PRE FEASIBILITY REPORT PRE-FEASIBILITY … · PRE FEASIBILITY REPORT 20 Document No: ... grain based distillery unit to 65 KLPD grain based distillery unit along with MW 1.5 ... Milling

Capacity expansion from 6KLPD (Grain/Molasses based) to 65KLPD (Grain based) Distillery Unit M/s Suidihi Distillery Private Limited. PRE FEASIBILITY REPORT

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Document No: 2016_VI_00011

PRE-FEASIBILITY REPORT

FOR

EXPANSION FROM 6 KLPD

(GRAIN/MOLASSES BASED) TO 65 KLPD

(GRAIN BASED) DISTILLERY UNIT ALONG

WITH 1.5 MW COGENERATION POWER

PLANT

FOR

SUIDIHI DISTILLERY PRIVATE LIMITED

At Village –Suidihi, P.O. Lathikata, District –

Sundargarh, Odisha

APPLICANT

M/s. Suidihi Distillery Private Limited Village Suidihi, Post: Lathikata, Dist:

Sundergarh, Odisha.


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PRE-FEASIBILITY REPORT 1.0 Executive Summary

Earlier, the assessment of the projects was done on Technical feasibility reports and Cost-Benefit-Ratio which mainly considered financial & technical resources. But no consideration was given to the environment protection in this evaluation and these flaws became apparent with continuous deterioration of environment. Thus in order to have more realistic evaluation, and keeping in view the deteriorating conditions, another dimension was added which is now called as “Environmental Impact Assessment” (E.I.A.). This forms an integral part of the project and is taken into account while appraising the project at different stages. Thus in the new comprehensive approach all considerations like, Technical, Financial & Environmental are given due weightage. M/s Suidihi Distillery Private Limited. is proposing for capacity expansion of 6 KLPD RS/ENA producing distillery unit to 65 KLPD TS/ENA producing distillery unit along with 1.5 MW Cogeneration Power Plant. As per EIA Notification dated 14th Sept., 2006 and amended from time to time, the proposed project falls under Category “A”, Project or Activity 5(g). They have to submit Form-I along with Pre-Feasibility Report and other relevant documents for getting Environmental Clearance. This pre-feasibility report has, therefore, been prepared by the consultant to assess the likely impact of the proposed on various factors which may be affected with the implementation of the program me and to suggest remedial/precautionary measures, if any.

2.0 INFORMATION OF PROJECT/BACKGROUND INFORMATION i) Identification Of Project And Project Proponent

Project: M/s Suidihi Distillery Private Limited. is proposing for capacity expansion of 6 KLPD RS/ENA producing distillery unit to 65 KLPD TS/ENA producing distillery unit along with 1.5 MW Cogeneration Power Plant.

Project Proponent Suidihi Distillery Pvt. Ltd. (SDPL) was incorporated on 20.10.2004 having its registered office at Village :Suidihi, Post: Lathikata, DistSundergarh, Odisha. The company is having two directors namely Shri Sunil Choudhary, and ShriMoniPoddar. The description of the directors is as below;

1. Shri Sunil Choudhary, Director, Age: 44 years

Father’s Name: Late Pawan Kumar Choudhary Address: F – 9, Civil Township Rourkela – 769004 Orissa, India Education Qualification: B. E. (ChE) U.S.A University of Louisiana

Experience : 15 years of Industrial Management 2. ShriMoniPoddar, Director,

Age: 64 years Father’s Name: Late GourangPoddar Address: Basanti Colony, Rourkela


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Education Qualification: B.Com Experience: 35 Years of Industrial Management Besides this, the management team comprises of many other senior members. The company is managed by well-qualified persons having progressive attitude and qualification.

The promoters of the project have already worked in their small distillery unit, M/s Suidihi Distillery Pvt. Ltd. at Village Suidihi, Post Lathikata, District Sundergarh, Odisha. This unit is the first grain based unit in the state of Odisha. The promoters having learnt from the operation of the unit strongly believe that there is ample scope for a larger integrated grain based distillery in the State of Odisha.

ii) Brief description of nature of project:

The proposed project of M/s. Suidihi Distillery Private Limited is for expansion of 6 KLPD grain based distillery unit to 65 KLPD grain based distillery unit along with 1.5 MW Cogeneration power plant at village Suidihi, Post Lathikata, District Sundergarh, Odisha.

iii) Need for the Project and it’s importance to the country and or region.

