Expansion of 30 KLPD Distillery plant to 60...

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PRE-FEASIBILITY REPORT

For

Expansion of 30 KLPD Distillery plant to 60

KLPD

To Produce

RECTIFIED SPIRITOR ANHYDROUS ALCOHOL

At

M/s Samartha Sahakari Sakhar Karkhana Ltd.

Ankushnagar Tah. Ambad, Dist. Jalna

Maharashtra

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Synopsis1. Introduction

2. Justification

3. Location

4. Resources

5. Process

6. Pollution Control

7. Background Study

8. Safety

9. Benefits

10. EIA Structure

11. Scoping

12. Conclusion

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1. Introduction

M/s Samartha Sahakari Sakhar Karkhana Ltd. Ankushnagar Tah. Ambad, Dist.

Jalna was registered under the Maharashtra Co-Operative Societies Act, 1960 vide

Registration No. JAL/PRG/A-1 dated 10th feb.1982. The Company is having 30

KLPD Distillery unit established in the year1992. The management of the factory

has decided to expand the capacity to 60KLPD.


Jalna is one of the efficient sugarmill of Maharashtra.The industrial growth in the

area, the sugar mill is also involved inseveral developmental activities to help

farmers and workers.To exploit more benefits from the industrial complex, the

management of the factory has decided toexpand its 30 KLPD distillery unit to60

KLPD based on latest fermentation and atmospheric distillation technology to

produce alcohol from cane molasses.It is stated that the Distillery unit will come

under “Category A" with screening it is necessary for M/s Samartha Sahakari

Sakhar Karkhana Ltd to approach Ministry of Environment Forests and Climate

Change (MoEF&CC), New Delhi for Environmental Clearance for this Distillery

unit. This Pre-feasibility Report is prepared for forminga 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 PrefeasibilityReport is an

accompaniment to the same.The Form I submitted by us generally has covered

Justification, Nearby Land Use, Resources,Process, Pollution Control, Aesthetics,

Risk Involved, Consequent Developments and EnvironmentalSensitive Issues.

2. Justification

Molasses based distillation was the route in India historically .This is an expansion

project wherealcohol is produced from cane molasses by fermentation and

atmospheric distillation technology. The latest technology is adopted with a

Justificationfor better productivity and qualityof alcohol.

The molasses based distilleries are linked with sugar factory and sugar producing

farmers will bebenefited by it. The sugar mill is also involved in several

developmental activities to help farmers andworkers. In the industry, effluent

produced is only water .Therefore, problems of pollution hazard are nil.Consent

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from Environmental Department and Pollution Control Board can be easily

obtained as amatter of routine.Cane growing needs a longer time to get the crop.

During over production of Sugar Cane and low prices for Sugar in the market shall

make viable tomanufacture Alcohol blended in directly from the Sugar Cane Juice

Syrup.

3. Location

The proposed location is in Village, Ankushnagar Tah. Ambad, Dist. Jalna

Maharashtra. This candidate site is in vicinity of potential sugarcane-growing area,

so that there is less transportation of Sugarcane/ Bagasse / Molasses, less spillage,

less accidental risk, less pollution, lessConsumption of fuel and less loss of

fermentable sugar.This is not Prime Agricultural Land. This is flat land whereby

Cutting-filling will be balanced andthere will be No/Low Borrowing from Nature.

This is procured by mutual agreement with goldenhand-shake.Within 10 km

Influence Zone, there is no Tropical Forest, Biosphere Reserve, National Park,

WildLife sanctuary and Coral Formation Reserve. The River, City Jalna, Railway

line, National Highway are sufficiently at a distance. The Clearance is obtained

from Gram Panchayat and hence will have public acceptability.

4. Resources


Jalna proposes to expand a 30 KLPD Distillery unit to 60KLPD Distillery, which

requires following resources

Location

1. Already existing plant.

2. Own raw material

3. Availability of utilities such as steam, electricity and water

4. Adequate land for Distillery and Effluent Treatment Plant

5.Avoiding likely odour nuisance to the residential colony and the public in general

6. Availability of technical assistance in case of necessity.

7. Well connected road network with ease of cane transport.

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Raw Materials Input

The capacity of the proposed distillery shall be 60 KLPD. For this the main and

sole raw material ismolasses. The yeast and enzymes bring about the change. Some

chemicals in small quantity are usedfor supporting propagation of the yeast and

help to fermentation. Thus,

In addition to the raw material, utilities are also required. These are:

• Power:The power required for proposed expansion project is 33960 kwh/day.

Existing power generation capacity of SSSKL is 18 MW through co-gen unit.

