1

Pre Feasibility Report

For

Molasses Based Fuel Ethanol Plant of

45 KLD

Along with 14 TPH Incineration

Boiler

At

Village – Mendrana

Tehsil- Pansemal

Distt – Badwani (MP)

Proposed By

M/S Shree Durga Khandsari Sugar Mills

(SDKSM)

Village- Mendrana, Tehsil- Pansemal, Dist.

Barwani, MP

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1. Identification of project and project proponent

M/s Shree Durga Khansari Sugar Mill (SDKSM) is as partnership firm registered

with State Govt and located at Village- Mendrana, Tehsil- Pansemal Dist

Barwani (MP)

The factory was established originally as Khandsari Sugar unit of 300 TCD in

1974. Initially factory was following traditional khandsari process which was

associated with number of disadvantages such as low sugar recovery, higher

sugar loss in bagasse and final molasses, high fuel consumption. In year 2004,

the unit upgraded the crushing capacity to 800 TCD and received permission for

conversion of khandsari unit to sugar plant. Presently SDKSM is operating plant

with expanded capacity of 2500 TCD.

Brief Description of Nature of the Project

The present proposal is for setting up a 45 KLD fuel ethanol plant (Molasses

based) with 14 TPH Incineration Boiler at Village Mendrana, Tehsil- Pansemal

Dist Barwani (MP) in the State of Madhya Pradesh at an estimated cost Rs. 4682

Lacs. The proposed project will be set up adjacent to the existing sugar unit

(2500 TCD & 11 MW power plant) of M/s SDKSM.

Most of the infrastructure facility is already available with the industry as

present sugar manufacturing operation is being continued from several years.

The Company proposes to set up an integrated pollution free (Zero discharge)

fuel ethanol plant in the State with an installed capacity of 45 KLD in the State

of Madhya Pradesh. The proposed Industrial Complex shall process molasses as

its raw material to produce RS & Dehydration:

Silent feature of the project

• Provided with most efficient Fed batch Fermentation technology

Distillation operating on Multi-Pressure Technology -a efficiently heat

integrated system, operating on fully automated PLC control system

On line cleaning system is provided for distillation equipment's to

minimize plant shut down period.

Process equipment's are designed as per TEMA/ ASME standards

Imported Buhler makes Mill and efficient Grain handling system is

considered.

Closed water recycles system and plant process is designed to minimize

fresh water requirement by recycling various effluents.

Zero Effluent Discharge norms is applied while designing the plant

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Sr. No. Particulate Description

1. Name of the proponent M/s Shree Durga Khandsari Surgar Mills

2. Project capacity 45 KLPD Molasses Based Ethanol Plant with 14

TPH Incineration Boiler. 3. Khasara No. & Location of the

project

Khasara No. 76/1 & 76/2, Village- Mendrana, Tahsil Pansemal, Dist. Barwani, MP.

4. Geographic Location 21°39'24.56" N and 74°39'14.41" E

217 m MSL 5. Land requirement Total land 8.0048 acres for proposed Distillery Unit

1.989 acre built up area 2.64 acre green belt area

6. Product Product:

Fuel Ethanol :45 KLPD With 14 TPH Incineration Boiler.

7. Operation days 270 days 8. Molasses required Molasses 158 TPD ( Fermentable sugar 42% w/w)

9. Total water 351 KLD (After recycling)

10. Source of water Borewell

11. Electricity Operational: 847 kWh Connected load: 1185 kWh

12. Turbine generator 1.20 MW 13. Steam 9.92 TPH

14. Fuel Concentrated spent wash: 117 TPD Bagasse – 115 TPD

15. Source Captive & Nearby Market 16. Boiler 14 TPH Incineration Boiler

17. DG Two DG sets of capacity 250 kVA

18. Effluent treatment System

Condensate Polishing Unit (CPU) will treat spent lees, cooling tower blow down, boiler blow down and process condensate. Spent wash will be

treated by multi effect evaporator followed by slope fired boiler.

19. Man-power 70 skilled and unskilled 20. Total project cost 4682 Lakhs

21 Land acquired 24.19 acres

22 Land required for proposed

plant

1.989 acres

23 Proposed area for plantation 2.64 acres

24 Existing area of plantation 2 acres

25 Capital Cost for

Environmental measures (proposed )

1050 Lacs 100 Lacs ( May be changed during EIA

study)

26 Recurring cost for environmental monitoring etc

(Proposed)

100 Lacs ( May be changed during EIA study)

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Existing Sugar And Cogeneration Plant Details

Sr. No Description Quantity Unit

1. Crushing capacity, TPD 2500 TCD

2. Number of crushing

days/year

(expected)

125

3. Boiler used 60 TPH

4. Power generation capacity 11 MW

5. Power consumption Season Offseason. MW

For sugar plant and cogen 4 0.001

Other In-house consumption N A N A

Power export N A N A

6. Bagasse generation 636 TPD @28.4%

7. Bagasse required for cogeneration

600 TPD

8. Saved bagasse 36 TPD

9. Molasses generation 117 MT TPD

10. Fresh water requirement for Sugar and cogeneration after

recycling.

Season Offseason. CuM/D

465 20

11. Water storage capacity 4700 CuM/D

12. Effluent generation form

sugar and cogeneration

plant

Sugar manufacturing

Process:

48 M3

From Cogeneration plant : 1

M3

CuM/D

13. Final disposal of treated

effluent

53 M3. -

14. Ash generation from existing plant

24 TPD

15. Pressmud 75 TPD

16. ETP Sludge 0.001 TPD

17. Lime sludge 0.008 TPD

18. WTP Sludge 0.001 TPD

19. Final disposal of Ash Given to farmer as manure. -

20. Storage capacity of Bagasse’s

yard 1000 MT

21. Storage capacity of Molasses 3000 MT

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22. Existing manpower requirement for Sugar/Cogeneration (skilled

and unskilled)

100 No.

Proposed manpower requirement for Distillery

(skilled and unskilled)

35 No.

23. Layout plan of existing sugar factory and cogeneration unit & proposed

Distillery unit with existing green belt, parking area, storage area etc -

Attached

3. Need for the project and its importance to the country and or region

Utilization of molasses for the production of ethanol in India will not only provide

value addition to the by-product, it also ensures better price stability and price

realization of molasses for the sugar mills. This will improve the viability of the sugar

mills, which will in turn benefit to cane growers.

Industry overview

Molasses is one of byproducts of sugar industry which is used to produce rectified

spirit/alcohol for making liquor and fuel. Traditionally, molasses has been used in

India to produce rectified spirit and alcohol of higher than 95% purity for producing

liquor for human consumption and for producing various chemicals. However, with

technological developments in the recent past, molasses has been effectively used to

produce bioethanol for blending with petrol as a fuel

Global scenario

Brazil is the second largest producer of ethanol globally after U.S. While U.S.

produces ethanol from corn, Brazil manufactures ethanol from sugarcane. Brazil

has mandatory blending ratio of ethanol in gasoline ranging from 18% to 25%. The

blend rate was as high as 25% before September 2011 and was reduced to 20% due

to drop in cane output hence affecting the ethanol production. Currently, flex-fuel

cars, which can use either ethanol or blended gasoline, in Brazil account for about

53% of the total car fleet and around 90% of the new vehicles sales. The proportion of

the flex-fuel cars are expected to cross 80% by 2020. Currently, the Brazilian light

vehicle fleet has been increasing by 6.7% y-o-y since 2003 with currently 90% of

the new vehicles being flex-fuel cars. Thus, there exists an increasing demand

in Brazil for ethanol which is encouraging for the sugarcane industry.

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Indian scenario

India has about 330 distilleries, which produce over 4 billion liters of rectified spirit

(alcohol) a year. Beyond total distilleries, about 120 distilleries have the capacity to

distillate 1.8 billion liters (an additional annual ethanol production capacity of 365

million liters was built up in the last three years) of conventional ethanol per year

which is sufficient to meet requirement for 5% ethanol blending with petrol.

Government policy

In 2006, GOI mandated 5% ethanol blending with petrol, EBP programme to directly

benefit the sugarcane farmers by assuring the sugar industry a stable and reasonable

return for the molasses and then passing a significant part of the same to the

farmers. But since then the programme has been struggling to take off despite the

fact that the Cabinet Committee on Economic Affairs (CCEA) in November 2009

directed that a financial penalty be imposed on oil marketing companies for their

failure to reach targets. In November 2012, the CCEA has made it mandatory for Oil

Marketing Companies (OMCs) - Bharat Petroleum, Hindustan Petroleum and Indian

Oil Corporation - to blend 5% ethanol with petrol. This is likely to reduce the fuel

import bill and lower India's dependence on fossil fuel as the ethanol prices are lower

than petrol. The OMCs have been blending ethanol with petrol for the past two years

but the policy was partially implemented in absence of any clear directive. The

committee, headed by the Prime Minister, has also approved market-based

pricing of the biofuel, opening the

market for ethanol producers - mostly sugar companies. This shall result in an

increased demand for ethanol by OMCs.

