INDEX [environmentclearance.nic.in]environmentclearance.nic.in/writereaddata/Online/TOR/16...Kanpur...

i

INDEX

S. NO. CONTENTS PAGENO.

1.0 EXECUTIVE SUMMARY 1-4

2.0 INTRODUCTION OF THE PROJECT/BACKGROUND INFORMATION 4-6

3.0 PROJECT DESCRIPTION 6-22

4.0 SITE ANALYSIS 22-24

5.0 PLANNING BRIEF 24-25

6.0 PROPOSED INFRASTRUCTURE 25-26

7.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN 26

8.0 PROJECT SCHEDULE & COST ESTIMATES 26

9.0 ANALYSIS OF PROPOSAL 26

ii

LIST OF TABLES

TABLE NO. CONTENTS PAGE NO.

1 Salient Features Of The Project 1

2 Raw Material Requirement 16

3 Fuel Requirement 17

4A Total Water Input 17

4B Total Water Output 18

4C Recycle & Utilization Streams 18

5 Steam Requirement 21

6 Boiler Details 21

7 Details Regarding the D.G. Sets 21

LIST OF FIGURES

FIGURE NO. CONTENTS PAGE NO.

1 Location Map 7

2 Map Showing Environmental Settings of the 10 Km Radius Study Area 8

3 Process flow chart for grain based distillery 13

4 Process flow diagram of Malt Spirit production 15

5 Process Flow Chart for Co-generation Power Plant 16

6 Water balance for 125 KLPD Grain based Distillery Operation 19

7 Water balance for 25 KLPD Malt Spirits Plant Operation 20

Proposed 125 KLPD Grain based Distillery, 25 KLPD Malt Spirit Plant and 4.5 MW Co-generation Power Plant At Village Chiraura, Tehsil Akbarpur, District Kanpur Dehat (U.P.)

Pre - Feasibility Report

Rajasthan Liquors Ltd. 1

PRE - FEASIBILITY REPORT

1.0 EXECUTIVE SUMMARY

(i) Introduction

Rajasthan Liquors Limited is proposing 125 KLPD Grain based Distillery, 25 KLPD Malt Spirit

Plant and 4.5 MW Co-generation Power Plant at Village Chiraura, Tehsil Akbarpur, District

Kanpur Dehat (U.P.). Also, 12000 cases per day IMFL/CL bottling unit will also be installed

within plant premises.

Grains such as damaged grain feed stock, broken rice, maize, bajra & sorghum will be used as

raw material which is easily available from the local market.

As per EIA Notification dated 14th September, 2006 and as amended from time to time; the

project falls in Category ‘A’, Project or Activity - 5(g)(ii) [Non-molasses based distilleries >60

KLD].

TABLE – 1 Salient Features of the Project

S. No. Particulars Details

A. Nature of Project Proposed Project

B. Size of the Project Units Proposed Capacity

Grain based Distillery 125 KLPD

Malt Spirit Plant 25 KLPD

Co- generation Power Plant 4.5 MW

IMFL/CL bottling unit 12000 cases per day

C. Location Details

Village Chiraura

Tehsil Akbarpur

District Kanpur Dehat

State Uttar Pradesh

Latitude 26°25'07.11" to 26°25'19.90"N

Longitude 80° 6'14.33" to 80° 6'27.84"E

Toposheet No. G 44I3 & G 44I2

D. Area Details

Total Project Area 9.7 ha (24 acres)

Greenbelt / Plantation Area 3.2 ha (7.91 acres) i .e. 33% of the plant area will be developed under greenbelt & plantation.

E. Environmental Setting Details (with approximate aerial distance & direction from plant site)

1. Nearest Village Chiraura Village (0.7 m in NNE direction)

2. Nearest Town & City Nearest Town - Rania (3.3 km in WSW direction) Nearest City - Kanpur (21 km in ENE direction)




3. Nearest National Highway / State Highway

NH - 19 (earlier known as NH 2) (0.5 km in West direction)

4. Nearest Railway station Paman Railway Station (7.0 km in SSW direction)

5. Nearest Airport Chaudhary Charan Singh International Airport, Lucknow (86 km in NE direction)

6. National Parks, Wildlife Sanctuaries, Biosphere Reserves, Tiger/ Elephant Reserves, Wildlife Corridors, Reserved Forest (RF)/ Protected forest (PF) etc. within 10 km radius

No National Parks, Wildlife Sanctuaries, Biosphere Reserves, Tiger/ Elephant Reserves, Wildlife Corridors, Reserved Forest (RF)/ Protected forest (PF) etc. lies within 10 km radius of the plant site.

