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PRE- FEASIBILITY REPORT

For

Proposed 60 KLPD Distillery unit

(Grains & Molasses based)

Pharmol India Pvt. Ltd. Kothuru-B Village,

Zaheerabad Mandal

Sangareddy District, Telangana

Pharmol India Pvt. Ltd.

60 KLPD Distillery unit

Pre-Feasibility report

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1.0 EXECUTIVE SUMMARY

Pharmol India Pvt. Ltd. has proposed to put up 60 KLPD Grains & Molasses based Distillery

unit along with 1.5 MW power plant in the premises of existing Sugar plant of M/s Trident

Sugars Limited. For this total 29 acres of land has been taken on lease bearing Sy. No.s 21,

22, 23, 24, 25 & 29 of Kothur – B Village, Zaheerabad mandal, Sangareddy District,

Telangana.

The following is the summary of the proposed Distillery unit

S. No. Parameters Description

1. Proposed Plant

capacity

Particulars Capacity

Rectified Spirit / ENA / Ethanol : 60 KLPD

Electricity : 1.5 MW

2. Total area taken on

lease

29 acres

3. Sy. No. of the land Survey no.s : 21, 22, 23, 24, 25 & 29

4. Project cost Rs. 71.4 Crores

5. Water requirement 600 KLD

a. Source of water Ground water / Surface water

Permission for drawing water will be obtained from

SGWB / Irrigation department

6. Waste water

generation

550 KLD

7. Effluent treatment

(proposed)

Molasses as raw material

Spent wash will be treated through Biomethanation,

concentrated in Multiple Effect Evaporators (MEE) and

concentrated spent wash will be bio- composted along

with pressmud.

Grains as raw material

Spent wash generated will be passed through decanter

and then the thin slop from Decanter will be dried in

Multiple Effect Evaporators (MEE) followed by Dryer up

to 90% solids w/w. This solid is known as DDGS. This

will be sold to outside parties.

The non process treated effluent after ensuring

compliance with SPCB standards will be utilized for

greenbelt development and ash conditioning.

8. Steam requirement Steam required will be met from proposed 25 TPH

9. Air emissions Emissions from Project will be Particulate matter, SO2




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S. No. Parameters Description

and NOx

Bagfilters will be provided to boiler to bring down the

particulate matter to below 100 mg/Nm3.

10. Noise levels Ambient Noise levels will be within the standards

prescribed by MoE&F Notification and its amendments

11. Solid waste generation

Yeast sludge generated will be bio-composted along

with concentrated spent wash

Ash generated will be given to brick manufacturers




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2.0 INTRODUCTION:

2.1 Identification of project and Project Proponent Pharmol India Pvt. Ltd. has proposed to put up 60 KLD Grains and Molasses based Distillery

unit in 29 acres of land taken on lease from M/s Trident Sugars Limited.

The Promoters

The following is the list of promoters of the company

S.No Name Designation

1. Shri Nandakumar Ramanujalu Director

2. Shri Dr. R.N. Ramnath Director

2.2 Brief Description of nature of Product:

2.2.1 DISTILLERY PRODUCTS

Extra Neutral Alcohol/Ethanol

ENA IS 6613 – 1972 is an Extra Neutral Alcohol, Basic raw material for IMFL.

Produced from Molasses, Sweet Swargam, Cane Juice and Grain etc.

Rectified Spirit IS 323 – 1959 Quality is inferior to ENA.

ENA is nothing but refined Rectified Spirit.

ENA Process is a physical process in which Aldehydes, Esters and Fusel Oils impurities

are separated by virtue of their difference in Boiling Points by steam Distillation.

ENA RS ETHANOL

01 Ethanol content percent by Volume at 15 . 6O C,Min

94.68 94.68 99.50

02 Acidity gms/100 ml1 Max 0.002 0.002 0.006

03 Residue on Evaporation gms/100 ml1 Max

0.002 0.005 0.005

04 Ester content gms/100 ml Max 0.01 0.02 0.02

05 Aldehydes gms/100 ml1 Max 0.004 0.006 0.006

06 PP Times, Minutes 30 Nil Nil

Demand – Supply Gap:

The use of alcohol as a drink is an age-old story. It appears that in India the technique for

fermentation and distillation was available even in the Vedic times. Alcohol is an integral part

of the Ayurvedic system of medicine also.




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Carew & Co. Ltd. set up the first distillery in the country at Cownpore (Kanpur) in 1805 for

manufacture of Rum for the British army. The technique of fermentation, distillation and

blending of alcoholic beverages was developed in India on the lines of practices adopted

overseas, particularly in Europe.

The original use of alcoholic fermentation was of course for preserving fruit juices. Now the

fermentation is adapted for the preparation of fermented grain beverages and then distilled

beverages. The utilization of Ethanol, for industrial use is a recent phenomenon. It became

important towards the end of the Second World War.

When large-scale production of alcoholic beverages was taken up, various Governments

found that alcohol was a good source for increasing government revenue through collection

of tax. When synthetic organic chemistry advanced rapidly, about a century ago, alcohol

became an indispensable chemical for this industry. However extensive manufacturing of

alcohol for industrial use was hampered due to excessive taxes. The problem was to device

a means for conserving government’s interest in tax collection on potable alcohol and at the

same time making alcohol for industrial use relatively free of tax. Thus different governments

introduced the process of denaturation of alcohol for industrial use.

During the Second World War, the demand for the industrial alcohol increased 4-5 times,

above the prewar period, due to the production of smokeless powder for weapons. The

imports of molasses were hampered due to war conditions. This leads to evolving the

process of grain fermentation for meeting the requirement of Ethanol.

In India, after the protection granted to the sugar Industry in 1932, a large number of sugar

factories were established in the country, particularly in Maharashtra and Uttar Pradesh

where irrigation facilities existed for cultivation of sugarcane. Increase in sugar production

resulted in accumulation of molasses, which resultantly, caused unmanageable

environmental problems. At that time the demand for molasses was almost insignificant and

the sugar mills had to incur considerable expenditure for disposal of molasses. For resolving

these problems a joint committee of U.P. and Bihar was constituted in 1938 to explore the

possibilities of using molasses for developing alcohol-based industries. The Committee

recommended establishment of distilleries for production of alcohol, utilizing molasses as a

substrate.

The committee also recommended that alcohol produced by the distilleries should be

admixed with petrol, to supplement motor fuel. This helped in solving the problems of

disposal of molasses. It also filled up the gap in the demand and supply of motor spirit.




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As a result, after meeting alcohol requirement for manufacture of gasohol, substantial

quantity of alcohol was diverted for production of alcohol based chemicals.

Present Status Fossil fuels are declining. Transportation sector consumes more than 50% of the fuels.

Environmental degradation from these fuels is a major problem all over the world. World oil

production is expected to last till 2125 A.D., if consumption at the present level is

maintained. On this background the use of Ethanol for fuel blending should be given a top

priority.

India requires ethanol for the following three major purposes:-

For potable liquor

For industrial use

For fuel blending

Today, the distillery industry of India uses only molasses for manufacturing alcohol. There

are handful of grain distillery units (e.g. Seagram Manufacturing Ltd.) and the alcohol

produced by them is used for captive use to make value added liquors.

All other liquor (IMFL) manufacturers use alcohol produced from molasses. In advanced

countries, liquor for human consumption is made only from grain alcohol. It is known that

alcohol produced from molasses can have residues such as sulphates, sulphites, higher

aldehydes, higher alcohols, higher acids and ketones etc., which are not present in alcohol

from, grains.

However, no such above-mentioned distinction is made in India. Thus alcohol produced only

from one source i.e. molasses is used for all 3 purposes (liquor, industrial use, fuel

blending). There is an urgent need to bring in above quality consciousness in the IMFL

industry and appropriate policy measures by the Govt.

