Bhairav Nath Pre Feasibility Report

PRE-FEASIBILITY REPORT FORBHAIRAVNATH SUGAR WORK’S LTD, SONARI

Highlights of Process

Fermentation:

We have incorporated mechanical educator in place of an air sparger, whichresults in increased Dissolved Oxygen (D/O) level, facilitates better contact between yeast and Fermentable Sugars, avoids hydraulically-dead zones, increases active yeast cell mass for high efficiency of conversion and therefore a better yield.

We have used Genetically Marked high osmo-tolerant yeast strain.

We have optimized the Cooling System to maintain fermenting broth temperature to 30C, which results in improved activity of the yeast cell mass. This is done by splitting the recirculation pumps to half of the full-load. During most of the sugar season the wet-bulb temperature will be far lower than the max wet-bulb of the area and this will require a far lower recirculation rates of Fermenting Wash. Splitting the Fermenting Wash Recirculation Pumps achieves lower electrical consumption (energy conservation).

Distillation and Reboiler:

We have incorporated axial-flow pump to maintain high velocities in the tubes of the Reboiler but with low consumption of electrical power. The high velocities are important to avoid the soft and hard scaling in Stripper Re-boiler.

Dehydration Plant

Offer three-bottle pressure swing adsorption, for smoother energy efficient operation and longer sieve life.

Lowest Utility consumption per lit of anhydrous alcohol. Maximum alcohol yield. Component design and selection to guarantee extensive service life. Fully automated with PLC based system.

Annexure – I

PRODUCT SPECIFICATION

1.1 Rectified Spirit (RS)

Characteristic Requirement of Alcohol (IS 323 – 1959)Ethanol Content (Minimum), % V/V at 15.6°C 96.0 v/vDegrees over proof 67.2Specific Gravity @ 15.6 C 0.81Alkalinity NilFusel oil max. 200 ppmAldehydes as acetaldehyde, mg/100 ml (Max.) 5Esters as ethyl acetate, mg/100 ml (Max.) 10Methanol, mg/100 ml (Max.) 5Butanol – 1 NilButanol – 2 NilIsobutanol – mg/100 ml. (Max.) 5Isopentanol – mg/100 ml. (Max.) 1Acidity as acetic acid mg/100 ml (Max.) 2Residue on evaporation, mg/100 ml (Max.) 2N-Propanol & Isopropanol, mg/100 ml. (Max.) 10Copper as Cu, mg/100 ml (Max.) 0.3Leas as Pb, mg/100 ml (Max.) 0.05Potassium permanganate reaction, time, minutes (min.) 20 1.2 Extra Neutral Alcohol (ENA) :

The material shall comply with the requirements prescribed in the following table.

S/N Characteristic Requirement of Alcohol (IS 6613– 1972)

1 Ethanol content (min), % V/V at 15.6C 96%2 Miscibility with water Miscible3 Alkalinity Nil4 Acidity (as CH2COOH), mg/100 ml (max.) 1.255 Residue on evaporation, mg/100 ml (max.) 26 Aldehydes mg/100 ml [max.] 0.57 Esters (CH3COO2H5), mg/100 ml (max.) 28 Lead as Pb mg / 100 ml (max.) Nil9 Methyl alcohol content, max. ppm 5

10 Furfural To pass the test11 Potassium permanganate reaction time,

minutes avg.(Min.) 3012 Copper as Cu, mg / 100 ml (max.) 0.213 Fusel oil content, mg / 100 ml (max.) 1.5 1.3 Anhydrous Alcohol (Ethanol):

Sr. Characteristic Requirement of Absolute No. Alcohol(IS : 321 : 1964)

1. Ethanol content (min.), % V/V 99.8%2. Miscibility with water Miscible3. Alkalinity Nil4. Acidity [as CH3 COOH], percent by weight, max. 0.0065. Residue on evaporation, percent by weight, max. 0.0056. Aldehydes content [as CH3 CHO] mg/100 ml (max.) 0.17. Ester content [as CH3COOC2H5], mg/100 ml (max.) 0.028. Copper as Cu, gm/100 ml. [max.] 0.00089. Lead [as Pb], gm/100 ml., max. 0.000110. Methyl alcohol content To satisfy the requirement

of the test11. Fusel oil content To satisfy the requirement

of the test12. Ketones, isopropyl alcohol and tertiary

butyl alcohol To satisfy the requirement of the test

13. Total sulfur and compounds of sulfur [as S] percent by weight, max. 0.00114. Sulphur dioxide [as SO2] percent by weight, max. 0.00005

Annexure – II 1. The Basis of design:

1.1 Raw Material

A. Distillery Plant : Sugarcane Molassesa. Fermentable Sugar in Molasses : 42%b. Density of Molasses : 85 Brix minc. F/NF Ratio : 1.1 or Higherd. Volatile Fatty Acid : < 5000 ppm

1.2 Product.1.2.1 Rectified Spirit + Impure Spirit : 28,500 LPD (RS) + 1,500 LPD (IS)1.2.2 Extra Neutral Alcohol + Impure Spirit : 28,500 LPD (ENA) + 1,500 LPD (IS)1.2.3 Fuel Alcohol : 30,000 LPD

1.3. Efficiency

1.3.1 Fermentation : 89% (VFA < 5,000 ppm, for everyIncrease of 1000 ppm Efficiencydecrease by 1%)

1.3.2 Distillation : 98.5%

1.3.3 Dehydration : 99.6%

1.4 Alcohol % in Fermented Wash : 8.0% v/v

1.5 Site ConditionsAltitude : < 100 m Above Sea LevelAmbient Temperature : Min. 20° C Max. 40° CHumidity : 80% RH at 30° CInstallation : Indoor

