PRE- FEASIBILITY REPORTenvironmentclearance.nic.in/writereaddata/Online/TOR/02... · 2019. 7. 2. · Pre-feasibility Report P a g e | 0 PRE- FEASIBILITY REPORT SUBMISSION TO MINISTRY

Pre-feasibility Report P a g e | 0

PRE- FEASIBILITY REPORT

SUBMISSION

TO

MINISTRY OF ENVIRONMENT, FOREST & CLIMATE CHANGE,

NEW DELHI

By

SHRI BAJRANG AGRO PROCESSING LIMITED (Phase – I: 1x120 KLPD Grain based & 1x60 KLPD Molasses based distillery plant to produce

Ethanol/RS/ENA/ Potable alcohol/Industrial Alcohol

& 6.0 MW Power plant

Phase-II: 1x120 KLPD Grain based & 1x60 KLPD Molasses based distillery plant to produce

Ethanol/RS/ENA/ Potable alcohol /Industrial Alcohol

& 6.0 MW Power plant)

Jalso Village,

Tilda Tehsil, Raipur District,

Chhattisgarh.

PREPARED BY

6-3-652 | Flat # 7-3 | Dhruvatara Apartments | Amrutha Estates | Erramanjil | Somajiguda | Hyderabad- 82 | E mail: [email protected], [email protected]|www.pioneerenvirolabs.com

| PEOPLE WHO CARE FOR ENVIRONMENT | SAVE ENVIRONMENT |

Accredited by ISO 9001: 2008 Certified

mailto:[email protected]

http://www.pioneerenvirolabs.com/

SHRI BAJRANG AGRO PROCESSING LIMITED DISTILLERY AND POWER PLANT


INDEX

S.NO ITEM PAGE NO

1. EXECUTIVE SUMMARY 2

2. INTRODUCTION OF THE PROJECT/BACKGROUND INFORMATION 4

3. PROJECT DESCRIPTION 11

4. SITE ANALYSIS 38

5. PLANNING BRIEF 39

6. PROPOSED INFRASTRUCTURE 41

7. REHABILITATION AND RESETTLEMENT (R & R) PLAN 44

8. PROJECT COST 45

9. ANALYSIS OF PROPOSALS (FINAL RECOMMENDATIONS) 46



1.0 EXECUTIVE SUMMARY

S.No

1 Title of the project Shri Bajrang Agro Processing Limited

2 Location of the project Jalso Village, Tilda Tehsil, Raipur District, Chhattisgarh

3 Land proposed 44.51 Acres (18.04 ha.)

4 Cost of the project Rs. 325 Crores

5 Proposed facilities and

production capacities

Phase-1 Phase- II

Grain based distillery plant : 1x120 KLPD 1x120 KLPD

(Ethanol/RS/ENA/Potable Alcohol/

Industrial alcohol)

Molasses based Distillery plant : 1x 60 KLPD 1x60 KLPD

(Ethanol/RS/ENA/Potable Alcohol/

Industrial alcohol)

Power generation : 6.0 MW 6.0 MW

6 Raw material required Distillery: Grains & Molasses

Boiler : Coal/ Biomass

7 Boiler details Phase-I : 1x34 TPH & 1x17 TPH

Phase-2 : 1 x34 TPH & 1x17 TPH

8 Number of days of

operation per annum

330 days

9 Air pollution control

system proposed for

Boilers

Electro Static Precipitators with outlet dust emission < 50

mg/Nm3.

10 Water requirement Phase-1 : 885 KLD + 524 KLD + 8 KLD (domestic) : 1417 KLD

Phase-II : 885 KLD + 524 KLD + 5 KLD (domestic) : 1414 KLD

Total water requirement : 2831 KLD

11 Waste water treatment With grains as feed stock :

Spent wash will pass through decanter and then the thin slop from Decanter will be treated in Multiple Effect Evaporators (MEE) followed by Dryer and concentrated up to 90% solids w/w to get DDGS. This will be sold as Cattle feed/Poultry /fish feed etc.,It is a ZLD plant as approved by CPCB.



With Molasses as feed stock: Spent wash will be concentrated in Multiple Effect Evaporators (MEE) to 55-60% solids and then incinerated in slop fired Boilers (2x17 TPH). Spent lees & condensate will be treated in Condensate Polishing Unit (CPU). Non-process effluents like DM plant regeneration water & boiler blow down will be neutralized in neutralization tank and will be mixed with Cooling tower blow down. This treated effluent after ensuring compliance with standards stipulated by CECB for wastewater for on land for irrigation, will be utilized for internal greenbelt development, dust suppression, ash conditioning.

12 Solid / hazardous waste

management and

disposal

(a) Grain based distillery : DDGS will be used cattle /fish/prawns feed. Yeast Sludge will be used as manure. Ash generated from the boilers (2x34 TPH) will be given to

brick manufacturing units.

(b) Molasses based Distillery: Yeast Sludge will be used as manure. Ash generated from slop fired Boiler (2x17 TPH) will be

given to Fertilizer manufacturing units.

13 Green belt Greenbelt will be developed in 15 acres covering more than 33%

of the total area.



2.0 INTRODUCTION

2.0 Introduction

India, the fourth largest economy in the world, has been maintaining a GDP growth rate of

more than 7% for more than a decade. Analysts have projected that India has the potential to

almost double her present rate of growth with labour and capital productivity improvements.

Industrial development plays an essential supportive role in improving labour and capital

productivity. Investment in industrial sector is also an indicator of economic growth in all market

economies. Ethanol is the basic raw material for the utilization in the chemical industry, for

potable purposes and is now being used for blending with the petrol as fuel.

Ethanol is a clear, colorless liquid with a characteristic, agreeable odour. In dilute aqueous

solution, it has a somewhat sweet flavor, but in more concentrated solutions it has a burning

taste. Ethanol melts at -114.1°C, boils at 78.5°C, and has a typical density of 0.789 g/ml at 20°C.

Ethanol has been made since ancient times by the fermentation of sugars. All the beverage

ethanol, and more than half of industrial ethanol, is still made by this process. Simple sugars are

the raw materials. Enzyme from yeast, changes the simple sugars into ethanol and carbon

dioxide. Starches from potatoes, corn, rice, wheat, and other grains can also be used in the

production of ethanol by fermentation. However, the starches must first be broken down into

simple sugars. The Enzymes used in Liquefaction & Scarification stages help convert the starches

into sugars, which can then be fermented using appropriate Yeast to convert into Ethyl Alcohol

(Ethanol), grades of Extra Neutral Alcohol (ENA) or Rectified Spirit (RS). This Alcohol may also be

utilized for Blending & Bottling and Potable purpose for making IMFL / IMIL / Liquors, etc.

Fuel Ethanol Market – India:

About 85% of petroleum oil need of India is being met through imports. Indian economy is

growing steadily resulting in rapid increase of vehicular population and demand for

transportation fuels. Indian Government has already mandated blending of ethanol in

gasoline by 10% to reduce the oil import. Bureau of Indian Standards is finalizing the

specification of 20% ethanol blended gasoline for use as vehicular fuel. In this context, this

review presents the current and future scenario of Indian transportation, petroleum oil and bio-

fuel sectors including global progress on utilization of ethanol as an alternative transportation

fuel in spark ignition vehicles. The data from various standard reference sources were compiled,

https://www.sciencedirect.com/topics/earth-and-planetary-sciences/biofuel

https://www.sciencedirect.com/topics/earth-and-planetary-sciences/biofuel

https://www.sciencedirect.com/topics/engineering/alternative-transportation-fuels

https://www.sciencedirect.com/topics/engineering/alternative-transportation-fuels

https://www.sciencedirect.com/topics/earth-and-planetary-sciences/spark-ignition

https://www.sciencedirect.com/topics/social-sciences/reference-sources

https://www.sciencedirect.com/topics/social-sciences/reference-sources



analyzed and is presented. The review indicates that the gasoline demand would be around 44

billion liters by the year 2020 and India has a potential to produce ethanol to the tune of 30

billion liters per annum in addition to existing capacity. Apart from augmenting production of

first generation ethanol, the second generation ligno- cellulosic ethanol and thermo-chemical

conversion of carbon-rich agricultural/petroleum residues are seen as alternative options. The

potential of such alternative feed stocks and ethanol conversion technologies need to be

exploited to increase ethanol availability for blending. The review indicates that ethanol is most

suitable fuel for spark ignition engines due to its higher octane number. Ethanol blending

reduces sulphur, aromatics, olefin and benzene content in gasoline and can reduce vehicular

emissions such as hydrocarbon, carbon monoxide and particulate matter.

