PREFEASIBILITY REPORT

For
PROPOSED
Sugar Mill, 3500 TCD
Co-gen. Power Plant, 19 MW, &
Alcohol Distillery, 45 KLPD

By
M/s Sree Angadi Dutt Sugar and Distilleries Pvt.
Ltd.,
At Village Hoswal, Taluka Dharwad,
District Dharwad, Karnataka
 INDEX

S. No. CONTENTS PAGE NO.

1 Introduction 3

2 Justification 3

3 Location 5

4 Resources 5

5 Process 7

6 Pollution Control 11

7 Background Study 20

8 Safety 21

9 EIA Study Report 22

10 Conclusion 22
 1. INTRODUCTION

Sree Angadi Dutt Sugar and Distilleries Pvt. Ltd., (referred as This Industry TI hereafter) is
desirous to establish three units at Village Hoswal, Taluka Dharwad, District Dharwad,
Karnataka. Thus,

# Production Unit No. Cat Unit Proposed

Capacity
1 Distillery 5(g) A KLPD 45
2 Sugar 5(j) B TCD 3500
3 Co-Gen Power 1(d) A MW 19

The Notification no. S. O. 3067(E) amended on 1st December 2009 h a s covered these
type of industries under its entry shown above. With Screening it is necessary for this
Industry to approach Ministry of Environment and Forests (MoEF), New Delhi for
Environmental Clearance for distillery and co-gen unit (while the sugar unit being less than
5000 TCD will need only consent from SPCB). This Pre- feasibility Report is prepared for
forming a framework for EIA study, Scoping and finalizing the Terms of Reference, for
distillery and co-gen.

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

The working days for sugar will be 180 days, for Co-gen 300 days, for distillery 270 days and
for composting 240 days.

This Company is Registered under Companies’ Act 1956, on January 2, 2009. Total Capital cost
of these three units is 288.57 crores.

2. JUSTIFICATION
Molasses is one of the waste products produced from sugar factory. Environmentally
speaking these are very undesirable & risky properties. However, it is possible to put it to
useful purpose by producing Alcohol. Molasses can be used as raw material for distillery.
The resultant alcohol has various uses in chemical industry, pharmaceutical industry and as
Ethanol. The liquid effluent however, is highly polluting though not poisonous or toxic. This
organic load can be converted to useful compost, which in turn can assist growth of sugarcane
for the member farmers. For making the compost press mud solid waste can be useful as filler
material and baggasse solid waste can be useful to produce much needed power for process. It
is likely that the ethanol may be used more as automobile fuel in the days to come & hence new
distillery unit is justifiable.

Distillery unit needs the raw material as molasses & press mud as filler material to be self
sufficient for this it is desired to have a sugar factory of our own. This area has very good soil &
availability of water. The people are enthusiastic about such crop & hence sugar factory is
justifiable.

Sugar factory will also produce baggasse, this baggasse has fuel value. We can convert this in
power & steam. Power will be useful to our units & colony for captive unit & surplus can be
given to State, as this State has short in power supply. Thus, spent steam at its tail end can still
3
be used for production of sugar & the alcohol. Thus, a power plant is justifiable.
Thus, this is a Waste Exchange Oriented Unit (WEOU) and deserves to be encouraged for
National Productivity and sustainable development.

There is Excellent irrigation facility around the selected candidate site, with favourable Black
Cotton soil. We expect required cane 6.30 lakh tonnes within 25 km in near future. Sugar
quality is good and recovery is expected to be in the range of 10.8 to 11.5

Project Proponents are devoted persons as Mr. Gaurav Kumar as Chairman & Managing
Director, with MBA from United Kingdom and presently looking after many projects here since
2001. He is ably supported by Mr. Sameer Agarwal, Director, who has very appropriate
experience with M/s Laxmipathi Balaji Sugar & Distilleries Pvt Ltd., since 2006.

In power transmission and distribution, the losses on an average are as high as 24.3%, which
will be saved by having our co-gen unit in the same premises power obtainable without any
transmission losses.
4
3. LOCATION
The proposed location is in Village Hoswal, Tehsil a n d D i s t r i c t D h a r w a d , in State
o f Karnataka. The land required for proposed industrial unit is already in
possession and is not prime Agricultural Land. This is flat Land whereby Cutting-filling
will be nearly balanced and there will be No/Low Borrowing from Nature.