Area : Fermentation – Non FlameproofDistillation – FlameproofDehydration – FlameproofEvaporator - Flameproof

Annexure – III

PERFORMANCE PARAMETERS

A] Performance Parameters

Feed Molasses for 60 KLPD (Total spirit) : 5,063 Kg/hr at 42% FS

Feed Molasses for 60 KLPD (Fuel Alcohol) : 5,370 Kg/hr at 42% FS

Alcohol Percentage in Wash : Approx. 8.0% v/v

Spent wash generated after distillation : 240 m3/day [[email protected]% After Spent Wash Recycle to w/w Dissolved Solids] 8.00 lit/lit

Fermentation

Spent wash generated after Integrated : 153 m3/day [approx.@ 24% w/wEvaporator (Spent Wash Recycle Option) Dissolved Solids] 5.11 lit/lit(ENA)

Spent wash generated after Integrated : 177 m3/day [approx.@ 21% w/wEvaporator (Spent Wash Recycle Option) Dissolved Solids] 5.90 lit/lit(RS)

Annexure – IV

UTILITIES REQUIREDa. Steam:

1. Rectified Spirit (RS) (Multi Pressure Distillation)

Saturated steam at 3.5 kg/cm2 (g), 148C at steam header in the plant. Variation in pressure: ± 0.1 kg/cm2 In saturated.

Required Steam 2.750 MT/hr (2.2 kg per lit of Total Spirit, at full capacity operation & the plant is insulated)

2. Extra Neutral Alcohol (ENA) (Multi Pressure Distillation)

Saturated steam at 3.5 kg/cm2 (g), 148C at steam header in the plant. Variation in pressure: ± 0.1 kg/cm2 In saturated.

Required Steam 4.375 MT/hr (3.5 kg per lit of Total Spirit, at full capacity operation & the plant is insulated)

3. Integrated Evaporator

Alcohol Water Vapours from Distillation are to be use as heat source forconcentrating the Spent Wash.

4. Dehydration Plant

Saturated steam at 6 kg/cm2 (g), 165C at steam header in the plant. Variation in pressure: ± 0.1 kg/cm2 in saturated.

Required Steam 0.690 MT/hr (0.55 kg per lit of Total Spirit, at full capacityoperation & the plant is insulated).

b. Cooling Water:

1. Fermentation

Recirculation water shall be filtered, soft water, free from algae,suspended solids, and hardness shall be less than 5 PPM.

310 m3/ hour (Re-circulation Rate) at pressure of 2.5 kg/cm2 (g) at the header in the plant. At temperature of 30C maximum. It will be returned with temperature rise of 2C maximum.

Requirement of make up water will be approx 149 m3/ day 2. Multi Pressure Distillation, Integrated Evaporator, Dehydration, Week Beer

Recycle Recirculation water shall be filtered, soft water, free from algae, suspended solids, and hardness shall be less than 5 PPM.

375 m3/ hour (Re-circulation Rate) At pressure of 2.5 kg/cm2 (g) at the header in the plant. At temperature of 30C maximum. It will be returned with temperature rise of 8C maximum.

Requirement of make up water will be approx 180 m3/ day

c. Process Water for Fermentation

Process water shall be Filtered, Chlorinated free from algae, suspended solids, Process Water requirement for dilution will be 230 m3 / day

d. DM Water for Distillation – ENA Option

DM Water requirement for dilution for Extraction Column will be 188 m3 / day Spent Lesse Recycle from Rectifier Column then D.M.Water Requirement for Dilution for Extraction Column thus reducing, the DM requirement will be 28 m3 / day

e. Compressed Air:

40 Nm3/hour at 6 bar (g) with dew point of – 40C dew point dryness. Free from particulate matter, suitable for instruments.

f. Electricity:415 V/4 Wire/3 Phase Frequency : 50 Hz

1. Fermentation : 70 kW2. Yeast Recycle : 50 kW3. Multi Pressure Distillation : 75 kW4. Integrated Evaporator : 50 kW5. Fuel Alcohol : 18 kW6. Cooling Tower : 97 kWTotal Connected Load Without Stand By : 360 kWMotor

g. Variation in Utility : ± 10 %.

RETURN STREAMS

a. Steam condensate:

1. Multi Pressure Distillation RS Option, Integrated Evaporator & Dehydration2.75 MT / hour considering losses (Equivalent to steam utilized in the plant)

2. Multi Pressure Distillation ENA Option, Integrated Evaporator & dehydration 4.05 MT / hour considering losses (Equivalent to steam utilized in the plant)

WASTE STREAMS

a. Spent Leese:

1. Multi Pressure Distillation ENA Option & Dehydration Plant 25 - 30 m3/day, depending on composition of feed. Other high boiling substances and non-volatile matter from rectified spirit will get carried into lees.

CHEMICAL REQUIRED

1. Nutrient : 30 Kg/day2. Biocide : 25 ppm3. TRO* (TFM Min 60) : 70 Kg/day4. Sulphuric Acid : 25 Kg/day5. Tolerance : +10%

Annexure – V

PROCESS DESCRIPTION

The process of converting molasses to RS/ENA can be divided into following sub sections:

1] Feed Preparation and weighing2] Yeast Propagation and Continuous Fermentation3] Multi-pressure Distillation with Integrated spent wash evaporator

1] FEED PREPARATION AND WEIGHING

Molasses Stored in a storage tank is first weighed in a tank with load cells so that accurate quantity can be fed to the fermentation section. The weighed molasses then transferred from tank to the dilutor in fermentation section where it is diluted with water and fed to the fermenter.

