Proposed 55 KLPD Grain Based Distillery · Proposed 55 KLPD Grain Based Distillery ... 3.9 Schematic representation of the feasibility drawing showing EIA ... cylinder or by tanks

Proposed 55 KLPD Grain Based Distillery At plot no. 200 to 208, block Khallikote, village- Kanaka,

District- Ganjam, Odisha, Pin- 761028

Chilika Distilleries Pvt. Ltd.

Prepared by

SMS Envocare Ltd

Accredited by QCI/NABET for EIA consultancy services 301 Pentagaon P3,

Magarpatta city, Hadapsar

Pune 411028

September 2015

http://www.smsenvocare.co.in/

Chilika Distilleries Pvt. Ltd. Prefeasibility Report

SMS Envocare Ltd 1

CONTENT Sr. No Particular Page No.

1. Executive summary 3

2. Introduction 3 2.1 Identification of Project & Project proponent 3 2.2 Nature & Magnitude of project 4 2.3 Need of project and its importance to the country and region 4 2.4 Demand supply gap and market scenario 5 2.5 Employment Generation 6

3. Project Description 6 3.1 Location 8

3.2 Products and Raw Materials 9

3.3 Manufacturing process 10 3.4 India Made Foreign Liquor (IMFL) Bottling Plant 16 3.5 Cogeneration Plant 16 3.6 Resource optimization 17 3.7 Infrastructure requirement 17 3.8 Quantity of waste to be generated & its disposal scheme 18 3.9 Schematic representation of the feasibility drawing showing EIA

purpose

19 4. Site Analysis 19 4.1 Connectivity 19 4.2 Land form, land use and ownership 19 4.3 Existing Infrastructure available at site 20 4.4 Soil Classification 20

4.5 Climate Details 20 4.6 Physiography and Drainage 21 4.7 Social infrastructure available 21

5. Planning Brief 21 5.1 Planning Concept 21 5.2 Population projection 22 5.3 Land use Planning 22 5.4 Assessment of infrastructure Demand 23 5.5 Proposed Infrastructure 23

6. Proposed Infrastructure 6.1 Environment Infrastructure 23

7. Rehabilitation and Resettlement (R & R) Plan 27 8. Project Schedule 27 8.1 Schedule and approval for implementation 27 8.2 Project Cost Estimation 28

9. Project Benefits 28


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LIST OF TABLE

Table No. Table name Page No.

1. Company details 3 2. Production and Consumption Trends in Alcohol 5 3. Demand of Alcohol 5 4. Demand and Supply Gap in Odisha 6 5. Project Highlights 6 6. List of Product and By Product 9 7. List of Raw material required 9 8. Steam Turbine Performance 17 9. Boiler details 17 10. Steam requirement 18 11. Waste generation and its disposal mechanism 19 12. Land use details of Ganjam District 19 13. Land Distribution 22 14. Project Infrastructure 23 15. Potential Impact and its mitigation 26 16. Project Implementation Planning 27 17. Project cost 28 18. Environment Management Cost 28

LIST OF FIGURE

Figure No. Figure Name Page No.

1. Map Showing General Location 8 2. Google Image showing Specific Proposed Distillery Location 8 3. Distillery Process Flow 10 4. Manufacturing Process Flow Diagram 11 5. Liquefaction process flow diagram 12 6. Effluent treatment Plant 24 7. Polishing Unit 24

LIST OF ANNEXURES

Annexures Number Name of Annexure Page No. 1. Project Layout 30

2. Toposheet 31

3. Rain water Harvesting 32


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PREFEASIBILITY REPORT

1. Executive Summary

Chillika Distilleries Pvt Ltd (CDPL) was incorporated in April 2015. The Members of Board of

Directors are Mr. Vikrant Kumar Sahu and Mr. Dillip Kumar Mahapatra and Mrs. Swarna Lata Sahu.

CDPL has acquired about 21 area of land in Ganjam District very close to Chillika Lake for Setting

up State of the Art Distillery and India Made Foreign Liquor project (IMFL). Once the distillery is,

operational Ganjam district will be catapulted into growth track of state with several associated

business mushrooming around distillery.

2. Introduction

2.1 Identification of Project & Project proponent

CDPL proposes to establish a state of Art Grain based Distillery Project of 55 KLPD capacity, IMFL

Bottling Unit of Initial Capacity 30 Lac LPL per annum and Two MW captive power plant.

