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PRE-FEASIBLITY REPORT

NSL Sugars Limited [Expansion of Sugar Plant from 5000 TCD to 7500 TCD

&

Molasses based Distillery plant from 60 KLPD to 75 KLPD]

At

Hurugalawadi & Chikkonahalli Villages,

Koppa hobli, Maddur Taluk,

Mandya District, Karnataka

NSL Sugars Ltd. (Koppa) Expansion of Sugar & Distillery Plant

Pre-feasibility Report

2

Chapter - 1

SUMMARY

1.1 ABOUT THE COMPANY AND PROJECT

NSL Sugars is a Public Limited Company, incorporated under Companies act, 1956 and

commenced the operation in the year 2003. It i s a s i s ter concern of Nuzuveedu Seeds

Limited who are pioneers in quality seeds with s trong network across India . The SCM

sugars has started i ts commercial production of Sugar and Co-gen during the year 2003

season. Dis ti l lery plant has been commiss ioned in Dec 2007.

The Chairman & Managing Director Sri M. Pra bhakar Rao and other directors manage the

company. They look after planning, execution and running of the industry.

NSL Sugar

The plant is located at Survey Numbers 60 to 62, 88 to 98 & 100 to 105 of Chikkonahal l i

vi l lage and Survey Numbers 55, 78 to 83 & 86 of Hurugalawadi vi l lage , Koppa – Hubl i ,

Maddur Taluk, Mandya District, Karnataka. It is situated on Bangalore – Mysore road. The

management has now proposed to expand the capacity of sugar plant from 5000 TCD to

7500 TCD & Molasses based Dis ti l lery pl ant from 60 KLPD to 75 KLPD. The proposed

expansion will be taken place in the existing premises. Following is the plant configuration

& production capaci ty:

S.No. Unit Product CAPACITY

Existing Permission

In Operation Proposed

Expansion Total

1 Sugar White Crysta l Sugar

5000 TCD 5000 TCD 2500 TCD 7500 TCD

2 Co-gen Power 26 MW 26 MW --- 26 MW

3 Dis tillery RS / ENA / Ethanol

60 KLPD Molasses / Cane

juice based 60 KLPD Grain

based Total Capacity :

120 KLPD

60 KLPD Molasses based

15 KLPD Molasses

based



based Total Capaci ty :

135 KLPD



3

Chapter - 2

PROJECT PROPONENT BACKGROUND

2.0 BACKGROUND OF THE PROMOTERS

M/s. Nuziveedu Seeds Ltd. (NSL) i s the flag ship company of the NSL Group and a leading

quality Seed, Agri-biotech and Infrastructure Company. The company commands above

35% market share in the proprietary hybrid cotton seed market in the country which i s a

proof of the company’s strengths in research, production, quality assurance and marketing

capabi l i ties in a complex and biologica l product sector l ike seeds .

M/s . NSL Sugars Ltd. i s promoted by M/s . Nuziveedu seeds Ltd., Hyderabad (A.P) .The

Company is managed by Mr. M. Prabhakar Rao, Cha irman & Managing Director.

Mr. M. Prabhakar Rao, B. Sc. (Agri ) a Rank holder from Banaras Hindu Univers i ty and a

Gold Medalist in Post-Graduation in Agricultural Science from the same Univers i ty with a

specialization in Agronomy, armed with the right acad emic background, instincts and

inborn business acumen coupled with enterprising spirit joined the family managed seed

Company in 1982.

Al l other Directors are well educated and have experience in running the sugar industry.

Their vast practical experience in sugar, power & ethanol industries wi l l be immensely

helpful in executing and operating the proposed integrated project.

NSLSL a l ready has appointed a technical / managerial team of highly qualified engineers ,

contract & arbi tration experts , agricul tura l officers and manageria l personnel for

implementation and operation of the captioned integrated project.

