FOR 55 KLPD GRAIN BASED DISTILLERY ALONG WITH...

Proposed 55 KLPD Grain Based Distillery along with 2.0 MW Co-generation Power Plant at Plot No. B - 2/6 & B – 2/7, UPSIDC Industrial Area, Sandila Phase IV, Lucknow Hardoi Road, Tehsil Sandila, District Hardoi, Uttar Pradesh by Shri Gang Industries and Allied Products Limited

PRE FEASIBILITY REPORTPRE FEASIBILITY REPORTPRE FEASIBILITY REPORTPRE FEASIBILITY REPORT

FOR

55 KLPD GRAIN BASED DISTILLERY

ALONG WITH

2 MW CO-GENERATION POWER PLANT At

PLOT NO. B - 2/6 & B – 2/7, UPSIDC INDUSTRIAL AREA, SANDILA

PHASE IV, LUCKNOW HARDOI ROAD, TEHSIL SANDILA,

DISTRICT HARDOI, UTTAR PRADESH

SHRI GANG INDUSTRIES & ALLIED PRODUCTS LTD.



PRE-FEASIBILITY REPORT

1.0 INTRODUCTION

Earlier, the assessment of the projects was done on Technical feasibility reports and Cost-Benefit-Ratio which mainly considered financial & technical resources. But no consideration was given to the environment protection in this evaluation and these flaws became apparent with continuous deterioration of environment. Thus in order to have more realistic evaluation, and keeping in view the deteriorating conditions, another dimension was added which is now called as “Environmental Impact Assessment” (E.I.A.). This forms an integral part of the project and is taken into account while appraising the project at different stages. Thus in the new comprehensive approach all considerations like, Technical, Financial & Environmental are given due weightage. M/s Shri Gang Industries & Allied Products Ltd. is proposing to install 55 KLPD Grain based Distillery along with 2 MW Co-generation Power Plant at Plot No. B - 2/6 & B – 2/7, UPSIDC Industrial Area, Sandila Phase IV, Lucknow Hardoi Road, Tehsil Sandila, District Hardoi, Uttar Pradesh. As per EIA Notification dated 14.09.2006 and as amended from time to time, the project falls in Cat. ‘B’, S. No. - 5(g), as capacity is 55 KLPD Grain Based alcohol production. They have to submit Form-I along with Pre-Feasibility Report and other relevant documents for getting Environmental Clearance. This pre-feasibility report has, therefore, been prepared by the consultant to assess the likely impact of the proposed on various factors which may be affected with the implementation of the program me and to suggest remedial/precautionary measures, if any.

2.0 PROFILE OF THE COMPANY & PROMOTORS.

U.P. State Industrial Development Corporation Ltd. has allotted the land admeasuring 11.9 acres (12.17 hectare / 121743.47 sq.m.) to Shri Gang Industries & Allied Products Ltd. M/s Shri Gang Industries and Allied Products Ltd. registered office is situated at Sikandrabad, District: Bulandshahr (U.P.). Shri Gang Industries and Allied Products Limited management comprises the following directors:

1) Janeshwar Kumar Jain 2) Gyan Chand Jain 3) Narendra Singh Bisht 4) Rajesh Kumar Gupta 5) Suchi Bahl 6) Syed Azizur Rahman.

REGISTERED OFFICE: A-26, UPSIDC Indl.Area, Sikandrabad, Dist: Bulandshahr-203205, U.P.

3.0 BASELINE ENVIRONMENTAL SETTING

3.1 The State

Uttar Pradesh abbreviated as UP, is a state located in Northern India. It was created on 1 April 1937 as the United Provinces, and was renamed Uttar Pradesh in 1950. Lucknow is the capital city of Uttar Pradesh. Ghaziabad, Kanpur, Gorakhpur, Allahabad, Raebareli, Moradabad, Bareilly, Aligarh, Sonbhadra and Varanasi are known for their industrial importance in the state. On 9 November 2000, a new state, Uttarakhand, was carved out from the Himalayan hill