India initiated the use of ethanol as an automotive fuel in the year 2003. The Ministry of

Petroleum and Natural Gas (MoPNG) issued a notification in September 2002 for mandatory

blending of 5 % ethanol in 9 major sugar producing states and four union territories in India

from the year 2003. Due to ethanol shortage during 2004-05, the blending mandate was made

optional in October 2004, and resumed in October 2006 in the second phase with a gradual rise

to 10% blending.

In 2008, the Ministry of New & Renewable Energy established a National Policy on Biofuels

to limit the country's future carbon footprint and dependence on foreign crude. Under this, the

blending level of bio-ethanol at 5 % with petrol was proposed from October 2008, leading to a

target of 20 % blending of bio-ethanol by 2017. It also laid down a roadmap for the phased

implementation of the programme. This was taken up by the oil marketing companies (OMCs) in

20 states and 4 union territories. The government has fixed the interim refinery gate price of

ethanol at Rs.47 per litre.

Potable Alcohol Market- India:

Liquors are manufactured in a synthetic way to imitate foreign liquors viz. Whisky, Brandy, Rum

and Gin. They are called Indian Made Foreign Liquor (I.M.F.L.). (Different varieties are produced

by addition of flavors & are called spiced liquor.) The excise duty on I.M.F.L. is much higher than

that on country liquor. Supply of country liquor at low rates is very much needed to keep away

the illicit liquor manufacturers & traders. The I.M.F.L. requires alcohol of very high purity and high

quality. For this purpose separate distillation plant to redistill and purify Rectified Spirit is

https://www.sciencedirect.com/topics/social-sciences/first-generation

https://www.sciencedirect.com/topics/engineering/thermochemical-conversion

https://www.sciencedirect.com/topics/engineering/thermochemical-conversion

https://www.sciencedirect.com/topics/earth-and-planetary-sciences/octane-number

https://www.sciencedirect.com/topics/engineering/aromatics

https://www.sciencedirect.com/topics/earth-and-planetary-sciences/alkene

https://www.sciencedirect.com/topics/earth-and-planetary-sciences/benzene

https://www.sciencedirect.com/topics/social-sciences/hydrocarbons

https://www.sciencedirect.com/topics/earth-and-planetary-sciences/particulate-matter



necessary. This alcohol is called Extra Neutral Alcohol. It is also useful in cosmetics and perfumes

manufacturing.

Extra Neutral Alcohol (ENA) is used as the main raw material in the manufacture of consumption

alcohol. There are two varieties of ENA: Molasses based ENA and Grain based ENA. The molasses

based ENA is mainly used to manufacture cheap liquor and Grain based ENA is used for premium

brands. In developed nations it has been declared that consumption alcohol should not be

manufactured from molasses as it is dangerous for human consumption. But in India there is an

acute shortage of Grain ENA and only available raw material for consumption alcohol is molasses

ENA so it is been widely used.

India has just topped the fastest-growing list of a popular research report recently; the country

also remains the most attractive destination for international alcobev companies despite high

duties. It is apparent from the number of new companies who have entered the market since last

year, and the number of new brands being introduced across the country. The alcoholic beverage

industry is a multi-billion dollar business. The Indian liquor industry is estimated over 55,000

Crores and has been growing at around CAGR 7% per annum in the financial years (FY 2009-14).

In volume terms, the IMFL industry is nearly 310 million cases with country liquor accounting for

another 220 million cases. Beer accounts for another 260 million cases. The IMFL market is

currently 60% whisky, 17% brandy, 15% rum, and 8% white spirits like vodka and gin. Wine

market is said to be about 2.7 million cases.

The following distilleries are operating in state of Chhattisgarh:

1) M/s. Chhattisgarh Distilleries Limited – 125 KLPD

2) M/s. Welcom Distilleries Private Limited -40 KLD

3) M/s. Bhatiya Wine Merchants Private Limited – 60 KLD

4) M/s. Continental Distilleries Private Limited – 30 KLPD

Hence, there is a lot of scope for establishment of Distilleries Chhattisgarh to cater to the growing

demand. This demand is increasing @ 8-10% annually due to demand of potable alcohol as well

as shifting of several UP based Distilleries to manufacture Ethyl Alcohol / Fuel grade Ethanol.

Hence, our company having focus on Bio-Fuels & Bio-Chemicals based on Absolute Alcohol

(Ethanol) are envisaging to set up this multi feed stock and multi product project in Chhattisgarh



State, which is presently short of capacity and needs several such projects for meeting the state’s

demand in future.

We feel that Chhattisgarh is the right place as we plan to utilize the available agro based raw

materials. The proposed project will change the agriculture statistics of the districts with assured

returns for the farmers. The proposed project with multi feed stock and multi product utilizes a

proven technology world-wide.

Shri Bajrang Agro Processing Limited is a newly formed company interested in venturing into

manufacturing of Ethanol/RS/ENA/ Potable alcohol/Industrial Alcohol along with its by-products

like CO2, DDGS and captive power generation. The project will be based on waste/damaged grains

like broken rice, maize and Molasses which is byproduct of Sugar industry, for utilization of their

starch to manufacture bio-ethanol / ENA and other constituents like protein & fibre to produce

value added cattle feed. The group wants to generate this environment friendly fuel to promote

the concept of sustainable development as well as to promote agro-based industries with assured

returns for the farmers. By setting up distilleries and manufacturing Ethanol/RS/ENA/ Potable

alcohol/Industrial Alcohol, the group wants to reduce the outflow of money from Chhattisgarh in

the form of oil import bill as well as environmental pollution levels. This venture would boost job

opportunities and would also spur indigenous technological development. According to the Govt.

of India Ethanol Blending Programme (EBP), India aims to achieve 20% ethanol blending in petrol

by 2030. Thus ethanol from waste grains, unfit for consumption, would be a great boost to the

EBP plan execution.

The project would comprise of a 2x120 KLPD Grain based Distillery & 2x60 KLPD Molasses based

distillery in both Phase-1 & Phase-2 put together to produce Ethanol /Rectified spirit / ENA/

Potable Alcohol/Industrial alcohol along with 12 MW captive power generations (both phases

together).

2.1 Identification of project and Project Proponent

Shri Bajrang Agro Processing Limited is a Limited Company, incorporated under Companies act,

1956 in the year 2019, having its registered office at Raipur, Chhattisgarh.

The Shri Bajrang Agro Processing Limited has identified 44.51 acres (18.04 Ha.) of land for the

proposed unit. Sufficient area will be made available for the green belt and Effluent Treatment

Facilities as it plans for zero liquid discharge. A good network of internal as well as main approach

roads would be prepared. The unit would be designed in a versatile fashion by adopting latest



CDM (Clean Development mechanism) process techniques as well as with state-of-the art

machinery. The project would be formulated in such a fashion and manner so that the utmost

care of Safety Norms & Environment Protection shall be taken care of.

The Promoters

The promoters are well experienced in Business, Management, and Technology and process

orchestration and have made a thorough study of entire project, planning as well as

implementation schedule. The names and designations of the Promoters are as under:

Name Designation

Shri. Suresh Goel Director

Shri. Anand Goel Director

Shri. Bajrang Goel Director

2.2 Brief Description of nature of Product:

The Bio-energy industry across the world has the potential to make significant contributions to

meet the world’s energy needs. In India, Bio-energy can contribute towards achieving the

country’s energy security and help reduce the dependence on fossil fuels. Large possibilities exist

for biomass resources, in particular energy crops to penetrate into Power Generation, Transport

Markets, Pharmaceutical Markets and Potable alcohol markets.

