PRE FEASIBILITY REPORT

Capacity enhancement of Sugar Plant at crush rate of 4500 TCD expandable to 8000 TCD

For

DUDHGANGA VEDHGANGA SAHAKARI SAKHAR KARKHANA LTD.

At

Bidri, Mouninagar, Tal. Kagal, Dist. Kolhapur- 416208

Prepared by

1.1 Introduction- Identification of project and project proponent This project is proposed by M/s. Dudhganga Ved Sakhar Karkhana Ltd., (KSSKL). The sugar factory is located at village Bidri, Mouninagar, Tal. Kagal, Dist. Kolhapur, Maharashtra. It is one of the progressive co-operative sugar factories in Maharashtra, set up in the year October 1956. The factory is registered under the Registration no. G279 of 1956, dated 10/10/1956. Hon’able Shri Arun P. Kakade is President Administrative Board of the factory. The present installed capacity of the sugar factory is 4,500 TCD. The management of the factory has undertaken extensive cane development activities and due to Increasing sugarcane plantation in area of operation, the factory has decided to expand its crushing capacity from 4,500 TCD to 8000 TCD (installed capacity). 1.2 Project Setting Since, the project is capacity enhancement of existing sugar unit, the VDSKL management has decided to install the proposed units within the existing premises. The factory is holding adequate land for the proposed units. The site meets the guidelines prescribed by Ministry of Environment, Forest and Climate Change for sitting of an industry. It is at Bidri. The factory is having connectivity with Kolhapur Railway Station which is at 40 Km from the project site. The geographical coordinates of the site are 18047’42.46”N, 74037’02.97” E. 1.3 Highlights of the Project

Table 1.1 Project Highlights 1. Name of the Proponent M/s. Dudhganga Vedganga sahakari Sakhar Karakhana. (DVSSKL) 2. Location of the project Ravindra Digamber Desai

(Managing Director) Shri. Dudhganga Vedganga sahakari Sakhar Karakhana LTD., Bidri (Mouninagar), Tal.- Kagal, Dist.- Kolhapur – 416208. Tel. No.: 02325 – 254922 to 26. Fax No.: 02325 – 254972. Email: klp_bidrisgr@sancharnet.in Klp_bidrisgr@rediffmail.com purchase.bidri@yahoo.in

3. Land Total land available with the factory = 7710120.00 sq.mt. Built up area= 653400.00 Sq.mt. including, Boiler, bagasse storage yard etc. Area available for the use of treated sewage / trade effluent for gardening / irrigation-3920400 sq.mt.

No need of acquisition of land as the proposed project will be set up in existing factory premises only

4 Project Capacity Enhancement of Sugar unit from 4,500 to 8000 TCD 5 Product Sugar Unit (Production figures are based on operational capacity

of 8000 TCD)

6 Operation days per annum

Average 160 days and Maximum 200 days

7 Raw material Sugar Unit (based on operational capacity) Sugar Cane: Lime Sulfur

8 Water Requirement

The water requirement for the project is received from Dudhganga, Vedgang and Chikotra River.

1.4 Need of project and its importance to the country and region India is one of the largest producers of sugarcane as well as sugar in the world. The sugar cane is cash crop for farmers. There are about 564 installed sugar factories in India. Most of the sugar industries are located in rural areas providing employment to rural masses. Cooperative sugar factories from Maharashtra is the backbone of rural economy. These factories have contributed for the development of conomy as well as infrastructure in rural areas, generated ample of employment opportunity to local people. The project proponent is one of the cooperative sugar factories from the region of Maharashtra. The cultivation of sugar cane is increasing every year in the command area of the factory and it is anticipated to grow gradually for next few seasons. In addition, the sugar factory is having plans to promote and support the cane development programme, in it command area.