region of Uttar Pradesh. The state is bordered by Rajasthan to the west, Haryana and Delhi to the northwest, Uttarakhand and the country of Nepal to the north, Bihar to the east, Madhya Pradesh to the south and touches the states of Jharkhand and Chhattisgarh to the south east. It covers 243,290 square kilometres (93,933 sq mi), equal to 6.88% of the total area of India, and is the fourth largest Indian state by area. With over 200 million inhabitants in 2011, it is the most populous state in the country as well as the most populous country subdivision in the world. Hindi is the official and most widely spoken language in its 75 districts. Uttar Pradesh is the third largest Indian state by economy, with a GDP of ₹9763 billion (US$150 billion). Agriculture and service industries are the largest parts of the state's economy. The service sector comprises travel and tourism, hotel industry, real estate, insurance and financial consultancies. Uttar Pradesh was home to powerful empires of ancient and medieval India. The two major rivers of the state, the Ganges and Yamuna, join at Allahabad and then flow as the Ganges further east. The state has several historical, natural, and religious tourist destinations, such as the Agra, Varanasi, Piprahwa, Raebareli, Kaushambi, Kanpur, Ballia, Shravasti, Gorakhpur, Unnao, Chauri Chaura situated in Gorakhpur, Kushinagar, Lucknow, Jhansi, Allahabad, Budaun, Meerut, Mathura, Jaunpur and Muzaffarnagar Uttar Pradesh, with a total area of 243,290 square kilometres (93,935 sq mi), is India’s fourth largest state in terms of land area. It is situated on the northern spout of India and shares an international boundary with Nepal. The Himalayas border the state on the north, but the plains that cover most of the state are distinctly different from those high mountains. The larger Gangetic Plain region is in the north; it includes the Ganges-Yamuna Doab, the Ghaghra plains, the Ganges plains and the Terai. The smaller Vindhya Range and plateau region is in the south. It is characterised by hard rock strata and a varied topography of hills, plains, valleys and plateaus. The Bhabhar tract gives place to the terai area which is covered with tall elephant grass and thick forests interspersed with marshes and swamps. The sluggish rivers of the bhabhar deepen in this area, their course running through a tangled mass of thick undergrowth. The terai runs parallel to the bhabhar in a thin strip. The entire alluvial plain is divided into three sub-regions. The first in the eastern tract consisting of 14 districts which are subject to periodical floods and droughts and have been classified as scarcity areas. These districts have the highest density of population which gives the lowest per capita land. The other two regions, the central and the western are comparatively better with a well-developed irrigation system.They suffer from waterlogging and large-scale user tracts. In addition, the area is fairly arid. The state has more than 32 large and small rivers; of them, the Ganges, Yamuna, Saraswati, Sarayu, Betwa, and Ghaghara are larger and of religious importance in Hinduism. Cultivation is intensive. The valley areas have fertile and rich soil. There is intensive cultivation on terraced hill slopes, but irrigation facilities are deficient. The Siwalik Range which forms the southern foothills of the Himalayas, slopes down into a boulder bed called 'bhadhar'. The transitional belt running along the entire length of the state is called the terai and bhabhar area. It has rich forests, cutting across it are innumerable streams which swell into raging torrents during the monsoon.

3.2 District: Hardoi

Hardoi district is a district of Lucknow Commissionaire in Uttar Pradesh Province of India. It is situated in between 26-53 to 27-46 North Latitude and 79-41 to 80-46 East Longitude. Its north border touches Shahjahanpur & Lakhimpur Kheri districts, Lucknow ( capital of U.P ) & Unnao are situated at south border, West borders touches Kanpur (Industrial City of U.P) & Farrukhabad and on eastern border Gomati river separates the district from Sitapur. Nemisharayan the Pilgrim of Dwapar age is just 45 km away from district headquarter. The length of this district from northwest to southeast is 125.529 km and width from east to west is 74.83 km. District Hardoi comprises of 5 tehsils ( Hardoi, Shahabad, Bilgram, Sandila &



Sawayajpur), 19 blocks, 191 Nyay Panchayat , 1101 Gram Sabha & 1901 habited revenue villages. It also has 7 Nagar Palika Parishads & 6 Nagar Panchayats . Geographical area is 5947 sq. km. As per census 2011 population of the district is 4091380, out of which Female are 1887116 & Male are 2204264

3.3 Project Site

The Plant site is located at Plot No. B - 2/6 & B – 2/7, UPSIDC Industrial Area, Sandila Phase IV, Lucknow Hardoi Road, Tehsil Sandila, District Hardoi, Uttar Pradesh. Project Site is 0.4 km from the nearest state high way SH-25. Nearest railway station is Sandila railway station which is 8.0 Km towards SE from the project site. Nearest airport is Lucknow which is 57 Km away from the project site (aerial distance). Nearest city which is densely populated is Sandila which is 8 Km away from the project site. Sandila is easily accessible by roads and railways network.

4.0 PROJECT DESCRIPTIONS

4.1 General

The Plant site is located at Plot No. B - 2/6 & B – 2/7, UPSIDC Industrial Area, Sandila Phase IV, Lucknow Hardoi Road, Tehsil Sandila, District Hardoi, Uttar Pradesh. Total Project area is 12.17 hectare. The total cost of the project is Rs. 90.00 Crores. PRODUCT DESCRIPTION, PROPERTIES AND SPECIFICATIONS :

Alcohol can be considered as a derivative of water in which one hydrogen is replaced by hydrocarbon radical (R).

H – OH + R R – OH

When only one hydroxyl group is introduced with a hydrocarbon chain, the resulting compound is monohydric alcohol.

CH3CH2 + (OH) CH3 CH2OH (Ethyl alcohol).

Monohydric alcohol can also be considered a hydrocarbon in which one atom of hydrogen is replaced by an OH group.

This is illustrated as follows:

C2H5H + H2O C2H5OH + H2

Ethane Ethanol

Ethyl alcohol is a clear, colourless, neutral and homogeneous liquid of molecular weight 46.87 which has an agreeable but pungent odour and sharp burning taste. Industrial alcohol is a mixture of Ethyl alcohol and water (usually 95% ethanol and 5% water by volume).

From commercial point of view the following grades of Alcohol are of interest which is obtained from industrial alcohol or rectified spirit.

