Bio-Mass Assessment Study

Transcription

1 Bio-Mass Assessment Study (Verification and Certification for Sustainability) Of Castor De-Oiled Cake and Saw Dust Based Power Plant For Abatement of Green House Gas (GHG) emissions through biomass residue based co-generation At Claris Lifesciences Ltd., Ahmedabad November By Ravi Energie 202 Manubhai Towers B Sayajigunj, Baroda INDIA

2 ACKNOWLEDGEMENT We take this opportunity to express our sincere appreciation to the management of M/s Claris Lifesciences Ltd., Ahmedabad for the confidence placed in us through award of this study. Information collected from various sources range from village level workers, Talaties, Sarpanches as well as district officials of various Government and Semi- Government Organisations including Gujarat Energy Development Agency (GEDA), Forest Department, Department of Agriculture, Agriculture Universities, etc. We deeply acknowledge the support received from them during the different stages of this study. We are also thankful to all the farmers and the industries surveyed for sparing their valuable time in helping our surveyors to get the feedback and useful information. We are indebted in person to following resource persons who have provided valuable information during this study: (1) Mr. S. B. Patil, I/C Deputy Director, GEDA (2) Mr. A. K. Chauhan, Senior Executive, GEDA (3) Mr. D. N. Bhatt, I/C Deputy Director, GEDA (4) Dr. H. C. Patel, Ex-Professor & Head of Agronomy Department, Navsari Agriculture University (5) Mr. Navin Shah, Ex-Director, Department of Agriculture, Government of Gujarat (6) Dr. J. C. Patel, Ex-Principal, Gujarat Agriculture University (7) Dr. H. R. Patel, Ex-Principal, BBIT, Vallabh Vidhyanagar Document no: RE/CLL/001/1208-Rev6

3 PREAMBLE As a part of commitment for integration of efforts for sustainable development, Ravi Energie Group has taken up the Biomass Assessment Study for the Project namely Abatement of Green House Gas (GHG) emissions through Biomass residue based Cogeneration, undertaken by Claris Lifesciences Ltd. with reference to role of all the stake holders. We certify that: The study has been confined to certain part of Gujarat for Castor DOC and Saw Dust only as Biomass being used as a fuel in a Co-generation based Power Plant. The correct primary and secondary data collected along with other information, with best possible accuracies, has been compiled and used to derive the Biomass availability to see that realistic figures are reported. We further certify that we have conducted the study with Full Social Accountability as a part of our business. Ravindra M Patel Group President, Ravi Energie Ravindra M Patel Certified Sustainable Development Professional (CSDP, USA; CSDP Number: 105) Certified Business Energy Professional (BEP, USA; BEP Number: 564) Certified Energy Manager (CEM, USA; CEM Number: 11177) Certified Energy Auditor (CEA, India; CEA Number: EA-3740/ Certificate No. 1130) PE (USA), Chartered Engineer (India) BE (Mech.), ME (Prodn. Engg.), PGD (Ref. & Air Cond.) LL.B.(Gen.), LL.B(Sp.), FIE(I), FIV(I) Life / Fellow Member: AEE (USA), ASHRAE (USA), ASME, SES (I), ISNT, ICC Document no: RE/CLL/001/1208-Rev6

4 TABLE OF CONTENTS Executive Summary... 3 CHAPTER 1:... 4 Gujarat at a glance... 4 Location... 4 Demography... 4 Agro climatic details... 4 Ports of Gujarat... 6 Industries of Gujarat... 6 BioEnergy in Gujarat... 7 Introduction... 8 M/s. Claris Lifesciences Limited... 8 Bio-Energy at Clarion... 8 Ravi Energie Group... 9 CHAPTER 2: Objectives Methodology...11 CHAPTER 3: Location of the Project CHAPTER 4: Biomass Generation Castor Seed and De oiled Cake Generation in Gujarat:...14 Generation of Saw Dust:...20 CHAPTER 5: Biomass Consumption Consumption of Castor De oiled Cake:...23 Consumption of Saw Dust:...25 CHAPTER 6: Surplus Availability Surplus Biomass (Castor De oiled Cake):...26 Surplus Biomass (Saw Dust):...26 Document no: RE/CLL/001/1208-Rev6 Page 1

5 CHAPTER 7: Characteristics of Biomass Characteristics of Castor De oiled Cake:...28 Characteristics of Saw Dust:...29 CHAPTER 8: Surveyor s Views and Recommendations Annexure-BAnnexure-C1 Annexure-C Annexure-C1 Annexure-C Annexure-C Annexure-D Annexure-E Annexure F Document no: RE/CLL/001/1208-Rev6 Page 2

6 EXECUTIVE SUMMARY M/s. Claris Lifesciences Limited (CLL) has its manufacturing campus known as Clarion Campus on Rajkot highway, which is 26 km away from city of Ahmedabad. Three major regions have been considered for survey of biomass (Castor De oiled Cake and Saw Dust only) assessment survey i.e. North Gujarat, Middle Gujarat and North West Gujarat. The major focus was upon following issues Collection of relevant primary and secondary data. Estimation of the available biomass feeds, their current and potential uses, estimation of biomass available specifically for said project. Evaluation of the stakeholders attitude, capabilities, limitations, etc. Evaluation of potential sources and their locations CLL has installed one 16 TPH FBC boiler along with 2.0 MW steam turbine in Phase-I. Phase-II of the same project includes another boiler of 10 TPH with 2.0 MW turbine. The cogeneration plant at Claris Lifesciences Ltd. consumes around MT per day of Castor De oiled Cake (Biomass) as a main fuel. The total requirements for both the phases would be around MT per day. Thus, the annual requirements of Castor De-oiled Cake during Phase-I and after completion of Phase II would be MT and MT respectively. However, to ensure the smooth operation of the facility, Saw Dust is a secondary fuel that can be used in Power Plant in case of insufficient supply of DOC. M/s. RAVI ENERGIE carried out a study to assess the availability of Biomass for Claris Lifesciences Limited in defined part of Gujarat. The primary and secondary data collected alongwith other information was compiled and analysed and is tabulated as follows. Sr. No. Details Castor De Oiled Cake Saw Dust 1 Generation per Annum (MT) MT MT 2 Consumption per Annum (MT) MT to MT MT 3 Surplus Available per Annum (MT) MT to MT MT Document no: RE/CLL/001/1208-Rev6 Page 3