2] YEAST PROPAGATION AND FERMENTATION

The Yeast from Slant is transferred to Shaker Flasks and grown to the required volume.

This “genetically marked” yeast strain is then further propagated, under aseptic conditions, in yeast culture vessel. These vessels are equipped with eductors which are designed to achieve enhanced efficiencies through better sugar / yeast contact by shearing and mixing, efficient oxygen transfer etc.

The ready yeast “seed” is then transferred from culture vessel to fermenter. The molasses is diluted by recycled weak beer (partially exhausted spentwash or vinasse) before fermentation. This recycle conserves corresponding amount of Dilution Water. The glucose in the Feed media gets converted to ethanol, in each of the 3 fermenters operating in Continuous Cascade mode. A plate heat exchanger and a circulation pump is provided to each fermenter, which will continuously re-circulate the Fermenting Wash through PHE for maintaining the Fermenters at 30 deg C. The nutrients, biocide, acid and anti-foam agents are fed to the fermenters as per process requirement. The CO2 liberated during fermentation is sent to CO2 Scrubber for recovery of ethanol otherwise being lost in vent.

The Fermented Wash is then sent to the Clarification Tank equipped with Lamella Separator. The settled sludge is sent to Sludge Washing Tank for recovery of alcohol.

3] MULTIPRESSURE DISTILLATION WITHOUT EVAPORATOR ( RS)

The fermented wash is fed to CO2 stripper column to remove CO2 gas present in wash. Alcohol is stripped off water in stripper column. The top vapors [alcohol + water] are fed to Beer Heater as heat source for preheat the Fermented Wash. Non Condensed vapour from Beer Heater fed to Principle Condenser & Vent Condenser Distillate from Beer Heater & Principle Condenser is fed to rectifier column as feed. In rectifier column RS is taken out from top tray. The impure spirit from top of CO2 stripper column, rectifier column are fed to fusel oil column. The final impure spirit cut is taken out from the fusel oil column and partly alcohol is recycled to rectifier column. The alcohol containing fusel oil from rectifier column is fed to fusel oil column.

Rectification column works under pressure. The CO2 stripper and stripping column works under vacuum and fusel oil column works under atmospheric condition.

The top vapours from rectifier column are condensed in Stripper Reboiler. The alcohol water vapours from stripping column are partly sent to CO2

stripper bottom for heating. The Rectifier column and fusel oil column gets heat from steam.The Distillation process is operated through PLC.

4] MULTIPRESSURE DISTILLATION WITH EVAPORATOR ( RS)

The fermented wash is fed to CO2 stripper column to remove CO2 gas present inwash. Alcohol is stripped off water in stripper column. The top vapors [alcohol + water] are fed to Calendria 1 as heat source for concentrating spent wash. Distillate from Calendria is fed to rectifier cum exhaust column as feed. In rectifier column RS is taken out from top tray. The impure spirit from top of CO2 stripper column, rectifier column are fed to fusel oil column. The final impure spirit cut is taken out from the fusel oil column and partly alcohol is recycled to rectifier column. The alcohol containing fusel oil from rectifier column is fed to fusel oil column.

Rectification column works under pressure. The CO2 stripper and stripping column works under vacuum and fusel oil column works under atmospheric condition. The top vapours from rectifier column are condensed in Stripper Reboiler. The alcohol water vapours from stripping column are partly sent to CO2 stripper bottom for heating. The Rectifier column and fusel oil column gets heat from steam.The Distillation process is operated through PLC.

5] MULTIPRESSURE DISTILLATION with Integrated Evaporator (ENA)

The fermentation mash containing Alcohol, non-fermentable solids and water is supplied to Distillation to separate the alcohol and other impurities, as a continuous flow.

The Distillation system is designed for premium quality extra neutral alcohol. The system details are as below:

The system consists of 7 main columns, namely, CO2 Stripper, Stripper Column, Prerectifier Column, Extraction Column, Rectification Column, Refining Column, Fusel Oil Column Cum HCC.

Wash is fed to CO2 stripper column to remove CO2 gas present in wash. Alcohol is stripped off in stripper column. The top vapours from stripper column are fed to Calendria 1. Distillate from Calendria 1 is feed to pre-rectifier column. Pre-rectifier remove most of the fusel oils. The distillate from pre-rectifier column is fed to extraction column after dilution where DM Water & Recycle Spent Lesse from Rectifier Bottom is used. In extraction column most of the high boiling impurities separate from ethanol in presence of water. The Alcohol Water Vapour from top of column is feed to Calendria 2. The bottom ethanol water mixture is pre-heated by steam condensate and spent Leese before being fed to rectifier column. In rectifier column product rectified spirit is taken out from top tray and fed to refining column where mainly methanol impurities are separated. Pure ENA is obtained at bottom, which is cooled and stored. The impure spirit from top of extraction column, rectifier column and refining column are fed to heads column. The final impure spirit cut is taken out from heads column top and balance alcohol is recycled to pre-rectifier column. The top Vapour is feed to Calendria 2. The alcohol containing fusel oil from pre-rectifier and rectifier column is fed to fusel oil column.

The rectifier column, fusel oil column and pre-rectifier column get heat from steam at 3.5 bar (g).

