Phase 1:- Phase 2:- -...

Proposed installation of Unit II – 500 KLPD Ethanol/RS Industrial/ENA/SDS Plant {(250 KLPD Grain Based in Phase I) & (125

KLPD Grain and 125 KLPD Molasses Based in Phase II)} & 40 MW Co-generation Power Plant {(20 MW in Phase I ) & (1 x 15 MW,

1 x 5 MW in Phase II)} in Existing Distillery Plant

At Village Sangat Kalan, Tehsil Bathinda, District Bathinda, Punjab

Pre Feasibility Report

M/s Om Sons Marketing Private Limited 1

PRE - FEASIBILITY REPORT

1.0 EXECUTIVE SUMMARY

(I) Introduction

Om Sons Marketing Private Limited is proposing installation of Unit II – 500 KLPD Ethanol/RS

Industrial/ENA/SDS Plant {(250 KLPD Grain Based in Phase I) & (125 KLPD Grain Based and 125

KLPD Molasses based in Phase II)} & 40 MW Co-generation Power Plant {(20 MW in Phase I)

and (1x15 MW, 1x5 MW in Phase II)} in Existing Distillery Plant at Village Sangat, Tehsil & District

Bathinda, Punjab.

The unit will be installed in two phases as mentioned below:-

Phase 1:-

a) 250 KLPD Ethanol/RS Industrial/ENA/SDS Plant Grain Based

b) 20 MW Co- Generation power plant

Phase 2:-

a) 125 KLPD Grain Based Ethanol/RS Industrial/ENA/SDS Plant

b) 125KLPD Molasses based Ethanol/RS Industrial/ENA/SDS Plant

c) 1 X 15 MW, 1 X 5 MW Co- Generation power plant

Grain will be used as a raw material in grain based operation which is easily available from the

local market. Molasses will also be used as a raw material in molasses based operation which is

available from nearby sugar mills.

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

Category ‘A’, Project or Activity - 5(g).

TABLE – 1

SALIENT FEATURES OF THE PROJECT

S.

NO.

PARTICULARS DETAILS

A. Nature & Size of the Project

Units Capacity

PHASE I

Grain based Ethanol/RS

Industrial/ENA /Denatured Spirit

Unit

250 KLD

Co-Generation Power 20 MW

CO2 Plant 112.5 TPD

DDGS/ Cattle Feed/ Poultry Feed 150 TPD

PHASE II

Grain based Ethanol/RS 125 KLPD







Industrial/ENA /Denatured Spirit

Unit

Molasses based Ethanol/RS

Industrial/ENA / Denatured Spirit

Unit

125 KLPD

Co-Generation Power 1 x 15 MW & 1x 5 MW

CO2 Plant 112.5 TPD

DDGS/ Cattle Feed/ Poultry Feed 75 TPD

B. Category of the Project As per EIA Notification dated 14th Sep., 2006 as amended from time

to time; the project falls in Category ‘A’, Project or Activity - 5(g).

C. Location Details

Village Sangat Kalan

Tehsil Bathinda

District Bathinda

State Punjab

Latitude 30˚ 03’ 47.8” N to 30˚ 04’ 03.85” N

Longitude 74˚ 51’ 15.77” E to 74˚ 51’ 31.13”” E

Toposheet No. H43116 & H43013

D. Area Details

Total Project Area 8.8 Ha (22.0 Acres)

Greenbelt/Plantation Area

(ha)

2.9 ha (~33 % of the total project area) has been proposed as Green

belt/Plantation

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

1. Nearest Village Sangat Kalan (1.5 km in NW direction)

2. Nearest Town/City Bathinda City (17.5 km in NNE direction)

3. Nearest National Highway /

State Highway

NH-64 (0.5 km in South direction)

4. Nearest Railway station Sangat Mandi Railway Station (3.0 km in NW direction)

5. Nearest Airport Sri Guru Ram Dass Jee International Airport, Amritsar (180 km in

North direction)

6. National Parks, Wildlife

Sanctuaries, Biosphere

Reserves, Tiger/ Elephant

Reserves, Wildlife Corridors

etc. within 10 km radius

No National Parks, Wildlife Sanctuaries, Biosphere Reserves, Tiger/

Elephant Reserves, Wildlife Corridors etc. lies within 10 km radius of

the project site.

7. Reserved Forests (RF) /

Protected Forests (PF) etc.

within 10 Km. radius

No Reserved Forests (RF) / Protected Forests (PF) etc. lies within 10

Km. radius of the project site.

8. River / Water Body (within 10

km radius)

� Lower Lassara Nallah (0.7 km in SE direction)

� Canal (1.0 km in SSW direction)

� Sirhind Canal (5.0 km in SE direction)

F. Cost Details

1. Total Cost of the Project Rs. 566 Crores







2. Cost for Environment

Management Plan

o Capital Cost - Rs. 56 Crores

o Recurring Cost - Rs. 10.0 Crores / annum

G. Basic Requirements for the project

Water Requirement (KLD) Phase I:

250 KLPD Grain Based Distillery - 2501 KLPD

Phase II:

125 KLPD Grain Based Distillery - 1027 KLPD

125 KLPD Molasses Based Distillery – 1039 KLPD

Total water requirement (500 KLPD) – 4567 KLPD

Source: Canal Water

Power Requirement (MW) 9.0 MW

Source: Proposed 40 MW Captive Power Plant & D.G. Sets- 3 x 1000

KVA (for Back-up purpose only)

Man Power Requirement 800 persons

Source: Unskilled / Semi-Skilled - Local Area; Skilled- Local & Outside

H. Working Days for Distillery 350 days/ annum

I. Product Ethanol/RS Industrial/ENA/SDS Plant

1.1 ENVIRONMENTAL MANAGEMENT PLAN FOR UNIT II

Particulars DETAILS

Air Quality Management

Possible Sources Boilers (Power Plant), Transportation vehicles, D.G. Sets etc.

Emissions � ESP will be installed with the proposed boilers.

� Adequate boiler stack height will be maintained.

� DG Sets will also have adequate stack of height as per CPCB guidelines.

� Adequate measures for Fugitive Dust Emissions will be taken.

� All the internal roads will be asphalted.

� Development of green belt around the periphery & within the premises of the plant

will help in attenuating the pollutants emitted by the plant.

Monitoring Ambient air quality and stack emission will be regularly monitored to ensure that

ambient air quality standards and suggested limits on stack emission loads would be

met honestly at all the time.

Water Management

Management � The project will be based on “Zero Effluent Discharge”.

� Fresh water requirement of the project will be met by ground water& Canal Water.

Efforts will be made to conserve as much water as possible by recycling and reuse.

� Record of wastewater returned back to process for utilization in

Fermentation/cooling tower and to gardening will be kept.

� Process condensate from MEE will be recycled back to the process for grain

dilution and cooling tower make up.

� Spent lees generation from distillation column will be recycled partly to the

columns for dilution and balance will be used for cooling tower make up.







