PRE FEASIBILITY PROJECT REPORT - …environmentclearance.nic.in/writereaddata/Online/TOR/15_Apr_2016... · Pre-Feasibility Project Report ... such as CO2, Fusel Oil, DDGS, Corn Oil

PRE FEASIBILITY PROJECT REPORT

for

EXPANSION OF EXISTING GRAIN BASED DISTILLERY PLANT FROM 125 KLPD TO 200 KLPD AND COGENERATION POWER PLANT FROM 3.65 MW TO 9.00 MW at A-2, A-3 AND A44, INDUSTRIAL GROWTH CENTER, VILLAGE RANIPUR, DEFENCE ROAD, TEHSIL AND DISTRICT PATHANKOT, PUNJAB By PIONEER INDUSTRIES LTD.

Pioneer Industries Ltd.

Pre-Feasibility Project Report – Expansion of Grain Based Distillery Unit from 125 to 200 KLPD and Cogeneration of Power from 3.65 to 9.0 MW 1

SUMMARY 1.0 Pioneer Industries Ltd. is a company registered under Indian Companies Act, 1956 having its

registered office at A-2, A-3 and A-4, Industrial Growth Center, Village Ranipur, Defence Road, Tehsil and District Pathankot, Punjab.

2.0 The company is planning to expand its existing grain based distillery plant from 125 KLPD to 200 KLPD and cogeneration power plant from 3.65 MW to 9.00 MW alongwith around 5000 cases/day of IMFL/PML bottling unit at their existing location at A-2, A-3 and A-4, Industrial Growth Center, Village Ranipur, Defence Road, Tehsil and District Pathankot, Punjab.

3.0 Pathankot is in the northwestern region of India and is a part of the Indo-Gangetic alluvial plains. The exact co-ordinates of Pathankot are latitude 32° 08' 56.0" N (southern limit) to 32° 30' 46.1" N (northern limit) and longitude 75° 20' 34.8" E (western limit) to 75° 37' 11.0" E (eastern limit). It has an average elevation from 300 to 900 meters. Situated in the picturesque foothills of Kangra and Dalhousie, with the river Ravi flowing close by, the city is often used as a rest-stop before heading into the mountains of Jammu and Kashmir, Dalhousie, Chamba, Kangra, Dharamshala, Mcleodganj, Jwalaji, Chintpurni and deep into the Himalayas. Average annual rainfall is in a range of 1600 mm. Total Geographical area of the district is 929 sq. kms.

4.0 The promoters of the project are already having 33 acres of land at A-2, A-3 and A-4, Industrial Growth Center, Village Ranipur, Defence Road, Tehsil and District Pathankot, Punjab. The benefits of the location are as below;

Required raw material is abundantly available in the nearby adjoining area. Raw materials can also be easily procured from grain surplus nearby states such as

Haryana, Rajasthan Good availability of ground water Well connected by road/rail network Proximity to spirit and ethanol consuming market Manpower available for industrial purposes

5.0 The grain based distillery process will have process steps namely - grains receiving, unloading, cleaning and storage, grains milling, slurry preparation/liquefaction, saccharification and instantaneous fermentation, fermentation, multi-pressure distillation, decantation, multi-effect evaporation, spirit storage & DDGS Dryer etc.

6.0 The industry would install 6.0 MW back pressure/extraction cum condensing turbine for the cogeneration power plant. The industry plans to install a 45 TPH capacity fluidized bed boiler

http://en.wikipedia.org/wiki/Indo-Gangetic_Plain

http://en.wikipedia.org/wiki/Indo-Gangetic_Plain



(FBC) for the production of 6.0 MW of cogeneration of power with steam. Biomass/Coal/Petcoke would be used as fuel for the boiler furnace.

7. 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. The daily fuel (biomass/coal/petcoke) requirements for the 45 TPH boiler furnace of the cogeneration power plant would be around 10 MT/hour or 240 MT/day.

9. Besides the main products as mentioned before, the company would also produce byproducts such as CO2, Fusel Oil, DDGS, Corn Oil (in case of maize used as raw material).

10. Fresh water requirements for the expansion project of the industry would be around 720 m3/day and total requirements would be around 1850 m3/day. This includes water requirements for grain based distillery operations, bottling requirements and boiler requirements. Cereal based products unit is excluded from this.

11. After the operation of the expansion project, waste water in the form of thin slope (930 m3/day), spent lees (250 m3/day), MEE condensate (800 m3/day) would be generated. Besides this, misc. effluent such as floor/fermenter washing effluent @ 25 m3/day, cooling towers blow down @ 50 m3/day, domestic effluent @ 18 m3/day, D.M. plant reject @ 50 m3/day and boiler blowdown @ 50 m3/day would also be generated.

12. The industry would install multiple effect evaporators for the treatment of spent wash thereby making the project as ZERO EFFLUENT DISCHARGE INDUSTRY. The spent less and MEE condensate would be reused in the process. The other misc. streams effluent after treatment would be used on land for irrigation purposes.

13. The estimated cost of expansion project for 75 KLPD distillery project, 5000 cases of bottling of country liquor/IMFL and cogeneration of 6.0 MW of power would be around Rs. 47.00 Crores. The cost does not include the land cost.



CHAPTER – 1

INTRODUCTION

Pioneer Industries Limited was incorporated in the year 1997, under the Companies Act 1956, with the objective of promoting agricultural activities and development of agro based industries at Pathankot (Punjab). Pioneer Industries Limited is a young and vibrant organization engaged in the manufacture and export of variety of cereals based products. Some of our products include Vital Wheat Gluten, Potable Alcohol, Maltodextrin Powder, Hydrolyzed Wheat Gluten, Liquid Glucose & High Maltose Syrup. Within a very short span of time, the Company has won accolades in markets due to our quality products. Introducing an eco-friendly production and distribution system in the manufacturing process, today PIL is the only company in India and the South Asian region that has a forward and backward integrated distillery plant.

i) Shri Rajinder Mittal, Chairman of the company, is a renowned industrialist and seasoned businessman in North India. He has been in the line of edible oils business from the last 30 years. He has ample experience in the business of edible oil and grain based distilleries. The most recent achievement has been the setup of a distillery plant at Pathankot and Bhathinda.

ii) Mr. Jagat Mohan Aggarwal, Managing Director is a man of few words; he has brought

innovative thinking to the execution level and raised the bar of achievement to newer heights. Armed with graduation in commerce, he did a Flour Milling and Flour Technology course from Central Food & Technology Research Centre, Mysore and City & Guild, London. He possesses more than 25 years of experience in agro-based industries. As a forward thinking industrial entrepreneur, he firmly believes in expansion of industries using latest technology to produce high quality products to match international standards and compete in global market.