Rectification column and pre-rectifier column works under positive pressure. The top vapours from rectifier column are condensed in stripper column for giving heat to stripper re-boiler. Most of the other columns work under vacuum.The Distillation process is operated through PLC

6] MULTIPRESSURE DISTILLATION WITHOUT INTEGRATED

EVAPORAOTR (ENA)

The fermentation mash containing Alcohol, non-fermentable solids and water is supplied to Distillation to separate the alcohol and other impurities, as a continuous flow.

The Distillation system is designed for premium quality extra neutral alcohol. The system details are as below:

The system consists of 7 main columns, namely, CO2 Stripper, Stripper Column, Prerectifier Column, Extraction Column, Rectification Column, Refining Column, Fusel Oil Column Cum HCC.

Wash is fed to CO2 stripper column to remove CO2 gas present in wash. Alcohol is stripped off in stripper column. The top vapours from stripper column are fed to Beer Heater, Principle & Vent Condenser. Distillate from Condensers is feed to pre-rectifier column. Pre-rectifier remove most of the fusel oils. The distillate from pre-rectifier column is fed to extraction column after dilution where DM Water & Recycle Spent Lesse from Rectifier Bottom is used. In extraction column most of the high boiling impurities separate from ethanol in presence of water. The bottom ethanol water mixture is pre-heated by steam condensate and spent Leese before being fed to rectifier column. In rectifier column product rectified spirit is taken out from top tray and fed to refining column where mainly methanol impurities are separated. Pure ENA is obtained at bottom, which is cooled and stored. The impure spirit from top of extraction column, rectifier column and refining column are fed to heads column. The final impure spirit cut is taken out from heads column top and balance alcohol is recycled to pre-rectifier column. The alcohol containing fusel oil from pre-rectifier and rectifier column is fed to fusel oil column.

The rectifier column, fusel oil column and pre-rectifier column get heat from steam at 3.5 bar (g).

Rectification column and pre-rectifier column works under positive pressure. The top vapours from rectifier column are condensed in stripper column for giving heat to stripper re-boiler. Most of the other columns work under vacuum.The Distillation process is operated through PLC

7] PROCESS DESCRIPTION FOR FA

Rectified Spirit at Azeotropic concentration is pumped by Feed Pump. This pump takes care of the entire backpressure of the system. The pump is in Stainless Steel material of construction for wetted parts complete with flameproof motor and mechanical seal.

The rectified spirit will first pass through feed Preheater (E-401), which will pass through vaporizer cum super heater (E-402) which will convert the Rectified Spirit feed to superheated Alcohol vapour stream ready to feed

to the Molecular Sieve bottles. The degree of superheat is control via a temperature control loop and the flow rate to the plant is control via flow control loop. The superheated vapours will pass through a Sieve bottle, which is already regenerated, and pressurize to working pressure via. a bleed flow from an operating sieve bottle. After the drying cycle the flow will be shifted to the next Sieve bottle, which is ready after duly regenerated and pressurize. This sequence minimizes the rate of rise and fall of pressure through the molecular sieve. Thus minimizing the attrition of the sieve beads. The sieve column after completion of drying cycle is evacuated to remove the adsorb water through an evacuation system via a condenser.

The mixture of Alcohol and water is preheat by Anhydrous Alcohol Vapour in Plate Heat Exchanger (E-405) before being feed to Recovery Column, which enriches the stream back to azeotropic composition. The bottom of recovery column get heat from partly by condensing Anhydrous Alcohol Vapour in Shell & Tube Heat Exchanger (E-407) & by steam in Shell & Tube Heat Exchanger (E-408) The Anhydrous Alcohol vapours condensed in product cooler. A flow indicator indicates the rate of Anhydrous Alcohol going to the Anhydrous Alcohol receivers

Annexure – VI

ADVANTAGES OF THREE BED SYSTEM

Rate of change of pressure from Atmospheric to Vacuum is less as the Regeneration is carried out in more time. Because of additional bed available for Regeneration, this enables almost complete Regeneration of bed and requires less sweep (Reversing movement of Anhydrous Alcohol Vapour, Dried Alcohol Vapour). This means the amount of Alcohol in recycle is less. Also, the amount of product fluctuation in vapor flow is minimum. Thus the system acts as continuous steady state system. Since the movement of bed is lower due to lower rate of change of pressure, the life of Sieve is better (due to less attrition).

Theoretically, in more number of beds, (even more than three) which works individually for individual functioning, like drying, depressurization, regeneration and sweep will always be better than when these functions are done by smaller number of beds. For e.g. if you use only one bed, then there will be disruption of product vapour flow completely when bed is under depressurization and regeneration.

Annexure – VII

1. CONTINUOUS CASCADE FERMENTATION SECTION

1.1 Molasses Handling Section

Sr.No. Description Technical Specification

1. Day Molasses Tank (T-101)a. Capacity 75 m3

b. Material of Construction MSc. Thickness 6 mmd. Quantity 1 No.

2. Automatic Molasses Weighing System with check Weighment and tank

(T-102)a. Accessories Load cellc. Quantity 1 No.

3. Weighed Molasses Receiving Tank (T-103)

a. Capacity 4 m3

b. Material MSc. Thickness - Shell/Bottom/Top 6 mmd. Quantity 1 No.

1.2 Yeast Propagation Section

1. Jacketed Yeast Vessel (YV 101)a. Capacity 150 litb. Material of Construction shell / jacket SS 304/Mild steelc. Accessories Nozzles for SG,LG

Pressure indicator, Temperature indicator, Safety valve, Air spurges etc.

d. Quantity 1 No. 2. Jacketed Yeast Vessel (YV 102)

a. Capacity 1500 litb. Material of Construction shell / jacket SS 304 / Mild steelc. Accessories Nozzles for SG, LG,

Pressure indicator,

Temperature indicator, LG, Safety valve, Air spurges etc.

d. Quantity 1 No. 3. Yeast Vessel (YV 103)

a. Capacity 15 m3

b. Material of Construction Mild Steelc. Accessories Nozzles for SG, LG,

Pressure indicator,Temperature indicator, LG, Safety valve, Air spurges, Diffuser etc

d. Quantity 1 No.