Table 1: Company details

Sr. No

Particular Description

1 Name Of Company Chlika Distilleries Pvt. Ltd.

2 Constitution Private Limited Company

3 CIN No & Date of Incorporation U15520OR2015PTC018855

4 Registered Office Plot No 547/902, Vadrabari Street, Behrampur 760001.

5 Location of Factory Kanaka, PS khalikote 1, District-Ganjam, Odisha 761028

6 Administrative Office Plot No N1/14, IRC Village, Nayapali, Bhubaneswar, Odisha.

7 Name of Directors Mrs. Swarn Lata Sahu

Mr. Vikrant Kumar Sahu

Mr. Dillip Kumar Mahapatra

8 Proposed Project Grain Distillery :55,000 Bulk Liter/ Day


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2.2 Nature & Magnitude of project

CDPL Proposes to establish is Grain Distillery with Multi-pressure vacuum Distillation of capacity

55 KLPD. The Proposed unit shall be having eight distillation column for production best quality

Extra Neutral ENA fit for Blending Premium Vodka, Gin & whisky. The Plant will be equipped with

decantation & Drying Unit for recovery of High Protein DDGS as by product which good feed for

Cattle, Poultry & Fish feed.

A Carbon Dioxide recovery Plant shall be installed to recover and use Carbon Dioxide emitted

during the Fermentation process. CO2 Recovered shall be processed and liquefied. The liquid CO2

manufactured can be supplied by CO2 cylinder or by tanks to Cold Drink plants & Brewery.

The Plant will be equipped with its own 2 MW Power Co-generation Plant to cater to its own

power requirement this will be further reduce the production cost and also it shall be an

Environmental friendly as it shall use rice husk for boiler. Along with Distillery, CDPL proposes to

establish a state of art IMFL Bottling Unit for Production of Super Premium Brands in all segments

for Sale in Local Market in Odisha and export to other states as well.

2.3 Need of Project and its Importance to the Country and Region

India is one of the major alcohol producing countries. Production of alcohol has gone up from a

meager 100 million liters in the fifties to the current level of more than 600 million liters. The

Russia, USA, Brazil, India, the UK, Japan and West Germany, are the leading alcohol producing

countries. India, has been exporting alcohol in substantial quantities.

According to a survey conducted by a UK-based trade magazine on liquor, three Indian brands

figured in the "TOP 25 Fastest Growing Brands in the world in 1994". While the survey is for both

local as well as foreign sales, it takes into account only those brands which "export or produce

more than 10 percent of their sales volumes overseas"- in other words, Indian-made Foreign

liquor (IMFL) could actually be well on its way to becoming a preferred foreign liquor. Indian

Consumption of whisky has grown at an average 14% annually for the past eight years, climbing

to 30 million cases (of 12 bottles of 750 ml each) per annum. That makes India the hottest whisky

market in the world.


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2.4. Demand supply gap and Market scenario

Change in the situation with a sharp increase in demand for alcohol following the implementation

of expansion and new schemes by SM Dyechem and Chemplast, which were increasing the output

of ethylene oxide, specialty chemicals, PVC resins and Mono ethylene glycol in a big way.

The output of alcohol-based chemicals would increase at a faster rate in future with the

independent units taking up new projects and sugar mills having their own distilleries establishing

downstream projects. The calculations in this regard have been upset largely by the sharp increase

in the cost of molasses and therefore alcohol.

The present availability of alcohol cannot meet the entire demand. Alcohol production is directly

linked with sugar output and availability of molasses. Table 2 shows the trend in alcohol

production and consumption will be observed that it is upward. To meet the needs of the growing

population, sugar production will continue to maintain this trend and as a result, alcohol

availability will improve. However, a disturbing factor is the diversion of a large proportion of

alcohol for potable use.

Table 2: Production and Consumption Trends in Alcohol

YEAR Production CONSUMPTION

Industrial

(Million Liters)

Potable

(Million Liters)

2001-02 9381 458 480.1

2002-03 1064.4 520 566.4

2003-04 1144.13 558 586.13

2004-05 1229.83 600 629.83

2005-06 1321.96 645 676.96

2006-07 1359 660 699

Table 3: Demand Of Alcohol (Potable + Industrial others)

Year Demand (Million liters.)

2007-08 2659

2008-09 3191

2009-10 3829


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The estimated Growth rate of demand is 20% per Annum with increase in population and other

industrial growth and consumption factor.

2.4.1 Demand and Supply Gap in Odisha

The Per Day Demand of Extra Neutral Alcohol and Rectified Spirit for IMFL Production in Odisha

State is mentioned in Table 4

Table 4: Demand and Supply Gap in Odisha

Column Year

2010-2011

Year

2011-12

Year

2012-13

Year

2013-14

ENA in BL/day 60966 76683 71383 74196

RS in BL/day 22546 16866 23666 22660

Total BL/day 83512 93549 95049 96856

Present Production Capacity of Units in State: 15,000 BL/day Seasonal during cane

harvesting only.

ENA Export Opportunity for Distillery in Odisha

1. West Bengal Imports; 100,000 BL /day

2. Present Export of grain ENA outside India: 450,000 BL/day

2.5. Employment Generation

A direct and indirect employment of 260 people is expected in Distillery Unit Development.

