PROJECT REPORT

OF

ADDITION OF 3 KLPD DEMONSTRATION PILOT PLANT

TO

EXISTING 30 KLPD DISTILLERY

FOR

PROCESSING OF 12 TONS PER DAY NON FOOD BIOMASS SUCH AS

AGRICULTURAL CROP RESIDUES INCLUDING SUGARCANE

BAGASSEAND OTHER AGRICULTURAL CROP RESIDUES (ON DRY

BASIS) FOR PRODUCTION OF ABSOLUTE ALCOHOL

BY

SHREENATH MHASKOBA SAKHAR KARKHANA LTD. Shreenathnagar, Patethan, Po. Rahu, Tal.Daund, Dist.Pune, Pin - 412207,

Maharashtra, India

Page 1 of 23

INDEX

CHAPTER NO. PARTICULARS PAGE NO.

1 Highlights of the Project 3

2 Introduction 4

3 Technical details of Demonstration Plant 9

4 Capital Investment 20

5 Variable cost of Production 21

6 Site plan and proposed plant layout 22

7 Conclusion 23

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CHAPTER-1

HIGHLIGHTS OF THE PROJECT

1. Name and Address :- Shreenath Mhaskoba Sakhar Karkhana Ltd. Shreenathnagar, Patethan, Po. Rahu, Tal.Daund, Dist.Pune, Pin - 412207

2. Constitution & Type :- Public Limited Company.

Sr.No. Description Bagasse

1. Product Details

Absolute Alcohol

Maximum 3 KLPD Total Ethanol production capacity will not exceed 30 KLPD at any time

2. Feedstock Details

Raw Material Requirement 12 TPD (on dry basis) 24TPD (as is basis)

Min . Cellulose 33% Min. Hemicellulose 24% Min. Lignin 17% Max. Moisture % 50% 3. Number of working days 3-5 days / month 4. Annual Installed Capacity 1.8 lakh Lit (AA) 5. Other Byproduct Details CO2 2.4 TPD

6. Utilities Requirement for Demonstration Plant

a. Steam 24TPD b. Power consumption 450 kWH

c. Fresh Water for process (Steady state Consumption) 24-26 m3 / day

d. Fresh Water for utility (Steady state Consumption) 29- 30 m3 / day

7. Personal Requirement Existing manpower will be used

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CHAPTER – 2

INTRODUCTION

2.1 PROJECT BACKGROUND

2.1.1 Shreenath Mhaskoba Sakhar Karkhana Ltd. (MHASKOBA) is adding consisting of 12 TPD

Demonstration Pilot Plant to existing 30 KLPD Distillery for processing of Non food Biomass such as agricultural crop residues mainly sugar cane bagasse and other Lignocellulosic feed stocks to produce Absolute Alcohol. There is availability of agricultural crop residues mainly sugar cane bagasse and other Lignocellulosic feed stocks in sufficient quantities in nearby area of the proposed project site. With experience of running sugar, ethanol, power complex for more than five years and looking at the need of producing ethanol from Non food agricultural crop residues, management of MHASKOBA is keen in adding consisting of 12 TPD Demonstration Pilot Plant. The demonstration plant will be designed for processing of Non food Biomass such as agricultural crop residues mainly sugar cane bagasse and other Lignocellulosic feed stocks to produce Absolute Alcohol Proposed demonstration plant will be designed for processing of 12 MT/day Non Food agricultural crop residues (on dry basis) to produce maximum 3 Kilo litres/ day of Absolute Alcohol. The plant will operate for 3-5 days/ month and will utilize ~720 MT Dry biomass / year. The proposed demonstration plant will be co-located within the existing sugar, power and ethanol complex of the company and will utilize Sugar cane bagasse, existing infrastructure such as ethanol storage, bio composting, cogeneration, water storage & water treatment plant and other utilities.

