PRE-FEASIBILITY REPORT FOR DISTILLERY...

Pre-feasibility Report: Expansion of grain based distillery unit

M/s. Ankur Biochem Pvt. Ltd., Dhanbad, Jharkhand

PRE-FEASIBILITY REPORT

PROPOSED EXPANSION FROM 60 TO 200 KLPD CAPACITY

OF GRAIN BASED DISTILLERY UNIT OF

M/S ANKUR BIOCHEM PVT. LTD., DHANBAD, JHARKHAND

SUMMARY

The proposed project is an expansion of existing grain based distillery unit of M/s. Ankur Biochem

Private Limited (ABPL). The capacity of existing unit is of 60 kilo litres per day (KLPD), which will be

enhanced to 200 KLPD. The existing unit is located at Tetulia More, Lakheiya Bridge Post Dubi,

Dhanbad, Jharkhand, (PIN 828205). The constructed area (including process, office, waste

management, storage, etc) of the existing unit is approximately four acres (~15,050 sq.m.). The

proposed unit will be installed within the existing industrial premises. It will require about two and

half acres of land (~9,900 sq.m.). The industry has 28 acres of land which is adequate for the

proposed expansion. The required raw material and resources such as grains and fuel (coal and rice

husk) will be made available from the local market. The machinery required for the unit is also

available indigenously. The capital cost of the project is Rs. 11,900 Lakhs of which Rs. 500 lakhs are

allocated for environment management purpose.

The effluent treatment scheme of existing unit comprised of decantation, evaporation and distillers’

dry grains with soluble (DDGS) units. Condensate Polishing Unit (CPU) has been provided to treat the

vapour condensate from DDGS. The effluent from proposed unit will also be treated by same

method but by adequately enhancing the capacity of existing units. During the effluent treatment,

DDGS of 115 Tons per day (TPD) is estimated to be generated as a solid waste. DDGS is popularly

used as a cattle or poultry feed and will be sold in the nearby markets. Steam condensate from

manufacturing process will be recycled as boiler feed water. The treated water from CPU will be

recycled in process and irrigation purpose. This way the industry has planned to achieve Zero Liquid

Discharge (ZLD) guideline prescribed under CREP norms.



2.1 Project Highlights

1 Name of the Proponent M/s. Ankur Biochem Private Limited (ABPL)

2 Type Large Scale Industry (private limited company )

3 Project Expansion of grain based distillery unit from 60 to 200 KLPD ( by

adding a unit of 140 KLPD)

4 Location of the project Tetulia More, Dubhi, P.S. Nirsa, Duvi, Dist: Dhanbad- 828 205

State: Jharkhand, India

Email: [email protected]

Tel. : 09434002234 / 09332075801

Fax: 0341-2303281

A Latitude & Longitude 23°47'7.18"N and 86°38'47.49"E (altitude 162m)

5 Environmental Settings of the Area

A Nearest National Highway NH-2/AH1 is ~2.7 Km away from site

B Nearest Railway Station Kalubatham is ~13 km (towards SE), Dhanbad: ~25Km

C Nearest air port Dhanbad: ~25Km, Kolkatta: ~240 Km

D National Park, Wild Life

Sanctuary, Biosphere Reserves

etc.) within 10

km radius

None within 10 km radius of the project site

E Nearest Town / City Dhanbad: ~ 25Km (towards West)

F Nearest River Khudia river ~ 0.8 km towards south

G Seismic Zone Seismic zone III as per IS: 1893 (Part-I) : 2002

6 Land Requirement 2.5 acres of land for proposed unit; 28.11 acres of land is

available with project proponent

7 Product and Raw material details

A Product Product Production

ENA

Impure Spirit/Technical alcohol

200.00 KLPD

10.00 KLPD

Distillers’ Dry Grain with

Soluble (DDGS)

115.00 TPD

B Operation Days per annum Around the year

C Main Raw Material Quantity

Grain Flour 530.00 TPD

Nutrients DAP and Urea ~0.5TPD each

Turkey Red Oil (TRO) As per requirement

D Water Requirement 1721 cum / day

Water will be drawn from three Source: 1) Ground water

(permission available for existing unit), 2) from Maithan

reservoir (permission available) and 3) from rivulet Khudia

(permission available)

mailto:[email protected]



E. Steam and Fuel Coal: Max. 13 TPH i.e. 312 TPD (for 200 KLPD capacity)

OR

Rice husk: ~13.4TPH i.e. 322 TPD (for proposed only)

