used for heating requirement

of sugar mill, de-aeration of incoming water and balance is condensed and

recycled

• The management is planning to add 7500 TCD sugar mill along with

proposed 32 MW Co-gen Power Plant

• The proposed cogeneration project will be equipped with a new 160 TPH

Travelling Grate Boiler along with 32MW extractions cum condensing Turbine

with existing set up. The process Flow Sheet is given in Figure 5.

Fig. 7: Co-gen Power Plant Process Flow



2.1.1 Fuel Handling System

During crushing season 100 % Bagasse will be the source of fuel. The

quantity of bagasse required will be 1632 TPD. A belt conveyer system of

capacity of 160.00 TPH is to be installed such that with this capacity to

meet the fuel requirement for the boiler in both option. All the safety

precautions including fire hazards have also been considered in the belt

conveyor to avoid any untoward incident.

Bagasse Handling System

The Heaps of Bagasse shall be Scratched by the Heap Scratcher Crane

cum Double Conveyor (1 Sets – HS-1) and shall be fed on to the Bagasse

Slat Chain Feeder (SC-01) which is designed in a way to feed the Boiler

from the bottom end on return side. The excess of bagasse shall be

brought back to the Storage Area by Return Bagasse Conveyor RBC-

01/2. RBC-02 shall be equipped with movable plough feeder to

accommodate the new heap formation.

Typical Composition of Fuel: Bagasse

S. No.

Parameters Bagasse

1. Carbon (%) 33.50

2. Hydrogen (%) 3.25

3. Nitrogen (%) 0.01

4. Sulphur (%) 0.02

5. Moisture (%) 50.00

6. Ash (%) 1.50

7. Gross Calorific Value(kcal/kg) 2272

During crushing season 100 % bagasse will be used as fuel with bagasse

consumption of 1632TPD.



Table 5 : Technical Data of Boiler

S. No.

Item Description Value

1. No. of Boilers One

2. Type of Boiler Travelling Grate

3. Tube Type Water tube boiler

4. Type of draft Balanced draft system

5. Type of feeding system

Over-bed fuels are to be fed from fuel yard by conveyor belt

6. Type of circulation Natural circulation

7. Type of support Top supported

Table 6 : Operating Parameter of Steam Generator

S. No.

Item Description Value Unit

1. Type of Boiler Travelling Grate Boiler

-

2. Number of boiler One -

3. Maximum continuous rating (MCR)

160 TPH

4. Steam Temp outlet at MCR 540 ± 5oC

Steam pressure at outlet of SH 87 kg/cm2(g)

5. Feed water temp at economizer inlet

1650 0C

6. SH Steam temperature control range

60 - 100 %

7 Temp of flue gas at inlet of ID Fan 150 0C

2.1.2 Ash Handling System

The proposed 160 TPH, Travelling Grate Boiler is fired with bagasse in crushing

season and fuel. The fuel forms ash on combustion. Ash content of Bagasse is

1.5-2.0 %. Ash generated by Bagasse is approximately 56.67 kg/hr (1.36 MTD)

in 160 TPH Travelling Grate Boiler.

• In Travelling Grate Boiler the ash from the bed is drained for maintaining the

bed inventory and to maintain the bed pressure drop.

• Bed ash is drained through the eight drain points provided at the bottom

of the bed. It is practice in Travelling Grate Boiler that the bed drains from



these drain points are cooled and then sewed to get the recommended bed

material size to be used as bed material as and when required

• The rejected portion of this bed ash can be manually handled / collected

through Ash disposal system

• Hence the ash collection points shall be from economizer (at two points),

air heater (at two points) and ESP (at 3 points).

• These ash collected will be carried out through the Dense Phase System

proposed by vendor to ash silo.

• The ash collection points from economizer and air pre heater etc.

Compressed air for the Dense Phase Pneumatic Conveying system is

obtained from two (one working 100% and one stand bye) reciprocating

air compressors and a receiver.

Bottom Ash Disposal System

• Bottom ash from boiler (bottom ash and bank ash) shall be collected in

water impounded surge hopper. The ash so collected in surge hopper

will be evacuated by Dense Phase Pneumatic (vacuum) conveying

system

• One number water cool surge hopper shall be provided under the

bottom ash and boiler bank hopper.

• Under this hopper, 1 No transporting vessel will be connected to the

hoper through material cut off valve and expansion joint.