Various grades of alcohol for different applications are as below:

1) Industrial alcohol or Rectified spirit. 2) Absolute Alcohol – Ethanol / Ethyl Alcohol.



3) Denatured Spirit / Special Denatured Spirit. 4) Extra Neutral Alcohol / Grain Neutral Spirit. 5) Perfumery grade alcohol.

For industrial alcohol, there are two grades, namely “Grade I” and “Grade II” conforming to IS:323 – 1959 (Revised). The alcohol conforming to “Grade I” shall be suitable for use as a reagent for pharmaceutical and medicinal purpose and for the production of alcoholic beverages. “Grade II” will be used for other industrial purposes.

PHYSICAL PROPERTIES OF ETHANOL

Sr.

No. Description

Absolute Alcohol 99.5%

v/v

Industrial Alcohol 95%

v/v

1 Boiling Point in oC 78.40 78.20

2 Flash Point oC 21.00 22.00

3 Viscosity at 20oC 1.22 1.41

4 Vap Pressure at 20oC,mm Hg. 44.80 43.00

5 Surgace tension at 20oC dynes/cm

22.30 22.00

6 Specific Heat at 20oC 0.58 0.62

7 Refractive Index 1.36 1.37

8 Ignition Temp. in air oC 371.43 -

9 Heat of Vaporisation, Cal/gm 284.30 -

10 Specific Gravity at 20 / 20 0.7908 0.8030

SPECIFICATIONS FOR RECTIFIED SPIRIT AS PER IS 323 – 1959

Sr.

No.

Characteristic Requirement for

Grade – I Grade – II

1 Specific gravity at 15.6oC / 15.6oC (or 60 / 60oF) max. 0.8171 0.8171

2 Ethanol content :

a) Percent by volume at 15.6oC (or 60oF) Min. b) Degrees over-proof, min.

94.68

66

94.68

66

3 Miscibility with water Miscible Miscible

4 Alkalinity NIL NIL

5 Acidity (as CH3COOH) percent by weight, max. 0.0002 0.01



6 Residue on evaporation, percent by weight, max. 0.005 0.01

7 Aldehyde content (as CH3 CHO), 9 per 100 ml. Max 0.005 0.01

8 Ester content (as CH3 COOC2H5), 9 per 100 ml. max. 0.02 -

9 Copper (as Cu.) 9 per 100 ml. max 0.006 0.10

10 Lead (as Pb), 9 per 100 ml.max. 0.0001 -

11 Methyl alcohol content To satisfy the requirement of the test

12 Fusel oil content - do - -

13 Furfural content - do - -

REQUIREMENTS FOR GRAIN NEUTRAL SPIRIT (ENA) FOR ALCOHOL DRINKS

S.no Characteristic Requirement

1 Relative density at 15/15oC 0.81245 to 0.81679

2 Ethanol content, percent by volume at 15.6oC 94 to 96

3 Miscibility with waters Miscible

4 Alkalinity NIL

5 Acidity (as (CH3COOH), gm / 100 ml. max. 0.002

6 Residue on evaporation, gm./200 ml. max. 0.002

7 Esters (as CH3COOC2H5) gm./200 ml. max. 0.01

8 Lead (as Pb), gm./100 ml.

9 Methyl alcohol content To pass test

10 Further content To pass test

11 Aldehyde (as CH3CHO), am./100 ml. max. 0.004

12 Permagnate reacting time, Minutes min. 30

13 Copper (as Cu.), gm./100 ml. 0.0002

14 Isopropyl alcohol, acetone and other Kethones To pass test

SPECIAL REQUIREMENT FOR NEUTRAL SPIRIT FOR VODKA MANUFACTURE:

SR. NO. Characteristic Requirement



1 Esters (as CH3COOC2H5) 0.005

2 Higher alcohols (as Amyl alcohol) percent by volume 0.03

3 Aldehyde (as CH3CH9) gm./110 ml. max. 0.002

4 Furfural (expressed in terms of 100 litres of absolute alcohol) NIL.

REQUIREMENT FOR ALCOHOL PERFUMERY GRADE:

SR.

NO.

Characteristic Requirement

1 Specific gravity at 15.6/15.6oC max. and at 15.0 / 15.0oC max.

0.8337

2 Ethanol content percent by volume

at 15.6oC min. and at 15.0oC min.

90

3 Miscibility with water 1 : 19 by volume Miscible

4 Acidity (as per CH3COOH) percent by weight, max

0.002

5 Residue on evaporation, percent by weight max.

0.002

6 Fusel oil and allied impurities Pass the test.

7 Aldehyde and oxidizable impurities Pass the test.

8 Isopropyl alcohol, acetone and other ketones

Pass the test.

REQUIREMENTS FOR COUNTRY SPIRIT (DISTILLERY)

SR.

NO. Characteristic Requirement

1 Total acids as tartaric acid (expressed in tems of 100 litres of absolute alcohol), max.

25 gm.

2 Volatile acids as acetic acid (expressed in term of 100 litres of absolute alcohol), max.

10 gm.

3 Esters as Ethyl Acetate (expressed in terms of 100 litres of absolute alcohol), max.

50 gm.