(iii) Mr. Ajay Goel, Joint Managing Director, joined his family business of trading of food grains and

oil supplies to defense. In 1993, he joined the team to promote Pioneer Agro Extracts Limited. He has been associated with Pioneer Industries Limited since its inception. Presently, he oversees the sales and marketing function of the group. With his vision he has helped the Company to create a niche for its products in the market.

Besides this, the company has two more regular directors namely (1) Mr. Krishan Bansal and (2) Mr. Pawan Sharma.



Based on the past experience, the company is now planning to expand its existing grain based distillery capacity from 125 KLPD to 200 KLPD by setting up another unit of 75 KLPD within the existing premises located at plot no. A-2, A-3 and A-4, Industrial Growth Center, Village Ranipur, Defence Road, Tehsil and District Pathankot, Punjab. The industry would also generate the additional power of 6.0 MW, thereby creating a total cogeneration power capacity of 9.0 MW. The proposed project shall be catering to the demand of Punjab State and neighboring States where-in almost all liquor companies like Pernod Ricard, Jagatjit, ABD, Radico, USL/Diageo and many others are manufacturing their reputed IMFL brands. Also, the demand of Ethanol is growing every year @ 10% to 12% average the government has made it mandatory for blending of minimum 10 % Ethanol in Petrol. The implementation of the project shall be within 2 years from the date of receipt of Environmental Clearance from MoEF. About the Existing Project: Pioneer Industries Ltd. is operating the industry as two distinct units within the same premises. Unit 1 is producing cereal based products such as Wheat Gluten, Potable Alcohol, Maltodextrin Powder, Hydrolyzed Wheat Gluten, Liquid Glucose & High Maltose Syrup etc. Unit 2 is producing potable alcohol, cogeneration of power, DDGS, CO2, IMFL and country liquor etc. The industry has made common utilities such as steam requirements, cooling water requirements, power requirements, ETP etc. for both the units. Unit wise capacity of existing products is depicted below;

Unit Products Existing Capacity (MT/day)

Cereal based products Starch/Grain Slurry Gluten Pentasones Liquid Glucose MDP

96

13.5 10.8

50 45

Distillery unit

ENA/RS/Impure Spirit, Country Spirit, Denatured Spirit/ Fuel Ethanol DDGS CO2 Cogeneration of Power IMFL/Country Liquor Fusel Oil

125 (KL)

50 80 3

90 (KL) 1.5 (KL)



CHAPTER – 2

PROJECT LOCATION

Pioneer Industries Ltd. are planning to expand its existing grain based distillery unit from 125 KLPD to 200 KLPD and cogeneration of power from 3.65 MW to 9.0 MW by setting up another unit of 75 KLPD grain based distillery unit and cogeneration of 6.0 MW of power within the existing premises located at plot no. A-2, A-3 and A-4, Industrial Growth Center, Village Ranipur, Defence Road, Tehsil and District Pathankot, Punjab. The company already has adequate land at the said location for the proposed expansion project. 2.1 About the State: Punjab is a state in the northwest of the Republic of India, forming part of the

larger Punjab region. The state is bordered by the Indian states of Himachal Pradesh to the east, Haryana to the south and southeast, Rajasthan to the southwest, and the Pakistani province of Punjab to the west. To the north it is bounded by the Indian state of Jammu and Kashmir. The state capital is located in Chandigarh, a Union Territory and also the capital of the neighboring state of Haryana.

Agriculture is the largest industry in Punjab. It is the largest single producer of wheat in India. Other major industries include the manufacturing of scientific instruments, agricultural goods, electrical goods, financial services, textiles, machine tools, sewing machines, sports goods, starch, tourism, fertilisers, bicycles, garments, and the processing of pine oil and sugar. Punjab also has the largest number of steel rolling mill plants in India, which are located in Steel Town Mandi Gobindgarh, District Fatehgarh Sahib.

http://en.wikipedia.org/wiki/States_and_union_territories_of_India

http://en.wikipedia.org/wiki/Republic_of_India

http://en.wikipedia.org/wiki/Punjab_region

http://en.wikipedia.org/wiki/Himachal_Pradesh

http://en.wikipedia.org/wiki/Haryana

http://en.wikipedia.org/wiki/Rajasthan

http://en.wikipedia.org/wiki/Punjab,_Pakistan

http://en.wikipedia.org/wiki/Jammu_and_Kashmir

http://en.wikipedia.org/wiki/Jammu_and_Kashmir

http://en.wikipedia.org/wiki/Chandigarh

http://en.wikipedia.org/wiki/Union_Territory

http://en.wikipedia.org/wiki/Haryana

http://en.wikipedia.org/wiki/Agriculture

http://en.wikipedia.org/wiki/Scientific_instruments

http://en.wikipedia.org/wiki/Financial_services

http://en.wikipedia.org/wiki/Textiles

http://en.wikipedia.org/wiki/Sewing_machines

http://en.wikipedia.org/wiki/Starch

http://en.wikipedia.org/wiki/Tourism

http://en.wikipedia.org/wiki/Fertilisers

http://en.wikipedia.org/wiki/Bicycles

http://en.wikipedia.org/wiki/Garments

http://en.wikipedia.org/wiki/Pine_oil

http://en.wikipedia.org/wiki/Sugar

http://en.wikipedia.org/wiki/Rolling

http://en.wikipedia.org/wiki/Mandi_Gobindgarh

http://en.wikipedia.org/wiki/Fatehgarh_Sahib



2.2 ABOUT THE DISTRICT

Pathankot, a newly formed district carved out of Gurdaspur district, was officially declared as district on 27 July, 2011 by Government of Punjab. In past, it was a tehsil of the District Gurdaspur in Punjab. It is a small district at latitude 32° 08' 56.0" N (southern limit) to 32° 30' 46.1" N (northern limit) and longitude 75° 20' 34.8" E (western limit) to 75° 37' 11.0" E (eastern limit). It is a meeting point of the three northern states Punjab, Himachal Pradesh and Jammu and Kashmir. Due to its ideal location, Pathankot serves as a travel hub for the three northerly states. It is the last city in Punjab on the national highway that connects Jammu and Kashmir with the rest of India. Situated in the picturesque foothills of Kangra and Dalhousie, with the river Ravi flowing close by, the city is often used as a rest-stop before heading into the mountains of Jammu and Kashmir, Dalhousie, Chamba, Kangra, Dharamshala, Mcleodganj, Jwalaji, Chintpurni and deep into the Himalayas. Pathankot also serves as education hub for the nearby areas of Jammu & Kshmir and Himachal. Many students basically from rural areas of these states come to study here. Total area of the district is 929 Sq. Km.