7 CHAPTER 1: GUJARAT AT A GLANCE LOCATION Gujarat is situated on the west coast of India between 20-6' N to 24-42' N north latitude and 68-10'E to 74-28'E east longitude. It is bounded by the Arabian Sea in the West, Rajasthan State in the North and North-East, Madhya Pradesh State in the East and Maharashtra State in the South and South East. Gujarat State at present comprises of 25 districts, sub-divided into 226 talukas, having villages and 242 towns. Gujarat has geographical area of 1.96 lacs sq. km and accounts for 6.19 percent of the total area of the country. DEMOGRAPHY According to the provisional results of Population Census 2001, the population of Gujarat as on 1st March 2001, stood at 5.06 crore, including the estimated population of earthquake affected areas. The decadal growth rate of the decade has increased in comparison to from percent to percent. The density of Gujarat is 258 persons per sq.km in The literacy rate in the State (excluding children in the age group 0-6 years) has increased from per cent in 1991 to per cent in About per cent population of Gujarat resides in urban areas (Excluding earthquake affected areas). Out of the total population of lacs in the state (excluding the earthquake affected areas), lacs (42.10 per cent) were workers and lacs (57.90 per cent) were non-workers. According to the provisional results of population census 2001, the total number of households was lacs. AGRO CLIMATIC DETAILS In terms of the standard climatic types, tropical climate such as sub-humid, arid and semiarid, is spread over different regions of the state. Out of total area of the state 58.60% falls under arid and semi-arid climatic zone. The arid zone contributes per cent, while the semi-arid zone forms per cent of the total area of the state. The regions in the extreme north comprising the district of Kutchh and the western parts of Banaskantha and Mehsana, the northern fringe (Jamnagar) and the western part of Saurashtra have arid climate while the rest of the State has semi-arid climate. Document no: RE/CLL/001/1208-Rev6 Page 4

8 The land of semi-black soil and sandy soil are most suitable for the crop of castor. The castor can be grown without irrigation, even in salty and semi acidic soils. Gujarat is classified mainly in sever different climatic zones as per followings: South Gujarat Middle Gujarat North Gujarat Bhal and Coastal Area South Saurashtra North Saurashtra North West Zone Out of above zones, the major and concentrated areas for study of Biomass (Castor Deoiled Cake and Saw Dust) assessment are North Gujarat, Middle Gujarat, and North West Zone, wherein major districts and crops are as under: North Gujarat Districts: (1) Sabarkantha district. (2) Part of Ahmedabad district (3) Kheda district (4) Mehsana district (5) Part of Banaskantha district Crops: Middle Gujarat Oil Seeds, Tobacco, Wheat, Jowar, Minor Millet, Vegetables, Spices and Condiments Districts: (1) Vadodara district (2) Part of Bharuch district (3) Borsad taluka of Kheda district Crops: North West Zone Cotton, Bajra, Tobacco, Pulses, Wheat, Paddy, Maize, Jowar, Oil Seeds and Sugarcane Districts: (1) Kutch district (2) Part of Rajkot district (3) Sami, Harij and Chanasma talukas of Mehsana district (4) Viramgam and Daskroi city of Ahmedabad district Crops: Oil Seeds, Tobacco, Wheat, Jowar, Minor Millet, Vegetables, Spices and Condiments Document no: RE/CLL/001/1208-Rev6 Page 5

9 PORTS OF GUJARAT The State has a long coastline of about 1600 kms. and is the longest among all States of country. There are 16 ports, which are in operation, three ports are under development and three are proposed. INDUSTRIES OF GUJARAT Over the years, Gujarat has diversified its industrial base. The state was known for textiles industry. Today, refined petroleum products has emerged as the largest industrial group followed by chemicals including dyes and pharma products, agro and food processing, engineering industries, basic metal industry, textiles and apparels and other industries in descending order in terms of value of output in all industry in Gujarat. Document no: RE/CLL/001/1208-Rev6 Page 6

10 BIOENERGY IN GUJARAT The BIOMASS / ORGANIC WASTE generated in our country (villages semi urban & urban areas) consists of following types: Biomass : Crop Residues/ Waste Agriculture waste Animal Dung Organic Waste : Agro food processing industries Pulp & paper Edible & non-edible oil exploring units waste Sugar/ Distilleries Industrial wastes Municipal waste Industrial waste The above wide range of industrial, urban, agricultural, crop and animal dung etc waste which is organic waste by nature is proved to be the best and effective source of energy generation. The energy produced from such Biomass or organic waste is well known as BIO-ENERGY. Gujarat has very good prospects of Crop residues, agriculture waste, agro food processing industries, edible and non-edible oil exploring units waste Document no: RE/CLL/001/1208-Rev6 Page 7