This proposed project of M/s. Shri Bajrang Agro Processing Limited aims to be part of the Agro-

Based Industry for manufacturing Ethanol /Rectified spirit /ENA/ Potable Alcohol/Industrial

Alcohol by using agricultural products such as broken rice other non-edible starch rich grains and

Molasses.

2.3 Demand – Supply Gap:

Alcohol has assumed very important place in the Country’s economy. It is a vital raw material for

a number of chemicals. It has been a source of a large amount of revenue by way of excise duty

levied by the Govt. on alcoholic liquors. It has a potential as fuel in the form of power alcohol for

blending with petrol & Diesel. Also, the fermentation alcohol has great demand in countries like

Japan, U.S.A., Canada, Sri Lanka etc. as the synthetic alcohol produced by these countries, from

naphtha of petroleum crude, is not useful for beverages.

https://www.zaubacorp.com/director/SURESH-GOEL/00115834

https://www.zaubacorp.com/director/ANAND-GOEL/00796135

https://www.zaubacorp.com/director/ANAND-GOEL/00796135



Teething problems in the 5% EBP program are primarily on account of the shortage of ethanol at

various locations across the country. Even in states where blending has taken off in full swing, it

has been seen that ethanol supply has not been adequate to meet demand. Even supply locations

in UP and Uttarakhand where supplies have been satisfactory so far are now facing a severe

shortfall of ethanol.

The petroleum industry however looks very committed to the use of ethanol as fuel, as it is

expected to benefit the farmers as well as the oil industry in the long run. Ethanol can be

produced from Sugar cane, wheat, corn, beet, sweet sorghum etc. Ethanol is one of the best tools

to fight vehicular pollution, contains 35% oxygen that helps complete combustion of fuel and thus

reduces harmful tailpipe

Expert Committee on Ethanol Blending

Indian Government had set up an Expert Group headed by the Executive Director of the Centre

for High Technology for examining various options of blending ethanol with petrol at

terminals/depots. Considering the logistical and financial advantages, this Group had

recommended blending of ethanol with petrol at supply locations (terminals / depots) of oil

companies. In view of the above, Government vide the Gazette notification of 3rdSeptember,

2002 No. P-45018/28/2000-C.C had mandated that with effect from 1-1-2003, 5% ethanol-doped

petrol will be supplied in following nine States and four contiguous Union Territories of Andhra

Pradesh, Gujarat, Haryana, Karnataka, Maharashtra, Punjab, Tamil Nadu, Uttar Pradesh,

Pondicherry, Daman & Diu, Goa, Dadra and Nagar Haveli & Chandigarh. This was the beginning of

ethanol implementation in 1st phase.

Government of India further announced to implement the Ethanol programme in 2nd phase. This

was intended to supply ethanol bended Gasoline across the country effective the year 2006 and

in 3rd phase switching over from the existing 5% to 10% blending of ethanol in selected states.

With implementation of the 5% Ethanol-Blended Petrol (EBP) programme throughout the country

still a distant dream due to various complications like ethanol shortages, the variable taxation

structure of state governments and regulatory restrictions, the petroleum ministry has decided to

defer the proposed rollout of mandatory 10% blending of ethanol, which was expected to take

place from October, 2008 onwards. Blending at the rate of 5% will require 1,050 million litres

ethanol annually. But the OMCs (Indian Oil, Bharat Petroleum and Hindustan Petroleum) have



procured only 400 million litres since January 2013. Blending in states like Uttar Pradesh,

Haryana, Punjab, Delhi and Karnataka has been taking place at 10% but in several other states like

Tamil Nadu, Andhra Pradesh, Maharashtra and Gujarat only 5% has been achieved. At the

national level, only 2 to 2.5% blending is happening against a target of 5%.

2.4 Employment generation (Direct & Indirect):

The man power required for the proposed project in Phase –I will be 160 Nos. and in phase –II will

be 100 Nos.



3.0 PROJECT DESCRIPTION

3.1 Type of project including interlinked and interdependent projects:

3.1.1 Type of the Project

The proposed Project mainly involves

Manufacturing of Ethanol/RS/ENA/Potable Alcohol/ Industrial alcohol from Grains by

fermentation method.

Manufacturing of Ethanol/RS/ENA/Potable Alcohol/ Industrial alcohol from Molasses by

fermentation method

Generation of power from the coal/biomass fired boilers in the distillery plant.

3.1.2. Interlinked Project:

No interlinked project is envisaged.

3.2 Location of Project

General Location:

Project is located at Jalso Village, Tilda Tehsil, Raipur District, Chhattisgarh.

Total land proposed project is 44.51 Acres (18.04 Ha.).

The entire project area is falling in the Survey of India topo sheet no. 64G/15.

The following area the coordinates of the proposed project site.

S.NO. LATITUDE LONGITUDE

1 21° 28' 22.05" N 81° 48' 20.06" E

2 21° 28' 18.80" N 81° 48' 20.44" E

3 21° 28' 07.19" N 81° 48' 13.04" E

4 21° 28' 07.81" N 81° 48' 07.61" E

5 21° 28' 00.88" N 81° 48' 06.84" E

6 21° 28' 00.77" N 81° 48' 03.74" E

7 21° 28' 06.33" N 81° 48' 03.46" E

8 21° 28' 06.23" N 81° 48' 01.45" E

9 21° 28' 09.04" N 81° 48' 02.02" E

10 21° 28' 08.72" N 81° 48' 00.21" E



11 21° 28' 11.97" N 81° 47' 59.84" E

12 21° 28' 12.54" N 81° 48' 02.24" E

13 21° 28' 16.33" N 81° 48' 01.22" E

14 21° 28' 19.30" N 81° 48' 11.02" E

15 21° 28' 15.38" N 81° 48' 11.47" E

16 21° 28' 15.39" N 81° 48' 13.03" E

17 21° 28' 19.76" N 81° 48' 12.51" E

Google earth map, General Location map, Topographical map showing 10 KM. radius of the

project site of is shown as Figure No. 1, 2 & 3.



Fig. No. 1

GOOGLE EARTH MAP SHOWING BOUNDARY OF THE PROPOSED PROJECT SITE



Fig. No. 2

GENERAL LOCATION MAP SHOWING PROJECT SITE



Fig. No. 3 : TOPOGRAPHICAL MAP OF PROJECT SITE



3.3 Details of the Alternate sites

The following three alternative sites have been considered for the project.

S. No Name of village Tehsil District

1 Neonara Berla Durg

2 Jalso Tilda Raipur

3 Jaraud Aarag Raipur

Topographical map showing the three alternative sites is enclosed as Annexure-1 for your kind

perusal. Based on the environmental considerations the site at Jalso has been chosen for the

proposed project.

3.4 Size or Magnitude of Operation

The following are the proposed production capacities in both the phases.

S. NO. NAME OF

UNIT

NAME OF THE PRODUCT PRODUCTION CAPACITY

PHASE-I PHASE-II TOTAL

1

Distillery plant Grain based distillery to

produce Ethanol/Rectified

spirit / ENA/ Potable Alcohol

/Industrial alcohol

120 KLPD 120 KLPD 240 KLPD

Molasses based Ethanol

distillery to produce

Ethanol/Rectified spirit /

ENA/ Potable Alcohol

/Industrial alcohol

60 KLPD 60 KLPD 120 KLPD

2 Power plant Co-generation Electricity 6.0 MW 6.0 MW 12.0 MW

By-Products

The following are the By-products & their production capacities

S. No By product Quantity (Phase-1 & 2 )

1 DDGS 150 TPD

2 CO2 recovery 165 TPD



3.5 Manufacturing Process details

3.5.1 Process description for grain based plant

Grain handling & storage:

Adequate grain storage is required to ensure continuous stable plant operation. Grain storage

capacity is decided based upon seasonal availability of grains and the site logistics. Normally,

capacities of grain storage silos are designed for about 30 days of plant operation.

Milling:

Grains from silos is passed through grain cleaning system for the removal of foreign matter and

taken into a surge Bin. A good grain cleaning system is must for removing the impurities/foreign

matter from grain before it goes for milling. Magnetic separators are also installed at critical

points for the removal of metallic particles.