Due to abundant availability of raw materials being used in the grain based distilleries there has been a huge demand for grain based extra neutral alcohol for the fast growing IMFL Industries and for blending in Foreign Liquor outside India which has been a multi-fold surge in demand. Due to substantial deficiency in supply of grain based ENA and potentiality of the national & international market M/s. Suidihi Distillery Private Limited have planned for expansion of 6 KLPD grain based distillery to 65 KLPD grain based distillery unit in the major grain producing area of Odisha. The proposed expansion of distillery project will play an important role in upliftment of the socio economic condition of the region particularly nearby villages.

iv) Demand Supply Gap

The total requirement of ENA / IMFL / Ethanol in India is 600 crores litres (25% ENA from grain & 75 % from molasses) and 350 Crore Litres for Ethanol as Fuel whereas, in India, total production of ENA from molasses and grain is 148 crores litres per annum. Next five year projected ENA from grain 40 % & from molasses 60 %. 275 Crore Litres of alcohol produced from molasses were used by oil companies in the year of 2014-15. Projection for the year 2015-16 is 50.50 crores litres by the oil companies. Post 2017 India will require 6.30 billion litres of alcohol mainly from molasses for the use in petrol by the oil companies. Therefore, the huge demand of ENA made out of grain will arise.

v) Imports vs. Indigenous Production Indian producers are not able to meet present alcohol demand. Approx 5-7% of total demand of alcohol is being imported from other countries. As far as ENA production is


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concerned, Indian market play a vital role at both domestic & international level. In this context, there is major requirement of indigenous grain based alcohol production to reduce the import load and save the revenue.

vi) Domestic/Export Market There is a huge demand of Indian made grain based alcohol in the national and

international market. vii) Employment Generation (Direct and indirect)

Due to the proposed expansion of distillery project in the region direct and indirect employment avenues will be created in the nearby areas. In existing 6 KLPD grain based distillery 25 manpower is currently employed. An additional 75 nos. of manpower including officers, management personnel and workers etc. will be employed after the establishment of the 65 KLPD distillery project.

3.0 PROJECT DESCRIPTION i) Type of Project including interlinked and interdependent projects, if any The proposed expansion project of distillery unit is for setting up of manufacturing facilities to produce Extra Neutral Alcohol (ENA). It is based on primarily agricultural products (grain based). The project will be equipped with fully diversified processing facilities. ii) Location (Map showing general location, specific location, and project

boundary and project site layout) with coordinates Location: Village: Suidihi Post: Lathikatha District: Sundergarh State: Odisha


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Figure 1: Google Image


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Figure 2: Key Plan showing 10 km radius study area


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Figure: 3 Layout Plan

Capacity expansion from 6KLPD (Grain/Molasses based) to 65KLPD (Grain based) Distillery Unit of M/s Suidihi Distillery Private Limited. PRE FEASIBILITY REPORT

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iii) Details of alternate sites Considered and the basis of selecting the proposed site, particularly the environment consideration gone into should be highlighted. No alternate sites have been considered for the proposed expansion of distillery project as the due to the existing distillery unit all the facilities are easily available and also has a well-developed infrastructure. Also, the land was easy available and area is rich in raw material sources with ease of accessibility.

Advantages of the Project Site

Required Raw Material (Broken Rice, damaged grains, etc.) & Fuel (Coal) is available easily in the nearby areas. Raw materials can be easily procured from Grain surplus states such as Chhattisgarh, West Bengal, Rajasthan, Uttar Pradesh & even Punjab.

Good availability of Water, Good Quality of Water. Well connected by Road / Rail Network Proximity of Liquor Consuming Markets Well located near Industrial Areas Manpower availability Land availability for carrying out Project expansion Existing infrastructure

iv) Size or magnitude of operation This is the expansion project of 6 KLPD grain based distillery unit to 65 KLPD grain based distillery unit along with 1.5 MW of Cogeneration power plant. 61,750 LPD ENA will be produced from the proposed expansion (65 KLPD).

v) Project description with process details: (a schematic diagram/flowchart layout, components of the project)

The distillery will use grains as raw material in the production of Extra Neutral Alcohol. The process description of alcohol production in using grain as raw materials is as follows:

A) Process Description of 6 KLPD Distillery Unit

Milling and Flour Handling

The incoming grain is first cleaned with the help of destoner and magnetic separators to remove stones and other material which may damage the hammers during milling. The grain is fed to hammer mill in controlled manner. In milling grains are crushed to flour of uniform size. Oversized screening rejects are segregated with the help of vibratory screen. These are taken to coarse bin before sending it to mill again. Intermediate hopper is provided for buffer capacity for flour storage. The flour is metered through a weigh feeder with load cell arrangement before transferring to the mixing tank for slurry preparation process.