11 INTRODUCTION M/S. CLARIS LIFESCIENCES LIMITED M/s. Claris Lifesciences Limited is a company incorporated in 1999 and is engaged in the business of manufacturing and marketing of sterile parenteral preparations, life saving medicines and hospital products, focusing on delivery systems, for treatment of critical illnesses and diseases. The company's range of products and delivery systems extends across Enteral and Parenteral Nutrition, Anesthesia, Blood Products and Plasma Volume Expanders, Anti- Infectives, Dialysis and Transplant, Cardiac Care, Infusion Therapy as well as Medical Disposables and Equipment. BIO-ENERGY AT CLARION Claris Lifesciences Limited has set up a biomass based cogeneration unit at its Clarion campus with state of the art technology. The biomass residue based combined steam and power-generating facility is designed in accordance with Indian Boiler act, Gujarat Pollution Control Board act, and Gujarat Electricity Board and Electrical & Factory Inspectors norms. The power and process steam requirements of the facilities within Clarion Campus will increase on account of the proposed expansion of manufacturing facilities. This power plant will be generating process steam and power by using Castor De oiled Cake (DOC) as primary fuel and Saw Dust as secondary fuel available in the state of Gujarat. The focused areas have been identified in various zones considering lead and distances from the plant and density of cultivation and resultant availability of Biomass. Document no: RE/CLL/001/1208-Rev6 Page 8

12 RAVI ENERGIE GROUP Ravi Energie (India) is a Branch of Ravi Energie Group engaged in Consultancy Services - in multi-disciplinary and multi-level fields including renewable energy and GHG issues. Ravi Energie Group is having presence in USA, Canada and UK and is headed by Ravindra Patel 2 a highly qualified professional. Ravi Energie Group has permanent tie-ups with renowned Laboratories and highly qualified Professionals who facilitate with their services for various Projects. Ravi Energie (India) was the recipient of First Prize - National Awards for Excellence in Consultancy Services, 1995; the award being given by CDC, Ministry of Science & Technology, Government of India - for their contribution in the field of Wind Energy and other forms of Renewable Energy. The contribution in the field of wind energy was also taken note of in international magazine Wind Power Monthly in March Ravi Energie Group s sister concern Ravindra M Patel & Co. has worked on various studies for Biomass Assessment under National Biomass Assessment Program by Ministry of Nonconventional Energy Sources (Now MNRE) and Gujarat Energy Development Agency. Ravi Energie has provided services to private and Government sector for many projects and assignments so far. Ravi Energie has carried out Bio Mass Assessment Study for 32 Taluka places so far which includes major areas in whole of Gujarat. Some of them are Dabhoi (Vadodara), Petlad (Anand), Prantij (Sabarkantha), Patan (Banaskantha) and many more. Ravi Energie Group is also in high-tech progressive farming activity, which demonstrates new technologies to farmers. (Green House farming in 1 Hectare area and Mango Plantation with three seeds and three stems in one tree- to be named). Ravindra Patel 1 having worked as an elected Chairman in one of the District Panchayats, has an in depth knowledge about farming, farmers mentalities, social impacts, change in farming practices and patterns etc. The team for Biomass Assessment Study and preparation of the report was led by Ravindra Patel and Assignment Based Consultant to Ravi Energie Group Mr. Raju K Patel 3. Raju K Patel, having worked as Assistant Director in Gujarat Energy Development Agency (GEDA)-for 13 Years, is having a very sound background in techno- commercial matters the field of Renewable Energy. The Study was also reviewed on-line by Dr. H R Patel, Ex-Principal of BBIT, Vallabh Vidhyanagar - a deemed University. 2 The qualifications of Ravindra Patel are: BE (Mech.), ME (Prod. Engg.), PGD (Ref. & Air Cond.), LL.B.(Gen), LL.B.(Sp.), Chartered Engineer(I), FIV(I), FIE(I), Certified Energy Auditor (India), PE(USA), Certified Energy Manager (CEM)-(USA), Certified Sustainable Development Professional (CSDP)-(USA), Business Energy Professional-(BEP)-(USA) 3 The qualifications of Raju K Patel are BE (Mech.), ME (Thermal Science Group), FICWA, Chartered Engineer (I), FIV(I), MIE(I), Certified Energy Auditor (India), MICA Document no: RE/CLL/001/1208-Rev6 Page 9

13 CHAPTER 2: OBJECTIVES The objective of this study is to assess whether Gujarat is generating enough Biomass (Castor De oiled Cake and Saw Dust) and thereby checking surplus availability to Power Plant of Claris Lifesciences Ltd. The following elements make up the overall scope of the work. Collection of relevant primary and secondary data. Estimation of the available biomass feeds, their current and potential uses, estimation of biomass available specifically for said project. Evaluation of the stakeholders attitude, capabilities, limitations, etc. Evaluation of potential sources and their locations Biomass Assessment was carried out in three zones of 50 km radius, 50 to 200 km radius and 200 to 400 km radius. Main districts producing biomass are examined for above objectives. Document no: RE/CLL/001/1208-Rev6 Page 10

14 METHODOLOGY a) Collection of Primary Data: Assignment based and trained team of field surveyors were sent to various districts of Gujarat state specially North Zone, Middle Zone and North West Zone to collect data, which leads to generation and consumption of concerned Biomass. Ravi Energie designed questionnaires and the field staff was trained to see that the focus is on concerned Biomass. The team targeted following groups for primary data collections Progressive Farmers Cooperative Bodies Castor Processing Units Extension Staff Of Agriculture Universities Government Offices Districts covered under 50 km of radial distance: Ahmedabad Gandhinagar Kheda Districts covered under 50 km 200 km of radial distance: Banaskantha Baroda (Vadodara) Anand Mehsana Patan Panchmahal Sabarkantha Districts covered under 200 km 400 km of radial distance: Kutch Rajkot b) Collection of Secondary Data: References were taken from the following sources: a) Official data/information from State Govt. Departments, Agricultural Universities in Gujarat, Districts Local Self Government Bodies b) District Industry Centre c) District Panchayat Offices d) Census Data e) Existing material of a similar nature Document no: RE/CLL/001/1208-Rev6 Page 11