3. Project Description

CDPL proposes to establish a state of Art Grain based Distillery Project of 55000 LPD capacity and

A IMFL Bottling Unit of Initial Capacity 30 Lac LPL per annum.

Table 5: Project Highlights

Sr. No. Particulate Description

1 Name of the Proponent Chillika Distilleries Private Limited(CDPL)

2. Project 55 KPLD Grain based Distillery Project

3 Location of the project Plot No. 200 TO 208, Block Khallikote, Village - Kanaka, District- Ganjam State - Orissa, Pin 761028


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Sr. No. Particulate Description

4 Land Requirement 21 acres

5 Product

Products

By Product

Carbon Dioxide: 35 to 40 TPD

DDGS: 2800 to 3000 LPD

Sr. No Product Quantity

1. ENA ( Extra Neutral Alcohol) 1.6456 Cr. lit / Annum

2. TA ( Technical Alcohol) 0.1144 Cr. lit / Annum

3. Fusel oil 35000 lit / Annum

6 Operation Days 320 days

7 Main Raw materials

Liquefying Enzyme, Saccharifying Enzyme, Viscosity Reducing Enzyme

Yeast

Anti-Bacterial Agent

Chemicals: Sodium Hydroxide Lye, Sulphuric Acid , Urea, Antifoam Agent, Sulphomic Acid (For Hot CIP), Nitric Acid, Caustic Lye

8 Total Water requirement 1752 m3/d

9 Electricity requirement (Operational)

1 000-1 400 MW

10 Steam 18 TPH

11 Fuel Indian Coal: 36480 TPA Rise husk: 40960 TPA

12 Boiler 20 TPH

13 DG Two DG sets of capacity 750 KVA

14 Effluent Treatment System (capacity)

Polishing Unit with ECOPHOTOX treatment system Decanter, Evaporator and Dryer

14 Man power 120 nos

15 Total Project Cost ` 67.25 Cr.

16 Total cost for EMP ` 2.73 Cr.


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3.1. Location

Proposed project will be located at village Kanaka, PS khalikote, Dist- Ganjam, Odisha with the

coordinates 190 34’43.83 N, 850 06’ 42.17’ E. The location plan & Google image of the project site

is shown below.

Figure 1: Map Showing General Location

Figure 2: Google Image showing 10 km radius of Proposed Distillery Location

Proposed Site

Location


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3.2. Products and Raw Materials

Product and Raw material details mentioned in Table No 6 and 7

Table 6: List of Product and By Product

Sr. No. Particulate Quantity

Product

1 ENA 1.6456 Cr. lit / Annum

2 Technical Alcohol 0.1144 Cr. lit / Annum

3 Fusel oil 35000 lit / Annum

By Product

1 Carbon Dioxide 35 to 40 TPD

2 DDGS 2800 to 3000 LPD

By- Product formation in the fermented Mash (mg/1000 ml)

1 Acetaldehyde 150-200

2 Ethylacetate 20-30

3 N-Propanol 50-70

4 Diacetyl 0.1-1

5 Methanol 10-15

6 Acetone 30-50

7 Iso Amyl Alcohol 50-70

8 Iso Butyl Alcohol 30-50

9 N-Butanol 5-10

10 Farfurol 0.1-1

11 Acetal 0.1-1

12 Acids 1000-3000

13 Volatiile Sulphur componds 0.1-0.5

Table 7: List of Raw material required

Sr. No Name Quantity Source Mode of Transport

1 Grain Flour 113 MTD Nearby Local market

BY Road

2 Liquefying Enzyme 25 to 30 kg/day

3 Saccharifying Enzyme 65 to 70 kg/day

4 Viscosity Reducing Enzyme 20 to 25 kg/day

5 Yeast 25 to 30 kg/day


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Sr. No Name Quantity Source Mode of Transport

6 Anti-Bacterial Agent 4 to 5 kg/day

7 Sodium Hydroxide Lye 120 to 130 kg/day

8 Sulphuric Acid* 60 to 65 Kg/day

9 Urea 155 to 160 kg/day

10 Antifoam Agent* As required

11 Sulphomic Acid (For Hot CIP) As required

12 Nitric Acid 60 to 65 kg

13 Caustic Lye 60 to 65 kg

3.3 Manufacturing process

General Distillery Process flow shown in below mentioned flow diagram,

Project is broadly divided into three sections,

1. Distillery Process Section to Produce Grain ENA about 55,000 LPD

2. IMFL Bottling Unit with initial capacity to Produce 30 Lac LPL/annum

3. A Common Utility with Cogeneration plant with ideal capacity Plants to cater to both

Distillery and IMFL Unit

Figure 3: Distillery Process Flow


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The grain based distillery process will have following steps/operations.