The objectives of the proposed expansion of sugar plant is mainly to manufacture qual i ty

sugar for national & international markets at optimum operating and energy efficiencies ,

as well as to provide raw materials for cogen power plant. The integrated project will push

the product, which has highest realization in the market at any given time, either sugar or

power. The design of the sugar mill would match the latest and modern technologies ,

being employed for the cogen power plant. At the same time, the flexibility of operation,

expans ion and divers i fication, a lso wi l l be avai lable.



4

Chapter - 3

PROJECT DESCRIPTION

3.1 TYPE OF THE PROJECT

Proposed project is expans ion of sugar plant from 5000 TCD to 7500 TCD & Molasses

based Distillery plant from 60 KLPD to 75 KLPD in the existing plant premises at Survey

Numbers 60 to 62, 88 to 98 & 100 to 105 of Chikkonahalli village and Survey Numbers 55,

78 to 83 & 86 of Hurugalawadi village, Koppa – Hubl i , Maddur Ta luk, Mandya Dis trict,

Karnataka.

Fol lowing i s the plant configuration & production capaci ty:

S.No. Unit Product

CAPACITY

Existing Permission


Expansion Total


5000 TCD 5000 TCD 2500 TCD 7500 TCD






120 KLPD


15 KLPD Molasses

based




135 KLPD

3.2 LOCATION OF THE PROJECT

NSL Sugars Ltd. is an existing plant, operating Sugar, Dis ti l lery plant and Cogeneration

plant at Survey Numbers 60 to 62, 88 to 98 & 100 to 105 of Chikkonahal l i vi l lage and

Survey Numbers 55, 78 to 83 & 86 of Hurugalawadi village, Koppa – Hubli, Maddur Ta luk,

Mandya Dis trict, Karnataka .

110.0 acres of land is in possession of management and proposed expansion of sugar plant

and dis ti l lery plant wi l l be taken in the exis ting plant only.



5

NSL Sugars - Koppa



6

3.3 DETAILS OF THE ALTERNATE SITES

No a l ternative sites have been considered as proposed expansion will be taken up in the

exis ting plant premises .

3.4 SIZE OR MAGNITUDE OF OPERATION

Fol lowing i s the plant configuration & production capaci ty:

S.No. Unit Product

CAPACITY

Existing Permission


Expansion Total


5000 TCD 5000 TCD 2500 TCD 7500 TCD






120 KLPD


15 KLPD Molasses

based




135 KLPD

3.5 MANUFACTURING PROCESS

3.5.1 SUGAR MANUFACTURING

Sugar cane procured from farmers in trucks and carts are weighed on the weighbridges

and unloaded into cane carrier. The unloaded cane is carried on the cane carrier and fed

to the cane leveler where the cane is cut into pieces by revolving knives of the leveler, the

cane chopper controls the cane feed for even and uniform feeding. The cut cane is fed to

the Fibrizor where cut pieces are made into fibers for extraction of juice in the succeeding

four / five mills tandem. The juice is extracted by passing cane fibers through the rollers of

the mi lls. Water is weighed and added at the last mill of the tandem to extract maximum

sugar from the bagasse by the method of compound imbibitions / the juice extracted by

the last mill is added in the third mill and so on. The juice so extracted by the mi l l s i s

screened in the rotary screen where the bagasse particles a re separated. The screened

juice i s pumped for further process ing through flow meter.



7

The weighed juice is pumped to the juice heater where i t is heated upto 700C. The heated

juice is treated with Mi lk of lime and sulphur dioxide gas in the juice sulphitor and the pH

is maintained at 7.2. The treated juice is heated upto 1020C in the juice heaters and sent

to the clari fier for settl ing.