� Grain: - DWGS is dried and final product DDGS will be sold as cattle feed.

� Molasses: The spent wash from molasses will be sent to MEE for concentration and

the concentrated spent wash will be mixed with fuel and will be burnt in the

incinerator boiler.

� The waste water generated from the sanitary blocks will be disposed off via septic

tank followed by soak Pit.

Noise Management

Management � Proper maintenance, oiling and greasing of machines at regular intervals.

� PPEs like earplugs and earmuffs to the workers exposed to high noise level.

� Development of green belt/plantation for 33% of the total project area.

� Regular monitoring of noise level will be done.

� D.G sets will be provided with acoustic enclosures to control the noise level within

the prescribed limit.

Monitoring Regular monitoring of noise levels will be carried out and corrective measures in

concerned machinery will be adapted accordingly to the possible extent.

Solid Waste Management

Management � Grain Operation - 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.

� Molasses operation - Concentrated spent wash will be mixed with fuel and will be

burnt in the incinerator boiler.

� Ash from the boiler will be sold to brick manufacturers.

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

will be sold out to the CPCB authorized recyclers.

Green belt Development/ Plantation

Management � 33% of total project area will be developed under green belt/plantation.

� All the barren areas will be vegetated.

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

� Green belt development along with the road & plant boundary will attenuate noise

level arrest dust and improve the environment in surrounding.

Odour Management

Management � Odour will be primarily controlled at source by good operational practices,

including physical and management control measures.

� Better housekeeping will be maintained with good hygiene condition by regular

steaming of all fermentation equipment.

� Use of efficient biocides to control bacterial contamination.

� Control of temperature during fermentation to avoid in-activation / killing of yeast.

� Avoiding staling of fermented wash.

� Regular use of bleaching powder 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

The Oasis Group has Hotels of star category at Mussoorie and Delhi under the world known

management group Carlson and brand name Country Inn & Suites by Carlson”

The group is also in luxury goods business under the brand name of “Dillano Luxurious

Jewels” which caters to the niche business class and participates in elite jewellery exhibitions

such as Wedding Asia etc.

Oasis Group, India Based Group are well known and highly reputed in the Luxury/hospitality

liquor/ business. The Group has wide distribution network for both Indian and foreign made

liquor in number of states. They have been engaged with this activity for more than 5 decades.

At present the group owned five running Distilleries, two bottling Units and expanding and

diversifying into different business at fast pace.

The Oasis Group is a highly reputed conglomerate with diverse interests that include Distillery,

Liquor Retailing, Hotels and Constructions. The Group’s rapid growth on Indian corporate

scene rests on its strong foundation of professional management and astute collective

enterprises. Over the last 15 years, the Malhotra Group has grown into a diversified

business and industrial house with a high growth rate and a total commitment to persistent

growth.

The group was founded by Shri Om Prakash Malhotra. It is his foresight and vision that has

promoted the organization to take its present shape. Its present Chairman and Director, Mr.

Deep Malhotra, a second-generation entrepreneur, carries with him rich experience coupled

with sharp commercial acumen. The Group has a team highly qualified, experienced, trusted

persons with a right mix of technocrats, Finance Experts and management professionals.

Group Companies:-

1. Country Inn & Suites By Carlson (A Unit of Diamond Resorts Pvt. Ltd.), Mussoorie

2. Oasis Resorts Pvt. Ltd., Delhi

3. Dillano Luxurious Jewels Ltd., Delhi

4. Oasis Commercial Pvt. Ltd., Haryana

5. Oasis Overseas Pvt. Ltd., Haryana

6. Malbros International Pvt. Ltd, Punjab

7. Oasis Distilleries Ltd, Indore

8. Gauravh Wines Pvt. Ltd., Punjab

9. Om Sons Marketing Pvt. Ltd, Punjab

10. Malbros Enterprises Pvt. Ltd, Delhi







11. Calx Paper Pvt. Ltd, Delhi

12. Gee Emm Bros. Distributors Pvt. Ltd., Delhi

13. Vijeta Beverages Pvt. Ltd., Rajasthan

14. Gautam Wines Pvt. Ltd., Punjab

ALCOHOL MANUFACTURING: - The Alcohol Distillation Unit has been designed as per multi

pressure distillation technology which gives maximum of output which minimum of input

energy. The ENA being made at our Plant meets best industrial specifications.

(ii) Brief description of nature of the project

Om Sons Marketing Pvt. Ltd. is proposing Unit II – 500 KLPD Ethanol/RS Industrial/ENA/SDS

Plant {(250 KLPD Grain Based in Phase I) & (125 KLPD Grain Based and 125 KLPD Molasses

based in Phase II)} & 40 MW Co-generation Power Plant {(20 MW in Phase I) and (1x15 MW, 1x5

MW in Phase II)} in Existing Distillery Plant at Village Sangat, Tehsil & District Bathinda, Punjab.

Grain/Molasses will we used at raw material which is easily available local market/neighbour

state.

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

Category ‘A’, Project or Activity - 5(g).

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

Advancement in science and technology has created so many products that have enhanced

the quality of human life in every passing year. The human race is largely dependent on

industrialization for up gradation in quality of life. Progress of the nation is judged through its

economic growth which is largely dependent on industrial productivity. In Indian economy

(which is agro based) many industries are dependent over agricultural produce for production

of luxury and need based commodities. Alcohol has assumed a very important place in the

Country’s economy. It is a vital raw material for a number of chemicals. It has been a source of

revenue by way of excise duty levied by the State Government on alcohol liquors. The use of

alcohol for the purpose of potable liquor is as high as its use for industrial purposes.

According to analysts, the Indian Ethanol industry is expected to witness accelerating growth

in coming years. Ethanol is an alcohol fuel that is added to petrol in some countries to lower

cost to the consumer, reduce consumption of oil, and lessen the environmental impact of

transportation. Mixed fuels are rated by the amount of ethanol contained; for example,

common blends are E10, which contains 10% ethanol, and E15, which contains 15% alcohol.

Another common blend is E85, also known as flex fuel, in which the ethanol ranges from 51% in

winters to 83% in summers.







In addition, though ethanol reduces air particulate pollution, its production results in fairly high

greenhouse gas emissions and negates any the environmental benefit of the shift from fossil

fuel.

The biggest concern with the addition of ethanol to India's fuel supply is that it will take up

scarce land set aside for grazing and other crops to grow fuel. With the demand likely to be

huge, there is bound to be a shift in land use from food crops to fuel crops. Agriculture will

become even more intensive. Without adequate reforms and education in the agricultural

sector to increase productivity, the shift to fuel crops will result in food price inflation. The

savings from reduced oil imports will be spent instead on subsidies and higher food prices.

Furthermore, technology can improve at two ends - energy efficiency at the EV end and

greater storage capacity at the EVB end. The latter would translate into better performing

vehicles without the consumer having to regularly upgrade his EV.

In the path of company’s growth and development this proposed project will serve as yet

another milestone.