2.2.1 Location: The Pathankot district is the northern most district of Punjab state. It falls in the

Jalandhar division and is sandwiched between river Ravi and Beas. It shares common boundaries with Kathua district of Jammu and Kashmir state in the north, Chamba and Kangra districts of Himachal Pradesh in the north-east, Hoshiarpur district in the south-east, Kapurthala district in the south, Gurdaspur district in the south west and Pakistan in the North West. Pathankot has an average elevation of 332 metres (1,089 ft). It is a green town with the Ravi



and Chakki rivers on either side. Shiwalik foothills kissing on the south and east and snow capped Himalayas in the back drop in north, Pathankot is last but not the least city of Punjab.

2.2.1 Topography : There are two tehsils in newly carved district i.e. Pathankot itself & Dhar kalan which is around 30 km from district Headquarters. The landscape of the Pathankot district has varied topography comprising the hilly tract, undulating plan, the flood plains of the Ravi and the Beas and the up land plain. The hilly tract covering the north-eastern parts of Pathankot and Dhar tehsils have typical land topography, ranging in elevation from about 381 to 930 meter above sea level. From north to south the tract consists of three small ranges running in north west to south east direction – The Siali Dhar-Dangahri Dhar range the Dhaula Dhar-Nag Dhar range and the Rata Dhar range. The Siali Dhar-Dangahri Dhar range lies to the extreme north. In its western part Siali Dhar is about 931 metres above sea level at its highest point and in the eastern part about 959 metres. This range is highly dissected by numerous streams. South of this is situated the Dhaul Dhar-Nag Dhar which is about 13 km long and at places about 2.5 km. wide and has an elevation varying from about 610 to 844 metres above sea level. The Rata Dhar is marking the boundary between the hilly tract at the dissected undulating plain having and elevation of about 665 metres above sea level. To its south lies an area of about 128 sq. kms which is highly dissected and is an undulating plain. Its elevation ranges from about 305 to 381 meters above sea level. It is traversed by a number of choas and has an undulating topography. The flood plains of the Ravi and the Beas are separated from the up land plain by sharp river cut bluffs. They are low lying, with slightly uneven topography. Sand dominates in the soil structure of the flood plains, but it diminishes in both quantity and coarseness in the upland plain.

2.2.2 Physiographics: The district has 2 sub-divisions, 6 Blocks, 2 Municipal Councils/Corporations

and 421 Villages. The total land area of the district is 929 Sq. Km.

2.2.3 Rainfall and Climate: During monsoon (from mid-June to mid-September), Pathankot receives moderate to heavy rainfall and sometimes heavy to very heavy rainfall (generally during the month of August or September). Usually, the rain bearing monsoon winds blow from south-west/ south-east. Mostly, the city receives heavy rain from south (which is mainly a persistent rain) but it generally receives most of its rain during monsoon either from North-west or North-east. Maximum amount of rain received by the city of Pathankot during monsoon season is 195.5 mm in a single day and annual average rainfall of the area is 1600 mm.



2.2.4 Temperature and Humidity: Because of the sub-tropical latitudinal nature of the Punjab state, temperature varies considerably from month to month. Though the minimum air temperature rarely drops below 0ºC, at times, it can go down to -2 to -3ºC. Ground frost is a common phenomenon during mid-winter. The rise in temperature is gradual when the air has high moisture content with the sky remaining overcast; the rise is however steep when the sky is clear and there is less moisture content in the air. The maximum air temperature goes up to 42ºC. In the district, annual minimum and maximum temperature range (of extreme variation) is 1-42ºC.

2.2.5 Soil and Land Classification: Pathankot district has varied topography comprising the hilly tract, undulating plan, the flood plains of the Ravi and the Beas and the up land plain. The total land area in the district is 929 Sq. Km. Out of which 270 Sq. Km. comes under forest cover. 480 Sq. Km. area is the net irrigated area of the district. The soil is fertile and the major crops grown in the districts are Wheat, Rice and Maize.

PATHANKOT DISTRICT AT A GLANCE

S. NO. Parameter 1. Total Geographical Area of the district 929 sq. km.

2. Area under Forests 270 sq. km. (29 %)

3. Net Sown area 480 sq. km.

4. Area sown more than once 455 sq. km.

4. Total population of the district 6,76,598

5. Sex ratio (female : male) 869 : 1000

6. Literacy Rate 84.6 %

Male Literacy Rate 89.2%

Female Literacy Rate 79.3%

7. Administrative setup

Number of Sub-Division 2

Number of Municipality 2

Number of N.A.C. 0

Number of Blocks 6

Number of Police Station 9

Number of Gram Panchayat 407



Total Number of villages 421

8. Total cropped area 910 Sq. Km.

Area under wheat cultivation 420 Sq. Km.

Area under Rice cultivation 290 Sq. Km

Area under Maize cultivation 90 Sq. Km

9. Crops production (MT/annum)

Paddy 78

Wheat 167

Other Cereals 28

Rapseed and Mustard 1.3

10. Medical Facilities

Total Hospitals 2

Primary Health centers 9

Dispensaries 27

Total Beds in Medical Institutions 427

Beds per Lakh of population 63

11. Educational Profile

Primary Schools 421

Middle Schools 183

Higher Senior Secondary Schools 204

Arts and Science College 5

12. Workers Profile

Total workers 216884

Main Workers 180241

Marginal Workers 36643

13. Miscellaneous

Total Metalled Road 1637 Kms.

