EXPANSION OF GRAIN BASED DISTILLERY PLANT FROM 50 …environmentclearance.nic.in/writereaddata/Online/TOR/0_0_09_Dec_2… · 5 Manufacturing Process of Grain Based Alcohol 13

EXPANSION OF GRAIN BASED DISTILLERY PLANT FROM 50 KLPD TO 130 KLPD

ATVILLAGE SEJWAYA, LEBAD CHOWKI,GHATABILLOD,

DISTRICT DHAR, MADHYA PRADESH.P

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FAS

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ITY

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Prepared ByMANTRAS GREEN RESOURCES LTD.

Engineers & Environment Consultant Flat No. B-5 and B-7, Flushing Meadows, Plot No. 3,Mahatma Nagar, Nasik-422 007, Maharashtra, IndiaPhone: +91-253-2355665, 2370086; Fax No.: +91-253-2316781E-mail:[email protected]

[email protected]

SUBMITTED BYGREAT GALLEON LIMITED.

160 KANCHAN BAGH, INDORE, MADHYA PRADESH

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Table of Contents

Sl. No. Contents Page Nos. 1.0 Introduction 1 1.1 Estimated project cost 1 1.2 Project proponent 1 1.3 Site location 2 1.4 Site selection criteria 6 1.5 Topography 7 1.6 Rainfall and Climate 8 1.7 Temperature and Humidity 8 1.8 Soil and Land Classification 9 1.9 List of surrounding Industries 11 2.0 Manufacturing Process 13 3.0 Utilities 20 3.1 Raw material 20 3.2 Water requirement 20

3.3 Source of Water 22 3.4 Fuel Requirement 22

3.5 Co-generation Power Plant 22 3.6 Boiler & Auxiliaries 22 3.7 Turbine & Auxiliaries 25 3.8 Generator & its Auxiliaries 25 4.0 Environmental management and pollution control 27 4.1 Fresh Water Requirements 27 4.2 Grain Based Distillery Process 27 4.3 Effluent Generation 28 4.4 Air Pollution Generation 30 4.5 Solid Wastes Generation 30 4.6 Hazardous Waste Generation 30 4.7 Wastewater Treatment System 30

4.8 Multiple Effect Evaporation 31 4.9 Falling Film Evaporation 31 5.0 Treatment of Effluent from Different Streams 33

5.1 Air pollution control system 34 5.2 Ash management 36 6.0 Project cost estimates 37 6.1 Budget allocation for EMP 37 6.2 Rehabilitation and Resettlement 38 6.3 Project Benefits 38 6.4 Employment Potential 39 6.5 Corporate Social Responsibility 39

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List of Tables

List of Figures

Sl. No. Figures Page Nos. 1 Topographical Map with 10KM Radius 5 2 Google Imagery of the project site 6 3 Detailed Project layout 7 4 Soil Investigation Report 10 5 Manufacturing Process of Grain Based Alcohol 13

6 Flow Chart of Grain based Distillery 19

7 Water Balance chart for proposed 80KLPD distillery 21 8 Effluent Treatment Scheme 28

List of Annexures:

Sl. No. Annexure Page Nos. 1 Grain Agreement copy 41 2 Coal supply agreement 43 3 NOC from Gram Panchayat 46 4 Layout of fire hydrant system 47 5 Water supply Permission letter 48 6 Proposed ETP Layout Plan 49 7 Proposed STP Layout plan 50

Sl. No.

Tables Page Nos.

1 Board of Directors 2 2 Land Area Breakup statement 2 3 Salient features 4 4 Industrial Glance of Dhar District 11 5 Dhar District at a Glance 12 6 Existing 50KLPD distillery water usage 20 7 Fresh water Requirement in M3/day for proposed 80KLPD Plant 20 8 The details of effluent generation from each unit 29 9 Polishing unit for condensate and other minor distillery effluents 33 10 Estimated overall project investment 37 11 EMP Budget 37 12 Manpower Requirement 39

Great Galleon Ltd Expansion of Grain Based Distillery from 50KLPD-130KLPD Pre-Feasibility Report

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1.0 INTRODUCTION

Great Galleon Ltd. (G G Ltd.) is a company registered under Indian Companies Act, 1956

having certificate of incorporation no. U15520MP1985PLC002815 of April 8, 1985 and having

its registered office at 160 Kanchan Bagh, Indore, Madhya Pradesh.

GGL company is planning to expand its existing Grain based distillery plant from 50 KLPD to

130 KLPD along with around 46000 cases/day of CLD bottling unit at their existing location at

village Sejwaya, Lebad Chowki, Ghatabillod, District Dhar, Madhya Pradesh.

The Ministry of Environment and Forests (MoEF&CC) Government of India has issued an EIA

notification, S .O. 1533 dated 14 September 2006 notification amended in 1 December 2009

wide no. 3067. Under Environmental (Protection) Act (EPA) 1986. Prior Environmental

Clearance from the EIA Authorities is mandatory for the establishment of projects/activities

listed in the schedule of above notification Distillery projects are categorized under 5(g) of

schedule of activities and therefore, require prior environmental clearance from the Expert

appraisal committee / authority. Hence project of Great Galleon Ltd. grain based distillery

unit is classified under 5(g) category A.

As the project was established before 1994, the project has an exemption from

Environmental Clearance. The project has procured Consent to Establishment and Consent to

Operate from MP Pollution Control Board. The latest consent to operate was issued with

ref.no. AWH-44671/MPPCB/DHR dated 03/09/2015. The industry has been submitting the

compliance of conditions to MPPCB as per the Terms and Conditions given in the consent

order.

1.1 Estimated Project Cost:

The estimated cost of expansion project from 50KLPD to 130 KLPD distillery project and

cogeneration of 5.77 MW of power would be around Rs.53.94 Crores. The cost does not

include the land cost.

1.2 PROJECT PROPONENT

The company has grown to manifolds during the last 10 to 12 years under the stewardship

of its Chairman/Managing Director. Profiles of the Board of Directors are given below:


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Table 1. Board of Directors

GGL has also appointed Mr. K. K Singh as General Manager for looking after day to day affairs of

GGL. He has vast experience in the Liquor industry.

GGL already has a strong technical / managerial team of highly qualified engineers, contractors &

arbitration experts, agricultural officers and managerial personnel for implementation and

operation of the Distillation plant.

1.3 SITE LOCATION

The Distillery will require land for entire basic infrastructure. Plant equipments, storage of plant

inputs and finished products. Besides this Administrative Office, Security arrangements, Fire

fighting arrangements etc shall also have to be considered. Plant layout is prepared keeping in

view, the above composition of project.

The Existing 50KLPD distillery has occupied an area of 5.81 Acres and proposed expansion will be

in 3.6 acres. The total plot area of the project will be 9.416 Acres. Detailed breakup has been

given in Annexure-1 below.