Today, Indian distillery industry broadly consists of two parts:

One is alcohol production from molasses for industrial alcohol and two alcohol production

from molasses for liquor purposes.

Ethanol demand for fuel blending is a recent phenomenon. For this purpose, alcohol from

molasses is used.




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The potable distillery producing Indian Made Foreign Liquor (IMFL) has a steady but limited

demand. The alcohol produced is now being utilized in the ratio of approximately 52 per cent

for potable purpose and the balance 48 percent for industrial purpose.

Ethanol blending Ethanol blending is the practice of blending petrol with ethanol. Many countries, including

India, have adopted ethanol blending in petrol in order to reduce vehicle exhaust emissions

and also to reduce the import burden on account of crude petroleum from which petrol is

produced. It is estimated that a 5% blending (105 crore litres) can result in replacement of

around 1.8 million Barrels of crude oil . The renewable ethanol content, which is a byproduct

of the sugar industry, is expected to result in a net reduction in the emission of carbon

dioxide, carbon monoxide (CO) and hydrocarbons (HC). Ethanol itself burns cleaner and

burns more completely than petrol it is blended into. In India, ethanol is mainly derived by

sugarcane molasses, which is a by-product in the conversion of sugar cane juice to sugar.

The practice of blending ethanol started in India in 2001. Government of India mandated

blending of 5% ethanol with petrol in 9 States and 4 Union Territories in the year 2003 and

subsequently mandated 5% blending of ethanol with petrol on an all-India basis in November

2006 (in 20 States and 8 Union Territories except a few North East states and Jammu &

Kashmir). This was also an attempt to reduce the Under-recovery of Public Sector Oil

Marketing Companies (OMCs). Ministry of Petroleum and Natural Gas, on 1 September,

2015, inter-alia has asked OMCs to target ten percent blending of ethanol in Petrol in as

many States as possible. In countries like US, blending is allowed upto 10%. Subsequent to

Brazil's bio-fuel programme, which began in 1976, close to 94% of cars sold in Brazil are

flexible fuel cars that can handle ethanol blends from 18 per cent upward .

Ethanol blending first found mention in the Auto fuel policy of 2003. It suggested developing

technologies for producing ethanol/ bio fuels from renewable energy sources and introducing

vehicles to utilise these bio fuels. Later, as per National Policy on Bio-fuels, announced in

December 2009, oil companies were required to sell petrol blended with at least 5% of

ethanol. It proposed that the blending level be increased to 20% by 2017.

Ethanol, being a by product of the sugar industry, was expected to be freely available.

However, Oil marketing companies (OMCs) were not even able to get bids for more than

50% of the amount offered for purchase . Further, the Government decided on 22.11.2012

that procurement price of ethanol will henceforth be decided between Oil Marketing

Companies (OMCs) and suppliers of ethanol. In addition, on 03.07.2013, it was decided that

ethanol would be procured only from domestic sources. This led to a rise in ethanol prices,

http://www.arthapedia.in/index.php?title=Under-recovery




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which to a great extent reportedly eroded the economy of the blend. At present, government

has permitted OMCs to implement the ethanol blending programme in notified 20 States and

4 Union Territories as per the availability of ethanol.

There are reportedly significant transaction barriers which impede smooth supplies of

ethanol for blending. In several States, State not only imposes levy on molasses but also

regulates the movement of non-levy molasses. Inter-state movement of ethanol requires No-

Objection-Certificates (NOCs) from the State Excise Authorities along with permits from

dispatching and receiving States. Most States impose ―Export/Import‖ duties on ethanol

leaving and entering their boundaries. There are some instances where Octroi is levied on

ethanol for entry into municipal limits. Hence States were requested by the Central

Government to liberalise restrictions on the supply of ethanol so that its blending with petrol

can be encouraged while improving the financial health of sugar sector and also liquidation

of cane dues of farmers.

As per the estimates given in Auto Fuel Vision and Policy 2025 issued in May 2014, blended

petrol is available only in 13 states and the average blend is 2%. During the sugar year

2014-15, OMCs have achieved a blending percentage of 2.3% as per the press release

dated 25 April 2016.

Hence, in order to improve the availability of ethanol, the Government, on December 10,

2014, fixed the price of Ethanol in the Range of Rs. 48.50 to Rs. 49.50, depending upon the

distance of distillery from the depot/installation of the OMCs. (The rates are inclusive of all

central and statutory levies, transportation cost etc, which would be borne by the Ethanol

suppliers). Fixation of ethanol price based on distance, has encouraged movement of

ethanol to longer distances, including States having lack of distilleries. Further, ethanol

produced from other non-food feedstocks besides molasses, like cellulosic and ligno

cellulosic materials including petrochemical route, has also been allowed to be procured

subject to meeting the relevant Bureau of Indian Standards (BIS) specifications.

2.2.2 Power

Power is generated by converting the thermal energy of steam into electrical energy through

Turbo-generator.

The power generated will be utilized for meeting the power requirements for Distillery and

other auxiliaries. Remaining power after meeting the power requirement for the project, will

be exported to nearest sub-station.




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2.4 Employment generation (Direct & Indirect): The man power required for the proposed project will be 60 Nos. which is inclusive of 30

nos. on permanent basis and rest all will be on Temporary or contract basis.

S.No. Particulars No. Employees

1. Technical & Administrative Staff 20

2. Skilled & Semi Skilled 20

3. Unskilled & Helpers 20

Total 60




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3.0 PROJECT DESCRIPTION:

3.1 Type of the Project:

The proposed Project mainly involves

Production of Rectified Spirit / ENA / Ethanol using Molasses and Grains as raw

material

3.2 Location: The proposed project will be taken up in the 29 acres of land taken on lease from M/s

Trident Sugar Limited located at Kothuru-B village, Zaheerabad mandal, Sangareddy

District, Telangana.

3.3 Details of the Alternate sites: No Alternate sites have been examined as the proposed project will be taken up in the

premises of existing Sugar plant of M/s Trident Sugars Limited.

3.4 Size or Magnitude of Operation: The following will be the capacity of the proposed Distillery unit

S.No. Units

Distillery plant Power generation

1. 60 KLPD

(Rectified Spirit /ENA / Ethanol)

1.5 MW

2. Raw material : Molasses / Grains Fuel : Coal / Bagasse

3.5 Process details:

3.5.1 Manufacturing Process (Rectified Spirit/Ethanol/ENA)

Molasses as raw material

Yeast propagation:

Yeast seed material is prepared in water-cooled yeast vessels by inoculating molasses with

yeast. The contents of the yeast vessel are then transferred to the Yeast activation vessel.

The purpose of aerated yeast activation in the yeast activation vessel is to allow time for the

yeast cell multiplication.

Fermentation: The fermentation technology adopted in the industry is of continuous fermentation with yeast

recycle with this technology the total spent wash generation will be restricted to a max. of 10

kl/kl of R.S. (As per latest CPCB recommendation).




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The purpose of fermentation is to convert the fermentable sugars into alcohol. During

fermentation, sugars are broken down into alcohol and carbon-di-oxide. Significant heat

release takes place during fermentation. However the fermentation temperature is

maintained at 32 – 35 0C by forced recirculation heat exchangers.

At the end of fermentation, the wash is fed through a yeast separator where the yeast cream

is separated, acidified in the yeast treatment tank and returned to the yeast activation vessel

for activation. Sludge is separated in a sludge decanter. The clear wash from both the yeast

separator and sludge separator flows to the clarified wash tank. The wash is then pumped to

distillation.

