To, Dated: 04/05/2016 Member Secretary Industry – 2 Projects Ministry of Environment Forest and Climate Change (MoEF&CC) Jor Bagh, New Delhi. Subject: 50 KLPD Multi Feed Distillery at Village Pimpalgaon (Nipani), Taluka – Niphad, District – Nasik, Maharashtra of M/s KGS Sugar and Infra Corporation Ltd. (regarding Environmental Clearance). Reference: Minutes of the meeting dated 31st March 2016 (Agenda No. 6.6.9). Sir, With Reference to above, hon’ble committee soughted following additional information: 1. At page xvi of the EIA report, it is mentioned that source of water supply is ground water.

However, during the presentation, it was informed that source of water supply is Godavari River. Discrepancy need to clarify.

2. Fresh water requirement shall not exceed 10 KL per KL of alcohol produced. Revise water balance chart to be submitted. Water requirement need to be reworked with existing sugar unit.

3. Adequate treatment scheme for spent wash generated from molasses based distillery.

4. Adequate Treatment scheme for spent wash generated from grain based distillery.

5. Submit plan (5% of project cost) earmarked towards the Enterprise Social Commitment (ESC) based on local needs and action plan with financial and physical breakup/details.

6. Submit layout plan for greenbelt.

7. Rain water harvesting facility to be provided.

8. Status of Environmental Clearance and consent to operate of the existing unit of sugar and CPP.

In this regard, point wise justification has been prepared and attached for your kind perusal. Thanking You For, KGS Sugar and Infra Corporation Ltd. Authorized Signatory Encl; Point wise Compliance Report

Point Wise Compliance Report

Point No 1

At page xvi of the EIA report, it is mentioned that source of water supply is ground water. However, during the presentation, it was informed that source of water supply is Godavari River. Discrepancy need to clarify.

Reply

We will not use the ground water at all for the same where as source of water supply will be Godavari

River as we have mentioned during presentation and we will take the water through pipeline.

Point No 2

Fresh water requirement shall not exceed 10 KL per KL of alcohol produced. Revise water balance chart to be submitted. Water requirement need to be reworked with existing sugar unit

Reply Fresh water requirement shall not exceed 10 KL per KL of alcohol produced. Required water balance is

tabulated with existing sugar unit.

Total Fresh water requirement of molasses based process is 492 m3/day. From sugar industry about

180 KLPD CPU treated water will be generate which will be used for Molasses based process. About

18 m3/day water will be sources from the rooftop harvested runoff. Hence, for the molasses based

process water withdrawal from the Godavari river will be reduced from 492 m3/day to 294 m3/day.

i.e. about 40% reduction in water requirement from Godavari river. Revised water balance is given

below:

Fresh Water Requirement in m3/day – Molasses based Process

Particulars Intake Consumption and Losses

Generated Effluent

Recycle and Reuse

Daily Net Requirement

Industrial Process 600 100 500 341 259 (241 +18*) Cooling Purpose 375 208 167 167 208 (28+180# ) Domestic 17 4 13 0 17 Other & Gardening 8 8 0 0 8 TOTAL 1000 320 680 508 492

Note: *18 m3/day from rain water harvesting (Annexure 1) # 180 m3/day from Sugar mill CPU treated water (Annexure 2)

During off season Sugar CPU water will not be available for grain based process. At that time water

requirement for 90 days will be remain same i.e. 481 m3/day which will be meet from Godavari river.

Point No 3

Adequate treatment scheme for spent wash generated from molasses based distillery.

About 339 KLD Spent wash will be generated from the Molasses based process. Adequate treatment

scheme for spent wash generated from molasses based distillery is given below.

Spent wash treatment for zero discharge for both operations:

Molasses based operation:

The spent wash of a distillery process is a serious problem by way of treat to the environment.

Effluent discharge from the distillation process commonly known as spent wash is one of the polluting

effluents with very high values of BOD and COD. The effluent is first treated in bio-methanation

system, which not only reduces the effluent load, but also produces methane rich biomass. This

biogas has a high calorific value and will be used to produce power to run dedicated boiler of the

distillery.

The effluent after bio-methanation is converted in to bio-manure in bio-composting plant. After

settling it will be pumped to anaerobic bio-digester for bio-methanation, concentration in MEE and

composting with press mud.