Within 10 km Influence Zone, there is no Tropical Forest, Biosphere Reserve, National

Park, Wild Life sanctuary and Coral Formation Reserve. The Malprabha River is at 25
km, R a i l w a y station, Tehsil & District Place Dharwad is 55 Km, National Highway 4
(Belgaum - Dharwad, 2 Km) is at a sufficient, s a f e distance. The Clearance is obtained
f r o m Local Grampanchayat and hence will have public acceptability. The rainfall is 609
mm with major contribution of south-west monsoon. The temperature range minimum and
maximum is between 14 and 42 degree C. We have surveyed three sites and finally selected
this candidate site.

4. RESOURCES
This Industry proposed to establish a molasses based 45 KLPD distillery, 3500TCD Sugar
Plant & 19MW Cogeneration Plant.

(A) The capacity of the proposed distillery shall be 45 KLPD. For this the main and sole raw
material is molasses. The yeast brings about the change. Some chemicals in small
quantity are used for supporting propagation of the yeast and help in fermentation.
Thus,

# Raw Material Quantity/day

1. Molasses 160 T
2. Sulfuric acid 80 lit
3. Nutrients N, P 40 kg
4. Turkey Red Oil (TRO) 80 kg
Our own molasses is not adequate for the purpose and hence MoU will be entered with
other sugar mills in the vicinity. The molasses will be transported with due responsible
Care.

(B) The capacity of the proposed sugar mill shall be 3 5 00 TCD. For this the main and sole
raw material is sugarcane. Some chemicals in small quantity are used for supporting.
Thus,
# Raw Material Quantity/day
1. Sugarcane 3500 TPD
2. Sulfur 2.0 T
3 Lime 7.2 T

(C) TI proposes to have a baggasse/ bio-mass based 19 MW Co-gen power plant, which
requires following resources. For this the main raw materials are baggasse and high
quality water. Some chemicals in small quantity are used for supporting. Thus,

5
 # Raw Material Quantity/day
1. Baggasse 932 TPD

Our own bagasse is not adequate for the purpose and hence we shall take help of surplus
biomass available, in this area. In this fertile and irrigated tehsil, we can get the agricultural
bio-mass in the form of Rice husk, Maize cobs, Tur stems, Cane trash, Cotton stems etc. Within
25 km from the site itself the availability is of 27466 tonnes and between a range of 25 to 50
km distance additionally 2,13,023 tonnes, thus totaling to 2,40,489. Out of this cane trash
within 25 km is 15,390 tonnes from which fields our cane is likely to come to us. This is
considering collection efficiency as 75 %. Bagasse is available during the crushing season of 6
months. The agro- biomass is also available from November to April i.e. six months. We have
two options for boiler fuel namely (a) either 180 days fully on bagasse and remaining 120
days on bagasse + biomass combination; or (b) all 300 days on bagasse + biomass uniformly
blended. For bio-mass handling important steps are like harvesting  transportation sizing
and  drying; before biomass is ready as fuel. By us, Biomass ‘banks’ will be located at
identified seven locally central places with sufficient space, equipments erected for weighing
 cutting/chipping  bailing and also connectivity.