Surge bin provides the buffer capacity between milling and grain storage systems. Surge bin is

provided with high- and low - level alarms with logical interlocks to ensure smooth operation

without any damage to upstream and downstream equipment.

Grain from surge bin is fed to a hammer mills for milling. Hammer mill sieves are designed to

ensure proper milling of grain to give an optimum particle size distribution. Particular size

distribution in the milled flour has significant influence on the process performance. Feed grain is

therefore milled to a uniform size to accelerate processing time and improve yields.

Liquefaction:

Milled grain and hot water are mixed in a paddle cum ribbon mixer to prepare mash, which flows

to mash tank. Mash tank is equipped with agitator to keep grain solids in suspension. Small

quantity of liquefying enzyme is also added to the mash tank to reduce viscosity and improve

pump-ability of the mash.

Mash cooking process is continuous and online. A high-pressure jet cooker is used for heating the

mash through direct steam injection and heated mash is held at high temperature for some time

to achieve proper cooking of grain starch. The cooked mash is then flashed to reduce its

temperature before liquefaction. Liquefaction enzyme is added to liquefaction tank for converting

starch to short chain dextrin. The contents of liquefaction tank are continuously agitated to

ensure proper mixing of enzyme and mash. The liquefied mash is cooled in mash coolers and then

sent to the fermentation area for conversion to ethanol.



As saccharifying enzyme and fermentation process requires a lower pH value than liquefaction

process, thin stillage from distillation section is added to mash to dilute it and to reduce the pH

value of the mash. In absence of the thin stillage process water can be used for dilution and some

acid might be required to adjust the mash pH.

CIP connections are provided at required points to ensure proper cleaning of equipment and

pipelines, to maintain sanitary conditions and control the contamination during liquefaction

process.

The offered plant will operate on SSF (Simultaneous Saccharification & Fermentation) Concept

during grain-based operation. SSF does away with separate saccharificatoion step before

fermentation. This minimizes contamination, reduces capital cost and simplifies the system to

ensure better control and efficiency.

Yeast culturing:

Yeast cell mass is grown in this section. It comprises of a yeast activation vessel, used for

activation of dry yeast. The vessel is provided with heating, cooling and steam sterilization

arrangements. Once yeast has been activated and grown to proper concentration, the mixture is

transferred to a pre- fermenter. Heat generated in the pre-fermenter is removed by circulating

contents of fermenters through pre-fermenter cooler.

Sterile air, necessary for yeast growth, is supplied to the yeast activation and pre-fermenter

vessels. Finally, cell-mass from the pre-fermenter is transferred to fermentation tanks.

Fermentation:

Offered fermentation process operates on the highly successful SSF (Simultaneous

Saccharification and Fermentation) Concept, which minimizes chances of contamination and

ensures better fermentation efficiencies resulting in higher yields while cutting down on process

hardware. The fermentation system consists of four fermentation tanks operating in Fed-batch

Mode. The fermenters serves as bioreactor vessels in which sugar, (converted from starch), is

converted to ethanol by the yeast (Saccharomyces cerevisiae). Fermenters are designed for

efficient heat removal and good mixing, to facilitate maintenance of uniform temperature and

sanitary environment for efficient fermentation process. This ensures good startup with rapid

fermentation and high ethanol content in fermenters.

Fermenter is filled with grain mash and yeast cell mass from the pre-fermenter is transferred to it

during the filling. Fermentation process is exothermic, i.e. heat is generated during the process.



To maintain an optimum temperature of around 320C in fermenters, the heat generated during

fermentation process is removed by circulating the fermenter contents through external heat

exchanges cooled by cooling water. Gases generated during the fermentation process are

collected and scrubbed in CO2 scrubber, to recover the ethanol carried over with vent gases.

After completion of the fermentation process, fermented beer is transferred to the beer well and

the fermentation tank is thoroughly cleaned for next fermentation cycle. Beer well provides surge

capacity between fermentation and distillation system. Efficient CIP system is provided for the

cleaning of fermentation tanks, heat exchangers and associated piping to ensure sanitary

conditions during fermentation. To ensure proper cleaning, each fermenter is fitted with high

pressure jet type rotating tank cleaner, connected to the system.

Salient features:

Rugged Process and ease of operation,

Better sanitation and low contamination result in faster fermentation and lower residence

time,

Proper sanitary conditions maintained by effective CIP system ensure low bacterial activity

and contamination levels in fermenters,

Consistently high-performance plant operation,

Higher Alcohol Concentration in fermenters leads to reduced steam consumption in

Distillation and lower effluent volume,

Clean -In-Place (CIP) system:

Efficient CIP System is provided to ensure proper cleaning of process equipment with inter-

connecting piping and minimize microbial contamination in the process. The system consists of

hot water tank, caustic solution tank, a high-pressure pump, tank cleaning nozzles and associated

piping. A good quality sterilant is used during the CIP cycle to disinfect the system, as and when

required.

Distillation:

Offered Multi-pressure Distillation System comprises of seven distillation columns operating at

different internal pressures, so that overhead vapors from the distillation columns operating

under higher pressure can be used to heat columns operating under lower pressure. This thermal

integration of distillation columns leads to a system where high-grade neutral alcohol can be

produced with very low energy consumption.



Fermented beer containing alcohol is preheated and fed to the degasifying column for removal of

entrained carbon dioxide and low boiling impurities. The degassed fermented beer is then fed to

beer stripper column, where alcohol is stripped from the fermented beer.

Raw alcohol recovered in beer stripper column is fed to pre-concentrator column, which

concentrates the raw alcohol and provides for first stage removal of low boiling impurities and

fusel oils. The impure spirit draws are taken to recovery column for further concentration and

recovery of ethanol.

Overhead vapors from pre-concentrator column are taken to integrated four effect evaporator

and provide the heat required for concentrating the spent wash. The shell side condensate from

evaporator is pumped back to pre-concentrator column as reflux.

Integrated Evaporator utilizes waste heat from distillation to concentrate the thin stillage

(decanted spent wash) without using any steam.

Concentrated alcohol from pre-concentrator column is diluted with soft water and recycled spent

lees and then fed to ED column where it undergoes extractive distillation under high dilution.

Extractive distillation process under high dilution conditions changes the volatile behavior of the

impurities and ensures high efficiency removal of all high and low boiling impurities from the top

of ED column.

Purified dilute alcohol from the base of ED column is fed to rectification column where it is

concentrated to about 96%v/v ethanol content. Side draws are taken from the rectification

column to remove fusel oils/heavier impurities, while light impurities are removed from the top

of rectification column. Impure spirit draws are taken to recovery column for further

concentration.

Neutral Alcohol draw from the top section of rectification column is taken to polishing column for

slow stripping and removal of any remaining light impurities, mainly methanol and diacetyl.

Purified premium quality neutral alcohol product is drawn from the bottom of polishing column

and transferred to ENA receivers after cooling in the product cooler.

Impure draws from all columns consisting of heads, esters and fusel oils are taken to recovery

column for the concentration of the impurities and to recover excess ethanol. Ethanol stream

recovered from the top of recovery column is recycled back to the system. This ensures lower

overall impure cuts during the distillation process.

A highly concentrated draw of impure spirit is taken from the vent condenser of recovery column

and transferred to impure spirit receiver. Fusel oil draws from the recovery column are taken to



fusel oil decanter where fusel oil is separated and transferred to fusel oil tank. The fusel oil

washings from the bottom of the decanter are taken back to the recovery column feed tank.

Salient features:

Simple Distillation Scheme with optimum number of distillation columns and easy plant

operation,

Energy Efficient thermally integrated Multi-pressure Column Operation leads to lower

steam consumption,

Thermal Integration with Spent Wash Evaporator helps substantially reduce spent wash

volume without using any steam, thus resulting in substantially energy savings over the

plant life,

Vacuum operation combined with the high turbulence tray design for Beer Stripper

column almost eliminates the scale formation, hence plant down time is substantially

reduced,

Indirect heating of Analyzer column to prevent undesired dilution of spent wash with

steam condensate

Mutli-pass design of condensers with higher tube velocities to minimize scaling inside

tubes and ensure higher heat transfer coefficients,

Highly efficient Fusel Oil Decanter with proper mixing, calming and separation zones

ensures proper separation of fusel oils,

Better quality product with effective separation of impurities,

Higher Distillation efficiency,

Fully automated plant with advanced control system eliminates chances of human error

and ensures consistent high distillation efficiencies and excellent product quality.