The national bio-fuel policy, approved by the Government of India, has plans for a

20% ethanol blending programme by 2017 from the current mandated 5% blending &

recently increased to 10%, to reduce India’s dependence on fossil fuel imports.

4. Demand –Supply Gap

The gap between the availability of alcohol and the requirement by the industry has

been widening. The existing requirement of alcohol by the industries is around 450

crore liters annually at 10% fuel ethanol blending, industrial alcohol and potable

alcohol and the production is around 285 crore liters. The trend is increasing as the

blending increases.

The Ministry of Petroleum recently issued gazette notification dated 11th Januray

2013 making 5% ethanol belnding with petrol mandatory across th country.

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Year Ethanol production Ethanol utilization Ethanol Blending

Petrol Demand

Molasses Cane Total Industry Potable Balance

2001-02`

1775 0 1175 600 648 527 5% 448 8960

10% 896

20% 1792

2006-07

2300 1485 3785 711 765 2309 5% 638 12672

10% 1276

20% 2552

2011-12

2300 1485 3785 844 887 2054 5% 814 16286

10% 162

20% 3257

2016-17

2300 1485 3785 1003 1028 1754 5% 1039 20785

10% 2078

20% 4157

From the above table it can be concluded that actual production of ethanol in India has not kept pace with the demand. Also with robust growth for chemical and potable industries it will mean greater shortage of ethanol in the coming years ahead. The Government of India has set an indicative target of 20% blending of ethanol with petrol and also for diesel with biodiesel across the country by 2017.

5. Imports Vs. Indigenous Production

No import is proposed as demand in domestic market is enough to consume

the product.

World Alcohol Production and Consumption (Billion Litres)

World Regions Years

2010 2011 2012 2013 2014

Americas 23.23 27.81 30.02 33.35 37.30

Asia 6.02 6.54 6.44 6.61 7.15

European Union 2.54 2.50 2.50 2.71 3.13

Rest of Europe 1.45 1.48 1.47 1.46 1.36 Africa 0.51 0.54 0.57 0.59 0.62

Oceania 0.18 0.16 0.15 0.15 0.17

World Total 33.93 39.03 41.15 44.87 49.73

India 1.80 1.90 1.65 1.70 2.0

* Projected

Source: F. O. Lichfs World Ethanol and Biofuels Report, Vol.4, No.17,

09/05/2006. Ethyl alcohol is basically used for three purposes i.e. 1)

Industrial alcohol for production of downstream chemicals, 2) Pptable Alcohol

for mamifacture of alcoholic beverages (Country Liquor and IMFL) and 3)

Fuel ethanol or Anhydrous alcohol, which can be blended with petrol or

diesel.

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Sr. No. Ethanol Consumption for (%)

1 Industrial 21

2 Potable 11 3 Fuel 68

Industrial Alcohol: -

Ethyl Alcohol is an Important feedstock for the manufacture of chemicals.

World ethyl alcohol consumption for the production of chemicals is

around 1%. These chemicals are primarily the basic carbon based products

like Acetic acid, Butanol, Butadiene, Acetic Anhydride, Vinyl Acetate, PVC

etc. The existing plants such as synthetic rubber requiring large

quantities of alcohol will certainly grow to a large capacity. Acetic acid &

Butanol, which are needed in pharmaceuticals, paints & in many other

areas are important industries as they are value added products. Ethylene,

Ethylene oxide & Mono-ethylene glycol are also produced from

petrochemical route. However latest technological development & taking

into account the increasing cost of petrochemical raw material, it is now

possible toproduce Ethylene oxide, Mono-ethylene glycol etc. starting from

ethanol.

During the last 5-6 years, a number of alcohol-based industries have come up&

the existing has marginally expanded. The raw material needs of the

alcohol based chemical industry have to be niet to facilitate maximum

capacity utilization of these units in order to meet the domestic demands

for the end products. These units are starving for want of raw materials. The

shortage is wide spread & it has hit a most of chemical drug & other

industries. The drug industry is also bedeviled by scarcity of industrial alcohol.

Producers of insulin, antibiotics, tonics & several other essential bulk drugs &

finished formulations are unable to obtain their quota of industrial

alcohol, which is a vital raw material for them. Thus, even in

Maharashtra, which should be a State with surplus production of

alcohol, drug & chemical units are in the group of acute shortage of

industrial alcohol. It follows that the supply of industrial alcohol to chemical

and drugs units in the country will remain below normal for some more

time. In order to maintain proper rate of growth of industries,

production of alcohol must increase.

6 Export Possibility

The company is setting up fuel ethanol plant, to supply the finish goods in the

country, at present is no export possibility at this capacity is envisaged.

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7 Domestic/Export Markets

As above

8 Employment generation (direct and indirect) due to the project

Existing employment at sugar unit : 100no.

Proposed Employment : 70 Nos. ( skilled and Direct )

Apart from that indirect employment generation is envisaged from the project.

Total manpower requirement Sr. No Staff Nos.

1. Distillery manager 1

2. Production manager 1

3. ETP in-charge 1

4. Lab chemist 4

5. Operators 8

6. Project Engineer / Shift Engineer 8

7. Electrician 4

8. Mechanical fitters 4

9. Office Peon 3

10. Office assistant 3

11. Excise officer 1

12. Waterman/ Pump man 4

13. Other Contractual staff 28

14. Total 70

9 Project Description

i. Type of the project including interlinked and interdependent project, if any

As submitted, the Ethanol Plant is proposed with the existing sugar unit of 2500

TCD. No interlinked and interdependent project is prpposed with the proposed

Ethanol plant. Incineration Boiler of 14 TPH is also proposed for implimetation

of zero discharge concept. CO2 will also generated as by product from the

fermentation process which is turn can be utilized after further treatment at

CO2plant in industrial or food grade application. It is also proposed

Evaporation plant of effluent to provide better environment conservation and

pollution control arrangement in the unit as well as for the surrounding area.

ii. Location (map showing general location, specific location, and project

boundary & project site layout) with Coordinates:

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The unit is spreaded over 24.19 acres of land in village Mendrana Tehsil,

Pansemal Dist. - Barwani of MP. The latitude and longitude of the site is as

below : 21°39'24.56"N - 74°39'14.41"E

Satellite Image of the Project area

Topographical Base Map

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iii. Details of Alternate Site:

The site is proposed on the piece of land where sugar unit ( 2500 TCD) with

cogen plant of 11 MW is already in operation. The entire land is about 24.19

acres and out of that proposed unit will require 32392 sq mt of land. Most of

the infrastructure is already available. Therefore proposed site suitable for the

project configuration.

iv. Size or magnitude of Operation:

It is proposed to produce 45 KLD of fuel ethanol from molasses based operation

along with 14 TPH Incineration Boiler. The unit shall adopt zero discharge

technology for the effluent disposal. .

v. Project Description With Process Details: The overall process is shown on the attached Block Flow Diagram, and Process

Flow Diagrams. The following describes the production of ENA and co-products

from grain. The process envisages use of own molasses, as well as procured molasses

from nearby sugar factories, for manufacture of ethanol during sugar mill season

and during off- season days.

Cane crushing system

Fermentation system

Distillation & Fuel Ethanol

Effluent treatment system

Following is a brief description of the process:

DETAIL PROCESS DESCRIPTION & PROCESS FLOW CHARTS

FERMENTATION

Molasses, diluted with water to the desired concentration is metered

continuously into a single tank fermenter. Additives likes urea (in the form of

pellets or prills) and defoaming oil are also introduced in the fermenter as

required. There is an automatic foam level sensing and dosing system for

defoaming oil.

Every Kilogram of alcohol produced, generates about 290 Kcal of heat. This

excess heat is removed by continuous circulation of fermenting wash through

an external plate heat exchanger called the Fermenter Cooler. The

fermenter temperature is always maintained between 32 and 35 deg. C, the

range optimum for efficient fermentation.

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The yeast for the fermentation is initially (i.e. during start-up of the plant)

developed in the Propagation Section described further on. Once propagated, a

viable cell population of about 500 million cells/ml is maintained by yeast

recycling and continuous aeration of the fermenter. Fluctuations in the yeast

count of +/- 20% have little effect on the overall fermenter productivity. Yeast

cell vitality which is usually above 70% may, in times of stress (such as

prolonged shut-downs) drop to 50% without affecting the fermentation.

Fermented wash passes through a series of hydro cyclones (one to three or

move in number depending on plant capacity), which remove grit, iron filings

and similar heavy particulate matter. This rejected material along with some

wash, is taken to the bottom portion of the wash column for alcohol recovery.

The overflow from the first hydro cyclone is taken a wash tank, also provided

with an arrangement to facilitate removal of heavy settable particulate matter.

Overflow from the wash tank is taken to the yeast separator, which clarifies

the wash. The hydro cyclone and the wash tank protect the separator from

erosion damage by removing grit and similar hard particles.