• The transporter shall be connected to a MS heavy duty ERW Pipe line

(as per IS: 1239) to dump the conveyed husk / ash into the silo through

an end receiver

Fly Ash Disposal System

• The fly ash from Economizer, Air pre-heater, ESP etc. shall be

transferred from each hopper via a transporting vessel under each

hopper shall be provided.

• The transporting vessel will be connected through hopper with the help

of adopter piece, valve and expansion joint



• The transporter shall be connected to a MS heavy duty ERW Pipe line

(as per IS: 1239) to pump the conveyed husk / ash into silo through an

end receiver

• It is also proposed to install 1 No. Silo with storage of 12 hrs for

unloading the fly ash

Compressed Air System

• Two numbers of reciprocating / rotary compressors with receiver are

required for operation of system. Air at 6- 7 kg /cm2 (g)

• For fluidizing of fly ash silo, two numbers of root blower (1+1) of

approximately shall also be required.

Silo Unloading

• For silo unloading one number each of plate valve, rotary feeder and

dust conditioner are provided the opening of silo for disposal of ash

through truck.

2.1.3 Electrostatic Precipitator (ESP)

• Thickness of the insulation shall be suitably designed in such a way

that the difference between the casing temperature and the ambient

temperature shall not be more than 20°C at still air condition

• Specific weight of ash may be taken as 650 kg/m3 (Rice husk) and 600

kg/m3 (for Bagasse) for calculating storage capacity and 1100 kg/m3 for

structural design

• Outlet size of the hopper bottom opening shall be 400 x 400 mm.

Straight length after the hopper shall be restricted to 50mm

• Bottom level of the ESP hopper (Rotary air lock valve outlet) shall have

2.5 m clearances from ground level

• All supporting steel structures required for ESP shall be provided in

accordance with IS: 800 including columns base plates, anchors, anchor

bolts, sleeves, inserts, beams, girders, hangers required for installation,

inspection / maintenance



• The structure shall be designed taking into consideration total

equipment weight, hopper dust load, live and dead loads and wind loads

in accordance with IS: 875. The design shall also take into account the

suitable seismic coefficient

• Local platform and ladder for approach to the ESP ash hoppers / access

doors shall be provided

• Precipitator main housing (all walls and roof, with required columns,

stiffeners, access door, etc)

• Thermal insulation LRB mattresses, (40 mm thickness and 100 kg/m3

density) complete with lagging, wire mesh fixing cleats and outer plain

aluminum cladding 24 SWG.

2.1.4 Demineralization Plant (DM Plant)

The DM plant shall be of indoor installation and mode of operation shall be

manual. All indicators, recorders, switches, push buttons, indicating lamps

and annunciated windows shall be mounted on local control panel.

Table 7: Raw Water Analysis

S. No. Parameters Value Unit

1. pH 7.6 -

2. Total hardness 221.0 mg/l

3. Alkalinity 'p' 384.0 mg/l

4. Total Dissolved Solids 432.0 mg/l

5. Chloride as Cl 10.0 mg/l

6. Silica as SiO2 1.8 mg/l

7. Potassium as K 2.2 mg/l

8. Calcium as Ca 67.0 mg/l

9. Magnesium as Mg 13.0 mg/l

10. Total Suspended Solids 18.0 mg/l

The output from the D.M / RO Plant should have the following requirement for

best feed water quality and Boiler operation.

Data Acquisition System (DAS)

The complete Power plant can be segmented by various systems such as:

o Boiler and its auxiliaries

o Turbine and its auxiliaries

o Over all electrical distribution system



o Fuel handling system

o Ash handling system

o DM water system

o Compressed air system

o Cooling water system and raw water system

In DAS system, the input and output process parameters such as pressure,

temperature, level, position indictor, flow etc. will be evaluated and

documented in a “data base” list which will contain:

o Analog input and output point

o Digital input and output point

The entire power plant will be divided as above systems and each will

contribute for smooth and healthy operation to get maximum availability of

the plant. The general input and output of analog nature will be as below:

o Pressure from pressure transmitter

o Level from level transmitter

o Flow from flow transmitter

o Temperature from temperature transmitter

Which acts on 4-20 mA signals to transmit to distributed processing unit

called DPU which ultimately worked as marshalling system of all the input /

output which contributes to DAS system. By using these inputs and outputs

the parameters can be changed to control the operation of the plant.