7. Water Body (within 10 km radius)

· Ghatampur Distributary (0.5 km in North direction) · Rind Nadi (1.5 km in SSW direction) · Supa Nala (3.5 km in NNE direction) · West Allahabad Branch (4.0 km in NE direction) · Non Nadi (7.5 km in SW direction)

8. Seismic Zone Zone – III [as per IS 1893 (Part-I):2002]

A. Cost Details

Total cost of the project Rs. 175.0 Crores

Cost for Environment Management Plan

· Capital Cost: Rs. 30.0 Crores · Recurring Cost: Rs. 1.75 Crores/annum

B. Basic Requirements for the project

Water Requirement (KLD) Total water requirement for the project will be 1354 KLPD. Source: Ground Water

Power Requirement (kWh)

Total power required will be 3 MW. Source: 4.5 MW Co-Generation Power Plant

Man Power Requirement Total manpower required will be 450 persons Source: Unskilled / Semi-Skilled - local area; Skilled – Local & outside areas

C. Product Mix Extra Neutral Alcohol (ENA) / Grain Neutral Spirit (GNS), IMFL (Indian Made Foreign Liquor), Country Liquor / Medium Liquor

D. By-products DDGS, CO2 & Impure Spirit (Technical Alcohol)

E. Working Days 350 days/annum

1.1 ENVIRONMENT MANAGEMENT PLAN

Air Quality Management:

Ø ESP with stack of adequate height will be installed with the boiler to control the

particulate and gaseous emissions due to combustion of fuel.

Ø CO2 generated during the fermentation process will be recovered by CO2 Scrubbers

and sold to beverage & packaging industry.




Ø DG Sets will have adequate stack height as per CPCB guidelines.

Ø All the internal roads will be asphalted.

Ø Online stack monitoring system will be installed.

Ø Greenbelt will be developed all around the plant boundary and within the plant

premises.

Ø Regular monitoring will be done to ensure that ambient air quality standards are met all

the time.

Water Quality Management:

Ø Grain based distillery will be based on “Zero Effluent Discharge”.

Ø Grain Slops (Spent Wash) will be passed through centrifuge decanters for separation of

suspended solids separated as Wet Cake (also known as DWG – Distillers Wet Grains).

Ø Thin Slops from the Decanter Centrifuge will be partly recycled back to process (20% to

35%) and the balance will be fed to Thin Slop Evaporation Plant for concentration of

remaining solids to form Syrup (35% TS).

Ø DWGS Drier: The Wet Cake and Syrup mixture (DWGS) will be dried in Steam Tube

Bundle Dryer for producing DDGS with 8-10% moisture (max.). The DDGS will be utilized

as Cattle, poultry and fish feed ingredients.

Ø The process condensate will be treated in condensate treatment plant. The treated

water will be recycled back in cooling tower makeup.

Ø Sewage from domestic activity will be disposed off through septic tank via soak pit

system.

Ø Rain Water harvesting will be done within the plant premises.

Noise Management:

Ø Personal Protective Equipment like earplugs and earmuffs will be provided to the

workers exposed to high noise level.

Ø D.G. sets will be provided with acoustic to control the noise level within the prescribed

limit.

Ø Proper maintenance, oiling and greasing of machines at regular intervals will be done to

reduce generation of noise.

Ø Greenbelt of appropriate width inside the plant premises and at the plant boundary will

be developed.

Ø Regular monitoring of noise level will be carried out and corrective measures in

concerned machinery are also being done.




Solid & Hazardous Waste Management:

Ø Solid wastes generated will be wet cake, yeast sludge and ash from the boiler.

Ø Solid waste from the grain based operations generally comprises of fibres and proteins

in the form of DDGS, which will be ideally used as Cattle Feed.

Ø Yeast sludge will be sent to the sludge drying beds or may be added to the wet cake.

Ø ETP sludge will be dewatered using filter press and will be used as manure.

Ø Ash from the boiler will be given to brick manufacturing unit.

Ø Used oil & grease generated from plant machinery/gear boxes as hazardous waste will

be sold out to the CPCB authorized recyclers.

Greenbelt Development & Plantation:

Ø Out of the total plant area of 9.7 ha (24 acres), 7.91 ha (3.2 ha) i.e. ~33 % of the total

plant area will be developed under greenbelt/ plantation.

Ø Native plant species will be planted in consultation with local horticulturist.

Ø Greenbelt development along with the road & plant boundary attenuates noise level;

arrest dusts and improve the environment in plant-surroundings.

Odour Management:

Ø Adequate greenbelt all around the periphery of the plant.

Ø Efficient CO2 scrubbing to avoid carryover of alcohol vapours & other fumes.

Ø DWGS dryer will be installed for complete drying of solids.

Ø Better housekeeping, hygienic conditions will be maintained inside as well as

surrounding areas of the plant.

Ø Regular use of disinfectants in the drains to avoid generation of putrefying micro-

organisms.

2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION:

(i) Identification of Project and Project Proponent:

Rajasthan Liquors Limited (RLL) is a public limited company, which was originally

incorporated 18th March, 1998 as Private Limited company with the main objective to carry on

the business as Manufacturers, Producers, Processors, Bottlers, Fermentators, Distillers,

Refiners or otherwise deal in beer, wine, whisky, gin, vodka or other alcoholic and non

alcoholic drinks, whether intoxicating or not etc. The Company was converted into a Public

Limited Company on 9th March, 2010.

