ANNEXURE -

GPS FILE

ANNEXURE -

SURVEY OF INDIA TOPOSHEET

ANNEXURE – I

LIST OF PRODUCTS, BY-PRODUCTS & RAW MATERIALS

LIST OF RAW MATERIAL, PRODUCT AND BY-PRODUCTS TO BE MANUFACTURED UNDER 90 KLPD MOLASSES BASED DISTILLERY

BY

“ M/S. AURANGABAD DISTILLERY LTD.” AT: RANGAON (RANMODWADI), WALCHANDNAGAR, TAL.

INDAPUR, DIST.: PUNE- (MS)

• RAW MATERIAL

Sr. No. Name of the

Raw Materials

Quantity MT / Month Suplplier Existing

(30 KLPD) Expansion (60 KLPD)

Total (90 KLPD)

1 Molasses 3600 6900 10500 Neighboring Sugar

Factories

• PROUCT & BY –PRODUCTS

Sr. No.

Description Quantity MT / Month

Existing (30 KLPD)

Expansion (60 KLPD)

Total (90 KLPD)

A Product

1 Rectified Spirit (RS) , Extra Neutral Alcohol (ENA) & Ethanol

900 1800 2700

B By – Product 1 Fusel Oil 1 60 61 2 Ammonium Sulphate - 456 456 3 Magnesium Sulphate - 870 870 4 Potasuim Nitrate - 402.6 402.6

ANNEXURE – II

PLOT LAYOUT PLAN

ANNEXURE – III

MANUFACTURING PROCESS DESCRIPTION & FLOW CHART

AURANGABAD DISTILLERY PVT. LTD., WALCHANDNAGAR

Process details

I) Fermentation Process :

Initially, yeast is developed in the laboratory from the single cell yeast culture. The yeast is propagated in test tube of 10 ml. Then it is transferred to a 500 ml flask and again transferred to a 5 liter flask containing the sterilized molasses solution. It is necessary to adjust pH of the molasses solution in the range of 4.5 to 5.0. It is also necessary to add nutrients such as urea, DAP etc. Each stage of development of yeast from 10 ml to 500 ml and 500 ml to 5 liters requires 24 hrs. in laboratory. On the plant side, there are again 3 stages of yeast propagation namely 100 lit, 500 lit, and 5000 lit. All these equipments are designed so as to facilitate boiling molasses solution in order to sterilize it and also cooling to bring it to proper temperature of 33°C and letting in culture and taking out culture. Boiling, cooling, introducing culture etc. is done in an aseptic manner i.e. keeping the fermentation medium free from any kind of infection. Further stages of yeast propagations are done in open tanks i.e. pre-fermenters requires about 8 hours in order to build up necessary concentration of yeast in them. Finally, the pre fermenters are emptied in empty fermenters, which is previously cleaned and kept ready, diluted molasses solution is allowed to flow in. Molasses from storage tanks is transferred to weighing system. This weighed molasses is diluted with water to maintain sugar concentration at about 16 to 17 % and transferred to fermentators. Nutrients like Urea/ DAP/ Enzymes are being added to fermentors in requisite doses. During fermentation process, yeast strains (Saccharomyces Cervisiae) converts sugar present in the molasses such as sucrose or Glucose to alcohol. This requires 24 to 30 hrs. for completion of reaction. This transformation can be represented as under; Cane sugar Glucose Alcohol C12 H22O 11 + H2O = 2 C6 H12 O6 = 2C2H5 OH + 2CO2 II) Distillation :

Process in which the components of a substance or liquid mixture are separated by heating it to a certain temperature and condensing the resulting vapors. Some substances have components that vaporize at different temperature and then can be separated by condensing their vapors. Vacuum distillations is a method of distillation where by the pressure above the liquid mixture to be distilled is reduced to less than its vapuor pressure causing evaporation of the most volatile