The impurities coagulate as precipitate & settle down in the clari fier and the same is

fi l tered by the vacuum fi l ter. The clear juice over-flows from the top of each

compartment. The clear juice wi l l have pH of 6.9 and i t i s pumped to multiple effect

evaporators where about 75% of water in the clear juice i s evaporated and the output i s

ca l led syrup. This syrup is taken to a clari fier after treating with phosphoric acid and

flocculent. The outlet of the clarifier is pumped to sulphiter where i t is again treated with

SO2 gas to adjust pH 4.8–5.2. The sulphited syrup is taken to syrup s torage tanks at the

pan floor. The scum coming out of the syrup clarifier i s taken to filtrate clarifier. The fi l ter

juice coming out of the rotary vacuum filter is treated with phosphoric acid and sent to

clari fier. The clear juice coming out of the clarifier i s taken to the main juice clari fier. The

scum coming out of the fi l trate clari fier i s ci rculated to mud tank.

The syrup is further concentrated in vacuum pans for crysta l l i zation. Total sugar in the

syrup cannot be extracted in s ingle s tage, as such three s tages boiling scheme is adopted.

The mixture of the sugar crystals & the molasses is ca lled massecuite. The three s tages are

named as A, B & C massecuites .

Syrup is boiled to make the A-massecuite. A-massecuite is cured in batch type centrifuges.

On purging this gives heavy, l ight molasses & white sugar. A-heavy molasses i s used for

boi ling B-massecuite. B-massecuite is cured in continuous centrifuges to get B-sugar and

B-heavy molasses . B-sugar i s taken for A-boi l ing. B-heavy molasses i s used for C-

massecuite boiling. C-massecuite on double curing in continuous centri fuges , gives C-

sugar, C-l ight molasses & final molasses. Final molasses is sent out as by-product & C-sugar

i s melted with water and taken to A-massecuite.

White sugar obtained out of batch centrifuge is dried & cooled in gross hoppers . After

drying the sugar is passed through sugar s izer where separation of different grades takes

place. Di fferent grades are col lected separately & packed in jute gunny bags .

The process flow diagram for sugar manufacturing i s shown below:



8



9

3.5.2 DISTILLERY – MOLASSES BASED

Yeast propagation:

Yeast seed material i s prepared in water-cooled yeast vessels by inoculating molasses with

yeast. The contents of the yeast vessel are then transferred to the Yeast activation vessel.

The purpose of aerated yeast activation in the yeast activation vessel is to a l low time for

the yeast cel l multipl ication.

Fermentation: The fermentation technology adopted in the industry i s of continuous fermentation. With

this technology, the total spent wash generation will be restricted to a max. of 8 kl/kl of

R.S. (As per prevai l ing condition s tipulated in the exis ting EC).

The purpose of fermentation is to convert the fermentable sugars into a lcohol . During

fermentation, sugars are broken down into alcohol and ca rbon-di-oxide. Signi ficant heat

release takes place during fermentation. However the fermentation temperature i s

mainta ined at 32 – 35 0C by forced reci rculation heat exchangers .

At the end of fermentation, the wash is fed through a yeast separator where the yeast

cream is separated, acidi fied in the yeast treatment tank and returned to the yeast

activation vessel for activation. Sludge is separated in a s ludge decanter. The clear wash

from both the yeast separator and sludge separator flows to the clarified wash tank. The

wash is then pumped to dis ti l lation.

Distillation: Fermented Wash about 8% v/v a lcohol is preheated in two stages i .e. in the beer heater

us ing the Rectifier vapours and then in the Fermented wash PHE us ing the effluent. The

preheated wash is then fed the Degasifying Column to remove residual CO2 and volati les .

The wash then flows down to Analyser Column, which acts as a total stripper. The alcohol

water vapour mixture which rises upward in this column is fed to the Recti fier Column.

The spent wash, which is devoid of alcohol, flows down the Analyser Column for sui table

treatment.

The lower boiling impurities are concentrated in the Aldehyde Column where about 5%

spiri t i s drawn off as impure spiri t with a minimum strength of 660 OP.