2.2 Magnitude of Operations

Following table clearly indicates all facets of proposed project to elaborate

magnitude of project:

Table 8: Magnitude of Operations

Sr.

No.

Feature Details

1. Area Statement

Land utilized for existing unit 25,855.81 m2

Land to be utilized for Proposed Unit 723311 m2

Total 7,49,166.81 m2



Sr.

No.

Feature Details

2. Working (days) 330

Season(days) 160

Off-season(days) 72

Non Working Season(days) 30

3. Existing Sugar Mill 2500 TCD

Proposed Sugar Mill with Cogen 7500 TCD 32 MW

Total Capacity Sugar Mill with Cogen. 10000 TCD 32 MW

4. Raw Material for Cogen. PP

Total Bagasse Generation after

Expansion

2700 TPD

Bagasse Requirement for 32 MW

Cogen. PP

1632 TPD

4. Water Resources

River Tailganga

5. Fresh Water Demand for full capacity

(10000 TCD)

3000 KLPD @30%

7. Backup power 1000 KVA

D G set rating 1000 KVA

Fuel used HSD

200 L/hour (at full load)

8. Man Power 577 Nos.

9. Total Investment Rs. 24685.30 lacks

10. Utilities 160 TPH boiler of sugar

mill (7500 TCD)

Steam generation capacity 87 ata pressure, 540oC

Boiler capacity (Cogeneration) 160 TPH

Fuel – Bagasse Requirement 1634 MT/day

11. Total Ash Generation 32.6 MT/day

Fly Ash expected 26.1 MT/day

Bottom Ash expected 6.5 MT/day

Fly Ash Dust collector ESP



Sr.

No.

Feature Details

Bottom ash & fly disposal Used as Manure &

Brick manufacturers

12. Height of chimney 82 m

Diameter chimney 4.5 m

Bottom Ash disposal Silo

ETP capacity (existing ETP of sugar

unit)

1000 m3/day

13. Solid waste

ETP Sludge from ETP/DM Plant

Fly ash : 26.1 MTD

Bottom ash: 6.5 MTD

36.92 m3/day

2.3 Utilities and Consumables

For phase II the utilities and consumables consumption norms is given below:

Table 9 : Utility Consumption Norms

S.

No.

Description Unit Consumption

Sugar Mill

1. Water % on Cane (30%)

2. Steam % on Cane (36%)

3. Power kWh/MT 30

• The Consultants have benchmarked the above utilities and consumables

consumption norms against industry standards and believe that these

norms are achievable

2.3.1 Water

• For fulfilling water requirement, the Company has taken on the bank of

the Tailganga river.

• The raw water so received will be stored in GSR tanks at site and will

be processed through DM/ RO plant for end use.



• Water requirement : Required water Quanity for existing & sugar unit :

2100 KLD and Required water Quanity for Proposed Cogen unit : 2688

m3/day

Source of water: The required water will be supplied from Tailganga

River. The required permission for extraction of water is given in

Annexure-III

2.3.2 Steam

• The steam turbine to be used in the project is extraction and

condensation type. The steam extracted from the turbine will be used in

process.

2.3.3 Power

• Power generated from the Co-gen will be used internally and the excess power

will be sold to grid.

• Any deficit of power will be met through grid purchase.

• Although the Company will be utilizing in-house power, still will have suitable

DG set with all the plants to safeguard any power failure situation.

2.3.4 Manpower

Manpower for phase II facilities is indicated as below:

• Sugar mill and Co-gen units will have 577 Nos. of employees and its

estimated annual manpower expenses shall be Rs. 13.83 Crores at

optimum capacity utilization.

• Indirect benefits of their projects are reaching too many people in the

area.

3.0 Environmental Management Plan (EMP)

JSMPL is an existing industry planning new unit and have well established

environmental management plan (EMP). The sugar plant and power plant

utilize resource such as water, cane sugar, bagasse etc. and discharge liquid,

gaseous and solid waste products. Mitigation measures are incorporated in the

project to protect environment against any harm. A comprehensive



environmental management plan is adopted consisting of proposed pollution

control measures and additional mitigation measures for abatement

undesirable impacts. Summary of these measures includes:

• Green belt and greenery development in the factory premises (about

33% of the plot area).

• Waste water management, Recycle and Reuse of condensate

• Paving and lining of roads, solid storage yards of ash etc.