Table 2: Land Area Breakup statement

SR. NO SECTION AREA IN SQ. M REMARKS 1 ADM/TIME OFFICE 78.5 Existing Distillery Area Distillery area 2 SECURITY OFFICE 5 Existing Distillery Area 3 EXCISE OFFICE 108.71 Existing Distillery Area 4 EXCISE OFFICE REST ROOM & VISITOR

OFFICE 47.38 Existing Distillery Area

5 TOILET Existing Distillery Area 6 HAND WASH & DRINKING WATER 2.23 Existing Distillery Area 7 ADMIN BLOCK 168.76 Existing Distillery Area 8 WORKSHOP & PRINTING 188.67 Existing Distillery Area 9 SHREE GANESHA TEMPLE 6.18 Existing Distillery Area 10 IMFL BOTTLING 3582.79 Existing Distillery Area 11 WASHING AREA 534.99 Existing Distillery Area 12 EMPTY BOTTLE GODOWN 631.48 Existing Distillery Area 13 DM PLANT 160.65 Existing Distillery Area

Name Role

1. Mr. Sunit Madhok Managing Director

2. Mr. V L Sawant Director

3. Mr. R K Gaur Director

4. Mr. M L Agrawal Director

5. Mr. Amit Kumar Director

6. Mr. Vinay Kumar Kedia Vice President

7. Mr. Rajeev Newatia Chief Executive Officer


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14 CL BOTTLING 2105.6 Existing Distillery Area 15 LABOUR LUNCH AREA 422.27 Existing Distillery Area 16 CREACH 20 Existing Distillery Area 17 HAND WASH & DRINKING WATER 24.72 Existing Distillery Area 18 LABOUR TOILET 2 25.84 Existing Distillery Area 19 H.T. YARD 289.8 Existing Distillery Area 20 ELECTRICAL CONTROL ROOM 365.85 Existing Distillery Area 21 COAL YARD 1521.17 Existing Distillery Area 22 BOILER 20MT/45KG 692.8 Existing Distillery Area 23 TURBINE 1.82 MW 394.61 Existing Distillery Area 24 RO/DM PLANT 2 86.94 Existing Distillery Area 25 DIST. PLANT 1930.42 Existing Distillery Area 26 SPIRIT STORAGE 712.25 Existing Distillery Area 27 PROCESS LAB 53.36 Existing Distillery Area 28 GRAIN GODOWN 965.72 Existing Distillery Area 29 GRAIN PLANT 771.82 Existing Distillery Area 30 FERMENTATION 2243.6 Existing Distillery Area 31 CO PLANT 610.16 Existing Distillery Area 32 C.T FERMENTATION 83.6 Existing Distillery Area 33 EFFLUENT TREATMENT PLANT 2015.44 Existing Distillery Area 34 HYDRENT SYSTEM 118.5 Existing Distillery Area 35 ASSEMBLY POINT NO.1 120 Existing Distillery Area 36 DIST. PLANT C.T. 91.52 Existing Distillery Area 37 WATER STORAGE TANK 269.8 Existing Distillery Area 38 RO 1 56.17 Existing Distillery Area 39 U/G WATER STORAGE 263.16 Existing Distillery Area 40 SCRAP YARD 542.36 Existing Distillery Area 41 G STORE 910.5 Existing Distillery Area 42 OPEN SHED 102.06 Existing Distillery Area 43 ASSEMBLY POINT NO.2 120 Existing Distillery Area 44 WEIGH BRIDGE 17.28 Existing Distillery Area 45 TOLL KATA OFFICE 10.75 Existing Distillery Area 46 DRYER 685 PROPOSED Distillery area 47 GREEN ZONE 9500 PROPOSED/Existing Distillery Area 48 TURBINE 500 PROPOSED Distillery area 49 BOILER 358 PROPOSED Distillery area 50 FERMENTATION 550 PROPOSED Distillery area 51 PET BOTTLE PLANT 1850 PROPOSED Distillery area 52 SPIRIT ROOM 1127.6 PROPOSED Distillery area


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Table3: Salient Features T

Sr. No. Feature Particulars

1. Location M/S Great Galleon Ltd. (G G Ltd.) village Sejwaya, Lebad Chowki, Ghatabillod, District Dhar, Madhya Pradesh- 454773

2. Latitude

Longitude

22º40'11.36 "N 75º28'39.90"E

3 Nearest Highway NH-59 – 0.3 km

4. Nearest village Sejwaya

5 Nearest Railway station Rau Railway Station –31.11kms in East

6. Nearest Airport Devi Ahilya Bai Holkar Airport (Indore)- 40

Km[E]

7. Nearest Town Dhar- 22 KM in SW direction.


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Fig 1. Topographical Map with 10KM Radius

Project Site


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Fig 2. Google Imagery of the project site

1.4 Site selection criteria:

The basic criteria for the expansion of site from 50KLPD to 130KLPD grain based distillery project

are as below:

o Raw material availability Raw materials can also be easily procured from grain suppliers in Madhya Pradesh and nearby states such as Chhattisgarh, Rajasthan, Maharashtra, Bihar.

o Raw material cost

o Transportation cost o Availability of Man power

o Accessibility to markets within and nearby states

o Availability of water

o Availability of land in abundance

o Connectivity of road/rail network.

o Market demand for final Product


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Fig 3. Detailed Project layout has been given below.

1.5 Topography :

The topographic profile of the region is evident from the fact that from this elevation of 582 m

above MSL the elevation drops down to 534 in a span of 4 km and then, the elevation runs

around534 m above MSL for a large area of almost 100 Sq Km. And though the area to the west

has a higher elevation than the site, the level difference does not go beyond 6 m, with the

highest elevation running for very limited extents at 540 m above MSL. At the site level, the

project site seems almost flat, but there is a gentle, almost and though invisible level difference

of 5 m from the South Western corner at 537 m above MSL to the North Western corner, the


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lowest part of the site with an elevation of 532 m above MSL. However, the average elevation at

site runs at 534 m above MSL. Thus the average slope at site is 1.7 %, while the maximum slope

is 3.5 %.

1.6 Rainfall and Climate:

Rains are due to southwest monsoons. The typical monsoon season goes from June 15 till mid-

September, contributing 32-35 inches of annual rains. 95% of rains occur during monsoon season.

The average annual rainfall for Dhar district is 836 mm. It is evident that rainfall in Dhar block at a

local level follows the regional trend of rainfall as measured for the entire Dhar District, while

remaining around 20 % higher than the annual average for the entire district. The long term

average rainfall as per the Land record of Dhar District administration is 784.73 mm, and for Dhar

Block (2006 -2010) is 988.82 mm. While the average for the last 10 years rainfall data available

for Dhar District (Indian Meteorological Department website) is 835.93, However this average is

due to high rainfall years of 2006, 2007, and 2013, while the rainfall in 2011 and 2012 has shown

a declining trend and increasing again in 2013. The study area falls in the Malwa Plateau agro

climatic zone and experiences semi-arid and hot climate. The study area has a typical sub-tropical

climate. Three distinct seasons are observed, summer, monsoon and winter. Summers start in

mid-March and can be extremely hot in April and May. The daytime temperatures can touch 40°C

on more than one occasion. Average summer temperature may go as high as 36–39 °C (100.4 °F)

but humidity is very low. Winters are moderate and usually dry. Lower temperatures can go as

low as 14°C-16°C on some nights. Usually the temperature ranges between 26°C-30°C during

winters.

1.7 Temperature and Humidity:

As per long term data available from IMD the predominant wind direction is from west.