The a lcohol vapours are concentrated in the Rectifier Column to produce Rectified Spirit of

95% v/v s trength. Higher boiling impurities, which are formed during fermentation, are



10

removed by taking side draw purges to a decanter from the Recti fier Column. A trace

s tream of spirit is drawn off as impure spirit (about 2% of plant capaci ty) to remove the

concentrated volatile compounds. The high grade Rectified Spirit is taken as a draw from

the upper trays of the Recti fier Column.

The Rectified spirit is fed to the purification column. Dilution water i s fed on the top most

tray of the column with a di lution ratio of 1: 9. This column serves to remove the

impurities based on the principle of HYDROEXTRACTION. The water is fed to the column

in such a way that it selects the higher alcohols and other impurities to move upwards and

extracts ethanol down. The purifier bottom alcohol composition i s mainta ined at 12 %

v/v. At this composition there is an inversion in relative volati les of higher a lcohols as

compared to ethanol and these a lcohols get separated in the top distillate. Top draw for

volati les i s fed to the Fusel oi l concentration column.

The purified dilute ethanol is removed from the bottom of the purification column and fed

to the recti fication column, which concentrates the ethanol to 96% v/v. The high grade

spirit is drawn from one of the upper trays of the rectification column. A small heads cut is

removed from the overhead s tream as technical alcohol (T.A.) cut to with draw impurities

and is fed to the heads concentration column. The lees from the exhaust column is

recycled as dilution water after a part of it is purged. The purged spentlees i s used to

preheat the make-up di lution water.

Lower s ide draw streams are taken from rectification column to avoid fusel oil build up in

the column. These s treams are then taken to the fusel oi l column. This column

concentrates the di lute s treams of ethanol containing esters and fusel oi l s to

approximately 95% v/v of ethanol. The concentrated ethanol is removed as T.A. cut from

the top of the column. T.A. cut i s removed out of the system in order to remove propanol

and remaining i s fed to the heads concentration column where the heads from the

puri fication column and rectification are fed to the s tatic mixer. Soft water, which has

been preheated, is used for diluting the high proof ethanol. An impure spirit cut of about

5% of the recti fied spirit feed is drawn from the top of the column. The di lute ethanol

solution at the bottom of this column is pumped ba ck to the puri fication column for

repuri fication.



11

Ethanol Production: This plant i s filled with imported 3A grade Molecular Sieve. It is operated with vaporized

Alcohol and removes water completely. Then Molecular s ieves are regenerated under

vacuum of 710 mm Hg. Feed Alcohol comes to this Plant in a Day Tank continuous ly from

bulk storage tank. From this tank a lcohol i s pumped to a s team vaporizer at 4 Kg/cm2

pressure. This is vaporized in a steam heater and then vapor is super-heated to 160oC in a

super heater and taken to Molecular Sieve Unit. This super-heated vapor now pressure

through one Molecular Sieve column for moisture removal. There are 2 Molecular Sieve

columns. At a time one column remain in drying cycle whi le other columns under goes

vacuum regeneration. Each column remains in cycle for 6 minutes . Here drying process

takes place at 3.0 Kg/cm2 pressure and dry a lcohol vapor of 99.8% puri ty comes out as

final product. This alcohol vapor i s condensed in a water cooler and then col lected in

another day tank. From this tank dry a lcohol is continuously pumped to bulk day s torage

tank through a level controller and a control va lve. In the regeneration process some left

over a lcohol also comes out which is condensed in regeneration condenser. This alcohol is

around 95% strength and is re -cycled in to recti fier column continuous ly.

The other Molecular Sieves column under goes regeneration by a vacuum pump. In this

column vacuum pumps pul ls and creates vacuum of 710 mm Hg. At this vacuum the

moisture from Molecular Sieve pores comes out and along with 30% pure alcohol from on

l ine Mole Sieve bed is sprayed. Thereafter during vacuum process, some left over a lcohol

and water from Molecular Sieves comes out and is condensed. Concentration of this lean

a lcohol is around 70% a lcohol , which can be recycled to the Recti fying Column. From

Recti fier the pure water wi l l be sent out automatica l ly.