(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 Ethanol production is concerned, Indian market play a vital role at both

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

(vi) Export Possibility

The possibility of alcohol export is very good. So Indian industries export alcohol in African,

Europe & Asian countries which is very profitable now days. After setup of this type of alcohol

industries government can collect more revenue.

(vii) Domestic / Export Markets

Presently the big Indian players in alcohol production and bottling are United Spirits Ltd, ABD

Pvt Ltd, Radico khaitan Ltd, Globus Spirits Ltd etc. So they try to fulfil the current requirement

of alcohol in domestic as well as export market.

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

Direct and indirect employment will be generated due to the proposed project. During

construction phase, employment opportunity to approximately 1000 persons is estimated.

The total manpower requirement for the proposed project will be 800 persons (inclusive of on

roll employees and on contract employees).







3.0 PROJECT DESCRIPTION

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

No, this project is not an interlinked project.

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

project site layout) with coordinates







Figure - 1: Location Map

Proposed installation of Unit II –500 KLPD Ethanol/RS Industrial/ENA/SDS Plant {(250 KLPD Grain Based in Phase I) & (125 KLPD Grain and 125 KLPD Molasses Based in Phase II)} & 40 MW Co-

generation Power Plant {(20 MW in Phase I ) & (1 x 15 MW, 1 x 5 MW in Phase II)} in Existing Distillery Plant




(iii) Key Plan

Figure - 2: Key Plan

Proposed installation of Unit II –500 KLPD Ethanol/RS Industrial/ENA/SDS Plant {(250 KLPD Grain Based in Phase I) &

(125 KLPD Grain and 125 KLPD Molasses Based in Phase II)} & 40 MW Co-generation Power Plant {(20 MW in Phase I ) & (1

x 15 MW, 1 x 5 MW in Phase II)} in Existing Distillery Plant


Form–I / Appendix–I

Om Sons Marketing Private Limited 11

(iv) 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.

Following factors were considered while selecting the site:-

� Suitable source of raw material.

� Location in rural area ensures adequate availability of manpower at marginally

lower rates, compared to metro cities of India.

� Nearness to NH-64 which makes it easier to transport raw materials & Products.

� There is no National Park, Biosphere Reserves, Tiger Reserves, Reserved / Protected

Forests within 10 km radius of study area.

(v) Size or magnitude of operation

M/s Om Sons Marketing Private Limited is proposing installation of Unit II – 500 KLPD

Ethanol/RS Industrial/ENA/SDS Plant {(250 KLPD Grain Based in Phase I) & (125 KLPD Grain

and 125 KLPD Molasses Based in Phase II)} & 40 MW Co-generation Power Plant {(20 MW

in Phase I) & (1 x 15 MW, 1 x 5 MW in Phase II)} in Existing Distillery Plant at Village Sangat

Kalan, Tehsil Bathinda, District Bathinda, Punjab.

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 Capacity

1. Ethanol/RS Industrial/ENA/SDS unit 500 KLPD

Phase 1:-

250 KLPD Grain Based Unit

Phase 2:-

a) 125 KLPD Grain Based Unit

b) 125KLPD Molasses based Unit

2. Co-Generation Power Plant 40 MW

Phase 1:- 20 MW

Phase 2:- 1 X 15 MW and 1 X 5 MW







(vi) 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:

• Grain storage

• Grain cleaning, milling and flour handling

• Slurry preparation & liquefaction

• Multi pressure alcohol distillation

• Alcohol daily receivers & bulk storage

• MEE & Dryer

MAIN PLANT & MACHINERY

1. Grain Storage :

Grains are procured from various sources, such as FCI Storage godowns through agencies

and are unloaded into large Storage Silos after Pre-Cleaning. Storage Silos are specially

designed to keep the Grains in good condition for longer durations and also avoid its

deterioration and theft, etc. It is being proposed to have 30 – 45 days of Grain Storage

facility in the Distillery.

2. Grain Cleaning, Milling and Flour Handling :

The grain is lifted in bucket elevators, screened followed by removal of stones and iron

matter. 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. The flour addition is metered through the Batch Tipping

Machine with load cell arrangement, before transferring the flour to the Slurry Tank

through another Screw Conveyor (pre-masher) for slurry preparation process. It is being

proposed to have 4 x 16 TPH as milling paraphernalia for this Distillery.

3. Slurry Preparation & Liquefaction :

Grain flour and process water is fed at controlled rate to Initial Liquefaction tank. Mixed

slurry is taken to the Initial Liquefaction Tank where additional quantity of water is added

as per requirement. Viscosity reduction Enzyme and stabilizing chemicals and a portion of

liquefying enzyme are also added at this stage. This slurry is then “cooked” in the jet

cooker.







The slurry is continuously pumped to a steam jet cooker where high-pressure steam

rapidly raises the slurry temperature. The mixture of slurry and steam is then passed

through the Retention Vessel. The retention vessel has sufficient capacity to provide the

desired retention time at a given flow rate. The cooked mash is discharged to a Flash

Tank.

The cooking process, accomplished in the above manner, converts the slurry into a

hydrated, sterilized suspension and is therefore susceptible to enzyme attack for

liquefaction.

The gelatinized mash from the Flash Tank is liquefied in the Final Liquefaction Tank where

liquefying enzyme (alpha-amylase) is added. The liquefied mash is cooled in Mash Cooler

and transferred to Saccharification cum fermentation section. This process initiates the

formation of sugar.

The gelatinized mash from the Flash Tank is liquefied in the Final Liquefaction Tank where

liquefying enzyme (alpha-amylase) is added. The liquefied mash is cooled in Mash Cooler

and transferred to Saccharification cum Fermentation section.

4. Hiferm-Nm Saccharification and Instantaneous Fermentation:

Yeast Activation:

Yeast seed material is prepared in water-cooled Yeast Activation Vessel by inoculating

sterilized mash with Active Dry Yeast. Optimum temperature is maintained by cooling

water. The contents of the Yeast Activation Vessel are then transferred to Fermenter.

Saccharification & Instantaneous Fermentation:

The Liquefied starch slurry comprising Dextrins is partly taken for Yeast development in

Yeast Activation vessel and majorly transferred into the Fermenter. Amyloglucozydase

and other nutrient Enzymes are first added to Saccharify the Starch Slurry causing

formation of Sugars. Immediately, the Active Yeast is introduced in the system for

simultaneous Fermentation. The process of fermentation is to convert the fermentable

substrate into alcohol. To prepare the mash for fermentation, it may have to be diluted

with water. The pH of the mash is adjusted by the addition of acid. Yeast is available in

sufficient quantity to initiate fermentation rapidly and complete it within the cycle time.

At the start of the cycle, the fermenter is charged with mash and contents of the Yeast

Activation Vessel. Significant heat release takes place during fermentation. This is







removed by passing cooling water through the Fermenter PHE’s to maintain an optimum

temperature. The recirculating pumps also serve to empty the fermenters into Beer Well.