i. Grains receiving and storage

ii. Grains handling and milling

iii. Slurry preparation/liquefaction

iv. Saccharification and instantaneous fermentation

v. Fermentation

vi. Multi-pressure distillation

vii. Decantation

viii. Multi-effect evaporation

ix. Spirit storage

Figure 4: Manufacturing Process Flow Diagram


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3.3.1 Grain Storage

An average of 113 MTD of grain (Rise, maize) would be required per day for production of 55KLPD

ENA. An onsite grain storage facility of 7000 ton is planned. This shall ensure continuous flow and

help procure rice at best price. The Grain storage silos shall be equipped with Fumigation facility

and raking arms to ensure a mold & pesticides free storage. The intake will have pre-cleaning

equipment’s. The Grain storage shall be of prefabricated Galvanized sheets (GI) complete with

Loading and off- loading arrangements.

3.3.2 Grain Milling

The Grains are cleaned of various impurities before grinding such as weed, stalks, pebbles,

lumps of soils, dust, metal particles etc. The equipment’s used are Seed cleaner, dust remover,

de-stoner, magnetic separator, Batch weighing machine and hammer mill the complete plant

is of 10 T/hr capacities.

3.3.3 Liquefaction

Figure 5: Liquefaction process flow diagram

Liquefaction methods involve a starch gelatinization process, wherein aqueous starch slurry is

heated so that the granular starch in the slurry swells and bursts, and dispersing starch molecules

into the solution. During the gelatinization process, there is a dramatic increase in viscosity. During

liquefaction, the long-chained starch molecules are degraded into smaller branched and linear

chains of glucose units (dextrin) by an enzyme, such as alpha-amylase (i.e., a-amylase).


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Liquefaction initiates the conversion of starch into simple molecules of dextrin. It is divided into

three sub processes.

3.3.4 Pre Liquefaction

This involves partial liquefaction of starch, in presence of enzyme, at a temperature well below the

gelatinization temperature. After milling, the flour is mixed with hot water at 600C in a small

slurry-making tank, which has low speed agitator. The gentle mixing of flour with hot water is

carried out to eliminate any lump formation. The slurry is then transferred to a main slurry tank,

where chemicals required for maintaining the stability of the enzymes and for adjusting pH and

some liquefaction enzymes also added. The slurry is then pumped to a high-pressure jet cooker

using slurry transfer pumps.

3.3.5 Jet Cooking

This step involves the cooking of starch slurry with live steam to instantaneously raise its

temperature. This gelatinizes and opens up starch molecules, thus making it accessible to enzyme

action. Jet cooking also sterilizes the slurry. The jet cooker is a Venturi type device where, the

heating of slurry takes place instantaneously from 600 C to 125 to 1300 C using high-pressure

steam at 7-bar g. The Jet cooker outlet cooked slurry passes through a holding coil for about 8 to

10 minutes at 125 to 130 0 C, which allows further break down of starch molecules in to smaller

molecules due to turbulence inside the coil.

At the end of the holding coil, the pressure is reduced and the slurry flash cooled into the flash

tank. The temperature drops to 98 to 100 deg C due to flashing of slurry and the escaped steam

vapors are condensed in flash condenser and sent back for slurry making in the slurry tank. The

cooled slurry is then taken to liquefaction tank for addition of liquefaction enzyme and for further

break down of starch molecules.

3.3.6 Post Liquefaction

The jet-cooked slurry is again held at high temperature in presence of enzyme to complete the

process of liquefaction in the liquefaction tank for about 1 hour at 900C. The pH is adjusted to 6.5

in this tank as the liquefaction enzyme is at its best an activity. After liquefaction, the slurry is


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cooled to 60 deg C using plate heat exchangers and sent to Saccharification tank.

3.3.7 Saccharification and Fermentation

Yeast seed material is prepared in Pre-ferment or by inoculating sterilized mash with yeast.

Optimum temperature is maintained by circulating cooling water. The contents of the Pre-

fermenter 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 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 with CIP using cleaning nozzles. After CIP, Fermenter is ready

for next batch to be filled. The overall transformation takes place into three steps:

n(C H O ) + n(H O) n(C H O )6 10 5 2 6 12 6

Amylase/Gluco-amylase

C H O + H O C H O + C H O12 22 11 2 6 12 6 6 12 6

Invertase

C H O 2C H OH+ 2CO6 12 6 2 5 2

Saccharomyces cerevisiae

n(162) n(18)

342 18

180

n(180)

180 180

92 88

3.3.8 Fermentation

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-

320 C by forced recirculation flow through plate heat exchangers. We have given a provision for

spent wash recycled to Fermentation depending on solids concentration in fermented wash.