Distillation: Fermented Wash about 8% v/v alcohol is preheated in two stages i.e. in the beer heater

using the Rectifier vapours and then in the Fermented wash PHE using the effluent. The

preheated wash is then fed the Degasifying Column to remove residual CO2 and volatiles.

The wash then flows down to Analyser Column, which acts as a total stripper. The alcohol

water vapour mixture which rises upward in this column is fed to the Rectifier Column. The

spent wash, which is devoid of alcohol, flows down the Analyser Column for suitable

treatment.

The lower boiling impurities are concentrated in the Aldehyde Column where about 5% spirit

is drawn off as impure spirit with a minimum strength of 660 OP.

The alcohol vapours are concentrated in the Rectifier Column to produce Rectified Spirit of

95% v/v strength. Higher boiling impurities, which are formed during fermentation, are

removed by taking side draw purges to a decanter from the Rectifier Column. A trace stream

of spirit is drawn off as impure spirit (about 2% of plant capacity) to remove the concentrated

volatile compounds. The high grade Rectified Spirit is taken as a draw from the upper trays

of the Rectifier Column.

The Rectified spirit is fed to the purification column. Dilution water is fed on the top most tray

of the column with a dilution ratio of 1: 9. This column serves to remove the impurities based

on the principle of HYDROEXTRACTION. The water is fed to the column in such a way that

it selects the higher alcohols and other impurities to move upwards and extracts ethanol

down. The purifier bottom alcohol composition is maintained at 12 % v/v. At this

composition there is an inversion in relative volatiles of higher alcohols as compared to




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ethanol and these alcohols get separated in the top distillate. Top draw for volatiles is fed to

the Fusel oil concentration column.

The purified dilute ethanol is removed from the bottom of the purification column and fed to

the rectification column, which concentrates the ethanol to 96% v/v. The high grade spirit is

drawn from one of the upper trays of the rectification column. A small heads cut is removed

from the overhead stream as technical alcohol (T.A.) cut to with draw impurities and is fed to

the heads concentration column. The lees from the exhaust column is recycled as dilution

water after a part of it is purged. The purged spentlees is used to preheat the make-up

dilution water.

Lower side draw streams are taken from rectification column to avoid fusel oil build up in the

column. These streams are then taken to the fusel oil column. This column concentrates

the dilute streams of ethanol containing esters and fusel oils to approximately 95% v/v of

ethanol. The concentrated ethanol is removed as T.A. cut from the top of the column. T.A.

cut is removed out of the system in order to remove propanol and remaining is fed to the

heads concentration column where the heads from the purification column and rectification

are fed to the static mixer. Soft water, which has been preheated, is used for diluting the

high proof ethanol. An impure spirit cut of about 5% of the rectified spirit feed is drawn from

the top of the column. The dilute ethanol solution at the bottom of this column is pumped

back to the purification column for repurification.

Carbon Dioxide Recovery System (By Product): Carbon dioxide produced during fermentation will be recovered by means of scrubbing

arrangement, chemical treatment drying process and finally liquefaction. The water utilized

for scrubbing will be recycled back into the fermentor.

CO2 gas will pass through scrubbing tower, where the gas is scrubbed with water. From the

scrubber after washing the gas will pass through air compressor and then the gas will pass

through a tower containing sodium dichromate to eliminate the impurities, if any and then to

drying arrangement with sulphuric acid. Subsequently it passes through a tower containing

coke coated with washing soda to eliminate odour. Finally it goes to the chilling unit to cool

the gas before passing through different cylinders, where the cooled gas will be filled into the

cylinders under pressure. The scrubber blowdown will be recycled into the fermenters.

Total CO2 production : 45.6 T/day

This carbon dioxide in cylinders will be sold to industries like soft drink manufacturing units,

etc.




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Ethanol Production: This plant is filled with imported 3A grade Molecular Sieve. It is operated with vaporized

Alcohol and removes water completely. Then Molecular sieves are regenerated under

vacuum of 710 mm Hg. Feed Alcohol comes to this Plant in a Day Tank continuously from

bulk storage tank. From this tank alcohol is pumped to a steam vaporizer at 4 Kg/cm2

pressure. This is vaporized in a steam heater and then vapor is super heated to 160oC in a

super heater and taken to Molecular Sieve Unit. This super heated vapor now pressure

through one Molecular Sieve column for moisture removal. There are 2 Molecular Sieve

columns. At a time one column remain in drying cycle while other columns under goes

vacuum regeneration. Each column remains in cycle for 6 minutes. Here drying process

takes place at 3.0 Kg/cm2 pressure and dry alcohol vapor of 99.8% purity comes out as final

product. This alcohol vapor is condensed in a water cooler and then collected in another day

tank. From this tank dry alcohol is continuously pumped to bulk day storage tank through a

level controller and a control valve. In the regeneration process some left over alcohol also

comes out which is condensed in regeneration condenser. This alcohol is around 95%

strength and is re-cycled in to rectifier column continuously.

The other Molecular Sieves column under goes regeneration by a vacuum pump. In this

column vacuum pumps pulls and creates vacuum of 710 mm Hg. At this vacuum the

moisture from Molecular Sieve pores comes out and along with 30% pure alcohol from on

line Mole Sieve bed is sprayed. Thereafter during vacuum process, some left over alcohol

and water from Molecular Sieves comes out and is condensed. Concentration of this lean

alcohol is around 70% alcohol, which can be recycled to the Rectifying Column. From

Rectifier the pure water will be sent out automatically.

Grains as raw material

The following are the steps involved in the manufacturing Process for Ethanol /ENA /Pharma

grade production

1. Milling

2. Liquefaction

3. Saccharification

4. Fermentation

Cleaning & Milling

The Grain is first pre-cleaned for removing stones, dust and foreign materials with the help of

destoner and magnetic separators, before milling. Milling involves processing grain through

a hammer mill (with screens between 3.2 to 4.0 mm) to production grain flour.




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Liquefaction

The whole grain flour is slurred with water, and heat-stable enzyme (a-amylase) is added.

The slurry from the milling operation is cooked with steam and this is known as ―liquefaction‖

Liquefaction is accomplished using jet-cookers that inject steam into the grain flour slurry to

cook it at temperatures above 100°C (212°F).

Saccharification

After liquefaction, the slurry, now called ―Liquefied Grain Slurry,‖ is cooled to approximately

30°C (86°F), and a second enzyme, Glucoamylase is added. Glucoamylase completes the

breakdown of the starch into simple sugar (glucose).

Fermentation

In the fermentation step, yeast is added to the grain mash to begin the process of

converting the simple sugars to ethanol. The other components of the grain (protein, oil, etc.)

remain largely unchanged during the fermentation process. Duration of fermentation is

around 48hrs.

Distillation

The vacuum distillation or multi-pressure distillation has many advantages over conventional

atmospheric distillation. Vacuum Distillation has lower energy requirement, consistently

produces very high quality alcohol and less scaling of distillation trays due to sludge. The

vacuum distillation produces ethanol of international quality standards and there is a lot of

demand for ethanol produced from the vacuum distillation process. Hence we propose to

use Vacuum Distillation technology for the Distillation process.

Effluent Treatment System Proposed Effluent Treatment System: Multiple Effect Evaporation ―Zero Pollution Effluent

Treatment System for handling distillery effluent.‖ The system is based on evaporation and

drying technology

Multiple Effect Evaporation is an operation used to remove water from a solution,

suspension, or emulsion by boiling off some of the liquid. It is thus a thermal separation, or

thermal concentration, process. We define the evaporation process as one that starts with a

liquid product and ends up with a more concentrated liquid as the main product from the

process. Before feeding the Spent Wash to Evaporation, the solids are separated out using

The Centrifugal Decanter. The separated Solids are then fed to DDGS along with the

concentrated spent wash from the Evaporation section.




