Pre Feasibility Report For Molasses Based Fuel...

Pre Feasibility Report

For

Molasses Based Fuel Ethanol Plant

of 60 KLD

Along with 25 TPH

Incineration Boiler

At

Village – Pondar, Post - Salichouka

Tehsil- Gadarwada

Distt – Narsinghpur (MP)

Proposed By

M/S Narmada Sugar Pvt Limited Village- Vill.- Thaini , Post – Bankhedi,

Dist .- Hoshangabad, MP- 461990

1. Identification of project and project proponent

M/s Narmada Sugar Pvt Limited (NSPL) is as partnership firm registered

with State Govt and located at Village- Pondar Tehsil- Gadarwada Dist

Narsinghpur (MP)

M/s. Narmada Sugar Private Limited (NSPL) is one of the pioneering sugar

factories of Madhya Pradesh and is in its 10th year of operation. NSPL

received its memorandum for manufacturing of vacuum pan sugar and

molasses along with other sugarcane by products from the Ministry of

Commerce & Industry in April 2005. The factory started its crushing

operations in the year of 2006-07. The licensed crushing capacity of the

plant is 4500 tonnes per day.

Brief Description of Nature of the Project

The present proposal is for setting up a 60 KLD fuel ethanol plant (Molasses

based) with 25 TPH Incineration Boiler at Village- Pondar Tehsil- Gadarwada

Dist Narsinghpur (MP) in the State of Madhya Pradesh at an estimated cost

Rs. 6358 Lacs. The proposed project will be set up within in premises of

existing sugar unit (4500 TCD & 30 MW power plant) of M/s NSPL.

Most of the infrastructure facility is already available with the industry as

present sugar manufacturing operation is being continued from several

years.

The Company proposes to set up an integrated pollution free (Zero

discharge) fuel ethanol plant in the State with an installed capacity of 60

KLD in the State of Madhya Pradesh. The proposed Industrial Complex shall

process molasses as its raw material to produce RS & Dehydration:

Silent feature of the project

• Provided with most efficient Fed batch Fermentation technology

Distillation operating on Multi-Pressure Technology -a efficiently heat

integrated system, operating on fully automated PLC control system

On line cleaning system is provided for distillation equipment's to

minimize plant shut down period.

Process equipment's are designed as per TEMA/ ASME standards

Closed water recycles system and plant process is designed to minimize

fresh water requirement by recycling various effluents.

Zero Effluent Discharge norms is applied while designing the plant

Sr. No. Particulate Description

1. Name of the proponent M/s Narmada Sugar Pvt. Limited (NSPL)

2. Project capacity 60 KLPD Molasses Based Fuel Ethanol Plant with

25 TPH Incineration Boiler 3. Khasara No. & Location of the

project

Khasra No. 132/1³

132/4 2.150 Acre

6/3 -2.100 Acre

Total-4.250 Acre

Village- Pondar Tehsil- Gadarwada Dist Narsinghpur (MP)

4. Geographic Location 1. 22°51'12.60"N- 78°39'2.67"E

2. 22°51'16.24"N- 78°38'58.12"E

3. 22°51'22.80"N- 78°39'5.94"E

4. 22°51'18.52"N- 78°39'12.07"E

348 m MSL 5. Land requirement 4.25 acres for proposed Distillery Unit

2.59 acre built up area of plant 1.66 acre for green belt area

6. Product Product: Fuel Ethanol:60 KLPD With 25 TPH Incineration Boiler.

7. Operation days 270 days 8. Molasses required Molasses 220 TPD ( Fermentable sugar 42% w/w)

9. Total water 466 KLD (After recycling)

10. Source of water Borewell 11. Electricity Operational: 1050 kWh

Connected load: 1360 kWh

12. Turbine generator 1.5 MW

13. Steam 13.20 TPH 14. Fuel Total Spent wash : 600 M3 TPD

Concentrated spent wash: 156 M3 TPD Bagasse – 180 TPD

15. Source Captive & sister concern

16. Boiler 25 TPH Incineration Boiler

17. DG Sets Existing DG sets of 63 KVA, 160 KVA and 400 KVA shall be used as standby arrangement

18. Effluent treatment System

Condensate Polishing Unit (CPU) will treat spent

lees, cooling tower blow down, boiler blow down and process condensate. Spent wash will be

treated by multi effect evaporator followed by slope fired boiler.

19. Man-power 90 skilled and unskilled 20. Total project cost 6358 Lakhs

21 Land acquired 35.298 acres inclusive of sugar unit

22 Land earmarked for

proposed distillery unit

4.250 acres

23 Proposed area for plantation

wrt distillery unit 1.66 acres

24 Existing area of plantation 2 acres

25 Capital Cost for Environmental measures

(proposed )

1200 Lacs

26 Recurring cost for environmental monitoring etc

(Proposed)

110 Lacs ( May be changed during EIA study)

Existing Sugar And Cogeneration Plant Details

Sr. No Description Quantity Unit

1. Crushing capacity, TPD 4500 TCD

2. Number of crushing days/year (expected)

120

3. Boiler used 150 TPH

4. Power generation capacity 30 MW

5. Power consumption Season Offseason. MW

For sugar plant and cogen 5.68 0.10

Other In-house consumption 2.80 2.95

Power export 21.52 26.95

6. Bagasse generation 56.25 TPD @30 %

7. Molasses generation 40851 Tonne

8. Fresh water requirement for Sugar and cogeneration after

recycling.

Season Offseason. CuM/D

280 40

9. Water storage capacity 5000 CuM/D

10. Effluent generation form

sugar and cogeneration

plant

358 CuM/D

11. Final disposal of treated

effluent

Within the premises for green belt development, dust suppression etc.

-

12. Ash generation from existing

plant 18.93 TPD

13. Press mud 135 TPD

14. ETP Sludge 0.04 TPD

15. Lime sludge 0.07 TPD

16. WTP Sludge 0.01 TPD

17. Final disposal of Ash Given to farmer as manure. -

18. Storage capacity of Bagasse’s

yard Kept at ground in bails form 6500 ft area

19. Storage capacity of Molasses 9300 MT

20. Existing manpower requirement for Sugar/Cogeneration (skilled and unskilled)

160 No.

Proposed manpower requirement for Distillery

(skilled and unskilled)

90 No.

21. Layout plan of existing sugar factory and cogeneration unit & proposed

Distillery unit with existing green belt, parking area, storage area etc -

Attached

3. Need for the project and its importance to the country and or region

Utilization of molasses for the production of ethanol in India will not only

provide value addition to the by-product, it also ensures better price stability and

price realization of molasses for the sugar mills. This will improve the viability of

the sugar mills, which will in turn benefit to cane growers.