Slurry Preparation / Liquefaction


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In liquefaction process, starch is hydrolyzed to dextrin. The Liquefaction is carried out in Single stage Liquefaction Tank. Feedstock Flour is transferred to Premasher and mixed with Recycle Streams and liquefying enzyme. Slurry from Premasher is taken to Liquefaction tank where temperature is maintained by means of steam. Necessary retention time is maintained in the Liquefaction Tank. Slurry pH is maintained by supplying dilute caustic solution. Contents in Slurry Tank are kept in suspension by Agitation. The Liquefied Slurry is then cooled in Slurry Cooler using cooling water supply and transferred to Pre-fermentation and Fermentation section.

SaccharificationAnd Fermentation

Yeast Propagation

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, it is diluted with water. Yeast is 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. CO2 can then be taken to CO2 vent line where it is vented out. After emptying of Fermenter, it is cleaned with CIP using cleaning nozzles.

After CIP, Fermenter is ready for next batch to be filled.

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. Significant heat release takes place during Fermentation. The fermenter temperature is maintained at around 30 – 32oC 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.

The carbon dioxide evolved during the process is scrubbed to prevent ethanol emissions by process water, which is taken to beer well. The flow diagram of process description of grain spirit production is shown in Fig. 3.1.

Wash to Extra Neutral Alcohol – Distillation


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Distillation system has various 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 Thermosyphonreboiler. Vapors of Degasser column are condensed and taken to Recovery Feed Tank. The condensed Analyser vapors are taken to Pre-Rectifier Column. Analyser Condensate is concentrated in Pre-Rectifier column, which operates under pressure. Condensing steam provides energy to pre-rectifier column through a vertical Thermosyphonreboiler. 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 its condensers 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 Thermosyphonre boiler. 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.

Decantation & Thin Slops Recycle Section


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Decantation section comprises of a Centrifuge Decanter for separation of suspended solids from Spent Wash coming out of Grain Distillation Plant. Wet cake has 30-32% 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 35-40% w/w solids. The concentrated thin slops called as Syrup is mixed with Wet cake and sold in wet form as cattle feed (DWGS) or the entire mixture can be dried in the sun as DDGS Sun Drying and then sold in dry form as Cattle feed (DDGS).

Bio Digestor System

UASB Reactor:

Up-flow Anaerobic Sludge Blanket reactor is provided for anaerobic treatment of dairy effluent. The UASB reactor shall be constructed in RCC. The reactor consists of three zones viz. Influent distribution zone, Reaction zone, Gas solid liquid separation zone.

Influent Distribution zone: The raw wastewater enters into the at the bottom through influent distribution zone. A sophisticatedly designed piping network is provided for uniform distribution of the effluent in the tank. The effluent then travels upward in the reactor.

Reaction Zone: In the reaction zone the anaerobic bacteria are maintained in the form of sludge blanket. The organic matter in the wastewater comes in contact with the bacterial population and is degraded anaerobically to methane rich biogas, the end product of anaerobic digestion. The process of conversion of organic matter in to the biogas is a two-stage process. In the first stage the organic matter in the raw effluent is converted in to the volatile acids by acid forming bacteria. In the second stage the acid produced in the first stage are converted in to methane by another group of bacteria i.e. methane formers. In UASB process both the stages are completed in single reactor. The biogas so produced is bubbled through the effluent and is separated out in the third section i.e. Gas-Solid-Liquid separation zone. The suspended solids are also separated to prevent escape of solids from the reactor. The UASB Reactor shall be fabricated in MS and painted with Epoxy paint.

Gas-Solid – Liquid Separation: In gas solid liquid separation a hood fabricated in MS and duly painted with corrosion resistant paint is provided. The hood separates the solid from the overflowing reactor content. Gas collectors are provided for collection and conveyance of gas. The treated effluent overflows through a launder and will take to a secondary treatment.