In addition to the raw material, utilities are also required. These are:
 Power: Need 1500 KW. Available through Govt. Electricity Board and own
generation.
 Man Power: Staff, skilled and unskilled totally 270 + 80 = 350 persons will be
required, and will be available. For essential people from Safety, Environment and
production point of view, a small colony will be provided in vicinity,
 Water Need is a b o u t 555 + 353 + 435 = 1343 cum/d and shall be met from
Malaprabha River (25Km away), with government permission.
 Molasses Storage Tanks (1 + 3 = 4.) of 5000 MT capacities each.
 Alcohol will be stored in steel tanks with dyke walls.
 Sugar will be stored in separate sugar godowns and for other materials, warehouses
provided.
 Building materials: This is not a heavy construction, and majority is in fabrication
from Mild steel structural. The orientation is so kept as to balance nearly the
cutting and filling. The small requirement is available systematically. The
construction -erection time will be small and will be done in daytime. Labor camp
is not necessary.
 Filler material for composting is press mud and is available from parent sugar
factory.
 The adjoining road has a carrying capacity of 3000 vehicles per day, and presently
serving us very comfortably
 Total proposed Cost for project is Rs. 125.40 + 103.17 + 60.0 = 288.57 Crores.
 Layout : Sugar plant will be accommodated on 8.09 ha including cane yard, sugar silos
–godowns; Cogen power plant will be accommodated on 6.07 ha including bagasse
storage, and for expansion, distillery, bio-compost, staff quarters, offices, internal
roads, open spaces RWH, and gardening 5.66 ha will be kept reserved; Thus totaling to
about 19.83 ha.
 The 110 kV Switch yard: this will include power transformers, insulators, tower
structure, circuit breakers, isolators, and corresponding meters

Thus all the resources are available and will be used economically and judiciously.
6
 5. PROCESS

(A) Distillery –

TI proposes to establish a molasses based 45 KLPD Distillery, the peculiarities of

manufacturing process are as follows,

This is a simple three step process namely molasses preparation, fermentation

and distillation. The standard flow sheet as will be adopted can be given as -------

For the sake of eco-friendly considerations continuous fermentation and multi- pressure
distillation will be practiced. The CO2 will be scrubbed in water and the water that
entraps escaping alcohol fumes will be recycled for molasses preparation.

(B) Sugar Unit –

TI proposes to establish sugarcane based 3500 TCD Sugar mill. The peculiarities of manufacturing
process are as follows,

This is a simple three step process namely Cane milling, Evaporation and Crystallization. The
standard flow sheet as will be adopted can be given as

7
Most of the sugar factories in India follow double sulphitation process and produce plantation
white sugar.

The major unit operations are shown in figure these are

1. Extraction of juice
2. Clarification
3. Evaporation
4. Crystallization
5. Centrifugation

8
 1. Extraction of Juice
The sugarcane is passed through devices like knives for cutting the stalks in to chips before
being subjected to crushing in a milling tandem comprising 4 to 6 three roller mills. Fine
preparation with its impact on final extraction, is receiving special attention & shredders &
particularly the fibrizers are gaining popularity. The mills are of modern design, being
equipped with turbine drive, special feeding devices, efficient compound imbibitions system
etc. In the best milling practice, more than 95% of the sugar in the cane goes into the juice, this
percentage being called the sucrose extraction or more simply the extraction.

A fibrous residue called bagasse; with a low sucrose content is produced about 25 to 30 % of
cane, which contains 45 to 55% moisture.

2. Clarification
The dark-green juice from the mills is acidic (pH 4.5) & turbid, called raw juice or mixed juice.
The mixed juice after being heated to 65 to 75 0 C is treated with phosphoric acid, sulphur
dioxide & milk of lime for removal of impurities in suspension in a continuously working
apparatus. The treated juice on boiling fed to continuous clarifier from which the clear juice is
decanted while the settled impurities known as mud is sent to the field as fertilizer. The clear
juice goes to the evaporators without further treatment.

3. Evaporation
The clarified juice contains about 85 % water. About 75% of this water is evaporated in
vacuum multiple effects consisting of a succeeding (generally four) of vacuum boiling cells
arranged in series so that each succeeding body has higher vacuum. The vapours from the
final body go to condenser. The syrup leaves the last body continuously with about 60% solids
& 40% water

4. Crystallization
The syrup is again treated with sulphur dioxide before being sent to the pan station for
crystallization of sugar. Crystallization takes place in single-effect vacuum pans, where the
syrup is evaporated until saturated with sugar. AT this point ‘seed grain’ is added to serve as a
nucleus for the sugar crystals & more syrup is added as water evaporates. The growth of the
crystals continues until the pan is full. Given a skilled sugar boiler (or adequate
instrumentation) the original crystals can be grown without the formation of additional
crystals, so that when the pan is just full, the crystals are all of desired size & the crystal &
syrup form a dense mass known as ‘massecuite’. The ‘strike’ is then discharged through a foot
valve into a crystallizer.