Maximum wind speeds are recorded in the summer season. As per the onsite meteorological

data collected for winter season, the predominant wind direction was observed to be North-east.

The average annual rainfall for Dhar district is 836 mm. The study area falls in the Malwa Plateau

agro climatic zone and experiences semi-arid and hot climate. The study area has a typical sub-

tropical climate. Three distinct seasons are observed, summer, monsoon and winter. Summers

start in mid-March and can be extremely hot in April and May. The daytime temperatures can

touch 40°C on more than one occasion. Average summer temperature may go as high as 36–39 °C

(100.4 °F) but humidity is very low. Winters are moderate and usually dry. Lower temperatures

can go as low as 14°C-16°C on some nights. Usually the temperature ranges between 26°C-30°C

during winters.


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1.8 Soil and Land Classification

At a regional level, the soil profile is highly varying. While most of the region is covered with

Black cotton soil, there are a few areas which have very thin soil profile., and some parts have

moderately thick soil profile with deep weathered zone. All these factors have guided us to

choose the target areas, and design the exploration activities accordingly. The thickness of

weathered zone decreases towards the eastern and southern part. The topsoil is typical black

cotton soil The soil is sticky in nature with fine sized grains. The soil is not well drained and has

high water retention capacity. The region is underlain by basaltic rocks of igneous origin. These

rocks belong to the geological formation known as Deccan traps. A layer of alluvium overlies

these basalts in the river beds, nallah beds and their flood plains.

The proposed distillery site has been analysed with soil investigation report as follows.


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Fig 4. Soil Investigation Report


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1.9. List of surrounding Industries:

Dhar district has a large industrial area named Pithampur. Pithampur auto Cluster has been

established by Ministry of Commerce and Industry, Govt. Of India.

Major Exportable Item are Sorbital, Sodium Chloride, G.P. G.C./ C.R./ Colour Coated coil/ Sheet,

Cold Rolled Steel Coil/ sheet, Auto parts, Tyres, Food items, Corrugated paper boards. It has Large

Scale Industries / Public Sector Undertakings, Medium Scale Enterprises and had a growth trend

of 2-3%.

Table 4. Industrial Glance of Dhar District

Sr No

Head Unit Particulars

1. Registered Industrial Unit No. 7292 2. Total Industrial Unit No. 7292 3. Registered Medium & Large Unit No. 116 4. Estimated Avg. No. of Daily Worker No. 12658

Employed In Small Scale Industries 5. Employment In Large And Medium No. 10678

Industries 6. No. of Industrial Area No. 5 7. Turnover of Small Scale Ind. In Lacs 24354 8. Turnover of Medium & Large Scale In Lacs 37400

Industries Source: DTIC Dhar, MPAKVN


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Table 5 : Dhar district at glance

Dhar District at Glance S. NO. Parameter Area Extent

1. Total Geographical Area of the district 806533 hectares

2. Area under Forests 120600 Hectare

3. Area under agriculture 743.9 Hectare

4. Total population of the district 2184672

5. Sex ratio (female : male) 961 : 1000

6. Literacy Ratio 60.57%

7. Population Density 270/sq. km.

8. Administrative setup District adm. Head qtr, in Dhar

9. Number of Sub-Division 5 10. Number of Municipality 1 (Dhar) 11. Number of Blocks 13 12. Number of Tehsils 8 13. Number of Police Station 20 14. Number of Gram Panchayat 762 15. Total Number of villages 1479 16. Total cultivable area 504.5 hectares Total Barren Land 14600 hectares 10. Non Agriculture land 174800 hectares

Area under paddy cultivation 297123 hectares

Total irrigable area (through any means other than rain water) 294000 hectares


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2.0 Manufacturing Process Proposed Distillery shall be set-up based on latest Design, Engineering and Supply technology for

grains receiving and storage, grains handling and milling, slurry preparation/liquefaction,

saccharification and instantaneous fermentation, Fermentation, Multi-pressure distillation,

Decantation, Multi-effect evaporation, Dryer, Spirit storage, Water treatment plant and Effluent

Treatment Plant so as to have the Plant compliance to Zero Discharge. Latest Technology ensures

incorporation of High efficiency Design, Higher fermentation efficiency and Effective heat

integration in distillation and evaporation. The Process Technology adds value to overall plant

engineering by incorporating global standards for Design, on safety norms and adherence to local

design codes. The distillery process runs with Continuous Fermentation.

Fig5. Manufacturing Process of Grain Based Alcohol.

Before the milling quality of the grain is being checked. After the quality check grain is cleaned for

removal of dust, lumps, sand, stone, iron etc. and finally store in Silo.


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Milling: The cleaned grain is sent to milling machines for grinding grain flour (size 400-700μ) is

conveyed to pre-masher for slurry preparation. In pre-masher, flour & required water of ratio 1:2

are mixed by agitator. Uniform grain slurry is made and transferred to another low shear tank

(slurry tank) for proper mixing. In slurry tank required pH of 6.0-6.2 is maintained by using lime if

required and temperature as 550C to 600C. An enzyme called α-amylase is added here in small

(20-25%) dose before the cooking process starts.

Cooking: The grain slurry is pumped to Jet Cooker (Hydro Heater) through open impeller

centrifugal pump. In jet cooker steam is applied at 8 to 10 kg/cm2 pressure to cook the starch

slurry to break down the chemical structure of starch in presence of enzymes. The temperature

of grain slurry at outlet of jet cooker is maintained between 115 to 1200C. After cooking the grain

slurry is passed through the holding coil, which has several ‘U’ bends in series and sufficient

capacity to provide desired retention time at a given flow rate to convert starch into dextrin. In

this step slurry pressure & viscosity reduces. The slurry which is hot is transferred into the flash

tank to reduce the temperature of the slurry to 90- 950C before sending to saccharification tank.

Flash tank is attached to flash condensers where vapours are condensed and condensate is sent

to slurry tank.

Liquefaction: Grain slurry is transferred to liquefaction tank from flash tank where remaining 75

to 80% of enzymes of α-amylase is added which convert starch to dextrin and 1-4 α-glycosidase

linkages are hydrolyzed into amylose and amylo pectin. Enzymatic activity rapidly breakdown the

starch to soluble dextrins and oligosaccharides. To have good conversion of starch to dextrin

retention time should be about 2 hrs.

Saccharification and Fermentation: Many distilleries have Partial Pre-Saccharification tanks for

saccharification process. Whereas conducting saccharification and fermentation together is

another process adopted. The liquefied slurry pumped through Plate Heat Exchanger (PHE) to the

fermenters. The outlet temperature of grain slurry from PHE is 32 to 350C. In fermenters

saccharification & fermentation takes place simultaneously by adding glycol-amylase enzyme and

yeast culture. Fermentation of starch from grain is somewhat more complex than fermentation

of molasses sugars because starch must first be converted to sugar and then to ethanol. Starch is

converted enzymatically to glucose either by diastase presents in sprouting grain or by fungal

amylase.


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The resulting dextrose is fermented to ethanol with the aid of yeast producing CO2 as co-product.

A second co-product of unfermented starch, fiber, protein and ash known as distillers grain (a

high protein cattle feed) is also produced. Glucoamylase hydrolise dextrin into maltose. In this

complete conversion of dextrin takes place and to reduce the viscosity further spent wash after

decanter is mixed to save water. Maltose further breaks into glucose & fructose. Yeast i.e.

