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GODAVARI BIOREFINERIES LIMITED  

SY. NOS‐ 13, 14,1 6, 21, 28, 29, 40 OF SAIDAPUR VILLAGE, 49, 50, 
53 OF HANDIGUND VILLAGE AND 69, 72, 73, 74 OF  
MADHABHAVI VILLAGE, SAMEERWADI POST, MUDHOL TALUK, 
BAGALKOT DISTRICT, KARNATAKA 
 
 

 
 
 
 
 
 
PRE‐FEASIBILITY REPORT 

 
 
 
 
 
 
 
 
 
 
   
 

Godavari Biorefineries Limited   
Somaiya Bhavan, 45‐47 , M.G. Road,       
PO Box No. 384, Fort, Mumbai – 400 001. 
Phone : (022) 22048272/61702100 
E-mail: suhas@somaiya.com 
SUBMITTED TO 
MINISTRY OF ENVIRONMENT AND FORESTS, 
GOVERNMENT OF INDIA,  
INDIRA PARYAVARAN BHAWAN, JOR BAGH ROAD, NEW DELHII 
 Godavari Biorefineries Limited     

Godavari Biorefineries Limited,


Sy. Nos- 13, 14,1 6, 21, 28, 29, 40 of Saidapur village,
49, 50, 53 of Handigund village and 69, 72, 73, 74of Madhabhavi village,
Sameerwadi Post, Mudhol Taluk,
Bagalkhot District, Karnataka

DISCLAIMER
The purpose and scope of this information memorandum is to introduce the subject matter and
provide a general idea and information on the said area. All the material included in this
document is based on data/information gathered from various sources and is based on certain
assumptions. Although, due care and diligence has been taken to compile this document, the
contained information may vary due to any change in any of the concerned factors, and the
actual results may differ substantially from the presented information. M/s. Godavari
Biorefineries Limited does not assume any liability for any financial or other loss resulting
from this memorandum in consequence of undertaking this activity. Therefore, the content of
this memorandum should not be relied upon for making any decision, investment or otherwise.
The prospective user of this memorandum is encouraged to carry out his/her own due
diligence and gather any information he/she considers necessary for making an informed
decision.

1. Executive Summary
M/s. Godavari Biorefineries Limited obtained consent for operation for synthetic organic
chemicals manufacturing at Sy. Nos- 13, 14,1 6, 21, 28, 29, 40 of Saidapur village, 49, 50, 53 of
Handigund village and 69, 72, 73, 74of Madhabhavi village, Sameerwadi Post, Mudhol Taluk,
Bagalkhot District, Karnataka. The unit obtained Consent for Operation Order no.AW- 300982
dated 17.09.2016.

M/s. Godavari Biorefineries Limited proposes for expand synthetic organic chemicals
manufacturing unit in existing sugar complex and establishment of co-generation power plant.
It is proposed to allocate 194.82 acres of existing area for expansion. It is proposed to increase
the product profile, capacity, utilities considering the developments in R&D facility and
establishment of co-generation power plant of 8 MW (2 No’s). The expansion entails a capital
cost of Rs. 350 crores towards additional production blocks, utilities and enhancement of
effluent treatment plant.

2. Introduction of the Project / Background Information:


2.1 Identification of Project and Project Proponent:
The objective of this pre-feasibility study is to provide information for proposed expansion of
synthetic organic chemicals from 153 TPM to 16859.95 TPM in addition to co-generation power
plant of 2 x 8 MW at Sy. Nos- 13, 14,1 6, 21, 28, 29, 40 of Saidapur village, 49, 50, 53 of

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Handigund village and 69, 72, 73, 74of Madhabhavi village, Sameerwadi Post, Mudhol Taluk,
Bagalkhot District, Karnataka.

2.2 Brief Description of Nature of the Project :


The synthetic organic chemicals manufacturing will involve series of chemical reactions to get
the final Product. The products of reaction are purified, filtered and dried before packing the
final product. The Chemical reactions require various supporting services like Heating, Cooling
and Agitation etc.

2.3 Need for the project and its importance to the country and or region:
The project is envisaged to meet the demand supply gap in both domestic market and export
market, as synthetic organics demand is increasing day by day.