• Self monitoring system is established in the industry with man power

and facilities to ascertain the compliances of environmental norms and

standards.

• Personal health care program, emergency management plan and safety

management systems will be implemented in the proposed project

activities.

• Operation and Maintenance of pollution control measures

• Establishment of waste reduction measure.

• The project is technically and financially viable, subject to the

assumptions made in this report found good.

3.1 Wastewater Management

Waste water management will include:

• Operation of ETP should be started at least one month before starting

of plant to achieve desired MLSS so as to meet the prescribed

standard from day one of the operation of the plant.

• Reduce waste generation

• Plant should achieve zero discharge to inland water surface

• Plant should provide 15 days storage capacity for treated effluent to

care for no demand for irrigation.

• Rain water harvesting scheme will be adopted.



Effluent Treatment Plant (ETP)

Effluent treatment is the process of removing contaminants from wastewater,

including household sewage and runoff (effluents). It includes physical,

chemical and biological processes to remove physical, chemical and biological

contaminants. Its objective is to produce an environmentally safe fluid waste

stream (or treated effluent) and a solid waste (or treated sludge) suitable for

disposal or reuse (usually as farm fertilizer). Fig. 8 gives an overview of a

typical effluent treatment plant.

Fig. 8: Effluent Treatment Plant (ETP)

The treatment processes are divided into stages:

• Pre-treatment: Pretreatment will consist of screening, oil & grease removal and Flow equalization.

Equalization

Tank

Bar

Screen

O&G

Removal

Secondary

Clarifier

Treated

Water Tank Sludge Drying Beds

Raw

Effluent

UASB Digester

Aeration Tank Clarified Water

Tank

PST

Cleaning Day Tank

Neutralization

Tank

Buffer Tank

IST Dual Media

Filter



• Primary or Chemical Treatment: Primary or chemical treatment will consist of neutralization, PST (Primary Settling Tank) and Buffer tank for neutralizing and pH correction of incoming effluent.

• Secondary / Biological Treatment: Secondary Treatment process will consist of UASB Digester and Clarification followed by recycle of anaerobic sludge. Anaerobic process is followed by Biological Aeration and Clarification. Aerobic sludge from Secondary Clarifier will be recycled to Aeration Tank

• Tertiary Treatment: process will consist of Sludge Drying Beds.

3.2 Emission Control

In order to control emission, the plant should provide ESP/Bag Filters/

high efficiency scrubbers to comply with the standards for particulate

matter emission to less than 150 mg/Nm3.

3.3 Environmental Impact and Mitigation measures

The plant can cause environmental pollution in the following forms:

• Air Pollution

• Water Pollution

• Noise Pollution

• Solid Waste Generation

3.3.1 Air pollution

Air Pollution Control :

Sources of Air pollution are: Boiler, Stack emissions, DG set emissions,

vehicular movement.

Table 12: Particulate Emissions from Existing 32TPH Boiler (2 Nos.)

S.No Particular Quantity

1. Existing boiler capacity of sugar mill 32 TPH

2. Fuel used Bagasse

3 Required Fuel Quantity 600 MT/day

4 Sulphur (%) (at max). 0.2 %

5 Fuel gas velocity 3.7 m/sec

6 Fuel gas flow rate 12 m/sec

7 Flue gas Temperature 150oC

8 SO2 Emission rate 100 kg/hr



9 Height of the stack required as per

CPCB standards

14 x (Q)0.3 = 55 m

10 Stack diameter 3.5 m

11 Existing stack height 52 m

Ash Emissions

12 Total Ash emissions 0.29 MT/hr

13 Fly ash Emissions 0.23 MT/hr

14 Bottom ash Emissions 0.058 MT/hr

Hence the stack height is adequate for effective dispersion of pollutants.

Table 11: Particulate emissions from Proposed 160TPH Boiler for

proposed expansion of Existing sugar mill and Cogen plants

S. No Particular Quantity

1. Proposed boiler capacity 160 TPH @ 87 kg.

2. Fuel used Bagasse

3 Required Fuel Quantity 1632 MT/day

4 Sulphur (%) (at max). 0.04%

5 NOx Kg/ton of Bagasse (at max) 0.02%

6 Stack Diameter 4.5 m

7. Flue gas Temperature 150oC

10. SO2 Emission rate 2.32 kg/hr

11. Height of the stack required as per CPCB

standards

74 H 0.27 based on particulate

emission= 76 m

12 Proposed stack height for expansion unit 82 m

Ash Emissions

9 Total Ash emissions 1.36 MT/hr

10 Fly ash Emissions 1.088 MT/hr

11 Bottom ash Emissions 0.272 MT/hr



Treatment Technology of Particulate emissions

The critical SPM concentration in the flue gas will be less than 150.0 mg/Nm3.