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Effluent Characteristics

S.No. Particulars Characteristics

1) pH : 4.5 to 5.0

2) Solids content : 7.0 to 10.0% w/w

3) B.O.D. : 60,000 ppm

4) C.O.D : 30,000 ppm

Scheme for Zero Discharge System (ETP) For Grain Based Distilleries:

The zero discharge system for grain based distillery effluent handling (DDGS Plant)

consists of following main processes.

A. Decantation System: To separate the suspended particles and thin liquor.

B. Evaporation System : To concentrate the thin liquor in vacuum evaporator

C. Mixing & Blending System : To mix the Wet cake and the concentrate

D. Steam Tube Drying: To dry the mix to get dried powder (DDGS).




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Process Flow Chart

Note : DDGS: Distillers Dried Grain Solubles

Effluent Treatment System: Multiple Effect Evaporation for Zero Discharge




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3.5.2 Power Plant

The power plant capacity is so designed that the plant will be able to feed steam and power

requirements of Distillery Complex. The capacity of the boiler will be 25 TPH at 20 ata and 320

+/- 5 deg C. The turbine capacity would be 1.5 MW at 20 ata and 320 ºC steam parameters.

The new turbine will be of Backpressure Turbine at 5kg/cm2 .

3.6 Raw Materials The following will be the raw material requirement for the for the proposed Distillery unit

S.No Raw Material Source Quantity

(TPD)

Method of

Transport

1. Molasses Existing sugar

plant

240 By Road

(By tankers)

Grains

(Maize, corn, Sorghum grain,

broken rice and other starch

based grains, etc.)

Local area

180 By Road

(Covered trucks)

2. Fuel

Imported Coal Indonesia /

Australia

80 By Sea, Rail, Road

(Covered trucks)

or

Indian Coal SCL 100 By Rail & Road

(Covered trucks)

or

Biomass Local Areas 150 By Road

(Covered trucks)

3.7 Resource Optimization / recycling and reuse: Molasses is used as raw material

The spent wash generated will be concentrated in Multiple Effect Evaporators (MEE) to 40%

solids and then the concentrated spent wash will be bio-composted along with pressmud

procured from Sugar plant. The manure generated from the Bio-composting will be sold as

manure

When Grains are used as raw material

Spent wash generated during the process of Fermentation, will be treated in Multiple Effective

Evaporators to concentrate the solids content up to 30% and concentrated syrup along with

wet cake will be dried in Dryer to concentrate the solids content up to 90%. This is known as

DDGS. This will be sold as Cattle feed.

EXISTING PROCESS FLOW

DIAGRAM (SUGAR)




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The condensate generated during the process of Multiple Effective Evaporators and Drying will

be reused in the Process thus decreasing the net water requirement.

Power Plant The effluent generated from the Plant will be treated in Neutralization pits and will be utilized

for dust suppression, ash conditioning and Greenbelt development after ensuring compliance

with stipulation for on land irrigation by MoEF / CPCB

3.8 Availability of Water: Water required for the proposed Distillery unit will be met from the Ground water / Surface

water resources. Required permissions will be obtained from SGWB / Irrigation department

before drawing water from Ground / Surface.

Water required for proposed distillery unit and

power plant

600 KLD

Total 600 KLD

3.9 Power Requirement:

The power required for the Distillery unit will be met from 1.5 MW captive power plant.

3.10 Quantity of wastes generated:

3.10.1 Waste water generation

Waste water generation from the Distillery will be 550 KLD.

3.10.2 Waste water Treatment: Molasses as raw material As per CPCB recommendations the spent wash quantity will be restricted to a maximum of 8

kl/kl of R.S. for Molasses by adopting continuous fermentation technology with yeast recycle.

The Maximum Spent wash input to Bio-methanation will be 480 KL/day

TREATMENT SCHEME

Spent wash generated will be treated in three stages

1. Bio-methanation

2. Evaporation

3. Bio-composting




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23

BIO-METHANATION

"CSTR" continuous flow stirred-tank reactor process will be adopted for Bio-methanation,

which is based on the concept of conversion of organic matter into biogas. The process of

conversion of organic matter into biogas occurs through a group of bacteria.

In 'CSTR' process, which is a high rate process, anaerobic digestion takes place in the

Mesophillic range of temperature, the pH inside the reactor is usually kept around 7.2 while

proper ratio of volatile acid and alkalinity is maintained.

The following three stages are involved in the process of anaerobic digestion

1. Hydrolysis: In the process of hydrolysis the complex molecular compounds i.e. polymers

are converted into the simple molecular form i.e. monomers.

2. Acidogenesis: The monomers so formed at the end of hydrolysis process are converted

into volatile fatty acids. Acetic acid forms the major portion of volatile fatty acids. The

process of conversion of monomers into acids is carried out by a group of anaerobic

bacteria known acid formers.

3. Methanogenesis: Acids produced at the end of Acidogenesis process are converted into

carbon dioxide and methane gases. The process of conversion of acid into gases is

carried out by group of anaerobic bacteria known as methane formers.

In CSTR process the bacteria responsible for digestion process are kept in suspension with

the help of Lateral as well as central mixers.

Sr. No Design Basis Input Output

I. Spent wash Volume 480 TPD @ 12 %w/w solids 480 TPD @5 %w/w solids

II. BOD (mg/lit) 65000 85-90% reduction

III. COD (mg/lit) 120000 60-65% reduction

IV. pH 3 to 4 6 to 7

SR. NO TREATMENT UNIT SPECIFICATION/VOLUME MOC

1. Buffer Tank Capacity : 100 m3 RCC Lined Lagoon

2. Bio digester feed Pump +

motor

Type-Open impeller; Horizontal,

Centrifugal, Self Priming Cap-16

m3/hr Qty-1+1 3 Phase squirrel

cage induction type Motor

SINGLE MECHANICAL SEAL

SS316

3. CSTR Digester Capacity-10700 m3

Qty -1 nos

Mild Steel, with

epoxy coating

inside




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4. Flare Stack Overall Ht: 10.0 m

Dia: 1.0 m

MS with epoxy

coating

5. Degasser Dia: 1.6 m

Overall Ht: 10 m

Mild Steel, with

epoxy coating

inside

6. Lamella Clarifier Surface Area: suitable Mild Steel, epoxy

coated inside

Provided with

FRP Packs

7. Gas Holder Suitable capacity MS Dome + RCC

Wet well

8. Bio-Methanated Spent

wash tank

Capacity : 50 m3 RCC

9. Lamella Sludge

recirculation pump

Horizontal Centrifugal Pump

having 15 m3/Hr Discharge and 25

mtrs Head. Qty-1+1 SINGLE

MECHANICAL SEAL

SS316

10. Agitators for Mixing in

Bio-digester

Quantity :4 Nos Wetted

partSS304

11. Bio Gas Blower Rotary Twin Lobe type

compressor of 600 m3/hr capacity

with pressure rating of 2500

mmHg. Provided with safety

Valve, Non Return Valve, Coupled

with flame proof motor

12. Lamella Clarifier Packs Lamella Packs in FRP Molded

sheets shall be provided. The

Lamella packs shall be inclined at

60 Deg with horizontal. Each Plate

shall have area of 2 sqm. Each

Lamella Pack Shall has Plates of

1 m x 2 m size each. Thickness of

FRP/PVC plates shall be of 3 mm




25


13. Liquid Flow Meter for SW

feed

Electro-magnetic flow meter

having flow range of 0-18 m3/Hr,

SS 316 material

SS316

14. Gas Flow Meter Vortex type gas Flow meter to

measure instantaneous and

integrated flow meter, bio gas flow

0-800 m3/Hr

15. Pressure gauges for liquid

pressure measurement

Bourdon type pressure gauges

with Vi" NPT connection, pressure

ratings 0-5.0 kg/cm2, 4" Dial Size

16. Pressure gauges for Gas

pressure measurement:

Diaphragm type pressure gauges

with V-i" NPT connection,

pressure ratings 0-700 mmwc g,

4" Dial Size.