4. Molasses Dilutera. Material of Construction SS 304b. Quantity 3 Nos.

1.3 Fermented Wash Preparation Section 1. Fermenters

a. Capacity 180 m3 Geometric volume

b. Material of Construction MS PU coated

c. Thickness 6 mm

d. Accessories Nozzles for Fermented Wash In, Out,CO2 Outlet, H2SO4, TRO, Biocide,Nutrient, Manhole

e. Quantity 3 Nos.

2 Fermenter Coolera. Type Plate Heat Exchanger

b. Material of Construction SS 316 Plate / MS Frame

c. Quantity 3 Nos.

1.4 Fermented Wash Post Clarification Section 1. Wash Settling Tank

a. Capacity 20 m3

b. Material of Construction MS with PU coatingc. Accessories Lamellar Assembly

c. Quantity 1 No.

2. Sludge Tanka. Capacity 1 m3

b. Material of Construction Mild Steelc. Quantity 1 No.

3. Clarified wash tanka. Capacity 30 m3

b. Material of Construction MS with PU coatingc. Quantity 1 No.

4. Sludge Settling tank (For option without Yeast Recycle)a. Capacity 5 m3

b. Material of Construction MS with PU coatingc. Quantity 1 No.

5. Decanter for sludge separation (Optional)

a. Type Centrifugalb. Material of Construction SS 304 [contact parts]c. Quantity 1 No.

1.5 Yeast Recycle System 1. Yeast Separator

a. Capacity 25 m3/hrb. Material of Construction SS 316c. Accessories Base Frame with motor, Yeast

Trough, etcd. Quantity 1 No.(Working) + 1 No. (standby)

2. Yeast Cream cum Acidification Tank with agitatora. Capacity 1.5 m3

b. Material of Construction SS 304c. Quantity 1 No.

3. Yeast Activation Tanka. Capacity 2 m3


1.6 Auxiliaries 1 Anti Foam Agent Tank

a. Capacity 1 m3

b. Material MSc. Quantity 1 No.

2 Nutrient Mixing tank with Agitatora. Capacity 1.0 m3

b. Material SS 304c. Quantity 1 No.

3 CO2 Scrubbera. Overall dimensions Dia.425 mm x 3000 mm Heightb. Material of Construction SS 304c. Type of Plate Sieved. Quantity 1 No.

1.7 Utility

1. Cooling tower for Fermentation a. Operating UT 2 Cb. Material of construction FRPc. Quantity 1 no.

2. Liquid ring blowera. Capacity 360 m3/hrb. Accessories HEPA Filter, Motor, Base frame

etc.c. Quantity 1 + 1 No.

Note: All dimensions and specifications are indicative. The specifications may vary after detailed design and engineering.

Annexure – VIII

2. MULTI PRESSURE DISTILLATION SECTION2.1 Columns 1. CO2 Stripping column (Under Vacuum) (RS/ENA)

a. Diameter 900 mmb. Material of Construction SS 304c. Type of Tray RH Grid d. No. of Trays 12e. Thickness Shell / Tray 4 mm / 2.5 mm

2. Stripping Column (Under Vacuum) (RS/ENA)a. Diameter 1,410 mmb. Material of Construction SS 304c. Type of Tray RH Gridd. No. of Trays 22e. Thickness Shell / Tray 4 / 2.5 mm

3. Prerectifier Column (Under Pressure) (ENA)a. Diameter 1,150 mmb. Material of Construction SS 304 / SS304 / SS304

Shell / Tray / B.Capc. Type of Tray Bubble capd. No. Of Trays 55e. Thickness [Shell / Tray / Cap] 4 / 2.5 / 1.6 mm

4. Extraction Column (Under Vacuum) (ENA)Diameter 1,150 mmMaterial of Construction Shell / Tray / B.Cap SS 304 / SS304 / SS304Type of Tray Bubble capNo. Of Trays 44Thickness [Shell / Tray / Cap] 4 / 2.5 / 1.6 mm

5. Rectifier Column (Under Pressure) (RS/ENA)Diameter 1,260 mmMaterial of Construction SS 304 / DOCShell / Tray / B.CapType of Tray Bubble cap

No. Of Trays 72 (37 DOC & 35 SS304)

Thickness [Shell / Tray / Cap] 4 / 2.5 / 1.6 mm

6. Refining Column (ENA)Diameter 700 mmMaterial of Construction DOC / DOC / DOCShell / Tray / B.CapType of Tray Bubble capNo. Of Trays 55Thickness [Shell / Tray / Cap] 4/ 2.5 / 1.6 mm

7. Fusel Oil ColumnDiameter 750 mmMaterial of Construction SS 304 / SS304 / SS304Shell / Tray / B.CapType of Tray Bubble capNo. Of Trays 72Thickness [Shell / Tray / Cap] 3 / 2.5 / 1.6 mm

2.2 Tanks

1. Cold water tanka. Capacity 15 m3

b. Material of Construction Mild steelc. Quantity 1 No.