Wash Preparation

For the plant mash, molasses is diluted with water to give a sugar

concentration of 14 to 18% and pumped directly into the fermenter. This mash

is usually not sterilized, although in certain cases it has been pasteurised with

a resultant slight increase in efficiency. The fermenter is issued when it is one

eighth to one fourth full with a large volume of active yeast. 2 to 4% of the

final volume to allow development of the yeast during the entire filling period,

which may amount to 8 hours and to avoid growth of contaminating

organisms during this period.

Nutrients

Blackstrap molasses usually contains enough yeast nutrients to give a fast,

efficient fermentation. In some cases, however, it is desirable to add small

quantities of ammonium salts, such as ammonium sulphate, to the mash

to increase the rate and efficiency of the fermentation. In such cases, the

amount of ammonium sulphate added varies between 0.5 liters and 3 liters per

10,000 liters of mash, depending on the molasses used, the optimum amount

being determined by laboratory in a blackstrap molasses fermentation.

Fermentation Temperatures

Fermenters are usually set at a temperature between 270 F and 300 C and are

held a 320 C by the use of water sprays on the rank internal cooling coils, or

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by circulation of the mash through external coolers. It is desirable to

maintain the temperature of the mash below 350 C. The amount of heat

liberated during the fermentation agrees with the theoretical value.

C2H12O 2C2H5OH + 2CO2+26.0 Calories

The heat produced from a fermentation involving 100 kg of sugar is 260

cal. If the fermenters are not cooled the temperature of the mash will rise as

much as 400 C.

• Yeast Recycling:

The yeast in the fermented wash is removed as a 45 to 55 v/v slurry, and is

returned to the fermenter. This feature ensures that a high yeast cell

concentration is achieved and maintained in the fermenter. By recirculating

grown, active yeast, sugar that would have otherwise been consumed in yeast

growth, is made available for alcohol production, ensuring high process

efficiency.

• Propagation:

The propagation section is a feeder unit to the fermenter. Yeast, either

Saccharomyees cereviseae or Schizosaccharomyees (the choice being

determined by other process parameters, mainly the downstream effluent

treatment system) is grown in 3 stages. The first two stages are designed for

aseptic growth. Propagation vessel III develops the inoculum using pasteurized

molasses solution as the medium. This vessel has a dual function. During

propagation, it serves for inoculum build-up. When the fermenter enters

the continuous production mode, Propagation Vessel III is used as an

intermediate wash tank. Propagation is carried out only to start up the

process initially or after very long shut-downs during which the fermenter is

emptied.

• CO2 Scrubbing and Recovery:

The carbon-di-oxide produced during fermentation is scrubbed with water in

packed- bed scrubber, to recover alcohol. The water from the scrubber is

returned to the fermenter. About 1.0% of the total alcohol production is

saved by scrubbing the fermenter off gas. In plants where it is desired to

recover carbon-di-oxide, a part of the wash is drawn into a separate vessel

and is aerated there. This external aeration allows the recovery of CO2

uncontaminated with air. More details of this system can be supplied on

request.

• Fermentation Parameters (Typical):

The pH of the fermenter is maintained between 4.0 & 4.8 usually without

addition of any acid. The alcohol concentration is maintained between 7.0 &

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7.5 % v/v, unless a highly concentrate effluent is to be produced. To reduce

the effluent volume, the fermenter is operated at a very high dissolved solids

level by increasing the proportion of weak wash recycle. Under these

conditions, alcohol concentration is reduced to between 5.5 to 6.0% v/v.

Conversion of sugar to alcohol is instantaneous, and the residual sugar

concentration is maintained below 0.2 % w/w as glucose. This usually

corresponds to a residual reducing substances concentration of 2.0 to 2.5 %

w/w in wash.

All the nutrient elements necessary for yeast growth exist in adequate

quantities as impurities in molasses. Occasionally, Nitrogen may have to be

supplemented. Defoaming oil (DFO), say Turkey Red Oil is added to the

fermenter by an automated DFO dosing system, to control foaming. Usually no

other additives are required.

• Flexibility:

This process accords tremendous flexibility to the operator. Process conditions

and plant design can be varied to suit individual requirements of alcohol

quality, effluent concentration and characteristics. This unit can give spent

wash suitable for use in any effluent treatment process.

2. Distillation:

Clarified or de-yeasted wash flows by gravity to the propagation vessel No. III,

which during continuous production, operates as an intermediate wash tank.

From here, fermented wash is pumped to the wash preheater, which uses

vapors from the rectifying column to preheat wash. Further heating is done in

an exchange of heat with weak wash and spent wash (see flow sheet for

primary distillation). Preheated wash then enters the degasifying column of the

distillation section.

• Primary Distillation: The CO2 and the degasifying section help remove the

CO2 and other non-condensable entrained in the wash. The wash column is

first column in the distillation section. It is also called the analyzer. Wash is

boiled in this column with steam either supplied as live steam from the

boiler (after pressure reduction and desuperheating) or from a reboiler which

generates steam by evaporating effluent wash.

Alcohol in wash vapourises and is carried, along with water vapor, to the top of

the wash column from where it goes to the rectification column. As wash

travels down the analyzer, it is progressively ‘stripped’ of its alcohol content.

At a point in the column, where the alcohol concentration is 0.5 to 1.0% v/v,

a portion of the wash is drawn off. This is called weak wash.

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• Weak Wash Recycling :

Weak wash recycling of weak wash helps maintain the desired level of

dissolved solids in the fermenter, so that an adequately high osmotic

pressure is achieved. Osmotic pressure and the concentration of alcohol in the

fermenter, together keep off infection and minimize sugar losses. Weak wash

recycling also reduces the quantity of effluent spent wash and reduces the

process water requirement of the plant.

Spent wash is the wash from which all alcohol has been removed, this emerges

from the bottom of the wash column at about 105 deg C. Some of the heat is

recovered to preheat fermented wash entering the degasifying column.

Spent wash may also be passed through a forced circulation reboiler to

generate vapors. This concentrates the effluent and reduces the volume

further.

Multi Pressure Vacuum Distillation:

After fermentation the next stage in the manufacture of alcohol is to separate

alcohol from fermented wash and to concentrate it to 95% alcohol called as

rectified spirit. For this purpose, distillation process is employed.

Distillation step consumes a considerable amount of energy and is also a

deciding factor in the quality of ENA produced. Hence, in line with the demand

of the industry, efforts have always been to minimize requirement of energy and

to improve the basic quality of alcohol produced. Ease of operation,

reliability, lower down time and flexibility of operations are other parameters

considered during the design.

Three basic types of plant are designed:

a) One is to produce primary quality of alcohol, usually referred to as 'Rectified

Spirit' (R.S.) from the fermented wash. Such plants are also referred to as

‘Primary distillation’ plants.

b) Second is to produce fine quality of spirit usually referred to as 'Extra Neutral

Alcohol' (ENA) starting from R.S. Such plants are also referred to as 'secondary

distillation' plants.

c) Third is to directly produce fine quality alcohol (ENA) from fermented wash.

Such plants are referred to as 'wash (mash) to ENA' plants, where the two

steps of primary and secondary distillation are combined. Such plants

usually have lower consumption of energy than two separate plants

Multi-pressure vacuum distillation system for production of Rectified

Spirit / ENA consists of following distillation columns namely

1. Degasifying cum analyzer column – Operation under vacuum

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2. Pre-rectification column – Operation under vacuum

3. Rectification cum Exhaust Column - Operated under pressure

4. Recovery column - Operated under atmospheric

5. Extractive distillation column – Operated under vacuum

6. Simmering column – Operated under atmospheric

Benefits of Pressure Vacuum Distillation: -

Following are the advantages of pressure vacuum distillation.

• Since the analyzer column operates under vacuum, the formation of byproducts

such as acetal may minimize there by improvement in quality of alcohol.

• Pre-rectification column ensure removal of sulfur compounds/mercaptans and

also reduces load of lower boiling volatile compounds passing on to Rectifier

cum exhaust column.

• The chances of scaling due to invert solubility of certain precipitating inorganic

salts are minimized in vacuum distillation.

• Vacuum distillation requires low steam consumption with re-boiler

Integrated Multi-products Concept: -

It is now possible to install a distillation system, which can produce different

products. In the proposed scheme; the production of rectified spirit have

been considered. This allows flexibility of operation and various products can

be manufactured depending on the market demand. This integrated multi-

product system involves less capital investment as compared to independent

system.

In this type of system, switching over from one product to another is quite easy

and there is no chance of contamination of one product with another. The

system can work under multi-pressure principle with few columns operating

under vacuum and few under pressure/atmospheric.

3. Dehydration of Alcohol: Molecular Sieve:

The process drives the rectified feed though a bed of desiccant beds. To allow

for bed regeneration in continuous operation, twin beds are provided of which

one is in dehydration mode while the other is regenerating. Depending on

feed and product specifications, the dehydration-regeneration process releases

the adsorbed water together with contained ethanol, it is recycled back to

regeneration column for reprocessing.