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Flare Stack

Flare stack fabricated in MS and painted with Epoxy paint shall be provided for Burning the Gas generated in UASB Reactor. The flare stack shall be ignited manually.

Gas Holder:

A gas Holder fabricated in MS shall be provided for storing the gas and carrying it for utilization. The gas holder shall consist of MS floating dome and RCC wet well. The gas stored in the Holder shall then be pumped to boiler using biogas Blower.

Figure 4 : Process Block Diagram for 6 KLPD Distillery


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B) Process Description of 65 KLPD Distillery Unit Grain Processing Section

Grains are unloaded from truck in grain unloading area, and sent to grain pre cleaning section, where the grains are passed through a series cleaning equipments such as Vibrating Screen, Destoner and Magnetic Separator to remove dust stones and fines. The flow through these equipments is under gravity. After cleaning, the cleaned grains are stored in Silos & from there they are conveyed to grain milling section using Screw Conveyors and Bucket Elevators. In milling section the particle size is reduced to as required by the process using Hammer mill. From hammer mill the flour is conveyed to Flour Bin (Intermediate storage for flour). From flour bin the flour is carried to Premasher unit. In Premasher flour is wetted with water.

Liquefaction Two Stage Liquefaction: Slurry from pre-masher is taken to Initial Liquefaction tank where liquefying enzyme is added. This slurry is then “cooked” in the jet cooker. The slurry is continuously pumped to a steam jet cooker where high-pressure steam rapidly raises the slurry temperature. The mixture of slurry and steam is then passed through the retention vessel (cook tube) having sufficient capacity to provide the desired retention time at a given flow rate. The cooked mash is discharged to a flash tank. The cooking process, accomplished in the above manner, converts the slurry into a hydrated, sterilized suspension (as starch molecule is solubilized) and is therefore susceptible to enzyme attack for liquefaction. The gelatinized mash from the flash tank is further liquefied in a liquefaction tank where liquefying enzyme is added. Then the liquefied mash is cooled in slurry cooler and transferred to Fermentation section.

FERMENTATION: Yeast Activation: Yeast seed material is prepared in Yeast Activation Vessel (Pre Fermenter) by inoculating sterilized mash with yeast. Optimum temperature is maintained by circulating cooling water. The contents of the Yeast Activation Vessel are then transferred to Fermenter. The purpose of Fermentation is to convert the fermentable substrate into alcohol. To prepare the mash for Fermentation, it is diluted with water. Yeast is 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 Yeast Activation Vessel (Pre Fermenter). 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. CO2 can then be taken to CO2 vent line where it is vented out. After emptying of Fermenter, it is cleaned for next batch.

DISTILLATION Wash to ENA Mode: - Following Columns will be under operation

• Analyser & Degassifier Column • Pre-Rectifier Column


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• Exhaust Column • Extractive Distillation Column • Rectifier cum Exhaust Column • Recovery Column • Simmering Column

Preheated fermented wash is fed at the top of the De gasifier column. Analyser Column is provided with reboiler. The alcohol is stripped out in analyser column. The rest of the fermented wash flows down the Analyser column and is taken out as the spent wash from Analyser column bottom. Low boiling impurities are concentrated in the Pre Rectifier column. A draw of impure alcohol is taken out from the top of the Pre-Rectifier column. RS draw is taken from the top of the Pre rectifier column, which further is sent to Extractive Distillation column. The Extractive Column operates on the principle of inversion of relative volatility. Low boiling impurities are separated in the Extractive Distillation column & bottom is sent to the Rectifier cum Exhaust column. The Rectifier/Exhaust column concentrates the alcohol. The high-grade spirit is drawn from the upper trays of the rectification column. Fusel oil build up is avoided in the Rectifier cum exhaust column by withdrawing side streams (fusel oils). Recovery column where the fusel oils are concentrated and then sent to decanter where these streams are diluted with water and fusel oil rich layer is separated. Washings are sent back to the column to recover alcohol. The High spirit Draw from the Rectifier column is sent to the Simmering column where methanol is separated in the form of a cut from the top and ENA is taken out from the bottom. ENA drawn from the Simmering Column is taken to the receiver after cooling in ENA cooler. Decantation:- The Thick slops (bottoms) from the distillation section are sent to decantation section. In decantation, thick slops are separated into thin slops and wet cake, based on their density difference. The thin slops separated are reused in liquefaction and distillation sections. The thin slops is sent to evaporation section for further concentration EVAPORATION:-