15 c) Study and Analysis of Assessed Data: The primary data (and its verification in comparison to the secondary data) helped in working out cropping pattern. It also established whether there is enough biomass to feed the plant on a daily basis. The information collected has been compiled in the following pages to offer an analysis of existing patterns, generation of biomass, consumption of biomass and surplus available. A direct source of Castor De oiled Cake is castor processing units castor solvent extraction processing units to be specific. However, castor, being raw materials for the processing units, we have tried to quantify production of castor seeds in Gujarat as a whole based on farmers interview, cropping area under cultivation, average yield of various types of castor varieties, percentage of castor de oiled cake generated during processing. The methodology for generation of sawdust is required to be considered differently as the generation of saw dust can never be correlated with the inputs and production of wood in India as the generation of sawdust is wastage during saw cutting and processing of imported timber. The schematic arrangement showing Modes Operandii is as per Annexure A. Document no: RE/CLL/001/1208-Rev6 Page 12

16 CHAPTER 3: LOCATION OF THE PROJECT Claris Lifesciences Limited has manufacturing campus named as Clarion Campus located at Ahmedabad - Bawla Highway, Village: Chacharwadi Vasna, Taluka Sanand, in the district of Ahmedabad. The geographical location of the district is N E. It is 26 km away from Ahmedabad in south west direction. The nearest railway station and airport is at Ahmedabad. This Power Plant is using Castor De-Oiled Cake as major fuel and Saw Dust as secondary fuel collectively and/or individually described as Biomass for generation of steam and power with the help of Turbine Generator installed in the power plant. Document no: RE/CLL/001/1208-Rev6 Page 13

17 CHAPTER 4: BIOMASS GENERATION CASTOR SEED AND DE OILED CAKE GENERATION IN GUJARAT: There are seven varieties of castor in produced Gujarat developed progressively since 1973 till 1999 tabulated below 4 : Average Yield as Sr. Year of Yield Variety of Castor per Farmers No. Development (Kg/Hectare) interview 1 GAUC These varieties are not produced 2 GAUCH now 3 GCH GCH GC GCH GCH GCH Reference: Annexure B Since, the latest developed variety GCH 7 is giving highest yield, majority of the farmers are inclined to shift their choice towards high yielding varieties due to extension activities by state agriculture department. Most of the farmers sow irrigated castor between July to August and non-irrigated castor during October and November. Major harvesting is carried out from December to March. However, the oil mills are running 24 x 365 days.\ A study suggests that 87% of total production of castor in country is contributed by Gujarat and Rajasthan state (71% and 16% respectively) 5. Mehsana and Banaskantha are the largest castor producing districts in Gujarat. In Gujarat majority of castor cultivation comes from 6 districts of North Gujarat, viz., Mehsana, Banaskantha, Sabarkantha, Gandhinagar, Patan and Kutch. 6 4 Source: Gujarat Agriculture University, Model Farm, Vadodara 5 Source: 8424_02 6 Source: Document no: RE/CLL/001/1208-Rev6 Page 14

18 District-wise Castor Seed Production Details for Gujarat state 7 District ( 000 MT) ( 000 MT) % Change Banaskantha % Gandhinagar % Kutch % Mahesana % Patan % Rajkot % Sabarkantha % Surendranagar % Jamnagar % Others % Total % Area of Crop in the Kharif Season as on September 2008 as compared to earlier years: Gujarat State (area in 00 Hectares) Sr. No. Crop Average of last 3 years Last (2007) Year Current Year (2008) % Change 1 Groundnut Teel Castor Soyabean Other oily crop Total Reference: Annexure C1 7 Source: Document no: RE/CLL/001/1208-Rev6 Page 15

19 Area, Production and yield of Castor from Year to Year of Gujarat State, Department of Agriculture 8,9 (Area in 00 Hectare, Production in 00 MT and Yield in Kg/Hectare) Sr. No. Year Area Production Yield Reference: Annexure D and Annexure E 8 Department of Agriculture, Government of Gujarat 9 Department of Agronomy, Navsari Agriculture University, Navsari Document no: RE/CLL/001/1208-Rev6 Page 16

20 State wise Area, Yield and Production of Castor Seed for Year State Area Cultivation ( 000 Hectare) under Estimated Production ( 000 MT) Gujarat Rajasthan Andhra Pradesh Others Total * *: Indicates average figure Estimated (Kg/Hectare) Yield The Indian variety of castor has oil content of 48%. Out of 48% about 42% of oil is being extracted and the cake retains the rest. The Castor seed products have widespread application in many industries like Paint, Lubricant, Pharmaceutical, Textiles, etc. However, even there are three different estimates; we can optimally consider the yield of 1800 Kg/Hectare for given objective. Estimated production of Castor Seed in State of Gujarat 11 as compared to earlier years is as per following details: Area Yield Production in Year ( 000 Hectare) (Kg/Hectare) ( 000 MT) ** **: Indicates estimated production for current year. 10 Source: 11 Source: Department of Agriculture, Government of Gujarat Document no: RE/CLL/001/1208-Rev6 Page 17