After the fermenters are emptied, they are cleaned with water and caustic solutions and

sterilized for the next batch. The carbon dioxide evolved during the process is vented to

atmosphere after recovery of alcohol in a scrubber.

5. Ethannol Distillation :

Fermented wash from wash holding tank T-01 is pumped by wash feed pump P-01 to the

top of degassing column (C-2) after preheating the same in beer heater E-02 and spent

wash heat exchanger E-01. The vapors along with non-condensable gases from the top of

degassing column (C-02) are rectified in Heads column (C-03), to expel the high volatiles,

technically known as heads. Bottom liquid from the degasser flows into analyzer column

(C-01) where alcohol is stripped from the liquid. The liquid from bottom of analyzer

column (C-01) is completely stripped of alcohol and is pumped out by thick slop discharge

pump P-02 through heat exchanger E-01 where it preheats the fermented wash before it

enters degassing column. The slop from the analyser column will be feed in to

decanter.The dilute alcohol vapors from near the top of analyzer column (C-01) are

condensed first in beer heater (E-02) while exchanging heat with wash feed and then in

analyzer condenser (E-03). Degasser and analyzer operate under vacuum. The

condensate from E-02 and E-03 is collected in Rectifier Feed Tank V-02. The vapors for

stripping alcohol are generated from analyzer column bottom liquid in the analyzer

column re-boiler (E-04) by using the rectified column top vapors, as discussed

subsequently.

Vapors from the top of heads column (C-03) are condensed in heads column condenser

(E-06) and then in head column vent condenser (E-07). Part of the condensate is returned

to column C-03 as reflux while a small portion is taken out as an impure spirit cut. Liquid

from bottom of C-03 is also taken into Rectified feed tank V-02.

Dilute alcohol water mixture from rectifier feed tank (V-02) are pumped by rectifier feed

pump (P-04) through rectifier feed pre-heater E-11 in to rectifying column (C-04). Rectifier

and its associated equipment work under pressure so that these vapors can supply the

necessary heat for generating the vapors.







The condensate from E-04 is then pumped as Reflux to rectifying column C-04. Rich

alcohol vapors at a concentration of 95.5% v/v from top of rectifying column (C-04) are

condensed first in Analyzer (E-04) and then in Reflux Vent Condenser (E-05). The liquid

from E04 and E-05 are collected in Rectifier Reflux Tank (V-01). Part of the liquid from E-

05 may be drawn off as impure spirit. The impure spirit cut will be maintained as little as

possible to maintain aldehyde levels to meet the required limits in Absolute Alcohol.

Liquid from the reflux tank (V-01) is pumped by Product Pump (P-03) partly as product

and partly as reflux to the top of the Rectifying Column (C-04). The necessary rectifying

vapors to C-04 are generated by boiling the C-04 bottom liquid in Rectifier Column Re-

boiler E-08 using medium pressure steam. Some side streams are drawn from rectifier

column as light and heavy fractions of higher alcohols called fusel oils and cooled in fusel

oil coolers E-09 and E-10 and are mixed with water and allowed to separate out in fuel oil

separator F-01. All vents from E-03, E-07, V-02 and E-05 are connected to Vent Gas

Absorber (C-05) where the vent gases are scrubbed with water to recover entrained

alcohol. The scrubber water is used for washing the fuel oils in fuel oil separator to

recover alcohol from the fuel oil fractions. The absorber vent is connected to vacuum

pump (G-01) which is used to create vacuum in the analyzer and degasser.

Absolute alcohol is manufactured by dehydration of Rectified Spirit. The process adopted

here is based on Pressure Swing Adsorption (PSA) system using Molecular Sieves (3-A).

The flow scheme is shown in above referred flow diagram.

Rectified spirit, after preheating by waste hot streams, is vaporized and superheated in E-

03 and E-04 by using medium pressure steam at 6 Kg/cm2g pressure. Hot vapors at

kg/cm² g pressure and 130° C temperature pass through PSA column S-01A/S-01B where

the water vapors are retained while water free alcohol is released as vapors. The vapors

are condensed in E-07 and E-08 and collected as Absolute Alcohol. When the molecular

sieve bed is saturated with water the alcohol vapors are shifted to the other tower and

the first tower is taken for regeneration. Regeneration is done first by pressure releasing

and creating vacuum and then by elutriating with dehydrated alcohol vapors from the

tower in dehydration operation. The vapors are condensed in E-06 and E-05 and the vent

vapors are recovered through scrubber C-02. Vacuum can be created vacuum by P-04.







(Eductor may also be considered for this duty). Product is cooled in E-09 and transferred

to Absolute Alcohol receiving tank and then on to storage tank.

6. Alcohol Daily Receivers & Bulk Storage :

Alcohol is first taken to Daily receiver storage tanks, which is based on the State Excise

laws, storage for three days considering the weekly holidays of two days. Thereafter, the

alcohol is transferred to Bulk Storage Tanks after taking the daily receiver Dip. This is

transferred using flameproof pumps. Final dispatch of alcohol is metered and again is

carried out using special flameproof pumps. The Bulk Spirit Storage is proposed to be set

up for 30 days.

EFFLUENT HANDLING SECTION

1. Decantation Section:

Decantation section comprises of Centrifuge Decanters, operating at high rpm which are

used for separation of suspended solids from Spent Slops coming out of Distillation

section. The Wet cake thus separated has 30-35% w/w solids, as removed from bottom of

Decanters. This is directly loaded on the trolleys parked below. Thin slops coming out of

Decanter are collected in a tank and are transferred for part recycle & further for

Evaporation into thick syrup.

2. Integrated Evaporation Section:

The suggested treatment scheme is a 2 FF + Finisher Evaporation Plant for Thin Slops

Evaporation. The following points will elucidate the basic working principle:

� Shell & Tube type Evaporators with highly efficient liquid distributor working on the

principle of Falling Film Evaporation have been used, with Plate type Preheaters for

preheating of FEED stream which serves the purpose of energy conservation.

� Analyzer vapour is fed to the first effect evaporator shell side at the given pressure

and temperature as the heating medium.

� The Feed from the Feed balance tank is taken to the PHCOND to make the best

heat recovery.

� The Feed after getting heated to the predetermined temperature in preheater is

fed from the first effect evaporator which is Falling Film Evaporator -1

� The flow path is given below.







INLET FEED - pH cond – E1 – E2 – OUTLET PRODUCT

� Vapours generated in 1st effect VLS (Vapour Liquid Separator) are used as heat

source in the 2nd effect.

� The product at the desired concentration of TS is obtained at the outlet of the

second effect, which is a Falling Film evaporator.

� A Shell & tube type Multi-pass Surface condenser is employed for condensing the

shell side vapours.

� The Pure and the process condensate are collected in receiving vessels.

� Highly efficient operating pumps will be provided for pumping the required fluid.

� The operation of the plant will be under vacuum. Vacuum is created with the help

of a water ring vacuum pump.

� The plant will have 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 vapours.