The suggested treatment scheme is (integrated) working on the principle of falling film Evaporation. Alcohol vapors are used as Heat Source & are fed to the first effect evaporator shell side. The Feed at predetermined temperature is fed to tube side from the top of First effect evaporator. Vapors generated in 1st effect VLS (Vapor Liquid Separator) are used as heat source in the 2nd effect & so on. Finally 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 is obtained. Each effect is provided with recirculation cum transfer pump. The condensate from surface condensers is collected in a common Process Condensate pot. The Process Condensate is transferred to further battery limits by using centrifugal pump. The Pure steam condensate is collected in Steam Condensate Tank and further it will be pumped as per battery limits. The system operates under vacuum. Water-ring vacuum pumps will be used to maintain a desired vacuum. Cooling water from


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cooling tower is used in the surface condensers for condensing the vapors. DWGS DRYER SECTION:- Wet distiller’s grains shall be fed into the dryer housing at controlled rate through a

suitable feeding system. The Rotary Tube Bundle is enclosed in an insulated dryer housing and on its outer flights are fixed. Dry saturated steam is to be supplied to the tube bundle through rotary joint at one end & the condensate is discharged through rotary joint mounted of another end

During the course of rotation, 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.

Figure 5 : Process Flow Chart for 65 KLPD Grain Based Distillery

Power Co-generation 1.5 MW Operations The unit proposes to set-up boiler and power turbine. In this proposed expansion project a 25

TPH boiler will be installed and based on Rice Husk/Coal and as available fuel options. This Boiler


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will operate mainly to feed steam to grain based operations and 1.5 MW power generations from Turbine.

Proposed 1 . 5 MW co-generation plant consists of a high pressure water tube steam boiler extraction cum condensing steam turbine. Fuel in the steam boiler will be burnt with the help of air in the boiler furnace. Water will be circulated in the boiler drum and tubes thus getting heated by the flame burning in the boiler furnace. Water comes out of the boiler drum located at the top of the boiler as steam. Flue gases rise in the boiler furnace and come in contact with the steam coming out of boiler drum. Steam after coming in contact with flue gases gets heated up further thus getting superheated. Super heated steam leaves the boiler in a pipe. Flue gases after super heating the steam pass through economizer where they pre-heat the boiler feed water before it enters the boiler drum. After economizer, flue gases pass through air pre-heaters where they heat the air which is fed to the boiler furnace for burning the fuel. After air pre heaters flue gases pass through Bag Filter/ESP where the dust particles are collected. High pressure superheated steam from boiler will be passed through a steam turbine, which will be used for distillery process operations. While passing through the turbine, the high pressure and temperature steam rotates the turbine rotor and an electric alternator mounted on the same shaft. Electric power will be generated by the alternator. This electric power generated will be consumed in house i.e. for running the distillery and utilities like boilers auxiliaries etc.

Figure 6: Process Flow Chart for Cogeneration Power Plant vi) Raw Material required along with estimated Quantity, likely source, marketing area of final products, mode of Transport of raw material & finished product.


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Table 1: Raw Material Requirement S. No. Particular Requirements Source of the Raw Material &

Mode of Transportation 6 KLPD Unit 65 KLPD Unit

1. Grains 17 MT/day 162-164 MT/day Nearby Market, by closed trucks

2. Steam 1.45 TPH 7.3 TPH From it’s own boiler of 25 TPH

Chemicals

3. Sodium Hydroxide

4.05 Kg/day As per the requirement

Nearby market

4. Sulphuric Acid 5 Kg/day As per the requirement

Nearby market

Enzymes 5. Saccharifying

Enzyme 7kg/day As per the

requirement Nearby market

6. NH2-CO-NH2 (Urea;46%N2)

8Kg/Day As per the requirement

Nearby market

Fuel Requirement 7. Coal Nil 15 MT Nearby market 8. Rice Husk 15 MT 25 MT Nearby market

vii) Resources optimization/recycling and reuse envisaged in the project, if any, should be briefly outlined.

M/s. Suidihi Distillery Private Ltd. will make optimum utilization, recycling and reuse. These resources include Land, Fuel (Rise husk and coal), Grain, Water and Electricity. Wastewater generated from Boiler and cooling tower blow down will be treated and recycled for further process, domestic & green belt development uses.

viii) Availability of Water its source, Energy/Power requirement and source should be given A) Water Requirement

Table 2: Water Requirement

B) Power Requirement Details of power consumption in the distillery are shown in Table 3.