Effluent characteristics Molasses which is used as a raw material in distillery contains large quantity of in-organic salts and

non fermentable organic matter as impurities. Major portion of these impurities end up as spent

wash. Traces of these impurities are also present in lees water and washings. The spent wash is highly

concentrated with organic and in-organic matter. The characteristics of spent wash are given below:

Characteristics of Spent wash S. No. Parameter Raw spent wash

1. pH 4.0 – 4.5 2. Total solids (mg/l) 132000 – 140600 3. Volatile acids 76900-82800 4. Ash (mg/l) 21200 – 24500 5. BOD (mg/l) 51800 - 62100 6. COD (mg/l) 125800 – 139100 7. Total nitrogen as N (mg/l) 4490 – 4940

8. Potassium as K2O (mg/l) 9480 – 10600

9. Sodium as Na (mg/l) 240 – 280

10. Phosphorus as P2O5 (mg/l) 990 – 1120

11. Sulphate as SO4 (mg/l) 2810 - 3145 12. Chloride as Cl (mg/l) 5700 - 6070 13. Volume of Spent wash (KLD) 400

Treatment of spent wash Spent wash is highly concentrated with organic and inorganic matter. It is rich in plant nutrients such

as potash and phosphate. Carbonaceous matter may be used as a source of energy or in the

production of bio-manure. The treatment scheme proposed for spent wash is to achieve zero

discharge of spent wash and also to recover the valuable products present in it for sustainable

development.

Treatment and disposal of spent wash:

Spent wash from distillery plant after cooling in a plate exchanger is collected in the pre-settling tank

and then pumped to bio methanation plant. Bio-gas generated from bio-methanation is utilized as

fuel in the boiler. The treated effluent from bio-methanation plant will be collected in spent wash

storage tank and from there it pumped to bio-compost plant. Bio-methanated spent wash is

composted along with press mud to produce bio-manure. Bio-manure is rich in plant nutrients and is

sold to farmers. The detailed process is as follows:

Anerobic Digester

The digester will be a mixed tank reactor and is provided with 3-4 numbers of specially designed

mechanical agitators. The digested product is passed through the laminar clarifier. The settled sludge

containing bio-mass is recycled to maintain the desired solid concentration in the digester. Clarified

spent wash is sent to the storage reservoir. Excess sludge collected from bottom of the digester and

laminar clarifier is filtered and filter cake containing spent yeast is dried and then utilized in

composting process.

Specification of bio-ethanation plant

The bio-methanation plant consists of following units:

A) Bio-Digester

B) Degassing Tank

C) Laminar Clarifier

D) Gas holder floating tank

E) Storage Tank For Bio-methanated Spent Wash

F) Bio-Gas Blower

Specification of these units and the characteristics of raw and bio-methanated is given below.

A. Bio-digester:

Specification of units Spent wash Flow rate in the digester 500 KLD COD content in inlet spent wash (mg/l) 135000 COD content in inlet spent wash kg/day 67500 COD reduction 65 % COD content in outlet spent wash (mg/l) 23635 Final COD reduced kg/day 43875 Capacity of each digester 7500 m3

Hydraulic retention period 15 days Average Bio-gas generation at about 0.5 m3per kg of COD 22000 Nm3/day

The digesters are fabricated of mild steel plates and complete with agitators, pumps, piping, blower

etc.

B) Degassing Tank

De-gasifying tanks are cylindrical vessels of 2 m diameter and 10 m height with conical bottom. They

are fabricated of mild steel plates.

C) Laminar Clarifier

Laminar clarifier is a parallel plate clarification unit and is fabricated of mild steel plates. It consists of

vertical shell with conical bottom and slanted plates inside.

D) Gas Holder Floating Tank

The floating tank will be a cylindrical tank fabricated of mild steel plates.

E) Storage Tank for Bio-methanated Spent Wash Total storage capacity required 12000 m3

No. of Tanks 3 Size of tank 70 m x 70 m x 2.5 m

The tanks are constructed at ground level by excavation of earth, construction of bunds and

compaction of surface as per standard practices. The tank interior lined with stone slabs and is

suitably lined as per CPCB guide lines to prevent the seepage of effluent.

