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Sugar Plant Expansion Cost Analysis

Khatav Man Taluka Agro Processing Ltd. proposes to expand its existing sugar production capacity from 2500 tons of cane per day to 7500 tons, expand its cogeneration power capacity from 12 MW to 32 MW, and set up a new 120 KLPD distillery plant. The project aims to enhance production to meet the needs of local farmers and utilize the increased availability of sugarcane. The company has acquired sufficient land for the proposed expansion and expects to begin operations in January 2022. The expansion is expected to boost the local economy by generating additional employment opportunities and income.

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100% found this document useful (1 vote)
2K views23 pages

Sugar Plant Expansion Cost Analysis

Khatav Man Taluka Agro Processing Ltd. proposes to expand its existing sugar production capacity from 2500 tons of cane per day to 7500 tons, expand its cogeneration power capacity from 12 MW to 32 MW, and set up a new 120 KLPD distillery plant. The project aims to enhance production to meet the needs of local farmers and utilize the increased availability of sugarcane. The company has acquired sufficient land for the proposed expansion and expects to begin operations in January 2022. The expansion is expected to boost the local economy by generating additional employment opportunities and income.

Uploaded by

Sanjay Patel
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd

EXECUTIVE SUMMARY

For

Proposed Expansion of Sugar capacity from 2500 TCD to 7500 TCD, Cogen power 12
MW to 32 MW and 120 KLPD new Distillery plant with 4 MW captive cogen power
plant

By
M/s. Khatav Man Taluka Agro Processing Ltd
Village : Padal, Tal. Khatav, Dist: Satara, State : Maharashtra

1
INDEX
[Link]. Particular Page No
1.0 Introduction 3
2.0 Introduction of the project 3
2.1 Promoter’s Background & Profile 3
2.2 Brief description of the Project 3
2.3 Project Description 5
2..4 Site Connectivity and environmental Sensitivity 6
2.5 Land and site development 8
2.6 Raw Material and its Sustainability 9
2.7 Water Requirement: 12
2.8 Power Requirement 13
3.0 Baseline Environment 13
3.1 Ambient Air Quality 13
3.2 Noise Level 14
3.3 Water Environment 14
3.4 Biological Environment 14
4.0 Anticipated Environment Impact and Mitigation 15
4.1 During Construction Phase 15
4.2 During Operation Phase 17
5.0 Environment Management Plan 17
5.1 Objectives of Environmental Management Plan 17
5.2 Wastewater Management 17
5.3 Air Pollution management 18
5.4 Solid Waste Generation and Management Solids (Ash & 19
5.5 Noise & vibration control 19
5.6 Socio-economic benefits. 20
5.7 Green Belt Development 20
5.8 Budget Provision For Environmental Management 21
6.0 Rehabilitation and Resettlement 21
7.0 Project Schedule & Cost estimate 21
8.0 Analysis of Proposal 22

2
1.0 Introduction :
Khatav Man Taluka Agro Processing Ltd. (KMTAPL) is incorporated as public limited
company mainly by Gharge, Ghorpade & Salunkhe family on 18/03/2011 vide CIN No.
U01122PN2011PLC138910.
The company has installed 2500 TCD sugar plant and 12 MW cogen power plant at
village Padal, Tal. Khatav, Dist. Satara. The plant is supplied by M/s ISGEC Heavy
Engineering Ltd., Noida. KMTAPL has undertaken 1st trial crushing season in 2018-19
and crushed about 33044 MT of cane and produced 32630 Qtl. of sugar with an average
recovery of 9.87% on cane. The Company has total land of 19.56 Ha at Padal Village
which sufficient for sugar and cogen expansion as well as for setting up 120 KLPD
distillery / ethanol plant. Company has constructed underground water storage tank and
temporary water supply scheme. Company is in process to construct permanent water
supply scheme from Yeralwadi Dam, which is about 8 Km from the site. The said dam
has gross storage capacity of 32.80 Million Cum.
KMTAPL is now planning to increase the cane crushing capacity from present 2500 TCD
to 7500 TCD (net addition of 5000 TCD). The company also proposes to increase its
cogen power capacity from existing 12 MW to 32 MW for export of surplus power to grid
and set up 120 KLPD Distillery /Ethanol plant with 4 MW captive cogen power plant.