Table 3 Power requirement S.No. Particulars Details Source

1 Power Requirement for existing 6 0.25 MW Source: WESCO (Western

S.No.

Particulars

Existing

Expansion

Total

Source

1 Water 87.6 KLPD 222.40 KLPD 310 KLPD Ground Water & Surface Water


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KLPD Distillery Unit Electricity Supply Company of Orissa and captive co-generation of electricity)

2 Power Requirement for proposed expansion 65 KLPD Unit

1.61 MW

3 Captive Power Production 1.5 MW C) Steam Requirement

Steam is required in the processes such as generation of Power, Liquefaction Process, Distillation and sterilization. Total steam requirement for the proposed project is shown in the table below:

Table 4: Steam Requirement S.No. Steam Requirement for

Existing 6 KLPD Distillery Unit

Steam Requirement for proposed Expansion to 65 KLPD Distillery Unit

Total Steam Requirement

1 35 TPD 175.20 TPD 210.20 TPD (ix) Quantity of waste to be generated (Liquid and solid) and scheme for their management.

Waste water generation & treatment Most of the water will be recycled back. Spent Wash generated will be passed through decanter for separation of soluble. The remaining from decanter is sun-dried to obtain DWGS. Effluent from washing and blow down process will be treated in existing ETP. Treated water will be used for green belt development. Domestic waste will be treated in septic tanks followed by soak pits. Rainwater would be utilized to recharge the underground water source through scientifically designed rain water harvesting system in coming day. Air Pollution The following air pollution control systems are to be installed in this project to reduce the anticipated adverse impacts: Air quality marginally may get affected due to emissions generated from burning fuel In boiler and D.G. sets; they are Particulate matter and small amount of SOX an NOX. To mitigate the impact, stack of appropriate height of 30 meters provided for 8 TPH boiler. To reduce particulate matter concentration multicyclone dust collector is being installed. Green belt is developed in 1.5 acres area. Additional 33% area will be developed as Green belt for proposed expansion which will acts like adsorbent of air pollutants. To combat fugitive emissions roads are paved and regularly swept. Water sprinklers are provided for suppression of dust. Vehicular exhaust is being maintained by providing regular maintenance and servicing of vehicles. Same will be continued for future also. Solid Waste Management All the solid waste generated will be managed as under:

Table 5: Solid Waste Generation Name of the Solid Waste Quantity Management Boiler Ash Existing: 3.75MT/day

Proposed: 10.75MT/day Land fill and fly ash brick make Fly ash brick manufacturing and land fill.

DDGS Existing : 4MT/day Proposed : 40MT/day at 90%

Will be used for the cattle feed


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w/w solids ETP Sludge Existing: 0.5mt/day

Proposed: Nil Will be used for the agriculture Evaporation and Dryer mixed with DDGS

4. SITE ANALYSIS i) Connectivity

The Plant site is located at village Suidihi, Post: Lathikata, Dist: Sundergarh, Odisha, approximately 1 KM from nearest National Highway (NH-23). The nearest Railway Station is Rourkela Railway Station approximately 16 km in North direction from the project site. The nearest town is Lathikata Town approximately 3 km in South direction. Sundergarh district headquater is approximately 110 km in North-west direction from the project site.

ii) Land form, Land Use and Land Ownership The existing land for 6 KLPD unit is 5.09 Acres. The land is completely acquired. Land papers are enclosed as Annexure 1. An additional land of 22.69 Acres is required for setting up 65 KLPD Distillery Unit. This area will be enough for the following areas of working:- 1. Storage for raw material and finished goods. 2. Plant and Machinery 3. Storage 4. Offices 5. Toilets 6. Water storage tanks Open space will be landscaped and trees will be planted in due course of time.