12

Process flow diagram (Molasses based)

3.6 RAW MATERIAL REQUIREMENT

Raw materia ls required are as fol lowed:

For Sugar plant:

S.No. RAW MATERIAL SOURCE QUANTITY METHOD OF TRANSPORT

1 Sugar Cane Local area 2500 TPD By trucks

2 Lime Local area 6.0 TPD Through covered trucks by Road

3 Sulphur Local area 1.75 TPD Through covered trucks by Road

4 Phosphoric Acid Local area 0.15TPD Through covered trucks by Road



13

Raw materia l required for Dis ti l lery plant:

S.NO RAW MATERIAL SOURCE QUANTITY METHOD OF TRANSPORT

Proposed Distillery Plant:

1 Molasses From own Sugar plant & External

65 TPD Through Pipel ine/Tanker

3.7 WATER REQUIREMENT AND ITS SOURCE

Water required for the proposed expansion of sugar plant and distillery plant wi l l be 700

KLD (250 KLD + 450 KLD) and same will be met from Shimsha river situated a dis tance of

2.2 Kms. from the s i te.

3.8 WASTE MANAGEMENT

Present effluent generation from sugar plant is 500 KLD and expected additional effluent

load from proposed sugar plant expansion is 250 KLD. (i .e total effluent generation is 750

KLD) The effluent from sugar plant will treated in the exis ting 800 KLD capaci ty Effluent

treatment plant, which i s consisting of UASB followed Activated sludge process and after

ensuring compliance with SPCB norms, the treated effluent will be utilized for on land for

i rrigation and gardening purposes

Bagasse generated will be used in Cogen boiler. Molasses will be used in dis ti l lery. Fi l ter

cake will be given to farmers to use as manure in the Agricul tura l fields and partly

composted. ETP Sludge wi l l be used manure after dried in the s ludge drying beds .

Spent wash treatment (Molasses):

The present spent wash generation from the existing 60 KLPD Molasses based Distillery i s

480 KLD and 120 KLD of additional spent wash wi l l be generated from the proposed

expansion of 15 KLPD distillery. The entire 600 KLD of Spent wash generated from 75 KLPD

Molasses based dis ti l lery (after expans ion) wi l l be treated in the exis ting 600 KLD

Biomethanisation plant followed by concentration in Multiple Effect Evaporation (MEE) to

40 % sol ids and part of the effluent from MEE wi ll be sent to Bio composting to achieve

zero discharge and the remaining quanti ty wi l l be sent to Rotary dryer to obtain the

mixture of spent wash & Bagasse, which wi l l be incinerated in the exis ting Boi ler.

This is a zero spent wash discharge treatment technology in accordance with the CPCB

stipulation.



14

Chapter - 4

SITE ANALYSIS

4.1 CONNECTIVITY

The proposed site i s well connected with Road – Ra il network. The following table gives

brief regarding connectivi ty of the proposed s i te:

Component Description Road : NH – 209 = 36.0 km Rai l : Nearest s tation – 15 km (Maddur RS) Air : Benguluru Air Port – 120 Kms.

Sea Port : Mangalore : 300 km

Below mentioned table gives brief regarding environmental setting of the project site

S.No Particulars Distance from the site 1. National Park = No national Park is situated within the

15 km radial distance periphery 2. Wi ld l ife sanctuaries = Ni l 3. Eco Sensitive Areas = Ni l 4. Forests = Ni l

5. Surface water bodies = Shims ha river – 2.2 Kms. 6. Costa l Regulation Zone [CRZ] = Ni l 7. Industrial Area = Ni l

4.2 Land use

Exis ting plant is located in Chikkonahalli & Hurugalawadi villages, Koppa – Hubl i , Maddur

Ta luk, Mandya Dis trict, Karnataka . The terra in of the land is a lmost pla in

4.3 Topography

The topography of the land is flat without undulations .