2.0 Introduction of the project


2.1 Promoter’s Background & Profile:-
Mr. Prabhakar D. Gharge, Director : He is in the field of cooperative banking for more than
22 years and now he is the Director of Satara DCC Bank Ltd. He is well known for
experiments in agriculture & is chief promoter of plant. He is also in the real estate
business and also set up Preeti Hotel at Satara. He was Director of Pratapgad Sahakari
Sakhar Karkhana Ltd., Dist Satara. He has represented Satara and Sangli constituency as
Member of Legislative Council through which is conversant with agriculture to
processing of sugar cane.
2.2 Brief description of the project
The proposed scheme envisages for enhancing the sugarcane crushing capacity by
addition of 5000 TCD to its 2500 TCD sugar plant (total capacity of 7500 TCD)
3
considering the huge potential raw material available from the nearby villages of
KMTAPL. The cogen power plant will be expanded from its existing capacity of 12 MW to
32 MW.
This expansion program shall be met by addition of equipments in milling and boiling
house sections and addition of equipment in cogen power plant.
The company also proposes to set up 120 KLPD distillery / ethanol plant along with
captive cogen power plant.
The proposed distillery / ethanol plant of 120 KLPD capacity will employ state of art
technology for production of fuel ethanol i.e. fermentation, multi pressure distillation
system, integrated and standalone evaporation section and spent wash fired
incineration based cogen power plant. Sugar factory will supply B-heavy molasses, while
the incineration boilers and turbines will supply steam and power to the proposed
ethanol plant. It will employ high pressure boiler of 25 TPH & 4 MW back pressure
steam turbine.

KMTAPL has already applied for amendment in IEMs for 7500 TCD sugar. KMTAPL has
already received IEMs for 36 MW cogen power plant and 120 KLPD distillery / ethanol
plant from the Ministry of Commerce & Industry, Govt. of India.

Existing land is sufficient for the proposed expansion project including 120 KLPD
distillery / ethanol plant.
The current policies for manufacture of fuel ethanol are getting progressively conducive
at the Centre & also in the State of Maharashtra. The Government of India has recently
approved the purchase price at Rs. 45.69 / litre of fuel ethanol from C-molasses,
Rs.57.61/Litre from B-heavy molasses and Rs.62.65/Litre from juice / syrup, excluding
GST and transport.

4
2.3 PROJECT DESCRIPTION :

SALIENT FEATURES OF THE PROJECT


Sr. PARTICULAR DETAILS
No
1 Name of the Company & M/s Khatav Man Taluka Agro Processing Ltd.
Regd. Office Address
Priya Agencies, Plot No. B-52/3, Ganesh Chowk,
Old MIDC, Satara – 415 003, Maharashtra.

2 Factory Site At Padal, Tal. Khatav, Dist. Satara 415 507,


Maharashtra

3 Constitution & Type Public Limited Company

4 Products & By Products 1. Sugar


2. Cogeneration power
3. Ethanol
5 Existing Capacity of the Sugar Plant: 2500 TCD
Project
Cogen Power Plant (12 MW: BEP type)

6 Proposed Expansion Expansion Sugar Plant: 5000 TCD


Capacities of the Project
Total installed capacity: 7500 TCD

Expansion Cogen Power : 20 MW

Total installed capacity: 32 MW

Distillery / Ethanol Plant : 120 KLPD

7 Commercial Operation January, 2022


Date- (C.O.D)
8 Working Days 160 days of sugar plant

160 days of cogen plant (Season)

5
88 days of cogen plant (Off-Season)

330 days of Distillery / ethanol plant

9 Basic Raw material 12.00 lakh MT of Sugarcane


requirement per annum
10 Bagasse, Molasses & Press Bagasse - 336000 MT per Annum
mud Available from
Diversion of Juice – 1600 TCD to Ethanol plant
sugarcane crushing
B-Heavy Molasses – 56640 MT/Annum + 9312
Procured

Press mud – 36000 MT / Annum

2.4 Site Connectivity and environmental Sensitivity

The site is well connected by the roads for transportation of sugarcane within the area of
operation.