Since the very inception of the company, its owns a Bottling unit situated at Jaipur, Rajasthan

facilitating five automatic bottling lines to bottle Indian Made Foreign Liquor (IMFL) with an

installed capacity of 20 lac cases per annum. Later on in 2003, a bottling unit was established

in Derabassi, Punjab which is currently operated with installed capacity of 60 Lac cases per

annum.




RLL has also installed a 120 Kilo Litre per day (KLPD) Grain based Distillery at the above cited

location in Derabassi, Punjab, thereby diversification towards new development and market

penetration by new product.

(ii) Brief description of nature of the project:

Rajasthan Liquors Limited is proposing 125 KLPD Grain based Distillery, 25 KLPD Malt Spirit

Plant and 4.5 MW Co-generation Power Plant at Village Chiraura, Tehsil Akbarpur, District

Kanpur Dehat (U.P.). Also, 12000 cases per day IMFL/CL bottling unit will also be installed

within plant premises.

As per EIA Notification dated 14th Sep., 2006 and as amended from time to time; the project

falls in Category ‘A’, Project or Activity - 5(g)(ii)[All non-molasses based distillery ≥ 60 KLPD].

(iii) Need for the project and its importance to the country and/ or region:

With hundreds of kind of alcoholic beverages being made and consumed in India, the

industry can be categorised into four broad groups’ viz. Indian Made Foreign Liquor (IMFL),

Country Liquor (CL), illicit liquor & Beer.

IMFL products contain about 42.85% of alcohol. The consumption of CL is slowly on the

decreasing trend as some cheap IMFL is available. In spite of this, the CL industry is growing

at around 8%. However, government is taking necessary steps to restrict the illicit liquor as it

causes loss of revenue and spoils the health of the people, also bad quality may lead to death

of consumer. The major consumption of alcohol as of now is for alcoholic beverages. Ethyl

alcohol has the potential to become the fuel of the future relegating gasoline to a secondary

place.

The ethanol produced from the grains is superior in quality as compared with that from

molasses. It is estimated that IMFL market will require around 3000 million litres in the year

2014 and expected to grow more than 50% in next 3 years. As Government declares 5%

mandatory mixing of fuel ethanol in the gasoline thus there is great potential for new

distillery establishment.

(iv) Demand- Supply Gap:

Not required in this Project. This depends on excise Department.

(v) Import vs. Indigenous Production:

Indian market could not meet present alcohol demand. So they import alcohol 5-7% of total

demand. As far as alcohol production is concerned, Indian market plays a vital role at both

domestic & international level. So they require producing more alcohol to meet the demand.

(vi) Export Possibility:

Export of Alcohol is currently governed by Govt. policy.




(vii) Domestic / export Markets

Market depends on Excise Department.

(viii) Employment Generation (Direct and Indirect) due to the project:

Direct and indirect employment will be generated due to the project. The total manpower

requirement for the project will be 450 persons (three shift operation).

S. No. Type Numbers

1 Skilled & Semi Skilled in Operation 70

2 Managerial, Accounts & Admin 20

3 Contractual Labour & Security 360

Total 450

Unskilled / semi-skilled manpower will be sourced from the local area and skilled manpower

will be sourced from outside / local.

3.0 PROJECT DESCRIPTION:

(i) Type of project including interlinked and independent projects, if any.

There are no interlinked projects related to this project.

(ii) Location (map showing general location, specific location, and plant boundary & plant

site layout) with coordinates




Figure - 1: Location Map




Figure - 2: Key Plan


Pre - feasibility Report


(iii) Details of alternative sites consideration and basis of selecting the proposed

site, particularly the environmental considerations gone into should be

highlighted.

No alternative site has been taken into consideration as the proposed site has been

acquired by the company keeping in mind following mentioned factors:

Ø Grant of state excise permissions (LOI) for setting up distillery in the

district/state.

Ø Raw material availability & markets for both products & by-products within the

state.

Ø Nearness to National Highway 19 (earlier known as NH 2) (~0.5 Km in West

direction) makes it easier to transport raw materials & final product to market.

(iv) Size or magnitude of operation

125 KLPD Grain based Distillery, 25 KLPD Malt Spirit Plant and 4.5 MW Co-generation

Power Plant at Village Chiraura, Tehsil Akbarpur, District Kanpur Dehat (U.P.). Also,

12000 cases/day IMFL /CL bottling unit will also be installed within plant premises.

As per EIA Notification dated 14th Sep., 2006 and as amended from time to time; the

project falls in Category ‘A’, Project or Activity - 5(g)(ii)[All non-molasses based

distillery ≥ 60 KLPD]

The process includes basic raw material requirement, sizing of equipment, utilities &

services, infrastructure facilities & sources of waste generation, their quantity,

treatment & safe disposal of the waste.