21 District wise Area under cultivation for Castor, Castor Seed Generation and Castor DOC Generation in Year 2008 of Gujarat State, Department of Agriculture considering Yield as 1800 Kg/Hectare Sr. No. Name of District Area under Cultivation for Castor (00 Hacter) Estimated Castor Seed Production (000 MT) 1 Ahmedabad Banaskantha Vadodara (Baroda) Bharuch Narmada Valsad Navsari Dang Gandhinagar Kheda Anand Mehsana Patan Panchmahal Dahod Sabarkantha Surat + Tapi Amreli Bhavnagar Jamnagar Estimated Castor DOC Production (000 MT) Document no: RE/CLL/001/1208-Rev6 Page 18

22 Sr. No. Name of District Area under Cultivation for Castor (00 Hacter) Estimated Castor Seed Production (000 MT) 21 Junagarh Porbandar Kachch Rajkot Surendranagar Total of Gujarat State Reference: Annexure: C2 Estimated Castor DOC Production (000 MT) For our purpose, the primary data of castor mills about generation of Castor DOC is required to be studied, which is linked with castor production in the state. There are approximately 20 units of castor processing who are generating castor de oiled cake as a byproduct as tabulated below. 12 Out of total units in Gujarat, we have surveyed some of the major castor seed processing units and details of survey are tabulated below: Major Players of castor seed processing industries in Gujarat: Processing Units Castor Seed Processing Capacity (Tons/Day) Castor DOC Generation Capacity (Tons/Day) N.K. Proteins Ltd Gujarat Ambuja Exports Ltd Sailani Agrotech Industries Ltd Kisan Agro Products lndustries Jayant Oil Mills Group (Bitor) Ihsedu Agrochem Pvt. Ltd Gokul Refoils and Solvent Limited Kanak Castor Products Pvt. Ltd Laxmi Oil Industry Rajena Industries Limited Source: _ _02 Document no: RE/CLL/001/1208-Rev6 Page 19

23 Processing Units Castor Seed Processing Capacity (Tons/Day) Castor DOC Generation Capacity (Tons/Day) Adani Wilmar Ltd Total Generally, there is no direct trading between farmers and processing units. It is always through traders and there are chances of interstate transfer of castor. We have not considered other state s data on production and consumption for the purpose of this survey. Quantity of Biomass (Castor De oiled Cake) Generation in Gujarat by processing units: From the primary data, the yield of Castor DOC turns out to be 55% to 60%. We also took the samples of castor and analyzed for oil content and worked out the percentage of cake by weight, which is found to be approximately 58%. Considering the total castor seed production of Tons, the net generation of Castor DOC shall be Tons. GENERATION OF SAW DUST: The only source of sawdust as the name implies is a Saw Mill and we concentrated our survey in a zone where there is a maximum density of sawmills., Kutch area in Gujarat is a thickly populated saw mill area because of nearby ports namely Kandla and Mundra, where majority of the wood is imported to India is unloaded. Import of all kinds of wood at Kandla Port Wood taken to Saw Mills Cutting and Processing of Woods Generation of Saw Dust Document no: RE/CLL/001/1208-Rev6 Page 20

24 The statistics of existing sawmills was obtained from Department of Forest and is attached as follows. Details for District wise Saw Mill of Gujarat State 13 Sr.No. Name of Districts With License Without License Total 1 Ahmedabad Amreli Banaskantha Bharuch Bhavnagar Dang Gandhinagar Jamnagar Junagadh Kutch Kheda Mahesana Panchmahal Rajkot Sabarkatha Surat Surendranagar Vadodara Valsad Dahod Narmada Patan Navsari Porbandar Anand Total 3,738 1,195 4, Source: JANAVA JEVU, book Published by Department of Forest, Government of Gujarat in Year Document no: RE/CLL/001/1208-Rev6 Page 21

25 The feedback given by various saw millers to the survey team are tabulated below: Quantity of Biomass (Saw Dust) Generation in Gujarat: As Claris Lifesciences Ltd. procures its sawdust, in case of requirement, from, Kutch, we have carried out primary survey at area. Major saw millers in -Kutch area are listed in Annexure-F. The data indicates on an average tons per Sawmill per annum of Sawdust is generated in a sawmills at Kandla. Thus, total Sawdust generation can be estimated as MT/Annum. As per the above-mentioned table, following is a total Generation of Saw Dust. Average Generation of Saw Dust per Saw Mill per Annum No. of Saw Mills Total Generation of Saw Dust per Annum Tons 250 Nos Tons Document no: RE/CLL/001/1208-Rev6 Page 22

26 CHAPTER 5: BIOMASS CONSUMPTION CONSUMPTION OF CASTOR DE OILED CAKE: As is a known fact, India is one of the largest producers of agriculture products like cereals, pulses and oilseeds. Gujarat is also a major state in field of producing various crops. Gujarat state is having variety of crops including Cereals like Paddy, Bajra, Barley, Maize, wheat, etc., Pulses like Tur, Moong, Urad, etc., and Oil seeds like Groundnut, Teel, Castor, Soya bean, Cottonseed, etc. The primary data for consumption of Castor De oiled Cake, being a sensitive data cannot be extrapolated using a small sample survey of end-users i.e. farmers. Mentality of farmers indicate that 5 % prefer organic manure and 95% prefer chemical fertilisers, which are available at subsidized rate and giving higher yield compared to cost incurred. In India, the chemical fertilisers with primary nutrients like Nitrogen (N), Phosphorous (P) and Potassium (K) are subsidized. In year , there was total subsidy outflow of around Rs Crores, which was more than budgeted amount. The levels of concession have been varying between Rs Rs per ton over the last decade, which is approximately 40%. 14 The consumption of 5% includes various De oiled Cakes including Castor DOC and cow dung. Thus, the only primary source of consumption is the industries selling Castor DOC for various purposes. The feedback given by various industries to the survey team is tabulated below: Processing Units Castor DOC Generation Capacity (Tons/Day) Total Consumption out of Generation (Tons/Day) N.K. Proteins Ltd Gujarat Ambuja Exports Ltd Sailani Agrotech Industries Ltd Kisan Agro Products lndustries Sources: Document no: RE/CLL/001/1208-Rev6 Page 23