Total Post Office 72

2.3 SELECTION OF SITE The basic criteria for the selection of site for the grain based distillery project are as below;

Raw material availability Raw material cost



Transportation cost Accessibility to markets within and nearby states Availability of water Availability of land in abundance Connectivity of road/rail network. Market for final Product

Based on the above assumptions, following states are fit for the installation of the grain based distillery projects; • Punjab • Haryana • Odisha • Jharkhand • Chhattisgarh • West Bengal

Advantages of the location at plot no. A-2, A-3 and A-4, Industrial Growth Center, Village Ranipur, Defence Road, Tehsil and District Pathankot, (Punjab) for the expansion of existing grain based distillery project from 125 KLPD to 200 KLPD and having 9.0 MW cogeneration power plant are as below; The promoters of the project are already having 33 acres of land at the site. The site is located within the notified industrial area of the Pathankot District. The promoters of the project are complying all the conditions of Environmental Clearance and

Consent to Operate issued by Punjab Pollution Control Board. Required raw material is abundantly available in the nearby adjoining area. Raw materials can also be easily procured from grain surplus nearby states such as Rajasthan,

Haryana etc. Good availability of ground water Well connected by road/rail network Manpower available for industrial purposes



CHAPTER – 3

PROCESS DESCRIPTION

3.0 Pioneer Industries Ltd. are planning to expand its existing grain based distillery unit from 125 KLPD to 200 KLPD and cogeneration of power from 3.65 MW to 9.0 MW by setting up another unit of 75 KLPD grain based distillery unit and cogeneration of 6.0 MW of power within the existing premises located at plot no. A-2, A-3 and A-4, Industrial Growth Center, Village Ranipur, Defence Road, Tehsil and District Pathankot, Punjab.

3.1 Grain based Distillery Process/Operations

The grain based distillery process will have following steps/operations. Similar process steps would be followed in both the phases. Accordingly, common process steps/operations for both the phases of the distillery project are described below;

a) Grains receiving and storage b) Grains handling and milling c) Slurry preparation/liquefaction d) Saccharification and instantaneous fermentation e) Fermentation f) Multi-pressure distillation g) Decantation h) Multi-effect evaporation i) Spirit storage j) DDGS Production Figure 1 shows the schematic flow diagram of the process operations.

3.1.1 Grain receiving and storage

Grains such as broken rice, rotten wheat, maize, bajra and other edible grains are procured from various sources, and are stored in silos.

3.1.2 Grain handling and milling

The grain would be lifted in bucket elevators, screened followed by removal of stones and iron matter. Cleaned grains would then be milled using dry milling process in hammer mills. The flour would be fed through the bucket elevators and conveyed to the load cell through a belt conveyor. The flour addition would be metered through the load cell arrangement,



before transferring the flour to the slurry tank through another screw conveyor (pre-masher) for slurry preparation process.

3.1.3 Slurry preparation

Feed stock flour is transferred to premasher and mixed with recycled streams & liquefying enzymes; slurry from premasher is taken in a tank and transferred to Initial Liquefaction tank.

3.1.4 Liquefaction

In liquefaction process, starch is hydrolyzed to dextrin. The Liquefaction is carried out in Double stage Liquefaction Tank. Slurry from premasher is taken to Initial Liquefaction tank where temperature is maintained by means of steam. Slurry pH is maintained by supplying dilute liquid ammonia. Contents in Slurry Tank are kept in suspension by Agitation. The slurry is cooked by hydrothermal Jet Cooker at required temperature & pressure the store in a Liquefaction tank. Necessary retention time is maintained in Liquefaction tank after adding the liquefying enzyme. The Liquefied Slurry is then cooled in Slurry Cooler using cooling water supply and transferred to Pre-fermentation and Fermentation section.

3.1.5 Saccharification and instantaneous fermentation

Yeast seed material is prepared in Prefermentor by inoculating sterilized mash with yeast. Optimum temperature is maintained by circulating cooling water. The contents of the Prefermentor are then transferred to Fermenter. The purpose of Fermentation is to convert the fermentable substrate into alcohol. To prepare the mash for Fermentation. Yeast & gluco amylases enzyme are added in sufficient quantity to complete Fermentation to produce alcohol. At the start of the cycle, the Fermenter is charged with mash and contents of the Prefermentor. Significant heat release takes place during Fermentation. This is removed by passing the mash through heat exchangers to maintain an optimum temperature. The recirculating pumps also serve to empty the Fermenters into Beer Well. After emptying of Fermenter, it is cleaned with CIP using cleaning nozzles. After CIP, Fermenter is ready for next batch to be filled.

3.1.6 Fermentation

The Fermentation process is engineered to operate in batch mode depending upon the quality of raw material. The purpose of Fermentation is to convert the fermentable sugars into alcohol. During Fermentation, sugars are broken down into alcohol and carbon-dioxide. CO2 can then



be taken to CO2 vent line where it is vented out. Significant heat release takes place during Fermentation. The fermenter temperature is maintained at around 32– 34 oC by forced recirculation flow through plate heat exchangers. We have given a provision for spent wash recycled to Fermentation depending on solids concentration in fermented wash.

3.1.7 Multi-Pressure Distillation

Multi-Pressure Distillation system has Seven Distillation columns operating at various pressure conditions. Heat energy from columns operating under high pressure is utilized for columns operating under low pressure to optimize the operation for energy consumption. Wash to ENA Mode: Following Columns will be under operation: 1. Analyser Column 2. Degasser Column 3. Pre-Rectifier Column 4. ED Column 5. Rectifier cum Exhaust Column 6. Recovery Column 7. Simmering Column Pre-heated fermented wash will be fed to Degasser column. Fermented wash is stripped off alcohol by ascending vapors in Analyser column. Rectifier vapors provide energy to Analyser column through a Thermosyphon reboiler. Vapors of Degasser column are condensed and taken to Recovery Feed Tank. The condensed Analyser vapors are taken to Pre-Rectifier Column. Analyser vapor is concentrated in Pre-Rectifier column, which operates under pressure. Condensing steam provides energy to pre-rectifier column through a vertical Thermosyphon reboiler. A Technical Alcohol cut of about 1-2% of total spirit is taken from the Pre-Rectifier column. Concentrated alcohol draw from Pre-Rectifier column is fed to ED column for purification. Dilution water in the ratio of 1:9 is added in this column for concentrating higher alcohol at the top. Top of this column is condensed in Thermosyphon reboiler of Simmering column and fed to recovery feed tank while bottoms are fed to Rectifier cum Exhaust Column for concentration. Rectifier Column operates under pressure and condensing steam provides energy to this column through a vertical Thermosyphon reboiler. Technical Alcohol cut is taken out from the top of this column while ENA draw is taken out from appropriate upper trays and fed



to Simmering Column after cooling. Fusel Oil build up is avoided by taking fusel oil draws from appropriate trays.

These fusel oils along with the condensate of Degasifying & Extractive Distillation columns are fed to recovery column for concentration. A technical alcohol cut is taken out from the top of this column. Simmering Column is operated under high reflux for better separation of methanol and di-acetyls. Final ENA product draw is taken from the bottom of this column.