SSSKL has planned to install a separate 2.0 MW capacity turbine for distillery

unit. The estimated requirement of power for 60 KLPD distillery will be generated

& ETPwill be 1.415 MW/hr. The required electricity for 60 KLPD distillery will

generate and supplied from the independent incineration boiler and TG set at an

average price of Rs. 1.00/unit as maintenance cost. Surplus power of 585 Kwh/hr

will be supplied to the grid. Power for idle days will be supplied through the DG

set of the sugar factory or purchased from State Electricity Board at the rate of

Rs.9.13/unit.

• Man Power: Staff, skilled and unskilled totally 98 persons will be required, and

will beavailable.

• Water Requirement: Total requirement of water for 60 KLPD distillery based on

Continuous fermentation, multi pressure vacuum distillation with integrated

evaporation, standalone evaporation system to concentrated spent wash & an

incineration boiler will be around 1600 M3 per day. The process condensate (520

M3 /day), spent wash (120 M3 /day) and other weak stream condensate (408 M3

/day) will also recycled back to boiler. Thus actual fresh water requirement after

recycled will be around 562 M3 /day. The SSSKL is drawing water from river and

jack well.

S.R. Raw Materials Quantity

1 Molasses 42,000 MT/Annum

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• Steam Requirement: The steam requirement for the 60 KLPD distillery,

standalone evaporation, deaerator and SCAPH of incineration boiler including

pipelines losses will be 19.00 MT/hr at 21 kg/cm2(g) pressure. SSSKL has planned

to install an independent 22 MT/hr capacity incineration boiler having 45

kg/cm2(g) pressure for distillery unit. Required steam and power will be made

available for distillery plant from the proposed incineration boiler of 22 MT/hr and

T.G. set of 2.0 Mw/hr capacity.

• Building materials: This is not a heavy construction, and majority is in

fabrication fromMild 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 besmall and will be done in day time. Labour camp

is not necessary.

• Total Cost for project will be Rs 7405.24 Lac

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

5. PROCESS


Jalna proposes to expand a 30 KLPD Distillery unit to 60 KLPD Distillery. The

peculiarities of manufacturing process are as follows:

Manufacturing Process for Molasses Based Distillery:

• Molasses or Sugar Cane Juice Syrup is the raw material used for the production

of the alcohol. Molasses contains about 50% total sugars, of which 30 to 33 % are

cane sugar andthe rest are reducing sugar .During the fermentation, yeast strains to

the speciesSaccharomyces cerevisieae, a living microorganism belonging to class

fungi converts’sugar present in the molasses such as sucrose or glucose into

alcohol.

Chemically the transformation for sucrose to alcohol can be approximated by

equation:

1) C12H22O11 + H2O2 C6H12O6

Cane sugar Glucose + Fructose

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2) C6H12O6 2C2H5OH + 2CO2

2X46 + 2X44

Glucose/Fructose Ethyl Alcohol Carbon Dioxide

For bringing out above biochemical reaction, there should be a proper and careful

handlingof yeast, optimum temperature and pH control and substrate

concentration, which results intoeffective conversion of sugars to alcohol.

• Yeast can be manufactured under strict controlled conditions or readymade under

strictControlled conditions or readymade compressed yeast may be used directly in

the prefermenter .Good quality of yeast is available for use in distillery. The yeast

is useful to obtaina good yield of alcohol by fermentation of molasses .The stages

of yeast propagation asdescribed above for producing yeast from laboratory scale

to pre fermenter stage may be totaleliminated .The fermentation of molasses in

fermenters take about 24 to 36 hrs forcompletely exhausting the sugars in

molasses.

• All the sugars are not converted to alcohol during the process or fermentation

becausechemicals like Glycerine, succinic acid, etc. are also produced by yeast

during theirmetabolic process .Therefore it is not possible to have 100% efficiency

of conversion ofsugars to alcohol. The average yield of alcohol from molasses is

about 250 litres from 1 MTof molasses.

• The different technologies like High brix fermentation, Multistage Continuous

fermentation,Immobilized enzyme fermentation, Continuous fermentation without

yeast separators areusing in the field of fermentation to get a high yield of 280 to

300 litres per MT of molasses.

• After fermentation the next stage in the manufacture of alcohol is to separate

alcohol fromFermented wash and to concentrate it to 95%alcohol called as

rectified spirit .For thispurpose, method of distillation is employed.

• The fermented wash first enters the beer heater, which is a condenser for

condensingalcoholic vapours by using wash a cooling medium .The objective of

this beer heater is torecover the heat from the hot vapours of alcohol .Fermented

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wash from the beer heater goes todegasifying column, degasifying column bottom

goes to the top plate of the wash column.

This column consists of 18 plates .The steam is admitted through the steam spurge

situatedat the bottom of the column .As the steam rise up, the wash descending

from the top to thebottom of the column gets heated and by the time it reaches to

bottom plate, it consistpractically no alcohol .The wash going out is called spent

wash, which is discharged to thedrainpipe.