liquids. This distillation method works on the principle that boiling occurs when the vapor pressure of a liquid exceeds the ambient pressure. Distillation process:- Fermented wash from the clarified wash tank is pumped to the fermented wash pre-heater (PHE) and preheated to about 60-70°C by circulating hot spent wash on the side. Incoming spent wash temperature is 80-82°C and other exchanging heat with fermented wash out let temperature of spent wash remains at 35 to 40°C. This hot fermented wash is then feed to the top of analyser column. A. Analyser column cum degasser: (19+5 Trays) Fermented wash is fed to the top of de-gasifyer column from degasifer low boiling impurities are removed. Feed flow to the column is measured by using magnetic flow meter. The vapour is drawn from top of the analyser column is feed to the per-rectifier column. Analyser column is provided with thermosyphon re-boiler for supplying heat input to the column. Thermosyphon re-boiler is provided with the standby arrangement. In degassifyer non condensable gasses escape from the top of column and condensed in condenser I & II. The condenser gets recycled back to the column. The non condensable gasses are connected to vacuum pump and scrubbed in alcohol scrubber. In thermosyphon re-boiler rectifier top vapour are condensed on the shell side and flash vapour are recirculated on the tube side. Vapour generated from the re-boiler are used in the analyser column for shipping the alcohol from the fermented wash. Spent wash from the analyser column is sent for treatment to the effluent treatment plant. The level in the column is controlled by LCV which is on the discharge line. Analyser column is maintained under vacuum for heat economy. B. Pre-rectifier column: (47 Trays) PRC is principally used for removed of low boiling impurities. The vapor coming out of the top of PRC are fed to the condenser I & II where condensation is done by using cooling water. The vapors are passed through the alcohol scrubber before going to vacuum pump. In the scrubber alcohol from the vapor are scrubbed by using soft water and scrubbed alcohol in the water is taken for recovery column. The condensed liquid is collected in the PRC reflux tank. It is then pumped back to the column as reflux. Impure spirit draw is taken from the reflux and fed to the T.A. mixing bottle were it is mixed with the I.S. coming from rectifier cum exhaust and Recovery column. Alcohol water mixture from the PRC is fed to the rectifier cum exhaust column via rectifier feed pump level controlled with control value. C. Rectifier column: (72 Trays) The column is designed for over pressure. In this column the alcohol is concentration is 96 % v/v. The product (Rectified Spirit) is drawn out near the top of the column and fed to the

simmering column (Polishing). The top vapors from the rectifier column pass the thermal energy to the analyser re-boiler and heat the column. The condensate get flash in flash vapor and the impurities – aldehyde, ethyl alcohol are condensed in vapor condenser and the small amount of vent is finally scrubbed in alcohol scrubber and CO2 and other gasses escape from the top of the scrubber. Pure alcohol is reflux to the column. The light and heavy heat oil are drawn from the trays of the column and fed to the recovery column for further concentration. The spentlees from the bottom of the column are free from alcohol and it is used for heating by passing through PHE. Spentlees are flashed in flush vessel and the vapors fed to the flasher. The bottom liquid is pumped through pump and liquid is partly to feed to flasher and to extractive distillation column. At the top of rectifier column Rectified Spirit is tapped out and send to the receiver as product. D. Extractive didistilation column: (45 Tray) This column is designed to separate all low boiling impurities, aldehyde, esters and sulfur compounds from the feed alcohol. Addition of soft water or spent lees increases volatility of low boiling compound with respect to alcohol (ethanol) in solution containing of water. In this process the pure ethanol water mixture gets removed at the bottom of the column and the impurities go on the top of portion of the column. The dilution water gets heated by passing through heat exchanger. The top vapour from the column are condensed in main condenser and vent condenser and reflux to the column. Partly fusel oil and other impurities fed to R.C. column and vent is connected to vacuum system. The bottom liquid contains alcohol water mixture fed to rectifier column. E. Recovery column: (50 Tray) Recovery column is mainly designed for low impure cut and receive maximum pure alcohol. The impure alcohol cuts from degasser rectifier vent, simmering vent, ester draw, alcohol scrubber washing water etc fed to this column. The top vapour from the column condensed in condenser 1St & 2nd. Reflux, the alcohol is send to recovery column and draw concentrated in heads vent condenser is cooled through cooler and sent to it draw receiver. Pure alcohol is draw from recovery column and sent to extractive column. F. Simmering column: (50 Trays) Simmering column is mainly designed for polishing the product by removing traces of volatile impurities and maintain the aroma and flavor to meet the premium quality of norms. Mainly methanol is removed from this column. The pure alcohol is removed from the bottom of the column after cooling pumped to ENA day storage section.

PROCESS DESCRIPTION FOR SPENTWASH

Sugar Based Distillery Spentwash comprises of Organics, Inorganics and Water. Organics mainly comprise of Organic Solids other than Sugars, Yeast, Glycerol and Volatile Acids. Inorganics are mainly Potassium, Calcium, Sodium, Sulfur, Chlorides, Iron and Magnesium. Total quantity of Organics and Inorganics varying from 10% to 30% based on various Ethanol Manufacturing Technologies. Majority of traditional distilleries are having 10-12% Total Solids in Spentwash. However Molasses requirement for 1 KL of Ethanol production approximates 3.9-4 Tonsin general.Typically 80 brix Molasses contains 3-3.5% Potash. Non Fermentable Organics are coming in spent wash. This Process is a combination of the systems which recovers Potash in form of KNO3 and Organics in form of CMS at desired concentration. This process is a composite solution of handling of spentwash to achieve Zero Liquid Discharge and convert majority of its constituents into Valuable Products with positive cashflow and revenue generation. First Stage of this process consisting of removal of Organics from Spent wash. Organics are being isolated from spentwashusing Lime and Sulfuric Acid. Since Lime/ Calcium Oxide is required for Treatment scheme gypsum is reacted with Ammonium Carbonate Solution which is a byproduct of Dyes and Intermediate Industries and convert gypsum into Calcium Carbonate and Ammonium Sulfate Solution. Ammonium Sulfate Solution follows Evaporation, Crystallization and Drying to produce Ammonium Sulfate.. After removal of organics from Spent Wash Potash is being isolated using recyclable Chemicals with Patented Technology and converted in KNO3 using Nitric Acid. Approximately 80% of available potash is coming out from Spent Wash at Purity more than 99%. After Potash Isolation balance Stream will be treated to generate Solids which can be suited for Land Filling. Water recovered from this process can be treated in Condensate Polishing Unit to make it suitable for recycling in Fermenter. Overall System flow is indicated below for easy understanding of Complete Process. System will comprise of Mainly Reaction, Filtration, Evaporation, Crystallization, Drying, Chemical Treatment and Biological Treatment. Main Consumable Chemicals in this Process are Lime, Sulfuric Acid, Nitric Acid, Sodium Carbonate and Calcium Nitrate. Some special grade chemicals are required for nominal dosing which will be made available. Nominal average quantity of KNO3 recovered from 1 KL of Ethanol Production is approximately 290 Kg and 70% of Organics are getting recovered in form of CMS. Total 80% of available water from Spent Wash can be made available for fermenter/ other usage.In a complete Cycle this system is a Zero Liquid Discharge with value added recoveries and recycling of precious natural resources.