5. Centrifugation
The massecuite from crystallizer is drawn in to revolving machines called centrifuges. The
perforated lining retains the sugar crystals, which may be washed with water if desired. The
mother liquor ‘molasses’ passes through the lining because of the centrifugal force exerted &
after the sugar is ‘Purged’ it is cut down leaving the centrifuge ready for another charge of
massecuite . Continuous centrifuges may purge low grades. The mother liquor separated from
commercial sugar is again sent to pan for boiling and re-crystallization. Three stages of re-
crystallization are adopted to ensure maximum recovery of sugar in crystal form. The final
molasses is sent out the factory as waste being unsuitable for recovery of sugar under
commercial condition from economical point of view.

9
(C) Co-Gen Power Plant- –

TI proposes to establish a bagasse based 19 MW Co-Gen Power Plant, the peculiarities of

manufacturing process are as follows,

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

Sugar Cane

Milling Juice (for sugar production)

Baggasse

Feed Water Boiler

Superheated Steam

Turbo Generator Steam (for sugar process)

Condensate

De-aerator Feed Water Tank

Industry

19 MW Colony
Govt.

Production care by Instrumentation with Electronic governor, programmable Logic Controls

with MMI & programming stations, DCS based interlocks & protection as well as for turbine
monitoring .

We propose to erect Data Acquisition & Control System. This will facilitate to operate, monitor
and control the entire Co-gen plant. This will cover boiler, turbine, generation and auxiliaries.
The software will govern all functional requirements, with interlocks, alarms and graphical
display.

10
 6. POLLUTION CONTROL
❖ Water Budget
The water input and wastewater output for collective alcohol production can be described
stepwise as follows:

[A] Water Budget for Distillery Unit

Sr. Utilization Water input cum/d Loss Water out cum/d

No.
1. Cooling Tower Fresh water in 120 60 Purging water, sober 60

2 Floor & Fresh water in 10 2 Effluent, moderate to ETP 8

vessel
Washing
3. Fermentation Fresh water 301 3 Wash sent to Distillation 477
From feed 85
Spent lees 84
CO2 Scrubbing 10
4. Distillation Fermented wash 477 5 Spent leese moderate to 28
in ETP
Spent lees recycled 84
Spent wash 360
5. CO2 Scrubbing Fresh Water 10 0 Scrubbed water to 10
Fermentation

Input side: Industrial

Fresh water for Industry 441 cum/d

Water from feed 85 cum/d
Internal recycle 94 cum/d
Total Input = 620

Output side: Industrial

Loss from Industrial Use 70 cum/d
Effluent sober nature sent for garden 60 cum/d
Effluent Moderately polluted 36 cum/d
Internal Recycle 94 cum/d
Effluent Highly polluted spent wash 360cum/d
TOTAL 620 cum/d

11
Effluent Treatment Plant:

Stream (A): Sober effluent: (60 cum/d)

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

Stream (B): Industrial moderately polluted wastewater: (36 cum/d)

The Moderately polluted wastewater is the spent lees stream, floor vessel washing which
has low PH however no low organic matter. After the pH correction and bio-oxidation of
this stream, it will be joined to treated sugar factory effluent guard pond, which can be
disposed on land for irrigation or recycled in process. This will also take care of the
condensate water post-MEE, 180 cum/day for treatment and disposal.

Stream (C): Industrial highly polluted wastewater: (360 cum/d)

Zero Pollution by Distillery Effluent - Technical Approach
The spent wash coming out of distillery is passed through heat exchanger to reduce the
temperature from incoming 90o-100o C to 30o-40o C. This is found necessary, as the
major culture grouping is in mesophillic range. The initially neutralized effluent is then
taken to the 1st phase process of methane bio-digestion.