Table 1.2: Expected cane availability for next five years Sr. No

Season Sugarcane area (Ha)

Yield (MT/ Ha)

Total cane Production (Lakhs MT)

Cane available to the factory

(LMT)

Expected Sugar

Recovery (%)

1 2016-17 20650 70.00 14.45 12.00 13.00 2 2017-18 20100 72.00 14.50 12.10 13.00 3 2018-19 20050 71.00 14.25 12.10 13.00 4 2019-20 20300 72.00 14.60 12.15 13.00 5 2020-21 21000 72.00 14.40 12.15 13.00

It is seen from the above table that more than 12.00 Lakh MT of the cane availability from the 2016-17 season of the sustainable basis of the evident and SDVSSKL will not face any major difficulty for achieving targeted crushing. 1.5 Power

Table 1.3.Need of power for sugar unit particular Season Off season Electricity consumption 22925900 2738000 1.6 Import vs. Indigenous production The processes of manufacturing for sugar are simple and straight line, available indigenously. The technologies even for the pollution control/disposal are also available indigenously. 1.7 Export Possibility The finished goods Sugar are having excellent potential of export. 2.0 PROJECT DESCRIPTION 2.1 Type of project Proposed project is capacity enhancement of existing sugar factory from 4,500 TCD to 8000 TCD. The project is placed under item 5 (j)-for sugar unit under ‘B’ category as per EIA Notification, 2006 (as amended in 2009) and will be appraised at state level.

2.2 Location with coordinate Project coordinates: 16025’41.72”N 74008’21.19”E

Figure 2.2: Satellite Image of the project site

Fig. 2.3 Master Layout

2.3 Details of alternative site consider and basis of selecting the proposed site Alternative sites for the proposed project are not considered, because of following reasons. i) The project is capacity enhancement of existing units. ii) The project proponents are having adequate land for the proposed capacity enhancement as well as ancillary units thereof such as storage, treatment, disposal units, etc. iii) The present site meets the guidelines for sitting of an industry prescribed by MoEF/CPCB 2.4 Size or magnitude of operation After Capacity Enhancement installed capacities of the project units will be Sugar unit of 4,500 TCD (installed capacity) and operational capacity will be 8000 TCD efficiency. 2.5 Project description with process details Process:

Extraction of Juice The sugarcane is passed through preparatory devices like knives for cutting the stalks into fine chips before being subjected to crushing in a milling tandem comprising 4 to 6 roller mills. In the best milling practice, more than 95% of the sugar of cane gets extracted into the juice.

Clarification 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 rotary drum vacuum filter for removal of unwanted stuff called filter cake. It is discarded or returned to the field as fertilizer.

Evaporation 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, and more syrup is added as water evaporates.

Centrifugation The massecuite from crystallizer is drawn into 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 and after the sugar is “purged” it is cut down leaving the centrifuge ready for another charge of massecuite.

Gradation & Packing The final product in the form of sugar crystal is dropped through pan section and this sugar is graded and picked in to the bags. The grade of the sugar depends on the size of the crystal viz. Small (S) and Medium (M).

Figure 2.4: Flowchart sugar manufacturing process

Raw Materials for Finished Products Raw materials for the proposed project will be available from the local market. Bagasse used as a fuel and molasses as raw material will be available from in-house only. Product wise raw material consumption is given below.

2.6 Resource optimization / recycle and reuse envisaged in the project In the proposed project, optimum utilization of the available resource is strived by the management, by using a renewable energy source of bagasse. Bagasse is a by-product of sugar factory; it will be used as a fuel for boilers that produces process steam. 2.7.1 Water Requirement and Its source Necessary water requirement for the proposed project will be met from Dudhganga, Vedhganga, Chikotra and canal 1 Km. Water will be required for domestic, process and utility purpose.

Used for Gardening and greenbelt ~ 400 cu.m. per day (Greenbelt area of ~ 20 acres) Seed plot and cane plantation area = 20 acres Water required for plantation and seed plot = 400 cu.m/day Treated water from ETP for irrigation = 290 cu.m.