Sr. no Particular Details


1 Nearest Village Padal which is 620 meter from project
site
2 Nearest Town / City Mayani city which is 6 km away from
project site
3 State Highway State Highway no. 145 is 3.07 km
4 Nearest National Highway National Highway no.4 is 49.12
5 Nearest Railway station Karad Railway Station 43.48 km
6 Nearest Airport Pune Airport 137.33 km away from
project site.
7 National Parks, Reserved Forests Reserve forest South West direction 4.56
(RF) / Protected Forests (PF), km, reserved forest south direction 6.29
Wildlife Sanctuaries, Biosphere
km.
Reserves, Tiger/ Elephant Reserves,
Wildlife Corridors etc. within 10 km
Radius

6
Site Location:

Google Image of the Project

7
Toposheet of 10 Km radius of Project site

2.6 Land and site development

The Company has total land of 21.34 Ha at Padal Village which sufficient for sugar and
cogen expansion as well as for setting up 120 KLPD distillery / ethanol plant. Necessary
facilities like roads, street lighting and green belt etc. are also being established.
Proposed Infrastructure:
Area Statement:
Sr. No Particular Area In Sq.M
1 Total area of land 213400
2 Total Built up area 34095
3 Total area under road 14050
4 Total area under green belt 69500
5 The cane Marshall & bagasse yard 22500
6 Total Open area 73255

8
Details of the alternate sites
No alternate sites have been examined, as proposed project will be located in existing
factory Premises.
2.7 Raw Material and its Sustainability
Sugar Plant

The command area of the KMTAPL has excellent irrigation facilities and potential for
ensured raw material supply for the sugar factory.

Company has reported that they have registered cane from farmers of about 12000 Ha.
The average per ha cane yield in the operational area is about 100 MT/ha. Therefore,
based on the registered cane with the factory, the company is expected to get cane . to
farmers through bank loans, by issuing suitable guarantees for recovery of bank loan

It is recommended that KMTAPL should also sponsor cane development schemes on


its own and / or with the help the farmers in its command area, for availing financial
assistance. This will help KMTAPL in ensuring assured availability of cane, on a long-
term basis.
KMTAPL has already appointed skilled & experienced personnel within Agronomy
Department. With these sustained efforts, KMTAPL is sure of getting the required
sugarcane for its expanded capacity, by the time plant is commissioned.
Cogen Power Plant

Bagasse is the main source of fuel that will be available from the sugarcane crushing
of 12.00 lakh MT after expansion. This is purely green source of fuel and will not
pose any pollution to environment.
The cogen plant will be operated for 160 days to cater steam to sugar process
during season. The sugar plant will generate about 3,36,000 MT of bagasse. Cogen
power plant after expanding it to 32 MW, will use around 266573 MT of bagasse
during season & balance bagasse around 69427 MT will be used in off-season for 88
days.
Ethanol Plant
The generation of B-heavy molasses of 56640 MT, considering the crushing of 12.00

9
lakh MT will be available. Further, cane juice of 1600 TCD/day will be diverted to
distillery / ethanol plant. For operation of fuel ethanol plant for 330 days at 100%
capacity utilization, additional C-molasses of 9312 MT will be met out through
procurement through nearby sugar factories / traders.
Hence, the company will not face any difficulty for its operation of distillery /
ethanol plant for 330 days.
Process Description of sugar plant