The characteristics of effluent treatment scheme are expected to be:

Characteristics of Effluents
# Parameter (C) Spent wash (A +B) Sober and Moderate
1 pH 4.0 – 4.5 5.5 – 6.5
2 Temperature 90-95 Co 45-850 C
3 Color Dark brown Faint
4 Total Solids 125000-137000 1300-1500
5 BOD 50000-55000 500-700
6 COD 120000-130000 1200-2000
7 Quantity CMD 720 139 (82 + 57)
(All Values from serial No. 4-6 are in mg/l)

The basic operation is divided into two phases as it is necessarily a two phase operation
and which gives greater stability to 2nd phase operation of ‘methane phase’. The
effluent after acid formation and regression enters the 2nd phase reactor, wherein it is
conditioned with return sludge/supernatant. Multiple entry inlet and weir outlet combined
with higher flow through jet mixers and sparger mechanism with high velocity gives the
‘upflow sludge blanket reactor with ‘complete mix’ facility. The effluent after methane phase
reactor is subjected to flash degasification to release entrapped gases. This is thereafter
subjected to settling operation to avoid carryover of biomass/solids which is recycled back
to the digester for maintenance of biomass. The supernatant is also partially recycled to
maintain inlet conditions as per design. The biogas is collected into a storage tank with
pressure maintenance facility and is used in the combustion device or flared.

The basic advantage of the process is, this overcomes all the practical problems of
various sub techniques, which is required to suit Indian Working conditions.

Composting is the decomposition of heterogeneous organic wastes by a mixed

12
microbial population in a moist, warm, aerobic environment. By gathering the inert base
material of Filter Cake, press mud from Sugar Factory into heaps and Spraying with
the Spent wash, along with the culture dosage, by conserving some of the heat of
fermentation, the temperature rises and rates of degradation result which are far
higher than those achieved under ambient conditions. The mature end product is
‘humus’, consisting largely of the humic acids. The aim of composting is to convert a
major proportion of organic wastes into a marketable product.

A judicious combination of treatment disposal techniques in the form of Anaerobic

Digester and aerobic Composting with Filter Cake from sugar factory is successfully
working at many factories.

It is however observed that in most of the cases, the material balance requirement of
Composting Process is not fulfilled; forcing the distillery managements to discharge
untreated / partially treated effluent in the environment / river for dilution. This
specifies the need of adopting a ‘Composite Approach’ wherein after Anaerobic Digestion,
with the help of Multi Effect Evaporator; the anaerobically digested Spent wash is
reduced to desired volume suitable for the mass balance of the composting process,
Filter Cake availability and ease of handling. This will also result in utilizable water of
neutral pH and low organic matter concentration to be reused after treatment.

This technique is really useful in achieving the fool - proof technology of zero pollution
by adopting the approach of, Bio-digestion + MEE + Aerobic Composting.

By adopting the above technology, it is possible to achieve not only zero pollution,
but also will utilize fully the nutrient values and organic matter of Spent wash for the
resource generation.

a) Treatment Unit Design

(i) Acid Phase Reactor Inlet characteristics-

(Max.) Wastewater flow 360 cum/d

COD (mg/l) 120000 – 130000
BOD (mg/l) 55000 - 60000
TSS (mg/l) 2000 - 3000

The spent wash from distillery is collected in a one-day holding tank working as
Acid Formation Reactor cum Lifting Sump from where pumping of the effluent
would be done to Bio-digester.

The high BOD effluent of spent wash is 360 cum/d, however bio-digester is design for
capacity of 400 cum/d for safety.

Initially, pH adjustment has to be carried out and the same tank would be used for
neutralization and initial mixing.

(Max.) wastewater flow 400 cum/day

Taking detention time 24 Hrs
Volume of equalization tank 400 cum
Taking a liquid depth 3m

13
Provided one tank with dimensions 12 x 12 x (3+0.5) m. Two chemical pumps (one
stand bye) of capacity 25 cum/hr and a total head 15m would be provided to pump
the effluent to anaerobic digester. Adequate mixing arrangement would be provided
for mixing the effluent with chemicals in the tank.

(ii) Anaerobic Digester

The effluent would then be pumped to anaerobic digester.