3.1.8 Decantation & Thin Slops Recycle Section

Decantation section comprises of a Centrifuge Decanter for separation of suspended solids from Spent Wash coming out of Grain Distillation Plant. Wet cake has 20-22% w/w solids as removed from bottom of Decanter which can be sold directly in wet form as cattle feed (DWG). Thin slops coming out of Decanter are collected in a tank and partly recycled into the process & further for Evaporation for concentration upto 30-32% w/w solids. The concentrated thin slops called as Syrup is mixed with Wet cake and dried in a DDGS Dryer and then sold in dry form as Cattle feed (DDGS).

3.1.9 Evaporation System - Integrated Evaporation Scheme

The suggested treatment scheme would be working on the principle of falling film & force circulation

• PRC & FOC is fed to the Integrated evaporator shell side and steam is fed to shell side of force circulation evaporator at the given pressure and temperature as the heating medium.

• Vapors from last effect are condensed in Surface Condenser. A Shell & tube type Multi-pass Surface condenser is employed for condensing the shell side vapors.

• The product at the desired concentration 30-32% is obtained at the outlet of Finisher.

• Each effect is provided with recirculation cum transfer pump.

• The condensate from surface condensers is collected in a common condensate pot. The condensate is transferred for further treatment / Recycle by using centrifugal pump.

• The Pure steam condensate are collected in receiving vessels and can be pumped to desired battery limit

• Highly efficient operating pumps have been provided for pumping the required fluid.

• The plant is having high level of automation to get consistent output at required concentration.



• The system operates under vacuum. Water-ring vacuum pumps are used to maintain a desired vacuum.

• Cooling water from cooling tower is used in the surface condensers for condensing vapors.

3.1.10 DWGS Dryer with Cooling and Conveying System

System Description for Dryer

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.

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.

Dry product partially recycled back to Feed conditioner for feed conditioning through Product Screw & Recycle Conveyor.

Entire operation of the Dryer is controlled through Control panel with PLC. 3.1.11 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 Ethanol/RS/ENA). Subsequently, after gauging, the spirit would be transferred to respective bulk storage tanks.



Figure 3.1 : Process Flow Chart of Grain based distillery

Grain

Fiber/Husk

Dirt/Dust

Milling Section

Liquefaction

MEE Cond./Spent Lees

Fresh Water

Steam

Fermentation

CO2

Multi-pressure Distillation

Spent Wash

Spent Lees

Steam Condensate

Alcohol

DM Water

Steam

Thin slops

Wet Cake

Decanter

Multi Effect Evap.

Thick Slops

MEE Condensate

Steam Condensate

Steam

Dryer (Wet Cake + Thick slops)

DDGS Steam



3.2 Bottling of country liquor/IMFL

PIL is having existing capacity of 10,000 cases per day of bottling plant for the production of Indian Made Foreign Liquor and country Liquor at its existing location.

The process would involve mixing of ENA with DM water along with liquor essence blends, caramels, and colours in stainless steel blending tanks. The ratio of spirit to DM water would be controlled by proof requirements in the end product. For example, one case (equivalent to 9 litres) of IMFL (75% proof) requires 4 litres of spirit and 5 litres of DM water. The blend would be subjected to physical filteration. Subsequently, the blend would be filled in bottles. The bottles would be labeled, packed, and stored for final dispatch. The industry would install 2 bottling lines for the production of Indian Made Foreign Liquor as per the requirement.

3.3 Co-generation Power Plant

Pioneer Industries Ltd. is having existing capacity of 3.65 MW of cogeneration of power based on biomass/coal at its existing premises. During expansion, the industry would add additional cogeneration power plant of 6.0 MW capacity, thereby making the total capacity of upto 9.0 MW based on biomass/coal/petcoke as fuel. The cogeneration power plant is divided in three parts, namely; Boiler & Auxiliaries Turbine & Auxiliaries Generator & Auxiliaries

3.3.1 Boiler & Auxiliaries Boiler: The industry plans to install additional 45 TPH capacity fluidized bed boiler (FBC) for

steam and additional 6.0 MW of cogeneration of power. 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 Fluidised Bed.



Combustion of fuel in this bed is termed as Fluidised Bed Combustion (FBC). The boiler would be having other auxiliaries as described below;

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 Fluidising Air Fan: It is used for fluidising the bed of fuel and giving the upward 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 two sets 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.

3.3.2 Turbine & Auxiliaries

Turbine: The turbine shall be horizontal, single cylinder, extraction cum condensing design coupled to a generator to generate the rated output of 6.0 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 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.

3.3.3 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.

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.

3.4 Utilities 3.4.1 Water treatment plant (DM Water Treatment Plant) – 1000 m3/day

It is proposed that the water to be used will be received from the ground water. The water quality will require pre-treatment to satisfy the quality required for boiler feed water, process requirement, and blending during bottling. Treatment will involve sedimentation, sand filtration, activated carbon filtration, softening and ion exchange treatment (as required for different process requirements), suitable for quality of water required.

3.4.2 Electrical system The plant power requirement (including that for power plant auxiliaries) will be about 6.5 MW in total after the expansion program. The surplus power, if any, after meeting in-house requirements, will be exported to state grid.



3.4.3 Standby electrical generator The industry is having an existing D G sets of 3200 KVA (4 x 500 KVA and 1 x 1200 KVA) capacity.

3.4.4 Cooling water – 5000 m3/hour recirculation The maximum process and power plant cooling water requirement will be 5000 m3/hour recirculation for the complete 200 KLPD distillery plant and 8.0 MW cogeneration power plant. The cooling tower will be counter/cross flow induced draft cooling tower with total capacity of about 5000 m3/hr capacity. The cooling tower shall be designed for a cooling range of 6°C, and an app roach of 5°C while operating under the atmospheric wet bulb temperature of about 27°C. The cooling tower shall be carefully sited such that there is no re-entertainment of the vapors into the cooling tower. Evaporation and drift loss will depend on season/weather conditions and an average figure will be less than 1.00 %. The cooling tower blow-downs will be approximately 50 m3/day. Whole of the quantity lost will be made-up by adding fresh water/treated condensate from the process.



CHAPTER – 4

RAW MATERIALS

4.0 Pioneer Industries Ltd. are planning to expand its existing grain based distillery unit from 125 KLPD to 200 KLPD and cogeneration of power from 3.65 MW to 9.0 MW by setting up another unit of 75 KLPD grain based distillery unit and cogeneration of 6.0 MW of power within the existing premises located at plot no. A-2, A-33 and A-4, Industrial Growth Center, Village Ranipur, Defence Road, Tehsil and District Pathankot, Punjab. The distillery would be operational for 330 days in a year.