4 Higher alcohols as Amyl alcohol (expressed in terms of 100 litres of absolute alcohol), max.

200 gm



5 Aldehyde as acealdehyde (expressed in terms of 100 litres of absolute alcohol), max.

45 gm

6 Furfural (expressed in terms of 100 litres of absolute alcohol) max. Traces

7 Copper (as Cu.) Mg/kg max. 10

4.2 Raw Materials Requirement

• Broken / damaged Rice,

• Millets (Bajra),

• Sorghum (Jowar),

• Corn / Maize

Table 2: Raw Material Requirement

Composition RAW MATERIAL

CORN/MAIZE BAJRA BROKEN RICE

Moisture 8-12 10-12 10-12

Starch 60-64 57-58 66-70

Protein 9-12 8 - 9 4-7

Fats & Oils 3.5 – 5.0 0.8-1.5 0.4-1.0

Crude Fiber 1.5.- 2.0 2.0 - 2.5 0.2-0.5

Ash 1.0 –1.5 0.5-0.7 0.5-0.7

Other Organics 7- 9 9-12 4-10

Yield of Alcohol @ 96% v/v

Per MT of Grain Flour. 402 - 430 380 - 390 442 – 468



4.3 PROCESS DESCRIPTION:

1. Liquefaction Section

In liquefaction process, starch is hydrolyzed to dextrin. The Liquefaction is carried out in Single stage Liquefaction Tank. Feedstock Flour is transferred to Premasher and mixed with Recycle Streams and liquefying enzyme. Slurry from Premasher is taken to Liquefaction tank where temperature is maintained by means of steam. Necessary retention time is maintained in the Liquefaction Tank. Slurry pH is maintained by supplying dilute caustic solution. Contents in Slurry Tank are kept in suspension by Agitation. The Liquefied Slurry is then cooled in Slurry Cooler using cooling water supply and transferred to Pre-fermentation and Fermentation section.

2. Saccharification & Fermentation: Yeast Activation

Yeast seed material is prepared in Prefermentor by inoculating sterilized mash with yeast. Optimum temperature is maintained by circulating cooling water. The contents of the Prefermentor are then transferred to Fermenter

The purpose of Fermentation is to convert the fermentable substrate into alcohol. To prepare the mash for Fermentation, it is diluted with water. Yeast is added in sufficient quantity to complete Fermentation to produce alcohol.

At the start of the cycle, the Fermenter is charged with mash and contents of the Prefermentor. Significant heat release takes place during Fermentation. This is removed by passing the mash through heat exchangers to maintain an optimum temperature. The recirculating pumps also serve to empty the Fermenters into Beer Well. CO2 can then be taken to CO2 vent line where it is vented out. After emptying of Fermenter, it is cleaned with CIP using cleaning nozzles.

After CIP, Fermenter is ready for next batch to be filled.

3. HIFERM Fermentation

The Fermentation process is engineered to operate in batch mode depending upon the quality of raw material. The purpose of Fermentation is to convert the fermentable sugars into alcohol. During Fermentation, sugars are broken down into alcohol and carbon-dioxide. Significant heat release takes place during Fermentation. The fermenter temperature is maintained at around 30 – 32oC by forced recirculation flow through plate heat exchangers. We have given a provision for spent wash recycled to Fermentation depending on solids concentration in fermented wash. 4. MPR WE Multi-Pressure Distillation

Multi-pressure (MPR) Distillation schemes under the above systems & applies various heat integration methods, for the optimal economic operation of the plant, keeping in mind the requirements of Distillery. Multi-Pressure Distillation system has Seven Distillation columns operating at various pressure conditions. Heat energy from columns operating under high pressure is utilized for columns operating under low pressure to optimize the operation for energy consumption.

Wash to ENA Mode:

Following Columns will be under operation:



1. Analyser Column 2. Degasser Column 3. Pre-Rectifier Column 4. ED Column 5. Rectifier cum Exhaust Column 6. Recovery Column 7. Simmering Column

Pre-heated fermented wash will be fed to Degasser column. Fermented wash is stripped off alcohol by ascending vapors in Analyser column. Rectifier vapors provide energy to Analyser column through a Thermosyphon reboiler. Vapors of Degasser column are condensed and taken to Recovery Feed Tank. The condensed Analyser vapors are taken to Pre-Rectifier Column. Analyser Condensate is concentrated in Pre-Rectifier column, which operates under pressure. Condensing steam provides energy to pre-rectifier column through a vertical Thermosyphon reboiler. A Technical Alcohol cut of about 1-2% of total spirit is taken from the Pre-Rectifier column.

Concentrated alcohol draw from Pre-Rectifier column is fed to ED column for purification. Dilution water in the ratio of 1:9 is added in this column for concentrating higher alcohol at the top. Top of this column is condensed in its condensers and fed to recovery feed tank while bottoms are fed to Rectifier cum Exhaust Column for concentration. Rectifier Column operates under pressure and condensing steam provides energy to this column through a vertical Thermosyphon reboiler. Technical Alcohol cut is taken out from the top of this column while ENA draw is taken out from appropriate upper trays and fed to Simmering Column after cooling. Fusel Oil build up is avoided by taking fusel oil draws from appropriate trays.