• The vapours coming from wash column now consists approximately 50%alchol

and 50%water with impurities such as higher alcohols, aldehydes ,acids ,sulphur

dioxide etc .Part ofthese vapours are led to Pre-rectifier column. Other portion of

the vapours, which is majorquantity, is led to rectifying column .This column

consist of 44 plates, which helps theremoval of based smelling fueloil, which is a

mixture of higher alcohol .As the vapourscoming from wash column rise to the top

of the rectifying column, the concentration ofalcohol goes on increasing and finally

it aches to the concentration of 95.5%alcohol.

• Actual product of rectified spirit is drawn from the 3 plate from the top and

cooled in alcoholcooler and taken out as a product. The fuel oil which is a mixture

of higher alcohol is drawnfrom the 6 to 10 plate from bottom of rectifying column

as a stream of vapours, it is Condensed and cooled and led into a decanter where it

is mixed with water .Fuel oil isrecovered at the rate of 0.2% of alcohol produced.

• The alcohol both pure and impure is first led into separate receivers. The quantity

of alcoholproduced is assessed daily in the receivers and it is finally transferred to

storage vas in thewarehouse .The spirit from storage vats could be issued for

denaturation, or for ownconsumption, or directly to the tankers of the customer

depending upon the type ofrequisition. All these precautions are taken.

Manufacturing process for Anhydrous Alcohol:

Alcohol as manufactured by Indian distilleries is rectified spirit ,which is

94.68%alcohol,and rest is water .It is not possible to remove remaining water from

rectified spirit by straight distillation as ethyl alcohol forms a constant boiling

mixture with water at this concentration and is known as azotrope. Therefore,

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special process for removal of water is required for manufacture of anhydrous

alcohol. In order to extract water from it is necessary to use some dehydrant or

entrainer, which is capable of separating, water from alcohol. The various process

used for dehydration of alcohol are Azeotropic distillation, Molecular sieve,

Prevaporation /Vapour permeation system.

Characteristics

Sr.

No.

Parameter Raw spent mash from continuous

fermentationprocess

1 PH 4.0 – 4.3

2 Temperature 450C

3 Color Dark brown

4 Chlorides 6000-7500

5 Solids-

Total

Total Volatile

Inorganic dissolved

4000 - 6000

1,30,000-1,60,000

60,000-75,000

35,000-45,000

6 BOD 55,000-65,000

7 COD 1,10,000-1,30,000

8 Sulphates 4,500-8,500(All Values except pH are in mg/l)

Treatment:

Stream (A)

The domestic effluent is of weak nature with biochemical demand BOD as 90-120

mg/lit andSuspended solids SS as 80-140 mg/lit. There is no toxicity involved and

is fully biodegradable.

This is treatable in a well designed septic tank of hydraulic retention time of more

than 24 hours.

This is compartmentalized by baffles.33The Domestic Waste Water (sewage

effluent) is required to be treated to bring it to the quality of100/100 (BOD/SS)

standards, suitable for use on gardening, irrigation. Sub-surface Irrigation

arrangement or disinfection at the end for freshening up, odour control,disinfection

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and safety for sewage farm workers shall be provided. This arrangement is found

tobe satisfactory.

Stream (B)

The reusable wastewater comes from spent lees and from CO2 scrubbing.This

shall be used again for various purposes such as for Boiler feed,Process, before or

at fermentation.

Stream (C)

The Sober wastewater stream comes from boiler blow down and cooling purging

water. Excepttemperature, it has no other objectionable characteristic. This is

cooled and used on gardenlocally. The quantity is small.

Stream (D)

Moderately polluted wastewater comes from de-min plant regeneration, excess

spent lees andfloor- vessel washings. This needs treatment and Biological

Oxidation is possible. The quantity,however, is so small that independent ETP is

untenable. Thus with small collection tank, it isallowed to mix with polluted

stream (D) and treated-disposed with it. This too serves as diluentsin case of

molasses based before its effluent goes into Bio-Digester.

Stream (E)

The Industrial wastewater is low in pH, has deep color, and has high BOD, COD

and TDS.

However, it is neither poisonous, nor toxic, nor hazardous. It is highly

Biodegradable, and aftertreatment, acceptable to the crops. It is proposed to treat

the effluent in two stages, by Anaerobicup-flow sludge blanket reactor (UASBR)

and by Aerobic Bio-composting Treatment.

I) Anaerobic Up-flow Sludge Blanket Reactor (UASB) will have following

units

Sr.No. Unit Unit Purpose Environmental

significance

1 Plate type heat Bringing down the Open lagoons for cooling

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exchanger temperature suitable to

microbes

avoided.

Heat is recovered.

Congenial toMicrobes.