4.1 Raw Materials Requirements for Grain based Distillery

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. Daily consumption of raw materials for the distillery plant (existing as well as proposed) is given below;

S. No.

Item Unit Existing Proposed Total

1. Broken rice, maize, bajra, jowar and other starch containing grains etc.

MT 315 185 500

2. Enzymes Kgs. 250 150 400

3. Sodium Hydroxide/ Liquid Ammonia

Kgs. 50 30 80

4. Nitrogen source Kgs. 650 400 1050

5. Anti-foam agent Kgs. 300 100 400

6. Yeast (Dry) Kgs. 60 35 95

4.2 Fuel Requirements for Boiler

Pioneer Industries Ltd. are having existing 3 boilers of 25 TPH (1 nos.) and 12 TPH (2 nos.) capacity. The industry plans to install another boiler of 45 TPH capacity for steam requirements and cogeneration of power @ 6.0 MW during the proposed expansion. The existing 2 no. of 12 TPH capacity boilers would be kept as standby. The industry would use biomass/coal/petcoke as fuel for the new boiler furnace. After the proposed expansion, the fuel requirements for the



steam production as well as cogeneration of power would be around 500 MT/day. The daily consumption of biomass/coal for the boiler and cogeneration power plant (existing as well as proposed) is given below;

S. No.

Item Unit Existing Capacity

Proposed Additional

Capacity

Total

1. Biomass consisting of rice husk, cotton stalk, mustard stalk etc. and/or Coal/ Petcoke

MT 300 200 500



CHAPTER – 5

PRODUCTION

5.0 Pioneer Industries Ltd. are planning to expand its existing grain based distillery unit from 125 KLPD to 200 KLPD and cogeneration of power from 3.65 MW to 9.0 MW by setting up another unit of 75 KLPD grain based distillery unit and cogeneration of 6.0 MW of power within the existing premises located at plot no. A-2, A-3 and A-4, Industrial Growth Center, Village Ranipur, Defence Road, Tehsil and District Pathankot, Punjab. The distillery would be operational for 330 days in a year.

5.1 Production from Grain based Distillery

Daily production of products and by-products from the distillery plant (existing as well as proposed) is given below;

S. No.


Proposed Additional

Capacity

Total

1. ENA/RS/ Impure spirit/ Country spirit/ Denatured spirit/ Fuel Ethanol

KL 125 75 200

2. By-products

CO2 MT 80 50 130

Fusel Oil MT 1.5 1 2.5

DDGS MT 50 30 80

Corn Oil (in case of maize used as raw material)

MT 5 3 8



5.2 Production from Bottling Plant

Daily production of IMFL/country liquor from the bottling plant (existing as well as proposed) is given below;

S. No.


Proposed Additional

Capacity

Total

1. IMFL/country liquor Cases 10000 5000 15000

5.3 Production from Cogeneration Power Plant

Daily production of power and steam from the cogeneration power plant (existing as well as proposed) is given below;

S. No.


Proposed Additional

Capacity

Total

1. Electrical Power MWH 3.0 5.0 8.0

2. Steam1 MT/day 1176 524 1700

1 The industry is having 1 no. of 25 TPH capacity boiler and 2 no. of 12 TPH capacity boilers The existing 2 no. of 12 TPH boiler would be kept standby after expansion, which is now operational.



CHAPTER – 6

ENVIRONMENTAL MANAGEMENT AND POLLUTION CONTROL

6.0 Pioneer Industries Ltd. are planning to expand its existing grain based distillery unit from 125 KLPD to 200 KLPD and cogeneration of power from 3.65 MW to 9.0 MW by setting up another unit of 75 KLPD grain based distillery unit and cogeneration of 6.0 MW of power within the existing premises located at plot no. A-2, A-3 and A-4, Industrial Growth Center, Village Ranipur, Defence Road, Tehsil and District Pathankot, Punjab. 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.

6.1 Fresh Water Requirements

6.1.1 Grain Based Distillery Process

The impending water uses and consequent water pollution that would be caused by the grain based distillery unit may be because of the following; a) Process and dilution water b) Cooling water make-up c) Washing (fermentor, floor, etc.) d) Water treatment plant maintenance/DM Plant e) Domestic consumption

Process and dilution water

The overall fresh water requirements for 200 KLPD distillery plant in the process (in distillation etc.) would be about 415 m3/day which would include 200 m3/day of DM water for ENA production and 215 m3/day for slurry preparation process. Balance, industry would be re-using MEE condensate/Lees @ 700 m3/day. Besides this, 200 MT/day of direct steam would be consumed in the process for liquefaction section.

Cooling water make-up and blowdown The overall cooling water recirculation rate requirements will be maximum 5000 m3/hour, after expansion. The average temperature difference in the cooling water in the cooling towers would be 6 oC. Therefore less than 1.00 % of the total recirculation water would be lost in



evaporation, drift, and blow-down losses. Fresh make-up water requirement in the cooling towers would be about 1200 m3/day. The blow-down rate would be around 50 m3/day.

Washing The wash water requirement (for washing of fermentor and floor) will be about 25 m3/day. Whole of this water will contribute to wastewater generation.

Water treatment plant (DM) maintenance

The soft water treatment requirement of Pioneer Industries Ltd. would be about 1000 m3/day (D M water – for boiler, process, bottling, etc., requirements), after expansion. Treatment plant maintenance will generate about 50 m3/day of reject water. Whole of this water will contribute to wastewater. The effluent will go to the effluent treatment plant for treatment.

Domestic consumption

Some of the water will be required for cooking, drinking, sanitation, etc. Average daily requirement is expected to be about 20 m3/day. Of this, less than 90%, i.e., ~18 m3/day will be obtained as domestic wastewater.

Overall water requirement

Total average fresh water consumption for the grain based distillery project can be summarized as under;

S. No.

Purpose Unit Existing (125 KLPD)

Proposed (75 KLPD)

Total (200 KLPD)

1. Process & dilution water m3/day 225 190 415 2. Cooling water/ Make up

water m3/day 500 350 850

3. Washing Requirements m3/day 15 10 25 4. Water treatment plant m3/day 30 20 50 5. Domestic requirement m3/day 10 8 18 6. Water requirement for

cereal plant m3/day 311 0 311

Total m3/day 1091 578 1669



6.1.2 Fresh Water Requirements for Bottl ing Process The average water requirement for blending during bottling of country liquor/IMFL will be about 100 m3/day, which will completely be present in final product. There will be no wastewater generation. The industry is using only pet bottles, no bottle washing is done.