2.4 Demands-Supply Gap :


The project is envisaged to meet the demand supply gap in both domestic market and export
market, as synthetic organics demand is increasing day by day.

2.5 Imports Vs. Indigenous Production:


The project shall meet the reduce imports in some of the intermediate products and also
enhance the foreign exchange reserves in view of the proposed exports of few products.

2.6 Domestic/export Markets:


The products shall cater to both domestic and export markets.

2.7 Employment Generation (Direct and Indirect) due to the project:


The present project for manufacturing of Synthetic Organic Chemicals requires substantial
handling of raw materials, goods in process and finished goods. The proposed expansion shall
increase the employment potential.

3. Project Description

3.1 Type of Project including interlinked and interdependent projects, if any:


M/s. Godavari Biorefineries Limited proposes for expand synthetic organic chemicals
manufacturing unit in existing sugar complex and establishment of co-generation power plant.
It is proposed to allocate 194.82 acres of existing area for expansion. It is proposed to increase
the product profile, capacity, utilities considering the developments in R&D facility and
establishment of co-generation power plant of 8 MW (2 No’s). The expansion entails a capital
cost of Rs. 350 crores towards additional production blocks, utilities and enhancement of
effluent treatment plant.

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3.2 Size or magnitude of operation:


Manufacturing Capacity
S.No Name of Product Capacity (TPM)
Existing Proposed Total after
Expansion
Regular Products
1 Acetaldehyde 2800 2800
2 Crotonaldehyde 1000 1000
3 Acetaldol60% 420 420
4 Crotonyldehyde Di- Urea (CDU) 78 78
5 Crotoresin 52 52
6 Paraldehyde 60 60
7 1, 3 Butylene Glycol 200 200
8 1-3 Butylene Glycol (Min 40%) 32.22 32.22
9 Butanol 117.7 117.7
10 2-Ethyl, 1, 3 Hexane Diol 33.33 33.33
11 3-Methoxy Butanol 275 275
12 3 Methoxy Butanol (Min 40%) 30 30
13 3-Methoxy Butyl Acetate 340 340
14 3-Methyl 3- Pentene -One (MPO) 500 500
15 Ketone Mixture 197.5 197.5
16 Sodium Sulphate 245 245
17 Acetaldehyde Oxime 175 175
18 Ammonium Sulphate 133.9 133.9
19 n- Hexanol 42 42
20 Acetaldehyde Diethyl Acetal 250 250
21 Ethyl Vinyl Ether 100 100
22 Phenyl Ethyl Alcohol 100 100
23 Styrene Oxide 117 117
24 Styrene Polymer 42 42
25 Acetophenone 175 175
26 Phenyl Methyl Carbinol 44.80 44.8
27 Benzoic Acid or Sodium Benzoate 36.9 36.9
28 Acetonitrile 425 425
29 Diethyl Oxalate 175 175
30 Gbamber 100 100
31 Polyol 100 100
32 Styrallyl Acetate 100 100
33 Acetic Acid 40.6 40.6
34 M-Toluic Acid 100 100
35 Crude M-Toluic Acid 17.00 17
36 Propyl Acetate/ Butyl Acetate 1000 1000
37 Crude Propyl Acetate or Crude Butyl Acetate 17.00 17.00
38 Sorbic Acid/ Potassium Sorbate 500.00 500.00
39 Tri Ethoxy Butane 100 100.00

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40 Ethyl Lactate/Methyl Lactate/ Iso Propyl Lactate 50 50 100.00


41 NaturoWax 100.00 100.00
42 Cellulose 3 750 753
43 Micro Crystalline Cellulose 700 700
44 Xylitol 350 350
45 Furfural 350 350
46 Lignosulphonate 600 600
47 Biocomposite 2500 2500
48 Biopolymer 1000 1000