Industry overview

Molasses is one of byproducts of sugar industry which is used to produce

rectified spirit/alcohol for making liquor and fuel. Traditionally, molasses has

been used in India to produce rectified spirit and alcohol of higher than 95%

purity for producing liquor for human consumption and for producing various

chemicals. However, with technological developments in the recent past,

molasses has been effectively used to produce bioethanol for blending with

petrol as a fuel

Global scenario

Brazil is the second largest producer of ethanol globally after U.S. While

U.S. produces ethanol from corn, Brazil manufactures ethanol from sugarcane.

Brazil has mandatory blending ratio of ethanol in gasoline ranging from 18% to

25%. The blend rate was as high as 25% before September 2011 and was reduced

to 20% due to drop in cane output hence affecting the ethanol production.

Currently, flex-fuel cars, which can use either ethanol or blended gasoline, in

Brazil account for about 53% of the total car fleet and around 90% of the new

vehicles sales. The proportion of the flex-fuel cars are expected to cross 80% by

2020. Currently, the Brazilian light vehicle fleet has been increasing by 6.7% y-o-

y since 2003 with currently 90% of the new vehicles being flex-fuel cars. Thus,

there exists an increasing demand in Brazil for ethanol which is encouraging for

the sugarcane industry.

Indian scenario

India has about 330 distilleries, which produce over 4 billion liters of rectified

spirit (alcohol) a year. Beyond total distilleries, about 120 distilleries have the

capacity to distillate 1.8 billion liters (an additional annual ethanol production

capacity of 365 million liters was built up in the last three years) of conventional

ethanol per year which is sufficient to meet requirement for 5% ethanol blending

with petrol.

Government policy

In 2006, GOI mandated 5% ethanol blending with petrol, EBP programme to

directly benefit the sugarcane farmers by assuring the sugar industry a stable

and reasonable return for the molasses and then passing a significant part of the

same to the farmers. But since then the programme has been struggling to take

off despite the fact that the Cabinet Committee on Economic Affairs (CCEA) in

November 2009 directed that a financial penalty be imposed on oil marketing

companies for their failure to reach targets. In November 2012, the CCEA has

made it mandatory for Oil Marketing Companies (OMCs) - Bharat Petroleum,

Hindustan Petroleum and Indian Oil Corporation - to blend 5% ethanol with

petrol. This is likely to reduce the fuel import bill and lower India's dependence on

fossil fuel as the ethanol prices are lower than petrol. The OMCs have been

blending ethanol with petrol for the past two years but the policy was partially

implemented in absence of any clear directive. The committee, headed by the

Prime Minister, has also approved market-based pricing of the biofuel,

opening the market for ethanol producers - mostly sugar companies. This shall

result in an increased demand for ethanol by OMCs.

The national bio-fuel policy, approved by the Government of India, has plans for a

20% ethanol blending programme by 2017 from the current mandated 5%

blending & recently increased to 10%, to reduce India’s dependence on fossil fuel

imports.

4. Demand –Supply Gap

The gap between the availability of alcohol and the requirement by the industry

has been widening. The existing requirement of alcohol by the industries is

around 450 crore liters annually at 10% fuel ethanol blending, industrial alcohol

and potable alcohol and the production is around 285 crore liters. The trend is

increasing as the blending increases. The Ministry of Petroleum recently issued

gazette notification dated 11th Januray 2013 making 5% ethanol blending with

petrol mandatory across the country. Year Ethanol production Ethanol utilization Ethanol

Blending Petrol Demand

Molasses Cane Total Industry Potable Balance 2001-02 1775 0 1175 600 648 527 5% 448 8960

10% 896

20% 1792

2006-07 2300 1485 3785 711 765 2309 5% 638 12672

10% 1276

20% 2552

2011-12 2300 1485 3785 844 887 2054 5% 814 16286

10% 162

20% 3257

2016-17 2300 1485 3785 1003 1028 1754 5% 1039 20785

10% 2078

20% 4157

From the above table it can be concluded that actual production of ethanol in India has not kept pace with the demand. Also with robust growth for chemical and potable industries it will mean greater shortage of ethanol in the coming years ahead. The Government of India has set an indicative target of 20% blending of ethanol with petrol and also for diesel with biodiesel across the country by 2017.

5. Imports Vs. Indigenous Production

No import is proposed as demand in domestic market is enough to

consume the product.

World Alcohol Production and Consumption (Billion Litres)

World Regions Years

2010 2011 2012 2013 2014

Americas 23.23 27.81 30.02 33.35 37.30

Asia 6.02 6.54 6.44 6.61 7.15

European Union 2.54 2.50 2.50 2.71 3.13

Rest of Europe 1.45 1.48 1.47 1.46 1.36 Africa 0.51 0.54 0.57 0.59 0.62

Oceania 0.18 0.16 0.15 0.15 0.17

World Total 33.93 39.03 41.15 44.87 49.73

India 1.80 1.90 1.65 1.70 2.0

* Projected

Source: F. O. Lichfs World Ethanol and Biofuels Report, Vol.4, No.17,

09/05/2006. Ethyl alcohol is basically used for three purposes i.e. 1) Industrial

alcohol for production of downstream chemicals, 2) Pptable Alcohol for

mamifacture of alcoholic beverages (Country Liquor and IMFL) and 3) Fuel

ethanol or Anhydrous alcohol, which can be blended with petrol or diesel.

Sr. No. Ethanol Consumption for (%)

1 Industrial 21

2 Potable 11 3 Fuel 68

Industrial Alcohol: -

Ethyl Alcohol is an Important feedstock for the manufacture of

chemicals.

World ethyl alcohol consumption for the production of chemicals is

around 1%. These chemicals are primarily the basic carbon based

products like Acetic acid, Butanol, Butadiene, Acetic Anhydride, Vinyl

Acetate, PVC etc. The existing plants such as synthetic rubber

requiring large quantities of alcohol will certainly grow to a large

capacity. Acetic acid & Butanol, which are needed in pharmaceuticals,

paints & in many other areas are important industries as they are value

added products. Ethylene, Ethylene oxide & Mono-ethylene glycol are

also produced from petrochemical route. However latest technological

development & taking into account the increasing cost of petrochemical

raw material, it is now possible toproduce Ethylene oxide, Mono-ethylene

glycol etc. starting from ethanol.