The feed is pumped to regeneration column after preheating in feed

preheater. The overhead vapor of regeneration column is superheated to the

required operating temperature and circulated to sieve bed 1 assumed in the

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description to be in dehydration mode. After passing though the desiccant,

the vapor is condensed, cooled and sent to storage.

A small portion of the product vapor is sent, under high vacuum, through

bed 2, in regeneration mode, to prepare the desiccant for cycle changeover when

bed 2 goes online. The regeneration operation forces the release of the moisture

from the desiccant, making the bed 2 ready for the next cycle. The recovered

low strength vapors are condensed and recycled back to the Regeneration

column.

4. Evaporation for Spent wash Treatment

As per recent Environmental Protection Norms from Ministry of

Environment and Forests (MoEF), it is Corporates Responsibility to achieve

Zero Discharge in Inland Surface Water. For 45 KLPD distillery plant nearly

about 117 M3/Day spent wash will produced. Considering the large volume of

spent and achieve Zero liquid discharge plant operation following three stage

process is proposed.

Multi pressure distillation – In this steam is utilized in direct way for heating.

Hence, spent wash quantity generated is less as compared to traditional

distillation technology. Integrated and Standalone Multi effect evaporation -

The spent wash evaporation technology is a multiple effect evaporator system in

which heat recovered from one effect is used to concentrate spent wash in

second effect evaporator with continuous recirculation of concentrated spent

wash within the system until desired concentration is obtained. This entire

concentration process is carried out under vacuum leading to less

consumption of steam and maximum concentration of spent wash with in less

period of time. This is the 3rd stage of effluent treatment wherein spent

wash after integrated evaporation is concentrated and used in incineration

boiler.

5. Spent wash Incineration Technology:

After spent wash evaporation, concentrated spent wash with desired

concentration is obtained is feed to incineration type of boiler. The

concentrated spent wash generated after entire process of evaporation is then

sprayed in a furnace with auxiliary fuel such as coal and is then burnt in a

boiler.

6. Process Condensate Treatment and Recycle:

The condensate polishing unit is also envisaged to take care of spent lees,

cooling tower blow down, washing and process condensate from evaporation

plant. After treatment all the stream at CPU, treated condensate can be

recycled to process for dilution and as cooling tower make up and will

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achieve zero liquid discharge (ZLD) Due to recycle of process condensate back

to process, fresh water demand can be reduced at large extent.

Quantity of Raw Materials Required;

Raw material requirement

Sr. No. Name of raw

material

Quantity Storage Transportation

Distillery

1. Molasses 158 TPD Tank Tanker

2. Coal NA N A N A

3. Sulfuric Acid 0.25kg/KL FRP Tank Tanker

4. Anti-foam reagent 0.25 Drum Truck

Sugar unit

1.

Sugarcane 2500TCD Open Area Truck & Tractor

2. Lime 658 MT/Year Bags Truck

3. Sulphur 158 MT/Year Bags Truck

4. Caustic soda (50%) 5.45MT/year Bags Truck

5. Caustic soda 5.45 MT/Year Bags Truck

SDKSM will generate about 14,688 MT of molasses from expected / sustained

cane crushing of 3.125 lakh MT / year, with minimum 4.7% molasses recovery.

The total requirement of molasses for the 270 days operation of the proposed

distillery plant at optimum level of operation will be around 45,000 MT and the

balance 28062 MT of molasses will be sourced from group units sugar factories.

The fuel ethanol yield from cane molasses will be at 270 lit/ton. The per day

requirement of molasses will be about 166 MT per day for 45 KLPD ethanol

production per day. The total requirement of molasses for the 270 days

operation of the proposed ethanol plant will be about 42,750 MT (at maximum

95% utilization level from 4th year onwards). At the projected average cane

crushing of 2500 TCD for 125 days or 3.125 lakh MT per year, 14,688 MT

molasses will be generated from the cane crushing. The balance quantity of

28,062 MT will be sourced from other units. In house molasses should be

adequate to run the ethanol plant for at least 270 days. All four unit in-house

molasses will be sufficient to run the 45 KLPD of distillery plant for 270 days

at 9500 TCD combined Crushing Capacity of all four units.

19

As the sugar plant is expected to crush about 3.125 lakh MT of sugarcane in

future, molasses of around 14,688 MT will be produced at 4.7 % molasses

generation on cane. The own molasses will be utilized by the fuel ethanol plant,

leaving 28,062 MT as other unit molasses, as the total molasses requirement is

42,750 MT for optimum level of operation.

The balance quantity of molasses will be sourced as procured molasses from

nearby sugar factories.

vii. Resource optimization/ recycling and reuse

Multi Pressure Distillation system has lower steam consumption as it is

designed for maximum heat integration to conserve energy.

Energy efficient Multi-Pressure Distillation system with a Steam Consumption

9.92 TPH of Total Spirit (depending on mode of operation).

Vacuum operation nearly eliminates scaling problem in Analyzer Column and

ensures better separation of impurities, which results into better quality

product.

Well-engineered Plants with high efficiency trays to ensure elaborate separation

and removal of impurities ensuring superior quality of Extra Neutral Alcohol.

Analyzer Column with Hyper-stat Rh-Grid trays ensure high turbulence on tray,

this minimizes chances of scaling. Also, this special construction of trays and

access to each tray helps in easier cleaning column internals.

Condensers are designed with multiple passes to ensure high velocity and to

minimize scaling inside tubes.

Alcohol is well known as an industrial raw material for manufacture of a variety

of organic chemicals including pharmaceuticals, cosmetics, polymers etc. A

large demand is anticipated for alcohol as a fuel. Alcohol is an eco-friendly

product

and is a substitute to the imported petroleum. Indeed fuel ethanol production

has been promoted for a variety of reasons as mentioned below,

It has less severe impact on the environment than conventional gasoline and

less dangerous to health. As oxygenates are compounds such as alcohols or

ethers which contain oxygen in their molecular structure. Oxygenated fuels tend

to give a more complete combustion of its carbon to carbon dioxide (rather than

monoxide) which leads to reduced air pollution from exhaust emissions. It

reduces the dependence on oil imports.

It helps to maintain rural economy.

Factory proposes zero liquid discharge method for waste water treatment.

Maximum waste water will be recycled back into the system.

20

Factory proposes to install Multiple Effect evaporator followed by Incineration

boiler. Advantages are as follows

Production of steam and power generation

Reduction in air pollution as compared to coal based boiler.

Reduction in water pollution and achieve zero discharge in inland surface water.

viii.: Availability of Water its source, energy / power requirement and source:

Water requirement:

Construction Phase – 20 kld

Operational Phase – Net fresh water requirement will be 351 KL per day

Source : Borewells

Water Balance

. Water inputs (In KLD)

1. Process water for fermentation section and CO2 scrubber 414

2. DM water for RS dilution 50

3. Water for vacuum pump, pump sealing, air blower & others

6

4. Soft water makeup for cooling towers 340

5. Other domestic usage, laboratory uses, cleaning 5

6. Boiler 15

7. Total water input at start-up 830

Water Out Put (In KLD)

1. Spent Lees (PR & Rect.) 120

2. Process condensate 395

3. CT Evaporation & Drift Losses 272

4. Water losses from vacuum pump, pump sealing, Air blower 0.2

5. Cooling tower and boiler blow down 67

6. Total Water Output 854.2

Recycled water (In KLD)

1. Lees recycle for cooling tower make up 120

2. Process condensate fermentation 120

3. Process condensate to cooling tower, CIP, Fermentation 233 4. Pumps Sealing Water Recycle cooling tower 5

5. CO2 scrubber beer well to process water for fermentation 1

6. Total Recycling water per day 479

Daily fresh water input 351

21

Water requirement for existing sugar and cogeneration

Sr. No

Particulars For sugar in KLD

For Cogeneration in KLD

During Off Season

1. Total water requirement 350 150 3 M3

2. Water recovered 135 25 -

3. Total daily fresh water

required after recycling

215 125 -

Wastewater generation of sugar and cogeneration

Sr. No.

Source Process KLD Treatment Final Disposal

1. Sugar Plant

Sugar manufacturing Process

200M3

ETP Treatment Units: Bar screen and grit chamber, oil and grease traps, reaction tank, equalization tank, anaerobic tank, aeration Tank I, aeration Tank II, secondary clarifier, sludge drying bed and polishing pond.

For ferti irrigation.

2. Co generati on 11 MW

Cooling Tower

15 For polishing pond for dilution with other effluent

For Ferti-Irrigation

Boiler Blow down

5 M3 For polishing pond for dilution with other effluent

For Ferti- Irrigation

D.M. Regeneration

50 M3

Neutralization followed bydisposal to polishing pond for dilution with other waste water stream.