CONCLUSION

The thick syrup thus obtained is mixed with the Wet Cake obtained from Decanter

Centrifuges using specially designed Ribbon type mixer and this enriches the protein

content in the fibrous suspended solids separated earlier in Decanter. This Protein & Fibre

rich DWGS is directly sellable as Cattle / Poultry Feed. However, in order to increase the

shelf life of such by-product, it is necessary to dry the product, with minimum possible

moisture content.

SYSTEM DESCRIPTION FOR DWGS 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 on its outer flights is 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 at other 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 vapours 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.

SYSTEM DESCRIPTION FOR COOLING & CONVEYING

� DWGS below product screw is discharged into charging hopper of pneumatic

conveying system.

� Rotary feeder feeds it into the conveying line.

� Ambient air is used for conveying.

� The material gets conveyed to product collector & discharged from rotary

discharge valve.

� Exhaust air is vented to atmosphere.

� The conveying system is lean phase suction type, using centrifugal blower as prime

mover. The conveying air quantity is designed considering cooling requirement & to

cool the product before discharge.







Figure - 3: Process flow chart For Grain Based Distillery

FOR MOLASSES BASED OPERATION

i) Molasses Unloading and Storage

Molasses from tankers will be unloaded at unloading point and transfer in to

molasses storage tank.

ii) Hiferm-Nm Saccharification and Instantaneous Fermentation:

Yeast Activation:

Yeast seed material is prepared in water-cooled Yeast Activation Vessel by inoculating

sterilized mash with Active Dry Yeast. Optimum temperature is maintained by cooling

water. The contents of the Yeast Activation Vessel are then transferred to Fermenter.

Fermentation:

The Molasses from storage tank to be pumped to Dilutor installed in Fermentation

section and diluted with water. The diluted Molasses called Wort will be feed into Pre







Fermenter for activation of Yeast. The activated yeast from the Yeast activation vessel

transfer into pre fermenter.

Once the yeast activated in Pre fermenters it will be transfer in to fermenters and diluted

molasses to be add The process of fermentation is to convert the fermentable substrate

into alcohol. The pH of the wort is adjusted by the addition of acid. Yeast is available in

sufficient quantity to initiate fermentation rapidly and complete it within the cycle time.

At the start of the cycle, the fermenter is charged with wort and contents of the Yeast

Activation Vessel. Significant heat release takes place during fermentation. This is

removed by passing cooling water through the Fermenter PHE’s to maintain an optimum

temperature. The recirculating pumps also serve to empty the fermenters into Beer Well.

After the fermenters are emptied, they are cleaned with water and caustic solutions and

sterilized for the next batch. The carbon dioxide evolved during the process is vented to

atmosphere after recovery of alcohol in a scrubber.

iii) Ethanol Distillation:

Fermented wash from wash holding tank T-01 is pumped by wash feed pump P-01 to the

top of degassing column (C-2) after preheating the same in beer heater E-02 and spent

wash heat exchanger E-01. The vapours along with non-condensable gases from the top

of degassing column (C-02) are rectified in Heads column (C-03), to expel the high

volatiles, technically known as heads. Bottom liquid from the degasser flows into analyzer

column (C-01) where alcohol is stripped from the liquid. The liquid from bottom of

analyzer column (C-01) is completely stripped of alcohol and is pumped out by thick slop

discharge pump P-02 through heat exchanger E-01 where it preheats the fermented wash

before it enters degassing column. The slop from the analyser column will be feed in to

decanter. The dilute alcohol vapours from near the top of analyzer column (C-01) are

condensed first in beer heater (E-02) while exchanging heat with wash feed and then in

analyzer condenser (E-03). Degasser and analyzer operate under vacuum. The

condensate from E-02 and E-03 is collected in Rectifier Feed Tank V-02. The vapours for

stripping alcohol are generated from analyzer column bottom liquid in the analyzer

column re-boiler (E-04) by using the rectified column top vapours, as discussed

subsequently.







Vapours from the top of heads column (C-03) are condensed in heads column condenser

(E-06) and then in head column vent condenser (E-07). Part of the condensate is returned

to column C-03 as reflux while a small portion is taken out as an impure spirit cut. Liquid

from bottom of C-03 is also taken into Rectified feed tank V-02.

Dilute alcohol water mixture from rectifier feed tank (V-02) are pumped by rectifier feed

pump (P-04) through rectifier feed pre-heater E-11 in to rectifying column (C-04). Rectifier

and its associated equipment work under pressure so that these vapours can supply the

necessary heat for generating the vapours.

The condensate from E-04 is then pumped as Reflux to rectifying column C-04. Rich

alcohol vapors at a concentration of 95.5% v/v from top of rectifying column (C-04) are

condensed first in Analyzer (E-04) and then in Reflux Vent Condenser (E-05). The liquid

from E- 04 and E- 05 are collected in Rectifier Reflux Tank (V-01). Part of the liquid from E-

05 may be drawn off as impure spirit. The impure spirit cut will be maintained as little as

possible to maintain aldehyde levels to meet the required limits in Absolute Alcohol.

Liquid from the reflux tank (V-01) is pumped by Product Pump (P-03) partly as product

and partly as reflux to the top of the Rectifying Column (C-04). The necessary rectifying

vapours to C-04 are generated by boiling the C-04 bottom liquid in Rectifier Column Re-

boiler E-08 using medium pressure steam. Some side streams are drawn from rectifier

column as light and heavy fractions of higher alcohols called fusel oils and cooled in fusel

oil coolers E-09 and E-10 and are mixed with water and allowed to separate out in fuel oil

separator F-01. All vents from E-03, E-07, V-02 and E-05 are connected to Vent Gas

Absorber (C-05) where the vent gases are scrubbed with water to recover entrained

alcohol. The scrubber water is used for washing the fuel oils in fuel oil separator to

recover alcohol from the fuel oil fractions. The absorber vent is connected to vacuum

pump (G-01) which is used to create vacuum in the analyzer and degasser.

Absolute alcohol is manufactured by dehydration of Rectified Spirit. The process adopted

here is based on Pressure Swing Adsorption (PSA) system using Molecular Sieves (3-A).

The flow scheme is shown in above referred flow diagram.

Rectified spirit, after preheating by waste hot streams, is vaporized and superheated in E-

03 and E-04 by using medium pressure steam at 6 Kg/cm2g pressure. Hot vapours at

kg/cm² g pressure and 130° C temperature pass through PSA column S-01A/S-01B where







the water vapours are retained while water free alcohol is released as vapours. The

vapours are condensed in E-07 and E-08 and collected as Absolute Alcohol. When the

molecular sieve bed is saturated with water the alcohol vapours are shifted to the other

tower and the first tower is taken for regeneration. Regeneration is done first by pressure

releasing and creating vacuum and then by elutriating with dehydrated alcohol vapours

from the tower in dehydration operation. The vapours are condensed in E-06 and E-05

and the vent vapours are recovered through scrubber C-02. Vacuum can be created

vacuum by P-04. (Educator may also be considered for this duty). Product is cooled in E-

09 and transferred to Absolute Alcohol receiving tank and then on to storage tank.

iv) Alcohol Daily Receivers & Bulk Storage:

Alcohol is first taken to Daily receiver storage tanks, which is based on the State Excise

laws, storage for three days considering the weekly holidays of two days. Thereafter, the

alcohol is transferred to Bulk Storage Tanks after taking the daily receiver Dip. This is

transferred using flameproof pumps. Final dispatch of alcohol is metered and again is

carried out using special flameproof pumps. The Bulk Spirit Storage is proposed to be set

up for 30 days.