3.3.9 Batch Fermentation

The Batch fermentation proposed is the latest and proven technology as compared to the old

fermentation technology. It has many advantages like continuity of operation, higher efficiency


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and ease of operation. Batch fermentation also results into consistent performance over a long

period as compared with batch fermentation

3.3.10. Multiple-pressure vacuum distillation system

In this vacuum distillation, alcohol is separated and concentrated using principal of fractional

distillation. This is based on difference in boiling points of volatile compounds in mixture.

There are eight distillation columns in the system

Pre-heated fermented wash is fed into a series of Distillation Columns to increase the alcohol

concentration and remove various impurities .The columns are termed as below:

i. Degasifier

ii. Analyzer

iii. Pre Rectifier

iv. Extractive Distillation

v. Exhaust

vi. Recovery

vii. Simmering

ENA drawn from the Simmering Column is taken to the receiver after cooling in ENA cooler.

3.3.11. Decantation & Evaporation

3.3.11.1 Decantation

Decantation section comprises of a two 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 a DDGS Dryer and then sold in dry form as Cattle feed (DDGS).


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3.3.11.2 Evaporation

The slop discharged from the Analyzer column is taken to the evaporation section for

concentrating the slop up to 40 % w/w solids. Treatment scheme is a series of evaporation effects

working on the principle of falling film Evaporation & Forced circulation.

3.3.12 Dryer

The concentrated syrup is mixed with the wet cake from the decantation section .This mixture is

termed as DWGS which is then fed in Dryer to reduce the moisture of up to 10 % .This by product

is termed as DDGS which is in a powder form.

3.4 India Made Foreign Liquor (IMFL) Bottling Plant

CDPL plans to initially start with a IMFL Packaging UNIT of capacity of 30 lac LPL per annum. The

stress is to develop various forms of packing and launch own brands with superior quality. The

Grain Neutral Alcohol received from Distillery is stored and bottled after blending. The process

would involve mixing of ENA with DM water along with liquor essence blends, caramels, and

colors in stainless steel blending tanks. The ratio of spirit to DM water would be controlled by

proof requirements in the product. The blend would be subjected to physical filtration.

Subsequently, the blend would be filled in bottles. The bottles would be labeled, packed, and

stored for final dispatch.

3.5. Co-generation Power Plant

CDPL will be having 2.0 MW of cogeneration of power based. Distillery shall require about 18 tons

per hour of steam on continuous basis at a pressure of 3.5 to 5 bar. As steam required is,

continuous CDPL looks opportunity to save upon the Power Cost by installing a Co-gen Plant.

Instead, a low pressure Boiler CDPL plans to Put a 44 bar steam pressure Boiler of capacity 25

Tons/hour. The Steam at higher pressure will feed High Pressure steam to Turbine, which will

release steam at 3-5 Bar required for Distillery Operation. Turbine shall in-turn generate enough

power to run both Distillery and IMFL unit there by reducing the operating cost towards purchase

of Power.


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Table 8: Steam Turbine Performance

Sr. No Particulate Unit Value

1. Inlet Steam

2. Pressure Kg/Cm2g 44

3. Temperature 0 C 440

4. Flow TPH 21.6

5. Exhaust Steam

6. Pressure Kg/Cm2g 4

7. Flow TPH 21.6

8. Generator Power KW 2000

3.6 Resource optimization / recycle and reuse envisaged in the project, if any, briefly describe

Management shall envisage 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 treatment in polishing unit and recycled for further

domestic, green belt development uses.

3.7 Infrastructure Requirement

3.7.1 Water

The fresh water requirement at the startup will be approximately 1752 m3/day. Water

requirement will be reduce after recycling of condensate water 491 m3 /day , spent lees of 611 m3.

Total daily fresh water requirement will be 540 m3/day. Thin slope will treated in decantation

followed by evaporation followed by dryers.

3.7.2 Boiler

A Boiler of Capacity 25 Ton is planned to be installed, the boiler will have dual fuel options i.e Rice

Husk and Coal. The Atmospherics Fluidized Bed Combustion (AFBC) boiler will completely

automated for best at efficiency part load operating condition.

Table 9: Boiler details

1. Capacity of The Boiler 20 TPH

2. Steaming Capacity 20 TPH

3. Steam Pressure @ 67 ata


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4. Steam Temperature At Outlet (0C) 490 +/- 50 C

5. Boiler Fuel Indian Coal / Rice Husk

3.7.3 Steam

Steam requirement for various units are mentioned below,

Table 10: Steam requirement

Sr. No. Name Quantity (TPD)

1. Liquefaction 24.75

2. Distillation 176

3. Evaporator 30.25

4. Dryer 101.75

Total 332.75

3.7.4 Electrical

CDPL will be having its own Co-gen Power Plant. The Turbine alternator will provide power at 440

V. The Power supply panel will have facility to synchronize power with stand by DG set. Two 750

KVA DG set will be installed as standby for power to Distillery. Estimated electrical power

requirement for Fermentation, Distillation and ENA section, Cooling Tower, Storage, Evaporator,

Dryer, Decanter and Boiler etc. is 1000-1400 MW/day. All Electrical Installations will follow

guidelines as laid down in Indian Electricity Rule 1956 and National Electrical Codes.