During the last 5-6 years, a number of alcohol-based industries have come

up& the existing has marginally expanded. The raw material needs

of the alcohol based chemical industry have to be niet to facilitate

maximum capacity utilization of these units in order to meet the

domestic demands for the end products. These units are starving for

want of raw materials. The shortage is wide spread & it has hit a most of

chemical drug & other industries. The drug industry is also bedeviled by

scarcity of industrial alcohol. Producers of insulin, antibiotics, tonics &

several other essential bulk drugs & finished formulations are unable to

obtain their quota of industrial alcohol, which is a vital raw

material for them. Thus, even in Maharashtra, which should be a

State with surplus production of alcohol, drug & chemical units are in

the group of acute shortage of industrial alcohol. It follows that the

supply of industrial alcohol to chemical and drugs units in the country

will remain below normal for some more time. In order to maintain

proper rate of growth of industries, production of alcohol must

increase.

6 Export Possibility

The company is setting up fuel ethanol plant, to supply the finish goods in

the country, at present is no export possibility at this capacity is envisaged.

7 Domestic/Export Markets

As above

8 Employment generation (direct and indirect) due to the project

Existing employment at sugar & co gen unit : 100+ 60 no.

Proposed Employment : 90 Nos. ( skilled and Direct )

Apart from that indirect employment generation is envisaged from the

project.

Total manpower requirement Sr. No Staff Nos.

1. Distillery manager 1

2. Production manager 1

3. ETP in-charge 1

4. Lab chemist 4

5. Operators 8

6. Project Engineer / Shift Engineer 8

7. Electrician 4

8. Mechanical fitters 4

9. Office Peon 3

10. Office assistant 3

11. Excise officer 1

12. Waterman/ Pump man 4

13. Other Contractual staff 48

14. Total 90

9 Project Description

i. Type of the project including interlinked and interdependent project, if any

As submitted, the Ethanol Plant is proposed with the existing sugar unit of 4500

TCD. Incineration Boiler of 25 TPH is also proposed for implementation of zero

discharge concept. CO2 will also generated as by product from the fermentation

process which is turn can be utilized after further treatment at CO2plant in

industrial or food grade application. It is also proposed Evaporation plant of

effluent to provide better environment conservation and pollution control

arrangement in the unit as well as for the surrounding area.

ii. Location (map showing general location, specific location, and project

boundary & project site layout) with Coordinates:

The unit is spreaded over 23.5+11.7968=35.2968 acres of land in village

Pondar Tehsil, Gardarwada Dist. – Narsinghpur of MP. The latitude and

longitude of the site is as below :

1. 22°51'12.60"N- 78°39'2.67"E

2. 22°51'16.24"N- 78°38'58.12"E

3. 22°51'22.80"N- 78°39'5.94"E

4. 22°51'18.52"N- 78°39'12.07"E

Satellite Image of the Project area

Topographical Base Map

iii. Details of Alternate Site:

The site is proposed on the piece of land where sugar unit ( 4500 TCD) with

cogen plant of 30 MW is already in operation. The entire land is about 35.298

acres and out of that proposed unit will require 4.25 of land. Most of the

infrastructure is already available. Therefore proposed site suitable for the

project configuration.

iv. Size or magnitude of Operation:

It is proposed to produce 60 KLD of fuel ethanol from molasses based operation

along with 25 TPH Incineration Boiler. The unit shall adopt zero discharge

technology for the effluent disposal. .

v. Project Description With Process Details: The overall process is shown on the attached Block Flow Diagram, and Process

Flow Diagrams. The following describes the production of ENA and co-products

from grain. The process envisages use of own molasses, as well as procured

molasses from nearby sugar factories, for manufacture of ethanol during sugar

mill season and during offseason days.

Cane crushing system

Fermentation system

Distillation & Fuel Ethanol

Effluent treatment system

Following is a brief description of the process:

Detail Process Description & Process Flow Charts

Fermentation

Molasses, diluted with water to the desired concentration is metered continuously

into a single tank fermenter. Additives likes urea (in the form of pellets or prills)

and defoaming oil are also introduced in the fermenter as required. There is an

automatic foam level sensing and dosing system for defoaming oil.

Every Kilogram of alcohol produced, generates about 290 Kcal of heat. This excess

heat is removed by continuous circulation of fermenting wash through an

external plate heat exchanger called the Fermenter Cooler. The fermenter

temperature is always maintained between 32 and 35 deg. C, the range optimum

for efficient fermentation.

The yeast for the fermentation is initially (i.e. during start-up of the plant)

developed in the Propagation Section described further on. Once propagated, a

viable cell population of about 500 million cells/ml is maintained by yeast

recycling and continuous aeration of the fermenter. Fluctuations in the yeast

count of +/- 20% have little effect on the overall fermenter productivity. Yeast cell

vitality which is usually above 70% may, in times of stress (such as prolonged

shut-downs) drop to 50% without affecting the fermentation.

Fermented wash passes through a series of hydro cyclones (one to three or

move in number depending on plant capacity), which remove grit, iron filings

and similar heavy particulate matter. This rejected material along with some

wash, is taken to the bottom portion of the wash column for alcohol recovery.

The overflow from the first hydro cyclone is taken a wash tank, also provided

with an arrangement to facilitate removal of heavy settable particulate matter.

Overflow from the wash tank is taken to the yeast separator, which clarifies the

wash. The hydro cyclone and the wash tank protect the separator from erosion

damage by removing grit and similar hard particles.

Wash Preparation

For the plant mash, molasses is diluted with water to give a sugar concentration

of 14 to 18% and pumped directly into the fermenter. This mash is usually not

sterilized, although in certain cases it has been pasteurised with a resultant

slight increase in efficiency. The fermenter is issued when it is one eighth to one

fourth full with a large volume of active yeast. 2 to 4% of the final volume to

allow development of the yeast during the entire filling period, which may

amount to 8 hours and to avoid growth of contaminating organisms during

this period.

Nutrients

Blackstrap molasses usually contains enough yeast nutrients to give a fast,

efficient fermentation. In some cases, however, it is desirable to add small

quantities of ammonium salts, such as ammonium sulphate, to the mash to

increase the rate and efficiency of the fermentation. In such cases, the amount

of ammonium sulphate added varies between 0.5 liters and 3 liters per 10,000

liters of mash, depending on the molasses used, the optimum amount being

determined by laboratory in a blackstrap molasses fermentation.

Fermentation Temperatures

Fermenters are usually set at a temperature between 27º F and 30º C and are

held a 32º C by the use of water sprays on the rank internal cooling coils, or by

circulation of the mash through external coolers. It is desirable to maintain the

temperature of the mash below 35º C. The amount of heat liberated during

the fermentation agrees with the theoretical value. C2H12O 2C2H5OH + 2CO2+26.0 Calories

The heat produced from a fermentation involving 100 kg of sugar is 260 cal.

If the fermenters are not cooled the temperature of the mash will rise as much as

40º C.