The management team of MHASKOBA presently led by visionary leader Mr. Vinodji Tawade, Hon. Minister for School Education, Sports & Youth Welfare, Higher & Technical Education, Medical Education, Marathi Language, Cultural Affairs, Government of Maharashtra and Mr. Pandurangji Raut as the Chief Executive & Managing Director. The day to day affairs of the company are being looked after by CE & MD Mr. Pandurangji Raut & CEO Mr. D. M. Raskar. The management team of the company will appoint competent technical, commercial and administrative staff for successful implementation and operation of this proposed demonstration plant. The successful implementation of 12 TPD Demonstration Pilot Plant will benefit the farming community for supplying the agricultural crop residues & will also generate rural employment.

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2.2 Global ethanol scenario :

In 2015, countries made commitments toward a more environmentally balanced future through the Sustainable Development Goals (SDGs), and now seek to expand policies for low-carbon development after the agreement reached in Paris at COP2. The year also marked a milestone in the bio-economy, as the point in time when the production of second-generation biofuels (2G) finally took off at commercial scale. Historically, the United States of America (US) has had the largest installed capacity for cellulosic ethanol production of deployed second-generation biofuel facilities, followed by China, Canada, European Union (EU) and Brazil, respectively. Projects in these countries vary significantly in their technological approaches and feedstocks used for fuel production, including the use of corn stover, sugarcane bagasse, municipal solid waste, and forestry residues, etc. 50% growth in the second-generation biofuels market has been forecast between 2014- 2020 and its value in 2020 has been estimated to amount to US$ 23.9 billion (Allied Market Research, 2014). Navigant Research (2014) forecasts that global biofuel consumption in the road transportation sector will grow from more than 122.6 billion litres per year in 2013 to more than 193.41 billion litres per year in 2022, which will increase demand for advanced biofuels. In the last ten years, an increase in ethanol production capacity in the US and Brazil, and biodiesel in Europe, has resulted in biofuels gaining an important position in the global market for liquid. Despite the extensive use of biomass as a source of energy production, some developing countries still depend on oil imports to satisfy their energy demand, which makes them vulnerable to high and volatile oil prices. Some countries, such as China, Brazil, Thailand and India, developed a strong first-generation biofuel sector that led to a significant production capacity and infrastructure.

2.3 Indian ethanol scenario:

The Government of India (GOI) approved the National Policy on Biofuels on December 24, 2009. The policy encourages use of renewable energy resources as alternate fuel to supplement transport fuels and had proposed an indicative target to replace 20% of petroleum fuel consumption with biofuels by end of 12th five-year plan (2017). To ensure implementation of ethanol blending program ‘Cabinet Committee on Economic Affairs (CCEA)’ recommended 5% mandatory blending of ethanol in gasoline in Nov-2012. At present, the estimated production of ethanol in the country is in the range of 2500- 3000 TKL which is primarily used for potable alcohol, chemical industries and ethanol blending. India’s ethanol production is mainly based on sugarcane molasses, which is limited. Any improvement in ethanol production is directly proportional to increase in sugarcane production. However, considering available infrastructure & irrigation resources, it is very difficult to increase sugar cane production.

The Oil Marketing Companies (OMCs) have been directed to sell Ethanol Blended Petrol with percentage of ethanol up to 10% and achieve a mandatory target of 5% overall Ethanol blending. So far, the ethanol availability is restricted to fulfil the blending of about 2-3% only. To meet indicative target of 20% ethanol blending by 2017 (as per National Policy on Biofuels, 2009), the required quantity of ethanol is estimated to be approximately 5500 TKL (CAGR @ 8.38%). Govt. of India has also emphasized on achieving energy security of the country with a target of reducing import dependence by 10% by the year 2022. The available surplus agricultural crop residues in India have potential to achieve these targets.

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All figures in Thousand KL

Particulars 2016-17 2017-18 2018-19 2019-20 2020-21 2021-22

Petrol Sale Projection (8.38 % CAGR)

27596 29909 32415 35131 38075 41266

Ethanol Requirement (@ 5% blending) 1380 1495 1621 1757 1904 2063 (@ 10% blending) 2760 2991 3241 3513 3808 4127 (@ 20% blending) 5519 5982 6483 7026 7615 8253

Some of the key ethanol industry updates are as follows: • Oil marketing companies includes ethanol made from non-food feedstock in latest ethanol

tender • CCEA fixes fuel ethanol price at ₹48.5 - ₹49.5/Liter (delivered at OMC depot) • Government removes excise duty on ethanol – net realization of producers to increase by