These fuel oils along with the condensate of Degasifying & Extractive Distillation columns are fed to recovery column for concentration. A technical alcohol cut is taken out from the top of this column.

Simmering Column is operated under high reflux for better separation of methanol and di-acetyls. Final ENA product draw is taken from the bottom of this column.

5. Decantation & Thin Slops Recycle Section

Decantation section comprises of a Centrifuge Decanter for separation of suspended solids from Spent Wash coming out of Grain Distillation Plant. Wet cake has 30-32% w/w solids as removed from bottom of Decanter which can be sold directly in wet form as cattle feed (DWG).

Thin slops coming out of Decanter are collected in a tank and partly recycled into the process & further for Evaporation for concentration upto 35-40% w/w solids. The concentrated thin slops called as Syrup is mixed with Wet cake and sold in wet form as cattle feed (DWGS) or the entire mixture can be dried in a DDGS Dryer and then sold in dry form as Cattle feed (DDGS).

6. ECOVAP Evaporation System - Integrated Evaporation Scheme

The suggested treatment scheme Effect working on the principle of falling film & Force Circulation

• Analyzer vapors is fed to the first effect evaporator shell side and steam is fed to shell side finisher at the given pressure and temperature as the heating medium.

• Vapors from last effect are condensed in Surface Condenser. A Shell & tube type Multi-pass Surface condenser is employed for condensing the shell side vapors.



• The product at the desired concentration 35-40% is obtained at the outlet of Finisher.

• Each effect is provided with recirculation cum transfer pump.

• The condensate from surface condensers is collected in a common condensate pot. The condensate is transferred for further treatment / Recycle by using centrifugal pump.

• The Pure steam condensate are collected in receiving vessels and can be pumped to desired battery limit

• Highly efficient operating pumps have been provided for pumping the required fluid.

• The plant is having high level of automation to get consistent output at required concentration.

• The system operates under vacuum. Water-ring vacuum pumps are used to maintain a desired vacuum.

• Cooling water from cooling tower is used in the surface condensers for condensing the vapors.

7. DWGS DRYER WITH COOLING AND CONVEYING SYSTEM: SYSTEM

DESCRIPTION FOR DRYER

� Wet distiller’s grains shall be fed into the dryer housing at controlled rate through a suitable feeding system. The Rotary Tube Bundle is enclosed in an insulated dryer housing and its outer flights are fixed. Dry saturated steam is to be supplied to the tube bundle through rotary joint at one end & the condensate is discharged through rotary joint mounted on another end.

� During the course of rotation, these flights pick up the material and shower them on to the tube bundles. The heat transfer is primarily by conduction. The water vapors are exhausted through an Exhaust Blower & passed through a cyclone separator for separating fines.

� Dry product partially recycled back to Feed conditioner for feed conditioning through Product Screw & Recycle Conveyor.

� Entire operation of the Dryer is controlled through Control panel.



SECTIONS IN GRAIN BASED DISTILLERY

STEAM WATER SUPPLY

Decantation

Section

DWGS DRYER

SLURRY PREPARATION &

LIQUEFACTION SECTION

SACCHARIFICATION & FERMENTATION

SECTION

MULTIPRESSURE DISTILLATION

SECTION

SPIRIT STORAGE SECTION

MULTI-EFFECT EVAPORATION PLANT

POWER

GENERATION

HOUSE

GRAIN CLEANING, MILLING AND

FLOUR HANDLING SECTION

WATER STORAGE &

TREATMENT

BOILER

TURBINE

PROCESS

CONDENSATE

TREATMENT &

RECYCLE

WET CAKE DWG

CONC.SYRUP

DDGS



GRAIN STORAGE Storage Silos and transfer systems

GRAIN CLEANING & MILLING

SECTION

Consisting of: - Bucket Elevator - Hopper Bin with Rotary Air Lock Valves - Vibratory Screen - De-Stoner - Magnetic Separators - Hammer Mills - Air Aspiration Systems - Bucket Elevator - Storage Silos with Rotary Air Lock Valves - Weighment Tank with Load Cell Arrangement - Batch Tipping Machine - Removable Screens - Piping and Valves

SLURRY PREPARATION &

LIQUEFACTION SECTION

Consisting of:

- Pre-Masher

- Liquefaction Tank

- Retention Vessel

- Flash Tank

- Recycle Stream Tank

- Slurry coolers

- CIP System

- Piping and Valves

- PLC Based Instrumentation

SACCHARIFICATION AND

INSTANTANEOUS FERMENTATION

SECTION

Consisting of: - Fermenters

- Yeast Activation System / Pre-Fermenter

- Accessories

- Beer Well / Wash Holding Tank

- Fermentor Cooling System with PHEs

- Agitators & Cleaning turbines



- Piping and Valves.

