PREFEASIBILITY REPORT For Proposed New Distillery (90 KLPD)

Transcription

1 PREFEASIBILITY REPORT For Proposed New Distillery (90 KLPD) By M/s Athani Sugars Ltd. Shahuwadi Unit Village Sonawade, Tehsil Shahuwadi, District Kolhapur, State: Maharashtra

2 INDEX SR.NO CONTENTS PAGE NO.. 1 Introduction 3 2 Justification 3 3 Location 4 4 Resources 4 5 Process 5 6 Pollution Control 6 7 Background Study 8 8 Safety 9 9 Benefits 9 10 EIA Structure 9 11 Conclusion 9

3 1. INTRODUCTION M/s Athani Sugars Ltd., Shahuwadi Unit (Distillery Plant) (referred hereafter as This Industry TI) is desirous to establish this unit at Village Sonawade, Tehsil Shahuwadi, Dist. Kolhapur, Maharashtra. The sister industry is M/s Athani Sugars Ltd., Shahuwadi unit (Sugar & Co-gen plant), is in the vicinity at village Sonawade Bambawade. Thus, # Production Unit No. Cat Unit Existing Additional Total 1 Distillery 5(g) A KLPD The EIA Notification 2006 and its amendments h a s covered these types of industries under its entry shown above. With Screening it is necessary for TI to approach Ministry of Environment, Forest and Climate Change (MoEF & CC), New Delhi for Environmental Clearance for this project. This Pre-feasibility Report is prepared for forming a framework for EIA study, Scoping and finalizing the Terms of Reference. Form I, as is prescribed by the said Notification is duly filled up and submitted. This Prefeasibility Report is an accompaniment to the same. The Form I contains details regarding Nearby Land Use, Resources, Process, Pollution Control, Aesthetics, Risk I n v o l v e d, Consequent Developments and Environmental Sensitive Issues. The working days for distillery will be 330 days. 2. JUSTIFICATION Molasses is one of the waste products produced from sugar factory. Environmentally speaking it has 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 effluent, (Spent Wash) is passes through Multi-effect Evaporator (MEE) for concentration. This concentrated spent wash is burned in the incinerator boiler along with coal. Ethanol is being used as automobile fuel in these days & hence new distillery unit is justifiable. Thus, this unit is downstream establishment to the sugar unit of the sister concern. After this distillery, there is no further downstream unit in this neighbourhood. Distillery unit needs the raw material as molasses & this can be fulfilled if we 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. Old Method 3

4 New Method Waste Exchange Oriented Unit (WEOU) 3. LOCATION The proposed location is in Village Sonawade, Tehsil Shahuwadi, Dist. K o l h a p u r, in State Maharashtra. This candidate site is stand alone, but sister industry of Sugar and Co-gen unit is in the vicinity. The land requirement for proposed industry 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 Kadvi River (4 Km), Warna River (6.3 Km), Tehsil place Shahuwadi (13 Km by Road), Railwa y station and District Place Kolhapur (34 Km), National Highway 166 (1.5 Km) is at a sufficient, s a f e distance. The Clearance is obtained from Local Grampanchayat and hence will have public acceptability. The site is procured from M/s Udaysingrao Gaikwad SSK Ltd. on lease for 22 years. The site was kept for industrial purpose by the said industrial unit. It is proposed to be used for the same industrial purpose. 4. RESOURCES TI proposes to establish a new molasses based 90 KLPD distillery Plant. The capacity of the proposed distillery totally shall be 90 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, 4