Excess condensate used for irrigation = 110 cu.m 2.7.2 Power & Fuel requirement and its source The existing power requirement is sourced from existing 20 MW back pressure TG set. Existing 2 Nos. of D.G. set of 320 KVA is/will be used as standby. A new 15 MW double extraction cum condensing (DECC) TG set will be installed for meeting the power requirement of proposed expansion. The total power generated during average crushing season of 160 days will be 22.15 MW. After meeting the in-plant requirements for factory, Co-generation unit, the power exported to the grid will be 14.65 MW. And during off-season total power generated will be 11.66 MW out of which 9.86 MW will be exported to the grid. Bagasse is the main fuel which will be used for proposed cogeneration expansion, which is sourced from own sugar factory. The power requirement of the proposed project in season is 22925900 units and in off season 2738000 units. Waste generation & disposal scheme Quantity of waste to be generates & scheme for their disposal are given in following chart: A. Liquid waste Sugar and cogeneration unit Effluent will be sent to sugar ETP and utilized for gardening/irrigation. Condensate water will be treated in condensate polishing unit (CPU). Sugar condensate water will be reused in sugar as well as proposed distillery unit to minimize the fresh water intake. Hot water from various sources will be cooled in cooling pond and recycled to respective activity after reaching to ambient temperature. The factory is having ~20 acres plantation area where treated water will be utilized.

Figure 2.6: Flowchart for effluent generation from Sugar along with cogeneration unit

B. Solid waste The proposed industrial activity at SDVSKL gives solid waste in the form of ETP sludge which is biodegradable and boiler ash. The solid waste will be used as a filler material in the composting process and for manufacturing of Briquette. The quantity and disposal technique is brief in following table.

Table 2.5: Solid waste generation and disposal # Waste Treatment Disposal Remark 1. Sugar ETP Disposal into

land/soil Sold to member farmer/own plot

Organic

2. Ash Disposal into land/soil

Used as a soil enriching material

Organic + Inorganic

Figure 2.7: Schematic Diagram of Existing ETP

2.7 Air Emission & Control There are existing DG set with adequate stack height and acoustic enclosures. 2.8 Noise Control Steam turbine generator will be the major noise source of the proposed project. Apart from that, noise is anticipated from pumps, motor drives, utilities etc. The plant and equipments will be specified and designed with a view to minimize noise pollution. The major noise producing equipments will be provided with sound proof devices and silencers. DG set will be provided with acoustic enclosures. Ear Plugs and ear muffs will be provided to the workers in utility section. Greenbelt will be developed. 2.9 Health and Safety Measures Being a cooperative sugar mill KSSKL is committed to the Health and Safety of all its employees. It strives to provide hygienic & safe work place and continually improve the effectiveness of Health & Safety system. To meet these objectives the SDVSKL will;

Comply with all relevant Laws, regulation, statutory provisions & codes of practice. Continually asses Risks & Hazards so as to evolve establish & upgrade hazard control measures,

emergency preparedness, & risks mitigation and correct the deficiency identified in timely manner. Ensure safe handling, storage, use and disposal of all substance & materials which are classified as

hazardous to Health & Environment. Create awareness in employees by providing appropriate training, motivation information’s so as to

create individual sense of duty, responsibility & participations & an institutionalize culture of continually improvement in Safety , Health & Environment matters.

Make HOD responsible to communicate the safety policy to all concerned in his department. Make supervisors responsible or implementation of the safety precautions, use of safety devices, &

the safety of the people. Empower employees at all levels to be responsible & accountable for their personal health & safety. Fire protection system shall be provided in accordance to the LPA regulations. The fire fighting

system shall consist of a hydrant network. Factory has already a fire protection system including electric driven pump, one diesel engine pump,

and one jockey pump. Portable fire extinguishers shall be provided in strategic locations in new construction area.

3.0 SITE ANALYSIS 3.1 Connectivity The site is well connected by road, railway as well as air network. It is having proper connectivity of Roads and Highway. Kolhapur Railway station is about . The international air port of Kolhapur is the nearest air ports to the site. 3.2 Land form, land use and ownership

The sugar factory is holding more than 77 acres of land. The land is flat, open and already under the industrial use (i.e. sugar factory and allied units).total Built up area of the project is 653400Sq.mt. Area available for the use of treated sewage / trade effluent for gardening / irrigation is 3920400 Sq.mt.