₹5/liter • Government of India is committed towards implementation of EBP and working to achieve 20%

ethanol blending target by 2022. 2.4 Indian biomass (agricultural crop residues) availability

The agricultural sector has long been the backbone of India's economy. It also presents a unique opportunity to develop second generation ethanol industry due to availability of vast agricultural residues. According to the various biomass assessment surveys the surplus crop residue availability in India is in range of 50-60 million tons annually. According to these report, by 2020 the available biomass residue could in theory be converted into between 10 billion and 15 billion litres of second generation ethanol annually sufficient to meet 20% ethanol blending mandates in India. Importance: This project would be a pioneering effort and first plant of its kind in India to demonstrate techno economic viability of producing bio-ethanol from agricultural crop residues. The project is strategically, socio-economically and environmentally vital for India. Overview of the reasons why this project is important for the nation is as follows:

2.5 Economic Importance:

The project will provide an opportunity to India to reduce its dependence on crude oil Imports. It will also reduce the impact of crude oil price volatility seen quite often in international markets. It will also help in reducing the subsidy burden of the Indian government since ethanol (produced locally from agricultural residue) displaces petrol from imported crude. By 2020, India’s total gasoline consumption is expected to touch 381 billion litres of which 20% can be replaced by bioethanol produced from lignocellulosic raw materials. Foreign exchange savings due to replacement of gasoline could be between US$ 8 billon -10 billion per year.

1 Praj Industries Company Estimates 2Source: http://www.atkearney.com/documents/10192/1011378/Cost-Effective+Green+Mobility_FINAL.pdf/e452618b-2a19-4463-a196-8c4c4fe8ae24

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2.6 Social Importance

There is potential to create 18 million jobs and hence will significantly improve the future of Indian bio economy. Farmers will benefit from the additional revenue generated by selling agricultural crop residues (corn cobs, rice straw, cotton stalk, sugarcane bagasse and sugarcane trash, etc.) and the rural economy will benefit from the jobs created. The economic value chain will result in distributed economic growth as the feedstock and product ethanol will be consumed locally replacing fuel purchased from outside the local economy. The money which would have been spent in procuring the equivalent amount of crude oil from foreign countries will now be injected into the local economy or country. This will have positive consequences in the growth of India’s gross domestic product. Successful implementation of this technology will create hundreds of thousands of direct and indirect jobs in India in the entire value chain from collection of lignocellulosic biomass to processing into bio-ethanol in small and medium manufacturing plants and finally marketing and selling of ethanol to oil marketing companies.

2.7 Environmental Importance

This technology gives India a formidable tool to reduce its GHG emissions and fulfill its responsibility towards the environment. As mention earlier the CII & AT Kearney joint report shows that by 2020, a CO2 reduction of 3-42 %( over those that existed in 2000) creating an abatement of 10 million to 12 million tons of CO2e is possible.

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2.8 LOCATION

The particulars of the location of M/s. Shreenath Mhaskoba Sakhar Karkhana Ltd. are as follows

a) Registered Office : Meghdoot building, 2nd floor, behind Bharat Petrol Pump, Lokhandi pool lane, opposite Akashwani Centre, Hadapsar, Pune - 411028, Mahrashtra, India

b) Factory Site: MHASKOBA proposes to erect plant at Shreenathnagar, Patethan, Po. Rahu,

Tal.Daund, Dist.Pune, Pin - 412207

c) The Site has following Advantages:-

a. Road: The site is around 31.7 Kms from Pune & Ahmednagar State Highway SH-27 & around 17 kms from Pune – Hyderabad National Highway NH-65 (Old number NH-9)

b. City: Nearest City is Pune at around 50 Kms

c. Railway Station: Nearest Railway station is Pune around 50 Kms from Site location.

d. Airport:

Nearest Airport is Pune around 50 Kms away from Proposed Site.

e. Availability of Water:

Bhima River f. Availability Of Electricity:

Own Turbine

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CHAPTER 3

TECHNICAL DETAILS OF DEMONSTRATION PLANT

About the Project:-

The company intends to add consisting of 12 TPD Demonstration Pilot Plant to existing 30 KLPD Distillery for processing of Non food agricultural crop residues mainly sugar cane bagasse and other Lignocellulosic feed stocks to produce Absolute Alcohol. Following are the different sections of the Demonstration Plant:

Section Description

A. Feed stock Storage &Material Handling & Milling Section

B. Wet Washing & Pretreatment Section

C. Enzymatic Hydrolysis

D. Co- Fermentation

E. Distillation Section

F. Solid Liquid Separation Section

G. Effluent Treatment Section

H. RS Storage Tank (In existing Alcohol storage section)

I. Auxiliaries like Cooling Towers & Pumping, Air Compressors, etc.

J. Fire fighting system

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BASIS OF DESIGN FOR

CONSISTING OF 12 TPD DEMONSTRATION PILOT PLANT

Sugar Cane Bagasse

1. Plant Capacity

Maximum 3 KLPD

Total Ethanol production capacity will not exceed 30 KLPD at any time

2. Feed stock Sugar Cane Bagasse (with min. 33% cellulose, 24% hemicellulose, 17% lignin)

3. Requirement of Feedstock

12 TPD (on dry basis) 24TPD (as is basis)

REQUIREMENT OF INPUTS

1. Feed stock (Non Food Biomass mainly sugar cane bagasse and other Lignocellulosic feed stocks)

12 MT/Day (Dry Basis) or 24MT/Day (As is Basis)

2. Steam consumption ~24 MT/Day

3. Process, Soft water for Main Process Plant and Cooling tower make-up 53-56 m3/day

4. Additives -

Acids, Enzymes, Caustic Lye, Ammonium Hydroxide, Antifoam Agent, Yeast (Active Dry Yeast/Distiller’s Yeast) (PRAJ Make) & Molasses

As per ….table

5. Estimated Power Consumption (KW / day) Operating Load for 24 hrs

a. Material Handling, Pre-treatment and Storage Sections 5964

b. Process Plant (Co Fermentation, Distillation, S/L Separation, Effluent Treatment) 2472

c. Utilities 1275

d. Plant Lighting and Others 960

TOTAL ELECTRICAL LOAD (Estimated) 10671

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REQUIREMENT OF INPUTS CHEMICALS

Sr. No. Description Sugar Cane Bagasse

1. Sulphuric Acid (98% w/w) 170 kg/day

2. Organic Acid 1 (85% w/w) 130 kg/day

3. Organic Acid 2 (85% w/w) -

4. Chemical 1 300 kg/day

5. Chemical 2 304 kg/day

6. Enzyme 113 kg/day

7. Yeast 800 g/day

8. Diammonium Phosphate 51 kg/day

9. Urea 103 kg/day

10. Magnesium Sulphate 1 kg/day

11. Additive 800 kg/day

12. Antifoam 12 kg/day

OUTPUT GENERATION On the basis of Design inputs, following are the out puts generating from the Different sections of the Entire Plant;