2 Collection

sump

Efficient mixing of all

effluent sub streams

and return stream

Adjusts, equalizes BOD,

pH, flow foreasier loading

ahead

3 Digestion tank Biological activity High HRT (15 days) given,

contactopportunity by

mixing 25 HP forhigher

efficiency

4 Clarifier Settling the active

biomass for returning

Reusing the skilled worker

increasesthe efficiency,

resulting in moreMethane

and less outgoing BOD

5 Gas holder To adjust the demand In no-demand period, no

need ofletting out the

methane

6 Other attendant

units

To suit Brings in the flexibility of

operation

There will also be attendant units like Pump House, Electrical Panel Room and

Sludge Drying Beds.

The treated effluent characteristics in this case shall be as under

Sr. No. Parameter After treatment

1 pH 5.5 to9.0

2 SS mg/lit < 100mg/lit

3 TDS mg/lit < 2100 mg/lit

4 BOD mg/lit < 100 mg/lit

5 COD mg/lit < 250 mg/lit

Laboratory and Documentation shall support all the systems above.

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Disposal:

The matter is very simple in the present case.

Stream (A)

The stream of domestic sewage / coming after treatment from Septic tank plant is

fit fordisposal by absorbing it on root zone of the plants/crops.

Stream (B)

The stream of usable water coming from Condensate is returned to Boiler asboiler

feed. The CO2 scrubbing water is used for dilution in Fermentation tank, as also

thespent less. No further problem of disposal remains.

Stream (C) (D) & (E)

The treated effluent will be fit for disposal by absorbing it on root zone of the

plants/crops.When once so recycled/ reused, nothing is left for further disposal.

The treated effluent issatisfactory for use on land and is acceptable to the farmers.

A demonstration plot will bearranged to show the results for various crops. For

this,adequate land is available in the immediate vicinity.

SOLID WASTE


Jalna the industrial activity at uses only one main raw material and it is in solid

form.

Following mitigation practice is the policy for future:

• Minimization at all levels will be attempted for discarded products, empty

containers(which are rare), packing surpluses, incoming raw material unloading

spillages (which israre) and fugitives. The factory has very little scrap materials.

All these, however, becarefully stored on raised platform with dwarf to walls all

around, and a roof over-head.

The contents shall not be held in the premises for more than a fortnight.

• These measures can easily be taken by M/s Samartha Sahakari Sakhar Karkhana

Ltd. Ankushnagar, Jalna because (1) they have no discards or off-specification

products, and (2) the waste is fully recycledboth in green stage and in dry stage.

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The municipalwaste canteen is thus controllable. This will be composted and used

in duecourse on own land as manure. Plastic use is discouraged. . Yeast is recycled

as the viablecommunity helps in more yield and conversion. Only some part is

wasted. This is organic nature andis suitable for getting composted. This is so

done. ETP sludge is organic and digested. Thus afterdewatering can be used on

land for conditioning. Office and packing trash is kept minimum anddisposed by

sales or reuse.

(b) Air Pollution:

The High Pressure Boiler will be provided with cyclone and scrubber. As the fuel

is methane gas,fear of SPM is non-existent and still a cyclone is provided. Any

other combustion gases will beabsorbed in scrubber. Tall stack is provided as per

norms. The exhaust steam of low pressure is putto second use in the unit. The

hydrocyclones, carbon dioxide scrubber to recover alcohol, efficientplate heat

exchangers for cooling recycled still age and for cooling fermented wash is

provided .TheCO2 which is liberated ,is scrubbed in water, with the of CO2

Scrubber. This CO2 contains ethanol,which is recovered by collecting CO2

scrubber water into sludge decantation.

The air pollution sources are known and accordingly measures of prevention,

abatement, control andmitigation will be taken. This can be summarized as –

Sr.

No.

Source Pollutant In-plant Measures Control Equipment

1 Boiler SPM ,

CO

Feed methane

more, rather than

bagasse.

Dampers, ID Fan, CO2

meter, Fly-asharrestor.

Light ash through very tall

stack.

2 Fermentation CO2 Tank covered Scrubbed in water

3 Distillation HC Closed circuit

4 Spent-mash HC, Heat Heat Exchanger (Not open to sky cooling)

5 ETP HC -------- Fully Aerobic turning

With these precautions air and odour pollution will be under check.

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7. Background Study:

This is important part of study.

(A) Natural Environment:

We have undertaken to do the sampling as –

• Surface Water: 2 Locations, 11 Parameters.

• Ground Water: 9 Locations, 9 Parameters. Includes1 up gradient and 2down

gradient of effluent land irrigation yard source.

• Air Quality: 3 Months, For SPM, RSPM, SO2 and NOx 9 Locations Includes

1upwind and 2 downwind of stack source.

• Noise: 9 Locations.

• Soil: 9 Locations, 2 locations in Actual land irrigation yard.

The stations will be selected in all the eight directions from the factory and in 10

km radius.