MULTI-PRESSURE DISTILLATION

SECTION

Consisting of :

- Distillation Columns - Reboilers

- Condensers & Coolers

- PLC based Instrumentation

- Piping and Valves

DECANTATION SECTION

Consisting of:

- Decanter Centrifuges

- Thin Slops Tank & Transfer pumps


- Piping and Valves

MULTI-EFFECT EVAPORATION

SECTION

Consisting of :

- Multi-Effect Falling Film Type Evaporators

- Thin Slops feed Tank with pumps

- Re-circulation pumps

- CIP System


- Piping and Valves

DWGS DRYER SECTION

Consisting of :

- Ribbon Mixer

- Steam Tube Bundle Dryer

- Cooling & Conveying System

- DDGS Storage Silo

- DDGS Bagging Machine




- Piping and Valves

SPIRIT RECEIVER AND BULK

STORAGE SECTION

Comprises of :

- Daily Receiver

- Bulk Alcohol Storage Tanks

- Pumps, piping and Valves

AUXILIARIES : COOLING WATER SYSTEM & INSTRUMENT AIR COMPRESSORS FOR LIQUEFACTION, FERMENTATION, MPR DISTILLATION AND MULTI-EFFECT EVAPORATION & DRYER SECTIONS

Consisting of :

- Cooling Towers

- Cooling water Recirculation Pumps

- DG driven emergency pumpset

- Piping and valves

- Instrument Air Compressors & Air Drier

BOILER AND TURBINE SECTION

Consisting of :

- Coal cum Rice Husk Fired

- Feed Handling System

- Accessories

- Back Pressure Turbine

- Alternator etc.

- Flue gas Handling Section

- Chimney

SOFTENING PLANT,

CHLORINATION PLANT AND DM

PLANT, TUBEWELL AND WATER

DISTRIBUTION SYSTEM

Consisting of :

- Soft Water Plant

- DM Water Plant

- Raw, Soft and DM water storage



- Pumps piping and valves

ELECTRICALS

Comprises of :

- Transformers, D.G. Sets

- PCC (Power Control Centre)

- Cable from PCC to each MCC

- Plant and Yard Lighting

- MCC’s for various section

- Distribution, earthing, pits etc.

CIVIL AND STRUCTURAL FOR ALL

SECTIONS

Consiting of :

- Civil Foundations

- Boundary, Sumps, Underground Water Storage, Roads, Buildings, Lab, Workshop, Lagoon, Green Belt, Drainage, Sewage Treatment,

- Structural Column, Truss, Gratings, Railings, Foundation Bolts, Inserts, Roof, Side cladding, etc.

4.4 INPUT REQUIREMENT FOR GRAIN BASED ENA PLANT:

1.

Raw Material: Grain Flour

(Broken Rice, Maize) as per specification

~ 129 to 144 MT/day

(At 60 % w/w average Starch content)



2.

Steam Consumption (Dry, Saturated):

Cooking & Liquefaction

MPR Distillation + Integrated Evaporation

DWGS Dryer

Add Steam for Sterilization of Fermentation, and Boiler Deaeration, etc.

1.33 TPH at 3.5 kg/cm2 (g)

6.55 TPH at 3.5 kg/cm2 (g)

5.00 TPH at 3.5 kg/cm2 (g)

4.5 TPH at 3.5 kg/cm2 (g)

3. Process Water for Dilution in Liquefaction / Fermentation

500-540 m3/day (without recycle)

100-150 m3/day (With recycling system)

4. DM Water for RS Dilution in Extractive Distillation Column

500 – 540 m3/day (w/o Lees recycle)

150 – 200 m3/day (with Lees recycle)

5. Soft Water for Scrubber, FO Decanter etc. 70 – 80 m3/day

6. Cooling Water Make-up for Cooling Towers mentioned above ( L+F+D+E )

300 – 350 m³ /day (Without recycle)

7. Antifoam Agent

As per process requirement

8. Sodium Hydroxide (47% w/w Lye)

9. Urea (46% N2)

10. Active Dry Yeast for Grain based operation

11. Steam for Sterilization in Fermentation

12. Liquefying Enzyme

13. Saccharifying Enzyme

14. Fermogen

As per process requirement

15. Nitric Acid for Evaporation Cleaning

16. Caustic for Evaporation Cleaning

17. Chemical for Evaporation process condensate treatment plant

18. Any other chemical required for operation of distillery plant



Power Requirement (Process Plant) Operating (KW) Connected (KW)

Grains Storage, Milling and Flour Handling

After Detailed Engg

After Detailed Engg

Liquefaction section After Detailed Engg

Fermentation Section After Detailed Engg

Distillation Section After Detailed Engg

Thin slops Evaporation Section After Detailed Engg

Decantation After Detailed Engg

DWGS Dryer section After Detailed Engg

Auxiliaries: Cooling Towers & IAC After Detailed Engg

EPCTP After Detailed Engg

Spirit Storage After Detailed Engg

Boiler and accessories After Detailed Engg

Bore well and water pumps, water treatment plant with water transfer pumps

After Detailed Engg

Blending and bottling section After Detailed Engg

Plant and Yard lighting After Detailed Engg

Office and admin building After Detailed Engg

CO2 Plant (Provisional) After Detailed Engg

TOTAL POWER Grain based operation

(Estimated) 2000 2300

TOTAL Consumed Power (Estimated) 1800 KW

Note:

• Figures mentioned above are indicative in nature and may vary to some extent. Exact requirement will be confirmed only after detailed engineering.