Sr No. Description Sugar Cane Bagasse

1. Absolute Alcohol (AA) 3.0 KLPD Maximum with 0.20% v/v moisture

2. Raw CO2 2.4 MTD

3. Lignin rich cake (34% w/w) 16.1 MTD

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PROCESS DESCRIPTION

1. Material Handling, Milling & Wet Washing Section:

The purpose of this section is to outline the technical specifications for Feed Stock Handling System for conveying the feed stock, de-stoning and screening, magnetic particle separation, intermediate storage, necessary safety controls and instrumentation for automatic operation, weighing system, vibratory screen system with rated capacity as per layout and parameters mentioned in these specifications. The Feed Stock handling system shall be designed for all feed stock materials mentioned in technical specifications and for the levels of moisture mentioned in the feed stock. The complete installation will be outdoor type. All components in system, instrumentation, motors, gearbox, etc shall be suitable for outdoor installation and necessary local canopies will be provided as per good engineering practices. A closed room will be provided for installation of M.C.C Panel only. From storage, raw material will be fed to the feed conveyor of Feed Stock handling system with the help of front end loaders etc. for further processing of size reduction, stones separation, and removal of foreign particles, intermediate storage and further conveying. A Permanent Magnet type metal separator shall be installed on feed conveyor to remove metallic foreign particles from the feed stock. A proper access will be provided to the magnetic separator for easy removal of separated metallic particles. The milling unit will be supplied to crush biomass and integrated with upward and downward conveying system including interconnecting chutes, bellows, hoods for Dust-Extraction system etc. will be included in the handling system. Intermediate storage silo will be engineered to prevent bridging / arching in the silo considering range of moisture levels in the feed stock material. The controlled flow rate from the silo shall be fed to the wet washing system for further processing. Washing will be done at ambient conditions. The wet biomass is further squeezed to increase it to desired solids. The wet washed, sized feed stock shall be conveyed from Wet Washing System to Pre-treatment section with Belt / Chain Conveyor and Washed water will be sent to clarification section for recycle. The clarified water will be recycled back to washing section and clarifier bottom will be sent for further treatment in Biomethanation section.

2. Pre-treatment Section:

In this section, mainly C5 hydrolysis is done (i.e. conversion of Xylan to Xylose) in a Digester, where a High Pressure steam is introduced inside the wet biomass slurry in presence of acid. The organic acid solution is mixed continuously as per the requirement. The slurry is cooked at required temperature and pressure for a given residence time. The slurry from Digester is then flashed in a Flash Vessel in order to reduce pressure and temperature and then pumped to Enzymatic Hydrolysis section.

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REACTION:

3. Enzymatic Hydrolysis and Co Fermentation Section:

The slurry from Pre-treatment section is fed to the Pre-hydrolysis reactor along with water and enzyme. In Pre-Hydrolysis Reactor, Reaction conditions are maintained so as to convert the cellulose into the sugars. The Partially hydrolysed slurry is then fed to Hydrolysis and Fermentation reactor where rest of the cellulose is converted to sugars. Sugars are fermented with the help of yeast and converted in to ethanol. In the process CO2 is evolved as by-product. Pre-fermentors are also provided for yeast propagation and different nutrients are added as per the required dosages. Once the desired alcohol is achieved; fermented wash is taken for distillation. REACTION:

4. Distillation & Dehydration Section:

The Distillation Plant is designed to operate with all columns under vacuum. In the Distillation Plant Alcohol from Fermented Mash is concentrated up to 94-95 %v/v. This is further concentrated in to existing Molecular Sieve Dehydration Plant to produce Fuel Ethanol with 99.5%v/v concentration. Mash Column: Mash Column is provided with Rh-Grid Trays and 1 No. of Disengagement Tray & Column is operated under vacuum. The purpose of Mash Column is to strip off alcohol from Fermented Mash. Vapours from column top are with Alcohol and Water & these vapours are fed to Rectifier Column. The alcohol concentration in the vapours varies with the alcohol concentration in the Fermented Mash feed. The alcohol depleted fermented mash flows down the Mash Column and is

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taken out as Spent Wash using Mash Column bottom Pump. The Spent Wash generated in Mash Column Bottom shall be pumped to Solid-Liquid Separation. Rectifier Column: Rectifier Column is provided with Bubble Cap trays & this Column is operated under vacuum. The vapours from mash column are directly fed to bottom of Rectifier column transferring the mass as well as energy from mash column to Rectifier column. The RS draw is drawn out from top tray as Hydrous Alcohol at about 94 - 95%v/v. The Rectifier Column vapours are condensed in condenser and the condensate is taken to Rectifier Reflux Tank. Alcohol Water Liquid from Rectifier Reflux Tank is pumped back to Rectifier Column as reflux. The RS draw as Hydrous Alcohol is pumped to Molecular Sieve Dehydration Section for further concentration.

5. Effluent Treatment Section:

A. SOLID-LIQUID SEPARATION: The Spent Wash generated from Distillation section shall be passed through Solid-Liquid Separation to separate the suspended solids such as lignin rich wet cake and the spent liquor. The lignin rich wet cake shall be used as supplementary fuel for the existing boiler. It shall be mixed with the primary fuel in the boiler to generate steam and power. The Spent liquor along with wet washing purge shall be sent to biomethanation plant.