B) EFFLUENT HANDLING SECTION

i) Evaporation Section:

The spent wash coming from Distillation section will be fed in to first calendria of the

evaporator section. There will be five calendria will be installed as per design to

concentrate the dissolved solids .suggested treatment scheme is a four FF + Finisher

Evaporation Plant for spent wash Evaporation. The following points will elucidate the

basic working principle:

� Shell & Tube type Evaporators with highly efficient liquid distributor working on

the principle of Falling Film Evaporation have been used, with Plate type

Preheaters for preheating of FEED stream which serves the purpose of energy

conservation.

� Analyzer vapour is fed to the first effect evaporator shell side at the given

pressure and temperature as the heating medium.

� The Feed from the Feed balance tank is taken to to make the best heat recovery.







� The Feed after getting heated to the predetermined temperature in preheater is

fed from the first effect evaporator which is Falling Film Evaporator -1

� Vapours generated in 1st effect VLS (Vapour Liquid Separator) are used as heat

source in the 2nd effect. and from 2nd to third and so on.

� The product at the desired concentration of TS is obtained at the outlet from the

final effect,

� A Shell & tube type Multi-pass Surface condenser is employed for condensing the

shell side vapours.

� The Pure and the process condensate are collected in receiving vessels.

� Highly efficient operating pumps will be provided for pumping the required fluid.

� The operation of the plant will be under vacuum. Vacuum is created with the help

of a water ring vacuum pump.

� The plant will have 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 vapours.

ii) Incinerator boiler:

The concentrated effluent is mixed with bagasse/coal and dried in a Rotary Dryer to

generate mixed fuel. This mixed fuel/biogas is burnt in Incinerator boiler of 40 TPH to

generate high pressure steam







Figure - 4: Process flow diagram of Molasses Based Distillery

Power Co-generation 40 MW {(20 MW in Phase I) and (1x15 MW, 1x5MW in Phase II)}

The unit proposes to set-up boiler and power turbine. 1 Nos. x 100 TPH, 1 x 60TPH Boilers

for Coal/Rice Husk/Pet Coke/ Biomass/Natural Gas as available fuel options and 1x40TPH

Boiler cum Incinerator will be installed for slop as available fuel options. This Boiler will

operate mainly to feed steam to grain based / molasses based operations and {40 MW (20

MW in Phase I) and (1x15 MW, 1x5MW in Phase II)} power generations from Turbine.

Proposed {40 MW (20 MW in Phase I) and (1x15 MW, 1x5MW in Phase II)} 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 ESP where the dust

particles are collected. The dust is collected from here.

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 Co-generation Power Plant

(vii) 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 Requirements

The raw materials required for the distillery can be broadly categorized as follows:

• Grain & Molasses







• Enzymes & Chemicals

• Steam

• Fuel

• Power, etc.

The basic raw material for the manufacturing will be Grain & Molasses. In the present

scenario, grains with different starch content are used like damaged grain feed stock,

nakku kinki, maize, bajra, sorghum, barley etc. The process requires the above grains to

be milled into specific flour size. Small quantity of sulphuric acid is sometimes required.

The raw material for the boiler fuel will be Coal, Rice Husk, Pet Coke, Bio Mass, Natural

Gas etc.

Table 2

RAW MATERIAL REQUIREMENT FOR GRAIN BASED DISTILLERY

S.

No.

Particular Requirements Source of the Raw

Material & Mode of

Transportation

1. Grain

(Damaged grain feed stock, nakku kinki,

maize, bajra, sorghum, barley etc.)

900-1000 TPD Nearby area and

states, by road or

Railway

2. Molasses 500-600 TPD Nearby Sugar Mills

3. Chemicals Quantity (TPD)

Sodium Hydroxide (Caustic) 2.0

Enzymes 1.0

Nutrients 2.0 – 3.0

Antifoam Agent 0.5 – 0.6

Yeast (Active Dry Yeast/Distiller’s Yeast 0.25 – 0.35

(b) Fuel Requirement

Table 3

RAW MATERIAL REQUIREMENT FOR GRAIN BASED DISTILLERY

Name of Raw Material Quantity (MT per day) Mode of transportation

Coal, Pet Coke 500-750 TPD By Railway

Rice Husk, Bio Mass 1000-1200 TPD Nearby Road

Slop From Molasses

Evaporator

300-350TPD@55-60%

Solids Pipe Line







(viii) 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.

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

given.

(a) Water Requirement and Source

The total fresh water requirement for this proposed project will be 4567 m3/day.

Source of Water: Canal Water.

Phase Mode of Operation and capacity Total Fresh

water

Phase I 250 KLPD Grain Based Distillery 2501

Phase II 125 KLPD Grain Based operation 1027

125 KLPD Molasses Based Operation 1039

Total 4567

Phase I - Water Requirement for Grain Based Operation - 250 KLPD

The total water requirement for the Grain based (250 KLPD Operation Phase I)

process is estimated at 2501 KLPD, worked out as per details given below:

TABLE - 4 (A) Total Water Input

S. No. Section Water Quantity (KLD)

1. Process water in Liqn 801

2. Boiler feed water 2287

3. DM water for Distillation 275

4. Soft water for Cooling Tower 2250

5. Soft water Distillation 325

6. Soft water pumps sealing 63

7. Fermenter washing 70

8. Floor washing 109

9. Domestic consumption 25

Total 6206

TABLE - 4 (B)







Total Water Output


1. Steam condensate 1309

2. Spent lees PR 313

3. Spent lees Rectifer 275

4. Spent wash (Grain slops) 402

5. Water in DDGS Dryer 425

6. CT Evaporation & Drift Losses 2250

7. Pump Sealing 63

8. Process Condensate 1012

9. Boiler Blow down 38

10. DM Plant Regeneration 120

Total 6206

TABLE - 4 (C) Total Water Recycle


1 Steam Condensate 1309

2 Thin Slops 402

3 R/E to Distillation 234

4 PR Lees to Fermentation 70

5 Pump Sealing 63

6 Boiler Blow down 38

7 Process Condensate 1012

8 Floor Washing 109

9 Prec Lees to CT 133

10 R/E to Less to CT 41

11 CT Blow down 174

12 DM Plant Regeneration 120

Total Recycling / Reutilization of water per day 3705

TOTAL FRESH WATER INPUT 2501

Hence, fresh water Requirement is 2501 KLPD. Water requirement for first run

would be 6206 KLPD.