4.5 RAW MATERIAL AND INPUT SPECIFICATION

A. Grain Flour: To be made available for Distillery

Clean Grain flour should be free from Fermentation inhibiting substances and micro-organism producing side products, sand and other foreign particles. The raw material (flour) should be of quality as mentioned below:

1. Moisture Content 10-12% w/w max.

2. Total Solids 88-90 % w/w



3. Convertible Starch 60 % w/w (minimum)

4. Others 30 % w/w

Desired Particle size distribution of Grain Flour:

a) 0.1 mm – 0.3 mm 20 % (Fines)

b) 0.3 mm – 0.8 mm 70 % (Medium)

c) 0.8 mm – 1.0 mm 10 % (Coarse)

Note: 1 mm = 1000 microns

B. Antifoam agent:

Turkey Red Oil to conform to IS: 1044- 1970, Grade - I, Composition as below:

1. Degree of Sulphation 6 min.

2. Total Alkali (KOH) 4 max.

3. Total fatty matter (TFM) 60 min.

4. Total Ash 8 min

5. pH 6.5 - 7.5

C. Sulphuric acid:

Concentrated, Commercial Grade, Composition as below value in % w/w

1. Sulphuric Acid 97% min

2. Lead 0.001 max.

3. Arsenic 0.0001 max.

4. Iron 0.03 max.

5. Moisture 2 max.

D. Di -Ammonium Phosphate (DAP):

In the form of powder, confirming to following specification. DAP should be of fertilizer grade and should be free from any petroleum products.

Values given below are in w/w %.

1. P2O5 50 min.



2. Nitrogen 20 min.

3. Arsenic 0.0001 max

4. Iron 0.01 max.

5. Lead 0.001 max

E. Water Specification:

i. Process water:

No Parameter Unit Value

1. pH - 6 – 9

2. Chloride (Cl-) (Expressed as NaCl) mg/lit < 250

3. H2S mg/lit Nil

4. Residual Free Chlorine mg/lit < 1

5. Silica (SiO2) mg/lit < 30

6. Turbidity NTU < 5

7. Total germs Nos./ml < 60 CFU

8. Coliform Bacteria Nos./ml Nil

9. E. Coli Nos./ml Nil

Note: Water shall be of Potable grade quality,

mg/lit – Parts Per Million (PPM)

ii. Soft Water:


1. pH - 6 – 9

2. Chloride (Cl-) (Expressed as NaCl) mg / lit < 250

3. H2S mg / lit Nil

4. Residual Free Chlorine mg / lit < 1

5. Silica (SiO2) mg / lit < 50

6. Total Hardness (Expressed as CaCO3) mg / lit < 5


8. Total Dissolved Solids mg / lit < 750

Note: Water shall be of potable grade quality, mg/lit – Parts Per Million (PPM)



iii. ED Dilution Water:


1. pH - 6 – 9

2. H2S mg / lit Nil

3. Residual Free Chlorine mg / lit < 1

4. Total Hardness (Expressed as CaCO3) mg/ lit < 5

5. Total Dissolved Solids mg/lit < 50


Note: Water shall be of potable grade quality, mg/lit – Parts per Million (PPM)

F. Utility Specification:

(i) Electricity: Electric supply should be 415 V, 3-phase, 4-wire, 50 cycles.

(ii) Steam:

• Dry, saturated and regulated steam at a constant pressure of 3.5 + 0.01 kg/cm2 (g) at the inlet of the steam header in the Distillation, Liquefaction and DWGS Dryer Section

• Dry, saturated and regulated steam at a constant pressure of 1.5 + 0.01 kg/cm2 (g) at the inlet of the steam header in the Integrated Evaporation Section.

G. Yeast:

Active Dry Yeast, as per specification, will be procured from the market by DISTILLERY.

H. Enzyme:

Various Enzymes, as per specification, will be procured from the market by DISTILLERY.

4.6. OUTPUT GENERATION FOR ENA PLANT:

NO. PARAMETERS WASH TO ENA

1. Main Product (ENA) 55,000 LPD of Extra Neutral Alcohol (ENA) of 96% v/v strength.

2. Impure Spirit / Technical Alcohol @ 95%

v/v (Max.)

~ 3,000 LPD

(~ 5% of Total Spirit)

3. Theoretical CO2 at the outlet of CO2 scrubber in Fermentation section

~ 42 TPD

(Recoverable CO2 ~ 30 MT/Day )



4.

DDGS at Outlet of DWGS dryer

(Qty. will depend on the non-starch solids content in the grains)

~ 30 TPD with 10 % w/w (max.) moisture

(Approx. for grain flour containing 60% w/w convertible starch.)

~ 26 TPD with 10% moisture – for grain flour having 68-72% Convertible Starch

5. Cooling Tower Blow down 150 - 180 m3/day

5.0 SITE ANALYSIS

(i) Connectivity

The Plant site is located at UPSIDC Industrial Area, Sandila Phase IV, Lucknow Hardoi Road, Tehsil Sandila, District Hardoi, Uttar Pradesh. It is about 8 KM from Sandila. It has an easy access to raw material availability and other infrastructural facilities e.g. land, power, water, transport and communication, approach through road & access distances from the nearest highway, railway station etc. The site is well connected with communication facilities like telephone, fax, wireless and telex and as such, no constraints are envisage in this aspect also.