Saccharomyces cerevisiae which produce invertase and zymase enzyme convert glucose &

fructose into alcohol. Above both processes takes place in a fermenter. Glucose is converted into

ethyl alcohol and carbon dioxide evolved is let out. The total duration required is 60 to 65 hours

The entire material is sent for distillation and yeast sludge in continuous process is settled at

bottom is mixed with water and used for fresh batch whereas in Batch process the entire yeast

sludge was let out. Due to more fermentation time side by-products i.e. acids & higher alcohols

are high as compared to molasses which affects proper alcoholic fermentation.

The pre fermenters are filled with mash and loaded with contents of the yeast vessel. The

purpose of the aerated pre-fermentation is to allow time for the yeast cells to multiply (01 gram

of dry yeast for 01 litre of Rectified Spirit) and reduce the chances of contamination. When the

pre-fermentor contents are transferred to the main fermenters, the concentration of yeast cells

is high enough to substantially reduce the leg time associated with yeast growth in fermentation

process.

The overall transformation takes place into three steps: Amylase / Gluco-amylase n(C6H10O5) + n(H2O) n(C6H12O6) n(162) n(18) n(180) Invertase C12H22O11 + H2O C6H12O6 + C6H12O6 342 18 180 180 Saccharomyces cerevisiae C6H12O6 2C2H5OH + 2CO2 180 92 88

The speed of this transformation process can be influenced by two elements i.e. temperature and

available quantity & quality of water


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CO2 Scrubbing and recovery

The carbon-di-oxide produced during fermentation from Fermenter I is scrubbed with water in

sieve tray scrubber to recover alcohol from vent gases. The vent gases from Fermenter II mainly

air and carbon dioxide are also scrubbed in sieve tray scrubber for alcohol recovery. The water

from both the scrubber is returned to respective Fermenters. About 1% of the total alcohol

production is saved by scrubbing the Fermenter off gases.

The CO2 produced from fermenters after scrubbing will be bottled to avoid air pollution.

MULTI-PRESSURE DISTILLATION

Multi-Pressure distillation scheme has distillation columns operating under different pressures.

Heat energy from columns operating under high pressure is recycled back to columns operating

under low pressure to conserve energy. The plant can be operated under 2 different modes to

produce RS or ENA as desired.

ENA PLANT DISTILLATION COLUMNS

OPERATIONAL MODE - 1:

WASH TO ENA PLANT

This scheme has total seven distillation columns.

The columns in order of flow are: -

1. Analyzer Cum Degasifying Column – vacuum.

2. Aldehyde Column – vacuum.

3. Pre-rectifier column – vacuum.

4. Pre-rectifier Stripper column – vacuum.

5. Purification Column – atmospheric pressure.

6. Rectification cum exhaust column – pressure

7. FOC (Recovery) Column – atmospheric pressure

8. Simmering Column – atmospheric pressure

Fermented wash is preheated in fermented wash pre –heater. The preheated wash is fed to

analyzer column, to remove light impurities, dissolved gasses etc. Vapor from this column are

passed to the bottom of the pre –rectifier and aldehyde Column. The Spent wash from the

bottom of analyzer column is sent through a PHE to heat the incoming fermented wash and

taken for further treatment or recycle to fermentation section.


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In Pre-rectifier column the alcohol is concentrated and in the top tray and a small impure sprit cut

is taken out. RS draw is taken from few trays below the top of Pre rectifier column, which is sent

to purification column.

Purifier column operates on the principle of inversion of relative volatility. Low boiling impurities

are separated in the purifier column & bottom is sent to rectifier cum exhaust column while the

top vapor draw is fed directly to Fusel oil concentration column. The Rectifier/Exhaust column

concentrates the ethanol to 96% v/v. The high-grade spirit is drawn from one of the upper trays

of the rectification column and fed to the Simmering Column.

Simmering Column removes methanol, di-acetyls from the top and ENA draw is taken from the

bottom. A small head cut is removed from the overhead stream to withdraw impurities. Fusel oil

build up is avoided in the Rectifier cum exhaust column by withdrawing outside streams (fusel

oils).

These are sent to the fusel oil concentration column where these fusel oils are concentrated and

sent to decanter where these streams are diluted with water and fusel oil rich layer is separated.

In this mode, rectifier column drives the analyzer and pre –rectifier column while purifier column

partially meets the heat requirement of simmering column, thus achieving maximum heat

integration and minimum steam consumption.

OPERATIONAL MODE – 2:

WASH TO RECTIFIED SPIRIT PLANT

In this mode, system will consists of three columns:

1. Analyzer Column

2. Pre –rectification Column

3. Pre –rectification Stripper Column

3. Rectification cum Exhaust Column

4. FOC (Recovery) Column

After preheating fermented wash in fermented wash pre-heater, the wash is fed at the top of the

Analyzer column in which alcohol is stripped from the wash. Spent wash is removed from the

bottom of the column. The vapors from uppermost tray Analyzer column are fed directly to the

Pre –rectification column, A top cut is taken out from the Pre –rectification top to remove low

boiling impurities.


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The RS draw from Pre-Rectification is fed to the Rectification cum Exhaust Column. Rectification

cum exhaust column concentrates the ethanol to 94.68 % v/v. The high-grade spirit is drawn from

one of the upper trays of Rectification cum exhaust column.

A small heads cut is removed from the overhead stream to withdraw impurities. The lees from

the column are drained out. Lower side draw streams are taken from Rectification cum Exhaust

column to avoid fusel oil build up. The fusel oils are fed to the fusel oil concentration column. In

this mode rectifier column drives the analyzer and pre –rectifier column. fusel oil concentration

columns are operating stand-alone.

De-Hydration Technology for Fuel Ethanol

Molecular sieve technology works on the principle of pressure swing adsorption. Here water is

removed by adsorbing on surface of `Molecular Sieves’ and then cyclically removing it under

different conditions (steaming).

Molecular sieves are synthetic Zeolite typically 3A Zeolite. Zeolites are synthetic crystalline

Alumino silicates. This material has strong affinity for water. They adsorb the water when heated

(and pressurized) and desorbs the water under vacuum. This principle is used to dehydrate

ethanol. The crystalline structure of Zeolite is complex and gives this material the ability to

adsorb or reject material based on molecular sizes. Water molecule can enter the sieve and be

adsorbed, but larger alcohol molecule will not be retained and will go through the bed. There can

be two beds in parallel. Once a particular bed is saturated with water, the anhydrous alcohol is

re-circulated to remove water from the bed under vacuum. The operation is called regeneration

of bed; so that adsorbed water is desorbed from the bed. Till that time, other bed is used for

dehydration.

DWGS Dryer with Cooling and Conveying System System Description for Dryer

1.Wet distiller’s grains shall be fed into the dryer housing at controlled rate through a suitable

feeding system. The Fluidised Bed Dryer is enclosed in an insulated dryer housing and its outer

flights are fixed. Dry saturated steam is to be supplied to the dryer through rotary joint at one

end & the condensate is discharged through joint mounted on another end.