• Yeast Recycling:

The yeast in the fermented wash is removed as a 45 to 55 v/v slurry, and is

returned to the fermenter. This feature ensures that a high yeast cell

concentration is achieved and maintained in the fermenter. By recirculating

grown, active yeast, sugar that would have otherwise been consumed in yeast

growth, is made available for alcohol production, ensuring high process

efficiency.

• Propagation:

The propagation section is a feeder unit to the fermenter. Yeast, either

Saccharomyees cereviseae or Schizosaccharomyees (the choice being

determined by other process parameters, mainly the downstream effluent

treatment system) is grown in 3 stages. The first two stages are designed for

aseptic growth. Propagation vessel III develops the inoculum using pasteurized

molasses solution as the medium. This vessel has a dual function. During

propagation, it serves for inoculum build-up. When the fermenter enters the

continuous production mode, Propagation Vessel III is used as an intermediate

wash tank. Propagation is carried out only to start up the process initially or

after very long shut-downs during which the fermenter is emptied.

• CO2 Scrubbing and Recovery:

The carbon-di-oxide produced during fermentation is scrubbed with water in

packed- bed scrubber, to recover alcohol. The water from the scrubber is

returned to the fermenter. About 1.0% of the total alcohol production is saved

by scrubbing the fermenter off gas. In plants where it is desired to recover

carbon-di-oxide, a part of the wash is drawn into a separate vessel and is

aerated there. This external aeration allows the recovery of CO2 uncontaminated

with air. More details of this system can be supplied on request.

• Fermentation Parameters (Typical):

The pH of the fermenter is maintained between 4.0 & 4.8 usually without addition

of any acid. The alcohol concentration is maintained between 7.0 & 7.5 % v/v,

unless a highly concentrate effluent is to be produced. To reduce the effluent

volume, the fermenter is operated at a very high dissolved solids level by

increasing the proportion of weak wash recycle. Under these conditions, alcohol

concentration is reduced to between 5.5 to 6.0% v/v.

Conversion of sugar to alcohol is instantaneous, and the residual sugar

concentration is maintained below 0.2 % w/w as glucose. This usually

corresponds to a residual reducing substances concentration of 2.0 to 2.5 %

w/w in wash.

All the nutrient elements necessary for yeast growth exist in adequate quantities

as impurities in molasses. Occasionally, Nitrogen may have to be supplemented.

Defoaming oil (DFO), say Turkey Red Oil is added to the fermenter by an

automated DFO dosing system, to control foaming. Usually no other additives are

required.

• Flexibility:

This process accords tremendous flexibility to the operator. Process conditions

and plant design can be varied to suit individual requirements of alcohol quality,

effluent concentration and characteristics. This unit can give spent wash

suitable for use in any effluent treatment process.

2. Distillation:

Clarified or de-yeasted wash flows by gravity to the propagation vessel No. III,

which during continuous production, operates as an intermediate wash tank.

From here, fermented wash is pumped to the wash preheater, which uses vapors

from the rectifying column to preheat wash. Further heating is done in an

exchange of heat with weak wash and spent wash (see flow sheet for primary

distillation). Preheated wash then enters the degasifying column of the

distillation section.

• Primary Distillation: The CO2 and the degasifying section help remove the CO2

and other non-condensable entrained in the wash. The wash column is first

column in the distillation section. It is also called the analyzer. Wash is boiled in

this column with steam either supplied as live steam from the boiler (after

pressure reduction and desuperheating) or from a reboiler which generates

steam by evaporating effluent wash.

Alcohol in wash vapourises and is carried, along with water vapor, to the top of

the wash column from where it goes to the rectification column. As wash travels

down the analyzer, it is progressively ‘stripped’ of its alcohol content. At a

point in the column, where the alcohol concentration is 0.5 to 1.0% v/v, a

portion of the wash is drawn off. This is called weak wash.

• Weak Wash Recycling :

Weak wash recycling of weak wash helps maintain the desired level of

dissolved solids in the fermenter, so that an adequately high osmotic pressure

is achieved. Osmotic pressure and the concentration of alcohol in the fermenter,

together keep off infection and minimize sugar losses. Weak wash recycling also

reduces the quantity of effluent spent wash and reduces the process water

requirement of the plant.

Spent wash is the wash from which all alcohol has been removed, this emerges

from the bottom of the wash column at about 105 deg C. Some of the heat is

recovered to preheat fermented wash entering the degasifying column.Spent wash

may also be passed through a forced circulation reboiler to generate vapors.

This concentrates the effluent and reduces the volume further.

Multi Pressure Vacuum Distillation:

After fermentation the next stage in the manufacture of alcohol is to separate

alcohol from fermented wash and to concentrate it to 95% alcohol called as

rectified spirit. For this purpose, distillation process is employed.

Distillation step consumes a considerable amount of energy and is also a

deciding factor in the quality of ENA produced. Hence, in line with the demand of

the industry, efforts have always been to minimize requirement of energy and to

improve the basic quality of alcohol produced. Ease of operation, reliability,

lower down time and flexibility of operations are other parameters considered

during the design.

Three basic types of plant are designed:

a) One is to produce primary quality of alcohol, usually referred to as 'Rectified

Spirit' (R.S.) from the fermented wash. Such plants are also referred to as

‘Primary distillation’ plants.

b) Second is to produce fine quality of spirit usually referred to as 'Extra Neutral

Alcohol' (ENA) starting from R.S. Such plants are also referred to as 'secondary

distillation' plants.

c) Third is to directly produce fine quality alcohol (ENA) from fermented wash.

Such plants are referred to as 'wash (mash) to ENA' plants, where the two steps

of primary and secondary distillation are combined. Such plants usually have

lower consumption of energy than two separate plants

Multi-pressure vacuum distillation system for production of Rectified Spirit

/ ENA consists of following distillation columns namely

1. Degasifying cum analyzer column – Operation under vacuum

2. Pre-rectification column – Operation under vacuum

3. Rectification cum Exhaust Column - Operated under pressure

4. Recovery column - Operated under atmospheric

5. Extractive distillation column – Operated under vacuum

6. Simmering column – Operated under atmospheric

Benefits of Pressure Vacuum Distillation: -

Following are the advantages of pressure vacuum distillation.

• Since the analyzer column operates under vacuum, the formation of byproducts

such as acetal may minimize there by improvement in quality of alcohol.

• Pre-rectification column ensure removal of sulfur compounds/mercaptans and

also reduces load of lower boiling volatile compounds passing on to Rectifier cum

exhaust column.

• The chances of scaling due to invert solubility of certain precipitating inorganic

salts are minimized in vacuum distillation.