S. No.

Purpose Existing Proposed Total

1. Water requirements for blending 75 m3/day 25 m3/day 100 m3/day

6.1.3 Fresh Water Requirements for Boiler After the proposed expansion, average steam requirements for the industry will be about 1700 MT/day. The steam requirements would be met by operating 45 TPH boiler (new proposed) and 25 TPH boiler (existing). Most of the water requirements for the boilers would be met by return condensate and the remaining water requirements would be met by fresh D M water. Accordingly, daily D M water requirements after the proposed expansion for the boilers would be around 390 m3/day. The boiler blowdown, contributing to wastewater generation will be a maximum of 50 m3/day.

S. No.

Purpose Existing Proposed Total

1. Boiler water requirements 275 m3/day 115 m3/day 390 m3/day



6.2 Effluent Generation After the proposed expansion of the distillery plant to 200 KLPD, the overall process will result in following types of effluents generation 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 @ 1200 m3/day would be generated during the production of alcohol @ 200 KL/day. The spent wash would be sent to the decanter where wet cake @ 270 MT/day would be separated and remaining thin slops @ 930 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 @ 250 m3/day would be generated and MEE condensate @ 800 m3/day would be generated from the industry. Out of the total generation of 1050 m3/day of condensates generation, 700 m3/day would be directly reused in slurry preparation process. The remaining 350 m3/day would be reused in the cooling towers after its treatment in the ETP/CPU.

c) Effluent from other processes : Besides the above mentioned streams, effluent would be generated from misc. other streams such as – floor/fermentor washing effluent @ 25 m3/day, cooling towers blow down @ 50 m3/day, domestic effluent @ 18 m3/day, D.M. plant reject @ 50 m3/day and boiler blowdown @ 50 m3/day, from the industry. This effluent would be moderately polluted and after treatment would be used on land for irrigation purposes.

The details of effluent generation from distillery unit are as given below;

S. No.

Purpose Unit Existing Proposed Total

1. Grain based distillery process

Thin slope m3/day 585 345 930 Spent Lees m3/day 150 100 250 MEE Condensate m3/day 500 300 800 Fermentor/floor washing m3/day 15 10 25 Cooling tower blow down m3/day 30 20 50 Domestic Effluent m3/day 9 9 18

Water Balance for 200 KLPD Grain based distillery

Grain (500)

Fiber/Husk (5)

Dirt/Dust (10)

Milling Section (500)

Liquefaction (1600)

MEE Cond./Spent Lees (700)

Fresh Water (215)

Steam (200)

Fermentation (1600)

CO2 (150)

Multi-pressure Distillation (1650)

Spent Wash (1200)

Spent Lees (250)

Steam Condensate (660)

Alcohol (200)

DM Water (200)

Steam (660)

Thin slops (930)

Wet Cake (270)

Decanter (1200)

Multi Effect Evap. (930)

Thick Slops (130)

MEE Condensate (800)


Steam (150)

Dryer (Wet Cake + Thick slops) (400)

DDGS (150) Steam (200)

Water Balance for 125 KLPD Grain based distillery

Grain (315)

Fiber/Husk (5)

Dirt/Dust (5)

Milling Section (315)

Liquefaction (1000)

MEE Cond./Spent Lees (470)

Fresh Water (100)

Steam (125)

Fermentation (1000)

CO2 (95)

Multi-pressure Distillation (1030)

Spent Wash (755)

Spent Lees (150)


Alcohol (125)

DM Water (125)

Steam (415)

Thin slops (585)

Wet Cake (170)

Decanter (755)

Multi Effect Evap. (585)

Thick Slops (85)

MEE Condensate (500)


Steam (90)

Dryer (Wet Cake + Thick slops) (255)

DDGS (95) Steam (125)

Ide

alise

d Stea

m Ba

lance

for 2

00 K

LPD

Disti

llery

Plan

t (Al

l valu

es ar

e in M

T/da

y)

Boile

rs (1

700 T

PD)

D M

Wate

r (39

0 TPD

)

Retur

n Con

dens

ate (1

310 T

PD)

St

eam

to Tu

rbine

Comm

on H

eade

r

Cere

al Ba

sed P

rodu

cts U

nit

(450

)

Disti

llery

Unit (

1250

)

Lique

factio

n (20

0)

Mu

lti-pr

essu

re D

istilla

tion (

660)

Multi

Effec

t Eva

pora

tion (

150)

Drye

r (20

0)

Cond

ensa

te Ta

nk (1

010)

Blow

down

to E

TP (5

0)

Cond

ensa

te Ta

nk (3

50)

Ide

alise

d Stea

m Ba

lance

for 1

25 K

LPD

Disti

llery

Plan

t (Al

l valu

es ar

e in M

T/da

y)

Boile

rs (1

175 T

PD)

D M

Wate

r (27

5 TPD

)

Retur

n Con

dens

ate (9

00 T

PD)

St

eam

to Tu

rbine

Comm

on H

eade

r

Cere

al Ba

sed P

rodu

cts U

nit

(395

)

Disti

llery

Unit (

780)

Lique

factio

n (12

5)

Mu

lti-pr

essu

re D

istilla

tion (

415)

Multi

Effec

t Eva

pora

tion (

90)

Dr

yer (

125)

Cond

ensa

te Ta

nk (6

30)

Blow

down

to E

TP (3

0)

Cond

ensa

te Ta

nk (3

00)



D M plant reject m3/day 30 20 50 2. Boiler Section Boiler Blowdown m3/day 30 20 50

6.3 Air Pollution Generation

The additional air pollution will be due to combustion emissions released by the boiler furnace attached to the proposed 45 TPH boiler. The boiler furnace, AFBC type, will use chiefly rice husk/wooden chips and coal as fuel, with a maximum consumption of about 10.0 MT/hour.

The critical SPM concentration in the flue gas will be less than 50.0 g/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 having four number of DG sets of 500 kVA capacity and 1 nos. of 1200 KVA capacity as backup power supply. As per the applicable norms, the DG sets have been housed in an acoustic chamber. The combustion emission outlet, of the DG set, have been provided with a muffler along with a minimum stack height of 6.5 m above the height of nearest building. There will be no addition in the D G sets.

6.4 Solid Wastes Generation Solid wastes in the form of boiler ash would be generated @ 70 MT/day.

6.5 Hazardous Wastes 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 sold to authorised recyclers.



6.6 THE POLLUTION CONTROL SYSTEM 6.6.1 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;

Multiple Effect Evaporation The suggested treatment scheme is working on the principle of falling film & forced circulation;

• PRC & FOC is fed to the Integrated evaporator shell side and steam is fed to shell side of force circulation evaporator at the given pressure and temperature as the heating medium.