2. During the course of fluidization, these flights pick up the material and shower them on to the

tube bundles. The heat transfer is primarily by conduction. The water vapors are exhausted

through an Exhaust Blower & passed through a cyclone separator for separating fines.

3.Dry product partially recycled back to Feed conditioner for feed conditioning through Product

Screw & Recycle Conveyor.

4. Entire operation of the Dryer is controlled through Control panel.


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High Speed Mixture

Grains Storage Bin & Ware House

Grain Milling Plant

Slurry Cooking and Conditioning

Husk Fractionation

Husk to Boiler Feed to Boiler

Milled Grains

Liquefaction

Fermentation

M E E (Integrated

System - 1

M E E ( Steam) System - 2

THICK SLOPE CONCENTRATOR

Alcohol Storage

For Cattle Feed/ Fishing/Poultry

Dryer Plant

RIBBON BLENDER

Decanter Separation System

Spent Wash Storage in SS Tank

Distillation

Sacchrifacation

Centrifuge Separation System

Spirit storage Spirit storage would be divided into two sections. One would be daily spirit receiver section and

the other would be bulk storage section. The spirit coming out of distillation would be transferred

to daily spirit receivers (separated for RS/ENA). Subsequently, after gauging, the spirit would be

transferred to respective bulk storage tanks.

Fig: 6 Flow Chart of Grain based Distillery

Recycle To Mixture


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3.0 UTILITIES

3.1 Raw material:

1. The distillery will use grains such as broken rice, maize, bajra, jowar and other starch

containing grains etc. as basic raw material. Besides this, processing chemicals would

be used for the production of ENA/RS/ethyl alcohol.

2. The existing 50KLPD distillery is using 110MT/day of grain as a raw material. After

expansion from 50KLPD to 130KLPD, the raw material requirement would be around

410MT/ day.

3. The required raw material will be procured from the registered vendors. The

declaration of supply of raw material has been enclosed as Annexure-1

3.2 Water Requirement

1. The existing 50KLPD distillery is utilizing 810m3/day ground water for running

the entire plant. The detailed breakup is given below.

Table 6.Existing 50KLPD distillery water usage

S.No Purpose/Use Quantity in KLD

1 Process 500

2 Cooling, DM water, Softner 85

3 Boiler 200

Total Water 800

2. The proposed expansion of 80KLPD distillery will require about 1608 M³/Day as fresh

water for startup. On operation, the daily net water requirement will be 772 M³/Day

which is below the norms of CPCB standards (8-10KL per KL of alcohol production). The

detailed water balance is given below Table.

Table 7. Fresh water Requirement in M3/day for proposed 80KLPD Plant

PARTICULARS INTAKE CONSUMPTION AND LOSSES

GENERATED EFFLUENT

REUSE AND RECYCLE

DAILY NET REQUIREMENT

INDUSTRIAL PROCESS 914 153 761 527 387 COOLING PURPOSE 602 347 255 255 347 DOMESTIC 26 6 20 0 26 OTHER AND GARDENING

12 12 0 0 12

TOTAL 1554 518 1036 782 772


21

Fig 7. Water Balance Chart for Proposed 80KLPD Distillery Plant


22

3.3 Source of Water:

The proposed requirement of 772KLPD water will be supplied by supplied by Chief Municipal

Corporation, Pithampur, Dist.Dhar (M.P) with Ref.no. 6137/N.P/15 dated 04/12/2015. The respective

permit letter has been enclosed in Annexure-5.

3.4 Fuel Requirement

1. The existing 50KLPD distillery is utilizing 90MT/day of coal for its operation with existing

20TPH Boiler.

2. Existing cogeneration capacity of the plant is 1.8MW.

3. The proposed expansion of 80KLPD will need 252MT/day of coal for its operation.

4. The industry has proposed 42TPH Boiler at pressure of 67Kg/cm2

3.5 Co-generation Power Plant GG Ltd. is having existing capacity of 1.8 MW of cogeneration of power based on coal at its

existing premises. During expansion, the industry would add additional cogeneration power plant

of 5.7 MW capacity, thereby making the total capacity of upto 5.77 MW based on coal as fuel.

The cogeneration power plant is divided in three parts, namely;

a. Boiler & Auxiliaries

b. Turbine & Auxiliaries

c. Generator &Auxiliaries

3.6 Boiler & Auxiliaries

Boiler: The industry plans to install additional 42 TPH@67 kg/ cm² pressure capacity fluidized

Bed boiler (FBC) for steam and additional 5.7 MW of cogeneration of power.

The existing 20 TPH boiler would be kept as standby boiler and would be used only in case if 50

KLPD of alcohol production is to be made. FBC boiler is most suitable technology for the biomass

and coal as fuel to be used. When air passes upward at low velocities through a mass of finely

divided solid particles (such as ash & crushed refractory) the particles are not disturbed. As air

flow is gradually increased, the particles become suspended. Further increase in the air flow

gives rise to bubble formation and vigorous turbulence. The bed of solid particles has the same

characteristics of the liquid and thus the bed is termed as Fluidized Bed. Combustion of fuel in

this bed is termed as Fluidised Bed Combustion (FBC). The boiler would be having other

auxiliaries as described below;


23

Drum : The feed input, separation of steam and water & blow down are all carried through the

drum.

Furnace: It is the primary part of boiler where the chemical energy available in the fuel is

converted to thermal energy by combustion. It is the designed for efficient & complete

combustion.

Super Heater: These are meant for raising the steam temperature above the saturation

temperature to a maximum of around 5500 C (due to the metallurgical problem, the percentage

of heat to super heater is approx 30%).

De-Super Heater : To control the super heater temperature & always try to maintain the steam

temperature constant during variation of load, de-super heater is used.

Draft System: The combustion process in a furnace can take place only when it receives a steady

flow of air & has the combustion gases are continuously removed.

Economizer: The economizer absorbs heat from the flue gas mainly as sensible heat to the feed

water. By this, the efficiency of boiler is improved.

Water Wall/Evaporator: Where water converted into steam by latent heat addition. Support: All modern boilers are top support units. The hanger rods are designed for the direct

tensile stress resulting from the weight of units & the bending stress from the pressure part

expansion.

Soot Blower: Deposits result from combustion of husk & relatively smaller extent from oil. Means

have to be provided to prevent an accumulation of deposit from chocking the boiler gas passes &

to maintain boiler heating surface in a suitably clean condition for effective heat transfer whilst

on load. Steam is used for soot blowing.

Air Heater: It is now an essential boiler auxiliary because hot air necessary for rapid & efficient

combustion in the furnace & also for the husk & to recover waste heat from the flue gas to

increase boiler efficiency.

Primary Fluidizing Air Fan: It is used for fluidising the bed of fuel and giving the upward


24

movement.

Forced Draft Fan : To take air from atmosphere at ambient temperature to supply essentially the

combustion air required, in addition to fluidising air.

Induced Draft Fan: To evacuate the gases out of the furnace & exhaust through the stack. The ID

Fan maintains the negative draft inside the furnace.