Considering steam requirement of 51TPH

fuel to steam ratio of 1:4 (coal) and 1:3.8 (Rice husk)

Source of coal : Local market at Dhanbad

Rice husk: markets from Jharkhand, Bengal and Bihar

8 Effluent Treatment System Decantation followed by evaporation followed by dryer

For Secondary effluent Primary followed by Ecophoto-X

followed by carbon filtration as a tertiary treatment

9 Man power Existing 65, additional about 20 persons = 85

11 Total Project Cost Rs. 11,900.00 Lakhs

12 Capital expenses for

environment management

Rs. 500.00 lakhs

INTRODUCTION

1.2 Project Proponent: M/s. Ankur Biochem Private Limited is a business unit belonging to a

business group that consists of M/s. Ankur Chemfood Pvt. Ltd, Gandhidham, Gujarat and M/s. Ankur

Salt Marketing. Mr. Mahendra Sharma is the project proponent. Mr. Sharma is also engaged in steel

industry as a Director of M/s. Kunj Bihari Steel Pvt. Ltd. Jamuria, West Bengal. His business roots are

largely spread over the states of Jharkhand and West Bengal. The average annual turnover of the

group is around Rs. 15,000 Lacs employing around 350 persons.

M/s. Ankur Biochem Pvt. Ltd. has planned to enhance/expand the existing grain based distillery

unit’s capacity from 60 – 200 KLPD. The industry is registered under the Companies Act 1956, having

Corporate Identity Number U24100WB2008PTC128390.

The proposed unit will manufacture mainly Extra Neutral Alcohol (ENA) and Impure Spirit using

grains as raw material. If needed, the plant will manufacture Rectified Spirit (RS). Distillers’ Wet

Grains with Soluble (DWGS) or DDGS will be a byproduct of the process which has a demand in the

market as cattle or poultry feed.

2.3 Need of project and its importance to the country and region

In India, mainly three types of alcohol are popularly produced, i.e. rectified spirit (RS), extra neutral

alcohol (ENA) and anhydrous alcohol (AA). Of these, RS is used for large number of industrial,

scientific, laboratory, medical and many other applications. Thus, demand for the same is immense

and it is ever increasing. ENA is used for making liquors and other alcoholic beverages.

2.4 Demand and Supply Gap

There are more than 300 distilleries in the country with a total installed capacity of 3,500 million

litres per annum. However, it is discouraging to note that in spite of such abundant licensed and

installed capacity alcohol production in the country has been lagging behind and is varying only

around 1,900-2,000 million litres per annum. Thus, it is not withstanding the great demand for

alcohol both for chemical industry and for potable purpose, The target of alcohol demand as

projected in the perspective plan for Chemical Industry; Department of Chemical & Petrochemicals,

Government of India is 2,710 million litres per annum.



2.5 Import vs. Indigenous production

The process is straight line and the technology even for the pollution control/disposal is available

indigenously.

2.6 Export Possibility

The finished products i.e. Extra Neutral Alcohol has an excellent export potential.

2.7 Domestic / export markets

Market places such as Kolkata, major cities of UP, Bihar, West Bengal as well as markets of Delhi are

the potential domestic market for ENA. ENA also has excellent export potential. Kolkata is the

nearest port for international export.

2.8 Employment Generation

Proposed project will generate about 20 new employment opportunities for skilled as well as

unskilled persons. Apart from this, the project is anticipated to give plenty of indirect opportunities

to transporters, shopkeepers, and various facility providers such as refreshment centres, etc.

3.0 PROJECT DESCRIPTION

3.1 Grain Storage

Grains will be procured in bulk and manually unloaded onto pit for bucket elevator. Unloaded grains

are pre-cleaned through de-stoner and classifier equipment and further stored in Grain Silos.

3.2 Grain Milling

Grains will be milled in to flour of desired quality and mesh size using hammer mill (dry milling

process). Different grains such as broken rice, maize, sorghum, millets, etc. can be used in the same

mills. However, the flour so obtained is passed through classifiers and screens to retain certain mesh

size as desirable by the process. Weighed quantity of Flour is sent into liquefaction process, where

the starch is liquefied completely.