(ii) Topography The topography of the area is flat.

(iii) Physiography The site surveyed is a plain land with a gentle south eastward gradient. The site is a part of the river basin of Ganga. It is an alluvial plain which gently slopes towards southeast. This being the main watershed in the region, the main drainage feature of the site is Ganga Rivers. The area is at about 132 m above mean sea level. The topography of the area is flat.

(iv) Climatic data from secondary sources The area falls in a humid subtropical, with extremes of climate in summer and winter. Dust storms are common during the summer months in the area and it experiences severe heat during May and June, with the highest temperatures hovering around 45+3oC and minimum temperatures touching lows of the order 3oC. The Southwest monsoon period between June and September is the main rainy season of the area when about 85% of the annual precipitation occurs. The mean annual rainfall is about 904 mm. The coefficient of variation is fairly low at 15 mm and the corresponding dispersion of mean rainfall is 20% with a 90 mm standard deviation. The air over this area is generally dry for most part of the year. The soils are sandy clays and fairly well drained.

(v) Social Infrastructure available There are primary schools, dispensaries, small hospitals, places of worship in nearby area of the project site.

(vi) Proposed infrastructure (a) Industrial Area (processing area)

It is an industrial land



(b) Residential Area (Non processing area)

Residential colony is not proposed for proposed project. The local labor will be preferred to provide employment opportunities.

(c) Green Belt

Greenbelt will be developed in 33% of the total area of the proposed project. (d) Social Infrastructure

Proposed project will result in growth of the surrounding areas by increased direct and indirect employment opportunities in the region including ancillary development and supporting infrastructure.

(e) Connectivity The project is well connected with Rail and Road. (f) Industrial Waste management

The proposed plant would be based on “ZERO EFFLUENT DISCHARGE”.

6.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN

No Rehabilitation and Resettlement plan is applicable because there are no Rehabilitation & Resettlement of the people.

7.0 PROJECT SCHEDULE AND COST ESTIMATES

The project will start only after obtaining Environmental Clearance and all other required clearance and will complete after two years of commencement. The Capital Cost of the project is 90.00 Crores.

8.0 WASTE MANAGEMENT

8.1 Liquid Effluent:

� The proposed grain based distillery would be based on “Zero Liquid Discharge” (ZLD). � Spent wash will be treated in MEE (Multiple Effect Evaporator), than the semisolid waste

from MEE (Multiple Effect Evaporator) will be sent in specially designed boiler for incineration.

� Condensate will be treated in condensate polishing unit and will used as water in cooling tower.

� A duly lined lagoon of 30 days capacity shall be provided. � Online effluent quality monitoring system will be installed at the outlet of the unit for

measurement of the parameters flow, pH, COD, BOD & TSS etc. and transmission of online data to Uttar Pradesh Pollution Control Board and CPCB will be done

8.2 Air Pollution:

� Air pollutant from a distillery plant is basically from boiler. � These are particulates and acidic constituents in the flue coming from fuel i.e. baggase. � The particulate emissions are controlled through Electrostatic Precipitator. � This is already provided in boiler configuration. Ash will be collected and sold to brick

manufacturers. � Also, this ash is potash rich and can be used as fertilizer. � Online Air monitoring system for stack emission (for Particulate Matter) will be installed

& transmission of online data to Bihar Pradesh Pollution Control Board and CPCB will be done.

8.3 Solid Waste

� Boiler ash collected and sold to brick manufacturers.



� Boiler ash collected from ESP is also rich in potassium and can be disposed of as blending in NPK fertilizer.

� The other solid wastes expected from the unit are containers, empty drums which are returned to the product seller or sold to authorize buyers after detoxification.

8.4 Noise Pollution Control

There is no danger of noise pollution from plant. The green belt will (plantation of dense trees across the boundary) help in reducing noise levels in proposed plant as a result of attenuation of noise generated due to plant operations, and transportation.

� Earmuffs would be used while running the equipments of the plant. � D.G sets are provided with acoustic to control the noise level within the prescribed limit. � A high standard of maintenance will be practiced for plant machinery and equipments, which

helps to avert potential noise problems. 9.0 GREEN BELT DEVELOPMENT/ PLANTATION

Green belt development in and around the project site helps in to attenuate the pollution level. About 33% land area of project will be developed as green belt and it will be maintained in future also. Green belt will be developed as per Central Pollution Control Board (CPCB) Norms. The Avenue plantation will give priority to native species, and the periphery will be devoted to generation of green belt area.

• Green belt development in and around the project site will help in to attenuate the pollution level.

• Native species will be given priority for Avenue plantation.

• The periphery will be devoted to generation of green belt area.

10.0 CSR Activities

Proposed project will result in growth of the surrounding areas by increased direct and indirect employment opportunities in the region including ancillary development and supporting infrastructure. Special emphasis on Financial and Social benefits will be given to the local people including tribal population, if any, in the area. Development of social amenities will be in the form of medical facilities, education to underprivileged and creation of self help groups. No adverse effect on environment is envisaged as proper mitigation measures will be taken up for the same.

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FOR 55 KLPD GRAIN BASED DISTILLERY ALONG WITH...

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