(B) Manmade environment :

This includes existing land-use, demography, employment, socio-economic

aspects andcommunity development needed and proposed. This will be for

entire area both rural andurban in this study zone.

• Socio-Economic Status in Influence Zone will include the study of Non-

Workerspercentage 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

ofTotal Land what percentage is already under Irrigation?

• If the land is not likely to support more people, then whether Industrialization

isnecessary 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 tothis industry. Safety policy will be in place. The unit will be registered

under Factory Act andare bound by State Factory Rules. Thus, First aid trained and

Fire-fighting trained person willbe available in every shift. Safety Officer will be

appointed, as also the competent personretained. Where necessary, provisions of

other Acts, where required like Petroleum act,Explosive Act, etc. will be obeyed.

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Fire fighting system is kept as per norms of InsuranceCompany 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

This industry will provide ENA alcohol as useful material for India, which will

earn foreignexchange in the potable alcohol cadre. This will not disturb the present

land use because ourarea occupied will be only small % of Influence zone 10 km.

Compatible Architecture will beadopted and No Prime Agriculture Land will be

put to this industrial use. Trees will bemaintained and not raised down. No

Rehabilitation is involved. The problematic wastematerials like solid waste will be

used as manure. Wastewater will bereused to grow the raw material, wastewater

will be used to get non conventional, renewableenergy, and greenery will be

increased. People will get some jobs here and the sugar cane offarmers will get

proper price and lifting at right time. Some incidental small employment

likeeatery, canteen, tyre repairs, and garage too will become available to genuine

people. Thiswill be beneficial to the society. Due to this project, farmer will get

more prices.

10. EIA Study Report

This will be finally prepared and submitted as per guidelines given by MoEF as --

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

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11. Scoping

We shall propose in “Scoping” the details of all above, as also the following

• Against the study area the land under distillery is merely less than 0.025 %.

Thus, there will not be change in land use pattern. The present land is already

non-agriculturaland under industrial use.

• Raw material requirement, water requirement, water balance, process

detailstechnology, product storage, etc.

• Ambient Air Quality Monitoring for three months except monsoon covering 7.5

kmradius around Industry and its impact.

• Ground water quality around plant and composting yard 1 km radius.

• Treatment scheme to achieving Zero discharge, towards surface or ground waters.

• Ground water 2 down gradient and 1 up gradient location in 1 km area.

• AAQ Ambient Air Quality stations 2 down wind and 1 up wind location in 1 km

area,from Stack.

V Alternate Analysis

Selection of Raw Materials, Site, Process, Machinery-

Hardware, Collaborators, Staff & Team

VI Monitoring = Stations, Parameters, Frequency, Statistics,

Rectify

VII Extra Innings Risk = To Environment, To

Health, To Bankers

Public Consultation Community = Ousters

Reporting Rehabilitation.

Others- Assistance

VIII Benefits = Physical, Social, Employment, Other Tangible.

Sustainable??

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

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• Soil quality monitoring, permeability and other details around compost yard.

• Scheme of Treatment, mode of treatment.

• The pollution source in this area will be villages nearby. No medium or large

scaleindustries present within 10 km radius. Moreover, this is rainfed area, there

is noagricultural return water going to river.

• Information of solid waste, no. of working days, CO2 emission from stack and

process,etc.

• Employment generation, Benefits of project.

• The only raw material use is grain, which is not covered under MSI rules.

Sulphuric acidis used in process in very small quantity. However, Risk

Assessment will be done andSubmitted.

• An Environmental Inventory will be prepared.

12. Conclusion

• This project is very necessary in view of converting useful foreignexchange saver

product.

• The local people desire that this industry 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 withEase.

• Full precautions will be taken for Pollution Control, Resource Conservation

andEnvironmental Protection.

• This is cost effective and Sustainable Development.

CHAPTER – I

EXECUTIVE SUMMARY

1.0.0 INTRODUCTION

1.1.0 PREAMBLE

M/s Samartha Sahakari Sakhar Karkhana Ltd. Ankushnagar Tah. Ambad, Jalna,

Maharashtra. The distillery has a capacity to manufacture of alcohol. The product is

well accepted in the market. To meet the increased market demand for the product

the company has now proposed to enhance the capacity of the industry from the

existing 30 KLD to 60 KLD. Salient features of the expansion project are given in

Table-1.

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1.2.0 OBJECTIVE OF THE EIA STUDY

Industrial and other developmental activities invariably involve utilization of

natural resources and generation of waste substances and therefore may have

adverse consequence to the environment. There is a need to harmonies

developmental activities with the environmental concern. Environmental Impact

Assessment (EIA) is one of the tool available with planners to achieve the above

goal. EIA is to foresee and address the environmental problems/concerns at an

early stage of project planning and design. It can often prevent future liabilities or

expensive alteration in project design.