Majority of the particulates (about 60-70%) will have sizes in the range of 2-10 µm.

The emissions are expected to have temperature in the range of 140-150°C.

1. JSML has installed Electrostatic Precipitator (ESP) of 99.9% efficiency for control

of particulate emission for the existing sugar plant.

2. JSML is proposing Electrostatic Precipitator (ESP) of 99.9% efficiency for

proposed & expansion of sugar & cogen unit.

The proposed 32MW Cogeneration plant will cause environmental

pollution in the following forms:

The plant can cause air pollution due to the following activities:

• Particulate matter emission from steam boiler

• Dust emission from un-paved access roads

• Emission from D G sets

• The elements polluting the ambient air that are discharged from the

proposed cogeneration plant that are dust, fly ash, NOx, SO2 in flue

gases.

• There will be provision of ESP which will reduce dust emission from

plant to the level < 100 mg/Nm3

• There will be provision of one number MS Chimney/stack of 65m

height will be considered for Travelling Grate Steam Generator of 160

TPH, 72 kg/cm2, 510 0C steam pressure and temperature.

• The air quality monitoring will also be undertaken to ensure that the

dust pollution levels is within limits.

• Adequate sampling opening will be provided in the stack. The

sampling at the Stack will be done once in six months to check on

performance of ESP.

Mitigation Measures

The Consultants suggest the following mitigation measures for air

pollution:



• Flue gas cyclone, filter bags/ESP/wet scrubbers to capture ash due to

burning of bagasse for boiler fuel

• Providing well designed chimney with adequate height for proper

dispersion of pollutants

• Providing road surface with black toping to avoid dust emission due to

transportation

• Use wet scrubbers for removal of dust from drying and cooling of

sugar

• Dust catchers to collect sugar from sugar graders

• Periodic monitoring of stack and ambient air quality to keep a check

on pollution parameters as per the directives of MSPCB

3.3.2 Water Pollution

Existing Sugar Mill Effluent Treatment:

• Existing 2500 TCD sugar mill has an ETP of 250 KLD capacity for the

treatment of the effluent generated from the sugar mill and cogen plants.

• Existing 250 KLD ETP plant will be upgraded to a capacity of 1000 KLD

capacity (which is 20% more for 1200 KLD effluent generation) with

advance treatment technology.

• ETP sludge will be used as manure.

• The treated water will be used for gardening and flushing purpose.

Domestic Sewage treatment

• JSML will construct a Sewage Treatment Plant of 60 KLD capacity with

latest technology for treatment of domestic sewage from the sugar mill

and Distillery plant.

• Treated sewage will be used for Gardening and plantation purpose.



The plant can cause water pollution due to the following activities:

• Main plant house wastewater due to continuous cooling and

intermittent floor washing

• Wastewater due to washing of utilities

• Spirit/ molasses mixed water

• DM plant blow down

• Sewage generation due to domestic activities

The plant should ensure that the treated effluent quality shall comply

with the norms set by the pollution control board.

Mitigation Measures

The Consultants recommend the following measures to mitigate water

pollution:

Process wastewater from the plant should be treated in an effluent

treatment plant. The most commonly used treatment option consists the

following:

• Preliminary treatment consisting of screens and oil and grease trap

• Equalization tank for maintaining the flow and load

• Sedimentation tank for removal of suspended solids

• Biological treatment consisting of extended aeration tank followed by

settling tank or anaerobic lagoons, aerobic lagoon based on the

imperviousness of soil in the area

• Disinfection by chlorination or ultra-filtration as per the

recommendation of Pollution Control Board

• Sludge generated can be provided with sludge thickener followed by

sludge drying beds

• Sewage generated can be treated along with process water or can be

segregated and provided with septic tank followed by soak pits as

recommended in the consent from MPCB.

• Treated effluent from the ETP can be used for irrigation or discharged

to sewer or to the common effluent treatment plant if available in the

area as per the recommendation of the Pollution Control Board.