27 Processing Units Jayant Oil Mills Group (Bitor) Ihsedu Agrochem Pvt. Ltd. Castor DOC Generation Capacity (Tons/Day) Total Consumption out of Generation (Tons/Day) Gokul Refoils and Solvent Limited Kanak Castor Products Pvt. Ltd Laxmi Oil Industry Rajena Industries Limited Adani Wilmar Ltd Total The feedback given by various suppliers to the survey team for industrial consumption of biomass as fuel is tabulated below: Sr. No. Supplier Company using Biomass as fuel for energy generation Quantity used in Industry (Tons/Annum) 1 Ardip Agencies Claris Lifesciences Ltd Dishman Pharmaceuticals & Chemicals Ltd Arvind Mills Ltd Rainbow Papers Ltd Anil Starch Ltd Bhagwati Associates Claris Lifesciences Ltd Dishman Pharmaceuticals & Chemicals Ltd Mark Biosciences M. J. Chem Claris Lifesciences Ltd Bell Ceramics 3600 Arvind Mills Ltd Ceramic Industries (Jaghadiya) 3600 Document no: RE/CLL/001/1208-Rev6 Page 24

28 4 Deejay Associates Claris Lifesciences Ltd Unimark Remedies Ltd Total The biomass is consumed as organic manure within or outside state of Gujarat. There is no other major use of biomass noted during survey to agro industries mentioned in above table. As per the survey, the average consumption of biomass is ranging from Tonnes/Annum to Tonnes/Annum. Out of average consumption, biomass used as organic manure is around Tonnes/Annum to Tonnes/Annum and other uses of biomass are approximately Tonnes/Annum to Tonnes/Annum out of total production. CONSUMPTION OF SAW DUST: The following are the main saw dust suppliers contacted for survey on availability of Saw Dust for Claris cogeneration power plant. The feedback given by various saw millers to the survey team are tabulated below: Following is a total Consumption of Saw Dust: Average Consumption of Saw Dust per Saw Mill per Annum No. of Saw Mills Total Consumption of Saw Dust per Annum Tons 250 Nos Tons Document no: RE/CLL/001/1208-Rev6 Page 25

29 CHAPTER 6: SURPLUS AVAILABILITY SURPLUS BIOMASS (CASTOR DE OILED CAKE): After estimating the biomass generation from the possible sources and the total biomass consumption, we can establish surplus biomass available from state as detailed below. As per survey carried out for major companies involved in the processing of Castor seeds and thereby producing Biomass (Castor De oiled Cake), on an average basis 72.5% to 77% of total Biomass production is sold out. Rest 23% to 27.5% remains unused and is of no use, which gradually goes on decay. They also have added that out of sold Biomass, approximately 74% is used as organic manure and 26% is used for any other unorganized use like energy generation or fertilizer. Total Percent of Total Generation Generation as Consumption of Castor Consumption of Castor DOC DOC as per Survey (C) (G) Consumption Other as Organic Manure (C1) Consumptions (C2=C C1) Surplus Biomass Available (S=G C) MT 72.5% MT MT MT MT MT 73% MT MT MT MT MT 74% MT MT MT MT MT 75% MT MT MT MT MT 77% MT MT MT MT SURPLUS BIOMASS (SAW DUST): Our survey team has observed large heaps of sawdust lying at sawmills, which are not completely utilised. As feedback given by saw millers, many times saw miller has to dispose of saw dust, which is costing to them. Normal consumption is done by particleboard industries, ceramic industry, brick industry, etc. These consumptions account for approximately at an average of Tons/Annum per sawmill thereby Document no: RE/CLL/001/1208-Rev6 Page 26

30 producing approximately 40% of total consumption as surplus availability as shown in table below: No. of Saw Millers Avg. Sawdust Generation per Sawmill (TPA) Total Generation (TPA) Total Commercial Use (TPA) Surplus Saw Dust Quantity (TPA) Document no: RE/CLL/001/1208-Rev6 Page 27

31 CHAPTER 7: CHARACTERISTICS OF BIOMASS CHARACTERISTICS OF CASTOR DE OILED CAKE: Castor oil mills in Gujarat, producing De oiled Cake, are facing problems related to bulk storage, disintegration of De oiled Cake, if not used, increase in fire hazard and subsequent increase in risk to be covered under insurance leading to increase in insurance premium. If not used, biodegradation of De oiled Cake leads to generation of Methane and hence leading to further damage to ozone layer. The solvent extracted cake, although rich in protein cannot be used as cattle feed because of its toxicity. However, it can be used as a fertilizer. The seeds and residual cake are highly poisonous and unless processed to remove the poisons cannot be fed to livestock. Poisons contained in the cake include ricin. 15 Chemical analysis of Castor de oil cake: We witnessed the chemical analysis at an industry, which showed following results: Sr. No. Test Parameters 1 Proximate Analysis Castor DOC Moisture (%) 9.70 Ash (%) 5.80 Volatile Matter (%) Fixed carbon % Gross calorific value (K.cal/Kg.) Source: Document no: RE/CLL/001/1208-Rev6 Page 28

32 CHARACTERISTICS OF SAW DUST: The sawdust is also carrying the issues same as Castor De oiled Cake except toxicity in terms of material handling. Chemical analysis of Saw Dust 16 : Sr. No. Test Parameters Saw Dust 1 Ultimate Analysis Carbon (%) Hydrogen (%) 5.20 Nitrogen (%) 0.47 Oxygen % Ash (%) Gross calorific value (K.cal/Kg.) Source: Anil Khadse, et al., Equilibrium model for Biomass gasification, Indian Institute of Technology, Mumbai. Document no: RE/CLL/001/1208-Rev6 Page 29