The Ministry of Environment and Forests (MoEF) Government of India has

recently issued an EIA notification S.O. 1533 dated 14.09.2006, under

Environmental (Protection) Act (EPA) 1986. Prior Environmental Clearance from

the EIA Authorities is mandatory for the establishment of projects/activities listed

in the Schedule to the above notification. Distillery projects are categorized under

5(g) of this Schedule and therefore, require prior environmental clearance from the

EIA authorities. Accordingly, M/s SSSKL have conducted EIA studies for their

proposed expansion project. EIA report along with prescribed application is

submitted to the authorities to seek prior environmental clearance for the proposed

project.

Table-1 Salient Features of the Industry

Sr.

No.

Feature Particulars

1 Name and address

of the Company

M/s Samartha Sahakari Sakhar Karkhana Ltd,Ankushnagar Tah. Ambad, Dist. Jalna,Maharashtra

2 Project Expansion of distillery capacity

3 Working days per year 298

4 Products, KLD

Rectified Spirit

OR

Anhydrous Alcohol

Proposed Expansion Plant

57 KLPD

54.29 KLPD

5 Main raw material 42,000MT/Annum

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Molasses

6 Man power in the

industry

98

7 Water source

& requirement

562 m3/day

Table-2 Location Features of the Site

Sl.

No

Feature Particulars

1 Location M/s Samartha Sahakari Sakhar Karkhana Ltd

Ankushnagar Tah. Ambad, Dist. Jalna,, State –

Maharashtra.

2 Nearest major road National Highway : NH 211

3 Nearest railway station Kodi Railway Stations, 47.5 Km

4 Nearest village Mahakala : 1Km

5 Nearest major city Jalna : 50.0 Km

6 Nearest water body Baraswada lake : 13.0 Km

Godawari River : 4.0 km

7 Sensitive locations Archaeological structures, Historical places,

Protected Forests, Sanctuaries and Biosphere

are not present within 20 km.

2.0.0 ENVIRONMENTAL MONITORING PROGRAMME

The effectiveness of these measures will be ascertained by systematic monitoring

of discharges at factory and receiving levels.

Environmental Cell

Environmental cell consisting Managing director and departmental heads will be

created to effectively manage the environmental activities in the distillery.

Environmental department will be formed with environmental scientist, laboratory

chemists and operators to implement and operate pollution control and

environmental protection measures.

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Monitoring Facilities and Schedule

A laboratory is established with man power and facilities to analyze water, waste

water, soil, stack emission, ambient air etc. The parameters monitored are

temperature, SPM, SO2

and NOX

for gaseous emissions and SPM, RSPM, SO2

and

NOX

ambient air.

The quality of discharges including spent wash, waste water, flue gas, yeast sludge

and the receiving bodies such as ambient air, water, surface water and soil will be

monitored for the desired parameters. Sampling locations and post project

monitoring schedule have been worked out.

Environmental Records

Environmental department will maintain log sheets and manuals for operation and

maintenance of pollution control and related facilities. Progress reports and statuary

records as per environmental acts will also be maintained.

3.0.0 ENVIRONMENTAL MANAGEMENT PLAN

The distillery utilizes resource such as water, molasses, fuel etc. and discharge

liquid, gaseous and solid waste products. They may cause adverse impacts on

environmental parameters including ground and surface water, air and soil.

Mitigation measures are incorporated in the project to protect environment against

these adverse impacts. A comprehensive environmental management plan is

adopted consisting of proposed pollution control measures and additional

mitigation measures for abatement undesirable impacts. Some of these additional

measures include-

i. Green belt and greenery development in and around the factory site

ii. Storm water management & Rain water harvesting

iii. Paving and lining of roads, solid storage yards of ash, husk etc.

iv. The compost yard and spent wash storage tanks will be suitably lined to

prevent percolation.

v. Self monitoring system is established in the industry with man power and

facilities to ascertain the compliances of environmental norms and

standards.

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vi. Personal health care programme, emergency management plan and safety

management systems will be implemented in the distillery.

vii. Operation and Maintenance of pollution control measures

viii. Establishment of waste reduction measure

4.0 PROJECT BENEFITS

The importance and utility of alcohol as an industrial raw material for manufacture

of a variety of organic chemicals including pharmaceuticals, cosmetics, potable

alcohol etc. It is now being increasingly appreciated all over the world. This is

partly due to high costs of products produced through petroleum route, consequent

to the phenomenal increase in petroleum price.

Further, it is a potential fuel in the form of power alcohol when blended with

petrol. Ethanol is substitute to the imported petroleum. Being produced from

renewable source it is an environmental friendly product. Large demand is also

anticipated for its use as fuel.

The industry on expansion will provide direct and indirect employment to more

than 98 local rural persons. With the industry, the road, communication and related

facilities in the region will also improve.