3.8 Quantity of waste to be generated & its disposal scheme

Source Quantity TPD Disposal

Ash from Boiler 36 TPD It will be collected in Ash silos( capacity 40 MT) and send to brick manufacturing units

DDGS ( Distillers Dried Grain Soluble ) from Dryer

33 This is in form of dry powder containing moisture less than 10%. This will be bagged in 50 Kgs bag and will be stored in warehouse. Cattle food manufacturers are purchasing this.

Yeast sludge ETP Sludge

1 -2 T 0.500-0.6

Mix with DDGS


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Table 11: Waste generation and its disposal mechanism

Sr. No.

Aspect Pollutant Treatment Disposal

1 Waste water Thin Slope(DDGS) Thin Slope converted to DDGS

It will sell as cattle feed

2 Air Emission SPM10, SPM2.5, SOx and NOx

Electrostatic precipitator (ESP)

Ash will be sell to brick manufacturer

3 Solid DDGS

Yeast sludge

ETP sludge

Ash (Bottom + fly ash)

Sludge(Yeast and ETP) will be sent to sludge drying bed and can be used as manure

3.9 Schematic representation of the feasibility drawing which give information of EIA purpose

4. Site Analysis

CDPL will be situated near Kanaka Village of Ganjam District. It is located on NH-5 highway at a

distance of 0.5 km. Chilikahrada, Gopakunda, haridamula, Hajapata, Kankadakuda and Dalibati

are the nearby villages situated at a distance of 0.5 , 0.7, 1.5, 2.7, 2.2 and 2.1 km respectively.

4.1 Connectivity

Nearest Road / Nearest Highway : NH-5 (Adjacent ): 0.5 km

Nearest Railway Station : Rambha Railway Station: 4 Km

Nearest Airport : Berhampur Airport : Approx. 38 km

4.2 Land form, land use and ownership

CDPL acquire 21 acres land in Kanaka Village District Ganjam. Present Land is barren land and

small agricultural patches are present in nearby area. Below mentioned Google earth images,

clears present land use of the proposed site Chilika Lake is 2.5 km far from proposed site, Costal

line 15 km away from project site . Nalaban Island, Chilika bird Santury is situated inside the

Chilika lake locate away from 22 km.

55 KLPD Grain

Based Distillery

Category A 5(g)

(Eco sensitive area in 10 km boundary of Nalaban

Sanctuary)

Application (Form I)

& Pre- Feasibility study To

MOEFCC


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Table 12: Landuse details of Ganjam District

4.3 Existing Infrastructure available at site

Land: 21 acres land at Khalikote 1 block, Kanaka village.

Water: Source- Ground water

Power: Own captive power plant 2 MW

Road: NH-5 0.3 km away from Proposed site

4.4 Soil Classification

The district has alluvial soil in its eastern part (coastal region) and laterite Soil in the west (with

small patches of black cotton soil at the center and in the northeast close to Chilika.

4.5. Climate Details

The district is characterized by an equable temperature all through the year, particularly in the

coastal regions and by high humidity’s. The cold season from December to February is followed by

hot season from March to May. The period from June to September marks the South West

Monsoon and 70% of annual precipitation has received during this period. The normal rainfall of

this district is 1444 mms. May is the hottest month. With the arrival of the monsoon by about the

second week of June the day temperature decreases slightly while the night temperature continue

as it was in the summer. Towards the end of September, after the withdrawal of southwest

monsoon, temperature decreases progressively. December is the coldest month. The relative

humidity are high throughout the year specially in coastal areas. Winds are strong particularly in

coastal regions in summer and monsoon months


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4.6. Physiography and Drainage

Based on homogeneity, continuity and physiographical characteristics, Odisha has been divided

into five major regions:

1. The coastal plains in the east

2. The middle mountainous and highlands region

3. The central plateaus

4. The western rolling uplands, and

5. The major flood plains

Ganjam has total geographical area of 8206.00 sq.km. having forest area of 3149.9 sq.km and total

cultivable area of 434000 ha. The permanent pasture and grazing land comprises 20,000 ha. area

out of the total area. The barren and un-cultivable wasteland comprises 37,000 ha. area and total

fallow land 28,000 ha.

4.7. Social infrastructure available

Most of its people depend on agriculture as their means of livelihood. About 50% people survive

on daily wages. Domestic animal resource, marine products and forest products help to add

additional income for the people of Ganjam. Only about 30% people are service holders in

Government as well as Non-Government/private sectors. Most of the working population is

working in the private sector outside the district.