(Max.) Volume of effluent 400 cum/day

C.O.D. concentration taken 125000 mg/l
Total C.O.D. load 50, 000 kg/d
C.O.D. loading rate 5.0 kg C.O.D./cum/d
Volume of Digester (totally) 10,000 cum

Provide two digesters with this volume and with suitable diameter/Height ratio.
Adequate recirculation would be done of the effluent from the digester outlet to
the inlet point. The inlet would be multiple inlets so that no dead pockets are formed.

The biogas formed would be collected in the upper space of the anaerobic digester,
which would also act as temporary storage arrangement. The biogas would be
taken for burning in the boilers.

The effluent at the digester and further unit of Lamella clarifier outlet is expec ted to
have following characteristics.

Flow : 360 cum/day

Temperature : Ambient
pH : 7-7.2
B.O.D. : 5000 - 6000 mg/l
C.O.D. : 40000 - 45000 mg/l
T.S.S. : 3000-4000 mg/l

b) MEE T echnology
It has been imperative that the waste volume should be reduced to as small as
possible. This is to achieve the critical material balance with the filler material i.e.
press mud, which is available seasonally, i.e. for a shorter duration, and therefore in a
limited quantity. This purpose is achieved with the help of Multi Effect Evaporator
system, which is specially designed for such application and effluent. This achieves
a dual purpose of not only volume reduction of the Spent wash, which is further
validities to achieve zero discharge, but more important, water recovery, which can
be reused in the process. By this volume will be reduced from 360 to 180 cum/day.

c) Composting
For scientific aerobic composting CPCB has laid following New Guidelines:
➢ Working days of Distilleries maximum : 270 days
➢ Spent wash storage capacity: less than 30 days
➢ Press-mud to Spent wash ratio 1:2.5
➢ Proper preparation of land for avoiding leaching and percolation.
➢ Land required for composting 850 MT/Acre/Cycle
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 ➢ Equipment: Homogenizing machine

Thus for our purpose, following ancillary units will be provided:

Sr. No. Unit Particulars

1 Storage tank of 30 days
2 Windrow Floor
3 Homogenizing machine
4 Spraying of spent wash
7 Maturation Yard
In earthwork, with HDPE lining.
Entire area concreted with LDPE lining
Sturdy design with heavy-duty rotor
construction and gear box
Auto-spray with fine droplets network
Storage and maturation of Compost before
dispatch, with sieving arrangements.

Material Balance Basis

Distillery capacity 45 KLPD
Working days of Distillery 270 days
Spent wash per day (After MEE) 180 cum
Spent wash annually 270 x 180 = 48600cum
PM : SW (Press mud to Spent wash) 1:2.5
ratio, Composting Cycle (60 days each)
PM required annually 48,600 / 2.5 = 19440 MT
PM Production daily from sister 140 MT
concern sugar factory (adjoining)
PM Production annually (180 days) 25,200 MT
Hence, the Press mud available is sufficient.
Land Required at the rate of 850 MT/Acre/Cycle
Duration of cycle 60 days
No. of Cycles per year Four
PM Tonnage per cycle 19,440 / 4 = 4,860 MT
Land Required for 4050 MT 4,860 / 850 = 5.71 acres
Provide 20% extra for roads, gutters etc. 6.85 acres
Area for Press Mud and Finished Product 1.5 acres
Laboratory, Admin. Office 0.40 acres
Lagoon Storage 1.5 acres
Total land requirement 10.24 acres

Total land of 11 acres is reserved for the purpose. Thus zero discharge is achieved
from the beginning.

DISPOSAL
Disposal is of predominant importance in total environmental management.

Stream (A)
The stream of utility water (cooling purging) after cooling is fit for joining
stream (B) & can served as diluents.
15
 Stream (B)
The stream of industrial effluent of only moderately polluted after full treatment it
is fit for disposal on land for irrigation, after bio-oxidation or for recycle after
tertiary. This will also include 180 m3 of condensate from MEE.

Stream (C)
The stream of industrial effluent of highly polluted type coming after Distillation,
Re-boiler and M.E.E. treatment is then converted in solid compost. The Compost has
following quality:

Moisture Content less than 35 %

Organic Carbon 20-25 %
Phosphorus 1.5 %
Nitrogen 1.5-2 %
Potassium 2 to 3.5 %
C:N ratio less than 17

The compost has a ready and developed demand in this area. This will largely
substitute the fertilizer and soil conditioners for the crop.