Integrated Evaporator:

Evaporation is a thermal operation used to remove a liquid from a solution by boiling off the

solution. The evaporation process starts with a liquid product and ends with a concentrate as the

main product from the process.

Offered Spent Wash Concentration System comprises of a Seven-effect evaporator unit thermally

integrated with the distillation plant. The integrated evaporator will use only waste heat from the

distillation plant for the concentration of thin stillage, without using any steam.



Vapors from the top of pre-concentrator and recovery columns will be used to heat the

evaporators of integrated four-effect evaporator and provide thermal energy required for

concentrating the thin stillage. The condensate from respective evaporators will be collected and

pumped back to the pre-concentrator and recovery columns as reflux.

Offered Integrated Evaporator System is a combination of falling film and forced circulation

evaporators, to optimize heat transfer requirements and electric power consumption of the

system. It is a four-effect evaporation system with three effects based on falling film concept and

one final effect based on forced circulation concept. The falling film evaporators having extremely

high thermal efficiency with low power consumption are used for the effects handling liquid with

lower solids content. For final effect, where solids content is high, forced circulation evaporator

has been used.

In forced circulation evaporator the liquid is circulated at very high flow rates through the heating

tubes. Forced circulation evaporators consume higher amount of electric energy but substantially

minimize the fouling rates and resulting down time for the Spent Wash Concentration Plant.

Salient features:

Energy efficient system running on waste heat from distillation section and requiring no

Steam for operation,

Lower fouling rates i.e. lower deposition of solids on tube surfaces results lower operating

costs with no chances of choking or system breakdown during operation.

Simplified Easy Plant Operation by full automation.

Process Condensate generated in process can be reused, minimizing the plant water

consumption.

Distillers Dry Grain & Solubles (DDGS):

After recovery of the alcohol, spent wash leaves distillation plant from the base of Beer Stripper

Column. The spent wash from grain-based distillery contains suspended and soluble grain solids

comprising of fibers, proteins, fat, etc. which remain unconverted during the fermentation

process and pass through as such, plus valuable yeast nutrients are added during the

fermentation process. The resulting product has high nutrient content and has great value as

cattle –feed.

Operation of DDGS Section can be divided broadly in three sub-sections, i.e. Decantation,

Evaporation and Drying.



a. Decantation:

Spent wash from the distillation section will pass through horizontal high-speed Decanters, which

separates suspended solids from the spent wash and split the spent wash feed stream into two

streams, as below:

Wet Cake: it is the solids stream from decanter consisting of majority of suspended solids.

It has approximately 30% solids and 70% water.

Thin stillage: Liquid stream consisting of mainly water with all dissolved solids and

remaining suspended solids.

A part of thin stillage is recycled back to the liquefaction section, thus reducing the

requirement of process water. Balance quantity of thin stillage is pumped to Evaporators

for concentration.

b. Evaporation:

In offered system thin stillage will be concentrated to a solids content of about 30% w/w, in an

Evaporator thermally integrated with distillation section. The concentrated thin stillage syrup

from evaporator will be mixed with wet cake from spent wash decanter. The mixture is known as

DWGS (Distillers Wet Grain and Soluble). It contains all required nutrients and has high value as

very good cattle feed. But due to its higher moisture content, it can’t be stored as such for a

longer time period and needs same day disposal form the plant.

c.Drying:

The thick slop from the multiple effect evaporator system will be mixed with wet cake from the

decanter in a specially designed paddle mixer. The ratio of thick slop & wet cake will be 50% &

50% respectively.

A portion of the dried DDGS product is recycled back to paddle mixer by a suitable conveyor

system. The mixed and conditioned wet feed is then fed at a constant rate via a screw feeder.

Back mixing of the product lowers the moisture content thus improving the physical form and

handling characteristics of the feed material.

In dryer the wet mass is indirectly heated by using dry & saturated steam. The steam tubes are

arranged concentrically with tube sheet & baffles. The steam enters the tube and heats the tube

walls. A rotary joint and circulate header is used to feed steam inside the tubes with proper

distribution of steam and condensate removal arrangement.



Wet mixed material comes in contact with the hot tubes, as it moves forward in the dryer drum.

The moisture in wet, material vaporizes and it gets dried. The dried fiber product is discharged

from the dryer drum through outlet port of the discharge manifold.

The vapors generated from the drying of mixture are removed from the dryer enclosure by an ID

Fan. The fine particles escaping with the purge air are trapped and collected by a cyclone

separator and discharged continuously via rotary valve. The humid air is exhausted into

atmosphere via cyclone outlet port.

The hot and dried product is cooled in an online cooler. The product cooler system is indirect and

water cooled. Tubular cooler with fixed shell and rotating tube bundle is considered.

Control system:

A PLC based control system will be provided to ensure continuous, stable and efficient plant

operation. Electronic field instruments linked to the PLC control panel will be used for measuring

the value of various process parameters.

All measured single such as temperature, differential/absolute pressures, flows and levels will be

continuously monitored and compared with set point values in PLC system. If any deviation is

observed form set point values for any particular process parameter, a suitable control action

based on programmed algorithms will be generated by PLC system. Desired control action will be

provided through control value or viable frequency drive.

Man machine interface will be provided through SCADA (Supervisory Control and Data

Acquisition) software running on a desktop computer. The operating panel will be located in the

control room and consists of operator work station with 20th color monitor and operator

keyboard. Features such as trends, graphics, process parameter indication, etc. well be

incorporated.

Control system will store all operating data and provide historical trending and real time analysis

for evaluating the anticipated and achieved plant performance. The panels for PLC hardware

installation and motor control switch gear will be installed in a control room, to be provided by

client, in ex-free area. The process flow diagram of grain based distillery plant is shown below:



3.5.1 Process description for Molasses based plant

Molasses handling &storage:

Molasses received in tankers is unloaded in a molasses unloading pit and pumped to bulk

molasses storage tanks. As and when required, molasses is pumped from bulk storage tanks to

molasses day tank in the fermentation areas though a weighing system.

Yeast culturing:

Yeast cell mass is grown in this section. Yeast culturing system comprises of three yeast

propagation vessels of incremental sizes, which are connected in series. Diluted molasses mash is

Grain receiving, Handling & Storage

Grain Cleaning & Milling

Mashing & Cooking

Liquefaction

Saccharification & fermentation

Distillation

Decanter

DDGS Dryer

Evaporation

DDGS

ENA & TA Storage

Steam generation

Power generation

Cooling Tower



taken in 1st vessel and yeast cell mass is pitched in it under hygienic corotiors. Cell-mass grows

and is then transferred to the pre-fermenter.

Series air, necessary for yeast growth, is supplied to yeast propagator and pre-fermenter vessels.

The heat generated in pre-fermenter is removed by circulating the corterts of pre-fermenter

through pre-fermenter cooler. Finally, a part of cell-mass from pre-fermenter is transferred to the

fermentation tanks. Alternatively, dry yeast can be used for directly seeding the pre-fermenters.

Fermentation:

Offered fermentation system consists of four fermentation tanks operating tanks operating in

FED-batch mode.

Fermenters serve as bioreactor vessels in which sugar, (converted from starch in case of grain-

based operation), is converted to ethanol by the yeast (Saccharomyces cerevisiae). The

fermenters are designed for efficient heat removal and good mixing to facilitate maintenance

process. This ensures good startup with rapid fermentation and high ethanol content in the

fermenters.

Each fermenter is filled with dilute molasses and yeast cell mass the pre-fermenter is transferred

to it during the filling process. The fermentation process is exothermic, i.e. heat is generated

during the process. To maintain an optimum temperature of around 32oC in fermenters, heat

generated during fermentation process is removed by circulating fermenter contents through

external heat exchangers, cooled by cooling water. The gases generated during fermentation

process are collected and scrubbed in CO2 scrubbed, to recover ethanol being carried over with

vent gases.