S. No. Units Total Proposed Capacity

1. Grain based Distillery 125 KLPD

2. Malt Spirit Plant 25 KLPD

3. Co-generation Power Plant 4.5 MW

4. IMFL /CL bottling unit 12000 cases/day

(v) Project description with process details (a schematic diagram/ flow chart

showing the project layout, components of the project etc. should be given)

Process Description

Distillery Unit - Production from Grain:

Ø Grain storage

Ø Grain cleaning, milling and flour handling

Ø Slurry preparation & liquefaction

Ø Multi pressure distillation




Ø Alcohol (ENA & IA) daily receivers & bulk storage

Ø MEE & Dryer

A) Grain Storage Silos, Cleaning, Handling and Milling Section:

Grain is received from various sources and is pre-cleaned off stones, husk, etc. and

then stored in specially designed storage silos. Grains are continuously lifted from the

bottom of the silos and screened followed by removal of stones in de-stoner and iron

matters in magnetic separators. Cleaned Grains are then milled using dry milling

process in Hammer Mills. The flour is fed through the bucket elevator and conveyed

to the Batch Tipping Machine through a Screw Conveyor.

B) Liquefaction Section

Grain flour mixed with recycle streams and water in Pre-masher and slurry has been

fed to Liquefaction tank. Required temperature has been maintained by applying

steam through steam sparger in liquefaction tank. The cooking process,

accomplished in the above manner, converts the slurry into a hydrated, sterilized

suspension (as starch molecule is solubilized) and is therefore susceptible to enzyme

attack for liquefaction. The liquefied mash is cooled in slurry cooler and transferred to

Fermentation section.

C) Fermentation Section

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

Yeast Activation Vessel (Pre-fermenter). Significant heat release takes place during

fermentation. This is removed by passing the mash through heat exchangers to

maintain an optimum temperature. The recirculation pumps also serve to empty the

Fermenters into Beer Well. CO2 evolved during fermentation carries along with it

some entrained alcohol. This CO2 is taken to a CO2 scrubber where it is washed with

water to remove the entrained alcohol. The scrubbed CO2 can then be taken to CO2

plant or 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.

D) MPR Distillation Wash to ENA:

Multi-Pressure Distillation system has eight 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. Following Columns will be under operation




Ø Analyser Column

Ø Degasifying Column

Ø Pre-Rectifier Column cum

Ø Exhaust Column

Ø Extractive Distillation Column

Ø Rectifier cum Exhaust Column

Ø Recovery Column

Ø Simmering Column

Pre-heated fermented wash is fed at the top of the Degasifying column. Analyser

Column is provided with Re boiler. Top vapors of Analyser column containing all the

alcohol in the wash are sent to Pre-Rectifier column. Rest of the fermented wash

flows down the Analyser column and is taken out as thick slops from Analyser column

bottom. Low boiling impurities are concentrated in the Pre-Rectifier column. A draw

of impure alcohol is taken out from the top of the Pre-Rectifier column. RS draw is

taken from the top of Pre rectifier column, which further is sent to Extractive

Distillation column. Dilution water is fed to this column. The Extractive Column

operates on the principle of inversion of relative volatility. Low boiling impurities are

separated in the Extractive Distillation Column & bottom is sent to Rectifier cum

Exhaust column. The Rectifier/Exhaust column concentrates the alcohol to 96% v/v.

The spirit is drawn from the upper trays of the Rectification Column. Fusel oil build up

is avoided in the Rectifier cum exhaust column by withdrawing side streams (fusel

oils). ED condensates, fusel oil draw from R/E column are sent to Recovery column

where these fusel oils are concentrated and then sent to decanter where these

streams are diluted with water and fusel oil rich layer is separated. Washings are sent

back to the column to recover alcohol. The spirit Draw from the Rectifier column is

sent to the Simmering column where methanol is separated in the form of a cut from

the top and ENA is taken out from the bottom. ENA drawn from the Simmering

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

E) Decantation Section Excluding Decanter Centrifuges

Decantation section comprises of a Centrifuge Decanters (Client scope) for

separation of suspended solids from Thick slop coming out of Grain Distillation Plant.

Wet cake is removed from bottom of Decanter. Thin slops coming out of Decanter

are collected in a tank and partly recycled into the process & Evaporation for further

concentration. 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

DWGS Dryer and then sold in dry form as Cattle feed (DDGS).




F) Integrated Evaporation

The suggested treatment scheme is a Multi Effect Evaporation Plant for Thin Slop

Evaporation. Shell & Tube type Evaporators with highly efficient liquid distributor

working on the principle of Falling Film and Forced circulation Evaporation has been

used.

The product at the desired concentration of 40%w/w Total Solid is obtained at the

outlet of the final effect. Each effect is provided with recirculation cum transfer

pumps. The condensate from surface condensers is collected in a common

condensate pot. The condensate is transferred for further treatment / drain by using

centrifugal pump. 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 vapours.

G) DWGS Dryer Section

Wet distiller’s grains shall be fed into the dryer housing at controlled rate through a

suitable feeding system. The Rotary Bundle is enclosed in an insulated dryer housing

and on its outer flights are fixed. Dry, saturated steam is to be supplied to the bundle

through rotary joint at one end & the condensate is discharged through rotary joint

mounted of 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 Local Indication cum Control

panel.