Figure – 6: Water balance Diagram 250 KLPD Grain Based Distillery







Phase II - Water Requirement for Grain Based Operation - 125 KLPD

The total water requirement for the Grain based (125 KLPD Operation Phase II)


TABLE - 5 (A)

Total Water Input


1. Process water in Liqn 397







8. Floor washing 55


Total 2904

TABLE - 5 (B)

Total Water Output





4. Spent wash (Grain slops) 201

5. Water in DDGS Dryer 189


7. Pump Sealing 31




Total 2904







TABLE - 5 (C)

Total Water Recycle



2 Thin Slops 201



5 Pump Sealing 31



8 Floor Washing 55

9 Prec Lees to CT 63

10 R/E to Less to CT 21

11 CT Blow down 100




Hence, fresh water Requirement is 1027 KLPD. Water requirement for first run

would be 2904 KLPD.







Figure – 7: Water balance Diagram 125 KLPD Grain Based Distillery







Phase II - Water Requirement for Molasses Based Operation - 125 KLPD

The total water requirement for the Molasses based (125 KLPD Operation Phase II)


TABLE - 6 (A) Total Water Input


1. Process water in Fermentation 798







8. Floor washing 159


Total 3454

TABLE - 6 (B) Total Water Output







6. Pump Sealing 88



Total 3454

TABLE - 6 (C) Total Water Recycle





4 Pump Sealing 38



7 Floor Washing 159

8 R/E to Less to Treatment Plant 56

9 CT Blow down 80




Hence, fresh water Requirement is 1039 KLPD. Water requirement for first run would be 3454 KLPD.

Proposed installation of Unit II –500 KLPD Ethanol/RS Industrial/ENA/SDS Plant {(250 KLPD Grain Based in Phase I) & (125 KLPD Grain and 125 KLPD Molasses Based in Phase II)} & 40 MW

Co-generation Power Plant {(20 MW in Phase I ) & (1 x 15 MW, 1 x 5 MW in Phase II)} in Existing Distillery Plant




Figure – 8: Water balance Diagram 125 KLPD Molasses Based Distillery

Proposed installation of Unit II –500 KLPD Ethanol/RS Industrial/ENA/SDS Plant {(250 KLPD Grain Based in Phase I) & (125 KLPD Grain and

125 KLPD Molasses Based in Phase II)} & 40 MW Co-generation Power Plant {(20 MW in Phase I ) & (1 x 15 MW, 1 x 5 MW in Phase II)} in

Existing Distillery Plant




(b) Power Requirement and Source

The total power requirement for proposed project will be 9 MW, which will be

sourced from own proposed 40 MW cogeneration power plant.

(c) Steam Requirement

Steam requirement is 155.32 TPH, which will be sourced from proposed boilers

(100TPH X 1 no, 60TPH X 1 no, and 40TPH X 1 no).

TABLE – 7 (A)

STEAM REQUIREMENT FOR GRAIN BASED DISTILLERY (250 KLPD & 125 KLPD)

S. No. Purpose Steam Requirement (TPH)

250 KLPD Mode

Steam Requirement (TPH)

125 KLPD Mode

1. Cooking & Liquefaction 8.0 4.0

2. Multi-pressure Distillation 32.60 16.30

3. Evaporation (Integrated) 3.2 1.6

4. DWGS Drier (DDGS) 36.0 18.0

5. Boiler De-aeration & HP

Heater 5.2

3.1

Total 85 43

TABLE – 7 (B)

STEAM REQUIREMENT FOR MOLASSES BASED DISTILLERY

S. No. Purpose Steam Requirement (TPH)

1. Vessels Sterilisation 1.30

2. Multi-pressure Distillation 16.66

3. Evaporation (Integrated) 7.80

4. Boiler De-aeration 1.56

Total 27.32

Boiler Details

(100TPH X 1 no, 60TPH X 1 No) Boilers and 40TPH X 1 No Boiler cum Incinerator with ESP as APCE

will be sufficient to meet the requirements. Others details regarding this are mentioned in the

table given below:

TABLE – 8 (A)

BOILER DETAILS

S. No. Details

1. Type of Fuel Coal , Rice Husk , Pet Coke , Bio Mass,

Natural Gas etc

2. Capacity of Boiler (100TPH X 1 no, 60TPHX 1 No)

3. Stack Height 63 MTS

4. Pollution Control Equipment Measures ESP







TABLE – 8 (B)

BOILER Cum INCINERATOR DETAILS

S. No. Details

1. Type of Fuel Slop From Molasses Evaporator with

supporting fuel of Rice husk/ Coal

2. Capacity of Boiler 40 TPH

3. Stack Height As per CPCB Guidelines

4. Pollution Control

Equipment Measures ESP

Details regarding the D.G. Sets

3 D.G. sets of 1000 KVA will be installed for the power backup. Details regarding the D.G. Sets are

mentioned in the table given below:

TABLE – 9

DETAILS REGARDING THE D.G.SETS

S. No. Details

1. Type of Fuel HSD

2. Capacity 3 X 1000 KVA

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

4. Pollution Control Equipment Measures Adequate stack height/ Acoustic

(x) Quantity of waste to be generated (liquid and solid) and scheme for their

management/disposal

o The proposed project is based on “ZERO EFFLUENT DISCHARGE”.

Molasses Based Operation:-

o Efforts will be made to conserve as much water as possible by recycling and reuse.

o Spent wash generated during Molasses operation, would be concentrated in Multi-

effect evaporator and then used as fuel in boiler.

o Record of wastewater returned back to process for utilization in

Fermentation/cooling tower and to gardening will be kept.

o Process condensate from MEE will be treated and recycled back in the process.

Grain Based Operation:-

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







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

of Suspended Solids separated as Wet Cake.

o Thin Slops from the Decanter Centrifuge will be partly recycled back to process (30-

35%) and partly taken to Thins Slops Evaporation Plant for concentration of

remaining solids to form a Syrup. This Syrup is mixed with the Wet Cake coming out

of Decanter Centrifuge and forms part of Cattle Feed. (Also known as Distillers Wet

Grain Solubles - Collectively known as DWGS).

o DWGS is taken to a dryer operating on steam and is dried to make it DDGS –

Distillers Dried Grain Solubles.

o The process condensate is cooled and collected into a neutralization tank with

sufficient residence time. After Neutralization, this process condensate will be

recycled into process and is used for green belt development within the complex.

o 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.

o Ash from the Boiler will be sold to Brick manufacturers.

o Yeast sludge will be sent to the Sludge Drying Beds or may be added to the Wet

Cake.

o 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

The project site is well connected to National Highway NH-64 (~0.5 km in South

direction). The nearest railway station is Sangat Mandi Railway Station (~ 3 km in

NW direction), nearest city is Nathinda (17.5 km in NNE direction) and nearest

airport is Sri Guru Ram Dass Jee International Airport, Amritsar (~ 180 km in North

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 project site.