2. Hot water Headera. Material of Construction Mild steelb. Quantity 1 No.

3. Prerectifier Reflux tanka. Capacity 2 m3


4. Rectifier Reflux tanka. Capacity 2 m3


5. Fusel Oil tanka. Capacity 1 m3


6. Steam Condensate tank

a. Capacity 2.5 m3

b. Material of Construction Mild Steelc. Quantity 1 No.

7. Fusel Oil De-cantera. Capacity 100 ltr.b. Material of Construction SS 304c. Quantity 1 No.

2.3 Shell & Tube Heat Exchangers

1. Re-boiler for Stripping Columna. Heat transfer area 115 m2

b. Material of construction shell / tube / SS 304/ SS 304 / Mild flange steel c. Tube (ERW) 38.1mm OD x 1.6 mm thkd. Quantity 1Nos.

2. Re-boiler for Prerectifier Columna. Heat transfer area 55 m2

b. Material of Construction shell / tube / Mild Steel / SS304 / flange Mild Steelc. Tube (ERW) 38.1mm OD x 1.6mm thkd. Quantity 1 No.

3. Re-boiler for Extraction Columna. Heat transfer area 40 m2

b. Material of Construction shell / tube / SS304 / SS304 / Mild flange Steelc. Tube (ERW) 38.1mm OD x 1.6mm thkd. Quantity 1 No.

4. Re-boiler for Rectifier Columna. Heat transfer area 100 m2

b. Material of Construction shell / tube / Mild Steel / SS304 / Mild Steel flangec. Tube (ERW) 38.1mm OD x 1.6mm thkd. Quantity 1 No.

5. Re-boiler for Refining Column

a. Heat transfer area 16 m2

b. Material of Construction shell / tube / SS304 / SS304 / Mild flange Steelc. Tube (ERW) 38.1mm OD x 1.6mm thkd. Quantity 1 No.

6. Re-boiler for Fusel Oil Columna. Heat transfer area10 m2b. Material of Construction shell / tube / Mild Steel / SS304 / Mild flange Steelc. Tube (ERW) 38.1mm OD x 1.6mm thk

d. Quantity 1 No.

7. Degasser CondenserHeat transfer area 7 m2

Material of Construction shell / tube / flange, SS 304 / SS 304 / Mild steelBonnet , Dished EndTube (ERW) 25.4mm OD x 1.6mm thkQuantity 1 No.

8. Vent Condenser for CO2 Strippera. Heat transfer area 4 m2

b. Material of Construction shell / tube / SS 304 / SS 304 / Mild steel flange, Bonnet , Dished End

c. Tube (ERW) 25.4mm OD x 1.6mm thkd. Quantity 1 No.

9. Beer Heater (For option without integrated Evap.)


b. Material of Construction shell / tube / SS 304 / SS 304 / Mild steel flangec. Tube (ERW) 25.4mm OD x 1.6mm thkd. Quantity 1 No.

10 Main Condenser for Stripper (For option without integrated Evap.)


b. Material of Construction shell/tube/ SS 304 / SS 304 / Mild steel flange, Bonnet , Dished End

c. Tube (ERW) 25.4mm OD x 1.6mm thkd. Quantity 1 No.

11 Vent Condenser for Stripper


b. Material of Construction shell/tube/ SS304 / SS304 / Mild steel flange, Bonnet , Dished Endc. Tube (ERW) 25.4mm OD x 1.6mm thkd. Quantity 1 No.

12 Main Condenser for Prerectifiera. Heat transfer area 6 m2


13 Vent Condenser for Prerectifiera. Heat transfer area 8 m2

b. Material of Construction shell/tube/ SS304 / SS304 / Mild steelflange, Bonnet , Dished Endc. Tube (ERW) 25.4mm OD x 1.6mm thkd. Quantity 1 No.

14 Main Condenser for Extraction (For option without integrated Evap.)



15 Main Condenser for Extractiona. Heat transfer area 6 m2

b. Material of Construction shell/tube/ SS304 / SS304 / Mild steel flange, Bonnet , Dished Endc. Tube (ERW) 25.4mm OD x 1.6mm thk

d. Quantity 1 No.

16 Vent Condenser for Rectifiera. Heat transfer area 8 m2


17 Main Condenser for Refininga. Heat transfer area 10 m2

b. Material of Construction shell/tube/ DOC / DOC / Mild steel flange, Bonnet , Dished Endc. Tube (ERW) 25.4mm OD x 1.6mm thkd. Quantity 1 No.

18 Vent Condenser for Refininga. Heat transfer area 5 m2


19 Main Condenser for Fusel Oil (For option without integrated Evap.)a. Heat transfer area 17 m2


20 Vent Condenser for Fusel Oila. Heat transfer area 5 m2

b. Material of Construction shell/tube/ SS304 / SS304 / Mild steelflange, Bonnet , Dished Endc. Tube (ERW) 25.4mm OD x 1.6mm thkd. Quantity 1 No.

21 Vent Scrub Heat Exchangera. Heat transfer area Suitableb. Material of Construction shell/tube/ SS 304 / SS 304 / Mild steel

flange, Bonnet , Dished Endc. Tube (ERW) 25.4mm OD x 1.6mm thkd. Quantity 1 No.

22 ENA Coolera. Heat transfer area 12 m2


23 Rectified Spirit Cooler


b. Material of Construction shell/tube/ SS 304 / SS 304 / Mild steel flange, Bonnet , Dished Endc. Tube (ERW) 25.4mm OD x 1.6mm thkd. Quantity 1 No.

24 Impure Spirit Coolera. Heat transfer area Suitableb. Material of Construction shell/tube/ SS 304 / SS 304 / Mild steel flange, Bonnet , Dished Endc. Tube (ERW) 25.4mm OD x 1.6mm thkd. Quantity 1 No.