5.0 CONCLUSIONS

i. Distillery produces alcohol from renewable resources (molasses) which is the

by-product of the sugar industry. Alcohol is a source of fuel and raw material

for many chemical products in addition to its use in beverages. It is a substitute

to petroleum which is scarce, costly and environmental unfriendly. The

proposed agro based distillery has national priority to over come energy and

foreign exchange crisis. Distillery industry also has export potentials to earn

foreign exchange.

ii. This industry does not produce any toxic products and does not have

significant adverse effect on the quality of land, water and air. The industry

has taken all the necessary preventive measures to mitigate even the small

effects which may be caused by industrial activities.

iii. The concept of Reduce, Recycle and Reuse is practiced in the industry. This

has resulted in reducing the effluent discharge to the Environment. The

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industry practices concentration, and composting technology along with bio-

methanation and land application. Thereby, fertilizer value of the spent wash is

advantageously used for dry land cultivation.

iv. The soil nutrients present in spent wash are recovered in compost or boiler

ash. These products are rich in micro and other nutrients and therefore useful

to the formers to enhance the nutrient values of the soil.

v. The industry adopted an effective environment management system and

environment management plan to protect the environment.

vi. The industry has given due priority for green belt development within and

around the factory premises.

vii. In the vicinity of the factory there are no protected forests, sanctuary,

archaeological important structures and sensitive locations. Therefore, the

proposed industry will not have adverse effect on the environment or the eco

system. Commencement of this industry will improve the economic status of

the population of this rural under- developed region.

viii. The EIA report prepared along with the suggested measures for pollution

control and the monitoring system is sufficient to protect the environment.

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CHAPTER II

INTRODUCTION OF PROJECT / BACKGROUND

2.1 Brief Description of the Project Proponent:

This is a proposal to expand an established molasses-based Distillery of 60 KLPD

in thepremises of existing M/s Samartha Sahakari Sakhar Karkhana Ltd (SSSKL)

at Ankushnagar Tah. Ambad, Dist. Jalna,, State –Maharashtra. The proposal, as

acknowledged by Government of India, Ministry of Commerce and Industry,

Entrepreneurial Assistance Unit, New Delhi is to produce:

Sr.

No.

Product Quantity

1 Rectified Spirit OR Anhydrous Alcohol 60 KLPD

Table No. 1.1: Proposed Production

This will be molasses-based, being run only one at a time and not increasing over

new 90 KLPD.This enterprise has been initially promoted by the eminent social

worker and respectedagriculturists of the area. The vision came from a group of

persons who made agriculturaland horticultural practices for over many years, and

disseminated their knowledge. Thegroup is associated with local social bodies,

educational institutes.

Totally this is a group of agriculturists, agro-industrialists and business persons

ingeneral, and in particular the present Directors of this limited company. They

collectively made progress to fulfill a dream of helping local farmers by founding

an agro-based Industry and running it well. The progress made so far isachieved

due to guidance from :

Table No. 1.2: Board of Directors

Sr. No. Name Desiganation1 Smt. ShardataiAnkushrao Tope Chairman

2 Shri. UttamraoKashinathPawar Vice Chairman.

3 Shri. AmarsinhaKashinathraoKharat Director

4 Shri. ShirangraoDamodharraoPaithane Director

5 Shri. SadarshighDhondusinghPawar Director

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6 Shri. ManojkumarJagnathMarkad Director

7 Shri. FattyabkhaMasumkhaPathan Director

8 Shri. SureshraoDasharanthraoAaute Director

9 ShriAmbadasVishwanathPawar Director

10 Shri. SheshraoNamdeoJagtap Director

11 Shri. VikasPrakashraoKavhale Director

12 Shri. KiranSubhashTarakh Director

13 Shri. NarshinghraoVithobaMundhe Director

14 Shri. BabasahebVitthalraoKolhe Director

15 Shri. Kailas DamodharJige Director

16 Shri. ParajiSheshraoSule Director

17 Shri. Dattu Anna Jadhav Director

18 Sau. SumitraSatishraoHonde Director

19 Shri. Trimbakrao Narayan Bulbule Director

20 Shri.AshokAnjiramAaghav Director

21 Smt. N.V. Gaikwad(Regional Director of Sugar, Aurangabad)

State Government Representative

22 Shri. BajiraoTukaramPawse Managing Director

The company will continue their efforts in making the proposed plant ideal

withstate of art hardware and same responsible working as other enterprises of the

proponentsgroup.

2.2 Brief Thoughts on Project:

Man needs Alcohol for day to day production of downstream industrial chemicals,

alsofor potable and medicinal usages and potentially as petrol additive to

oxygenate,replacing tetraethyl lead.The target of alcohol demand as projected in

the perspective plan for chemical industry,Department of chemical and

petrochemicals is increasing for next few years. In addition,now a day, there is a

good potential to export alcohol out of country.