The treated domestic sewage coming out of septic tank and anaerobic filter shall
be disposed on land for gardening by subsurface irrigation.

180

360 180

[B] Water Budgeting for Sugar Unit

# Use station Input Loss Effluent

Sober Moderate
1 Cooling Fresh 180 90 90 -
2 Floor & vessel washing 15 5 10
3 For Process 350 40 310
4 Lab Fresh 10 4 6
Total 555 139 90 326
Input side (Industrial):
Water for Industry,(Sugar) - 555cum/d

Total Input - 555cum/d

Output side:
a. Loss from Industrial Use - 139 cum/d
b. Effluent sober nature sent for ETP - 90 cum/d
c. Moderate effluent recycle - 326 cum/d

Total Output - 555 cum/d

16
 The Sober & moderately polluted effluent after ETP will be recycled collectively.

[C] Water Budgeting: - Co-gen unit

# Step Water input cum/d Loss Wastewater out cum/d

1 Regeneration Fresh = 8 1 Moderate BOD to ETP = 7
De-min
2 Boiler Fresh = 125 (Make-up) 110 Sober to ETP = 15
3 Cooling 150 (Make-up) 130 Sober to ETP = 20
4 Pump Blower Fresh = 60 3 Sober to ETP = 57
Sealing water
5 Floor & vessel Fresh = 10 2 Mod. To ETP = 8
washing
353 246 Mod. 15 + Sober 92 =107
Table: Details of water balance

Input side (Industrial):

a. Fresh Water for Industry, (Co-gen) - 353cum/d

Total Input 353 cum/d

The Sober & moderately polluted effluent after ETP will be recycled collectively as180
m3/day.

Output side:

a. Loss from Industrial Use - 246 cum/d

b. Effluent sober nature sent for ETP - 92 cum/d
c. Effluent Moderately polluted sent to ETP - 15 cum/d

Total Output 353 cum/d

Effluent Treatment Plant:

Stream (A): Industrial Sober Wastewater

This is sober water except temperature, comes from cooling-purging and boiler blow-
down. A detention tank with suitable holding capacity and shallow depth shall be
provided. The water after cooling will be suitable for irrigation purpose. As an alternative,
this will be used as diluents to moderate effluent, stream (B) below and further treated.

Stream (B): Industrial moderately polluted wastewater

The Moderately polluted wastewater is the floor vessel washing, de-min plant, laboratory
and process, which has low pH and has organic matter. After the pH correction of this
stream, it will be taken to b i o - o xi d a ti o n , f ol l o w e d b y t e r t i a r y tr e a t m e n t b y
w a y o f d u a l m e di a fi l t e r , which can be disposed on land for irrigation or re-cycled to
plant. This can also take care of condensate water.

17
Domestic effluent:
The Sober wastewater stream comes from boiler blow down, pump cooling and cooling
purging water. Except temperature, it has little other objectionable characteristic. This is can
be treated by physic-chemical treatment, lowering the temperature to ambient, giving
detention for some time and recycle either for industrial purpose or gardening or using as
diluents to moderately polluted waste water before treatment. This effluent is from three
units

Moderate Bio-oxidation and Tertiary

799

Thus, the summary is:

# Unit Input cum/d Sober cum/d Moderate cum/d

1 Sugar 555 90 326
2 Co-gen 353 92 15
3 Distillery 441 60 36
4 MEE Condensate -- -- 180
Sub-total 1349 242 557
Total 799

Solid Waste:
This is not a big problem. The solid in process generate only as yeast s pent residue.
This is highly biodegradable and can be taken to compost yard without difficulty.
Waste Qty Treatment Disposal
Canteen 35 kg/day Vermi-composting Own Garden
ETP Sludge 40 kg/day Composting Sales
Sweepings 20 kg/day Segregation Sales
Garden trash 20 kg/day Collection Mulching
Ash 32 T /day Collection Brick kiln & composting

Note (1): Ash handling water will be collected. It will be further subjected to Settling tank,
with alum and lime dosing and again recycled for ash handling. Ash handling = Submerged
belt conveyer (250 mm) takes out ash from boiler bed, screw conveyer feeds this ash from
APH & economizer to cross belt conveyer, screw conveyer also feeds ash from ESP hoppers to
cross belt conveyer and cross belt conveyer conveys ash to ash silos 50 cum capacity. Ash
expected is 6211 MT/A. will be mixed with press mud and then to farmers.
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 Note (2): Bagasse handling will be done using conveyer belts up to silos and then to drum
feeders.