iii) Topography (along with map): Geographically, the district is not a compact unit and consists of widely, dissimilar tracts of expansive and fairly open country, dotted with isolated peaks, inaccessible forests, river valley and mountainous terrain. Broadly speaking it is an undulating tableland of different elevations broken up by rugged hill ranges and cut off by torrential hill streams and the river lb and Brahmani. The general slope of the district is from north to south. There is a open well-cultivated plain country along the valley of the lb river particularly in the south. The rest of the Sadar sub-division consists of undulating table-land about 700 ft. in average height, dotted here and there with hills and peaks rising to about 2000ft., in the western most tracts at Hemgiri P.S. in the north there is a gradual rise to the table-land of Chhotanagur. The portion occupied by Bonai sub-division to the southeast has rugged forest and hills intersected by gorges and passes and having a narrow valley of the Brahmani River and its tributaries. For a short spell of time during the rainy season the rapid current of the hill-streams cut off communication. The east and west of the brahmani valley is filled with high range of mountains, ft.) Chheliatoka (3331 ft.) and Bichakani (2964 ft.) in the east. The last hill has acquired importance as it contains million of tonnes of iron-ore for use in Rourkela steel plant. The territory of Sundargah and Panposh sub-divisions comprising the ex-states of Ganagpuris about 700 ft. above the sea level. Bonai sub-division comprising ex-State of Bonai


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is about 800 ft. above the sea level. The forest of the district is of northern tropical dry deciduous type, mainly containing Sal, Assan and Kurum. The eastern half of Bonai and Rajagangapur contain better quality of vegetation. The forest area is mostly studded with rich mineral deposits, like iron ore, manganese, limestone, lead; also forest products like bamboo, timber and kendu leaf which are export-oriented. The district was a very inaccessible tract having no proper communication. The tribal people living in the area used to subsist for the most part of shifting cultivation which resulted in denudation of forest The forest occupy an area of 3534.92 sq.kms which includes 2664.64 sq. kms. under reserved forest and 612.07 sq.kms. under protected forest. The forests are of northern tropical dry deciduous type. Sal is the dominant species. The eastern half of Bonai contains better quality of vegetation. The plant is proposed to be located near town Rourkela, of Sundargarh district in the state of Odisha.

Figure 7: District Map of Odisha vi) Climatic Data The climate of this District is characterized by extremely hot summers and cool winters. Climate is hot and moist sub humid. Normal rainfall of the District is approximately 1230 mm, but there is a deviation in receipt of rainfall pattern which is influencing crop production. Maximum temperature in the district goes up to 48ͦ C and minimum temperature goes down to 6ͦ C. Table 6 : Rainfall status of 2016 of Sundergarh District

S.No Months Average Rainfall in mm 1 January 6.0 2 February 18.6 3 March 11.6 4 April 0.0 5 May 23.3 6 June 90.4


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7 July 330.1 8 August 307.1 9 September 233.6 10 October 31.3 11 November 0.0 12 December 0.0

vii) Social Infrastructure Available The entire social infrastructure, as mentioned below, is available within 10 - 20 Km. of proposed distillery Project Site. • Schools (Primary as well as secondary) • Colleges (Science, commerce, Arts, engineering, medical, pharmacy, education) • Health centers, dispensaries, hospitals • Electricity • Drinking water supply • Banks (Cooperative as well as nationalized) and credit societies

Table 7: Details of 10 km radius study area S. No. Particulars Details 1 Location

a) Village/ Town/Plot No. Suidihi b) District Sundergarh c) State Odisha d) Latitude 22°9’4.706” to 22°9’18.371” N e) Longitude 84°52’29.89” to 84°52’42.04” E f) Toposheet No. 73B/16,73B/15, 73B/12

2 Elevation 610 ft 3 Land use at the project site Industrial 4 Climatic Conditions Temperature

Rainfall Relative Humidity, %

Min:10oC, Max:45oC 1451.2 mm (average) Min: 30% and Max: 80% at 8:30 hrs Min: 25% and Max: 80% at 17:30 hrs

5 Nearest highway NH-23, 1 KM approx. 6 Nearest Railway Station Rourkela Railway Station, approx 16 km North

direction from the project site. 7 Nearest airport Ranchi Airport, 190km in NE direction from the

project site. 8 Nearest city/settlement Lathikata Town, approx 3 km in South direction


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from the project site. 10 Features with 10 km : i) Defence installations Nil ii) Archaeological important places Nil iii) Wild life sanctuaries Nil Iv) Reserved/Protected forest No Reserved/Protected forest within 10KM of

Project unit area. vi) Rivers Suidihi Nala – 0.5 km- South direction

Brahmini River-3 km - West direction vii) Hill ranges Nil viii) State Boundary Nil