Social life is the indicator of economic status of a community. Though the district has rich socio-

cultural background, the economic status of the community is not sound. Poverty stands as a

barrier in the path of progress. The district’s cultural heritage is dominated and influenced by

Telugu people. Its cultural heritage is obviously glamorous. They do not prohibit traditional

practices and have not abandoned many of their traditional cultural practices. Other social

infrastructures are available at District Headquarter at Chatrapur 30 kms.

5. Planning Brief

5.1 Planning concept

Type of industry: Manufacturing industry (Grain based distillery unit from 55 KLPD)


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Facilities for the drinking water: Water treatment units will be provided. Water will be taken

through ground water source

Power Supply: Captive power will be used in the proposed project.

Facilities for transport: NH-5 0.3 km away from site.

Town and country planning / Development authority classification: The project site came under

the jurisdiction of Khallikote Gram Panchyat.

5.2 Population projection

The proposed activity will generate 120 employee opportunities and opportunity preferably will

be given to people residing in nearby area. Thus, influx, migration of population could be

negligible.

5.3 Land use Planning

Total Area in possession = 21 acres

Area available for Greenery = 8.63 acres

Table 13: Land Distribution

Sl. No Particulars Area in Acres

1 Process Plant 2.57

2 Boiler, Turbine, fuel yard 1.0

3 WTP, ETP, Water storage 0.6

4 Raw Material, Product storage 0.8

5 Bottling 2.4

6 Roads(External & Internal) 2.99

7 Admin office, canteen etc. 0.25

8 Truck movement, Parking 1.0

9 Green Belt (40%) 8.63

Total 19.64

Remaining 1.36 Acre will be utilized for Rainwater harvesting.


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5.4 Assessment of infrastructure Demand (Physical & Social)

The infrastructures such as land, roads, power, water, transportation, Raw material and fuel will

be available locally.

5.5 Proposed Infrastructure

Basic infrastructure such as Water, Electricity and connectivity is mentioned below,

Table 14: Project Infrastructure

Sr.

No.

Particulate Description

1 Industrial Area (Processing area) 21 acres

3 Green belt Adequate land has earmarked as open spaces and for

other non-building purposes. Nearly, 8.63 acres land

will be used for green belt development by planting

various types of trees and area has been beautified

with plantation of ornamental trees.

4 Social Infrastructure CDPL will be developing the road which will available to

to local people residing nearby area

5 Connectivity NH-5 nearly 0.5 km away from proposed site.

6 Drinking Water Management Water Treatment Plant will be providing for drinking

water purpose.

7 Sewage system Generated sewage will be treated in Proposed ETP

Septic Tank

8 Electricity 2 MW Captive Power plant

6.1 Environment Infrastructure

6.1.1. Waste management

The proposed Wastewater Treatment Plant will consist of following treatment units.


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Figure 6: Flow chart of Effluent treatment system

Figure 7: Polishing Unit


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6.1.2 Rain Water Harvesting (RWH)

CDPL will be installing Rainwater Harvesting System. Rainwater harvesting Layout and schematic is

attached as Annexure III It is proposed to pump water from the rainwater harvesting PVC storage

tank to the roof tank on top of the station / office building. Collected water from the tank is

distributed by gravity through PVC pipes to desired locations for non-potable use.

6.1.3 Air Pollution

The air pollution is mainly from emissions of air pollutants from the stacks and dust from the coal.

Very little emission from fugitive sources is also predicted. Total power requirement is about 1400

KVA which is sourced from own captive plant. Two D.G Set of 750 KVA capacities (fuel required

HSD – 140 liters/hr) will be used as a stand-by source of electricity. The emissions from the boilers

are passed through ESP before releasing into atmosphere through a stack. The stack heights 35- 38

m will be provided.

6.1.4 Solid waste

Solid wastes are generated from the Fermentation (Yeast sludge), distillation (DDGS), collection/

neutralization tank (ETP Sludge), spent oil from DG sets, and used batteries from DG sets. The ash

from boiler is sold to brick manufacturers. Spent oil will be mixed with coal and burnt in the boiler.

Since DG set will be used at the time of power failure only, spent oil from D.G set will be negligible. The

waste oil and used batteries shall be sent to authorized recyclers. The other solid wastes expected

from the unit are containers, empty drums which is used for packing product, and or returned to

the product seller or sold to authorized buyers after detoxification.

For avoiding any kind of fire incident leakages inside the factory premises, the following safety

measures have to be undertaken:

6.1.5 Safety Equipment

Risk assessment for storage and handling of alcohol and mitigation measure due to fire and

explosion and handling areas. Alcohol storage and handling area with firefighting facility as per

norms.