Total - I 153 16571.95 16724.95


Campaign Basis
1 Ethyl Crotonate 7.5 7.5
2 Methyl Crotonate 9 9
3 Methyl Beta Amino Crotonate 15 15
4 Ethyl Beta Amino Crotonate 30 30
5 Acetaldehyde Dimethyl Acetal 15 15
6 Formaldehyde Dimethyl Acetal 15 15
7 Formaldehyde Diethyl Acetal 15 15
8 Acetaldehyde Dibutyl Acetal 15 15
9 Acetaldehyde di-Iso Propyl Acetal 15 15
10 Acetaldehyde di-iso amyl acetal 15 15
11 Crotonaldehyde Diethyl Acetal 15 15
12 Butyraldehyde Dimethyl Acetal 15 15
13 Cinnamaldehyde Diethyl acetal 15 15
14 Tri Methoxy Butane 15 15
15 Acetaldehyde Propylene Glycol Acetal 15 15
16 Butane Diol polyester 15 15
17 Ethyl Levulinate 15 15
18 Ethyl Butyrate 15 15
19 Diethyl Succinate 15 15
20 Dimethyl Phthalate 15 15
21 Isopropyl Crotonate 15 15
22 Hexyl Acetate 15 15
23 Hexyl Salisilate 15 15
24 Valerolactone 15 15
25 Diethyl Phthalate 15 15
26 Ethyl Formate 15 15
27 Butaraldehyde Oxime 20 20
28 Methyl Ethyl Ketone Oxime 20 20
29 Butyraldehyde 20 20
30 2-Ethyl butyraldehyde 20 20
31 2-Ethyl Hexenal 20 20
32 2-Ethyl Hexanal 20 20
33 2- Ethyl Crotonaldehyde 20 20

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34 Cinnamaldehyde 20 20
35 Sorbaldehyde 20 20
36 Butyric acid 20 20
37 Crotonic acid 20 20
38 Levulinic acid 3 3
39 Hydroxy Methyl Fufural 3 3
40 Formic acid 1.5 1.5
41 Styrene Phosphonic acid 1.25 1.25
42 Hydrochloric acid    1.25 1.25
43 2-ethyl Butanol 20 20
44 2-Ethyl Hexanol 20 20
45 Hexanol 20 20
46 Sorbic Alcohol 20 20
47 Crotyl Alcohol 20 20
48 Cinnamic Alcohol 20 20
49 Polycosonol 20 20
50 Trimethylol Propane 20 20
51 Sorbic Alcohol (Min 30%) 1.78 1.78
52 Crotyl Alochol (Min 30%) 2.46 2.46
53 Cinnamyl Alcohol (Min 30%) 7.84 7.84
54 Isobutanol 14 14
55 2,5 Furan Dimethanol 20 20
56 Propionitrile 20 20
57 Butyronitrile 20 20
58 Isobutyro nitrile 20 20
59 Valeronitrile 9 9
60 Acetone 20 20
61 3-Methyl 2-Pentanone 20 20
62 Methyl Ethyl Ketone 20 20
63 Diethyl Ketone 20 20
64 Isopropenyl Acetate 20 20
65 Acrylic ester 20 20
66 Ketene 5 5
67 Isobutyl Vinyl ether 20 20
68 1-ethoxy Ethyl Acetate 20 20
69 Methyl vinyl Ether 20 20
70 Butyl Vinyl Ether 20 20
71 Diethyl Ether 20 20
72 NaturoWax 20 20
73 Hexyl cinnmaldehyde 20.00 20
74 Crude Hexyl Cinnamaldehyde 8 8
75 Ethyl propionate 20.00 20
76 Tri-Ethyl Phosphate (TEP) 20.00 20
77 Tri n Butyl Phosphate (TBP) 20.00 20
Total - II (Any 6 product at a time) 130 130

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78 R & D Products 5 5
Total - III 5 5
Grand Total (I+II+III) - Total 46 from regular, -- products 153 16706.95 16859.95
from campaign products and R&D products.
79 Co-Generation Power Plant 2 x 8.0 MW 2 x 8.0 MW

3.3 Process Description with process details (a schematic diagram/flow chart)


3.4 Raw material required along with estimated quantity likely source, marketing area of
final product/s, mode of transport of raw material and finished product.

All the raw materials required for manufacturing mostly available in India or from abroad.
There are no banned chemicals or products which are proposed to be used.

It is proposed to enter into long term arrangements with some of the raw material suppliers
both in India and overseas to avoid shortages at any time.