3. 3 Liquefaction Section

In liquefaction process, starch is hydrolyzed to dextrin. The liquefaction is carried out in single stage

liquefaction tank. Feedstock flour is transferred to pre-masher and mixed with recycle streams and

liquefying enzyme. Slurry from pre-masher is taken to liquefaction tank where temperature is

maintained by means of steam. Necessary retention time is maintained in the liquefaction tank.

Slurry pH is maintained by supplying dilute caustic solution. Contents in slurry tank are kept in

suspension by agitation. The liquefied slurry is then cooled in slurry cooler using cooling water

supply and transferred to pre-fermentation and fermentation section.

3. 4 Saccharification & Fermentation

Yeast Activation

Yeast seed material is prepared in pre-fermenter by inoculating sterilized mash with yeast. Optimum

temperature is maintained by circulating cooling water. The contents of the pre-fermenter are then

transferred to fermenter. The purpose of fermentation is to convert the fermentable substrate into

alcohol.



3.5 Distillation

Pre-heated fermented wash will be fed to degasser column. Alcohol is stripped off from fermented

wash by ascending vapours in analyser column. Rectifier vapours provide energy to analyser column

through a thermosyphon reboiler. Vapours of degasser column are condensed and taken to recovery

feed tank. The condensed analyser vapors are taken to pre-rectifier column. Analyser condensate is

concentrated in pre-rectifier column, which operates under pressure. Condensing steam provides

energy to pre-rectifier column through a vertical thermosyphon reboiler. A technical alcohol cut of

about 1-2% of total spirit is taken from the pre-rectifier column. Concentrated alcohol draw from

pre-rectifier column is fed to ED column for purification. Dilution water in the ratio of 1:9 is added in

this column for concentrating higher alcohol at the top. Technical alcohol cut is taken out from the

top of this column while ENA draw is taken out from appropriate upper trays and fed to simmering

column after cooling. Fusel oil build up is avoided by taking fusel oil draws from appropriate trays.

These fusel oils along with the condensate of degasifying & extractive distillation columns are fed to

recovery column for concentration. A technical alcohol cut is taken out from the top of this column.

3.6 Decantation & Thin Slops Recycle Section

Decantation section comprises of a centrifuge decanter for separation of suspended solids from

spent wash coming out of grain distillation plant. Wet cake has 30-32% solids (w/w) as removed

from bottom of decanter which can be sold directly in wet form as cattle feed (DWGS).

Thin slops coming out of decanter are collected in a tank and partly recycled into the process and

further for evaporation for concentration up to 35-40% w/w solids. The concentrated thin slops

called as Syrup is mixed with wet cake and sold in wet form as cattle feed (DWGS) or the entire

mixture can be dried in a DDGS Dryer and then sold in dry form as cattle feed (DDGS).

3.7 DWGS DRYER WITH COOLING AND CONVEYING SYSTEM

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

system. The Rotary tube bundle is enclosed in an insulated dryer housing and its outer flights are

fixed. Dry saturated steam is to be supplied to the tube bundle through rotary joint at one end and

the condensate is discharged through rotary joint mounted on another end. During the course of

rotation, these flights pick up the material and shower them on to the tube bundles. The heat

transfer is primarily by conduction. The water vapours are exhausted through an exhaust blower &

passed through a cyclone separator for separating fines. Dry product is partially recycled back to

feed conditioner through product screw and recycle conveyor.



Fig 1: Flow Diagram of manufacturing process

Grain Cleaning, Milling And Flour Handling Section

Slurry Preparation & Liquefaction Section

FERMENTATION SECTION

Multipressure Distillation Section

Decantation

Section

Spirit Storage Section

(ENA/TA)

EVAPORATION PLANT

Water Storage

Power Generation

House

Boiler

Turbine

Process

Condensate Treatment &

Recycle

DWGS Dryer

Steam & Water Supply

Wet cake

Conc. Syrup

DDGS



3.6 Raw materials

Table 1: Availability raw materials & finish good product and transport mode

Raw materials

Estimated quantity /day

Source/ market

final product

Estimated quantity KL/day

Source/ market

Transport mode

Grain 530MT Damaged grain and surplus grain from markets of Jharkhand, West Bengal, Bihar, Uttar Pradesh

ENA + Impure Spirit (Technical alcohol) DDGS

200 KLPD 10KLPD 115TPD

Major markets of India from West Bengal, Bihar, Uttar Pradesh

Surface transport using track and Tankers

Nutrients N, P

As per requirement

Local market at Dhanbad, Ranchi, Kolkatta

- - -- Surface transport using Trucks/ Tempo

Turkey Red Oil (TRO)

As per requirement

Local market at Dhanbad, Ranchi

- - --

Surface transport using Trucks/ Tempo

3.7 Resource optimization / recycle and reuse envisaged in the project, if any, briefly describe

Optimum utilization of the available resources is strived by the management. These resources

include land, coal, steam, grain and power.