• Vapors from last effect are condensed in Surface Condenser. A Shell & tube type Multi-pass Surface condenser is employed for condensing the shell side vapors.

• The product at the desired concentration 30-32% is obtained at the outlet of Finisher.

• Each effect is provided with recirculation cum transfer pump.

• The condensate from surface condensers is collected in a common condensate pot. The condensate is transferred for further treatment / Recycle by using centrifugal pump.

• The Pure steam condensate are collected in receiving vessels and can be pumped to desired battery limit

• Highly efficient operating pumps have been provided for pumping the required fluid.

• The plant is having high level of automation to get consistent output at required concentration.

• The system operates under vacuum. Water-ring vacuum pumps are used to maintain a desired vacuum.

• Cooling water from cooling tower is used in the surface condensers for condensing vapors.

Treatment of Effluent from Different Streams

The industry would be generating less than 200 m3/day (193 m3/day) of effluent from different streams from the proposed 200 KLPD distillery unit. The effluent would be having organic impurities which need to be treated before its disposal on land for irrigation purposes. The overall effluent generation from the industry after expansion from the distillery unit would be less than 500 m3/day (including effluent from cereal based products unit). The industry has already installed an ETP that is sufficient to handle effluent more than 500 KL/day.



Septic Tank for Domestic Treatment The septic tank will provide and effective HRT of at least 48 hours, for maximum daily flow, to biologically stabilize, partially, the organic pollution load. A two compartment septic tank will be used for the purpose. The stabilisation compartment (first compartment) will have volumetric capacity of 40 m3/day, with aspect ratio (length:width) of at least 3. Floor slope at 1:5 will be provided for sludge accumulation. The effective submerged depth of tank will not exceed 2.5 m. Provision will be made for periodic withdrawal (pumping out) of accumulated sludge. The actual tank dimensions will be worked out to suit the process and site requirements.

Disposal of treated wastewater The industrial unit will generate a maximum of 500 m3/day of wastewater (from the proposed expansion project as well as the existing project) which needs to be disposed off on land for irrigation purposes. The treated wastewater will be used for watering/irrigation of the green area (horticulture and plantation) within the project site. Area available for this purpose is more than 40000 m2 within the industrial premises. Nominal water application rate for watering/irrigation can be safely assumed to be about 1.5 cm/day. Thus, maximum green area requirement for disposal of 500 m3 of wastewater is about 34,000 m2, which is much less than the area available for the purpose.

6.6.2 Air pollution control system

The air pollution control system, for the combustion emissions from the 45 TPH 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

The ESP will have following technical specifications;

1. Design gas flow rate – 85000 m3/hour 2. Temperature – 140-150ºC 3. Maximum inlet dust load – 22 g/Nm3 4. Outlet emission dust load – <100 mg/Nm3 5. Plate area – 2700 m2 6. Specific collection area – 111.69 m2/m3s 7. Velocity through ESP – 0.50 m/s 8. Treatment time – ~22.00 s 9. Migration velocity – ~5.0 cm/s 10. Number of fields – 3 11. Efficiency – > 99.6%

Collection electrode specifications;

1. Height of Panel – 6 meters 2. Material – IS 513/CRCA 3. Total no. of plates – 300 4. Width of panel – 735 mm 5. Thickness – 18 SWG

Emitting (discharge) electrode specifications;

1. Height of panel – 6 meters 2. Total no. of electrodes – 1350 3. Type – Spiral 4. Material – ERW tubes and carbon steel studs 5. Spacing between emitter &

collector electrode – 200 mm

6. Spacing between collecting plates

- 400 mm



Electrical specifications;

1. TR sets – 3 nos. 2. TR control type – Microprocessor controlled 3. Nos. per field – 1 4. TR rating

Output voltage Output current

– –

120 kV DC 3 x 300 mA

Rapping system specifications;

1. Type – Microprocessor based electromagnetic plunger

2. Total no. of rapper per unit – 18 3. Rapper impact force (max.) – 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 150 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 99.6%, resulting in emission discharge with SPM concentration of less than 100 mg/Nm3.

Stack

The stack shall have adequate height to properly disperse SO2 generated or 30 m, whichever is more. The stack height is calculated using the equation; H = 14 (Q)0.3

Where, H is stack height (in m), and Q is quantity of SO2 generated (in kg/hour).

a) Rate of fuel combustion = 8000 kg/hour b) Rate of combustion of S (maximum) = 40 kg/hour (@ 0.5 % Sulphur in coal)



c) Maximum SO2 in the emissions = 80 kg/hour d) Stack height (minimum) = 52.15 m e) Stack diameter = 1.5 m f) Height of sampling port above inlet = 15 m (minimum) A sampling port with platform shall be provided for monitoring purposes. A ladder arrangement shall be provided to access the sampling port.

6.6.3 Ash management The air pollution control system, for the new boiler furnace, will comprise of; a) Ash vessels b) Conveying pipes c) Ash silo 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 for the making of flyash bricks within the premises.



CHAPTER – 7

PROJECT ESTIMATES

ESTIMATED OVERALL PROJECT INVESTMENT The estimated cost of project for the expansion of the 75 KLPD distillery project and cogeneration of 6.0 MW of power would be as below; S. No. Particulars Cost (Rs. In Lakhs) 1. Milling, Liquefaction and Sacherification 75.00

2. Fermentation 200.00

3. Plate Heat Exchangers 50.00

4. Distillation and MEE 1300.00

5. Cooling Towers 40.00

6. Drier 200.00

7. Boiler and Turbine 1800.00

8. Pipelines 50.00

9. Civil Works 450.00

10. Storage Tanks 85.00

11. Electrical Work 100.00

12. MS structure 100.00

13. DM Plant, Softner, RO 50.00

Total 4500.00 TOTAL PROJECT COST : 75 KLPD OF DISTILLERY PROJECT EXPANSION WITH 6.0 MW OF POWER COGENERATION

S. No. Description Amount 1 Total Fixed Assets 4500.00 2 Pre-Operative Expenses 100.00 3 Contingencies 100.00

TOTAL PROJECT COST 4700.00

Documents

PRE FEASIBILITY PROJECT REPORT - …environmentclearance.nic.in/writereaddata/Online/TOR/15_Apr_2016... · Pre-Feasibility Project Report ... such as CO2, Fusel Oil, DDGS, Corn Oil