• Vacuum distillation requires low steam consumption with re-boiler

Integrated Multi-products Concept: -

It is now possible to install a distillation system, which can produce different

products. In the proposed scheme; the production of rectified spirit have been

considered. This allows flexibility of operation and various products can be

manufactured depending on the market demand. This integrated multi-product

system involves less capital investment as compared to independent system.

In this type of system, switching over from one product to another is quite easy

and there is no chance of contamination of one product with another. The

system can work under multi-pressure principle with few columns operating

under vacuum and few under pressure/atmospheric.

3. Dehydration of Alcohol: Molecular Sieve:

The process drives the rectified feed though a bed of desiccant beds. To allow for

bed regeneration in continuous operation, twin beds are provided of which one

is in dehydration mode while the other is regenerating. Depending on feed

and product specifications, the dehydration-regeneration process releases the

adsorbed water together with contained ethanol, it is recycled back to

regeneration column for reprocessing.

The feed is pumped to regeneration column after preheating in feed

preheater. The overhead vapor of regeneration column is superheated to the

required operating temperature and circulated to sieve bed 1 assumed in the

description to be in dehydration mode. After passing though the desiccant, the

vapor is condensed, cooled and sent to storage.

A small portion of the product vapor is sent, under high vacuum, through bed

2, in regeneration mode, to prepare the desiccant for cycle changeover when bed 2

goes online. The regeneration operation forces the release of the moisture from

the desiccant, making the bed 2 ready for the next cycle. The recovered low

strength vapors are condensed and recycled back to the Regeneration column.

4. Evaporation for Spent wash Treatment

As per recent Environmental Protection Norms from Ministry of Environment

and Forests (MoEF), it is Corporates Responsibility to achieve Zero Discharge

in Inland Surface Water. For 60 KLPD distillery plant nearly about 600 M3/Day

spent wash will produced. Considering the large volume of spent and achieve Zero

liquid discharge plant operation following three stage process is proposed.

Multi pressure distillation – In this steam is utilized in direct way for heating.

Hence, spent wash quantity generated is less as compared to traditional

distillation technology. Integrated and Standalone Multi effect evaporation - The

spent wash evaporation technology is a multiple effect evaporator system in which

heat recovered from one effect is used to concentrate spent wash in second

effect evaporator with continuous recirculation of concentrated spent wash

within the system until desired concentration is obtained. This entire

concentration process is carried out under vacuum leading to less consumption

of steam and maximum concentration of spent wash with in less period of time.

This is the 3rd stage of effluent treatment wherein spent wash after integrated

evaporation is concentrated and used in incineration boiler.

5. Spent wash Incineration Technology:

After spent wash evaporation, concentrated spent wash with desired

concentration is obtained is feed to incineration type of boiler. The

concentrated spent wash generated after entire process of evaporation is then

sprayed in a furnace with auxiliary fuel such as coal and is then burnt in a

boiler.

6. Process Condensate Treatment and Recycle:

The condensate polishing unit is also envisaged to take care of spent lees, cooling

tower blow down, washing and process condensate from evaporation plant. After

treatment all the stream at CPU, treated condensate can be recycled to process

for dilution and as cooling tower make up and will achieve zero liquid discharge

(ZLD) Due to recycle of process condensate back to process, fresh water demand

can be reduced at large extent.

Quantity of Raw Materials Required;

Raw Material Requirement

Sr. No. Name of raw material

Quantity Storage Transportation

Distillery

1. Molasses 220 TPD Tank Tanker

2. Sulfuric Acid 0.25kg/KL FRP Tank Tanker

3. Anti-foam reagent 0.25 kg/KL Drum Truck

Sugar Unit

1. Sugarcane 4500TCD Open Area Truck & Tractor

2. Lime 540 MT/Year Bags Truck

3. Caustic soda 20 MT/Year Bags Truck

NSPL will generate about 40851 MT of molasses from expected / sustained cane

crushing of 54 Lacs MT / year, with minimum 4.7% molasses recovery. M olasses

will be sourced from parent sugar unit and group sugar factories. The fuel ethanol

yield from cane molasses will be at 270 lit/ton. The per day requirement of

molasses will be about 220 MT per day for 60 KLPD ethanol production per

day. The total requirement of molasses for the 270 days operation of the

proposed ethanol plant will be about 59400 MT (at maximum 95% utilization

level from 4th year onwards).

vii. Resource optimization/ recycling and reuse

Multi Pressure Distillation system has lower steam consumption as it is designed

for maximum heat integration to conserve energy.

Energy efficient Multi-Pressure Distillation system with a Steam Consumption

13.20 TPH of Total Spirit (depending on mode of operation).

Vacuum operation nearly eliminates scaling problem in Analyzer Column and

ensures better separation of impurities, which results into better quality product.

Well-engineered Plants with high efficiency trays to ensure elaborate separation

and removal of impurities ensuring superior quality of Extra Neutral Alcohol.

Analyzer Column with Hyper-stat Rh-Grid trays ensure high turbulence on tray,

this minimizes chances of scaling. Also, this special construction of trays and

access to each tray helps in easier cleaning column internals.

Condensers are designed with multiple passes to ensure high velocity and to

minimize scaling inside tubes.

Alcohol is well known as an industrial raw material for manufacture of a variety

of organic chemicals including pharmaceuticals, cosmetics, polymers etc. A large

demand is anticipated for alcohol as a fuel. Alcohol is an eco-friendly product and

is a substitute to the imported petroleum. Indeed fuel ethanol production has

been promoted for a variety of reasons as mentioned below,

It has less severe impact on the environment than conventional gasoline and

less dangerous to health. As oxygenates are compounds such as alcohols or

ethers which contain oxygen in their molecular structure. Oxygenated fuels tend

to give a more complete combustion of its carbon to carbon dioxide (rather than

monoxide) which leads to reduced air pollution from exhaust emissions. It

reduces the dependence on oil imports.

It helps to maintain rural economy.

Factory proposes zero liquid discharge method for waste water treatment.

Maximum waste water will be recycled back into the system.

Factory proposes to install Multiple Effect evaporator followed by Incineration

boiler. Advantages are as follows

Production of steam and power generation

Reduction in air pollution as compared to coal based boiler.