3.8 Availability of water and its source

a) Source: Water required for the proposed capacity will be 1,721 cum for day-to-day operations. It

will be drawn from (a) bore well, (b) rivulet Khudiya and (c) from reservoir at Maithan. The

permissions for water drawl from respective authorities are available with project proponent.

Power: Power requirement for the proposed capacity (i.e. 200KLPD) will be of 4000kWh. Captive

power will be used. Presently, turbine of 2 MW is installed, in addition to which a new turbine of 4

MW will be installed. These two turbines together will fulfill the power requirement of the proposed

distillery capacity.

Fuel: Coal or rice husk will be use as a fuel for the steam generation activity. If coal (Indian) is

utilized, its requirement will be maximum 13 TPH i.e. 312 Tons per day. If rice husk is utilized its

requirement will be Max. 13.4 TPH i.e. 322 TPD for the operation of distillery at proposed capacity

(i.e. 200 KLPD). This is based on steam requirement of 51 TPH and fuel (coal and rice husk) to steam

ratio of 1:4 for coal and 1:3.8 for rice husk.



3.9 Quantity of waste to be generated & its disposal scheme

A) Liquid waste

Daily water intake will be of 1,721 m3/day. Reduction in water requirement will be due to recycling

of (i) condensate water at 40TPH i.e. 960 m3/day as well as spent lees of 600m3 (considering 3 L of

lees per liter of ENA). Thin slope can be treated by decantation followed by multi effect evaporation

followed by dryers. The DWGS can covert in to the DDGS and sold in the market as cattle or poultry

feed.

Fig 2 Flow diagram of Thin liquor and effluent stillage treatment

Effluent grain stillage

Decantation

Section

EVAPORATION PLANT

Process

Condensate Treatment &

Recycle

DWGS Dryer

Wet cake

Conc. Syrup

DDGS

115 TPD

Thin Liquor re-circulated to

Distillery



Other wastewater such as process condensate, boiler blow down, etc. will be treated in effluent

treatment plant (condensate polishing unit – CPU). The quantity of this effluent would be about 589

cum. Treated water will be recycled to process, cooling tower makeup and gardening.

Air emission and its control measures

From the proposed project, flue gas emissions would be in the form of PM, SOx and NOx due to use

of coal or rice husk as a fuel for boiler. Adequate capacity of ESP along with 45 metres height of

chimney will be provided to control the PM level below 100 mg/m3.

Solid waste

The proposed industrial activity will generate solid waste in the form of ETP sludge, Yeast sludge and

boiler ash. Generated DDGS can be sold to the market as a cattle feed as well as poultry feed. The

sludge from ETO has the biodegradability in nature hence it used to prepared manure. The ash can

sold to the brick manufacturers.

Figure 3: Flow sheet for Secondary treatment



Table 2: Solid waste generation and disposal

# Waste Quantity/day Treatment Disposal Remark

1 DDGS 115 MT --- To sell as cattle feed or

poultry feed Organic

2 Yeast sludge 1.2 MT Compost Mixed with DDGS Organic

3 ETP sludge 0.600 MT Compost Mixed with DDGS Organic

4. Ash (Bottom +

fly ash)

125 MT (for

coal) Or 80.5MT

(for rice husk)

- Nearby brick

manufacturing unit Inorganic

Fig 4: Schematic representation of the feasibility drawing which give information of EIA purpose

Expansion of grain based distillery from 60 to 200 KLPD capacity

Application (Form I) and Pre- Feasibility study as project proposal

Categorization as per EIA notification Sep. 2006 and its amendment till the date –

Category A; project activity 5 (g)

Submitted to Ministry of Environment and Forest (MoEF), Govt. of India for obtaining

‘Environmental Clearance’



4. SITE ANALYSIS

4.1 Connectivity

Table 4: Connectivity of the project

4.2 Land form, land use and ownership

The land required for the proposed distillery expansion (along with ancillary units) is two and half acre

(i.e. ~ 9,990 sq.m.). The industry already has 28 acres of land. The proposed distillery unit along with

ancillary units for treatment and disposal of wastewater as well as solid waste will be established

within existing industrial premises. Hence, there will not be any change in the existing land use. The

land is already procured by the project proponent.