After completion of fermentation process, fermented beer is transferred to the beer well and

fermenter tank is thoroughly cleaned for the next fermentation cycle. Beer well provides the

surge capacity between fermentation and distillation systems.

Efficient CIP system is provided for cleaning of fermentation tanks, heat exchangers and

associated piping to ensure sanitary conditions during fermentation. To provide proper cleaning,

each fermenter is fitted with high pressure jet type rotating tank cleaner connected to the CIP

system.

Salient features

Rugged process and ease of operation



Better sanitation and low contamination result in faster fermentation and lower residence

time.

Proper sanitary conditions maintained by effective CIP system ensure Low bacterial

activity and contamination levels in fermenters.

Consistently high-performance plant operation, as every batch is fresh and seeds

independently,

Higher alcohol concentration in fermenters leads to reduced steam consumption in

distillation and lower effluent volume.

Clean-In-Place (CLP) system:

Efficient CLP system is provided to ensure proper cleaning of process equipment with inter-

connecting piping and minimize microbial contamination in the process. The system consists of

hot water tank, a high-pressure pump with tank cleaning nozzles and associated piping. A good

quality sterilant is used during the CLP cycle to disinfect the system, as and when required.

Distillation:

Offered multi-pressure distillation system comprises of seven distillation columns operating at

different internal pressures, so that overhead vapors from the distillation columns operating

under higher pressure can be used to heat columns operating under lower pressure. This thermal

integration columns leads to system where high-grade neutral alcohol can be produced with very

low energy consumption.

Fermented beer containing alcohol is preheated and fed to the degasifying column for removal of

entrained alcohol carbon dioxide and low boiling impurities. The degassed fermented beer is then

fed to beer stripper column, where alcohol is stripped from the fermented beer.

Raw alcohol recovered in beer stripper column is fed to pre-concentrator column, which

concentrates the alcohol and provided for first stage removal of low boiling impurities and fusel

oils. The impure spirit draws are taken to recovery column for further concentration and recovery

of ethanol.

Overhead vapors from pre-concentrator column are taken to pre rectifier condensers and liquid is

pumped back to column top as reflux.

Concentrated alcohol from top of the pre-concentrator column is diluted with soft water and

recycled spent lees and then ED column where it undergoes extractive distillation under high

dilution. Extractive distillation process under high efficiency removal of all high and low boiling



impurities and ensure high efficiency removal of all high and low boiling impurities from the top

of ED column.

Purified dilute alcohol from the base of ED column is fed to rectification column where it is

concentrated to about 90% v/v ethanol content. Side draws are taken from the rectification

column to remove fusel oils/heavier impurities, while light impurities are removed from the top

of rectification column. Impure spirit draws taken to recovery column for further column for

further concentration.

Neutral alcohol draw from the top section of rectification column is taken to polishing column for

slow stripping and removal of any remaining light impurities, mainly methanol and diacetyl.

Purified premium quality neutral alcohol product is draw from the bottom of polishing column

and transferred to ENA receivers after cooling in the product cooler.

Impure draws from all columns consisting of heads, esters and fusel oils are taken to recovery

column for the concentration of the impurities and to recover excess ethanol. Ethanol stream

recovered from the top of recovery column is recycled back to the system. This ensure lower

overall impure cuts during the distillation process.

A highly concentrated draw of impure spirit taken from the vent condenser of recovery column

and transferred to impure spirit receiver. Fusel oil draws from the recovery column are taken to

fusel oil decanter where fusel oil is separated and transferred to fusel oil tank. The fusel oil

washings from the bottom of the decanter are taken back to the recovery column feed tank.

Salient features:

SAMPLE SISTILLATION SCHEME with optimum number of distillation column and easy

plant operations,

Energy efficient thermally integrated multi-pressure column operation leads to lower

steam consumption,

Vacuum operation combined with the high turbulence tray design for beer stripper

column almost eliminates the scale formation, hence plant down time is substantially

reduced,

Indirect heating of analyzer column to prevent undesired dilution of spent wash with

steam condensate

Multi-pass design of condensers with higher tube velocities to minimize scaling inside

tubes and ensure higher heat transfer coefficient,



Highly efficient fusel oil decanter with proper mixing, calming and separation zones

ensures proper separation of fusel oils,

Better quality product with effective separation of impurities,

Higher distillation efficiency,

Fully automated plant with advanced control system eliminates chances of human error

and ensures consistent high distillation efficiencies and excellent product quality,

Integrated Evaporator:

Evaporation is a thermal operation used to remove a liquid from a solution by boiling off the

solution. The evaporation process starts with a liquid product and ends with a concentrate as the

main product from process.

Offered integrated spent wash concentration system comprises of seven effect evaporator unit

thermally integrated with the distillation plant. The integrated evaporator will use heat from the

distillation plant (Alcohol vapours) for the concentration of RSW along with partial steam during

molasses mode whereas for the grain mode no steam shall be required and alcohol vapours shall

be sufficient to evaporate the thin slops. As part of heat source vapors from the top of pre

rectifier and recovery column will be used to heat the falling film evaporators which are on top of

these columns.

The alcohol condensate from respective evaporators will be collected and pumped back to the

respective column as reflux.

Salient features:

Energy efficient system running waste heat from distillation section and requiring

minimum steam for operation during the molasses mode

Lower fouling rates i.e. lower deposition of solids on tube surface result slower operating

costs with chances of choking or system breakdown during operation.

Simplified easy plant operation by full automation.

Process condensate generated in process can reused, minimizing the plant water

consumption.

MSDH:

Ethyl alcohol dehydration plant take advantage of a unique property of the molecular sieves. The

grade of molecular sieve chosen is such that it will selectively adsorb water molecules but will

reject ethanol molecules because they are too large under the correct operating circumstance



molecular sieve beads will absorb water from ethanol and water azeotrope. Leaving the ethanol

essentially stripped of water. The plant will be designed to operate in stand-alone mode. The

plant will produce anhydrous ethanol product with 0.20% (v/v) water content by processing a

feed of alcohol/water mixture with maximum 5.0% (v/v) water content.

Feed is preheated in feed economizer, against anhydrous ethanol product and vaporized in a

vaporizer. The hydrous ethanol vapor from the vaporizer passes down the molecular sieve bed in

one of adsorption column, where water molecules are absorbed into the pores of molecular sieve

and ethanol molecules pass through the dehydrated product alcohol leaves the adsorption

column and is condensed back. To the liquid phase and cooled to the ambient temperature in the

product cooler.

One molecular sieve column is always in the adsorption mode while the other in regeneration

mode. In regeneration mode, the adsorbed water is removed by applying deep vacuum to the

molecular sieve column under regeneration. Stream generated during the regeneration step,

which contains all of the water from saturated molecular sieve bed and some ethanol, is taken to

the recovery column. The ethanol is concentrated to the azeotropic point in the recovery column

and recycled back to the system, while the water leaves the system from the column.

Control system:

To provide continuous stable and efficient plant a PLC (programmable logic controller) based

plant control system with computer based SCADA (Supervisory Control and Data Acquisition)

operator interface will be provided.

All filed sensors will be electronic and the control action will be provided through pneumatically

controlled valves. All measured signals such as temperature, differential pressure, absolute

pressure, flows and levels are processed in a PLC and required control action will be decided

based on programmed algorithms in the PLC.

Man machine interface will be provided through SCADA software running on desktop computer is

located in the control room and connected to a 19” color monitor. The system will also store all

operating data for a minimum period of one month and provide historical trending and real time

analysis facilities.

The panel for motor control and the data hardware installation of the PLC and computers will be

installed in an ex free room, to be provided by client.

The process flow diagram of Molasses based distillery plant is shown below:



CO2 RECOVERY PLANT

During the biochemical reaction in fermentation section, CO2 is generated as by product along

with ethyl alcohol. This raw CO2 gas having 99% v/v purity (DB) is taken for purification followed

liquefaction.