17. Temperature Gauges for

Panel Indication:

Dia Type temperature Indicator

with 0-100 deg C range. Qty-2 nos

—

18. Pressure switches for

flare stake

Pressure switches for High & Low

Pressure Indication and Blower

operation. Qty-2 nos

—

19. Flame Arrestor: Suitable Dia. SS Flame arrestor

suitable for biogas flow of 800

m3/Hr, Flanged connection.

—

20. Breather Valve 200 / 100 mm Dia Dead weight

type breather valve, pressure

setting 500 mm WCG and

vacuum setting 70 mmhg Qty-1 no

—

21. Level Indicator: Glass Tube level indicator with a

range of 0-1000 mmhg to

measure the water seal in flare

stack. Qty-1 no

—




26

EVAPORATION PROCESS

Evaporation is an operation used to remove a liquid from a solution, suspension, or emulsion

by boiling off some of the liquid. It is thus a thermal separation, or thermal concentration,

process. Evaporation process can be defined as one that starts with a liquid product and ends

up with a more concentrated liquid as the main product from the process.

In first evaporation stage,

Bio-methanated Spent wash will be subjected to heat through steam

Spent wash vaporized in first stage will give energy to second stage.

There will be total four falling film evaporator and one forced circulation evaporator.

These Evaporators will be in forward feed arrangement.

Vapours of Second evaporator will be fed to third effect Evaporator. Vapours of Third

evaporator will be fed to fourth effect Evaporator. Then, Vapours of fourth evaporator will

be fed to fifth effect Evaporator.

Falling film evaporators will be operated at very low temperature differences between the

heating media and the boiling liquid, and they also have very short product contact times,

typically just a few seconds per pass.

These characteristics make the falling film evaporator particularly suitable for spent wash

evaporation.

This is specifically designed Spent wash distributors for the proper distribution of Spent

wash in tubes. Specific design of the liquid distribution system achieve full and even

product wetting of the tubes. Because of the low liquid holding volume in this type of unit,

the falling film Evaporator can be started up quickly and changed to cleaning mode

easily.

Falling film evaporators are highly responsive to alterations of parameters such as

energy supply, vacuum, feed rate, concentrations, etc. it will be equipped with a well-

designed automatic control system therefore it can produce a very consistent

concentrated product.

BIO METHANATED SPENT WASH EVAPORATION SECTION

Spent wash feed : 480 TPD

Feed Solid Concentration : 5%

Process Condensate Qty : 400 TPD

Final Spent Wash after evaporation : 80 TPD

Final Spent wash Solids concentration : 30%




27

Sr. No. DESCRIPTION SPECIFICATIONS MOC

1. Flash tank Type: Vertical/ Cylindrical-

conical bottom Capacity: 4 m3

SS304

2. Biomethanated spent

wash Pre heater

Type - Shell & tube.

Quantity- 3 No.

SS304

3. Spent wash feed tank Type: Vertical/ Cylindrical-

conical bottom Capacity : 15

m3

SS304

4. Vacuum Blower for

flash tank

Type : Water Ring Blower

Capacity: 200 Nm3/Hr. Qty:

1+1 no.

Cl/ SS 304

Internals

5. Flash vessel condenser Type - Shell & tube,

Quantity-1 No. HTA-51 M2

SS304

6. Feed Pump motor Capacity: 18 m3/hr Type -

Centrifugal Type, Quantity-1

+ 1 Nos. Single Mechanical

Seal

Wetted Parts

SS 316

7. Falling Film

Evaporators

Type : Shell and Tube Qty: 4

FF Evaporator HTA FF1: 100

m2 FF2: 150 m2 FF1: 150 m2

FF1: 150 m2

SS 304 Shell

with SS 316

tubes

8. Forced Circulation

Evaporator

Type : Shell and Tube Qty: 1

FC Evaporator HTA : 170

SS 304 Shell

with SS 316

tubes

BIO-COMPOSTING

FEATURES OF BIO COMPOSTING TECHNOLOGY

Zero discharge concept

Complete Destruction of BOD in effluent

Flies & odour free

High quality product

Dry baggable product, easy to handle and transport.

PROCESS OF BIO COMPOSTING A Composting cycle takes 8 weeks to complete and involves the following activities.

1st week

1. Collection of raw material:

First week Filter Cake, Boiler Ash and organic residues compose one compost batch. They

are hauled from storage yard to the bioearth compost area, a level and well-drained land that

permit heavy equipment operations.




28

2. Formation of Windrows & Trimming

Using a pay loader the press mud is spread in piled windrows and trim to allow passage of

Aero tiller. Each windrow consists of 100-150 metric tons of press mud. Each windrow is of

1.5m width at bottom and 100m length.

2nd week

1. Aerating and mixing:

Make the first pans of the mixovator on windrows.

2. Inoculation of bioearth:

After the first aeration pass, the material will have achieved moderate mixing and ready

for application of acitobactor and Phosphorous soluble reagent at ½ kg per ton of

waste. This will accelerate composting stabilize temperature 65-750C and enhance

beneficial microbes.

3. Aerate the pile after inoculation and retrim.

3rd to 6th week

1. Maintenance of Moisture:

The Moisture of the pile is maintained to 50% to 60% heat is evolved during process,

this built up together with solar heat and other factor increases. Temperature resulting

to evaporation. Moisture drops to a level of about 30%to35%.

2. Application of Distillery effluent after Digesters:

Excessive/ inadequate moisture slows down composting exhibited by drop in

temperature from the trend established. Windrows are watered back to desired

moisture level using distillery effluent as moisturizing agent. The total volume

applicable each week is sprayed three times during the week.

3. Aeration:

Make one to two pass of the Mixovator after each effluent application and then retrim.

Mixovator grinds, blends, spreads, aerate and disperse the growing fungi for a uniform

and thorough decomposition of the windrow.

4. Inoculation with culture

During the 5th week, culture is again applied at 0.5 kg/ton in order to restimulate

microbial activity and to stop the development of odour.

5. Curing, Aging and Drying

7th week:




29

Effluent application is stopped at the end of the 6th week and the compost is allowed to cure

and age. Water is applied during the 7th week while mixing is continued twice in a week until

moisture stabilizes at 20%to 30%.

8th week:

Disposal of Bio earth to End –user Farms:

Transport the bio earth to end-user farm or a suitable storage in order to vacate the area

occupied by the compost and accommodate another batch Otherwise, a large bio-earth

composting area may be needed to process the annual production of waste.

LAND REQUIREMENT FOR BIOCOMPOSTING

Quantity of Bio-methanated evaporated spent wash 80 KLD

No. of operating days 270 days

Annual Quantity of Bio-methanated evaporated spent wash 21,600 KL

Off seasonal run-off from compost yard 400 KL

Total effluent to be sent to compost yard 22,000 KL

Pressmud to effluent ratio 1:1.5

Filler material requirement per Annum 14,667

Composting cycle 60 days

No. of cycles 4

Filler material required per cycle 3667 T

Filler material that can be processed in 1 Acre: 1000 Tons/cycle

Land required for composting 3.7 acres

Total land requirement

Land required for composting 3.7 acres

Land required for storage of filler material 1.1 acre

Land required for storage of finished product 0.8 acre

Total land required for composting 5.6 acres

Quantity of organic compost 7,920 T

Availability of Pressmud Total Pressmud generation from sugar plant 45,000 TPA against the requirement 14,667 TPA.