B. BIOMETHANATION: Anaerobic Biomethanation system:

Anaerobic Biomethanation System uses a specially designed Mixed Tank Reactor (MTR) called Biodigester to convert organic matter into useful energy in the form of Biogas. The Biological Process of conversion takes place at mesophillic temperature in a controlled atmosphere ensuring maximum conversion efficiency and production of Biogas. Following are the salient features of the System -

• Equalization tank: Before entering to the Biodigester, spent liquor and purge from wet washing system will be mixed in the equalization tank before feeding to Mixed Tank Reactor

• pH control: Total waste water pH is adjusted to 6.5 - 7.0 by adding caustic solution and recycling part of the Treated Effluent.

• Mixing in Biodigester: Mixing is done by re-circulation of biomass using scientifically designed mixing system & further enhanced by gas propagation. Efficient mixing helps microorganisms to reach fresh food in favourable living condition & convert organic matter into methane & carbon dioxide. Hydraulic Retention Time (HRT) & Solid Retention Time (SRT): Biodigester is designed for adequate hydraulic retention time, to achieve design parameters, reducing the effects of shock loads & making the process sturdy. The digested effluent from biodigester flows to a parallel plate clarifier via degassing pond. The entrapped gases in the digested effluent are released in degassing pond. The sludge is settled in the parallel plate clarifier and recycled to increase solid retention time in the biodigester. The supernatant liquid

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(spent Liquor / Recycle Water) from clarifier is recycled back to process and the balance liquid is sent to secondary treatment (RO) section for further treatment. Excess biomass & sludge is removed from the bottom of biodigester intermittently and sent to existing biocomposting.

• Gas collection & Handling: The biogas produced in biodigester is collected from top of the biodigester& flows to the gasholder. The gasholder acts as intermediate gas storage & pressure control device. The biogas is transferred to the boiler as a fuel or to the flare unit gas for burning.

• Safety System: For safe operation, Flame Arresters are provided on gas lines to protect the biodigester from backfire & pressure relief valves are provided on biodigester and gasholder to protect from excess pressure or vacuum.

• Control System: The smooth & safe operation of the system is ensured by controlling pH, temp. Volatile acidity & alkalinity by following the operating instructions using various control features provided.

C. SECONDARY TREATMENT PLANT: The balance spent liquor stream after recycle to process plant shall be treated in secondary treatment plant (RO). When a semi-permeable membrane separates two aqueous solutions of different concentrations, the solvent travels from the dilute solution to the concentrated solution. This phenomenon, called osmosis, continues till equilibrium is reached between the two solutions. In reverse osmosis, the flow of solvent (water) is reversed by application of external pressure to the concentrated solution (brackish or saline water). The water that passes through the membrane would be substantially free from the chemical impurities present in the brackish or saline water. The water that passes through the membrane is called permeate or product. The water that does not pass through the membrane is continuously drained and called concentrate or reject. Similarly the Biomethanated Spent Liquor will be treated through Reverse Osmosis membranes. The Permeate water from the Reverse Osmosis system will be Recycled back to Main ethanol Processing Plant or for cooling tower make-up as per requirement. The Reject shall be sent to existing bio composting plant. Membrane system is also most proven system for recycling the treated effluents from industries effluent such as Molasses based Ethanol Distillery, Pharmaceutical, Textile, Tannery, etc.