4.4 Existing land use pattern

NSL Sugars Ltd. is an existing plant at Chikkonahal l i & Hurugalawadi vi l lages , Koppa –

Hubl i, Maddur Taluk, Mandya District, Karnataka. 110.0 acres of land is in possess ion of

management and proposed expansion will be taken up in the exis ting plant premises .

There are no ecologically sensitive places l ike national park, s anctuary, biosphere



15

reserve, reserve forest etc. around 10 Kms. radius of the s i te. There i s no route of

migratory animals within the project s i te .

4.4 EXISTING INFRASTRUCTURE

Water supply in most of the vi llages i s available. Inter-village transport facility i s available

only for the selected vi llages. While educational faci l i ties & health faci l i ties are not

encouraging in most of the vi l lages . There i s wel l establ ished road connection.



16

Chapter - 5

PLANNING BRIEF

5.1 PLANNING CONCEPT





Fol lowing i s the plant configuration & pro duction capaci ty:

S.No. Unit Product

CAPACITY

Existing Permission


Expansion Total


5000 TCD 5000 TCD 2500 TCD 7500 TCD






120 KLPD


15 KLPD Molasses

based




135 KLPD

5.2 POPULATION PROJECTION

According to the 2011 census Mandya dis trict h as a population of 1,808,680, roughly

equal to the nation of The Gambia or the US s tate of Nebraska. This gives i t a ranking of

263rd in India (out of a tota l of 640). The dis trict has a population dens i ty of 365

inhabitants per s quare kilometre (950/sq mi) . Its population growth rate over the decade

2001-2011 was 2.55%. Mandya has a sex ratio of 989 females for every 1000 males, and a

l i teracy rate of 70.14%.

The project will be providing direct employment to nearly 100 workers. The local persons

wi l l be given preference in employment as per the qual i fication and technica l

competencies. Necessary tra ining will be given to tra in the unemployed youths of the

nearby vi llages as per the qualification and technical competencies. Indirect employment



17

opportunities will be created in the periphery of the project automatica l ly as the

project s tarted operation in the region. In order to operate and maintain the plant

faci lities, including i ts technical general administration needs, the manpower for the

proposed expansion will be 100. The above manpower covers the top management,

middle and junior level executives and other supporting s taff including w orkforce.

5.3 LAND USE PLANNING





110.0 acres of land is in possession of management and proposed expansion of sugar plant

and dis ti l lery plant wi l l be taken in the exis ting plant only.

Following is the land use break up:

Item Area in Acres Bui lt up area with ancillaries 15.0 Internal roads 15.0 Storage yard (Raw material & Product) 7.0 Greenbelt 42.0 Open area 31.0 Total land 110.0

5.4 AMENITIES / FACILITIES

Faci lities like canteen, rest room and indoor games facilities has already been provided in

the existing plant as basic facilities to workers. No other additional facilities are proposed.



18

Chapter - 6

PROPOSED INFRASTRUCTURE

6.1 INDUSTRIAL AREA (PROCESSING AREA)

Li s t of sugar mi l l machinery

Mill House & Power House

Mil l House E.O.T. Crane & Gantry

Cane Unloaders , Table Feeders

Cane Cutters , Cane Level lers & Kickers

Cane Carriers , Intercarriers with Chains , Slats . Bagasse Elevators complete

Headstocks , Crown Pinions , Scrappers , Trash Plates , Cou pl ing

Bagasse Bal ing Presses

Al l Types of Chains , Slats . Rakes , Sprockets

Power House Crane & Gantry

Boiling House; Clarification House; Bagging House And Centrifugal Accessories

Automatic Juice Weighing Scales. Water Weighing Scale. Molasses Weighing Sca les

Juice Heaters - Conventional & Dynamics

Semi - Kestners . Fa l l ing Fi lm Evaporators . Evaporator bodies , quad set

Juice Sulphitation Unit, Mi lk of Lime Station,Carbonation Tanks

Lime Ki lns

Sulphur Burners - Conventional and Digi ta l

Fabricated Right Angle Valves & Double Beat Valves

Clari fiers & Fi l ters

Calendria Vacuum Pans , Continuous Pans for A, B & C Massecti i tes

Barometric Condensers , Multi jet Condensers

Crysta l l i zers -Air Cooled, Water Cooled, Seed & Vacuum. Vertica l Crysta l l i zers

Automation of Pans , P.H. Control , Sulphur Burner, Molasses Conditioners etc.