(ii) Land from Land use and Land ownership Total land requirement for the proposed

project is 8.8 Ha (22.0 Acre) and has been completely acquired by Om Sons

Marketing Private Limited.







(iii) Topography

Topography of the core zone for 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

TABLE – 10

Environmental Settings of the Area

S.

NO. PARTICULARS

DETAILS

(with approximate aerial distance & direction from project

site)

1. Nearest Village Sangat Kalan (1.5 km in NW direction)

2. Nearest Town/City Bathinda City (Approx. 17.5 km in NNE direction)

3. Nearest National Highway /

State Highway

NH-64 (Approx. 0.5 km in South direction)

4. Nearest Railway station Sangat Mandi Railway Station (3.0 km in NW direction)

5. Nearest Airport Sri Guru Ram Dass Jee International Airport, Amritsar (~ 180 km

in North direction)

6. National Parks, Wild Life

Sanctuaries, Biosphere

Reserves, Tiger/ Elephant

Reserves, Wildlife Corridors

etc. within 10 km radius

No National Parks, Wild Life Sanctuaries, Biosphere Reserves,

Tiger/ Elephant Reserves, Wildlife Corridors etc. lies within 10

km radius of the project site.

7. Reserved Forests (RF) /

Protected Forests (PF) etc.

within 10 Km. radius

No Reserved Forests (RF) / Protected Forests (PF) etc. lies

within 10 Km. radius of the project site.

8. River / Water Body (within 10

km radius)

� Lower Lassara Nallah (0.7 km in SE direction)

� Canal (1.0 km in SSW direction)

� Sirhind Canal (5 km in SE direction)

(v) Existing Infrastructure

Proposed installation will be done within the existing 120 KLPD Grain based Distillery.

(vi) Soil classification

The district has two types of soils, the arid brown soils and siezoram soils. The arid brown

soils are calcareous in nature; these soils are imperfectly to moderately drain. Salinity and

alkalinity are the principal problems of this soil. In siezoram soils the accumulation of

calcium carbonate is in amorphous or concretionary form (kankar). Presence of high







amount of calcium carbonate and poor fertility is the main problem of this soil. The arid

brown soils are found in mostly eastern parts of the district and siezoram soils are found

in the western part of the district.

(vii) Climatic data from secondary sources

The climate of the district can be classified as tropical desert, arid and hot. The area

receives about 389 mm annual normal rainfalls which is unevenly distributed over the

area in 23 days, out of which about 79% occurs during south west monsoon. Rain fall in

the district decreases from north east to south west. The district lies in the South-

western region of the State and in far away from the Shivalik ranges in the North of the

state. It is the nearest to the Thar Desert of Rajasthan and also far away from the Major

rivers lines that run through the state. Therefore, climatically, the district has a very hot in

summer and frequently scorching heat is in full swing. The climate of Bathinda district can

be classified as tropical steppee, semi arid and hot which is mainly dry except in rainy

months and characterised by intensely hot summer and cold winter. During three months

of monsoon season from July to September, the moist air of oceanic origin penetrates

into the district and causes high humidity, cloudiness and good monsoon rainfall. The

period from October to November constitutes post monsoon season. The cold weather

season prevails from December to February followed by the hot weather season or Pre-

monsoon season which ends upto the last week of June.

Rain fall: The normal annual rainfall of Bhatinda District is 408 mm in 20 days which is

unevenly distributed over the district. The southwest monsoon sets in last week of June

and withdrawn towards end of September and contributes about 82% of annual rainfall.

July and August are the rainiest months. Rest 18% of the annual rainfall occurs during non

of the year in the form of thunder storm and western disturbances. Rainfall in the district

increases from southwest to northeast.

Rainfall

Normal Annual Rainfall: 408 mm

Normal monsoon Rainfall: 335 mm

Normal Rain days: 20

Temperature

Mean Maximum: 420C (May & June)

Mean Minimum: 3.90C (January)

(viii) Social Infrastructure available







There are primary schools, dispensaries, small hospitals, places of worship in nearby area

of the project site.

5.0 PLANNING BRIEF

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

country Planning/ Development authority classification.

The project is installation of Ethanol/RS Industrial/ENA/SDS Plant within existing

distillery. Facilities required for the proposed 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

proposed project area.

(ii) Population Projection

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

will generally be outsider. A projection may be made by a governmental

organization, or by those unaffiliated with a government.

(iii) Land use planning

Total Plant area is 8.8 Ha (22.0 acres). Proposed installation project will be set up in

the existing plant premises. No additional land will be required. About 33 % of the

total plant area is being/will be covered under green belt & plantation in order to

reduce dust & noise pollution levels & to increase aesthetic beauty of the area. The

same will be maintained.

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

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

area of the proposed site and will be developed in under corporate social

responsibilities programs.

(v) Amenities/Facilities

The Company will develop the Amenities/Facilities in nearby area of the proposed

project site as per requirement of local people of the nearby area under corporate

social responsibilities programs.

6.0 PROPOSED INFRASTRUCTURE

(i) Industrial Area (Processing Area)

Total Plant area is 8.8 Ha (22.0 acres). Proposed installation project will be set up in

the existing plant premises.

(ii) Residential area (Non Processing area)







Residential colony is not proposed for the project. The local labor will be preferred

to provide employment opportunities.

(iii) Green Belt

Out of the total project area ~33 % is being/will be developed under greenbelt area

& plantation in order to reduce noise pollution levels & to increase aesthetic beauty

of the area.

(iv) 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.

(v) Connectivity

The proposed project is well connected with Rail and Road.

(vi) Drinking Water

10 m3/day of water will be required for drinking & domestic purpose in the

proposed project which will be sourced from Canal Water.

(vii) Sewerage System

The waste water generated from the sanitary blocks will be disposed off in soak pit

via septic tanks.

(viii) Industrial Waste management

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

(ix) Solid Waste Management

� Grain Operation - 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.

� Molasses Operation - Spent wash generated during Molasses operation, would

be concentrated in Multi-effect evaporator and then used as fuel in boiler.

� Ash from the Boiler will be sold to Brick manufacturers.

(x) Power requirement and source

The total power requirement for the proposed project will be 9 MW, which will be

sourced from proposed Co generation power plant of 40 MW & D.G Sets (for

emergency).

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.







Proposed installation will be done within the existing plant premises. No additional

land is required for the same. Therefore, there will not be displacement of people

and hence, Rehabilitation & Resettlement 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 clearance and will complete after two years of commencement.

(ii) Estimated project cost

� Total cost of the Project: Rs. 566 Crores

� Cost for Environment Protection Measues:

� Capital Cost: Rs. 56 Crores

� Recurring Cost/annum: Rs. 10 Crores/annum

9.0 ANALYSIS OF PROPOSAL

(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 activity and the management will support local administration and provide

other form of assistance for the development of public amenities in the region. Plantation

will be developed in and around the project area. The project will help in improving the

overall status of the area.

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