Performance of bio-methanation plant

The characteristics of spent wash before and after bio-methanation are given below. An average of 5

m3 bio-gas is generated per kg of COD reduced in the bio-methanation plant.

Characteristics Raw & Bio-methanated Spent wash

S. No. Parameter Raw spent wash Bio-methanated spent wash

1 pH 4.0 – 4.5 7.3 – 7.5 2 Total solids (mg/l) 132000-140600 66000-70300 3 Volatile acids (mg/l) 76900-82800 5500-6000 4 Ash (mg/l) 21200 – 24500 18800 – 21700 5 BOD (mg/l) 51800 - 62100 5500 - 6000 6 COD (mg/l) 125800–139100 50000 - 55000 7 Total nitrogen as N (mg/l) 4490 – 4940 1200 – 1340 8 Potassium as K2O (mg/l) 9480 – 10600 8400 – 8900 9 Sodium as Na (mg/l) 240 – 280 230 – 270

10 Phosphorus as P2O5 (mg/l) 990 – 1120 900 - 1050 11 Sulphate as SO4 (mg/l) 2810-3145 280 - 310 12 Chloride as Cl (mg/l) 5700 - 6070 5300 - 5800

Composting Process Composting is a process where in the waste bio-mass is decomposed and/or stabilized in the presence

of micro-organism (culture) and moisture to produce bio-manure containing stable humus and soil

like product. In the present industry the bio-mass is composted along with spent wash and it is carried

out on the specially constructed yard (compost yard) to avoid spillage and seepage of material. The

bio-mass consists of mainly press mud. Nutrients such as potash and phosphate present in spent wash

are passed on to the composted product. The bio-manure thus produced is a valuable substitute to

chemical fertilizer for use in agriculture.

The press mud and the other bio-mass brought from sugar unit is formed as wind rows on the

concreted compost yard and laid into 200 m x 3 m x 1.2 m windrows. Aerobic microbial culture is

applied to the windrows. Spent wash is drawn from spent wash storage tank through pump and hose

pipes and then sprayed on windrows on a regular interval of 2 to 3 days for about 6 to 8 weeks. With

the application of spent wash the moisture content in press mud increases to about 65% to 70%. In

the presence of culture and adequate moisture the microbial reaction starts and heat is generated. It

increases temperature of the press mud to about 60-65oC. At such temperatures some of the water is

evaporated and moisture content in press mud reduces. This slows down the reaction and thereby the

temperature of press mud reduces. In the meantime, the windrows are again sprayed with spent

wash to enhance its moisture content and composting process. The windrows are intermittently

aerated by reshuffling with mechanical aero tiller to keep the mass under aerobic condition.

The optimum moisture content and temperature for composting is 55 % and 450C, respectively. After

composting brown coloured free flowing bio manure is produced. The product is cured for about 2

weeks on the yard. The product is pulverized, screened, packed in 50 Kg HDPE bags and then stored in

the godown. The product is dispatched to farmers through lorry or tractor transport.

Bio-composting

A. Compost yard

Press mud is spread on the compost yard in the form of wind roses. Space is also provided in the

compost yard for storage of press mud and composted manure. Space is also provided in the yard for

movement of vehicles in between and around the wind roses. Compost yard is constructed as per

CPCB guide lines to avoid seepage of spent wash / leachate. The ground is leveled, compacted and

covered with 300 mm thick granite stone soling. The flooring is constructed with concrete slab 150

mm thick. The floor has a gradient of 3 % so that the rain water flows freely to the garland canals

provided. The specifications of compost and storage yard are given below:

Area Requirement for Composting and Storage S. No. Particulars Specification

1. Distillery Capacity 50 KLD 2. Working days/yr Molasses ased operation 240 3. Total spent wash (at 339 KLD for 240 days) 81360 KL/yr 4. Spent wash to press mud ratio at 60 d cycle 2.5 : 1.0 5. Requirement of press mud

(81360 KL/yr) / (2.5 : 1.0 KL/T) 32544 T/yr

136 MT/day

6. Compost cycles per annum at 60 day cycle 4 7. Requirement of press mud per cycle

(27120 T/yr)/ 4 cycles 8136 MT/cycle

8. Requirement of compost area for 850 T press mud /acre (8136 T) / (850 T/acre) 9.57 acres

9. Press mud storage capacity ( Press mud of one cycle) 8316 MT/cycle

10. Density of Press mud 0.5 T/m3 11. Pressmud storage area (press mud of one

cycle to be stored for 2 m height) + 20 % area for movement of vehicles (8316X 1.2) / (0.5 X 2)