4.3. Information of District

4.3.1 Information about Dhanbad

Dhanbad is famous for its coal mining and has some of the largest mines in India. Tata steel, BCCL,

ECL and IISCO (Indian Iron And Steel Company) are some of the companies having coal mines in the

district. The Indian School of Mines is located in Dhanbad. Among the rail divisions of Indian Railway,

Dhanbad Rail Division is the second largest in terms of revenue generation after Mumbai division.

4.3.2 Geographical features

The location of proposed grain based distillery project of Ankur Biochem Private Limited, is at village

Dubhi, Nirsa, District Dhanbad Jharkhand. National highway 2 (NH2) which was earlier known as

Grand Trunk road is about 1.5 km away towards the north of the site. The site is situated on a flat

terrain. There are no hills or hillocks in the surrounding of the site. There are approx 75 villages in

the 10 km radius of the site. The surrounding land use is mainly agricultural and residential. The

main crops of the district are rice, ragi, maize, wheat, red gram, etc. The geographical coordinates of

the site are 23047’N and 86038’E; the proposed site region is at elevation of 155m above the mean

sea level. The nearest surface water body is a rivulet Khudia, situated at a distance of 0.8 km from

the site towards south

Location of the project Within existing distillery premises at Tetulia More, Lakheiya Bridge Po-Dubhi, Dist: Dhanbad, Jharkhand, India

Nearest City/Town Dhanabad 25 Km

Asansol (West Bengal) ~50 Km

Road NH-2 - 1.5 km away towards north

Railway Station Dhanabad 25 Km & Asansol (West Bengal state) -40 Km

Air Port Kolkata, 250km from project site

State Boundary West Bengal approx 20 km towards south and 35km towards east

http://en.wikipedia.org/wiki/Coal_mining

http://en.wikipedia.org/wiki/Bharat_Coking_Coal

http://en.wikipedia.org/wiki/IISCO



4.4 Existing land use pattern of Nirsa block

Land use of the Nirsa block was distributed as, out of total area, 694.79 ha is under forest, 4601.31

ha is under culturable waste, 12066.67 ha is under unculturable wasteland (Area not available for

cultivation) The irrigation is done on, 18.21 ha with Government canal, 2523.2 ha with well (without

Electricity), 126.81 ha by well (with Electricity), 207.44 ha with tube-well (without Electricity),

3343.94 ha with Tank, 734.27 ha with River, 7.15 ha with Lake, 4606.09 ha with Others

Total Irrigated Area: 11567.11

Total Unirrigated Area: 11467.04 ha

Since, the project will be requiring 4 ha of unculturable land, which is 12066.67 ha, in the said block

(Nirsa). Therefore, the land use change under the head uncultivable land will be 0.0033% of the total

land.

4.5 Existing Infrastructure

Land 19 acres of land available with sugar factory of which 10 acres will be used

for capacity expansion of distillery and ancillary units as well as greenbelt

Water Source: from 1) rivulet Khudia and 2) existing bore/tube well

Power Captive power supply from 3.0 MW TG set

Road approach road of 1.5 KM connecting to National Highway 2 (NH 2)

Medical, banking

facilities

Easily available at Nirsa and Dhanbad

Education Available at village Dubhi, Nirsa as well as at Dhanbad

Telephone, cell phone, post office, etc are available

4.6 Soil classification

The region mainly comprises soils developed on granite gneiss (32.6%) and granite schists

(14.2%). There is practically no problem of soil salinity or flooding. Soil acidity problem (pH <5.5) is

observed in some areas of the district. The land surfaces being uneven are subject to sheet and gully

erosion, causing loss of soil and plant nutrients.

The soils of the region have very poor water holding capacity. These soils contain less 'Humus'

organic matter. The soil and pH of the soil are suitable for cultivation of cereals such as rice,

sorghum, etc.