3.5 Availability of water its source, energy/power requirement and source should be given
The total water requirement for proposed expansion of synthetic organics manufacturing and co-
generation power plant is 10164 KLD out of which 5144 KLD will be fresh water requirement
and 5020 KLD is recycled water. The total fresh water requirement shall be met from
Ghataprabhu river canal. Total water balance is presented in Table below.
Total Water Balance
Purpose INPUT (KLD) OUTPUT (KLD)
Fresh Water Recycled Water Loss Effluent
Process 2229 1650 3954.5*
Washings 120 120
Scrubber 80 80
Boiler Feed 765 704 61
Cooling Tower 1450 3100 3870 680
DM Regenration 190 190
R&D 10 10
Domestic 300** 30 270
Gardening 270 270
Gross Total 5144 5020 4874 5365.5
Total 10164 10239.5
* Includes water formed during reaction and water in raw material
** Includes residential

3.5.1 Electricity:
It is proposed to set up Co-generation power plant of capacity 2 x 8 MW. Further, due to the
nature of the reactions and requirement of continuous power, the management proposes to put

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in place 100% self generation of power by DG sets of 6 x 1500 KVA proposed. Therefore no
delay or difficulty is foreseen on the power front.

3.6 Quantity of wastes to be generated (liquid and solid) and Scheme for their
Management/disposal
Quantity of Effluent Generated and Mode of Treatment for proposed Expansion - Tentative
Description Quantity Mode of Treatment
(KLD)
Process 3955 Sent to biological treatment plant followed by RO. RO
Washings 120 rejects sent to MEE and permeate reused for cooling
Scrubber Effluent 80 towers make-up
DM rejects 190
R&D 10
Boiler Blow downs 61 Sent to settling tank followed by RO. RO rejects sent to
Cooling Tower Blow 680 MEE and permeate reused for cooling towers make-
downs up.
Domestic 270 Sent to Sewage treatment plant and treated
wastewater is reused for gardening.
Total 5365.5

Solid Wastes and Disposal – After Expansion of Proposed Synthetic Organic Chemicals
(Tentative)
S.No. Description of waste Unit Quantity Disposal method
1 Process/Distillation residue TPD 22 TSDF / Cement Industry
2 Spent Carbon TPD 0.3 TSDF / Cement Industry
3 Hyflow Kg/day 20 TSDF
4 Mixed Spent Solvents KLD 180 TSDF / Cement Industry
5 Boiler Ash TPD 280 TSDF to use as a stabilizing
agent / Brick manufactures
6 Used Oil KLPA 280 Authorized recyclers
7 Lead acid batteries No's/Year 6 Authorized recyclers
8 Softener / DM Plant Resins TPA 120 TSDF
9 Forced Evaporation Salts TPD 12.57 TSDF
10 ETP Sludge TPD 4.95 TSDF
11 STP Sludge TPD 0.3 Composted and used as
manure
12 Used/Discarded Filter Bags Nos /year 0.42 TSDF for Incineration
13 Used / Discarded RO TPA 120 TSDF for Incineration
Membranes
14 HDPE containers No's/ 0.2 Detoxified and reuse
Month
15 Liners & Bags TPM 150 Authorized recyclers
16 Used Filters (HEPA filters, Nos /year 0.5 TSDF for Incineration
Oil Filters etc)
17 Insulation and Glass wool TPM 100 TSDF

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Waste
18 Discarded PPE TPA 1.7 TSDF for Incineration
19 Glass Bottles No's/ 0.5 Dispose off to outside
Month agencies after detoxification
20 Paper, cotton waste & TPA 120 Sale to outside agencies/
Packing materials i.e. wood, recyclers
carton , ropes
21 Waste packing wood/ TPA 5.2 Sale to outside agencies/
broken glass etc recyclers
22 Metal scrap TPA 5.4 Sale to outside agencies/
recyclers
23 Plastic Waste TPA 30 Authorized recyclers
24 Canteen Waste Kg/day 0.85 Composted and used as
manure
25 Bio Medical Waste TPA 2.1 Sent to Bio Medical Waste
Treatment Facility
26 E- Waste TPA 45 Authorized agencies

4. Site Analysis
4.1 Plant Location
The site is having a longitude 75002’37”E and latitude 16023’29”N’’. The site is surrounded road
connecting Mahalingapur to industry in south direction, open lands in north direction,
residential colony of the plant in west direction. There are no reserve forests, national parks,
sanctuaries within 10 km radius of the site.