The above Bio-compost will be given to farmers to be used as manure in the agricultural fields.

Hence availability of pressmud will not be a problem.




30

Leachate collection system A leachate collection system will be provided will be constructed with RCC M20 grade

concrete along with 250 micron HDPE lining to make it leak proof as per CPCB/BIS

specifications.

Specifications for compost plant Specification of floor of compost yard will be as under (with arrangement of leachate collection

& surface runoff and its pumping to holding lagoon and laying of pipe network for automatic

spraying of spent wash)

I. Compaction of soil

II. 5 cm local sand cushion (bottom)

III. 250 micron HDPE sheet (as per BIS specification)

IV. 5 cm sand cushion (top)

V. Brick / stone soling (not less than 6 cm in case of brick & 3 cm in case of stone

soling)

In case the coefficient of permeability is less than 10-8 cm/sec (as in black cotton soil), 30 cm

depth of impervious soil, compacted with 30 cm depth of murum at the top may also be used.

The bio-compost yard will be kept dry before starting of the monsoon period. The compost

yard is surrounded by garland canal to divert storm water from outside entering inside and

bund to prevent the surface run off from going outside the compost yard during rainy days.

Outside the garland canal greenbelt will be prepared for aesthetic reason and for avoiding

erosion. 10 acres of land will be prepared for Bio composting as per CPCB guidelines.

Specification for storage of filler material Press mud will be transferred to compost yard before on set of monsoon and covered with

HDPE / PVC sheet / tarpaulin.

Specification for storage of finished product (compost) Land area is raised by about 30 cm above ground level. The maximum height of storage is

restricted to 4m. Finished compost will be kept. Covered with PVC / HDPE sheet / Tarpaulin to

prevent soaking from rain water.




31

Compost quality

Moisture content : < 35%

Organic carbon : 20 -25%

Phosphorous : 1.5 - 2.0%

Nitrogen : 1.5 - 2.0%

Potassium : 2.0 - 3.5%

C: N ratio : <17

Equipment & Machinery available for composting in the plant (as per CPCB protocol)

1. Tractor for transportation of press mud from storage site to compost area - 1 No.

2. Homogenising machine along with auto spraying system with 70 HP tractor

(for churning up to the bottom) - 1 No.

3. Front end loader with tractor or JCB of bucket capacity of 600 -1000 kg -1 No.

4. Automatic windrow forming mechanism – 1 No

5. Sieving Machine - 1 No.

6. Sewing machine for bagging of compost (finished product) - 1 No.

Organic compost produced in the treatment of spent wash with pressmud will be supplied to

the farmers at subsidized prices. With this the usage of compost chemical fertilizers

consumption will come down. With compost the sugar cane yield will increase by about 25%.

Storage of Pressmud

Pressmud will be transferred to compost yard before on set of rainy season and shall be

covered with tarpaulin.

Biomethanated Evaporated Spent wash storage lagoon

During the monsoon period bio-composting cannot be carried out. Hence distillery will be not

be operated during monsoon season and will be operated for only 270 days in a year.

Biomethanated Evaporated Spent wash storage lagoon size will be restricted to 5 days instead

of 30 days.

The storage lagoon will be made impervious constructed with RCC M20 grade concrete along

with 250 micron HDPE lining. The storage capacity of the lagoon will be for 5 days. The

capacity of the Bio-methanated Evaporated Spent wash storage tank will be 12.5 m x 8 m x

4.3 m.

Leachate collection Tank

Leachate Collection tank will be made impervious with 250 micron HDPE lining as per CPCB

specifications.




32

Spent wash storage lagoon Spent wash storage lagoon having storage capacity for 3 days, which is far below the CPCB

norm of 30 days. This storage lagoon will be made impervious by providing 500 micron HDPE

lining as per CPCB specifications. The size of the lagoon will be 21.5 m x 17 m x 4.3 m

(including a freeboard of 0.3m).

Grains as raw material Decantation of Spent Wash

Spent wash from mash column bottom is fed to decanter centrifuge after cooling in fermented

mash pre-heater. The decanter concentrates the solids present in the spent mash to desired

level.

The wet cake is separated in decanter at 25% to 30% solids. This wet cake will be sold

directly as cattle feed or mixed with concentrated Thin slop for further concentrating in Dryer.

Evaporation Process

The objective of Evaporation is to concentrate a solution consisting of a volatile solute and a

volatile solvent. Evaporation is conducted by vaporizing a portion of the solvent to produce a

concentrated solution of thick liquor with 30% solids and 70 % moisture content.

The evaporation system consists of Evaporators connected, in series. The spent wash will be

pumped from distillation section, which will be fed to the evaporator by using feed pump. Gas

Liquid separator (5 Nos.) will be used to separate the vapor and liquid. Both Vapor & Spent

wash will be fed to the next evaporation effect so it is called as Feed Forward Effect

Evaporation. The vapor from last evaporator will be condensed in condenser and transferred

to the dryer while the condensate from the evaporators is first utilized for heat recovery. While

vacuum pump maintains vacuum in the entire system. Product final thin slop with 30% solids

will be transferred to the drying system where it is further concentrated to 88 - 90 % solids.

The condensate from evaporation will be recycled.

Drying Process

The wet cake from the Decanter and the concentrated syrup with 30% solids from the

Evaporator will be dried in a steam tube bundle dryer to produce DDGS with 10% moisture

and 90% solids, which will be sold as cattle feed. It is totally a zero discharge process, which

is in accordance with the CREP recommendations.

Zero discharge will be implemented as per CREP recommendations.




33

Non Process Effluent Treatment & Disposal:

The boiler blow down & DM Plant & Softener regeneration water will be treated in a

neutralization tank and after treatment it will be mixed with CT Blow down. All these treated

effluent streams will be stored in a Central Monitoring Basin (CMB). The treated effluent will be

used for dust suppression / ash conditioning and onland for irrigation within the premises after

ensuring compliance with CPCB / APPCB standards. The scrubbed water from CO2 Scrubber

will be consumed in the Fermentation section. The effluent will be used for greenbelt

development within the plant premises after ensuring the compliance with CPCB/APPCB

standards.

Storage Lagoon:

A Spent wash storage lagoon of storage capacity of 5 days which is less than 30 days will be

provided as per CPCB protocol. Closed storage tank will be provided.

3.11 Solid Waste:

The following are the solid waste generation & disposal.

S. No Solid waste Total Quantity

(TPD) Disposal

1. Yeast sludge 7.2 Will be bio-composted along with concentrated Spent wash

2. DDGS (with 90% solids)

54 Will be sold as cattle feed.

3. Boiler Ash

With 100 % biomass

30

Ash generated will be utilized as manure, when rice husk is used as fuel. Ash generated will be given to brick manufacturers / cement plant, when coal is used as fuel.

or

With 100 % India

coal 45

or

With 100 % Imported

coal 6.4




34

4.0 SITE ANALYSIS

4.1 Connectivity:

Component Description

Road The site can be well approached by a SH # 4 (Zaheerabad – Bidar)

Rail Nearest Railway station located at 5.8 Km (Mettalkunta)

Air port Nearest Airport located at Hyderabad which is at distance of 100 Kms

from the Plant site

Sea Port Krishnapatnam port is at a distance of 450 Kms from the Plant site

4.2 Land form, Land use and Land ownership: The present use of the land is Industrial as existing sugar plant is under operation. Now the

proposed Distillery unit activities will be taken in the existing plant premises only in the leased

land of 29 acres.