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

Air Pollution details

# Source Pollutant In-plant Control Equipment
Measures
1 Boiler 100 TPH SPM, CO Dry Baggasse boiler ESP & dispersion through tall Stack
feed with height as per MoEF/ CPCB
design.
2 D. G. Set 1000 SO2 As per CPCB --
KVA, norms
2 Nos.
3 Fermentation CO2 Tank Covered Scrubbed in Water

4 Anaerobic H2S Closed Roof. --

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

7. BACKGROUND STUDY:
This is important part of study.

(A) Natural Environment :-

We shall conduct this study with sampling as –
# Media Stations Parameters Frequency
1 Ground Water 5 17 1
2 Ambient Air 9 5 3 months
3 Ambient Noise 9 2 1
4 Soil 9 15 1
The stations will be selected in all the eight directions from the factory and in 10 km
radius. The 10 km study area is shown in Google Image.

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(B) Manmade environment :-
 This will include existing land-use, demography, employment, s o c i o - economic
aspects and community development needed and proposed. This will be for entire
area both rural and urban in this study zone.
 Socio-Economic Status in Influence Zone will include the study of Non- Workers
percentage whether high, from the percentage employed population on
Agricultural, how far is the scope for other avenues of livelihood like Live Stock,
Forestry, Fishing, Hunting, Orchards, Mining, Trade Commerce.
 Further Out of Total Land what percentage is already under Cultivation and
Out of Total Land what percentage is already under Irrigation.
 If the land is not likely to support more people, then whether Industrialization is
necessary to improve the situation. All this will be studied as cost benefit ratio.

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

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

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

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9. EIA Study Report

This finally prepared and submitted as per guidelines given by MoEF will be as follows
Chapters Contents
I Proponents, ToR, Purpose
II Project explained. Why this, Why needed, Why here, What priorities,
What options
III Environment Setting Natural & Man-made
Material, Method, Approach Delphi technique
IV High Significant Impact ® Low Insignificant Impact & Shield
Proper Site ® Prevention ® Abatement ® Treatment ®
Mitigation ® Smooth Disposal
V Alternate Analysis
Selection of Raw Materials, Site, Process, Machinery-
Hardware, Collaborators, Staff & Team
VI Monitoring = Stations, Parameters, Frequency, Statistics, Rectify
VII Risk = To Environment, To Health, To Bankers
Public Consultation Community = Oustees
Reporting Rehabilitation.
Others- Assistance
VIII Benefits = Physical, Social, Employment, Other Tangible.
Sustainable considerations
IX Cost-Benefit. If Project Done? If No-Project??
X EMP = Plan, Cell, Schedule, Watch-dog, Monitoring,
Documentation, Reporting
XI Summary, Conclusion, Justification, Mitigation.
XII EIA Team = Proponent, Consultant, Associates, Future

10. CONCLUSION

 This project is very necessary in view of producing Ethanol, a useful foreign

exchange saver product which the nation requires as a useful resource for
development.
 The local people have already accepted this industry and further up- gradation
for their benefit will be welcome in their area.
 The candidate site is suitable from general MoEF expectations.
 Water, power, raw material, Filler Material and Market is assured and found
available with ease.
 Full precautions will be taken for Pollution Control, Resource Conservation
and Environmental Protection.
 This is cost effective and Sustainable Development.

======================

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 Declaration

I hereby give an undertaking that, the data and information given in the application and
enclosures are true to the best of my knowledge and belief and I am aware that if any
part of the data and information submitted is found to be false or misleading at any
stage the project will be rejected and clearance given, if any to the project will be
revoked at our risk and cost.

Date: 16.06.2015
Place: Dharwad

--o—

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