H) Process Condensate Treatment Section

The process condensate from the evaporation section is treated in this unit and this

treated condensate is then recycled back to process thus reducing the fresh water

consumption.




Figure - 3: Process flow chart For Grain Based Distillery




Malt Spirit Plant (25 KLPD)

Malt Spirit Production process is given below:

Ø Malt handling- Malt is usually stored in silos before being milled and mashed. It has a

low moisture content of between 3 and 5%. The main processes in malt handling are

Intake, storage, conveying, removing unwanted materials & stones, weighing.

Ø Milling - The objective of milling is to reduce the malt to particles sizes, which will yield

the most economic extract (wort) and will operate satisfactorily under brewhouse

conditions and throughout the brewing process. The more extensive the malt is milled,

the greater the extract production.

Ø Mashing- Mashing is the process of combining a mix of milled grain (typically malted

barley with supplementary grains such as corn, sorghum, rye or wheat), known as the

"grain bill", and water, known as "liquor", and heating this mixture. Mashing allows the

enzymes in the malt to break down the starch in the grain into sugars, typically maltose

to create malty liquid called wort.

Ø Fermentation- Fermentation is an essential stage in the brewing process. It involves

adding yeasts to the cooled malt. These yeasts are fed by the amino acids in the brew

and produce alcohol from the sugar that is present. These natural reactions also

produce carbon dioxide.

Ø Pot Distillation- Malt Whisky is distilled twice - although a few distilleries may undertake

a third distillation - in Pot Stills which resemble huge copper kettles. The spirit is driven

off from the fermented liquid as a vapour and is then condensed back to a liquid. In the

first distillation the fermented liquid, or wash, is put into the Wash Still which is heated

either directly by fire or by steam-heated coils. At this stage the wash contains yeast,

crude alcohol, some unfermentable matter and the by-products of fermentation.

During the process of boiling the wash, changes take place in its constituents which are

vital to the flavour and character of the whisky. As the wash boils, vapours pass up the

neck of the still and then pass through a water-cooled condenser or a worm, a coiled

copper pipe of decreasing diameter enclosed in a water jacket through which cold

water circulates. This condenses the vapours and the resulting distillate, known as low

wines, is collected for re- distilling. The liquor remaining in the Wash Still is known as

pot ale or burnt ale and is usually treated and converted into distillers' solubles for

animal feed.

Ø Decantation- The decantation section comprises of a Centrifuge Decanter for

separation of suspended solids from Spent Wash coming out of distillation Plant.




Ø Wet cake/DWGS- Spent grains also known as DWGS, has a commercial value and can be

sold as by-products for livestock feed or Wet cake / DWGS will be passed through steam

tube bundle drier for drying into cake with 10 - 12% moisture (max.) to give higher shelf

life.

Figure 4: Process flow diagram of Malt Spirit production

Power Co-Generation (4.5 MW)

OPERATIONS

Proposed 4.5 MW co-generation plant consists of a high pressure water tube steam boiler

extraction cum condensing steam turbine. Fuel in the steam boiler will be burnt with the help

of air in the boiler furnace. Water will be circulated in the boiler drum and tubes thus getting

heated by the flame burning in the boiler furnace. Water comes out of the boiler drum

located at the top of the boiler as steam. Flue gases rise in the boiler furnace and come in

contact with the steam coming out of boiler drum. Steam after coming in contact with flue

gases gets heated up further thus getting superheated. Super heated steam leaves the boiler

in a pipe. Flue gases after super heating the steam pass through economizer where they pre-

heat the boiler feed water before it enters the boiler drum. After economizer, flue gases pass

through air pre-heaters where they heat the air which is fed to the boiler furnace for burning

the fuel. After air pre heaters flue gases pass through an ESP where the dust particles are

collected on charged electrodes. The dust is collected from the bottom of the ESP.

High pressure superheated steam from boiler is passed through a steam turbine, which is

used for distillery process operations. While passing through the turbine, the high pressure

and temperature steam rotates the turbine rotor and an electric alternator mounted on the

same shaft. Electric power is generated by the alternator. This electric power generated is

consumed in house i.e. for running the distillery and utilities like boilers auxiliaries etc.




Figure 5: Process flow chart for Proposed Co-generation Power Plant

(vi) Raw material required along with estimated quantity, likely source, marketing area of

final products, mode of transport of raw material and finished product.

(a) Raw Material Requirement:

The basic raw material for the manufacturing of alcohol will be grain which is unfit for human

consumption. In the present scenario, waste grain with different starch content is used like

broken rice, sorghum, baira, maize etc. The process requires the above waste grains to be

milled into specific flour size. The raw materials for the boiler fuel are Indian coal/ rice husk.