4.7 Climate

The climate of the region ranges from dry semi-humid to humid semi arid type. During summer, the

climate is hot and humid. Rains during June to September are occasionally heavy. Summer season is



observed during mid of March to May, there is a steady increase in the temperature, with maximum

temperatures of the year occurring in April and May. It is very pleasant during the cold weather from

November to February. Thereafter the climate becomes warm. It remains hot until the monsoon

breaks towards the middle of June. With the setting in of rains the temperature falls and humidity

rises, July to October are the rainy months. The monsoon winds from Bay of Bengal bring rains to the

region. July and August are the wettest months. The average annual rainfall in the Dhanbad district

is approximately 1400mm.The sky is generally clear during non-rainy season

4.8 Social Infrastructure available

Infrastructure such as roads, schools, electricity supply, health centers/hospitals, transportation,

banking, market, communication and postal facilities are available to the local people easily.

Table 8: Summery of demography

The study area encompasses total 75 villages of Nirsa and Gobindpur block. The population details for

Nirsa block are as follows

Community Children Population Below 7 Years

Literates Workers All 921

Total SC ST Others Total Main Margi-nal

Non-Worker

SC 927

Total 240766 3689

2

48580 155294 37945 113117 69912 44034 25878 170854 ST 998

Male 125341 1914

4

24311 81886 19323 76070 57698 40070 17628 67643 Other

s

896

Female 115425 1774

8

24269 73408 18622 37047 12214 3964 8250 103211 Childs

.

964

Table 9: Basic infrastructure

Name of Block Primary School Middle School Total

Dhanbad 104 51 155

Govindpur 115 29 144

Nirsa 163 52 215

Within 10km Area

There is no tropical forest

There is no biosphere reserve

There is no national park

There is no wildlife sanctuary

There is no coral formation

No defense installations;

No historically important site, monument,

structure, etc (Declared by Archeological Survey of

India)

No recreational site or pilgrimage centre etc.



5.0 PLANNING

5.1 planning concept

Type of industry: Manufacturing industry (Expansion of existing grain based distillery unit

from 60 to 200 KLPD)

Facilities for the drinking water: Water filtration units have been provided in the existing

unit. The main sources of water in Nirsa Block are 27 Tap Water schemes, 215 Well Water, 155 Tank

Water, 47 Tube well water, 158 Hand pump, 3 Canals

Facilities for transport: Grand Trunk road i.e. National Highway 2 (NH 2) Highway 1.5 KM

away from Industry. Telephone as well as mobile phone services are available in the region. This

block is linked with 13 Bus Services, 3 Railway Services, 1 Navigable water way including River, Canal

etc.

Post & Telegraph: There are 18 Post Office, Telephone connectivity is also available in the

region.

Power Supply: Captive power will be used in the proposed project. I

Town and country planning / Development authority classification

The project site came under the jurisdiction of Belkupa Gram Panchyat. The Gram panchayat has

issued ‘No Objection Certificate’ letter on dated 02/06/2014 for this proposed capacity expansion of

grained based distillery from 60 to 200 KLPD.

5.2 Population projection: The proposed expansion activity is generating approx 85 opportunities.

Sons of the soils will be preferred while selecting the employee. Thus, migration of sizable

population near the project will automatically avoid. Skilled and semi-skilled workers could be easily

available in the district, since engineering college as well as ITI are available in the district and

surrounding areas. Thus, influx of population could be negligible.

5.3 Land use Planning: The proposed distillery will be within the existing industrial premises.

Table 10: Land allocation for proposed unit

Unit Land (in Acres)

Existing distillery unit including storage of raw material,

finished products, solid and liquid waste handling and

disposal, etc.

04.00

Proposed unit 02.50

Greenbelt (33% of built-up area) 02.20

open space 19.41

Total Land available 28.11



5.4 Assessment of infrastructure Demand (Physical & Social)

The infrastructures such as land, roads, power, water, transportation, etc are easily available for the

proposed unit. Raw material and fuel will also be available locally.

As explained earlier, very minor influx of population is anticipated due to the project. Available

social infrastructure such as schools, colleges, market, medical facilities, etc. is adequate to support

the probable minor population increase.

5.5 Amenities/ Facilities

The following amenities/facilities are available industry

Canteen

Medical facility

Separate dedicated parking facility for goods vehicle and personal vehicles at site

Provision of street light within premises as well as on approach road

Rest room

Security check post and round the clock security persons on duty

Fire extinguishing facilities

Drinking water

Diesel generator as a backup facility

Fresh water and wastewater treatment plants

6.0 PROPOSED INFRASTRUCTURE

Social Infrastructure: The road developed for the existing distillery unit will remain available for the

local population.