• Monitoring of inlet and outlet effluent quality from ETP to keep a

check on pollution parameters.

• Compressive Water Management plan has been planned with the site-

wide strategies for minimizing water use efficiency, minimizing

wastewater discharge and encouraging a policy of reuse and recycle to

control a plant’s water footprint

• The effluent will then be pumped into the effluent Treatment Ponds

which form a part of the power plant’s effluent disposal system

• The rejects form WTP which will be used for clean purposes in the

project activities and also for plantation

• The chlorine dose of 0.2 ppm done mainly to prevent biological growth

in the cooling tower system

• Process water from sugar plant is required to be treated in ETP and

inlet and outlet to be check regularly on pollution parameters

3.3.3 Noise pollution

• The proposed cogeneration plant cause noise pollution due to

presence of centrifugal pumps, motors, DG sets, EOT Crane etc.

• The Consultants believe that noise pollution can be controlled to a

considerable extent by providing proper maintenance to equipment

and providing suitable acoustic enclosure to DG sets.

• Providing thick green belt (33%) area in and around the plant

premises can also attenuate noise pollution.

• This noise pollution can be controlled up to a certain limits as per

pollution control boards norms

• There should be provision of acoustic enclosure to DG sets

• The plant should ensure that the ambient noise quality standards set

by the Pollution Control Board as indicated below

Table 12 :Ambient Noise Quality Standards w.r.t Noise

Area Category of Limits in dB(A) Leq



Code Area/Zone

Day Time Night Time

(A) Industrial Area 75 70

(B) Commercial Area 65 55

(C) Residential Area 55 45

(D) Silence Area 50 40

Source:CPCB Norms

3.3.4 Solid Waste Pollution

The plant can generate solid waste in the following form:

Mention the Quantities

• Press Mud: 23 TPD existing and expansion 70 TPD

• Sludge from DM Plant: 0.28 m3/day

• Sludge from ETP: 36.64 m3/day

• Fly ash and bottom ash : 26.1 MTD & 6.5 MTD respectively

• Press mud can be used as manure after composting.

• In case of double carbonation the press mud formed can be sent to

landfill.

• Sludge from ETP can also be send to landfill or used as manure as per

the direction of MSPCB

• Establishment of waste reduction measures will be adopted.

3.3.5 Flora and Fauna

Flora: Most dominant plant species found in this area are Kaju, Neem

/ Kadunimb, Palas, Pimpal, Adulsa, Lajalu, Nirgudi, Ashoka, Peepal,

Babul, Mango, Gulmohar, Bel, Neem, Eucalyptus globulus, Coconut,

Bor, Chinch, Sitafal, Tantani, Tarwad etc. The common grasses found in

this area are Marvel, Kusli, Kunda and Goshya.

Fauna: The common species of animals and birds found in the region

includes the following:

• Among the mammals found in the region are the jackal, Kolha or Sheal,

Canis aureus the hyena, the wild cat.



• The herbivorous animals commonly found are Indian Gazelle, monkey;

Harine

• Animals such as the Hare, Khargosh, Parempine are also found in

almost all the forest areas.

• Among the birds the peafowl, Grey and painted partridges, Tetar,

Pater, pigeons are found in some varieties of ducks, kingfisher etc. are

found near water bodies.

• There is no endangered flora or fauna or rare species plant or animal

existent at this location.

• Adequate environment protection systems will be put in place for the

treatment of all liquid, solid and gaseous discharges from the power

plant to achieve the required emission levels well within the permissible

limits of state pollution boards.

• As a result there shall be no adverse impact on either the air or water

quality in and around the sugar cogeneration complex

3.3.6 Environmental Monitoring Program

• JSMPL will ensure effectiveness of pollution control measures will be

ascertained by systematic monitoring of discharges at factory and

receiving levels.

• Environmental Management Cell (EMC) consisting of Departmental

Heads will be created to effectively manage the environmental activities

in the parent plant and the power plant.

• Environmental department will be formed with environmental scientist,

laboratory chemists and operators to implement and operate pollution

control and environmental protection measures.

• Third party monitoring will be carried out to double check

effectiveness of mitigation measures



• Proponent analysis report, third party report will be corroborated with

statuary body, so that results are in line with standards all time.