25 Fusel Oil Coolera. Heat transfer area Suitableb. Material of Construction shell/tube/ SS 304 / SS 304 / Mild steel flange, Bonnet , Dished Endc. Tube (ERW) 25.4mm OD x 1.6mm thk

d. Quantity 1 No.

2.3.1 Plate Heat Exchangers

1. Plate Heat Exchangers for PreheatingPrerectifier & Rectifier Feeda. Material of Construction Plate – SS316, Frame – MS with

anticorrosive coatingb. Quantity 4 Nos.

2. Plate Heat Exchangers for preheating (FeedPre Heating - Fermented Wash)a. Material of Construction Plate – SS316, Frame – MS with

anticorrosive coating

b. Quantity 1 No. (for option without IntegratedEvaporator) &2 Nos. (for option with IntegratedEvaporator)

3 Plate Heat Exchangers for Preheating (Week Bear Recycle Cooler)a. Material of Construction Plate – SS316, Frame – MS with

anticorrosive coatingb. Quantity 1 No.

2.4 Utility1. Cooling tower for distillation + Evaporation + Weak Bear Recycle +

Dehydration Planta. Operating T 8 Cb. Material of construction FRP/Woodc. Quantity 1 no.

2. Air Compressora. Capacity 40 m3/hrb. Accessories Pressure Switch, Air Dryer etc.c. Quantity 1 no.


Annexure – IX

3.0 SPENT WASH EVAPORATOR INTEGRATED WITH DISTILLATION (for Concentration up to 24%)

3.1 Equipments 1 Evaporator Calendria

a. Type Multiple effect Falling Filmb. Material of Construction Shell SS 304/ mild steel

Tubes SS 304c. Quantity 4 Nos.

2 Vapour Separatora. Material of Construction SS 304b. Quantity 4 Nos.

3 Barometric Condensera. Material of Construction SS304b. Type Shell & Tubec. Quantity 1 No.

3.2 Auxiliary1 Vapour Duct

a. Material of Construction SS304

2 Piping fora. Condensate, non-condensate SS304b. Product, etc. SS 304

Note: All dimensions and specifications are indicative. The specifications may vary after detailed design and engineering

Annexure –X

4.0 TECHNICAL SPECIFICATION FOR PLANT AND MACHINERY FOR 30 KLPD ANHYDROUS ALCOHOL PLANT BASED ON MOLECULAR SIEVE TECHNOLOGY

5.1 Equipments

1. Adsorber bed with molecular sieve packing and internalsa. Over all dimension ø 800 mmb. Material of Construction Mild Steelc. Thickness 6 mmd. Quantity 3 Nos.

2. Recovery Columna. Over all dimension ø 508b. Material of Construction AISI 304c. Thickness shell / tray / cap 3 / 2.5 / 1.6 mmd. Quantity 1 No.

3.2 Heat Exchanger

3. Feed Sieve Vaporizer cum Super Heatera. Type Shell and tubeb. Heat transfer area Suitablec. Material of Construction shell/tube MS / AISI 304d. Thickness shell / tube 6 / 1.6 mme. Quantity 1 No.

4. Recovery Column Re-boiler 1Type Shell and tubeHeat transfer area SuitableMaterial of Construction shell / tube MS / AISI 304Thickness shell / tube 6 / 1.6 mma. Quantity 1 No.

5. Recovery Column Re-boiler 2

Type Shell and tubeHeat transfer area SuitableMaterial of Construction shell / tube AISI 304 / AISI 304Thickness shell / tube4 / 1.6 mm

b. Quantity 1 No.

3.2.1 Plate Heat Exchanger

6. Feed Economizera. Type Plate heat exchangerb. Plate material SS 316c. Frame material PHE M. S duly paintedd. Plate thickness 0.5 mme. Quantity 1 No

7. Regeneration Coolera. Type Plate heat exchangerb. Plate material SS 316c. Frame material M S duly paintedd. Plate thickness 0.5 mme. Quantity 1 No.

8. Product Coolera. Type Plate heat exchangerb. Plate material SS 316c. Frame material M S duly paintedd. Plate thickness 0.5 mme. Quantity 1 No.

9. Regenerating Condensera. Type Plate heat exchangerb. Plate material SS 316c. Frame material M S duly paintedd. Plate thickness 0.5 mme. Quantity 1 No.

10. Proof Condensera. Type Plate heat exchangerb. Plate material SS 316c. Frame material M S duly paintedd. Plate thickness 0.5 mme. Quantity 1 No.

3.3 Tanks

11. Regeneration Tanka. Capacity 650 ltrs.b. Material of construction AISI SS 304

c. Thickness 2 mmd. Quantity 1 No.

12. Reflux Tanka. Capacity 50 ltrs.b. Material of construction AISI SS 304c. Thickness 2 mmd. Quantity 1 No.

3.4 Auxiliary

13. Vacuum EductorType Liquid Jet EductorMaterial of Construction BronzeQuantity 1 No.

14. Chilling plant with pump, motors / starters/ push buttonsMaterial of construction Mild steelMake Premier / EquivalentQuantity 1 no.


Annexure – XIPumps & Motors

1.1 Fermentation Section

Sr. No.