Fig : Flow diagram of sugar manufacturing process

10
Fig : Flow diagram of Cogeneration power

Molasses from Sugar unit

Molasses Weighing

Dilution of molasses
Addition yeast cullture

Fermentation

Distillation

Ethanol/ Anhydrous alcohol

Fig : Ethanol production process flow chart


Production details

Particulars 2018-19 2019-20

Sugar Cane Crushed (Lakh MT) 0.33 3.28

Bagasse (MT) 8931 92856

Molasses (MT) 13752 1864

Sugar Produced (Lakh Qtl) 0.33 3.64

Sugar Recovery (%) 9.87 11.10

Molasses (% on cane) 5.64 4.20

Bagasse (% on cane) 27.03 28.33

11
Performance Details

Particulars 2018-19 2019-20

Gross Season Days 31.27 133.58

Net Season Days 29 123

Mill Extraction 93.08 95.29

Reduced Mill Extraction 92.71 95.68

Boiling House Extraction 81.31 88.36

Reduced Boiling House Extraction 83.69 88.92

Overall Extraction 75.69 84.20

Reduced Overall Extraction 77.78 85.08

Total sugar losses 3.17 2.08

Crushing capacity achieved

- Including Stoppages 1152.75 2849.95

- Excluding Stoppages 1152.75 2676.37

2.8 Water Requirement:

Company has constructed underground water storage tank and temporary water supply
scheme. Company is in process to construct permanent water supply scheme from
Yeralwadi Dam, which is about 8 Km from the site. The said dam has gross storage capacity
of 32.80 Million Cum.

Total process and cooling water requirement for the proposed project after recycling and
reuse is estimated at 1650 m3/day.
The water for distillery and allied projects to be met from existing water supply of the
sugar mill. However, the process water will be treated separately in the water treatment

12
plant to be provided in the distillery project.
2.9 Power Requirement

Company has proposed to install separate incineration boiler of 25 TPH and back pressure
turbine of 4 MW

3.0 Baseline Environment


3.1 Ambient Air Quality
Ambient air quality of the study area has been assessed during study period January 2021
to March 2021, through a network of Nine ambient air quality stations within an area of 10
km region around the project site.
Based on the established selection criteria the locations of ambient air quality monitoring
(AAQM) stations have been identified. The concentrations of PM10, PM2.5 , SO2 and NOX
samples were collected as 24 hourly average by drawing air at the rate of 1.0 -1.5 m3/min
through glass fibre filter paper and analyzing by the gravimetric method.

Table 3.1 Ambient Air Monitoring Locations

Distance
Sr No Locations Geocodes Direction from Project
site in Km
17°30'20.54"N
1 Project site - 0
74°34'29.80"E
17°31'24.90"N
2 Kanharwadi NE 3.60
74°36'27.16"E
17°30'7.36"N
3 Hivarwadi SEE 3.72
74°36'36.33"E
17°29'8.18"N
4 Dhondewadi W 5.47
74°31'23.74"E
17°30'10.29"N
5 Padal SE 0.67
74°35'9.12"E
17°26'40.67"N
6 Mayani SW 6.88
74°32'50.29"E
17°32'53.22"N
7 Yaralwadi NW 8.49
74°30'4.61"E
17°32'15.30"N
8 Pasalgaon NNW 4.08
74°32'56.62"E

13
3.2 NOISE LEVEL

Noise level measurements were carried out using Sound Level Meter of Pulsecho
Systems (Bombay) private Limited make in nearby villages to establish their
background levels.
Noise levels monitored at Project Site, Kanharwadi, Hivarwadi, Dhondewadi, Padal,
Mayani, Yaralwadi and Palasgaon villages were analysed in terms of Residual, Medium,
Peak, Equivalent, Daytime and Night Time Noise Levels

3.3 WATER ENVIRONMENT


3.3.1 Ground water Quality

Ground water samples from bore well or dug well were collected from Project Site,
Kanharwadi, Hivarwadi, Dhondewadi, Padal, Mayani, Yaralwadi and Palasgaon villages
and analyzed.

3.3.2 Surface Water Quality

The surface water sample at Yaralwadi dam and at Kadamwadi village has been collected
and analysed.