For Ferti- Irrigation

3. Total - 270 M3

- -

Summary of effluent generation from proposed distillery, existing sugar and cogeneration unit

Source Effluent Quantity Disposal

Proposed Distiller Spent wash Raw spent wash generation 450 KLD concentrated spent wash 117 KLD

Conc. Spent Wash Feed in Incineration Boiler.

Sugar Molasses 117 TPD

Effluent 200 KLD

Co generation Blow down from the cooling tower &

70 KLD

22

boilers

Domestic Waste water

Sewage generation 20 KLD

ix. Power Requirement:

Construction Phase – 30 kw

Electricity consumption bifurcation

Sr. No Section Connected load (kWh)

Operating load (kWh)

1. Fermentation

1185 KWH

847 KWH

2. Distillation

3. MSDH

4. Integrated RSW evaporation

5. Process condensate treatment plant

6. Alcohol storage

7. Utility (Cooling tower)

8. Instrument air compressor

9. Total 1185 KWH 847 KWH

During operation phase , the required power will be taken from cogeneration

power plant. One DG set of 1010 KVA shall be kept as standby arrangement

Fuel consumption

Sr. No Fuel Quantity

1. Concentrated spent wash 117.84 TPD

2. Spent wash concentrate, GCV 1600 kcal/kg

3. Coal GCV N A

4 Bagasse 115.20 TPD

5 Bagasse GCV 2250 kcal/kg

23

Steam Requirement

Sr. No. Section Quantity (TPH)

Steam utilization for Distillery

1. Steam for Distillation (Wash to ENA mode) N A

Or Steam for Distillation (Wash to EQRS) 4.82 TPH

2. Steam for Integrated Evaporation 4 TPH

3. Steam for MSDH 1.10 TPH

4. Total 9.92 TPH

Steam utilization for sugar factory

5. Crushing rate 2500 TCD

6. Steam Generation 1440 MTD

7. Steam Requirement 1161 MTD

8. Steam Condensate 113 MTD

Steam Requirement

S no Purpose Quantity

1 Ethanol Fuel 3.5 kg/lit

2 Evaporation 1.8 kg/lit

X. Quantity of wastes to be generated (liquid and solid) and Scheme for their

management/ disposal

For Liquid Waste

The total water requirement at the startup will be around 830 m3/day, and

after recycling daily fresh water requirement will be 479 CMD. Source of water

will be Bore well. Water storage facility is available with the sugar factory.

Detail water breakup is given in Table

Water requirement for existing sugar

Sr. No

Particulars For sugar

During Off Season

1. Total water requirement 350 M3 3 M3

2. Water recovered 135 M3 N A

3. Total daily fresh water required after recycling

215 kld NA

24

Wastewater Generation Of Sugar And Cogeneration

Sr. No.

Source Process KLD Treatment Final Disposal

1. Sugar Plant Sugar manufacturing Process

200 M3

ETP Treatment Units: Bar screen and grit chamber, oil and grease traps, reaction tank, equalization tank, anaerobic tank, aeration Tank I, aeration Tank II, secondary clarifier, sludge drying bed and polishing pond.

For ferti irrigation.

2 CO Gen Plant

Cooling Tower

15 For polishing pond for dilution with other effluent

For Ferti- Irrigation

Boiler Blow down

5 For polishing pond for dilution with other effluent

For Ferti- Irrigation

D.M. Regeneration

50 Neutralization followed bydisposal to polishing pond for dilution with other waste water stream.

For Ferti- Irrigation

2. Total - 270

M3

- -

Summary of effluent generation from proposed distillery, existing sugar and cogeneration unit

Source Effluent Quantity Disposal

Proposed Distillery Spent wast Raw spent wash generation 450 KLD concentrated spent wash 117 KLD

Conc. Spent Wash Feed in Incineration Boiler.

Sugar Molasses 117 TPD ETP

Effluent 200 KLD

Co generation Blow down from the cooling tower & boilers

70 KLD

Domestic Waste water

Sewage generation 20 KLD Septic tank and soak pit

Solid And Hazardous Waste Management

Yeast sludge mixed with spent wash and incinerated in the boiler or used as

manure.

Ash generated will be given to brick manufacturers.

Sludge from ETP will be used as manure.

25

Solid Waste Details

Sn Type of waste Quantity Disposal

From existing sugar &-cogeneration plant

Proposed Distillery

Yeast Sludge N A 0.2 Kg/day Fertilizer

Lime Sludge 0.008 MT/day N A Fertilizer

WTP Sludge 0.001 MT/day N A Fertilizer

ETP Sludge 0.001 MT/day - Fertilizer

Ash Bagasse ash: 24 MT/day

Coal Ash : Spent wash Ash ;

N A 1.73 MT/day

Domestic waste 0.01 MT/day N A

Waste Oil 0.0001 Ltr/day N A

4.0 Site Analysis:

i. Connectivity

Location : Own land at Village Mendrana

Tehsil –Pansemal, District- Barwani (MP)

Place : Tehsil –Pansemal

District : District- Barwani (MP)

S.

No.

Particulars Details

1 Co-ordinate 1. 21°39'24.56"N - 74°39'14.41"E

2

3 Height above mean sea level

217 m MSL

4 Nearest Town Pansemal – 4.50km

5 Nearest Railway

Station/Town

Dondaicha – 37.25km

6 Nearest Airport Shirpur – 48.00km

7 Nearest Highway/Road Khetia- Sendhwa Road SH 36 - 0.17 km

- S

8 Hills/Valley Toramal Hill – NEE – 8.75km

9 Ecological Sensitive Zone None

10 Reserve Forest RF- NNE – 8.75km RF- ENE – 9.75km

11 Nearest Village Mendrana – E – 0.90km

12 Nearest River/ Nalla Bandbhara Buzurg nadi – N- 0.09km Gomai River – SE – 1.25km

Umri Nadi – W – 3.25km

14 Surrounding Features

26

ii. Land Form, Land use and Land Ownership

Project Proponent is having 24.19 acres of land which is possession and

diverted for industrial purposes.

iii. Topography

Topography of the area is almost plain. Map is given in point No. 3.2

iv. Existing Land use pattern

The land use of the project area is pertaining to industrial activity only. Out of

project area is predominantly being used or agricultural purposes.

Land use Break-Up for Existing and proposed unit

Area in Sq Mt

Particular Existing Sugar Unit Proposed Distillery unit

Built up Area of main plant and machineries

20245 8049

Road area 2024 2024

Raw Material storage area 8098 100

Fuel Storage Area 4049 2024

Roof Area 2025 N A

Parking area 2025 Common

Green Belt 20245 8098

Open Land 39235 12097

Total area 97946 Sq. Mtr. (24.19 Acre) 32392

Land Bifurcation Of Proposed Distillery Unit

No. Units Area (sq. m.)

1. Molasses Storage Tanks 1020

2. Fermentation Section 1040

3. Distillation Section 700

4. Evaporation Section 710

5. Product Storage & Receiver Section 1020

6. Cooling Tower for Fermentation 200

7. Cooling Tower for Disti. + Int. Evaporation 300

8. Cooling Tower for MSDH Section 200

9. PCTP Section 50

10. WTP & Raw Water Storage Tank 729

11. Weigh Bridge 30

12. Administration Office 80

13. Excise Office 20

27

14. Security Cabin 20

15. Time Office 20

16. Boiler House 900

17. Coal Yard N A

18. Lagoon & Settling Pit 1000

19. Fire Water Pump House 10

Total area of Plant & Machineries 8049 Sq. Meter

In Acres 1.98 Acres

Total area earmarked for project 8.0048 acres

v. Existing Infrastructure

The required infrastructure is already in place as proposed site is in operation.

State Highway is passing at 170 mtrs from the industry.

vi. Soil Classification

The soils in the area are generally of sedimentary type soil .

vii. Climate data from Secondary Source:

Meteorological data month of 1st March to 31st May 2017

Date

Temperature OC Relative Humidity %

Morning (8.00) Evening (15.00) Cloudiness

Octas

Max Min Avg. Max Min Avg. Wind Dir.

Wind

Speed km/h

Wind Dir.

Wind

Speed km/h

Mor. Eve.