Screw Conveyors .

Sugar Melter - Horizontal & Vertica l , Magma Mixers

Sugar Elevators , Sugar Graders , Hoppers

Molasses Storage Tanks , Spray pond



19

Complete Plant Staging and Process Piping. Misc. Tanks

Boilers

Staging & Ducting, M.S. Chimney

Return Bagasse Carrier with Chain, Slats etc.

IBR Pipe Line

6.2 RESIDENTIAL AREA (NON PROCESSING AREA)

No colonization is proposed; however facilities like canteen, rest room and indoor games

faci lities will be provided in the proposed plant and one Admin building is also proposed.

6.3 GREEN BELT

More than 1/3rd of tota l land avai labi l i ty i s reserved for plantation i .e. greenery.

Greenbelt development plan

Local DFO wi l l be consulted in developing the green belt.

Greenbelt of 33% of the area will be developed in the plant premises as per CPCB

guidel ines .

15 m wide greenbelt i s being mainta ined a l l around the plant.

The tree species to be selected for the plantation are pol lutant tolerant, fast

growing, wind firm, deep rooted. A three tier plantation is proposed comprising of

an outer most belt of ta ller trees which will act as barrier, middle core acting as a i r

cleaner and the innermost core which may be termed as absorptive layer

cons isting of trees which are known to be particularly tolerant to pol lutants .

6.4 SOCIAL INFRASTRUCTURE

Social infrastructure will be developed as per need based in the Vi l lages of the close

vicini ty of the project.

6.5 CONNECTIVITY

The proposed site i s well connected with Road – Ra il network. The following table gives

brief regarding connectivi ty of the proposed s i te:

Component Description

Road : NH – 209 = 36.0 km Rai l : Nearest s tation – 15 km (Maddur RS)



20

Air : Benguluru Air Port – 120 Kms. Sea Port : Mangalore : 300 kms

6.6 DRINKING WATER MANAGEMENT

It i s estimated that 10 KLD of water wi l l be required for domestic purpose during

operation of expans ion project.

6.7 SEWERAGE SYSTEM

Domestic effluent collected through toilet blocks and other areas will be collected through

wel l designed sewer network and send to Septic tanks followed by dispers ion trench. No

effluent wi l l be left-out after Soak pi ts .

6.8 INDUSTRIAL WASTE MANAGEMENT

Present effluent generation from sugar plant is 500 KLD and expected additional effluent

load from proposed sugar plant expansion is 250 KLD. (i .e total effluent generation is 750

KLD) The effluent from sugar plant will treated in the exis ting 800 KLD capaci ty Effluent

treatment plant, which i s consisting of UASB followed Activated sludge process and after

ensuring compliance with SPCB norms, the treated effluent will be utilized for on land for

i rrigation and green belt development purposes .

Bagasse generated will be used in Cogen boiler. Molasses will be used in dis ti l lery. Fi l ter

cake will be given to farmers to use as manure in the Agricultural fields. ETP Sludge will be

used manure.

Spent wash treatment (Molasses):

The present spent wash generation from the existing 60 KLPD Molasses based Distillery i s

480 KLD and 120 KLD of additional spent wa sh wi l l be generated from the proposed

expansion of 15 KLPD distillery. The entire 600 KLD of Spent wash generated from 75 KLPD

Molasses based dis ti l lery (after expans ion) wi l l be treated in the exis ting 600 KLD

Biomethanisation plant followed by concentration in Multiple Effect Evaporation (MEE) to

40 % sol ids and part of the effluent from MEE wi ll be sent to Bio composting to achieve

zero discharge and the remaining quanti ty wi l l be sent to Rotary dryer to obtain the

mixture of spent wash & Bagasse, which wi l l be incinerated in the exis ting Boi ler.