3.4 Biological Environment


Biodiversity encompasses the variety and variability of life on Earth. It refers to the
differences within and between all living organisms at this different level of biological
Organization
Botanical Name Common Name Family

Trees
1. *Acacia catechu Khair Fabaceae
2. *Acacia Arabica Babhul Fabaceae
3. *Abitulon indicum Sweet neem
4. Annona squamosal Sitaphal Annonaceae
5. Artocarpus hirsutus Wild Jack Moraceae

14
6. *Azadiracha Indica Neem Meliaceae
7. *Bauhinia racemosa Apta Fabaceae
8. *Butea monosperma Palas Fabaceae
9. Cordia dichotoma Bhokar Boraginaceae
10. Dalbergia sissoo Shisu Fabaceae
11. Erythrina indica Pangara Fabaceae

List of Dominant Fauna Observed in Study Area

[Link]. Name Scientific Name Conservation status

Mammals
1 Common mongoose Herpestes edwardsi Least concern
2 Indian hare Lepus nigricollis Least concern
3 Indian porcupine Hystrix indica Least concern
4 Jackal (gidar) Canis aureus Least concern
5 Indian fox Vulpes bengalensis Least concern
6 *Plam Squirrel Funambulus pennati Least concern
7 Sheep Ovis Least concern

4.0 Anticipated Environment Impact and Mitigation measures


Identification of impacts and mitigation measures of the same in Environmental Impact
Assessment study helps in quantification and evaluation of impacts.
4.1 During Construction Phase
Land Environment
This is an existing operating sugar plant and adequate land is available within the premises
for distillery unit. The area identified for the distillery unit is almost flat and not much of
leveling work is expected.

15
Mitigation Measures
 All earth work will be completed in such a way so that the soil erosion and carryover of
the materials in other areas are protected.
 The packaging materials which may consist of wooden boxes and jute wrappers will be
stored at suitable place and disposed off suitably.
 Excavated soil will be used for green-belt development.
Water Environment

 Due to construction activities, the surface run-off during rainy season may
contain more of
 eroded soil and other loose matter. With segregation of construction area and
proper drainages, the water contamination is prevented
requirements for labour and staff onsite.
Mitigation Measures
 The earth work (cutting and filling) will be avoided during rainy season and will be
Completed during the winter and summer seasons only
 Stone pitching on the slopes and construction of concrete drains for storm water to
Minimize soil erosion in the area will be undertaken
 To strengthen the green belt in and around plant will be undertaken during the
monsoon season
Air Environment

 The main sources for impact of air quality during construction period is due to
movement of vehicles and construction equipment at site, dust emitted during
leveling, foundation works, transportation of construction material etc.
Mitigation Measures:
Following measures would greatly reduce the impacts during the construction phase
 The approach roads will be paved or tarred and vehicles will be kept in good order
to minimize the pollution due to vehicular traffic.
 It is necessary to control the dust emissions particularly during dry weather. This
will be achieved by regular water sprinkling all over the exposed area, at least twice
a day using truck-mounted sprinklers.

16
4.2 During Operation Phase
Operational phase activities may have impacts minor or major, positive or negative on
environmental discipline such as soils, surface and ground water hydrology, micro
meteorology, water use, water and air quality, ecology, socio economics & noise
environment.
This phase includes following activities:
- Raw material storage
- Product manufacturing
- Product storage
- Transportation
- Gaseous emission
- Effluent discharge
- Solid waste generation
- Occasional equipment failure/ process upset and related problems

5.0 ENVIRONMENT MANAGEMENT PLAN

5.1 Objectives of Environmental Management Plan


The main objectives in formulating the environment management plan are

 To treat all the pollutants i.e. effluent, air emission, noise & solid waste, which
contribute to the degradation of environment, with appropriate technology.

5.2 Wastewater Management


Sewerage system
Domestic waste water generated will be sent to septic tank and soak pit.

Waste Water and its Disposal

Waste water or liquid effluent is normally generated from the following

1. Water treatment plant


2. Boiler blow-down
3. Waste water from various places like toilets, laboratory, washing etc.

17
Total effluent by way of above and effluent generated from sugar mill will be around 500
m3/day after expansion.

Wastewater treatment will be based on discharges of the various waste water to ponds for
clarification and filtration. Oily water, if any, will be treated separately to remove oil /
grease, before discharge into the effluent pond. The oily water collection in the plant is
basically due to floor cleaning, leaky oil filters, etc.