33 CHAPTER 8: SURVEYOR S VIEWS AND RECOMMENDATIONS 1. It was difficult to get feedback with clarity from farmers. 2. Replies related to production and cropped area from the farmers were without consistency due to changes in cropping pattern year by year. 3. All were happy with good rainy seasons in past few year in addition to irrigation canals of Narmada reaching to various corners of the State. 4. All inclination was observed towards cash crops like cotton, tobacco, castor, vegetables, etc. 5. Castor has advantages like (a) No damage by cattle to the crop (b) Little less security required for farms (c) Security required at the time of harvesting only (d) Sow and Forget mentality of farmers should be given thought, as good farming practice is always good for better yield 6. Transportation costs for different fertilizers like cow dung and DOC is a major drawback for its usage as organic manure. 7. Industries were inclined towards optimisation of their profits, finding opportunities for sale of the DOC. 8. Suspicion about adulteration with soil and other materials in Castor DOC is a limiting factor for use as organic manure by farmers. 9. Huge heaps of DOC and sawdust were noted probably leading to disposal issues for industries. 10. There was a general opinion about increase in production of Castor DOC in future. 11. The sawmills are facing problems of storage and disposal of saw dust. Sawdust, generally, is stored in open space. Due to high winds in -Kutch area, losses are too high and polluting the surrounding atmosphere. 12. Decay of Sawdust occurs very fast during monsoon and because of dew in winter. Document no: RE/CLL/001/1208-Rev6 Page 30

34 ANNEXURE-A Modes Operandii Conducting Bio-Mass Assessment Study RAVI ENERGIE RAVI GROUP ENERGIE Biomass Assessment Study for Claris Life science Field Reports/ Lab Tests Literature/ Internet Other Associated Consultants Design Forms/ Process of BBIT Navsari Agri University Dr H.R. Patel- Ex-Principal BBIT, Dr H C. Patel- Ex-Prof. Agronomy, Raju K Patel, Ravindra Patel. Field Workers// Surveyors Biomass Assessment Studies Training Analysis/& Report Preparation Evaluating Professional s GEDA Other Nodal Agencies Academic Institutes Dr. H C Patel Dr. H R Patel Ravindra Patel FINAL REPORTS Document no: RE/CLL/001/1208-Rev6 Page 31

35 ANNEXURE-B Document no: RE/CLL/001/1208-Rev6 Page 32

36 ANNEXURE-C1 Document no: RE/CLL/001/1208-Rev6 Page 33

37 ANNEXURE-C2 Document no: RE/CLL/001/1208-Rev6 Page 34

38 ANNEXURE-D Document no: RE/CLL/001/1208-Rev6 Page 35

39 Document no: RE/CLL/001/1208-Rev6 Page 36

40 Document no: RE/CLL/001/1208-Rev6 Page 37

41 Document no: RE/CLL/001/1208-Rev6 Page 38

42 ANNEXURE-E Document no: RE/CLL/001/1208-Rev6 Page 39

43 ANNEXURE F Major Supplier and Manufacturers of Saw Dust in Gujarat Name of Saw Miller Ajay associates Ajeet Enterprise Ajeet Mills Ambica trading co. Anand Swarup Mittal Anil Enterprise Anmol Woods Products Pvt. Ltd. Annapurna Timbers Ashapura Saw Mill Ashirvad Impex Pvt Ltd. Ashita Impex Pvt Ltd. Address Survey no 514/1/C, Modvadar road, N.H., Mithi rohar, Main bazaar road, Plot no 281, 12B, D-13, GIDC Area, Plot no 281-2B, Shop no 4, Krishna chamber, Plot no 115, 489/3, Mithirohar, Survey no: 491-Mithi rohar, Plot no. 32, Sec-10/c, GIDC, B-193, Apana nagar, S. No. 260/2 & 261/1, Mothi rohar, Survey no. 62, Near reliance petrol pump, Meghpar Borichi, B D 128, Golden arcade, Document no: RE/CLL/001/1208-Rev6 Page 40

44 Name of Saw Miller Address Assam Timber Store, Bansal Enterprise Bansal Impex Bansal timber corporation Bhavesh Saw Mill Bhavin Saw Mill Bholenath Saw Mill Chamunda International Ltd. Chirag Industries Chopra Enterprises D K Patel & Co. D N Enterprise Dayal Timber Store Survey no. 262, N.H. 8A, Opp. Panjarpole, 185/a, Chuduva, Plot no. 136, GIDC, Oswal plot, N.H. 8A, Plot no. 28 Sec 10A, Industrial area, Plot no. 73, Sector 10/A, Plot no. 19, Sector 10/B, GIDC, Survey no. 164, N.H. 8A, Padana,. Survey no. 89/1, Opp. Krishna petrol pump, N.H. 8A, Village-Padana, Plot no. 109A, Shastri nagar, N.H. 8A, Chudva, Survey no. 6, Chudva, Plot no. 25, survey no. 29, Meghpar Borichi, Plot no. 4, S.N. 297/1, Mithi rohar, Document no: RE/CLL/001/1208-Rev6 Page 41