5. PLANNING BRIEF i) Planning concept (type of Industries, facilities, transportation etc) Town and country

planning/Development authority classification. Type of Industry As per EIA Notification dated 14th Sept., 2006 and amended from time to time, the proposed project falls under Category “A”, Project or Activity 5(g).

ii) Population Projection Unskilled Man Power required for the proposed expansion Project will be met from the local villages completely. Qualified semi-skilled man power requires will be met from local villages if available. Hence there will not be much population increase in the area. iii) Land Use Planning The existing 6 KLPD plant is set up in an area of 5.09 Acres. The proposed 65 KLPD Distillery plant will be set up in an area of 22.69 Acres. The land use break up is as follows:

Table 8: Land Use Break Up for Expansion Project of 65 KLPD S.No Land Usage Area in Acres 1 Distillery Plant 7.00 2 Power Plant 2.00 3 IMFL Bottling Plant 2.00 4 Effluent Treatment Plant 0.50 5 Fly Ash Brick 0.50 6 Housing Colony 1.00 7 Green Plantation 6.69 8 Rain Water Harvesting System 2.00 9 Internal Road 1.00 Total Area 22.69

i) Amenities/Facilities Facilities like canteen, rest rooms and recreation facilities will be provided in the proposed expansion project. No other additional facilities are proposed. 6. PROPOSED INFRASTRUCTURE


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The following plant and machinery will be installed in the Industrial processing area. Table 9: List of Plant & Machinery

S.No. Description 1. Grain storage section 2. Grain Handling Section 3. Liquefaction Section 4. Fermentation Section 5. Distillation Section 6. Steam Boiler with accessories 7. Steam Turbine 8. Steam Condensers 9. Air Compressors 10. Storage Section 11. Centrifugal Machines 12. DDGS Drying Section 13. Multiple Effect Evaporator Section 14. Raw water Treatment 15. R.O Plant for Boiler water 16. Fire Protection Equipments for entire Plant 17. Water Storage Tanks 18. Electricals 19. Piping works 20. Lab Equipments

ii) Residential Area Facilities like canteen, rest room and indoor games facilities will be provided in the proposed project. iv) Green Belt Green belt is developed in 1.5 acres area. Additional approximately 33% area will be developed as Green belt for proposed expansion project. Green belt will be developed in 6.69 Acres of land. v) Social Infrastructure Social infrastructure will be developed as per need based in the Villages. vi) Connectivity The Plant site is located at village Suidihi, Post: Lathikata, Dist: Sundergarh, Odisha, and approximately 1 KM from nearest National Highway (NH-23). The nearest Railway Station is Rourkela Railway Station approximately 16 km in North direction from the project site. vii) Drinking water management Proper Drinking water will be made available to the workers by RO within the plant premises. viii) Sewerage System Domestic waste will be treated in septic tanks followed by soak pits. viii) Industrial Waste Management Waste water generated from the proposed Project will be treated in Effluent Treatment Plant.


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ix)Solid Waste Management All the solid waste generated will be managed as under: Name of the Solid Waste Quantity Management Boiler Ash Existing: 3.75MT/day

Proposed: 10.75MT/day Land fill and fly ash brick make Fly ash brick manufacturing and land fill.

DDGS Existing : 4MT/day Proposed : 40MT/day at 90% w/w solids

Will be used for the cattle feed

ETP Sludge Existing: 0.5mt/day Proposed: Nil

Will be used for the agriculture Evaporation and Dryer mixed with DDGS

x) Power requirement & Supply / Source: The power requirement shall be met from WESCO supply of 250 KVA. The remaining will be sourced from its own turbine.

7.0 REHABILITATION & RESETTLEMENT 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 project will start only after obtaining Environmental Clearance and all other required clearance and will complete after two years of commencement. The Capital Cost of the expansion project will be 17865 Lakhs.

9.0 ANALYSIS OF PROPOSAL (Final Recommendations) With the implementation of proposed expansion 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 social status of the people in the area. Educational institutes will also come up and will lead to improvement of educational status of the people in the area. Primary health centers will also come up and medical facilities will certainly improve due to the proposed project.

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 • Creating harmonious relationships • Helping locals to conduct sports


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• Training to the unskilled manpower 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

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Documents

PRE FEASIBILITY REPORT PRE-FEASIBILITY … · PRE FEASIBILITY REPORT 20 Document No: ... grain based distillery unit to 65 KLPD grain based distillery unit along with MW 1.5 ... Milling