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RS/ENA storage tank

Tank diameter: 8.12 m

Tank height: 8.75 m

Type of tank: above ground cone roof vertical tank (flat bottomed)

Storage temperature: Ambient temperature i.e., 300C

Storage pressure: Atmospheric pressure (1 bar)

No of tanks: 5 nos

For avoiding any kind of fire incident leakages inside the factory premises, the following safety

measures have to be undertaken:

Fire extinguisher

Fire detectors

Fire Alarm

Fire hydrant, fire extinguisher 16 nos

DCP type extinguisher for alcohol tank + plant area + 6 nos sand buckets

Provision of foam system for firefighting to control fire from the alcohol storage tank.

Fire brigade vehicle

Fire tender with foam arrangement viz.

Foam type as follows: - Foam compound, aqueous film forming compound 3% to 6% alcohol

resistance foam concentrated bearing ISI mark 4889.

Table 15: Potential Impact and its mitigation

Potential Impact Action to be Followed Parameters for

Monitoring

Frequency of Monitoring

Emergency

preparedness

such as fire

fighting

Fire protection and safety

measures to take care of

fire and explosion hazards,

to be assessed and their

prevention.

Mock drill records, on

site emergency plan,

evacuation plan

Monthly during operation phase


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6.1.6 Occupational Safety & Health

All precautionary methods will be adopted by the company to reduce the risk of exposure

of employees to occupational safety and health hazards.

Pre & post medical check-ups will be done of all the employees. Employees will be

regularly examined and the medical records will be maintained for each employee.

For the safety of workers, personnel protective appliances like hand gloves, goggles,

aprons, ear mufflers, nose mask etc. will be provided. Nose mask will be provided at

places, where there is possibility of dust generation. In high noise generation areas ear

mufflers will be provided for the workmen. Proper ventilation system will be provided in the

process area

7. Rehabilitation and Resettlement (R & R) Plan

Not applicable as the Project site is situated in MIDC.

8. PROJECT SCHEDULE

8.1 Schedule and approval for implementation

Table 16: Project Implementation Planning

S.No. Activity Period Start Date Finish Date

1 Basic Engineering 6 weeks 1/6/2015 15/7/2015

2 Specification of Tender 2 weeks 15/7/2015 1/8/2015

3 Commercial Bidding 6 weeks 1/8/2015 15/9/2015

4 Bid Review & Finalization 6 weeks 15/9/2015 1/11/2015

5 Layout Finalization 2 weeks 1/11/2015 15/11/2015

6 Load Data 4 weeks 1/11/2015 1/12/2015

7 Civils 24 weeks 1/12/2015 1/6/2016

8 Structural work 20 weeks 1/2/2016 1/7/2016

9 Equipment manufacturing 28 weeks 1/11/2015 1/6/2016

10 Dispatch 4 weeks 1/6/2015 1/7/2016

11 Installation 12 weeks 1/7/2015 1/10/2016

12 Local fabrications 12 weeks 1/6/2015 1/9/2016

13 Piping 20 weeks 1/7/2016 1/11/2016

14 Water Trials & commissioning 4 weeks 1/12/2016 1/1/2017

15 Commercial Production & handover 4 weeks 1/1/2017 1/2/2017


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Project Implementation

• In the Above activity chart, Government approvals would be taken within the activity

period.

• Project would kick off once State Government of Odisha grants Letter of Intent.

• The Release of advance & orders would be as per the Delivery schedule.

• Longest Deliver & installation time required is for Power Plant.

• Activities are subject to free fund flow.

8.2 Project Cost Estimation

Estimated Project Cost for the project is Rs 67.25 Cr, Cost for Environment management plan

Table 17: Environment Management Cost(EMP)

9. Project Benefit

1. Direct Employment

2. Increase in Revenue

3. Fish, Poultry & Dairy farming development by way of DDGS availability

4. Economic Growth of State

Sr. No. Description Capital Cost

(Rs in Lakhs)

Recurring Cost per

annum (Rs in Lakhs)

1 Air Pollution Control 100 10

2 Water Pollution Control 80 5

3 Environment monitoring and

Management

- 7

4 Rain water Harvesting 25 3

5 Occupational Health 10 5

6 Green Belt 10 3

7 Solid waste management 10 5

Total 235 38


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ANNEXURE I

Project Layout


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ANNEXURE II

TOPOSHEET


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ANNEXURE III

RAIN WATER HARVESTING LAYOUT


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(Rain water Harvesting Continue ….)

SCHEMATIC OF RAIN WATER HARVESTING


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(Rain water Harvesting Continue ….)

Figure 1: Design of Filter Chamber

Figure 2: Strom Water Conveyance Schematic

Documents

Proposed 55 KLPD Grain Based Distillery · Proposed 55 KLPD Grain Based Distillery ... 3.9 Schematic representation of the feasibility drawing showing EIA ... cylinder or by tanks