45 Name of Saw Miller Address Deepak Enterprise Dembla Timber Co. Pvt. Ltd. Durga Trading Co. Fairdeal Lumbers Pvt. Ltd. G D International G P Timber Saw Mill Garg Lumbers Pvt. Ltd. Gayatri Saw Mill Gee Cee International Global Wood Products Green Gold Timber Pvt. Ltd Hardik Saw Mill Harekrishna Saw Mill Haria Industries 297/1, Mithi rohar, Plot no. 1, S.N. 248/1, Mithi rohar, , S.No.565, N.H., Mithi Rohar, Plot No 31/32, Sec.10/C, G I DC,. Survey No 258/1, Mithirohar, Plot No.40, Survey No.29, Meghpar Borichi, Anjar N.H.8A, Galpadar Road, Mithi rohar, PlotNo.13. Sector 10/C, G I D C, Opp Kandia Way Bridge, N.H., Mithi Rohar, Plot No 62, Sec 9A, Survey No 558, Mithi Rohar, S.NO186/187, Opp V. Arjoon Weigh Brige, Near Maruti Petrol Pump, Mithi Rohar, Plot No 56, Sector No 11, G I DC, 21, Ojas Complex, 1st Floor, Sector-9-C, PlotNo.62, Sector-11,G I DC, Document no: RE/CLL/001/1208-Rev6 Page 42

46 Name of Saw Miller Address Harihar Timber Mart International Timber Jawahar Saw Mill Jindal Cement Jali Works Jyoti Timbers 21, Ojas Complex, 1st Floor, Sec-9/C,. Survey No. 21/1, Galpadar Meghpar Road,. Near Laxmi Motors N.H. 8A, Plot No 297/1, Mithi Rohar, N.H.8, Survey No. 25 B, Mithirohar, K P Timber Karan Saw Mills Kusal Timber Pvt.Ltd. Laxman Timbers Pvt.Ltd. Laxmi Timber Industries PlotNo.10/A, Plot No 9, Survey No 27, Meghpar Borichi, Plot No 31 S.N.29, Meghpar Borichi, Anjar. S.No.573, Mithi Rohar, Galpadar Road, G C Chember, Shop No 21, Plot No 66, Sec 9 N.H. 8, Mahalaxmi Werehousing & Allied Ind. S.No 210/211, Mithi Rohar, Mahavir Saw Mill Plot No 10, Sec 1OC, GIDC, Mahesh Timber Pvt.Ltd. Survey No. 250/1. Mithirohar,. Maheshwari Mittal Ocean Trade Pvt.Ltd. Mukesh Kumar & Co. Nandkishore & Sons Om Prakash Satish Kumar Oswal Lumber Pvt.Ltd. Plot No 29, Sec.10/A, Bahind I.T.I., Survey No 514/1/C, Modvadar Road, Mithi Rohar, 267/5 Mithi Rohar, Survey No 27,28, Plot No 7, Meghper Borichi Anjar Survey No 215 Chudwa Mithi Rohar S.NO.262, N.H.8A, Mithi Rohar Document no: RE/CLL/001/1208-Rev6 Page 43

47 Name of Saw Miller Address P M Chopra & Co Parasmani Industries Popular Timber Prabhudas Vrajdas Punjab Saw Mill Pvt.Ltd. R C International Radhe Shyam Ravi Prakash Russaka Ply India Ltd. S P Kothari S P Timber S S Timber Sadhuram Jaiprakash Sharma Saw Mill Shri Chamunda Saw Mill Shree Devi Gayatri Saw Mill Shree Shanker Vijay Saw Mill Shri Shiv Agency Shree Umiya Vijay Saw Mill Plot No 109, Shastri Nagar, N.H.8A, Chudva Plot No 83, Sec-10/A, Kamakhya Lumber Men Complex, Plot No. 13, Survey No. 77/78, N.H. 8A, Padana, Survey No. 245/1, Plot No. 12, N.H. 8/A, Mittirohar, S.No.248/1, Mithi Rohar, 250/1 Galpader Road, N.H.8A, MithiRohar, S.N.201 Vill. Dhudava, 350 Mile Stone, N.H.8A, 286/12C, Lilashah Nagar, 102, Gokulpark, Ward 12/B, Plot No 356, Survey No.29, Plot No.40, Meghpar Borichi Road, Taluka Anjar, Plot No 210, N.H.8, Mithirohar, Near Agrawal Petrol Pump S. No. 506/1 & 508/1, Plot No. 6 & 8, Mithirohar,. D.B.Z.-N16, Po. Box No.255, Plot No 15, SedOA, GIDC, S.No.245/1, Mithi Rohar,. Plot No 11, Sec-11, GIDC. PlotNo21, S.No.80, Meghpar Borichi, Anjar PlotNo19S.No.245/1, Mithi Rohar,. Document no: RE/CLL/001/1208-Rev6 Page 44

48 Name of Saw Miller Address Sitaram & Company Pvt.Ltd. SLK Trade Link SS Timber Traders Starlite Industries Ltd. Tirupati Trishul Saw Mill Utkal Lumbers Pvt.Ltd. V K Timber Pvt. Ltd. Valram Timber Mart Vardhman Timber Industries Vishwakarma Timber Industry Vraj Timber Survey No.26/1, Mithirohar, N.H.8-A, N.H.8, Kamakhya Lumber Complex, Padana,. Survey No 487/1, Mithi Rohar, Survey No 231/1, Plot No 3, Mithi Rohar, PlotNo.13-14/A, Survey No. 245, Mithirohar,. Plot No 77, Sec. 10 A, Floor No. 1, Annam Commercial Centre, Plot No. 37, Sector 9 A, S.No. 24/3, N. H., Mithi Rohar,. Plot No 34, Sector No 10-C, Light Industries Area, Shed No I 33/34, 3rd Gali, G I D C, Plot No.63-64/75-76, GIDC, 4 & 5 Mani Chamber, Plot No 67, Sec No 9, N. H., Document no: RE/CLL/001/1208-Rev6 Page 45