9972 m2

2.47 acres

12. Yield of bio-manure per T of press mud 0.6 T 13. Quantity of bio-manure per year

(8316 X 0.6 X 4) 19958 MT /year

83 MTD

14. Density of Bio-manure 0.5 T/m3 15. Storage capacity of bio-manure at 0.33 % of

annual capacity (19958 T x 0.33) 6586 m3

12. Land area for storage of bio-manure to be stored for 2 m height + 20 % area for movement of vehicles (6586 X 1.2) / (2 X 0.5)

7903 m2

1.95 acres

13. Total land area for compost plant 14 acres or 56658 sq meter 14. Leachate storage capacity for collection 500 m3 15. Size of leachate tanks 20m x10m x2.5m

The floor is sloped (3%) to provide free flow of surface run off. A garland gutter is provided all around

the yard to receive and lead the surface runoff to the leachate collection tank. A parapet wall of 0.6 m

height is constructed all around the yard to prevent the spillage of material.

B. Area for Storage of Pressmud

Space is provided in the compost yard itself for bulk storage of press mud. Provision is made to store

the quantity of press mud needed for one cycle of compost process.

C. Area for Storage of Bio-manure

Space is provided in the compost yard itself for bulk storage of bio-manure. Provision is made to store

33.3 % of the annual bio-manure produced in the plant.

D. Leachate collection tank Press-mud and composted manure are stored in the compost yard during process of composting for

several days. Hence storm water from compost area forms leachate with composting material.

Storage tanks are constructed to collect leachate/storm water from the compost yard during rains.

Storm water from the yard is directed to surrounding garland gutter and then lead to the leachate

storage tank. The tank is constructed in earthen work and its interior is suitably finished with plastic

sheets and stone slabs to prevent seepage. The leachate, thus collected is continuously recycled to

the spent wash storage tank.

E. Godown for bio-manure processing

A building is to be provided to locate facilities such as pulverizer, sieving, packing and storage of

bagged bio-manure. The storage space shall be adequate to stock about 3 day’s production of packed

bio manure:

F. Machineries for composting process

Following equipments are provided for composting of press mud:

Equipments used for composting of press mud S. No. Machineries Quantity

1. Tractor for transportation of press mud from storage site to compost yard and bio-compost from compost yard to finishing building

2

2. Aero tiller along with spent wash spraying system 1 3. Front end loader 1 4. Sieving machine 1 5. Pulverizer 1 6. Bagging and sewing machine 1 set 7. Balance 1

Performance of bio-compost plant

The quality of bio-manure observed is given below:

Characteristics of composted bio-manure S. No. Parameters Observed value Desirable value

1. Colour Brown Tea brown 2. Smell Sweet Smell Agreeable smell 3. Nitrogen 1.60 – 1.68 % 1.5-1.8 % 4. Organic Carbon 21 -25 % 20-25 % 5. C/N ratio 13.7 – 14.9 <15 6. Moisture content 28 – 32 % <26-30 % 7. P2O5 1.3-1.6 % 1.5-2.0 % 8. K2O 3.3-3.6% 3.0-3.5%

Thus the spent wash generated from molasses based operation is fully converted to bio-compost and

the plant becomes a zero discharge unit.

Point No 4

Adequate Treatment scheme for spent wash generated from grain based distillery.

Reply About 334 KLD spent wash will be generated from the grain based process. Grain which is proposed

for use as raw material in distillery contains large quantity of in-organic salts and non fermentable

organic matter, fibrous material as impurities. Major portion of these impurities are separated in

decanter. Traces of these impurities are also present in lees water and washings. After decantation

the separated water is concentrated in multiple effect evaporators. Concentrated spent wash is

sprayed on the decanted material which is further dried in a drier to yield DDGS.