Reduction in water pollution and achieve zero discharge in inland surface water.

viii.: Availability of Water its source, energy / power requirement and source:

Water requirement:

Construction Phase – 20 kld

Operational Phase – Net fresh water requirement will be 466 KL per day

Source : Borewells

Water Balance

. Water inputs (In KLD)

1. Process water for fermentation section and CO2 scrubber 552

2. DM water for RS dilution 65

3. Water for vacuum pump, pump sealing, air blower & others

8

4. Soft water makeup for cooling towers 453

5. Other domestic usage, laboratory uses, cleaning 5

6. Boiler 20

7. Total water input at start-up 1103

Water Out Put (In KLD)

1. Spent Lees (PR & Rect.) 160

2. Process condensate 525

3. CT Evaporation & Drift Losses 362

4. Water losses from vacuum pump, pump sealing, Air blower 0.2

5. Cooling tower and boiler blow down 89

6. Total Water Output 1136

Recycled water (In KLD)

1. Lees recycle for cooling tower make up 160

2. Process condensate fermentation 160

3. Process condensate to cooling tower, CIP, Fermentation 310 4. Pumps Sealing Water Recycle cooling tower 6

5. CO2 scrubber beer well to process water for fermentation 1

6. Total Recycling water per day 637

Daily fresh water input 466

Wastewater generation from sugar unit and cogeneration

Sr. No.

Source Process KLD Treatment Final Disposal

1. Sugar Plant

Sugar manufacturing Process

266 ETP Treatment Units: Bar screen and grit chamber, oil and grease traps, reaction tank, equalization tank, anaerobic tank, aeration Tank I, aeration Tank II, secondary clarifier, sludge drying bed and polishing pond.

For ferti irrigation.

2. Co generation 11 MW

Cooling Tower

20 For polishing pond for dilution with other effluent

For Ferti-Irrigation

Boiler Blow down


For Ferti- Irrigation

D.M. Regeneration

66 Neutralization followed bydisposal to polishing pond for dilution with other waste water stream.


Total - 358 - -

Summary of effluent generation from proposed distillery, existing sugar and cogeneration unit

Source Effluent Quantity Disposal

Proposed Distiller Spent wash Raw spent wash Generation : 600 KLD Concentrated spent Wash : 156 KLD

Conc. Spent Wash Feed in Incineration Boiler.

Sugar Molasses 220 TPD

Effluent 266 KLD

Co generation Blow down from the cooling tower & boilers

92 KLD

Domestic Waste water Sewage generation 20 KLD

ix. Power Requirement:

Construction Phase – 30 kw

Electricity consumption bifurcation

Sr. No Section Connected load (kWh)

Operating load (kWh)

1. Fermentation

1050 KWH

1360 KWH

2. Distillation

3. MSDH

4. Integrated RSW evaporation 5. Process condensate treatment plant

6. Alcohol storage

7. Utility (Cooling tower)

8. Instrument air compressor

9. Total 1050 KWH

1360 KWH

During operation phase , the required power will be taken from cogeneration

power plant. Existing DG sets of 63 KVA, 160 KVA and 400 KVA shall be

used as standby arrangement.

Fuel consumption

Sr. No Fuel Quantity

1. Concentrated spent wash 156 TPD

2. Spent wash concentrate, GCV 1600 kcal/kg

3. Bagasse 56.25 TPD

4 Bagasse GCV 2250 kcal/kg

Steam Requirement

Sr. No. Section Quantity (TPH)

Steam utilization for Distillery

1. Steam for Distillation (Wash to ENA mode) N A

Or Steam for Distillation (Wash to EQRS) 6.42 TPH

2. Steam for Integrated Evaporation 5.32 TPH

3. Steam for MSDH 1.46 TPH

4. Total 13.20 TPH

Steam utilization for sugar factory

5. Crushing rate 4500 TCD

6. Steam Generation 3300 MTD

7. Steam Requirement 1800 MTD

8. Steam Condensate 1500 MTD

Steam Requirement

S no Purpose Quantity

1 Ethanol Fuel 3.5 kg/lit

2 Evaporation 1.8 kg/lit

X. Quantity of wastes to be generated (liquid and solid) and Scheme for their

management/ disposal

For Liquid Waste

The total water requirement at the startup will be around 1103 m3/day, and after

recycling daily fresh water requirement will be 466 KL per day. Source of water

will be Bore well. Water storage facility is available with the sugar factory. Detail

water breakup is given in Table

Water Requirement For Existing Sugar Unit

Sr. No Particulars For sugar

During Off Season

1. Total water requirement 460 M3 3 M3

2. Water recovered 180 M3 N A

3. Total daily fresh water

required after recycling

280 M3 NA

Wastewater Generation Of Sugar And Cogeneration

Sr. No.

Source Process KLD Treatment Final Disposal

1. Sugar Plant Sugar manufacturing Process

266 ETP Treatment Units: Bar screen and grit chamber, oil and grease traps, reaction tank, equalization tank, anaerobic tank, aeration Tank I, aeration Tank II, secondary clarifier, sludge drying bed and polishing pond.

For ferti irrigation.

2 CO Gen Plant

Cooling Tower



Boiler Blow down



D.M. Regeneration

66 Neutralization followed bydisposal to polishing pond for dilution with other waste water stream.


Total - 358 - -

Summary Of Effluent Generation From Proposed Distillery, Existing Sugar And Cogeneration Unit

Source Effluent Quantity Disposal

Proposed Distillery Spent wast Raw spent wash generation : 600 KLD concentrated spent wash : 156 KLD

Conc. Spent Wash Feed in Incineration Boiler.

Sugar Molasses 220 TPD ETP

Effluent 266 KLD

Co generation Blow down from the cooling tower & boilers

92 KLD

Domestic Waste water

Sewage generation 20 KLD Septic tank and soak pit

Solid And Hazardous Waste Management

Yeast sludge mixed with spent wash and incinerated in the boiler or used as

manure.

Ash generated will be given to brick manufacturers.

Sludge from ETP will be used as manure.

Solid Waste Details

Sn Type of waste Quantity Disposal

From existing sugar &-cogeneration plant

Proposed Distillery

Yeast Sludge N A 0.25 Kg/day Fertilizer

Lime Sludge 0.07 MT/day N A Fertilizer

WTP Sludge 0.01 MT/day N A Fertilizer

ETP Sludge 0.04 MT/day - Fertilizer

Ash Bagasse ash:

18.93 TPD

Coal Ash : Spent wash Ash ;

N A 2.3 MT/day

Domestic waste 0.01 MT/day N A

Waste Oil 0.0001 Ltr/day N A

4.0 Site Analysis:

S. No.

Particulars Details

1. Locations

A. Village Pondar

B. Tehsil Gadarwara

C. District Narsinghpur

D. State Madhya Pradesh

Toposheet No. 55J/9

2. Latitude

Longitude

22°51'12.60"N

78°39'2.67"E

3. Co-ordinate of four corners

22°51'12.60"N- 78°39'2.67"E

22°51'16.24"N- 78°38'58.12"E

22°51'22.80"N- 78°39'5.94"E

22°51'18.52"N- 78°39'12.07"E

4. General ground level 348 above MSL

5. Nearest National/ State Highway

Pipariya- Gadarwara - SH-22 – 350 mt - N

6. Nearest Railway Station Salichouka Road – 3.50km - SE

7. Nearest Airport Jabalpur - 148km

8. Nearest Tourist Place None within 10km radius

9. Archaeological Important Place

None within 10km radius

10. Ecological Sensitive Areas

(Wild Life Sanctuaries)


11. Reserved / Protected Forest within 10km radius


12. Nearest Town / City None

13. Surrounding village within 1 km area of the

project.