ANNEXURE – IV

WATER LIFTING PERMISSION

ANNEXURE – V

WATER BUDGET

DAILY WATER BUDGET FOR 30 KLPD MOLASSES BASED DISTILLERY OF

M/S. AURANGABAD DISTILLERY LTD., TAL. - INDAPUR, DIST. - PUNE

Daily Requirement of Water is 273 M3/Day (Process 270 M3/Day + Domestic 3 M3/Day)

(#183 + *90)

* - Treated water from Distillery CPU. # - Fresh water taken from Nira -Left Bank canal.

Sewage 2 KL

Septic tank followed by Soak pit

Total Wash 451 K.L. (250 KL + 85 KL = 335 KL)

Fermentation

CO2 Gas to Bottling plant

Plus Molasses 120 M.T. (Vol. 85 KL)

Yeast Sludge 2 KL

Condenser Cooling Replenishment *15 KL

Fermentation Dilution 250 KL #180 KL+*70 KL

For Washing and Laboratory *5 KL

Domestic 3 KL (#3)

Distillation

333KL

Steam From Boiler, 107 MT (3.7 T/KL of Alcohol) Condensation Water

240 KL Spent wash 30 KL Alcohol 63 KL Spent Lees

Steam Condensate 107 KL (To Boiler)

Proposed Distillery CPU (about 68.4 KL)

Compost

30 days lagoon

Forward to compost

Biomethanation 240 KL

Effluent Generated 4 KL

Other effluent 5.4 KL

Effluent 1.4 KL

5.4 KL Distillery CPU

Used as manure for agriculture

5 days Storage

DAILY WATER BUDGET FOR 60 KLPD MOLASSES BASED DISTILLERY

Daily Requirement of Water is 1090 M3/Day (Process 1088 M3/Day + Domestic 2 M3/Day)

(#617 + *473)

* - Treated water from Distillery CPU. # - Fresh water taken from Nira -Left Bank canal.

Sewage 1.5 KL

Septic tank followed by Soak pit

Total Wash 780 K.L. (616 KL + 164 KL = 670 KL)

Fermentation

CO2 Gas to Bottling Plant

Plus Molasses 230 M.T. (Vol 164 KL)

Yeast Sludge 6 KL

Condenser Cooling Replenishment *387 KL (120 KL CPU + 267 Softner

Fermentation Dilution 506 KL (#163 + *343)

For Washing and Laboratory *10 KL

Domestic 2 KL (#2)

Distillation

664KL

Steam From Existing Boiler, 210 MT (3.5 T/KL of Alcohol) Condensation Water

480 KL Spent wash 60 KL Alcohol 124 KL Spent Lees

Steam Condensate 210 KL

579.3 KL Condensate

POTASH RECOVERY FROM SPENT WASH

Proposed Distillery CPU (about 870.7 KL)

783.6 KL used in process or cooling tower make up , Gardening & irrigation Purpose

Reject 87.1 KL

Forward to compost

Effluent Generated 9 KL

Other effluent 99 KL

Boiler #150 KL

Effluent 40 KL

Boiler blow down 15 KL

Softner & DM Plant

regeneration #35 KL

Effluent 35 KL

Water loss 62.36 KL

Ammonium Sulphate 15.20 MT

Magnesium Sulphate 29.0 MT

Water to reaction (161 KL) 73.30 KL recyle

Potasuim Nitrate 13.42 MT

68.4 KL from 30 KLPD unit

5 days Storage

ADDITIONAL ATTACHMENTS

MPCB CONSENT ORDER

RENEWAL OF CONSENT TO OPERATE OF EXISTING

30KLPD DISTILLEY

AMENDMENT IN CONSENT TO ESTABLISH (EXPANSION)

EC EXTENSION LETTER

ENVIRONMENTAL

CLEARANCE LETTER

CERTIFICATE &

OTHER DOCCUMENT

NO OBJECTION

CERTIFICATE

(NOC)