Ash Collection: The method used for removal of ash from the flue gas consists of mechanical dust

collector & electrostatic precipitator. The mechanical dust collector removes the coarser particles

through cyclones.The ESP consists of three field two types of electrodes. Wires which are charged

at HVDC are called emitting electrodes. The collecting electrodes are in the form of plates, which

are at earth potential.The dust particles in the flue gas get charged while coming in contact with

the emitting electrodes. The charged particles are attracted to the earthed collecting particles

and get discharged and fall down the hopper. Very high efficiency of ash collection upto 99.90%

can be achieved in the ESP

Boiler Feed Pump: It is multistage pump provided for pumping feed water from the deaerator

storage tank to economizer of the boiler. Generally two pumps each of 100% capacity are

provided.

3.7 Turbine & Auxiliaries

Turbine : The turbine shall be horizontal, single cylinder, back pressure design coupled to a

generator to generate the rated output of 5.77 MW of electricity with the steam inlet parameters

as specified in this specifications. The steam turbine, gear box, main oil pump with its interconnecting piping and its supports shall be assembled and aligned on a single skid and

shall be delivered. All the cabling within the skid shall be laid in the metal conduits and shall be

fixed to the base frame with respective junction boxes mounted on the skid. Main component &

associated system of the Turbine are described below;

Casing : It is essentially a pressure vessel, which must be capable of withstanding the working

pressure & temperature of the steam. The casing is supported on each end, with provision to

permit expansion at one end. The fixed blades (Orifice) are supported in the casing.

Rotor : It supports the moving blade. Blades : These are the most important component of turbine as these are responsible for the

converting heat energy to mechanical.

Gland Sealing System : Glands are used on turbine to prevent or reduce the leakage of steam air

between rotating & stationary components which have a pressure difference with the


25

atmosphere. If the cylinder pressure is higher than the atmospheric pressure then there will be a

leakage of steam outward (HP sides). If the cylinder is below atmospheric pressure, then there

will be leakage of air (LP side). Steam is generally used for sealing of labyrinth glands.

LP Heater: The condensate pumped by the condensate pump is heated in the LP heater by steam

extracted from the turbine after it has performed some useful work. This improves the cycle

efficiency.

Deaerator : The presence of certain gases like oxygen, carbon dioxide, & ammonia dissolved in

water is harmful because of their corrosive action on boiler metal parts particularly at elevated

temperatures. The condensate is sprayed inside the deaerator and it is heated by the extraction

steam from the turbine. The airs etc are thus liberated from the condensate. The deaerated

condensate thus comes to the storage tanks, from which the boiler feed pump pumps the

condensate to the boiler.

Turbine Oil System : The high pressure hydraulic oil for turbine control, oil for bearing lubrication

of turbine generator are received from the turbine shaft mounted main oil pump. Start up AC and

emergency DC pumps are provided for start up and maintain bearing oil flow during turbine trip.

Turbine Oil Coolers are provided to cool the bearing oil.

Turbine Governing System : The main purpose of governor is to maintain speed of turbine during

fluctuation of load on the generator by varying steam input to the turbine. The governing system

consists of hydraulically operated Control Valves. It helps to start the turbine from rest to rated

speed and synchronizing with the grid. The load on the generator can be controlled in a pre-

determined manner by the control valves. Emergency stop valve is provided to shut off the steam

supply to the turbine completely in abnormal & emergency situation.

3.8 Generator & its Auxiliaries Generator : The generator shall be of CACW, brush less design with horizontal shaft mounted AC

exciter driven by a steam turbine through reduction gearing and fitted with one PMG on the

extended shaft of alternator. Supplier shall clearly specify the

Excitation arrangement in case PMG is not applicable. The Generator shall be capable of

delivering the maximum output obtainable from the steam turbine under any operating

conditions at 0.8 power factor lag, 11 kv output with a frequency of 50 Hz. Main component &

associated system of the generator are described below;

Stator: The stator houses the armature winding also supports the rotor bearings. The insulation

of the windings is Class “F”, but designed for temp rise for Class “B” insulation.


26

Rotor: The generator rotor is cylindrical in construction and carries the DC field windings. The

field is normally of 2 or 4 pole design.

Generator Bearing: These are the pedestal type of spherical sealing to show self-alignment &

are support on s separate pedestal on suffering sides & turbine side.

Generator Cooling System: The heat loss in the generator windings are dissipated by air

circulated by the rotor mounted fans. This heat should be taken off for safe operation of the

generator. The air is in turn could be generator air coolers, located at four corners. Water is the

cooling medium.

Generator Excitation System: The DC Power supply to the field winding will be given either

through a static excitation system or through shaft mounted brush-less excitation system. The

control system varies the DC Current to change the terminal voltage or reactive power.

Generator Protection: Generator has to protected from faults occurring within generator stator

or rotor & also from external faults/ abnormal operating condition in the grid which effected the

generator. Various devise are used to detect which can give warning alarm or trip the unit

automatically as required.


27

4.0 ENVIRONMENTAL MANAGEMENT AND POLLUTION CONTROL

G G Ltd. are planning to expand its existing grain based distillery project from 50 KLPD to

130 KLPD at their existing premises located at village Sejwaya, Lebad Chowki, Ghatabillod,

District Dhar, Madhya Pradesh. During the operation of the distillery unit, bottling plant and the cogeneration power plant,

environmental pollution would be generated from different sources. The industry would

adopt the latest technologies for the abetment of pollution generated by the production

process.

4.1 Fresh Water Requirements

4.2 Grain Based Distillery Process

The impending water uses and consequent water pollution that would be caused by the

grain based distillery may be because of the following;

a. Process and dilution water

b. Cooling water make-up

c. Washing (Fermenter, floor, etc.)

d. Water treatment plant maintenance

e. Domestic consumption The proposed expansion of 80KLPD distillery will require about 1554 M³/Day as fresh water for

startup. On operation, the daily net water requirement will be 772 M³/Day which is below the

norms of CPCB standards (8-10KL per KL of alcohol production). The detailed water balance is

given Table 3.2 under Fresh water Requirement and water balance chart in Fig 3.1

Gardening/ Green Belt development The treated water of 12m3/day from the Condensate polishing unit will be used for Green

belt development.

Domestic consumption Some of the water will be required for drinking, sanitation, etc. Average daily requirement is

expected to be about 26 m3/day. And losses would be around 6 m3/day. An STP of 25KLD


28

capacity has been proposed for treatment of Domestic wastewater. The detailed layout was

enclosed in Annexure-7

4.3 Effluent Generation

Fig 8 Effluent Treatment Scheme


29

The proposed expansion of the grain based distillery process will result in generation of following

types of effluents from the process operations;

a) Spent Wash from Distillation Process : The project would result in generation of spent wash from the distillation process. Spent wash @ 480 m3/day would be generated for 80

KL/day. The spent wash would be sent to the decanter where wet cake @ 164 MT/day would

be separated and remaining thin slops @ 117 m3/day would be treated in multi-effect

evaporation system.

b) Condensates from Process and MEE : The project would result in generation of process

condensates (spent lees) from the distillation process and multiple effect evaporation condensates. Spent lees @ 185 m3/day would be generated and MEE condensate @ 342 m3/day would be generated from the proposed expansion. Out of the total generation of 520 m3/day of condensates generation, which would be directly reused in the liquification process.