4.3 Topography: The topography of the land is more or less flat without undulations.

4.4 Existing land use pattern: The present use of the land is Industrial

4.5 Existing Infrastructure: The infrastructure required for Distillery unit will be developed in the leased land.

4.6 Soil classification: The soil at the site is Sandy loam

4.7 Climatologically data: District climate is classified as tropical. The summers here have a good deal of rainfall, while

the winters have very little. The climate here is classified as AW by the Köppen-Geiger

system. The average temperature in Sangareddy is 26.3 °C. The average annual rainfall is

861 mm.




35

4.8 Social Infrastructure Available: Education

An IIT was established in 2008 near to Sangareddy at Kandi. And also JNTUH College of

Engineering Sultanpur at Sultanpur which is near by the city has been established recently.

Road:

Since Sangareddy is near Hyderabad, it is well connected to other areas like Hitech city, DLF

Gachibowli (appx 35 km away), Panjagutta and Secunderabad. The NH-9 passes through the

city. Sangareddy has two Bus Stations, the Old for Ordinary service and the new for luxury

and other services.

About 15 km Away from Sangareddy there is an outer ring road which connects to

Shamshabad airport- Rajiv Gandhi International Airport Hyderabad and to Gachibowli and

Medchal.

Rail

The nearest railway stations are Lingampally which is about 30 km, Secunderabad about 50

km and Nampally Station around 55 km. In coming years it is expected that there will be Metro

rail/ MMTS track to connect the city to Lingampally.

Air

Nearest Airport is Hyderabad International Airport which is 70 km from Sangareddy.

5.0 PLANNING BRIEF

5.1 Planning Concept: The Distillery plant is planned in the leased land taken from M/s Trident Sugars Limited to

utilize the Molasses generated from the existing Sugar plant.

Along with the Molasses, pressmud generated from the Sugar plant also will be utilized for

treatment of Spent wash.

During the non-availability of Molasses, Grains will be used as raw material.




36

5.2 Population Projection: Unskilled Man Power required for the proposed Project will be met from the local villages

completely. Qualified semi-skilled man power required will be met from local villages if

available. Hence there will not be much population increase in the area.

5.3 Land use Planning: The following is the Land use Planning of the area

ITEM LAND IN ACRES

Built up area 5.0

Internal roads 2.0

Effluent treatment plant 2.0

Green belt area 10.0

Bio-composting 8.0

Truck parking 1.0

Rain water harvesting reservoir 1.0

Total 29.0

5.4 Amenities / Facilities: Facilities like canteen, rest rooms and recreation facilities will be provided in the proposed

Distillery project.

6.0 PROPOSED INFRASTRUCTURE:

6.1 Industrial area

The following Plant and machinery will be installed in the Industrial processing area

List of Plant and Machinery for proposed project

Distillery Plant:

SECTION I : FERMENTATION HOUSE :

MOLASSES WEIGHING SECTION :

1] Weighscale / Loadcell for Check : 1 No.

weighment. Capacity : 3 MT

2] Molasses feed tank : 1 No.

Material of construction : M.S

Capacity : 50 MT

- FERMENTATION EQUIPMENTS




37

1. PROCESS TANKS

A] Fermenter : 2 Nos

Material of construction : MS

Capacity : 500m3

Equipped with roof manholes, air sparger in stainless steel construction, sight and light

glass assemblies, level indicator, defoaming oil sensor, pressure relief device and

required nozzles and fittings.

All internal surface will be sand blasted and epoxy coated ( 1 primer coat followed by

2 finish coats - min. DFT (150 micron ).

B] Propagation Vessel I

Design code : ASME VIII, Div. 1

Material of construction : SS 304

Capacity : 180 L

Equipped with sight glass, air sparger, cooling jacket, relief valve and necessary

nozzles and fittings.

C] Propagation Vessel II

Design code : ASME VIII, Div. 1


Capacity : 2000 L

Equipped with sight glass, manhole, air sparger, relief valve and necessary nozzle and

fittings.

D] Propagation Vessel III

Geometric Capacity : 100,000 L

Design code : IS 803

Material of construction : MS (epoxy lined)

Equipped with shell and roof manholes, air sparger, sight and light glass assembly and

necessary nozzles and fittings.

All internal surfaces will be sand blasted and epoxy coated (1 primer coat followed by 2

finish coats - min. DFT 150 micron).

E] Defoaming Oil Day Tank.

Capacity : 1000 L

Material of construction : MS

2. PROCESS PUMPS :

A] Molasses feed pump : 1 + 1 standby.

Type : Positive displacement

Material of construction : CI with SS wetted parts.




38

Shaft sealing. : Gland packing.

Drive : Variable speed

-Molasses storage to feed : 1+1

-Weighing to diluter : 1+1

B] Fermenter Cooling Pump : 2 + 1 standby

Type : Centrifugal


C] Fermenter Discharge Pump : 1 + 1 standby

Type : Centrifugal


D] Wash Transfer Pump : 1 + 1 No.

Type : Centrifugal


E] Sludge Pump : 1 + 1 No.

Type : Centrifugal


F] Recycle Pump : 1 + 1 standby

Type : Centrifugal


G] Propagation II Cooling Pump : 1 Nos.

Type : Centrifugal


H] Defoaming oil dosing Pump : 1

Type : Positive displacement.

Material of construction : GI

3. PLATE HEAT EXCHANGERS. [ Alfa Laval make ]

M.O.C of Qty

Plates Nos.

a] Prop II Temp. Control PHE SS 316 1

b] Fermenter Cooling PHE SS 316 2

(Min.AK 20 FMI 168 plates each with back flushing arrangement)

4. MISCELLANEOUS :

A] Positive Displacement Blowers : 1 + 1 standby

Type : Twin lobe

Material of construction : CI body, cast steel.




39

Braided with suction/discharge silencers, relief valve, non-return valve & suction filter.(

water cooled) OR

Alternatively Vacuum Pump may be considered for same duty.

Capacity : 1700nm3/hr+900nm3/hr

Head : 9 MWC

B] Carbon-di-oxide Scrubber : 2 Nos.

Type : Sieve plate column


Plate material : SS 304

Diameter : 600mm

With water spraying arrangement in AISI 304, sight glass and packing support grid.

C] Strainers - : 3 Nos.

For : 1) Fermented wash

2) Recycle.

3) Diluted Molasses

Type : Basket

Material of construction : AISI 304

Hole size : 0.6 mm

D] Sterile Air filters : 2 Nos.

Capacity : 20 M3/Hr. & 120 M3/Hr

E] Water molasses static mixer in AISI 304 : 1 No.

F] Air Compressor for Instrumentation Air : 1No+1No (Common for entire

plant including Mol. Sieve plant)

5. YEAST RECYCLING SYSTEM :

A] Yeast Separator [Alfa Laval make] 2 + 1 Nos.

Indigenous model DX 409

B] Chain Pulley block with travelling trolley : 1 No.

Capacity 1 MT

C] Cleaning table for separator in MS : 1 No.

D] Yeast Cream Funnel : 3 Nos.

Material of construction : SS304

E] Hydrocyclones : 1 Set.

Material of construction :

- Body : AISI 304

- Cone : Ceramic




40

6. CIP SYSTEM :

I CIP tank/Hot water tank : 1 No each.

Capacity : 2000 L

Material of Construction : AISI 304

II CIP Pump : 1 No.

Type : Centrifugal


7. Cooling Tower : 2 Nos. 400 Cu.m./ hr.

SECTION II : Distillation

1 Analysing Column (Vacuum) Material of Construction : SS304

Type of Trays : Sieve

No. of trays : 50

Tray spacing : 750mm

Diameter : 1698mm / 2195mm

(min. diameters mentioned)

2 Rectifying Column (Under pressure) Material of Construction : SS304


No. of trays : 144

Tray spacing : 300

Diameter : 1790mm


3 Aldehyde Column Material of Construction : SS304


No. of Trays : 60

Tray spacing : 250mm

Diameter : 710mm


7 Beer Pre-heater : Shell & Tube type

Material of Construction : SS 304

Tube length : 3000mm

Tube thickness : 1.25mm

8 Analysing coloumn Reboiler : Shell & Tube type

Material of Construction : Shell: 304Tubes: SS316




41



Qty : 1+1

9 Stripper Rectifier Column Reboiler

Type: Shell & Tube

MOC: Tubes : SS304 Shell : CS, Ends : CS

Qty : 1 Nos.