1 35 17 26 64 14 31 E 5 SW 15 2 0

2 33 16 24 53 15 33 NW 7 WSW 18 3 2

3 32 15 23 60 12 35 NW 6 WSW 19 4 1

4 31 14 22 73 17 43 ESE 7 W 14 0 0

5 29 16 23 64 24 44 NE 10 NNW 7 0 3

6 30 16 23 68 19 36 ENE 13 SE 4 0 0

7 33 16 24 49 9 25 ESE 11 SW 13 6 3

8 31 16 23 49 15 31 WNW 14 W 20 6 10

9 31 16 23 52 14 31 WNW 14 WSW 22 7 9

10 29 16 22 53 26 40 W 21 WNW 21 8 43

11 28 15 21 77 11 33 W 21 WNW 23 10 2

12 27 9 18 47 9 26 NNE 11 N 8 0 0

13 30 14 22 42 9 25 ENE 7 W 5 2 0

14 31 13 22 42 5 24 E 12 ESE 6 0 51

15 32 16 24 35 7 18 ESE 17 SSW 9 14 1

16 34 18 26 74 9 22 SE 15 WSW 13 4 2

17 33 15 24 40 9 21 NNW 12 NW 18 0 0

18 33 18 26 49 15 28 WNW 21 WNW 23 15 10

19 33 17 25 52 16 34 ESE 10 WNW 27 7 6

20 33 17 24 60 15 34 NE 12 NE 8 1 1

21 34 19 27 52 8 28 E 9 SE 4 0 0

22 37 18 28 46 10 25 SSE 6 SW 10 0 0

23 37 19 28 38 10 23 NW 5 WSW 7 0 0

28

24 37 21 29 47 11 25 NNW 14 WNW 15 1 0

25 38 19 29 49 11 26 NW 10 WNW 18 0 0

26 39 18 29 53 12 29 E 5 WNW 10 0 0

27 38 23 31 47 14 27 NE 10 NNE 11 0 0

28 40 20 30 35 12 24 NW 6 NW 6 0 0

29 41 23 32 36 12 21 N 15 NW 8 0 0

30 40 22 31 28 12 19 N 15 WNW 17 0 0

31 39 23 31 39 13 26 NW 10 W 15 0 0

Table no. 3.2 (B)

Meteorological data month of 1st April to 30th April

Date

Temperature OC Relative Humidity %

Morning (8.00) Evening (17.00) Cloudiness

Octas

Max Min Avg. Max Min Avg Wind Dir.

Wind Speed km/h

Wind Dir.

Wind Speed km/h

Mor. Eve.

1 39 23 31 39 6 20 NW 17 W 24 0 0

2 38 22 30 38 6 16 WNW 21 W 21 0 0

3 38 18 28 34 7 20 W 18 WSW 18 0 0

4 38 19 29 60 8 29 W 19 WSW 24 0 0

5 37 20 29 48 13 32 W 17 W 21 0 0

6 38 22 30 53 7 26 W 23 WSW 24 0 0

7 36 19 28 57 5 25 WNW 19 W 22 0 0

8 36 16 26 33 4 15 NNE 12 NNW 6 0 0

9 36 20 28 31 4 13 NE 13 NNW 7 0 0

10 36 20 28 26 4 13 NE 19 NNE 13 0 0

11 38 18 28 23 4 12 SE 9 WSW 17 0 0

12 39 19 29 33 5 14 NNW 7 N 14 0 0

13 41 21 31 33 5 16 NNW 10 NNW 15 0 0

14 41 22 31 38 5 15 NNW 22 NNW 15 0 0

15 41 22 32 26 5 14 NW 23 NNW 19 0 0

16 41 22 32 29 7 15 NW 21 NNW 15 0 0

17 41 24 33 25 8 15 NNW 18 NW 14 0 0

18 41 23 32 32 8 17 NW 21 WNW 17 0 0

19 41 23 32 29 5 14 W 20 W 26 0 0

20 40 22 31 27 5 14 W 26 WNW 27 0 0

21 39 23 31 42 7 20 W 24 WSW 22 0 0

22 37 21 29 58 10 28 W 22 WSW 21 0 0

23 37 21 29 54 9 26 WNW 19 W 19 0 0

24 36 19 28 53 8 28 W 22 WSW 23 0 0

25 36 21 29 51 12 30 W 20 W 20 0 0

26 37 20 28 60 6 25 WNW 17 W 18 0 0

29

27 38 19 29 39 4 17 NW 12 WSW 11 0 0

28 39 21 30 27 5 14 WNW 15 WSW 24 0 0

29 39 24 31 37 10 23 W 17 W 17 0 0

30 37 21 29 41 15 28 W 18 WSW 18 0 0

Table No. 3.2 (C)

Meteorological Data Month Of 1st May To 31st May 2017

Date

Temperature OC Relative Humidity

% Morning (8.00) Evening (17.00)

Cloudiness

Octas

Max Min Avg Max Min Avg Wind

Dir.

Wind

Speed

km/h

Wind

Dir.

Wind

Speed

km/h

Mor. Eve.

1 39 23 31 50 6 25 WNW 16 W 14 0 0

2 40 25 32 25 6 16 NE 11 SW 11 0 0

3 40 24 32 37 9 19 WNW 14 WSW 16 0 0

4 41 24 32 41 6 18 NW 14 WNW 10 0 0

5 41 25 33 35 6 18 NW 16 WSW 13 0 0

6 41 24 33 30 6 16 NW 19 WNW 15 0 0

7 40 24 32 29 9 20 WNW 8 WSW 13 0 0

8 41 25 33 51 12 30 WNW 13 W 6 0 4

9 39 24 32 51 13 29 W 15 WSW 13 0 0

10 40 23 32 45 11 27 W 14 WSW 13 0 0

11 41 23 32 43 12 24 WNW 9 WNW 10 0 2

12 42 26 33 42 13 26 NNW 13 NNW 10 0 0

13 42 27 34 34 12 20 NNW 15 NNW 10 0 0

14 42 28 35 28 13 20 NNW 14 NW 14 0 0

15 41 26 33 35 12 22 WNW 18 W 17 0 0

16 40 26 33 51 10 24 WNW 19 W 19 0 0

17 40 27 33 36 9 23 WNW 19 W 20 0 0

18 41 26 33 55 11 27 WNW 16 WNW 18 0 0

19 41 26 33 51 10 26 WNW 21 W 19 0 0

20 41 26 33 43 9 24 WNW 20 WSW 18 0 0

21 39 26 32 61 16 33 W 22 W 15 0 0

22 40 24 32 54 14 31 W 14 WNW 18 0 0

23 40 25 32 49 19 40 NW 18 WNW 12 0 0

24 42 24 33 61 18 32 NW 18 WSW 9 0 0

25 42 24 33 83 17 44 NW 15 WNW 9 0 5

26 41 23 32 65 22 44 WNW 15 W 10 0 0

27 42 27 34 66 20 40 WNW 12 W 17 0 0

28 39 26 32 70 27 44 W 20 WSW 24 0 0

30

29 37 25 31 65 27 47 W 18 WSW 25 0 0

30 36 22 29 78 26 55 W 16 W 13 1 5

31 40 25 32 69 26 51 WSW 12 SSW 9 0 2

viii. Social Infrastructure available

Social infrastructure like community center, hospital and electricity is available in Pansemal as well as in Barwani (MP)

5.0 Planning Brief:

i. Planning Concept :

The grain base unit shall be installed after receiving environment clearance and

consent under air and water act from the MPPCB. 14 Months has been

considered for the same.

ii. Population Projection:

The project is small in magnitude. No influx of population is expected as labour

shall be deployed from the local villages.

iii Land use planning

As above

Amenities / facilities

First aid facility has already been provided at site.

The area shall not being used at all by general public.

A rest shelter is there for workers.

Guards during day & night has already been deputed at site to prevent

unauthorized entry.

In case of natural hazards such as earthquake we will take assistance from the

local competent authority of Govt.

6.0 Proposed Infrastructure

The major plant & machinery required for the proposed project is as given

under.

Outline Technical Specifications For 45 Klpd Ethanol

Storage & Handling:

31

Sr. No.

Equipment Technical Specification Qty. MOC

1 Raw Molasses transfer pump

Type- Screw/Gear type Capacity- 20 MT/hr

1+1 CI

2 Day Molasses Tank Capacity- 250 MT 1 MS

3 Molasses Transfer Pump Type- Screw/Gear type Capacity- 20MT/hr

1+1 CI

4 Molasses Filter Type- Basket Strainer 1+1 MS

5 Molasses Receiving Tank Type- Cyl/Vert. Shell with

Open Top & Conical Bottom, Capacity- 3 MT

1 MS

6 Molasses Weighing System

Type- Load Cell Capacity 4 MT Per

Trip

1 MS

7 Weighed Molasses Tank Type- Cyl/Vert. Shell with Conical Top & Sloping Bottom, Capacity- 20 MT

1 MS

8 Weighed Molasses Transfer Pump with Motor

Type- Screw/Gear type Capacity- 15 MT/hr

1+1 CI

9 Molasses Diluter For Yeast Vessel

Type- Static Mixer 1 AISI304

Fermentation Section:

Sr.

No.

Equipment Technical Specification Qty. MOC

1 CO2 Scrubber Type: Sieve Trays Dia: 500 mm

1 AISI 304

2 Culture Vessel-I with Air Sparger

Type - Cyl/Vert Shell, Jacketed with Dished Ends.

1 AISI 304

3 Culture Vessel-II with Air Sparger

Type - Cyl/Vert Shell, Jacketed with Dished Ends.