Hence the plant is envisaged as ZERO DISCHARGE unit

Design philosophy

The plant has been conceived as a ZERO LIQUID DISCHARGE UNIT and there will be no effluent

discharge from the Plant. This will be achieved by combination of a horizontal high speed Decanter

and a Multi-effect Evaporation Plant. After removal of alcohol produced in fermentation section,

Effluent leaves the distillation section from the base of beer stripper column. Spent wash contains

suspended and soluble grain solids comprising of fibers, proteins, fat, etc. which remain unconverted

in fermentation and pass through as such, plus valuable yeast nutrients added during the

fermentation process in the plant. The resulting product has high nutrient content and has great value

as cattle-feed.

Operation of DWGS (Distillers Wet Grain and Solubles), Section can be divided broadly in three sub-

sections showed in following Figure :

A. Decantation Effluent from the distillation section is passed through horizontal high speed decanters, which

separates suspended grain fiber and solids from the spent wash and splits effluent feed stream

into two streams, as below:

Wet Cake: solids stream consisting of majority of the suspended solids. Wet cake from the

decanter has approximately 30 % solids and 70 % water. Wet cake from decanter is mixed with

the concentrated stillage syrup from the multi-effect evaporator unit to produce DWGS.

Thin Stillage: liquid stream consisting of mainly water with all dissolved solids and remaining

suspended solids. Liquid stream from the decanter (thin stillage) is collected in a tank. A part

of thin stillage is recycled back to the liquefaction section.

This recycling reduces the requirement of process water, chemicals and nutrients for the plant.

The remaining portion of thin stillage is pumped to a steam heated highly energy efficient

Multi-effect Evaporator System for concentration.

B. Evaporation Evaporation is a thermal operation used to remove a liquid from a solution by boiling off the

solution. The evaporation process starts with a liquid product and ends up with a more

concentrated as the main product from the process. The evaporation system comprises of

highly energy efficient Five Effect Evaporator Unit. In five effect evaporator unit there will be

five evaporator bodies and one kg of steam will be used to evaporate five kg of water from the

spent wash.

Low pressure exhaust steam from backpressure steam turbine will be used as heating media

and evaporator unit will remove water from the thin stillage. The flow pattern through the

evaporator bodies is specially designed for the optimum utilization of available energy.

Adequate flow, temperature and level controls are provided for all effects to ensure trouble

free operation of evaporation unit.

The thin stillage from the decantation section is concentrated to about 50% solids content by

removing water from it. Process condensate from the evaporator is recycled back to the

liquefaction section and steam condensate from the evaporator is recycled back to the boiler,

thus substantially reducing the requirement of process water in the plant.

Concentrated syrup from the multi-effect evaporator system is mixed with wet cake from

spent wash decanter. The mixture is known as DWGS (Distillers Wet Grain and Solubles),

contains all nutrients and is very good cattle feed.

It can be sold as such to the local cattle feedlots/dairies for same day consumption. But, as it

cannot be stored as such for a longer time period, (due to its higher moisture content). To

improve the shelf life of DWGS it will be dried in an industrial drier to reduce its moisture

content and the resultant product is known as DDGS (Distillers Dried Grain and Solubles).

C. Drying To improve the shelf life of DWGS it will be dried to reduce its moisture content and the

resultant product is known as DDGS (Distillers Dried Grain and Solubles). DDGS can be packed

and stored for longer time.

DDGS is produced in a Steam Tube Bundle Rotary Dryer, producing premium quality product.

Wet cake from spent wash decanter is blended with concentrated syrup from the evaporator

and conveyed to the DDGS Dryer. The dryer rotates, providing direct contact between the

dryer feed and hot gases. The dry DDGS leaving the dryer drum is separated from the exhaust

vapor and transferred to the storage. The advantages of DWGS/DDGS System are:

Ensuring Zero Discharge Status for the Distillery Unit with clean and hygienic operation.

Conserving the water resources by drastically reducing the water requirement in the fermentation process

Reducing the land requirement, as no large lagoons, composting yards, etc. are required

Removing the nuisance of bad odor associated with distillery

In this way with grain based operation also zero effluent discharge will be ensured.

Point No 5

Submit plan (5% of project cost) earmarked towards the Enterprise Social Commitment (ESC) based on local needs and action plan with financial and physical breakup/details.

Reply The total capital cost of the project is INR 86.96 Cr and about INR 4.4 Cr will be earmarked towards

Enterprise Social Commitment (ESC). Detailed action plan is given below:

Sr. no.