3.3 Topography The terrain is almost flat, no hills in the surroundings. The geographical coordinates of the area are 16025’41.72”N 74008’21.19”E. 3.4 Salient Features The proposed project requires no additional land. Therefore, no social issues are involved. There won’tbe change in the land use pattern since the land is already used for industrial purpose. There is no sanctuary, bio-sphere reserve or national park in the 10km radius area. The project surrounding land is either fallow land or used for agricultural purpose. 3.5. Meteorological Conditions

The climate of the region is tropical maritime with high relative humidity throughout the year. The general climatic regime is fairly equitable since seasonal fluctuations of temperature are not significantly large. The moderating effects of the nearby sea and the fairly high amount of relative humidity in the atmosphere have restricted the variability. The seasonal variation of temperature follows closely the course of the sun. January is invariably the coldest month and May the warmest. With the onset of monsoon in early June the temperature decreases and remains more or less steady. Again the temperature rises in October and falls gradually till January. The maximum day temperature ranges in between 35˚C to 42˚C while the minimum temperature ranges in between 17˚C to 28˚ C. The average relative humidity varies from owest in the month of December to the highest of 65 % during July. The humidity is relatively higher in the morning hours than in the evening hours. The daily humidity values do not show any significant or sudden changes. The relatively high humidity has a considerable impact on the atmosphere in reducing its variability. The monsoon generally sets in around the second week of June and continues till late September. July and August are the wettest months all over the region.

3.6. Sources of Information- Secondary information on meteorological conditions has been collected from www.worldclimate.com. Temperature, relative humidity, rainfall, wind speed and direction are measured twice a day viz., at 0830 and 1730 hr. The wind speed and direction data of IMD, station has been obtained. The data for the remaining parameters has been collected for the last 10 years and processed.

Chapter 4

RISK ASSESSMENT AND SAFETY MANAGEMENT

Risk Assessment involves the identification and assessment of risks the persons involved in the proposed project and the neighboring populations are exposed to as a result of hazard occurrence. This requires a thorough knowledge of failure probability, credible accident scenario, vulnerability of population etc. Consequently, the risk analysis is often confined to maximum credible accident scenario and the analysis of the potential effects of environmental hazards to human health.

These accidents can be minimized to a great extent by proper procedures, handling and training. But it may be difficult to reach zero risk or absolute safety level. Whenever such incidents do occur in order to prevent loss of lives and damage to property, it becomes necessary to take immediate steps to control the situation. This can be achieved through a planned advance preparation to face such a situation with respect to both on site and off site emergencies.

Chapter 5

PROJECT SCHEDUE AND COST

5.1 Proposed Schedule for Approval & Implementation

Company has obtained consent from MPCB Manufacturer has proposed addition of new products and applied for consent to establish from Maharashtra Pollution Control Board. The manufacturing of new product has planned to start after one month from obtaining environmental clearance.

5.2 Project Cost`

The estimated cost for proposed expansion is about 14704.44 Lakhs

Chapter 6

PROJECT BENEFITS

6.1 Introduction

The proposed project will be provided job opportunity at maximum extent to the surrounding population. The project shell affect the socio-economy, physical infrastructure and biological environment. The project will result in the improvement of life relative localities. Some important beneficial impact of the projects as follows:

Improvement in the physical infrastructure Improvement in the social infrastructure Employment

6.2 Improvement in the Social Infrastructure

This project will be provided better livelihood to the local people. After the set up of this project all basic facilities would be here. This zone will de attracts the people at global level. And this area would be connected with world other areas in the respect of transportation, communication etc.

6.3 Employment

The project will provide employment opportunity for the local community in the construction phase as well as in operation phase. Tender specification for construction and operation would include a favorable employment opportunities for the locals. The main principles are outlined below:

Employment strategy would provide for preferential employment of local labor. General recruitment procedures will be transparent, public and open to all. Recruitment procedures will be publicized in advance. There will be no discrimination on basis of gender, caste or other factors.

Contractors would be required to abide to employment priority towards locals and abide by the Indian labor laws regarding standards on employee terms and conditions.

Chapter-7 CONCLUSIONS

We may conclude as under:

The proponents are following all the safety rules and regulations as prescribed by Ministry of Environment and Forest, Government of India and MPCB.

Wastewater will be treated in full-fledged Wastewater Treatment Plant. Ambient Air Quality of the project site will be within the permissible limit as prescribed by

National Ambient Air Quality Standards. Noise is expected to be on higher side during construction phase. In the operational phase it

will be only due to the machines. No significant impact is seen on flora and fauna. The project will generate employment opportunities during construction stage and also at

operational phase. The standard of living of local people due to employment is likely to be better, so we may say that it is positive socioeconomic impact.

In short we can say that this project has no negative impact on environment.