Pump Qty Type Flow Rate (m3/hr)

Head(mWc)

Shaft Seal MOC

1. Raw Molasses Transfer Pump

1 Gear 6 MT 30 -- Contact Part – CI Case-CI

2. Fermenting WashCirculation Pump

1 Centrifugal 120 15 Single Mech. Contact Part-SS304Case-SS304

3. Fermenting Wash Circulation Pump


4. Fermenting Wash Circulation Pump


5. Clarified Wash Transfer Pump


6. Sludge Transfer Pump

2 Screw 1 15 Single Mech. Contact Part-SS304Case-SS304

7. Nutrient Dosing Pump

2 Metering 0.5 15 Gland PTFE Contact Part-SS304Case-SS304

8. TRO Dosing Pump

2 Metering 0.5 15 Gland PTFE Contact Part-SS304Case-SS304

9. Cooling Water 2 Centrifugal 310 18 Gland Packing

Contact Part-SS304Case-SS304

1.2 Yeast Recycle Section

Sr. No.


Head(mWc)

Shaft Seal MOC

1. Yeast Cream Pump


1.3 Multi Pressure Distillation (RS/ENA)

Sr. No.


Head(mWc)

Shaft Seal MOC

1. CO2 Stripper Reflux Pump


2. Stripper Bottom Pump (Spent Wash)


3. Prerectifier Feed Pump


4. Prerectifier Reflux Pump


5. Rectifier Feed Pump


6. Rectifier Reflux Pump


7. Fusel Oil Column Feed Pump


8. Condensate Transfer Pump

2 Centrifugal 6 15 Gland packing

Contact Part-MSCase-CI

9. Axial Flow Pump 1 -- Suitable 6 Double Mech. Contact Part-SS304Case-SS304

10. Cooling Water Pump

2 Centrifugal 375 25 Gland Packing

Contact Part-CICase-CI

11. Vacuum Pump 2 -- 20 -- Body-CIContact Part-SS304

1.4 Integrated Evaporation Section

Sr. No.


Head(mWc)

Shaft Seal MOC

1. Circulation Pump for Calendria I

1 Centrifugal Suitable 15 Double Mech. Contact Part-SS304Case-SS304

2. Circulation Pump for Calendria II


3. Circulation Pump for Calendria III


4. Circulation Pump for Calendria IV


5. Condensate Transfer Pump

2 Centrifugal Suitable 15 Single Mech. Contact Part-SS304Case-SS304

6. Stripper Distillate Pump


7. Extraction Distillate Pump


8. FOC Reflux Pump


9. Vacuum Pump 2 -- Suitable -- Body-CIContact Part-SS304

10. Feed Pump 2 Centrifugal Suitable 35 Double Mech. Contact Part-SS304Case-SS304

1.5 Dehydration Plant

Sr. No.


Head(mWc)

Shaft Seal MOC

1. R.S. Feed Pump 2 Multi Stage 4 65 Single Mech. Contact Part-SS304Case-SS304

2. Regeneration Pump

2 Multi Stage 22 85 Single Mech. Contact Part-SS304Case-SS304

3. Proof Pump 2 Multi Stage 2.5 20 Single Mech. Contact Part-SS304Case-SS304

Note: All specifications are indicative. The specifications may vary after detailed design and engineering.

Annexure – XII

INSTRUMENTATION, PIPING & VALVES

1.1 FERMENTATION

1 Magnetic Flow Meter 22 Glass Tube Rota meter 123 Metal Tube Rota meter 44 Pressure Gauges 255 Temp Element 136 On / Off Valve 2

1.2 DISTILLATION (RS/ENA)

1 Temp Element 582 Pressure Transmitter 73 Pressure Gauges 224 Level Transmitter 95 Glass Tube Rota meter 246 Metal Tube Rota meter 107 Control Valve (Level, Pressure, Temp) 19

1.3 DEHYDRATION

1 Temp Element 232 Pressure Transmitter 43 Pressure Gauges 224 Level Transmitter 95 Glass Tube Rota meter 246 Metal Tube Rota meter 97 Control Valve (Level, Pressure, Temp) 6

1.4 INTEGRATED EVAPORATOR

1 Level Transmitter 32 Control Valve 33 Pressure Gauge 124 RTD 4

1.5 Motor Control Centre for Fermentation, Multi Pressure Distillation, Integrated Evaporator, Dehydration Plant

1.5.1 a. Material of Construction MS CRCAb. Quantity 1 No.

c. Accessories Electrical like Relay, Fuses, Starter, Pushbuttons, Indicating Lamps, etc.

1.6 PLC for Multi Pressure Distillation, Integrated Evaporator, Dehydration

1.6.1 PLC Modules and Rack, Software (SCADA)For Multipressure Distillation, Integrated 1 Set.Evaporator,Communication Cable 1 LotPC with Monitor and Printer 1 No.

Piping1. Molasses MS ‘B’ Class

Acid PPNutrient SS304CO2 PVC/HDPEYeast_ SS304Sludge SS304Fermented Wash SS304Spent Wash SS304Instrument Air GIExtra Neutral Alcohol SS304 up to CoolerRectified Spirit SS304 up to CoolerFuel Alcohol SS304 up to CoolerFusel Oil SS304 up to DecanterImpure Spirit SS304 up to CoolerSteam MS ‘C’ ClassSteam Condensate MS ‘C’ ClassSpent Lesse SS304Cooling Water Supply MS ‘B’ ClassCooling Water Return MS ‘B’ ClassVacuum SS304

Valves

2. Above 50 NB Butterfly ValveUp to 50 NB Ball Valve

MOCa. SS304 Piping Contact Part SS304,

Non Contact Part CI

b. MS Piping CI

Note: All specifications are indicative. The specifications may vary after detailed design and engineering.

Bhairav Nath Pre Feasibility Report

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