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PROCESS SCHEME

Lignin rich Wet Cake

BIOMETHANATION PLANT

Permeate Recycled to Process Plant

To Boiler

MATERIAL HANDLING & WASHING

PRETREATMENT

ENZYMATIC HYDROLYSIS

CO-FERMENTATION

DISTILLATION & DEHYDRATION

SOLID-LIQUID SEPARATION

Enzyme

Chemical

Steam

Nutrient

Steam

CO2

Ethanol

Recycle Water

Agricultural Crop Residue

Biogas

REVERSE OSMOSIS PLANT

Reject to Bio-composting

Fresh Water

Recycled to Process Plant

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FIRE FIGHTING SYSTEM

In addition to the existing Fire Fighting System, separate Fire safety system is planned to be installed for 3 KLPD Demonstration Pilot Plant, which will cover its following sections : 1. Feed stock storage & Material Handling & Milling 2. Wet Washing & Pretreatment Section 3. Enzymatic Hydrolysis 4. Co- Fermentation 5. Distillation 6. Solid Liquid Separation 7. Effluent Treatment section 8. RS Storage Tank (In existing Alcohol storage section) 9. Fire Fighting System 10. Cooling Towers 11. Labs and Control room. 12. Office and Admin Buildings Fire system has been designed primarily as per TAC guidelines. Fire safety system includes -

a) Hydrant System with water cum foam monitor for the Complete Plant b) Wet Riser System for Milling, Pre-treatment, Solid Liquid Separation/Filter Press,

Fermentation and Distillation c) Suitable Fire Alarm & Detection system for the Complete Plant The existing RS tank will be used to store RS produced from the 12 TPD Demo plant and associated with necessary fire safety system.

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UTILITIES & MANPOWER

Power:- We plan to source 0.5-1 MWH power from Existing Cogen Plant which will be sufficient for plant consumption. Water:- Water requirement for the unit will be around 53-56 m3/day. This includes water required for Process, Cooling tower Make –up, Sealing water etc. Existing Water treatment arrangement will be used in order to supply disinfected water to Process. This demand of water for new 3 KLPD Demo Pilot Plant will be fulfilled from the existing sanctioned water source

Steam:- Existing Boiler will be utilized to provide Dry, saturated steam at the inlet of steam header in respective section as mentioned in requirement of Input. Maximum variation in steam pressure shall not be more than +/- 0.1 Kg/cm2

Manpower:- No additional manpower is required for this plant. Karkhana will operate the addition of 3 KLPD Demonstration Pilot Plant to existing 30 KLPD Distillery with the existing manpower available.

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CHAPTER-4

CAPITAL INVESTMENT

Cost of Project:- The details of Investment for addition of consisting of 12 TPD Demonstration Pilot Plant are as follows;

Sr. No Particulars Amount In INR (Lacs)

1.

Land, Site development, Infrastructural facilities, Construction facilities, Roads, Non plant buildings, Civil foundations, Plant buildings & structures

515

2.

Design, engineering, consultancy, statutory fees, travelling, conveyance, Project management, Construction management etc.

190

3. Main Plant & Machinery including packing, taxes & duties, transportation 1890

4. Construction period expenses, start-up & commissioning expenses 465

TOTAL 3060

(Variation of +/- 10%)

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CHAPTER – 5

VARIABLE COST OF PRODUCTION

Sugar Cane Bagasse

Component Cost in Rs. per Lit of Ethanol

Total cost of Production per day in Rs.

Utilities 4.50 13500

Consumables 17.80 53400

Conversion Cost 22.30 66900

Feedstock 15.20 45600

Labour & Routine Maintenance 2.50 7500

Total Cost of Production 40.00 120000

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CHAPTER- 6

SITE PLAN- PROPOSED PLANT LAYOUT

Attached copy

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CHAPTER – 7

CONCLUSION

1) Shreenath Mhaskoba Sakhar Karkhana Ltd. (MHASKOBA) is adding consisting of 12 TPD Demonstration Pilot Plant to existing 30 KLPD Distillery for processing of Non Food Biomass such as agricultural crop residues mainly sugar cane bagasse and other Lignocellulosic feed stocks including to produce Absolute Alcohol.

2) This Demonstration Pilot Plant will be added to the existing sugar, Ethanol & cogeneration complex and completely integrated to optimize the energy consumption, reuse and recycle of waste water streams by reducing overall capital investment & the cost of production.

3) The demonstration plant will be Zero liquid Discharge since all the waste water streams are recycled back to the main process.

4) After demonstration of all the above aspects this technology can be scaled up to commercial scale which will address the energy security, foreign exchange savings, Farmer upliftment, rural employment, reduction in greenhouse Gas emissions for the nation & the globe.

For SHREENATH MHASKOBA SAKHAR KARKHANA LTD. Authorised Signatory

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