Oil and grease free effluent is transferred to a Neutralizing cum settling tank to settle out
large suspended particles and the pH is also corrected if required by addition of acid or
alkali. Coagulants, Chemical agents and polymers are added to condition finer & colloidal
particles, to enable their settling. The effluent will be passed through a sand filter unit and
will store in the treated water storage tank. The water will be used for maintaining the
Green Belt.

Ethanol Plant

The spent wash treatment plant will use latest technologies to achieve zero discharge. The
multistage evaporation system will be used to reduce the spent wash quantity. The details
of spent wash generation is given below for use of juice/syrup, B heavy molasses and C
molasses.

5.3 Air Pollution management


Main air polluting elements discharged from the proposed Cogen Project include dust
particulate from fly ash, Nitrogen oxides and Sulphur-di-oxide in the flue gas
ESP is already installed to arrest the fly ash and same will be collected and sent to ash silo.
ESP will be designed to maintain the particulate matter emission below 50 mg/Nm3.

Bagasse contains minor quantity of sulphur. Hence, the chimney height is calculated as per
the designated formula the problem of Sulphur can be tackled. The temperatures
encountered in the boiler while burning high moisture bagasse are lower enough to
minimize the nitrogen-oxides production. Moreover, the tender specification for boiler will
stipulate over fire air system with staged combustion, to ensure reduction in nitrogen-

18
oxide emission. Hence, no separate measures are taken to contain the nitrogen oxide
pollutants.

5.4 Solid Waste Generation and Management Solids (Ash & its Disposal)
Solids are generated by way of ash by burning the bagasse. As bagasse is renewable fuel
and creates less harm to the environment is considered as an environment friendly fuel as
compared to coal. Ash generated from the bagasse is also very less as compared to the coal.
Ash generated from bagasse is only around 2% against 35% by burning Indian coal and
10% by burning imported coal. While in distillery, ash will be generated 25 MT/day.

In this project only bagasse as fuel is considered and no coal will be used. Total bagasse
utilized during season will be 266573 MT and 69427 MT bagasse will be used in off-season.
Ash generated will be 5332 MT & 1389 MT. In distillery, the total ash will be generated
about 16500 MT (total 23221 MT for integrated project).

Total ash is generated as bottom ash which is collected at the bottom of the boiler below
grate (travelling grate or dumping grate) and fly ash which fly along with exhaust gases.

ESP is already installed to arrest the fly ash and same will be collected and sent to ash silo.
ESP will be designed to maintain the particulate matter emission below 50 mg/Nm3.

The ash generated will be initially stored in silos and suitably supplied to the brick
manufactures through trucks and also can be used to mix in the farms. As the ash generated
from the bagasse has high potash value, same can be used to mix with press mud and use
for bio-compost production and then sell it to farmers as fertilizer.

5.5 Noise & vibration control

Relevant noise emitters at KMTAPL are noise-making equipment such as compressors,


pumps, centrifuges, blowers, cranes, conveyor belts, boilers, turbo generator etc. All the
equipment produce continuous noise. As deliberated in chapter -IV, noise level impacts of
KMTAPL operations are significant only on the operators of machinery and are negligible
within buffer zone.

19
5.6 Socio-economic benefits.

 Ample power will be available from local grid due to decentralization of power
generation

 Power from grid on no charge basis or low charge basis can be available in this area.

 This can be an initiative for many units to start.

 Many sorts of direct as well as indirect job opportunities will be on the horizon due to
expansion of sugar, co-generation and new distillery plant.