Pondar – 0.80km – NWN Salichouka - 1.0 km – ENE

14. Nearest village Pondar – 0.80km – NWN

15. Nearest River Dudhi River - 4.50km - SW

Umar (Shkhi) Nadi - 3.50km - NE

16. Nearest Lake/ Ponds Bagha nalla - Along the eastern boundary Ulgana Nalla - 3.75km - SW

Gahra Nalla - 5.0km - E

17. Nearest Hill Ranges None within 10 km radius

18. Other major industries in

10 km radius

None within 10 km radius

19. Surrounding Features North : Sugar plant & SH-22

South : Agricultural Land

East : Agricultural Land

West : Agricultural Land

i. Land Form, Land use and Land Ownership

Project Proponent is having around 35.298 acres of land which is possession

and diverted for industrial purposes.

ii. Topography

Topography of the area is almost plain. Map is given in point No. 3.2

iii. Existing Land use pattern

The land use of the project area is pertaining to industrial activity only. Out of

project area is predominantly being used or agricultural purposes.

Land use Break-Up for Existing and proposed unit

Area in Sq Mt

Particular Existing Sugar Unit Proposed Distillery

unit

Built up Area of main plant and

machineries

The unit is having total

around 35.298 acres of land. Existing sugar and

cogen unit covers over 23.5 acres of land. Out of that green belt have

been developed over about 2 acres of land.

10517

Road area 1200

Raw Material storage area 150

Fuel Storage Area 1000

Parking area Common

Green Belt 5500

Open Land 986

Total area ( 4.250 acres)

Land Bifurcation Of Proposed Distillery Unit

No. Units Area (sq. m.)

1. Molasses Storage Tanks 1800

2. Fermentation Section 200

3. Distillation Section 312

4. Evaporation Section 600

5. Product Storage & Receiver Section 2800

6. Cooling Tower for Fermentation 40

7. Cooling Tower for Disti. + Int. Evaporation 40

8. Cooling Tower for MSDH Section 40

9. PCTP Section 400

10. WTP & Raw Water Storage Tank 450

11. Weigh Bridge 150

12. Administration Office 400

13. Excise Office 240

14. Security Cabin 25

15. Time Office 120

16. Boiler House 1800

17. Coal Yard NIL

18. Lagoon & Settling Pit 900

19. Fire Water Pump House 200

Total area of Plant & Machineries 10517

In Acres 2.59 acres

Total area earmarked for proposed project 4.250

iv. Existing Infrastructure

The required infrastructure is already in place as proposed site is in

operation. State Highway is passing at 200 mtrs from the proposed project .

v. Soil Classification

The soils in the area are generally of sedimentary type soil .

vi. Climate data from Secondary Source:

Meteorological data month of 1st Feb to 31st April 2016

Meteorological Data Month of 1st Feb., 16 to 29th Feb., 2016

Date

Temperature OC Relative Humidity

% Morning (8.00)

Evening

(17.00)

Cloudiness

Octas

Rain

fall in

mm

Max Avg Min Max Avg Min Wind

Dir.

Wind

Speed

km/h

Wind

Dir.

Wind

Speed

km/h

Mor Eve.

1 30 22 13 80 52 18 NNE 6 WNW 4 0 0 0

2 27 20 14 79 56 30 NE 7 WNW 6 0 0 0

3 24 18 12 72 50 27 NE 8 NNE 5 0 0 0

4 24 16 9 73 43 15 ENE 4 NNE 6 0 0 0

5 26 17 8 69 48 18 ENE 6 NE 7 0 0 0

6 30 20 10 59 42 14 ESE 8 E 2 0 0 0

7 28 22 15 60 38 24 SSE 5 WNW 9 0 0 0

8 24 18 12 71 45 22 NNE 6 WNW 3 0 0 0

9 25 17 9 72 46 17 ESE 4 NW 4 0 0 0

10 29 20 11 77 47 23 ESE 5 WNW 7 0 0 0

11 29 22 14 64 41 11 WNW 3 W 9 0 0 0

12 28 20 11 63 40 14 ESE 1 NW 8 0 0 0

13 29 21 13 66 42 17 NNE 1 WNW 7 0 0 0

14 28 21 14 71 43 15 WNW 3 WNW 7 0 0 0

15 27 21 15 70 53 45 NE 8 WSW 2 0 0 0.2

16 29 23 17 75 54 32 E 6 NNE 14 0 0 1.4

17 32 24 15 71 54 19 ENE 5 NE 8 0 0 0

18 32 25 18 81 54 27 ESE 9 NE 6 0 0 0

19 34 26 17 75 44 19 ESE 5 N 5 0 0 0

20 33 26 18 65 37 14 WSW 5 W 6 0 0 0

21 29 24 20 69 57 37 NE 1 WNW 8 0 0 0

22 29 22 15 76 40 17 NE 5 WNW 5 0 0 0

23 29 21 13 55 33 8 ENE 3 NW 5 0 0 0

24 30 21 12 59 32 7 E 5 N 8 0 0 0

25 30 22 13 51 33 16 ENE 8 N 10 0 0 0

26 28 23 18 69 43 34 ENE 7 ESE 5 0 0 0.2

27 29 22 16 88 57 18 NE 5 NNE 7 0 0 0

28 31 22 13 74 45 16 ENE 5 NNE 7 0 0 0

29 30 23 16 70 54 30 ENE 5 NNW 6 0 0 0

Table

Meteorological data for month of 1st March to 31st March, 16

Date


% Morning (8.00)

Evening

(17.00)

Cloudiness

Octas

Rain

fall in

mm Max Avg Min Max Avg Min Wind

Dir.

Wind

Speed

km/h

Wind

Dir.

Wind

Speed

km/h

Mor Eve.