6.1 Connectivity

Table 11: Connectivity of the project

Nearest City/Town Dhanabad 25 Km

Asansol (Weast Bangel state) -50 Km

Road NH-2 - 1.5 km away towards north

Railway Station Dhanabad 25 Km & Asansol (West Bengal state) 50 Km

Air Port Kolkata, 250km from project site

6.2 Drinking water Management: The industry has installed fresh water treatment plant to treat

the water for drinking purpose and supplies it to employees.

Sewage Management: Available system of septic tank and soak pits for sewage

management will be used even after expansion of the unit.

6.3 Power Requirement and source



Daily requirement of power is about 4000 KWh. Power will be made available through own captive

power generation system.

7.0 Industrial waste management

The proposed unit will produce thin liquor slope and grain stillage which usually treated by

decantation followed by concentration followed by drier. During this treatment, DWGS is converted

in to the DDGS. This DDGS can be sold as a cattle feed and poultry feed.

7.1.2 Effluent treatment plant for spent lees and condensate from evaporators:

The effluent from the evaporation unit and spent lees will have collective volume of ~589 cum per

day and will be treated in condensate polishing unit (ETP).

Table 9: ETP Units for spent lees and condensate combined effluent

Unit Purpose

Primary Settling Tank To remove suspended and colloidal solids (settle able)

Bag filter unit To remove the suspended particles form wastewater

Ecophoto-X unit For photo oxidation of organic matter of condensate and other

wastewater

Carbon filtration To filter the treated water

7.2 Solid waste management: The proposed industrial activity gives solid waste in the form of

yeast sludge, boiler ash which is biodegradable. The solid waste will uses as a filler materials in the

composting process. The quantity and disposal technique is brief in following table

Effluent grain stillage

Decantation Section

EVAPORATION UNIT

Process Condensate Treatment & Recycle

DWGS Dryer

Wet cake

Conc. Syrup

DDGS

Thin Liquor re-circulated to Distillery



Table 10: Solid waste generation, treatment & disposal

# Waste Quantity/day Treatment Disposal Remark

1 DDGS 115 MT --- To sell as cattle feed or

poultry feed Organic

2 Yeast sludge 1.2 MT Compost Mixed with DDGS Organic

3 ETP sludge 0.600 MT Compost Mixed with DDGS Organic

4. Ash (Bottom +

fly ash)

125 MT (for

coal) Or 80.5MT

(for rice husk)

- Nearby brick

manufacturing unit Inorganic

8.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN

The required land is already available with project proponent hence; there is no question of

rehabilitation and resettlement (R & R) Plan.

9.0 PROJECT SCHEDULED & COST ESTIMATES

1. Date of start of construction (tentative) March 2016

2. Date of completion (estimated) Dec. 2016

3. Project cost Rs. 11,900.00 lakhs

4. EMP cost Rs. 550.00 Lakhs

10.0 ANALYSIS OF PROPOSAL

I) Benefits

The process is eco-friendly. The effluent problems are non-existent in the case of a grain-based

distillery.

A grain-based distillery has no dependence on the supply of molasses as raw material, having

high elasticity and sensitivity of demand and supply.

The manufacturing technology is indigenously available.

The project is flexible and can handle a variety of raw materials like cereal grain, vegetables rich

in starch like potatoes, cassava, etc.

A high protein source in the form of distiller’s wet or dry grain with soluble (DWGS/DDGS) can be

produced in the distillery. This can be sold as a cattle feed. Additional revenue can be generated

by selling DWGS/DDGS.



The promoter can take up the grains on contract farming from the nearby farmers. However in

order to minimize dependency of the project on the farmers, grains from outside markets can be

procured.

Grain alcohol is superior in quality to molasses alcohol. Nowhere in the world, the molasses

alcohol being termed as Indian whisky, brandy etc. if they are produced from molasses alcohol,

they are termed as Indian Spirits.

Grain based CO2 is food grade. Therefore, in future, there is a scope to put-up a food grade /

beverages grade CO2 plant. It is also possible to go for liquor project (Country liquor or IMFL) in

future, which will further improve the economic viability of the project.

II) conclusion

a) This project will help to improve the economic conditions of local people

b) The candidate site is suitable as per general MoEFCC expectations

c) Water, power, raw material and market is found available with ease

d) Full precautions will be taken for pollution control, resource conservation and

environmental protection

e) This is cost effective and sustainable development

PRE-FEASIBILITY REPORT FOR DISTILLERY...

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