21

This is a zero spent wash discharge treatment technology in accordance with CPCB

guidel ines .

Sanitary waste water will be treated in septic tank followed by subsurface dispersion. Zero

effluent discharge wi l l be mainta ined after expans ion a lso.

6.9 SOLID WASTE MANAGEMENT & ITS DISPOSAL

Bagasse generated wi l l be used in Cogen boi ler.

Molasses wi l l be used in dis ti l lery.

Fi l ter cake will be composted partly in the factory premises and balance quanti ty

wi l l be given to farmers to use as manure in the Agricul tura l fields .

ETP Sludge wi l l be used manure.

Yeast Sludge generated wi l l be used as cattle feed

6.10 STEAM & POWER REQUIREMENT & ITS SOURCE

The existing 100 TPH boiler will be revamped to 120 TPH suitably. Steam & Power required

for the proposed sugar expansion project will be sourced from the Cogen boiler & 26 MW

cogen plant. Steam & power required for proposed Distillery expansion proposal wi l l be

met from exis ting 25 TPH dis ti l lery Boi ler & 2.1 MW Captive power plant.



22

Chapter - 7

REHABILITATION & RESETTLEMENT (R & R) PLAN

No rehabilitation and resettlement is required as proposed expans ion sugar plant wi l l be

taken up in the exis ting plant premises .



23

Chapter - 8

PROJECT SCHEDULE & COST ESTIMATES

8.1 PROJECT SCHEDULE

The plant will be implemented in 12 months from the date of receipt of Environmental

Clearance from the Hon’ble MoEF & NOC from KSPCB.

8.1 PROJECT COST

The estimated cost for the proposed expans ion project wi l l be Rs 4500 lacs .

S.NO. PARTICULARS AMOUNT IN Rs. Lacs 1. Land and Site Development 15.00 2. Bui lding and Civil Work 400.00 3. Plant and Machinery

3400.00

4. Electrical. Installation

400.00 5. Pol lution Equipments

75.00

6. Misc. Fixed Assets

75.00 7. Prel . and Preop. Exp.

50.00

8. Contingencies

50.00 9. Marg. Money for Working Cap. 35.00

T O T A L

4500.00

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Chapter - 9

ANALYSIS OF PROPOSAL

9.1 FINANCIAL AND SOCIAL BENEFITS

With the implementation of the proposed project, the socio-economic s tatus of the loca l

people will improve substantially. The land rates in the area wi l l improve in the nearby

areas due to the proposed activity. This will help in upliftment of the socia l s tatus of the

people in the area. Educational institutions will also come-up and will lead to improvement

of educational s tatus of the people in the area. Primary health centre wi l l a lso be

developed by us and the medical faci l i ties wi l l certa inly improve due to the proposed

project.

9.2 SOCIO-ECONOMIC DEVELOPMENTAL ACTIVITIES

The management i s committed to upl i ft the s tandards of l iving of the vi l lagers by

undertaking fol lowing activi ties / respons ibi l i ties as the part of Corporate Socia l

Respons ibi l i ty.

Health & hygiene

Drinking water

Education for poor

Vi l lage roads

Lighting

HEALTH & HYGINE

Personal and domestic hygiene,

Maintaining clean neighborhood,

Weekly health camps offering free -check up & medicines

Ambulance services

Education & drug de -addiction, a ids .

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DRINKING WATER

Making drinking water avai lable a t centra l i zed locations in the vi l lage,

SUPPORTING EDUCATION

Providing books to a l l poor chi ldren,

Conducting annual sports festiva l in the vi l lage schools ,

Providing amenities l ike fans , lavatories ,

Maintain playground etc.

pre-feasiblity report - welcome to...

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