Initially gas is taken to Foam trap to eliminate liquid particle carried over from fermentation

section. Here process water is used to rinse down the foam. Clean gas from Foam trap is then fed

to Low pressure organic removal system with the use of booster blower. Organic impurities

associated with carbon dioxide gas are scrubbed using high efficiency packing. Main impurities

like ethanol, aldehyde, ethyl acetate, are extracted in the scrubbing water through counter

current operation of the scrubber. This purified gas is then fed liquid knock out drum for removal

Molasses receiving, Handling & Storage

Fermentation

Distillation Section

Integrated Evaporation

RS/ENA/AA & By Products

Steam Generation

Power Generation

Cooling Tower



of water traces. Purified gas is compressed in two stages reciprocating non lubricated water

cooled compressor. This high pressure gas is cooled down to desired temperature in water cooled

after cooler. Additional impurity separation step is used to enhance CO2 gas purity by scrubbing

impurities present in traces by use of potable water.

Odour producing hydrocarbons and other sulphur based compounds will be removed in

adsorption tower by using activated carbon as a media. De odorized high pressure carbon dioxide

gas will be cooled down to remove significant portion of moisture using ammonia as coolant. It

will be further dried in molecular sieve dehydration unit. This step is essentially required to avoid

ice formation during liquefaction of carbon dioxide. This purified is carbon dioxide gas will be then

liquefied by using refrigeration system. Refrigeration system consists of screw compressor, pre

cooler, refrigerant condenser and accessories. Liquid CO2 still contains non condensable gases like

nitrogen, oxygen which are removed through venting. Liquid CO2 stripper is used to avoid high

vent CO2 losses which uses packed tower with reboiler and reflux condenser. Oxygenates of

nitrogen are removed through molecular sieve NOx tower. Purified liquid CO2 of desired quality

will be then sent to liquid CO2 storage tank. Liquid storage tank will be equipped with all

necessary accessories like pressure safety valves, insulation.

After the scrubber, the pressurized CO2 will be liquefied and stored in the storage container which

will be disposed through tankers to the soft drink manufacturing units. Total CO2 production will

be 165 T/day.

3.5.2 Raw Materials:

The Industry will use wide range of Agro based raw materials available in different seasons. The

Government of India and Chhattisgarh State Government is encouraging Agro based Industries in

production of Ethanol and other related products to benefit farmers, create rural employment for

agricultural labourers. The following will be the raw material requirement.

S.No

Raw Material Source Quantity

(TPD)

Method of Transport

Grain Based Distillery plant:

1 Grains (Maize, corn, Sorghum grain, broken rice and other starch based grains, etc.)

Chhattisgarh 524 Through covered trucks by

Road

Molasses Based Distillery plant:

1 Molasses From Sugar 484 Through tankers by Road



plants

(or)

Fuel (2x34 TPH Boilers & 2x17 TPH Boilers)

1. Biomass Local 380 Through covered conveyor

(or)

2. Indian coal Korba Chhattisgarh

340 Through road by covered trucks

(or)

3. Imported coal Australia/ Indonesia

250 Sea / Rail / Through covered trucks by Road

3.5.3 Resource Optimization / recycling and reuse:

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

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

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

This will be sold as Cattle feed/fish feed.

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

reused in the Process thus decreasing the net water requirement.

3.5.4 Availability of Water:

Water requirement for the proposed project will be 2831 KLD. Water requirement for the

proposed project will be sourced from shivnath river. Prior permission from the Water Resources

Department , Govt. of Chhattisgarh will be obtained before drawing water. A water storage tank

is proposed on site to ensure adequate water supply. Efforts will be taken to minimize & conserve

water. Water harvesting measures will be taken up to augment the ground water table.

3.5.5 Power Requirement:

The power required for the proposed plant is estimated to be 12 MW. The power requirements

will be met from co-gen power plant proposed. Change over to CSPDCL connection is proposed to

facilitate start-up operations and as a backup option.

3.5.6 Quantity of wastes generated:

3.5.6.1 Waste water generation and treatment:

Grain based Distillery:



As per CPCB recommendations the spent wash quantity will be restricted to less than 6 KL/KL of

R.S. for Grain based distillery by adopting fermentation technology. The Maximum Spent wash

from the 2x120 KLPD Distillery plant will be 1440 KL/day.

Decantation of Spent Wash:

Spent wash from mash column bottom will be fed to decanter centrifuge after cooling in

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

desired level.

The wet cake will be separated in decanter at 30% solids. This wet cake will be mixed with

concentrated Thin slop for further concentrating in Dryer.

Evaporation Process:

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

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

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

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

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

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

next evaporation effect so it is called as Feed Forward Effect Evaporation. The vapor from last

evaporator will be condensed in condenser and transferred to the dryer while the condensate

from the evaporators is first utilized for heat recovery. While vacuum pump maintains vacuum in

the entire system. Product final thin slop with 30% solids will be transferred to the drying system

where it is further concentrated to 90 % solids. The condensate from evaporation will be recycled.

Drying Process:

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

will be dried in a steam tube bundle dryer to produce DDGS with 10% moisture and 90% solids,

which will be sold as cattle feed. It is totally a zero discharge process, which is in accordance with

the CREP recommendations.

Zero discharge will be implemented as per CREP recommendations. Scheme for Zero Discharge

System (ETP) For Grain Based Distilleries:



Spent wash Characteristics:

S.No. Particulars Characteristics

1. pH : 4.5 to 5.0

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

3. B.O.D. : 25,000 - 30,000 ppm

4. C.O.D : 55,000 - 60,000 ppm

Molasses based Distillery:

As per CPCB recommendations the spent wash quantity will be restricted to a maximum of 8 kl/kl

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

Maximum Spent wash generation from the proposed 2x60 KLPD plant with Molasses as raw

material will be 960 KL/day.

The spent wash will be concentrated to 60% solids in Multiple Effect Evaporators and then will be

incinerated in exclusive 2x17 TPH Boilers. This is a Zero Liquid discharge system approved by

Central Pollution Control Board.

EVAPORATION SYSTEM

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

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

concentrated solution of thick liquor with 60% solids and 40 % moisture content.

The evaporation system consists of 5 evaporators, which are connected, in series. The spent wash

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

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

wash will be fed to the next evaporation effect so it is called as feed forward effect evaporation.

The vapor from last evaporator will be condensed in condenser and transferred to the dryer while

the condensate from the evaporators is first utilized for heat recovery. While vacuum pump



maintains vacuum in the entire system. Product final thick spent wash with 60% solids will be

used in boiler for incineration.

INCINERATION OF CONCENTRATED SPENT WASH

The final concentrate from the Evaporators (60% solids w/w) will be incinerated in the Boiler by

mixing with coal. The condensate from the Evaporation system will be reused in the plant

operation. Zero discharge will be implemented as per CREP recommendations. ETP diagram

shown in figure below.

Non-Process Effluent Treatment & Disposal:

Spent lees & condensate will be treated in Condensate Polishing Unit (CPU). Non-process effluents

like DM plant regeneration water & boiler blow down will be neutralized in neutralization tank

and will be mixed with Cooling tower blow down. This treated effluent after ensuring compliance

with standards stipulated by CECB for wastewater for on land for irrigation, will be utilized for

internal greenbelt development, dust suppression, ash conditioning after ensuring compliance



with CPCB/CECB standards. The scrubbed water from CO2 Scrubber will be consumed in the

Fermentation section.

3.5.7 Solid Waste

The following are the solid waste generation & disposal.

S. No Solid waste Quantity (TPD) Disposal

Phase-I Phase-II

1. DDGS (with 90% solids)

75 75 will be sold as Cattle /fish/prawns feed

2 Yeast Sludge 2.2 2.2 Will be used as manure

3. Boiler Ash

With 100 % biomass

34.2 34.2 Ash generated will be given to brick manufacturers when rice husk is used as fuel. Ash generated will be given to brick manufacturers / cement plant, when coal is used as fuel.

Or

With 100 % India coal

68 68

Or

With 100 % Imported

coal 30 30



4.0 SITE ANALYSIS

4.1 Connectivity:

The project Site can be approached by NH&200. The project site is at a distance of 8.1 Kms.( By

Road) from Tilda.