1 AISI 304

4 Culture Vessel-III with Air Sparger

Type - Cyl/Vert Shell, Jacketed with Dished

Ends. Capacity- 12 m3

1 AISI 304

5 Cell Mass Transfer Pump with Motor

Type- Centrifugal with

Trolley Capacity- 10 m3

1

6 Fermenter with Agitator, SG, LG

Type- Cyl/Vert. Shell with Conical Top & Sloping Bottom, Capacity-

300 m3

4 AISI 304

7 Molasses Broth Mixer for Fermenter

Type- Static Mixer 3 SS 304

32

8 Fermenter Recirculation Pump with Motor

Type- Centrifugal Capacity-

250m3/hr

4+1 CF8

9 Fermenter Wash Cooler Type- PHE 4 Plates AISI 316 10 Pre fermenter

/Yeast Activation Vessel with SG,LG

Type- Cyl/Vert. Shell with Conical Top & Sloping

Bottom, Capacity- 40m3

2 AISI 304

11 Molasses Broth Mixer for Yeast Activation Vessel

Type- Static Mixer 2 AISI 304

12 Yeast Activation Vessel Transfer Pump with Motor

Type- Centrifugal Capacity- 30

m3/hr

1+1 CF8

13 Yeast Activation Vessel Cooler

Type- PHE 1 Plates AISI 316 Frame MS 14 Wash Holding Tank Type – Cyl/Vert. Shell

with Conical Top & Sloping Bottom, Capacity –

200 m3

1 MS Epoxy

15 Wash Transfer Pump Type- Centrifugal Capacity-

25 m3/hr

1+1 CF8

(Wetted Parts Only) 16 Air Filter Type- HEPA 1+1 MS Frame

17 Air Blower with Motor Type- Watering Capacity-

220 Am3/hr

1+1 CI

18 Nutrient Dosing Tank with Agitator

Capacity- 1 m3 1 AISI 304

19 Nutrient Dosing Pump Type- Centrifugal

Capacity- 1 m3/hr

1+1 CI

20 Acid Dosing Tank Type- Cylindrical,

Vertical Capacity- 1 m3

1 MS

21 Acid Dosing Pump Type- Centrifugal

Capacity- 1 m3/hr

1+1 Wetted Parts Alloy 20

22 Antifoam Dosing Tank Type- Cylindrical,

Vertical Capacity- 1 m3

1 MS

23 Antifoam Dosing Pump Type: Gear Capacity- 1 m3/hr 1+1 CI

24 CIP tank Type- Cylindrical,

Vertical Capacity- 25

m3

1 AISI304

25 CIP Pump Type- Centrifugal Capacity-

12 m3/hr

1+1 Wetted Parts Alloy 20

33

26 Piping, Valves

Instrumentati

on

As Per Standards Lot

DISTILLATION SECTION:

Sr.

No.

Description

MOC

Tech. Specs.

Qty.

1 Analyser Column (Rh Grid Trays) AISI 304

Dia: 1200 mm No. of Trays :

19

1

2 Degasifying Column

(Seive Trays) AISI 304 Dia: 700mm No. of Trays :

5

1

3 Pre-Rectifier Column

(Bubble Cap Trays) AISI 304 Dia: 800 mm

No. of Trays :

56

1

4 Extractive Column

(Bubble Cap Trays) AISI 304 Dia: 600 mm No. of Trays :

45

1

5

Rectifier Cum Exhaust Column (Bubble Cap Trays)

Shell : AISI

304 Trays

AISI 304

Dia: 1000 mm

No. of Trays : 72

1

6 Recovery Column

(Bubble Cap) AISI 304

Dia: 500 mm

No. of Trays : 50

1

7 Alcohol Scrubber AISI 304 1

Re boilers

1 Analyzer Column Reboiler Shell & Tube Type AISI 304 1

2 ED Column Reboiler Shell & Tube Type AISI 304 1

3 Rectifier Cum Exhaust Column Reboiler Shell & Tube Type AISI 304 1

4 Pre Rectifier Column Reboiler Shell & Tube Type AISI 304 1

Co ndensers & Coolers

5 DG Condenser I Shell & Tube Type AISI 304 1

6 DG Condenser II Shell & Tube Type AISI 304 1

7 Analyser Condenser I & II Shell & Tube Type AISI 304 3

8 ED Condenser I & II Shell & Tube Type AISI 304 2

9 Recovery Condenser Shell & Tube Type AISI 304 1

10 Vent Condenser for Analyzer Shell & Tube Type AISI 304 2

11 PCV Condenser Shell & Tube Type AISI 304 2

12 Product Alcohol Cooler Shell & Tube Type DOW Cu 1

34

13 Product (RS) Cooler Shell & Tube Type AISI 304 1

14 TA Cooler Shell & Tube Type AISI 304 1

15 FO Cooler Shell & Tube Type AISI 304 4

16 R/E Alcohol Cooler Shell & Tube Type AISI 304 1

17 ED Feed Cooler Shell & Tube Type AISI 304 1

OUTLINE TECHNICAL SPECIFICATIONS FOR 45 KLPD ETHANOL

PHE's, Pumps

19 DM Water Preheater PHE SS 316 Plates /MS

Frame

1

20 Rectifier Feed Preheater PHE SS 316 Plates /MS

Frame

1

21 PR Feed Preheater PHE SS 316 Plates /MS

Frame

1

22 Analyser Bottom

Transfer Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1

23 Rectifier Lees Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1

24 PR Lees Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1

25 Pre Rectifier Feed Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1

26 PR Refux Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1

27 Rectifier Reflux Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1

28 FO Washing Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1

29 ED Bottom Transfer Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1

30 Alcohol Transfer Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1

31 Recovery Feed Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1

32 Steam Condensate Pump Centrifugal Type CI 1+1

33 Vacuum Pump Water Ring Type CI 1+1

34 Emergency Water Supply Set Standard 1

Others

Sr.

No.

Description Tech. Specs. Qty.

1 FO Decanters As Per Standard 2

2 Mixing Bottle (For ED/Purifier

Column)

As Per Standard 1

3 Vapour Bottles As Per Standard Lot

4 Manometer Bottles As Per Standard 2

5 Seal Pot As Per Standard 1

6 Siphon For Recovery Column As Per Standard 1

35

7 TA Mixing Bottle As Per Standard 1

8 Pipes & Fittings, Valves and

Instrument

As Per Standard Lot

ABSOLUTE ALCOHOL PLANT:

Sr.

No.

Description MOC Qty. Tech. Specs.

1 Absorber Bed AISI 304 2 Diameter : 900 mm

2 Evaporator Column AISI 304 1 Diameter : 900

mm with Trays

3 Evaporator Column Re boiler AISI 304 1 Suitable

4 Feed Preheater AISI 304 1 Suitable

5 Regeneration Preheater AISI 304 1 Suitable

6 Product Condenser AISI 304 1 Suitable

7 Product Cooler AISI 304 1 Suitable

8 Regeneration Condenser AISI 304 1 Suitable

9 Regeneration Cooler Plates:

SS 316

1 PHE

10 Super heater AISI 304 1 Suitable

11 Regeneration Receiver AISI 304 1 Suitable

12 Product Receiver AISI 304 1 Suitable

13 Vacuum Educator AISI 304 1 Suitable

14 Feed Pump with Motor AISI 304 1+1 Suitable

15 Regeneration Pump with Motor AISI 304 1+1 Suitable

16 Product Pump with Motor AISI 304 1+1 Suitable

17 Filters CS 3

18 RS Feed Tank MS 1 Capacity : 50 m3

19 Instrumentation Standard Lot

20 Piping and Valves Standard Lot

21 Electricals Standard Lot

Sr.

No.

Equipment Technical

Specification

MOC Qty.

1 RS Receivers Capacity: 50 m3 MS 3

2 IS Receivers Capacity: 10 m3 MS 1

36

3 Ethanol Receiver Capacity: 50 m3 MS 3

4 RS Storage Tank with Vent

Condenser & Flame Arrestors

Capacity: 900 m3 MS 2

5 Ethanol Storage Tank with

Vent Condenser & Flame

Arrestors

Capacity: 900 m3 MS 1

6 IS Bulk Storage Tank with

Vent Condenser & Flame

Arrestors

Capacity: 400m3 MS 1

7 FO Storage Capacity: 8 m3 MS 1

8 Alcohol Pumps with

Flameproof Motor

Centrifugal Wetted Parts

CF 8

Suitable

9 Issue Measures PD Flowmeters Standard 3

10 Piping & Fittings Standard Standard 1 Lot

INTEGRATED EVAPORATOR:

Sr.

No.

Description Qty. Technical data M.O.C.

1 Multiple effect

evaporator

Suitable Shell & Tube

type, Falling

Film

SS304

2 Vapor Separator Suitable Cylindrical SS304

3 Surface condenser 1 Sheet & Tube type SS304

4 Circulation pump Suitable Double Mech Shaft Contact Part SS 304

5 Process

Condensate

pump

1+1 Contact Part SS 304

6 Concentrated Spent

wash transfer pump

1+1 Contact Part SS 304

7 Condensate Pump 1+1 Contact Part SS 304

8 Vacuum pump 1+1 Contact Part SS 304

9 Piping & Valves Lot Suitable

10 Electrical &

Instrumentatio

n

Lot With Std.