5. Planning Brief:
The project is envisages to be completed by 2020 as it involves installation of higher capacity
processing equipment’s besides improving of yield and the production shall be initiated
thereon. Consultants are identified for preparing the detailed project report.

6. Proposed Infrastructure:
6.1 Power Requirement and Supply/Source
It is proposed to set up Co-generation power plant of capacity 2 x 8 MW. Further, due to the
nature of the reactions and requirement of continuous power, the management proposes to put
in place 100% self generation of power by DG sets of 4 x 1000 KVA proposed in addition to
existing 590 KVA capacity. Therefore no delay or difficulty is foreseen on the power front.

6.2 Utilities
List of Utilities – for proposed expansion
S. No Description Unit Capacity
1 Bagasse/Coal Fired Boilers TPH 2 x 75
2 Thermic Fluid Heater K.Cal/hr 2 x 2 Lac
1 x 10 Lac
3 Hydrogen Generator Cum/day 5200X3

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4 Nitrogen Generator Cum/day 1000


5 DG Set* KVA 6 x 1500
*DG sets will be used during load shut down period only.

Equipments
The basic technology involved in the manufacturing of synthetic organic chemicals is the
process Kettles, Heat Exchangers, Centrifuges, and Storage Tanks. To support the process
equipment Boilers, Chilling plants, Cooling Towers Etc. are required. All the above equipment
can be sourced indigenously and the lead time to supply the equipment will not exceed 20
weeks. Whereas the equipment’s related to the installation of 2 x 8 MW cogeneration power
plant is available indigenously and lead time to supply will not exceed 48 weeks.

6.3 Waste management


Liquid Effluents
The effluent generated from the proposed expansion of is mainly from process, washings,
scrubbers, cooling towers & boiler blow downs, RO/DM rejects from pre-treatment of water
and domestic wastewater. It is proposed to treat effluent from process, washings, scrubbers
and R&D in biological treatment plant followed by RO. Blow downs are sent to settling tank
followed by RO. Rejects from RO sent to MEE and permeate is used for cooling towers as make
up.

Air Pollution
It is proposed to establish 2 x 75 TPH coal fired boilers, 2 x 2 Lac K.Cal/hr and 1 x 10 lac.
K.cal/hr thermic fluid heaters and 6 x 1500 kVA standby DG sets for proposed expansion of
synthetic organic chemicals and establishment of co-generation power plant. Electro static
precipitators (ESP) will be provided for 2 x 75 TPH Boilers as air pollution control equipment.
DG sets shall be provided with stack heights based on the CPCB formula for effective stack
height. HCl and SO2 gases generated from process scrubbed in two stage scrubbers. Water is
used as scrubbing media in primary scrubbers and caustic in secondary scrubbers.

Solid waste
Solid wastes are generated from the process, solvent distillation, collection/neutralization tank,
waste oil from DG sets, used batteries from DG sets. The ash from boiler is sold to brick
manufacturers. The solid wastes; evaporation salts, wastes from the process in inorganic form
i.e., process salts and filtration aids shall be disposed to the TSDF, while the hazardous wastes
of organic nature i.e., distillation residues shall be disposed to authorized cement units and
other wastes like used oil and used batteries shall be sent to authorized recyclers. The other
solid wastes expected from the unit are containers, empty drums which will be used for packing
product, and or returned to the product seller or sold to authorized buyers after detoxification,
while the sludge from treatment plant shall be sent to TSDF.

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7. Rehabilitation and Resettlement (R&R) Plan


Not applicable as the land area is in the existing plant premises.

8. Project Schedule & Cost Estimates


8.1 Likely date of start of construction and likely date of completion (Time schedule for the
project to be given)
Within three months as it involves installation of higher capacity processing equipment’s
besides improving of yield and the production shall be initiated there upon.

8.2 Estimated project cost along with analysis in terms of economic viability of the project
The estimated cost of the project is approximately Rs. 350Crores.

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