Particulars Amount(in lakhs) (INR)

1. Sanitation facilities in surrounding villages 65 2. Fund allocation under “Swaccha Bharat Abhiyan” 55 3. Social forestry 25 4. Organization of medical camps in surrounding villages. 65 5. Training, awareness and skill development programmes 55 6. Women empowerment 40 7. Drinking water facility 75 8. Educational facility 60

Total 440

Point No 6

Submit layout plan for greenbelt

Reply Green belt planning will be done with ecological perspectives for distillery plant of KGS Sugar and Infra

Corporation Ltd. About 5.3 ha (33% of the plant area) will be developed as greenbelt area details are

given in related Table and Figure (Annexure 3).

Greenbelt Development Plan Sr. No. Year Greenbelt Area (Ha) Total Plants (@2500/ha)

1 1st Year 1.0 2500 2 2nd Year 1.0 2500 3 3rd Year 1.5 3750 4 4th Year 1.8 4500

Total 5.3 13250

Point No 7

Rain water harvesting facility to be provided

Reply Annually, about 30200.85 m3 water will be conserved by rain water harvesting system. Out of this

about 4314.60*m3 will be used in molasses based process and remaining 25886.25 m3 will be

discharged in ground water through open well and structure details are given in Figure. Detailed

calculation is given blow:

S. No. Particulars Catchment Area

in m2 (A) Runoff

Coefficient (C) Rainfall Intensity in

mm/Annum (I) Discharge

(m3) 1 Rooftop area 6768 0.85 0.75 4314.60* 2 Green area 53100 0.65 0.75 25886.25

Total 30200.85

Note: 4314.60*m3(4314.60/240 days =18.0 m3/day) will be routed to water storage tank through

pipe and will be used in process water during molasses based operation. And reaming 25886.25 m3

will be treated in settling pond and recharged in ground water.

Point No 8

Status of Environmental Clearance and consent to operate of the existing unit of sugar and CPP.

Reply Existing sugar industry is having capacity of 4000 TCD and not comes under the EIA Notification 2006

preview. The copy of the latest consent to operate is attached as Annexure 4.

Annexure 1

Rain Water Harvesting

Annually, about 30200.85 m3 water will be conserved by rain water harvesting system. Out of

this about 4314.60*m3 will be used in molasses based process and remaining 25886.25 m3 will

be discharged in ground water through open well and structure details are given in Figure 1.

Detailed calculation is given blow:

S. No. Particulars Catchment Area

in m2 (A) Runoff

Coefficient (C) Rainfall Intensity in

mm/Annum (I) Discharge

(m3) 1 Rooftop area 6768 0.85 0.75 4314.60* 2 Green area 53100 0.65 0.75 25886.25

Total 30200.85

Note: 4314.60*m3(4314.60/240 days =18.0 m3/day) will be routed to water storage tank

through pipe and will be used in process water during molasses based operation.

FIGURE 1 OPEN WELL

Annexure 2

Water Balance of Sugar Industry

Sr. No. Water Uses Water Consumption (m3/d)

Losses (m3/d)

Recycle (m3/d)

Effluent Generation (m3/d)

1 Processing of Sugar Mill 640 90 300 250 2 Cooling for cogeneration 360 300 - 60 3 Heating for Sugar Mill 740 15 700 25 4 Heating for Cogeneration

Plant 2120 142 1920 58

5 Washing (Common) 16 0 0 16 6 Miscellaneous (Common) 40 0 0 40 7 Domestic use 20 20 0 0 8 Green Belt Development 150 150 0 0 Total 4086 717 2920 449 9 Lees Recycle 2920 - - -

10 Fresh Water Requirement 1166 - - - Effluents Generations TOR Point No. 46

11 Less water used for ash quenching

- - - 118

12 Green Belt Development - - - 150 13 Balance Effluent (Process

Condensate Water) - - - 180*

14 Recycle of Treated Effluent 150 - - - 15 Fresh Water Requirement

after using of treated effluent

1016 - - -

Note: *180 m3/day will be used for Molasses based operation in proposed distillery project.

Annexure 4Status of Environment Clearance and Copy of Consent to Operate

Consent to Operate