Table - 2 Raw Material Requirement

S. No.

Particular Total Requirement

Source & Mode of Transportation

1 Grain - Broken Rice, Sorghum, Baira, Maize etc.

300 to 305 MT/day

Through Grain suppliers By road

2. Barley Malt & adj Flour for Malt Plant 55 to 58 MT/Day Through Malt suppliers By road

3. Process Chemicals Near-by Markets by road

Sodium Hydroxide (Caustic) 480 Kg/day Nutrients 300 Kg/day Enzymes 300 Kg/day

Antifoam Agent 145 Kg/day Yeast (Active Dry Yeast/Distiller’s Yeast) 130 Kg/day




(b) Fuel Requirement for Boilers:

TABLE – 3 Fuel Requirement

Name of Raw Material Total Requirement Source & Mode of Transportation

Rice husk 250 TPD From authorized dealers by road

or

Indian Coal 200 TPD

(vii) Resources optimization/ recycling and reuse envisaged in the project, if any, should be

briefly outlined.

Water as a resource will be recycled at each possible step of the process and latest

technology and methodology will be adopted to conserve and reuse the resources.

Ø The distillery will be Zero Effluent Discharge so does not pose any threat to ground or

surface water quality.

Ø Incorporation of advanced technique i.e. Multi Effect Evaporator and dryer will enable

substantial reduction of final effluent.

Ø Water will be conserved at every stage of process. Large quantity of water is re-used &

recycled.

Ø Rainwater from rooftop will be collected and stored in water tanks and reused.

(viii) Availability of water it’s source, energy /power requirement and source should be

given.

(a) Water Requirement and Source

Total water requirement will be 1354 KLD which will be sourced from Ground Water.

Water Requirement for proposed project

The water requirement for the first run for project would be 3509 KLPD, which will be further

reduced through recycling to 2155 KLPD. Hence, fresh water requirement is 1354 KLD. Details

given below:

TABLE - 4 (A) Total Water Input

S. No. Section Water Consumption in KLPD

1 Process water in Liqn & Fermentation 944

2 DM Water for RS Dilution 225

3 DM water for boiler feed 960

4 Soft Water for Analyser Flash Tank 200

5 Soft Water for Vacuum Pump & Others 100




6 Blending & Bottling (12000 Cases ) 60

7 Bottle Washings 40

8 Soft Water Makeup for Cooling Tower 950

9 Misc. Washing water 10

10 Other Domestic Usage 20

Total 3509

TABLE -4(B) Total Water Output


1 Steam condensate 716

2 Spent lees PR 190

3 Spent lees rectifer 225

4 Water in spent wash (grain slops) 1198

5 Soft water for vacuum pump & others 100

6 Water in product 60

7 Bottle washing 40

8 CT evaporation & drift losses 950

9 Washing water 10

10 Domestic consumption 20

Total 3509

TABLE – 4 (C) Recycle & Utilization Streams


1 Vacuum pump water recirculation 100

2 Steam condensate recycle for boiler 716

3 Spent lees (Rect) - cooling tower makeup 225

4 Thin slops recycle to Liqn & mashing process 565

5 Process condensate to process 529

6 Washings water & CW blow down for greenbelt 20

Total recycling /re-utilisations of water per day 2155

Total fresh water input 1354




Figure 6: Water balance for 125 KLPD Grain based Distillery Operation




Figure 7: Water balance for 25 KLPD Malt Spirits Plant Operation




(b) Power Requirement and Source

The total power requirement will be 3.0 MW, which will be sourced from 4.5 MW Co-

Generation Power Plant.

(c) Steam Requirement

Total Steam requirement will be 36 TPH which will be met by boiler (40 TPH).

The steam requirement for different purposes is given below:

TABLE – 5 Steam Requirement

S. No.

Purpose Steam (TPH)

Details

1 Steam for Grain Distillery

30 TPH (4.2 TPH Liquefaction + 16.6 TPH Distillation + 1.9 TPH MEE + 7.3 TPH Dryer)

2 Steam for Malt Spirit 6 TPH (2 TPH Fermentation + 4 TPH Pot stills) Total 36 TPH

(d) Boiler Details:

40 TPH boiler is proposed. Details regarding boilers are mentioned in the table given below:

TABLE – 6 Boiler Details

S. No. Item Boiler details

1. Boiler Capacity 40 TPH

2 Type of Fuel Rice husk/ Indian coal

3. Stack Height 55 Metres

4. Pollution Control Equipment Measures ESP

(e) Details regarding the D.G. Sets

2 nos. of D. G. Sets of capacity 1000 KVA each will be installed with the plant for emergency

back-up. Details regarding the D.G. Sets are mentioned in the table given below:

TABLE – 7 Details Regarding the D.G. Sets

S. No. Details

1. Type of Fuel HSD

2. Capacity 2 x 1000 KVA

3. Stack Height (above roof level) As per CPCB/SPCB norms

4. Pollution Control Equipment Measures Adequate stack height/ Acoustic Enclosure




(ix) Quantity of Waste to be generated (liquid and solid) and Scheme for their

Management/Disposal:

Waste Water Generation and management:

Ø The project will be based on “ZERO EFFLUENT DISCHARGE”.

Ø Fresh water requirement of the project will be met by ground water. Efforts will be

made to conserve as much water as possible by recycling and reusing waste water.