Project Proponent has made SWOT Analysis and finds the overall

summation,encouraging. The SWOT (Strength, Weakness, Opportunity and

Threat) analysis is madeand all this goes to suggest that the Project Proponents

have made a serious homeworkand have seen that the environmental impact will

be minimal.

2.3 Brief Summary of the Project Objectives:

The Objective of this Project of power Alcohol Ethanol is best summarised in a

Paperpublished by Union Petroleum Minister, Government of India, Hon'ble Ram

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Naik. Hon'ble Minister states, "Brazil produces 14 billion litres of ethanol from

molasses andsugarcane juice against our production of 1.3 billion litres from

molasses and nil fromdirect sugarcane juice. The present level of production in

India shows tremendouspotential for increasing thereof. This can be achieved only

by major investments in thetechnology up gradation/ expansion of distilleries or by

setting up new distilleries."

This is precisely the main objective of this project, which will be supported by low

or nodiscards and conservation of resources. This type of plant is likely to be more

viable inview of present situation, when the Sugar has low demand in the market,

molasses is anenvironmental risk (of pollution and auto-combustion), and ethanol

has a foreignexchangesaving potential.

2.4 Brief Summary of the Peculiarities:

• The first peculiarity is this, that the Project Proponent has made a provision

ofabout 25% of their capital outlay for pollution control and greening drive inthe

outset itself.

• The raw material molasses is used immediately after harvesting. This

istransported and also transferred without any chance of losing sucrosecontents.

This has become possible due to nearness of site to the sugar unitsand tar roads in

the vicinity. The size is controllable.

• It is possible to select good molasses answering following specifications:

"Molasses should be free from any foreign material including any

Caramalisation products and known inhibitory elements of Yeast metabolismsuch

as lead, arsenic, polyelectrolytes etc. or micro-organisms producing sideProducts.

Such available molasses will have:

Table No. 1.3 : Selection of Molasses

Sr. No. Particulars Specification

1 Fermentable Sugar FS Min. 36% (w/w)

2 F/N Ratio Min. 0.9

3 Sulfated Ash Max. 15% (w/w)

4 Volatile Acids Max. 10000 ppm

5 Bacterial Content Max 10 Cfu/gm

6 Sludge Content Max. 10% by volume at 1:1 dilution

7 Butyric Acid Max. 100 ppm

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• Selection of correct quality molasses is possible because in addition to ourown

sugar unit, there are a number of other in reachable distance both in thisand

adjoining Districts, this being on the common boundary.

• When the weighing is done, the sucrose contents also will be recorded,

whichkeeps an eye on recovery, resource conservation and waste minimization.

Excess sugar in bagasse makes problems of air borne hydrocarbons or

fermentation if goes to any water body. This is prevention of pollution.

• Waste heat (exhaust steam) and wastewater (hot condensate) too is reuse fully.

• The selection of hardware has offered further advantages which have typical

environmental significance (A) Vacuum Distillation (B) ContinuousFermentation

(A) Environmental benefits of Vacuum Distillation:

1. Minimizes by-products

2.Lessload passed to Rectifier column

3. Scaling minimized

4. Lower steam consumption

(B) Environmental Benefit by Continuous Fermentation

Two systems of continuous fermentation are successfully adopted in Maharashtra,

Biostil plants and Cascade system are in operation in this state. The biostil process

appears to berobust, the cascade system is rather sensitive to quality of molasses

and water. Quality of spirit in Biostil is average but can be improved by addition of

fuel oil column; quality ofspirit in cascade system is found superior.

The biostil process works under higher osmotic pressure and it is not susceptible

toinfection; the cascade system is susceptible to infection. To adopt continuous

process offermentation is an appropriate step towards the updating technology of

alcoholproduction for efficient performance.

2.5 ENVIRONMENTAL POLICY

M/s. Samartha Sahakari Sakhar Karkhana Ltd. is committed to

• Prevent pollution in its activities associated with manufacturing and supply of

Industrial Alcohol

• Continually improve environmental performance

• Comply with environmental legislations and regulations

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These shall be implemented by -

• Reducing the spillages and fugitive pollutants emissions through

extensivemonitoring

• Conserving energy and other resources through optimum utilization and

wasteminimization

• Training and involving the employees for development of Clean and

GreenEnvironment.

2.6 Chapter Conclusion:

SSSKL will be now producingAlcohol. This can be a foreign exchange earner for

the nation. It proposes to establish amodern state-of-art factory at a site

Ankushnagar (Ambad) district Jalna and by making full utilization of its capacity

wishes to feed the demand in the vicinity. At the same time SSSKL has kept the

concept of sustainable development in mind. For fulfilling all this,the process of

Impact Assessment is undertaken and reported in the following chapters.

Expansion of 30 KLPD Distillery plant to 60...

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