5.7 Green Belt Development


Company to be planted several trees around factory premises
No. Scientific name of tree Common Name
1 Azadirachta indica Neem
2 Pongamia pinnata Karanj
3 Magnifera indica Mango
4 Ficus benghalensis Banyan
5 Tamarindus indica. Linn Chinch
6 Cocos nucifera coconut tree
7 Hibiscus rosa-sinensis Jaswand
8 Eucalyptus Nilgiri
9 Terminalia catappa Badam
10 Phyllanthus emblica Awala
11 Casuarina equisetifolia Suru
12 Ficus religiosa Pimpal
13 Saraca asok Ashok
14 Dalbergia sissoo Shisam
15 Tectona grandis Sag
16 Vitex negundo Nirgudi
17 Limonia acidissima kavath
18 Nerium oleander Kanher
19 Annona squamosa Sitafal
Total 4250

20
5.8 Budget Provision For Environmental Management
Sl. Particulars Capital Recurring
No. cost Cost
(Rs. (Rs.
Lakhs) Lakh/annu
m)
1 Air Pollution Control; to 50 3.00
co-gen boiler comprising
of ESP, stack of 76 meter
height
2 Water Pollution control; 300 5.00
ETP Facility comprising of
full-fledged ETP- Primary,
Secondary treatment with
online monitoring system
3 Noise pollution control 4.00 0.45
Enclosures for DG set
4 Occupational health; 5 0.50
annual health check up
5 Environment monitoring 0.50 2.00
and management
6 Green Belt development 20 0.85
Total 379.85 11.80

5.9 Land & Site Development:

The sugar factory has already in possession which is sufficient for the proposed expansion.
Most of the land is plain with not much level difference and strata of the land are quite
hard.

6.0 Rehabilitation and Resettlement


The project site is in possession over the years. This is a working factory since long. The
present proposal is only for expansion Thus, no Rehabilitation or Resettlement issues are
any more involved with no human settlement.
7.0 Project Schedule & Cost estimate
The promoters have planned to complete the proposed integrated expansion by January
2022.

21
Cost of the project
Sr. Description Sugar Cogen Ethanol Total in
no Lakhs
1 Land 0.00 0.00 0.00 0.00

2 Site Development 18.00 18.00 108.00 144.00

3 Civil Works 168.00 786.00 1356.00 2310.00

4 Plant and Machinery 3780.00 5298.00 9263.00 18341.00

5 Misc. Fixed Assets 295.00 230.00 1056.00 1581.00


Prelim. & Pre-op.
6 Expenses 293.00 400.00 321.00 1014.00

7 Contingencies 46.00 68.00 121.00 235.00


Working capital
8 margin 0.00 0.00 75.00 75.00
Total Project Cost 4600.00 6800.00 12300.00 23700.00

8.0 Analysis of Proposal


With sustained raw material availability for the project on long term basis and best
technologies available to produce excellent quality of various products, the project is
technically feasible. The market for these products is excellent with very good price.

Financial viability of the project is worked out and shows excellent financial results.
Assumptions made are on conservative side and any increase in the crushing of the sugar
mills and increase in prices of the final product will enhance the viability further.

Hence, considering sustained availability of raw material, excellent market and price for
finished products, flexibility of producing variety of different products with market and
price trend makes this project extremely feasible.

All the measures are taken to protect the environment and all the latest instruments like
ESP, evaporation and ETP, CPU are considered to achieve the zero emission from the
project.

22
Hence, it is recommended to go ahead with the project. This project will be win-win
situation for both promoters and financial institutions along with farmers in the area.

23

Common questions

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The expansion could potentially impact land, water, and air environments. Construction activities might lead to soil erosion and increased run-off, managed by planned earthworks before monsoon and proper drainage systems . Increased air pollution due to construction dust and vehicular emissions will be mitigated by sprinkling water over dust-prone areas . The operation phase will focus on managing emissions from the cogeneration project using techniques like ESPs to control particulate matter emissions. Additionally, the project aims for a zero discharge policy for wastewater from the ethanol plant, involving multi-stage evaporation systems .

The expansion is expected to provide substantial socio-economic benefits, including increased job opportunities both directly and indirectly due to the enlarged sugar plant and new distillery . The decentralization of power generation will make local grid power more available, which can stimulate regional economic initiatives and offer affordable power to new units. These advantages should boost the local economy and support the community’s development .