Ø Grain Slops (Spent Wash) will be taken through Decanters Centrifuge for separation of

Suspended Solids separated as Wet Cake.

Ø Thin Slops from the Decanter Centrifuge will be partly (20%) recycled back to

Liquefaction Process), partly (20%) used in Analyser Column Reboiler for flash steam

generation under vacuum and the balance (60%) taken to Multi Effect Evaporation

Plant for concentration of thin slop to form a Syrup. This Syrup as Condensed Distillery

Solubles (CDS) is mixed with the Wet Cake coming out of Decanter Centrifuge and the

mixture is known as Distillers Wet Grain with Solubles (DWGS).

Ø DWGS will be fed to Dryers operating on steam and is dried to make it DDGS – Distillers

Dried Grain with Solubles.

Ø Process condensate is cooled and collected into an equalization tank with sufficient

residence time. After equalization, this process condensate will be fed for Ecophotox

and after treatment it will be used for greenbelt development within the complex.


in the form of DDGS, which will be ideally used as cattle feed.

Ø Ash from the boiler will be given to brick manufacturing unit.

Ø Yeast sludge may be added to the wet cake.

Ø Used oil & grease generated from plant machinery / gear boxes & D.G. Set will be partly

used in oiling & greasing as lubrication of external parts of machinery & partly will be

sold to the CPCB authorized recycler.

4.0 SITE ANALYSIS

(i) Connectivity

Plant site is well connected to NH 19 (earlier known as NH 2) at about ~0.5 km in West

direction. The nearest railway station is Paman Railway Station (~7.0 km in SSW direction).

The site is suitably located with respect to availability of raw material, water, road network,

skilled/semi skilled/unskilled and professional manpower etc. All communication facilities

such as telephone, telefax & internet are available in the vicinity of the plant site.




(ii) Land from Land use and Land ownership

Total plant area i.e. 9.7 ha (24 acres) has already been acquired by the company.

(iii) Topography

Topography of the core zone of the project is almost flat.

(iv) Existing land use pattern (agriculture, non-agriculture, forest, water bodies (including

area under CRZ), shortest distances from the periphery of the project to periphery of

the forests, national park, wild life sanctuary, eco sensitive areas, water bodies

(distance from the HFL of the river), CRZ. In case of notified industrial area, a copy of

the Gazette notification should be given

Environmental Settings of the Area

S. No.

Particulars Details (with approximate aerial distance and direction from

project site)

1. Nearest Village Chiraura Village (0.7 m in NNE direction)

2. Nearest Town & City Nearest Town - Rania (3.3 km in WSW direction) Nearest City - Kanpur (21 km in ENE direction)

3. Nearest National Highway / State Highway

NH - 19 (earlier known as NH 2) (0.5 km in West direction)

4. Nearest Railway station Paman Railway Station (7.0 km in SSW direction)

5. Nearest Airport Chaudhary Charan Singh International Airport, Lucknow (86 km in NE direction)

6. National Parks, Wildlife Sanctuaries, Biosphere Reserves, Tiger/ Elephant Reserves, Wildlife Corridors, Reserved Forest (RF)/ Protected forest (PF) etc. within 10 km radius

No National Parks, Wildlife Sanctuaries, Biosphere Reserves, Tiger/ Elephant Reserves, Wildlife Corridors, Reserved Forest (RF)/ Protected forest (PF) etc. lies within 10 km radius of the plant site.

7. Water Body (within 10 km radius) · Ghatampur Distributary (0.5 km in North direction) · Rind Nadi (1.5 km in SSW direction) · Supa Nala (3.5 km in NNE direction) · West Allahabad Branch (4.0 km in NE direction) · Non Nadi (7.5 km in SW direction)

8. Seismic Zone Zone – III [as per IS 1893 (Part-I):2002]

(v) Existing Infrastructure

There is no existing infrastructure within the project site.

(vi) Soil classification

The Kanpur Dehat district occupies a part of the Gaga-Yamuna doab in the Indo-Gangetic

Plain. More than 90% of the district area exhibits more or less a flat topography with a gentle

slope towards south-west. The elevation of the land surface varies from 117 m to 139 m amsl.




Geo-morphologically, the area can be classified into three broad geomorphic units viz. Older

Alluvial Plain, Older Flood Plain of rivers Yamuna, Sengar, Rind and Pandu and Active Flood

Plain of these rivers (Plate II).

The major area (about 90%) falls under Yamuna sub basin is covered by older alluvial soils

consisting broadly of 'Bhur' or sandy soil occupying high mounds, Matiyar or clay rich soil in

depressions and 'Domat' or loam in the plains.

(vii) Climatic data from secondary sources

The average annual rainfall of the district is 782.8 mm the climate is sub-humid and it is

characterised by a hot summer and general dryness except during the southwest monsoon.

About 90% of rainfall takes place from June to September.

During monsoon surplus water is available for percolation to ground water. May is the

hottest month of the year. The mean daily maximum temperature in May is 41.70C. The mean

daily minimum temperature is 8.60C and maximum temperature varies upto 450C.