10 Final Condensor : Shell & Tube type

Material of Construction : Tube and tube sheet are in

SS 304, water side in CS



11 Aldehyde Condensor : Shell & Tube type




12 Aldehyde Vent Condensor : Shell & Tube type




13 Final Product Cooler : PHE

Material of Construction : SS 304 plates

Area : Suitable

14 Fusel Oil / Heads Spirit Cooler : Vertical type


15 Fusel Oil washer decanter : Vertical type


16 Steam Chest : 1 No.

Material of Construction : MS

17 Hot water tank

Capacity : 1 M3

Material of Construction : MS

18 Reflux Tanks : 2 Nos.

19 Plate Heat Exchangers:




42

Sr. Description M.O.C. (Plates) Qty.

I Wash Pre-heating PHE SS316 2

II Recycle Wash Cooler (Recycle) PHE SS316 1

III Spent Wash Cooler PHE SS316 1

20 Pumps : With flame proof motors, mechanical seals & back pull out rotor design.

Sr. Description M.O.C. Qty.

IV Rectifier Reflux Pump SS316 1+1

V Weak Alcohol feed pump SS316 1+1

21. Cooling Tower : 2 Nos. 375 Cu.m. / hr.

SECTION III: Molecular Sieve Dehydration:

1 Mol Sieve Superheater

Type: Shell & Tube

MOC: Tubes: SS304 Shell: CS Bonnets: CS

Qty : 1 Nos

2 Mol Sieve Unit

Type: Dished ends; with packed bed of Molecular Sieves

MOC: SS

Qty: 2 Nos

3 Mol Sieve Condenser

Type : Shell & Tube

MOC: Tubes: SS304 Shell: CS Bonnets: CS

Qty : 1 Nos.

4 Mol Sieve Product Cooler

Type: PHE

Qty : 1 Nos.

5 Mol Sieve Regenerant Condenser

Type: Shell & Tube

MOC: Tubes : SS304 Shell : CS Ends : CS

Qty : 1 Nos.

6 Mol Sieve Regenerant Drum

Type: Dished top & bottom

MOC : SS

Qty: 1 Nos




43

7 Mol Sieve Vacuum Pump Drum

Type: Dished top & bottom

MOC : SS

Qty: 1 Nos. 1

8 Mol Sieve Recirculation Cooler

Type: PHE

Qty : 1 Nos.

9 Mol Sieve Regenerant Pump

Type: Centrifugal

MOC: Impeller:SS Casing: CI

Qty: 1 + 1 No.

10 Mol Sieve Vacuum Pump

Type: Liquid Ring

Qty : 1 No+1No

11 Rectified Spirit Day Tanks: 2 Nos. MS , Capacity : 100 KL Each.

Additional Columns for ENA Production.

Extractive Distillation Column

Recovery Column

Polishing Column

6.2 Residential Area (Non Processing area): Facilities like canteen, rest room and indoor games facilities will be provided in the proposed

project.

6.3 Green Belt: Total 1/3rd of the total area including existing will be developed in the Plant premises.

Greenbelt development plan

Local DFO will be consulted in developing the green belt.

Greenbelt of 10 acres will be developed in the plant premises as per CPCB guidelines.

15 m wide greenbelt will be developed all around the plant.

The tree species to be selected for the plantation are pollutant tolerant, fast growing,

wind firm, deep rooted. A three tier plantation is proposed comprising of an outer most

belt of taller trees which will act as barrier, middle core acting as air cleaner and the




44

innermost core which may be termed as absorptive layer consisting of trees which are

known to be particularly tolerant to pollutants.

6.4 Social Infrastructure: Social infrastructure will be developed as per need based in the nearby Villages.

6.5 Connectivity:

Component Description

Road The site can be well approached by a SH # 4 (Zaheerabad – Bidar)

Rail Nearest Railway station located at 5.8 Km (Mettalkunta)

Air port Nearest Airport located at Hyderabad which is at distance of 100 Kms

from the Plant site

Sea Port Krishnapatnam port is at a distance of 450 Kms from the Plant site

6.6 Drinking water management: Drinking water required for the workers will be met from ground water resources.

6.7 Sewerage system: Domestic waste water generated will be treated in septic tank followed by Sub-surface

dispersion

6.8 Industrial waste management:

6.8.1 Waste Water Management Waste water generated from the proposed Project will be treated in Effluent Treatment

proposed which is furnished under paragraph 3.10.2

6.8.2 Solid Waste Management

Solid wastes disposal in proposed project is discussed in paragraph 3.11

6.9 Power requirement & Supply / Source: The power required for the project will be met from 1.5 MW captive power plant




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7.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN

No rehabilitation or resettlement plan is proposed as there are no habitations in the in the

Plant site.

8.0 PROJECT SCHEDULE & COST ESTIMATES

The total cost of the project has been estimated at Rs. 71.4 Crores.

Detailed breakup of the Cost is given below.

S.No. Particulars AMOUNT

(Rs. in crores)

1. Land cost : 8.7

2. Land development, Roads , Boundary wall : 2

3. Civil : 6

4. Structure : 18

5. Plant and Machinery : 23

6. Ware Housing : 4

7. Miscellaneous : 2

8. Preliminary expenses : 2

9. Working capital margin : 1.50

10. Interest during construction : 4.20

Total project cost : 71.40

MEANS OF FINANCE

1. PROMOTERS (33%) : 31.40

2. TERM LOANS (67%) 40.00

Total : 71.40




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9.0 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)

With the implementation of the proposed project, the socio-economic status of the local people

will improve substantially. The land rates in the area will improve in the nearby areas due to

the proposed activity. This will help in upliftment of the social status of the people in the area.

Educational institutions will also come-up and will lead to improvement of educational status of

the people in the area. Primary health center will also come-up and the medical facilities will

certainly improve due to the proposed project.

EMPLOYMENT POTENTIAL The following will be the man power requirement for the proposed Project

S.No. Particulars No. Employees

1. Technical & Administrative Staff 20

2. Skilled & Semi Skilled (Contract basis) 20

3. Unskilled & Helpers (Contract basis) 20

Total 60

OTHER TANGIBLE BENEFITS

The following are the other benefits to the area due to the proposed project.

Educational status will improve in the area

Medical standards will improve due to the proposed project.

Overall economic up-liftment of socio-economic status of people in the area.

Ancillary developmental activities like CO2 plant, Cattle feed plants will be created due

to the establishment of the proposed unit.

SOCIO-ECONOMIC DEVELOPMENTAL ACTIVITIES

The management is committed to uplift the standards of living of the villagers by undertaking

following activities / responsibilities.

Health & hygiene

Drinking water

Education for poor

Village roads

Lighting

Helping locals to conduct sports

Training to the unskilled manpower




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HEALTH & HYGINE

1. Personal and domestic hygiene,

2. Maintaining clean neighborhood,

3. Weekly health camps offering free-check up & medicines

4. Ambulance services

5. Education & drug de-addiction, aids.

DRINKING WATER

Making drinking water available at centralized locations in the village,

SUPPORTING EDUCATION

1. Providing books to all poor children,

2. Conducting annual sports festival in the village schools,

3. Providing amenities like fans, lavatories,

4. Maintain play ground etc.

Documents

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