Table 8: The details of effluent generation from each unit are as given below; PARTICULARS INTAKE CONSUMPTIO

N AND LOSSES

GENERATED EFFLUENT

REUSE AND RECYCLE

DAILY NET REQUIREMENT

INDUSTRIAL PROCESS 914 153 761 527 387 COOLING PURPOSE 602 347 255 255 347 DOMESTIC 26 6 20 0 26 OTHER AND GARDENING

12 12 0 0 12

TOTAL 1554 518 1036 782 772


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4.4 Air Pollution Generation

The air pollution will be due to combustion emissions released by the boiler furnace attached

to the proposed 42 TPH boiler. The boiler furnace, AFBC type, will use coal as fuel, with a

maximum consumption of about 8.0 MT/hour. The critical SPM concentration in the flue gas will be less than 150.0 mg/Nm3. Majority of the

particulates (about 60-70%) will have sizes in the range of 2-10 µm. The emissions are

expected to have temperature in the range of 140-150°C. As per the statutory norms (as applicable to the industry), the flue gas emission shall not have SPM levels (in the stack) exceeding 50 mg/Nm3. Additionally, the stack height requirements

for discharge of emissions will need to be complied with. DG sets : The industrial unit is planning to have one DG set of 500 kVA as backup to state

power supply. As per the applicable norms, the DG sets will be housed in an acoustic

chamber. The combustion emission outlet, of the DG set, will be provided with a muffler along

with a minimum stack height of 6.5 m above the height of nearest building.

4.5 Solid Wastes Generation The grain based fermentation will result in high protein solids at a rate of 166 MT/day

@15% moisture from each of the unit. It has potential to be used for cattle feed

making.

4.6 Hazardous Waste Generation

The plant facility will result in generation of about 1 kL/year of spent oils (lubricants and

transformer oil), which will be stored on site and used as lubrication for pumps and other

machinery.

4.7 Wastewater Treatment System The industry would install multiple effect evaporators for the treatment of spent wash

generated from the proposed expansion unit. Whole of the spent wash after decantation

would be sent to the MEE for concentration of solids. The details of the MEE for spent wash

are as given below;


31

4.8.1 Multiple Effect Evaporation Falling Film Evaporation (Stage –I) The spent wash from analyzer column would be first taken into a feed tank and then fed to the

falling film evaporation system through pre-heater in 1st effect in mixed feed mode and it flows

from first to second and second to third effect.

The concentrated syrup with 13.5 % w/w total solids is taken out from the third effect. The

analyzer vapours are fed to the first effect on shell side.

Vapours generated in the first effect are used as a heating medium in the second effect &

vapours generated in the second effect are used in the third effect.

The spent wash feed would be concentrated from the initial concentration of 6 %w/w to 13.5

% w/w as it travels through the three-stage evaporation. The vapours evolved from the final

effect are condensed in surface condensers. Each effect is provided with re-circulation pump.

The condensate from third effect and surface condensers condensate is collected in a

condensate tank. The condensate is transferred for further treatment using a centrifugal

pump.

The system operates under vacuum. Water-ring vacuum pumps would be used to maintain

desired vacuum in the last effect. The last effect is at lowest temperature.

Cooling water from cooling tower would be used in the condensers for condensing the vapors.

Total cooling water recirculation requirements would be 1925 m3/hour for the stage I.

4.9 Falling Film Evaporation (Stage –II) The suggested treatment scheme is a FOUR EFFECT Evaporation Plant for spent wash

evaporation. The following points will elucidate the basic working principle:

Shell & Tube type evaporators with highly efficient liquid distribution working on the


32

principle of Falling Film Evaporation and Forced Circulation would be used. Shell &

Tube type pre-heaters for pre-heating of FEED stream would be used which would

serve the purpose of energy conservation.

Steam would be fed to the first effect evaporator on shell side at the given pressure

and temperature as the heating medium.

The feed from the feed balance tank would be taken to the PHE-1 to make the best

heat recovery.

The feed after getting heated to the predetermined temperature in pre-heaters

would be fed from the top of the second effect evaporator which is Falling Film

Evaporator -2.

Then the feed from the second effect would be given to third effect evaporator and

follows the flow path.

Vapors generated in 1st effect VLS (Vapor Liquid Separator) would be used as heat source in the 2nd effect.

Vapors generated in the 2nd effect VLS would be subsequently used as heat source for

3rd effect.

Vapors from 3rd effect would be used on shell side of 4th effect and finally Vapors from 4th effect would be condensed on shell side of surface condenser of the evaporator.

The product from the final effect at the desired concentration of 45 % w/w total

solids is obtained.

A shell & tube type multi-pass surface condenser is employed for condensing the shell

side vapors.

The condensates are collected in receiving vessels and are sent for treatment before

its reuse for makeup water in cooling towers.

Highly efficient operating pumps would be provided for pumping the required fluid.

The operation of the plant would be under vacuum. Vacuum would be created with

the help of a water ring vacuum pump.

The plant would be having high level of automation to get consistent output at


33

required concentration Cooling water from cooling tower would be used in the

surface condensers for condensing the vapors in stage II falling film evaporation. Total

quantity of cooling water recirculation requirements would be around 350 m3/hour.

5.0 Treatment of Effluent from Different Streams

Polishing Unit for Condensate, spent lees and other minor distillery effluents

Wastewater sources such as spent lees, steam condensate and blow-down water will be treated

through polishing unit. Treated water will be reused for cooling tower make-up water, water for

the gardening/irrigation activity. Steam condensate will be recycled back as a boiler feed water.

Thus, the industry is determined to put its sincere efforts for the recycle/reuse of water.

The industry would be generating around 1036 m3/day of effluent from different streams from

the proposed 80 KLPD distillery expansion. The effluent would be having organic impurities

which need to be treated before its disposal on land for irrigation purposes. Around 782

m3/day will be recycled and reused for industrial process, Green belt development. The spent

wash formation will be less than 6KL/KL of alcohol production. The overall effluent generation

after expansion from the distillery unit would be less than 10 m3/day. The industry would do

make the necessary changes in the mechanical equipment of the ETP and no civil work would

be required for the same. The detailed drawings of the existing ETP are attached in

Annexure-6


34

5.1 Air pollution control system The air pollution control system, for the combustion emissions from boiler furnace,

will comprise of;

a) Ducting arrangement to transport emissions to the APCD,

b) an APCD – electro-static precipitator

c) an ID fan, and d) a stack to discharge the cleaned flue gas at adequate height.

The boiler furnace emissions will be conveyed into the APCD, the electro-static precipitator (ESP),

where it will get cleaned (removal of SPM) before being discharged into the atmosphere, through

a stack of adequate height.