Mr. Gharge serves as a chief promoter and director of the project, leveraging his extensive experience in cooperative banking and agriculture. His past role as a director in another sugar factory and as an elected representative demonstrates his familiarity with both the agricultural sector and the legislative processes affecting sugar processing .

Noise pollution management at Khatav Man Taluka Agro Processing Ltd involves the use of noise suppression equipment like compressors and blowers, alongside implementing operational strategies that buffer machinery noise impacts primarily affecting equipment operators rather than those in nearby zones, thus mitigating broader environmental noise impacts .

The cogeneration power plant is equipped with Electrostatic Precipitators (ESPs) to arrest fly ash emissions, maintaining particulate matter levels below 50 mg/Nm3. The plant also calculates chimney height scientifically to manage sulfur emissions and employs boiler technologies that reduce nitrogen oxides formation due to lower burning temperatures of bagasse .

Khatav Man Taluka Agro Processing Ltd plans to ensure water availability for the new distillery plant by constructing a permanent water supply scheme from Yeralwadi Dam, which has a storage capacity of 32.80 Million Cum and is approximately 8 km from the site. This infrastructure is critical to meet the water demands of the expanded operations .

The decision to use the current site for expansion without considering alternatives is based on the existing infrastructure's adequacy. The 21.34 Ha of land at Padal Village is already equipped to support both the sugar and cogeneration plant expansion, as well as the new distillery plant. This choice minimizes additional land acquisition and development costs, leveraging the locale’s favorable conditions .

The company ensures raw material sustainability by relying on excellent irrigation facilities in its command area, registering cane from farmers covering approximately 12,000 hectares. With an average yield of 100 MT/ha, this ensures a reliable and consistent sugarcane supply for both sugar production and ethanol manufacturing .

The company proposes several waste management practices, including treating domestic and industrial effluents through septic tanks and detoxifying ponds. Oily waste will be isolated, and effluents will be treated with coagulants to settle out impurities. A sand-filtered treatment system will reclaim water for green belt maintenance. Notably, the ethanol plant will employ a multi-stage evaporation system to achieve zero discharge for spent wash .

The project expansion is well-aligned with India's supportive policies on ethanol production. The government's favorable purchase prices for ethanol derived from B-heavy molasses and juice/syrup encourage production, which aligns with the company's plan to set up a 120 KLPD distillery . This alignment reflects a strategic response to national biofuel policies encouraging ethanol production as a sustainable fuel alternative.

1 
 
 
 
 
 
 
 
 
EXECUTIVE SUMMARY 
 
For 
 
Proposed Expansion of Sugar capacity from 2500 TCD to 7500 TCD, Cogen power 12
2 
 
INDEX 
Sr.no. 
Particular 
Page No 
1.0 
Introduction 
3 
2.0 
Introduction of the project 
3 
2.1 
Promoter’s Backgroun
3 
 
   1.0 Introduction :  
Khatav Man Taluka Agro Processing Ltd. (KMTAPL) is incorporated as public limited 
company mainl
4 
 
considering the huge potential raw material available from the nearby villages of 
KMTAPL. The cogen power plant will be
5 
 
2.3  PROJECT DESCRIPTION : 
SALIENT FEATURES OF THE PROJECT 
Sr. 
No 
PARTICULAR  
DETAILS 
1 
Name of the Company & 
Re
6 
 
88 days of cogen plant (Off-Season) 
330 days of Distillery / ethanol plant 
9 
Basic Raw material 
requirement per annu
7 
 
Site Location:  
 
Google Image of the Project
8 
 
Toposheet of 10 Km radius of Project site 
2.6  Land and site development  
The Company has total land of 21.34 Ha at Pa
9 
 
Details of the alternate sites 
No alternate sites have been examined, as proposed project will be located in existing
10 
 
lakh MT will be available. Further, cane juice of 1600 TCD/day will be diverted to 
distillery / ethanol plant.  For op

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