5 # Raw Material Quantity/day Unit 1. Molasses 360 T 2. Sulfuric acid 180 lit 3. Nutrients N, P 90 Kg 4. Turkey Red Oil (TRO) 180 Kg In addition to the raw material, utilities are also required. These are: Power: Need 2500 KW. Available through Govt. Electricity Board and own c a p t i v e generation. Power can also be made available from sister industry namely M/s Athani Sugars Ltd., Shahuwadi unit (Sugar & Co-gen plant), by arrangement of needful short transmission lines and poles. A suitable back-up by DG Set is provided. Man Power: Staff, skilled and unskilled totally around 120 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 nearby if needed. Water Need is a b o u t 1400 cum/d and shall be met partly from Kadvi Warne River and partly by recycle. (Govt. has sanctioned water and the same is received here and some part is diverted towards the sister industry namely M/s Athani Sugars Ltd., Shahuwadi unit (Sugar & Co-gen plant). A small size pipeline may also be considered if the treated wastewater is to be used in the sister concern. Two Molasses Storage Tanks of MT capacities each are proposed. The sister concern will be sparing their produced molasses for us. This transport may either be through tankers or may be through a short pipeline. Alcohol will be stored in steel tanks with dyke walls. 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 day-time. Labour camp is not necessary. Total Cost for proposed project is Rs. 115 Crores. Thus all the resources are available and will be used economically and judiciously. 5. PROCESS 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

6 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. 6. POLLUTION CONTROL This is only a downstream plant, with sugar co-gen plant of sister unit. The pollution control will be designed for both and cumulative effect will be considered totally. Effluent Treatment Plant: Stream (A): Sober 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 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: The Moderately polluted wastewater is the spent lees stream, floor vessel washing which has low PH however no low organic matter. We shall use ETP with UASB technology for this treatment. Treated water can be disposed on land for irrigation or recycled in process. This will also take care of the condensate water post-mee for treatment and disposal. 6

7 Stream (C): Industrial highly polluted wastewater: Zero Pollution by Distillery Effluent - Technical Approach The Industrial wastewater (720 m 3 ) is acidic in ph, has deep color, and has high BOD, COD and TDS. However, it is neither poisonous, nor toxic, nor hazardous, is highly biodegradable, and has good calorific value. It is proposed to treat the effluent employing Evaporation (MEE) and concentration, as fuel & incineration in boiler. 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 serve as diluents. Stream (B) The stream of industrial effluent of only moderately polluted after full treatment in ETP with UASB technology it is fit for disposal on land for irrigation or for recycle after tertiary. This will also include the 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 concentrated Spent Wash. The Spent wash will be used as fuel in incinerator boiler after mixing it with coal. The Characteristics of this effluent stream are expected to be: Characteristics of Effluents # Parameter (C) Spent wash (A +B) Sober and Moderate 1 ph Temperature o C C 3 Color Dark brown Faint 4 Total Solids BOD COD Quantity CMD ( ) (All Values from serial No. 4-6 are in mg/l) Domestic effluent: The domestic effluent shall be treated in STP or septic tank and then shall be used for gardening. Solid Waste: This is not a big problem. The solid in process generate only as yeast spent residue. This is highly biodegradable and can be taken to compost yard without difficulty. Waste Treatment Disposal Canteen Vermi composting Own Garden ETP Sludge Composting Sales Sweepings Segregation Sales Garden trash Collection Mulching Ash Collection Brick kiln & composting 7

8 Hazardous waste like empty containers, lube oil etc. will be re-used or sent to authorized reprocessor. Air Pollution details # Source Pollutant In-plant Measures Control Equipment 1 Boiler SPM, CO Dry Baggasse boiler feed ESP & stack as per norms 2 D. G. Set SO 2 As per CPCB norms Stack 3 Fermentation CO 2 Tank Covered Scrubbed in Water 4 Anaerobic Digester H 2 S Closed Roof. No foul smell ETP CO 2 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 Surface Water Ambient Air months 3 Ambient Noise Soil 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. Fig.: Google Image of 10 Km Radius 8

9 (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 Livestock, 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. 8. 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 Rules. 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. 9. 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 percentage 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. 10. EIA Study Report The Terms of Reference (ToR) is proposed to be kept identical to what MoEF & CC has recently published (April 2015) for these type of industries. 11. 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. 9

10 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. ====================== 10