3.3.7 Monitoring Facilities and Schedule

• A laboratory will be established with manpower and facilities to

analyze water, wastewater, etc. Stack emission, ambient air

monitoring will be outsourced.

• The parameters monitored will be temperature, SPM, SO2

and NOX

for

gaseous emissions and RSPM, SO2

and NOX

ambient air. Analysis is

also carried out by competent third party for cross checking.

• The quality of discharges including wastewater, flue gas, and the

receiving bodies such as ambient air, water, surface water and soil

will be monitored for the desired parameters.

• Sampling locations and post project monitoring schedule have been

worked out.

3.3.8 Environmental Records

• Environmental department will maintain log sheets and manuals for

operation and maintenance of pollution control and related facilities

• Progress reports and statuary records as per environmental acts will

also be maintained

• JSMPL is an existing industry planning new unit and we have well

established environmental management plan (EMP)

• A comprehensive environmental management plan is adopted

consisting of proposed pollution control measures and additional

mitigation measures for abatement undesirable impacts

3.3.9 Budget Allocation for EMP

The EMP Budget is given below:



Table 13:Budget allocation for EMP

S. No.

Particulars

Capital cost

Annual Recurring cost

Rupees in lacs.

1. Air Pollution control equipments 49 16.50

2. Chimney 25.63 4.00

3. Ash collection system 8.75 2.45

4. Water pollution control treatment 100.00 14.00

5. Noise Pollution control 6.15 2.34

6. Solid waste Management 30.00 7.66

7. Occupational health 12.85 4.80

8. Safety Management 18.22 4.90

9. Development of green belt 28.95 1.00

10. Maintenance of pollution control devices

86.66 46.48

11. Expenses of CSR activities 617.13 50.50

Total 983.34 154.63

4.0 Project Benefits

• The industry on expansion will provide direct and indirect

employment to many local rural people.

• The project will be a boon as power will be fed to grid for other users

in a power deficit state as is ours.

5.0 CSR Activity

About 2.5 % of the capital cost will be earmarked for CSR activity the

approximate amount will be 617.00 lacks.

Give the Breakup of the CSR Fund Allocation and the activities, amount

spending in approximate quantities

Table 14: CSR Activity

S. No.

Activities Social Benefits Expenses (Rs. Lacs)



1 Education Development

a. Providing scholarships and prize amounts for merit students

b. Providing reimbursement of cost of uniform, notebooks for factory employee children’s.

c. Providing skill development trainings d. Conducting Art of Living classes to the

employees and villagers so as to create value in the lives of people.

90.00

2 Rural Road Development

a. Provide Road infrastructure facilities from the factory connecting to nearby villages.

b. Providing repairs for the damaged roads due to the vehicular movement.

115.00

2. Drip Irrigation

a. To save water, increase crop production b. Minimize use of water

45.00

3. Rain water Harvesting

a. Water collection from factory terrace b. Rain water for reuse, landscape

irrigation c. Greenbelt development

100.00

4. Plantation a. Greenery for ecological balance b. Enrich local biodiversity c. Control Air & Noise pollution, windbreak d. Helpful to control soil erosion e. Plan for plantations

85.00

5. Health Programme

a. Conducting frequent health Checkups for all the workers regularly.

b. Providing Personnel Protective Equipment (PPE) for all the workers

c. Providing safety training programs for all workers

d. Providing safe drinking water with RO Treatment facility.

e. Providing hygienic toilets to the workers and cane truck drivers.

125.00

6. Organic Farming: Supply of Bio-Fertilizer. Bio-compost distribution at subsidized rates to the farmers and cane growers

57.00

TOTAL FUND FOR CSR ACTIVITY 617.00

6.0 Conclusions



• The raw material is bagasse produced in own sugar plant will be used as

fuel for boiler

• This industry is eco friendly and does not have adverse effect on the

quality of land, water and air.

• The industry will be taken all the necessary preventive measures to

mitigate even the small effects which may be caused by industrial

activities.

• The concept of Reduce, Recycle and Reuse is proposed in the industry.

This will result in reducing the water and air pollutants discharge to the

environment.

• The industry has adopted an effective environment management system

and environment management plan to protect the environment.

• The industry has given due priority for 33% green belt development

within and around the factory premises.

• In the vicinity of the factory there are no protected forests, sanctuary, or

any exotic flora and endangered fauna. Therefore, the proposed

expansion will not have adverse effect on the environment or the eco

system.

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