Electro-static precipitator

1. Design gas flow rate – 97200 m3/hour 2. Temperature – 170ºC

3. Maximum inlet dust load – 56 g/Nm3

4. Outlet emission dust load – <50 mg/Nm3

5. Plate area – 3075 m2

6. Specific collection area – 113.90 m2/m3s

7. Velocity through ESP – 0.48 m/s

8. Treatment time – ~23.1 s

9. Migration velocity – ~6.16 cm/s

10. Number of fields – 3

11. Efficiency – > 99.54% Collection electrode specifications;


35

1. Height of Panel – 10.67 meters 2. Material – CRCA sheet 1.2mm 3 Total no. of plates 378 4. Width of panel – 400 mm

5 Thickness – 18 SWG

Emitting (discharge) electrode specifications;

Height of panel 10.67 meters Electrical specifications; 1. TR sets – 3 nos. 2. TR control type – Microprocessor controlled 3. Nos. per field – 1 4. TR rating Output voltage – 111 kV DC Output current – 200 to 300 mA Rapping system specifications

1. Type – Electromech impulse gravity impactor

2. Total no. of rapper per unit – 40 nvs. 3. Rapper impact force (max.) – 0-20 ft. lb. (adjustable) Design pressure 1 Maximum – ± 300 mm WG

2. Maximum pressure drop – flange to flange – 20-25 mm WG

Power consumption

• Maximum 50 kW – this includes corona (without losses), rapper, PA

system, insulator heaters, Hopper heaters, RAVs.

• Power consumption is at steady state for the rated inlet parameters in

the basis of design. The flue gas cleaning system will achieve SPM removal efficiency of more than 99.91%, resulting in emission discharge with SPM concentration of less than 50 mg/Nm3.

Total height- 54 m rate & fuel consumption @ 8.75ton/hr

Bottom dia- 5m

Top dia- 1.8 m


36

5.2 Ash management

The air pollution control system, for the new boiler furnace, will comprise of;

a) Ash vessels (5 cold ports and 4 hot ports)

b) Conveying pipes

c) Ash silo – 80 tons capacity.

d) Ash storage

e) Ash disposal

This ash handling will be totally enclosed system. The ash handling system shall be designed

to take care of 100% fuel burning. Ash collected from the bottom of furnace (bottom ash)

and the ash collected in the air heater hoppers and ESP (air pollution control system) hoppers

will be taken to an ash silo through a pneumatic conveying system. Ash silo will have the

capacity of storage for 1 day of ash. The ash from the silo will be unloaded through the ash

conditioner and stored on land. This ash will be finally used by brick manufactures; they

utilize heat value in their brick kiln.


37

6.0 PROJECT COST ESTIMATES Table 10. ESTIMATED OVERALL PROJECT INVESTMENT

S. No. Particulars Cost (Rs. In Lakhs) 1. Cooling Tower – Plant & Mill 115 2. Silo 116 3. Grain Mill 41 4. Pet Bottle Plant 1142 5. R O Plant (2) 200 6. Drier 325 7. Turbine 454 8. Boiler + ESP+ COAL HANDLING + ASH HANDLING +STACK 1140 9. Drier 2 With Storage 285 10. Sprit Storage Tanks 175 11. 80 KPLD Distillation Plant, MEE, FERM 1100 12. Condensate Polishing Unit (CPU) 46

13. Budget for Environment Management Plan + other services 255

Total 5394

6.1 BUDGET ALLOCATION FOR EMP:

Table 11. EMP Budget

Sr. No. Particulars Capital cost Annual recurring cost Rupees in lacs.

1. ESP+ Coal Handling + Ash Handling + Stack 540 55

2. MEE 200 25

3. Condensate Polishing Unit (CPU) 46 5 4. Sewage treatment plant 12 4 5. Monitoring of pollution parameters -- 7 6. Laboratory and chemicals 5 4 7. Safety and healthcare 3 1 8. Salary of EMP staff -- 36 9. Development of green belt 12 5

Total 818 142


38

6.2 REHABILITATION AND RESETTLEMENT:

Rehabilitation or resettlement will not be required in case of proposed project as the site is

within the existing distillery premises with no human settlement.

6.3. Project Benefits

Any industrial activity will help in improving the socio-economic benefits like employment,

communication, education etc.

Dispersion of particulate emission will be done by Electrostatic Precipitator with 99.8%

efficiency.

Stack height of chimney will be taken care as per the CPCB standards for effective

dispersion of Sox.

PP has initiated a zero discharge system for spent wash by Multiple Effective Evaporator

followed by condensate polishing unit.

Raw material (Grain) will be sufficiently available from the local suppliers for continuous

operation of the plant.

Project Proponent is going to install 5.77MW cogen plant for uninterrupted power supply.

Self dependent for power requirement.

Rain water harvesting, recycling of water, etc in the project areas reduce the demand of

fresh water

The easy availability of infrastructure, man power, raw materials will reduce the

production cost as well as demand supply gap. The same will bring revenue to the state

exchequer by way of Duties and Taxes.

The existing distillery plant has huge space with wide development of green belt in and

around the plant premises which will improve on the aesthetics of the area.

Moreover, it will help in reducing the noise levels within the plant boundary.

The setting up of the proposed plant will help in providing employment to local people.

There will be an increase in indirect employment and earnings of the small time shop

owners like tea vendors, transporters, etc.

The implementation of Rain Water Harvesting Scheme will help in increasing the ground

water level of the area.


39

6.4 Employment Potential

Great Galleon Ltd is already having a full-fledged man power of 260 no’s both skilled, semi skilled

employees. There is an additional employment of 73 more will be expected to generate on

commencement of this expansion activity. The detailed breakup has been given below.

Table 12: Manpower Requirement

Employment Description No. of Employees Existing 50KLPD Distillery

plant (as on date 20.10.2015)

Proposed Distillery

High Skilled 67 26 Skilled 22 7 Semi Skilled 154 22 Unskilled Workers 17 18 Total 260 73

The Project proponent has planned to contribute in socio-economic development of the area and

will organize Health awareness campaigns, regular health checkup for the employees, Education

Programmes etc. and will continue to do so.

6.5 Corporate Social Responsibility

Corporate social responsibility is the commitment of businesses to contribute to sustainable

economic development by working with the employees, their families, local community and

society at large to improve their lives in ways that are good for business as well as overall

development. It is a voluntary activity of a company that supports social interests and

environmental issues. It is a principle through which the business houses contribute to the welfare

of the society and not only maximize their profits. CSR, in fact, is about business giving back to the

society.

Great Galleon Ltd has invested an amount of Rs.14, 84,324.00 (Fourteen Lacs Eight Four Thousand

Three Twenty Four only) during the financial year 01.04.2014 to 31.03.2015. Further to that the

industry is planning to develop nearby villages under CSR activity in the nearby villages.


40

Following activities are planned

Provision of safe drinking water within the premises of factory.

Women Empowerment through training and financial support.

Infrastructural support by providing classrooms, extension of school / college building.

Supporting Primary Health Centers by up-gradation of existing building, providing new

building and medical facilities etc.

Agriculture Development Program by advising use of fertilizer and pesticides.


41

Annexure-1

.

GRAIN SUPPLY AGREEMENT


42


43

Annexure-2

COAL SUPPLY AGREEMENT


44


45


46

Annexure-3

NOC FROM GRAM PANCHAYAT


47

Annexure-4

LAYOUT OF FIRE HYDRANT SYSTEM


48

Annexure-5

Water Supply Permission Letter


49

Annexure-6

Proposed ETP Layout (75KLPD capacity)


50

Annexure-7

Proposed STP Layout (25KLPD capacity)

Documents

EXPANSION OF GRAIN BASED DISTILLERY PLANT FROM 50 …environmentclearance.nic.in/writereaddata/Online/TOR/0_0_09_Dec_2… · 5 Manufacturing Process of Grain Based Alcohol 13