With the onset of the monsoon in third week of June the day temperature drops down

appreciably. The January is the coldest month with mean daily maximum temperature 22.80C

and mean daily minimum temperature at 8.60C. The mean monthly maximum temperature is

32.20C and means monthly minimum temperature is 19.50C. During monsoon season, the

relative humidity is high and in summer season, relative humidity is less. The mean monthly

morning relative humidity is 69% and means monthly evening relative humidity is 50%. The

mean wind velocity is 9.6Km/hr. The potential evapotranspiration is 1660 mm.

(viii) Social Infrastructure available

Nearest town is Rania ~3.3 km in WSW direction. There are primary schools, dispensaries,

small hospitals, places of worship in nearby area of the project site. Most of the villages are

electrified. Telephone, Medical facilities and Telegraph facilities are available in the nearby

towns.

5.0 PLANNING BRIEF

(i) Planning Concept (type of industries, facilities, transportation etc.) Town and country

Planning/Development authority classification.

Proposed industry is a grain based distillery. Facilities required for the project will be provided

as per requirement. Transportation of raw material and final product will be done via existing

road network and cement concrete road will be developed within the plant premises.

(ii) Population Projection

Temporary influx of people will be there as the managerial and supervisory staff will generally

be outsiders. A projection may be made by a governmental organization, or by those

unaffiliated with a government.




(iii) Land use planning

Total project area is 9.7 ha (24 ares) of which about 33 % area will be developed under

greenbelt & plantation in order to reduce dust & noise pollution levels & to increase aesthetic

beauty of the area.

(iv) Assessment of infrastructure demand (Physical & Social)

The company will assess the demand of infrastructure (Physical & Social) in nearby area of

the project site and will be developed in under corporate social responsibilities programs.

(iv) Amenities/ Facilities

The company will develop the amenities/facilities in nearby area of the project site as per

requirement of local people under corporate social responsibilities programs.

6.0 PROPOSED INFRASTRUCTURE

(i) Industrial Area (Processing Area)

Integrated Distillery Project (Distillery Plant, Malt Spirit Plant, C0-generation Power Plant &

IMFL/CL Bottling Plant) of proposed capacity will be set up on 9.7 ha (24 acres) existing land

which has already been acquired by the company & converted to industrial use.

(ii) Residential area (Non Processing area)

Residential colony is not proposed for the plant. The local labour will be preferred for

employment opportunities.

(iii) Greenbelt

Out of the total plant area of 9.7 ha, 33% of the total plant area will be developed under

greenbelt/ plantation

(iv) Social Infrastructure

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.

(v) Connectivity

The plant is well connected with rail and road.

(vi) Drinking Water Management

Around 5 KLD of water will be required for drinking purpose

(vii) Sewerage System

Sewage from domestic activity will be disposed off through septic tank via soak pit system.

(viii) Industrial Waste management

The distillery will be based on “ZERO EFFLUENT DISCHARGE”. Waste water generated from

plant premises will be treated in ETP.




(ix) Solid Waste Management


in the form of DDGS, which will be ideally used as cattle/poultry/fish feed.

Ø Ash from the boiler will be given to brick manufacturers.

Ø ETP sludge will be dewatered in filter press and used as manure.

Ø Yeast sludge will be sent to the sludge drying beds or may be added to the wet cake.

(x) Power Requirement and Supply/Source

The total power requirement will be 3.0 MW which will be sourced from the 4.5 MW

Cogeneration Plant.

7.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN

(i) Policy to be adopted (Central/State) in respect of the project affected persons

including home oustees, land oustees and landless labourers (a brief outline to be

given).

Total project area is 9.7 ha (24 acres) which is already acquired by the company. Any

rehabilitation and resettlement plan is not applicable.

8.0 PROJECT SCHEDULE AND COST ESTIMATES

(i) Likely date of start of construction and likely date of completion (time schedule for

the project to be given).

The project will start only after obtaining Environmental Clearance and all other required

clearances from the statutory authorities.

(ii) Estimated project cost along with analysis in term of economic viability of the project.

Ø Total cost of the Project: Rs. 175.0 Crores

Ø Cost for Environment Protection Measures:

v Capital Cost: Rs. 30.0 Crores

v Recurring Cost/annum: Rs. 1.75 Crores/annum

9.0 ANALYSIS OF PROPOSAL (Final Recommendations)

(i) Financial and social benefits with special emphasis on the benefit to the local people

including tribal population, if any, in the area.

The project will result in growth of the surrounding areas by increasing 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. Uttar Pradesh state will get revenues in terms of taxes. Business

opportunities for local community will be available like transport of raw material/product to

market, fly ash transport to brick manufactures, maintenance & house-keeping contract work

etc.

INDEX [environmentclearance.nic.in]environmentclearance.nic.in/writereaddata/Online/TOR/16...Kanpur...

Documents

Transcript of INDEX [environmentclearance.nic.in]environmentclearance.nic.in/writereaddata/Online/TOR/16...Kanpur...