4.2 Land form, Land use and Land ownership:

The proposed land is private land. The present use of the land is Dry Land ( Non-Agriculture).

Total land for the project is 44.51 acres. Land diversion to industrial purpose is under process.

After diversification of land , land will be taken on long term lease

4.3 Topography:

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

4.4 Existing land use pattern:

The present use of the land is Dry Land ( Non-Agriculture).

4.5 Existing Infrastructure:

The site is well connected by NH which is at a distance of 23 Kms.( By road). Nearest railway

station is Baikunth at a distance of 3.5 Kms. from the plant

4.6 Soil classification:

The soil at the site is red soil.

4.7 Climatologically data:

The climatic conditions of the district consist of extremely hot summers and mild winters. The

period starting from April to June is the hottest. The annual rainfall in the region is about 1385

mm and is contributed to by the Southwest monsoon.

4.8 Social Infrastructure Available:

The area lacks in education. Hence will contribute to the improvement of education in the

area by improvising the existing facilities in the schools in the area.

The villages in the area are connected by road. The existing road network will be

adequate during the operation of the plant.

Medical facilities in the area needs improvement. Will contribute for improvement under

CER activities.



5.0 PLANNING BRIEF

5.1 Planning Concept:

The proposed Project is fermentation type industry in which starch containing raw materials will

be fermented for manufacturing Ethanol/RS/ENA/Potable Alcohol/ Industrial alcohol and power

generation from proposed AFBC Coal/ Biomass ( Rice Husk) fired boilers.

5.2 Population Projection:

Tilda Tehsil of Raipur district has total population of 238,157 as per the Census 2011. Out of which

119,467 are males while 118,690 are females. In 2011 there were total 49,233 families residing in

Tilda Tehsil. The Average Sex Ratio of Tilda Tehsil is 993.

As per Census 2011 out of total population, 19.3% people lives in Urban areas while 80.7% lives in

the Rural areas. The average literacy rate in urban areas is 80.4% while that in the rural areas is

73.2%. Also the Sex Ratio of Urban areas in Tilda Tehsil is 990 while that of Rural areas is 994.

The population of Children of age 0-6 years in Tilda Tehsil is 34173 which is 14% of the total

population. There are 17269 male children and 16904 female children between the age 0-6 years.

Thus as per the Census 2011 the Child Sex Ratio of Tilda Tehsil is 979 which is less than Average

Sex Ratio ( 993 ) of Tilda Tehsil.

The total literacy rate of Tilda Tehsil is 74.61%. The male literacy rate is 72.45% and the female

literacy rate is 55.3% in Tilda Tehsil.

5.3 Land use Planning:

The following is the Land use planning of the proposed project area.

ITEM EXTENT OF LAND

(ACRES)

Built-up area 11.0

Internal roads 4.5

Storage areas

(raw material, products)

6.0

ETP 2.0

Greenbelt 15.0

Parking area 1.0



Other uses 5.01

Total 44.51

5.4 Amenities / Facilities:

Facilities like canteen, rest rooms and recreation facilities will be provided in the proposed

project.



6.0 PROPOSED INFRASTRUCTURE

6.1 Industrial area

Grain based Distillery:

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

machinery.

List of Plant and Machinery

S. No. Description

1. Grain Storage Section –Silo

2. Grain Handling Section

3. Liquefaction Section

4. Fermentation Section

5. Distillation Section

6. Steam Boilers with Accessories

7. Steam turbine with Step down transformer & synchronization

8. Steam condensers

9. Air compressor

10. Storage section (Daily Receiver Section, Bulk Storage tanks)

11. Centrifugal Machines

12. CO2 Recovery Plant (In future)

13. DDGS Drying section

14. Multiple Effect Evaporation Section

15. Raw water treatment plant

16. R.O. Plant for boiler water

17. Fire protection equipments for entire plant

18. Weigh bridge

19. Water storage tanks

20. Electricals

21. Piping works

22. Lab equipments



Molasses based Distillery:

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

List of Plant and Machinery

S.No. Description

1. Molasses Storage Section

2. Molasses Handling Section

3. Fermentation Section

4. Distillation Section

5. Steam Boiler with Accessories

6. Steam turbine with Step down transformer & synchronization

7 Steam condensers

8 Air compressor

9 Storage section (Daily Receiver Section, Bulk Storage tanks)

10 D C Canters

11 CO2 Recovery Plant (In future)

12 Multiple Effect Evaporation Section

13 Incineration Boilers

14 Fire protection equipments for entire plant

15 Weigh bridge

16 Water storage tanks

17 Electricals

18 Piping works

19 Lab equipments

6.2 Residential Area (Non-Processing area):

Facilities like canteen, rest room and indoor games etc. will be provided to the Employees in the

proposed project.

6.3 Green Belt:

15 Acres (more than 33 % of the total area) of Green belt will be developed in the plant premises

as per CPCB norms.

Greenbelt development plan

Local DFO will be consulted in developing the green belt.

10 m wide greenbelt will be developed along the boundary of the proposed project area.

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

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

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



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

known to be particularly tolerant to pollutants.

6.4 Social Infrastructure:

Social infrastructure will be developed as per need based in the Villages.

6.5 Connectivity:

The project Site can be approached by NH&200. The project site is at a distance of 8.1 Kms.( By

Road) from Tilda.

6.6 Drinking water management:

Drinking water required for the workers will be sourced from ground water resources.

6.7 Sewerage system:

Domestic waste water generated will be treated in septic tank followed by soak pit.

6.8 Industrial waste management:

Waste water generated from the proposed Project will be treated in the proposed ETP proposed

which is furnished under paragraph 3.5.6.

6.9 Solid waste management:

Solid waste generated and proposed disposal method from the proposed Project is furnished

under paragraph 3.5.7.

6.10 Power requirement & Supply / Source:

The power required for the proposed plant is estimated to be 12 MW. The power requirements

will be met from co-gen power plant proposed. Change over to CSPDCL connection is proposed to

facilitate start-up operations and as a backup option.



7.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN

7.1 Policy to be adopted in respect of the project affected persons:

No Rehabilitation & Resettlement plan is proposed as there are no habitations in the proposed

project area.



8.0 PROJECT SCHEDULE & COST ESTIMATES

8.1 Likely date of start of construction and likely date of completion:

The proposed Phase-I project will be implemented within 12-18 months from the date of issue of

Environmental Clearance by the Hon`ble Ministry of Environment & Forests & Consent To

Establishment by SPCB.

The proposed Phase-II project will be implemented within 48 - 60 months from the date of issue

of Environmental Clearance by the Hon`ble Ministry of Environment & Forests & Consent To

Establishment by SPCB.

8.2 Estimated project:

The total cost of the project has been estimated at Rs. 325 Crores. The following is the detailed

breakup of the project cost.

S.No. ITEM (In Crores )

1 Land & site development 10.0

2 Civil Works 28.8

3 Plant & Machinery 272.0

4 Working capital margin & IDC 10.0

5 CER budget 4.2

TOTAL COST OF THE PROJECT 325.0

Means of finance

1. Promoters (30 %) : 97.5

2. Term loans (70 %) : 227.5

Total : 325.0



9.0 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS) 9.1 FINANCIAL AND SOCIAL BENEFITS:

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

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

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

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

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

certainly improve due to the proposed project.

EMPLOYMENT POTENTIAL

The man power required for the proposed project in Phase –I will be 160 Nos. and in phase –II will

be 100 Nos.

OTHER TANGIBLE BENEFITS

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

Educational status will improve in the area

Medical standards will improve due to the proposed project.

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

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

the establishment of the proposed unit.

SOCIO-ECONOMIC DEVELOPMENTAL ACTIVITIES

Corporate Environment Responsibility (CER) activities will be taken up once the plant is

commissioned. Budget will be allocated for CER activities as per MOEF&CC norms. The CER

activities may include the following.

Health & hygiene

Installation of safe drinking water in the village

Education promotion

Tree plantation and conservation of water resources in near by villages

Helping locals to conduct sports

Training to the unemployed youth for skill development

CER activities will be finalized in consultation with the village panchayat based on need based

assessment.



Annexure - I



Documents

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