Specificatio

n

INDEPENDENT EVAPORATOR:

Sr.

No

Description Qty. Technical data M.O.C.

1 Feed and Product Tank 2 Type:- Rectangular SS304

37

2 Feed Pump & Spent

wash pump

1 + 1 each Type - Centrifugal type

Suitable

SS 316

3 Evaporators Suitable Type : Forced circulation SS304

4 Vapor Liquid Separators Suitable Type : Gas

liquid separator

type

SS304

5 Evaporation Pump Suitable Recirculation pump SS 316

6 Surface Condenser 1 Type : shell & tube; SS 304

9 Vacuum Pump 1 + 1 Type - Water ring type SS 316

10 Condensate Tank 1 Capacity – Suitable SS 304

11 Condensate Pump 1 + 1 Type - Centrifugal type SS 316

12 Piping and Valve, Electrical and Instruments

UTILITIEs: COOLING TOWER:

Sr.

No.

Equipment Description Specifications Qty. (Nos)

1 Cooling tower for Fermentation plant 1000 M Kcal/hr 1

2 Cooling tower for Distillation 2000 M Kcal/hr 1

3 Cooling tower for Ethanol 600 M Kcal/hr 1

4 Cooling tower for evaporation 3000 M Kcal/hr 1

5 CW Recirculation pump for

Fermentation

Suitable. Centrifugal, 1+1

6 CW Recirculation pump for Distillation Suitable. Centrifugal, 1+1

7 CW Recirculation pump for evaporation Suitable. Centrifugal, 1+1

8 CW Recirculation pump for Ethanol Suitable. Centrifugal, 1+1

9 PRDS Suitable. 2

10 Instrument Air compressor & dryer Suitable capacity 1+1

11 Piping, Valves standard Lot

12 Instrumentation standard Lot

Slop Fired Incinerator Boiler & Turbine

Sr.

No.

Particulars Specification

1 Slop fired incinerator boiler with coal as supporting fuel

14 TPH, 45 Kg/Cm2 (g) Pressure

2 Turbine Suitable capacity of 1.2 MW back pressure with exhaust pressure of

4.5 Kg/Cm2(g)

38

Water Treatment Area Filtration Plant

1. Multi grade Sand Filter 1 No.

Pressure vessel internally painted with black

bituminous and externally with red oxide primer

:MOC

1 No.MS with epoxy coating

Piping works with valves 1 No.

Graded filtering sand specifically selected and

graded

1 No.

2. Activated Carbon Filter 1 No.

Pressure vessel internally painted with black

bituminous and externally with red oxide primer

:MOC

1 No. MS with epoxy coating

Piping works with valves 1 No.

3. Softener 1 No.

Pressure with rubber lining from inside and

externally with red oxide primer

1 No.

Piping works with valves 1 set

Cation Exchange resign 1 set

Hardness test kit 1 set

Brine saturated tank of MS construction 1 No.

Brine distribution system 1 Lot

4. D.M. PLANT ( 1 No.)

1 Strong acid cation 1 No.

2 Degasser tower & pump 1 No.

3 Strong acid anion 1 No.

4 Mixed bed exchanger 1No.

Fire Fighting & Protection

Fire protection system to be offered based on site plan. The system is designed

as per International rules (NFPA) & equivalent standards.

Molasses Bulk Storage Section.

Sr.

No.

Equipment Technical Specification

Qty. M.O.C.

1 Molasses Storage Tank 4000 MT storage capacity.

2

Nos.

Mild steel, painted

39

2 Raw molasses Transfer pumps.

Gear type positive displacement pumps

2+2

Nos.

C.S.

3 Interconnecting piping. Carbon steel pipes. LOT MS

ii Residential area (Non Processing area)

As the local people from nearby villages shall be engaged in project activity.

Therefore no housing / building is proposed.

iii Greenbelt

Approx 2 acres area has been covered with the good green belt. Further it is

proposed to cover 2.64 acres in next 05 years of time.

iv Social Infrastructure

Company shall evaluate the need base program under CSR and shall execute as

per the given plan.

v Connectivity

Site is well connected with by State Highway Khetia- Sendhwa road. .

vi Drinking water management

Drinking water will be supplied through bore well with proper RO system.

vii Sewerage System

The domestic waste shall be taken to soak pit and septic tank.

viii Industrial waste management

As described earlier.

ix Solid waste management

As described earlier.

x Power Requirement and supply / source

As described earlier.

7.0 Rehabilitation & Resettlement Plan

No R & R plan is required.

8.0 Project Schedule and Cost estimate

40

i. Likely date of start of construction and likely date of completion

After obtaining environmental clearance and water / air consent the company

shall start the project. Proposed date shall be July 2018 (subject to clearances)

ii. Estimated project cost along with analysis in terms of economic viability

of the project

a. Land & Site Development (Refer Annexure – 1)

SDKSM has already earmarked 8 acres of land for the proposed fuel ethanol plant.

The site development expenses is estimated at Rs. 49 lakh which include leveling,

fencing, gates, internal roads, green belt development, etc

Civil Works

The main civil works for the fuel ethanol plant and their estimated costs are

indicated in the following table.

Item Cost, Rs.

Lakh

Main plant building, admin building, lab, Excise Office,

stores Weigh bridge, storage, distillery machinery

foundations, Structural for evaporation, distillation &

fermentation, Pipe Racks, Cooling tower civil works (Basin

Only), Raw water tank, Treated Water storage tanks, Fire

water storage tank, Raw & Concentrated Spent wash holding

tank, Condensate Polishing Unit civil work, Boiler

foundations & Axillaries, Turbine foundations DG set

foundation, structural work for Boiler & Turbine, Ash & Fuel

handling system foundations etc., staging structure and

foundations

450.00

Architect fees 9.00

Total 459.00

Based on the actual civil costs incurred for similar capacity fuel ethanol

plant and preliminary estimates from the project architect, the civil estimates

have been worked out at Rs. 459 lakh, including Architect’s fees. The

appointed architect for the project will work out detailed estimates and civil

drawings (based on the inputs received by the equipment suppliers and labour

/ material rates at the site location).

Equipment

The main items of equipment for the fuel ethanol plant and their estimated

erected costs are given in the following table:

Item and brief specifications Estimated

Erected

Cost, Rs.

lakh

41

1) 45 KLPD Capacity distillery plant, including incl.

Molasses storage & handling, Fermentation, Multi-Pressure

Distillation & Ethanol, Integrated & Independent

Evaporation for spent wash concentration, Utility Equipment

- Cooling Towers, Condensate Polishing Unit, Blower, Alcohol

Storage & auxiliaries, interface piping, electrical &

instrumentation, Air compressor, structural work, Erection

& Commissioning etc.

1525.00

2) 14 TPH Capacity, 45 kg/cm2 pressure slop fired

Boiler & auxiliaries

1050.00

3) 1.2 MW Capacity matching back pressure TG set &

auxiliaries 150.00

4) Balance of Plant equipment incl. PRDS, DCS, etc. 175.00 Sub-total including erection & commissioning, packing

forwarding, insurance, etc.

2900.00

Avg. Taxes & Duties (18 %) 522.00 Total 3422.00

Based on the budgetary offers received from reputed machinery suppliers &

possible negotiation margins, the estimated erected cost of plant and equipment

for the proposed fuel ethanol plant including Boiler & Turbine has been worked

out at Rs.3422.00 lakh

Item Year

1 2 3 4 5

Installed Capacity-KLPD 45 45 45 45 45

Number of shift/day 3 3 3 3 3

No. of days 180 270 270 270 270

No. of hrs. 24 24 24 24 24

Annual Installed Capacity 8100 12150 12150 12150 12150 Capacity utilization, % 80 90 95 95 100

Net Production Fuel Ethanol,

KL

6480 10935 10935 11543 12150

Cost Summary

Based on the capital cost break up worked out, the project cost summary for

the entire integrated project is given in the following table

Particulars Distillery Plant

(Rs. Lakh) Land and Site Development 49

42

Buildings 459 Indigenous Plant and Machinery 3422 Miscellaneous Fixed Assets 248 Prelim. & Preoperative Expenses 308 Contingencies 68 Working capital margin 128 Total 4682

9.0 Analysis of Proposal (Final Recommendation)

Financial and social benefits with special emphasis on the benefit to the

local people including tribal population, if any, in the area.

From the foregoing analysis, it is observed that proposal is environmental

compatible and will helps to people improving their financial status,

performance and repayment capability. This also helps the company in

venturing into production of niche specialty products which will eventually

better their profits and also their ranking in the industry. CSR programme

shall be executed through the group discussion and need base programme will

be proposed for the area, by which people of the area will be benefitted.