1 32 24 15 76 43 11 E 3 NNE 6 0 0 0

2 33 24 14 58 33 9 SE 7 NE 5 0 0 0

3 34 26 17 65 39 20 SE 5 NW 3 0 0 0.2

4 34 26 18 53 35 17 W 8 WNW 8 0 0 0.4

5 34 27 20 70 37 17 SW 6 SSW 7 0 0 0

6 29 24 20 86 60 31 E 4 SW 14 0 0 1.1

7 31 24 16 87 64 28 S 16 SSW 8 0 0 0.1

8 31 24 18 89 63 39 W 2 W 8 0 0 0

9 32 25 18 86 60 27 NE 6 WNW 8 0 0 0

10 32 25 18 80 51 27 ENE 2 W 7 0 0 0

11 34 26 18 76 42 21 SE 3 W 7 0 0 0

12 34 26 19 65 47 23 S 10 SW 1 0 0 0.7

13 26 22 19 69 62 49 S 4 SSE 18 0 0 0.5

14 31 24 18 86 53 21 SE 7 NNW 6 0 0 1.6

15 31 24 17 80 45 15 ENE 4 NE 14 0 0 0

16 31 24 16 65 33 16 ENE 8 NNW 4 0 0 0

17 33 24 16 47 31 14 SE 6 S 8 0 0 0

18 35 27 19 58 36 15 WSW 13 W 10 0 0 0

19 35 28 22 38 26 11 W 12 W 12 0 0 0

20 36 28 21 42 23 8 W 13 WNW 10 0 0 0

21 35 27 19 35 22 9 W 13 NW 7 0 0 0

22 37 27 17 42 25 10 NE 10 NW 6 0 0 0

23 34 25 16 38 20 4 NNE 5 N 4 0 0 0

24 36 26 16 34 19 5 ENE 4 NE 5 0 0 0

25 37 27 17 39 23 6 SE 8 NNE 5 0 0 0

26 39 29 19 55 23 5 SE 9 ENE 5 0 0 0

27 29 26 21 55 41 23 NW 5 S 4 0 0 0

28 35 26 18 77 47 16 SE 5 WNW 7 0 0 0

29 36 28 19 67 34 11 NE 7 W 6 0 0 0

30 37 28 19 52 26 6 NE 7 NW 5 0 0 0

31 37 28 19 45 25 8 SE 10 WNW 3 0 0 0

Table

Meteorological data for month of 1st April, 16 to 30th April, 16

Date


% Morning (8.00) Evening (17.00)

Cloudiness

Octas

Rain

fall

in

mm Max Avg Min Max Avg Min Wind

Dir.

Wind

Speed

km/h

Wind

Dir.

Wind

Speed

km/h

Mor. Eve

1 38 30 21 36 21 6 W 9 SW 5 0 0 0

2 40 30 21 41 24 7 WNW 7 W 2 0 0 0

3 41 32 22 51 23 7 SW 3 WNW 5 0 0 0

4 41 32 23 43 24 10 NW 12 S 6 0 0 0

5 38 30 23 40 20 9 W 10 W 11 0 0 0

6 38 31 24 31 17 8 W 15 WSW 10 0 0 0

7 38 32 26 34 19 8 W 12 W 13 0 0 0

8 38 30 22 39 23 10 SSE 4 SSW 9 0 0 0

9 39 31 23 45 25 8 WNW 8 W 10 0 0 0

10 40 32 23 52 22 6 NW 9 W 12 0 0 0

11 39 32 26 28 16 6 WNW 10 WNW 17 0 0 0

12 38 30 22 32 21 8 N 12 WNW 18 0 0 0

13 38 30 21 38 18 6 NNE 9 WNW 15 0 0 0

14 40 31 22 30 15 6 W 10 W 9 0 0 0

15 41 32 22 42 15 4 W 12 WSW 10 0 0 0

16 42 33 24 22 12 4 W 9 W 14 0 0 0

17 40 34 27 23 13 7 W 15 W 15 0 0 0

18 40 32 23 30 18 7 WNW 12 W 15 0 0 0

19 41 33 25 31 18 6 W 8 W 15 0 0 0

20 42 34 26 25 16 7 W 9 WNW 11 0 0 0

21 41 33 25 30 15 5 WNW 3 WNW 12 0 0 0

22 41 34 27 18 10 5 W 13 W 12 0 0 0

23 39 32 26 26 15 8 WNW 13 WNW 11 0 0 0

24 39 30 22 40 15 4 W 10 WNW 11 0 0 0

25 40 32 23 29 16 5 WNW 6 W 8 0 0 0

26 41 32 23 40 18 4 WNW 6 W 8 0 0 0

27 41 33 25 31 17 6 WNW 6 W 10 0 0 0

28 41 34 26 27 14 5 W 4 W 9 0 0 0

29 41 33 25 30 17 5 WNW 6 W 10 0 0 0

30 42 33 24 36 15 4 WNW 7 W 8 0 0 0

Source: IMD, Climatological Normals, Office of the Additional Director General of Meteorology (Research), IMD, Pune

32

vii. Social Infrastructure available

Social infrastructure like community center, hospital and electricity is available in

Salichouka, Pondar, Gadarwara as well as in Narsingpur (MP)

Planning Brief:

i. Planning Concept :

The grain base unit shall be installed after receiving environment clearance and

consent under air and water act from the MPPCB. 14 Months has been considered

for the same.

ii. Population Projection:

The project is small in magnitude. No influx of population is expected as labour

shall be deployed from the local villages.

iii Land use planning

As above

Amenities / facilities

First aid facility has already been provided at site.

The area shall not being used at all by general public.

A rest shelter is there for workers.

Guards during day & night has already been deputed at site to prevent

unauthorized entry.

In case of natural hazards such as earthquake we will take assistance from the

local competent authority of Govt.

5.0 Proposed Infrastructure

The major plant & machinery required for the proposed project is as given under.

Outline Technical Specifications For 60 Klpd Ethanol

Storage & Handling:

SN Equipment Technical Specification Qty. MOC

1 Raw Molasses transfer pump

Type- Screw/Gear type Capacity- 25 MT/hr

1+1 CI

2 Day Molasses Tank Capacity- 300 MT 1 MS

3 Molasses Transfer Pump Type- Screw/Gear type Capacity- 25MT/hr

1+1 CI

4 Molasses Filter Type- Basket Strainer 1+1 MS

5 Molasses Receiving Tank Type- Cyl/Vert. Shell with Open Top & Conical Bottom, Capacity- 3 MT

1 MS

33

6 Molasses Weighing System Type- Load Cell Capacity 4 MT Per Trip

1 MS

7 Weighed Molasses Tank Type- Cyl/Vert. Shell with Conical Top & Sloping Bottom, Capacity- 25 MT

1 MS

8 Weighed Molasses Transfer Pump with Motor


1+1 CI

9 Molasses Diluter For Yeast Vessel

Type- Static Mixer 1 AISI304

Fermentation Section:

Sr.

No.

Equipment Technical Specification Qty. MOC

1 CO2 Scrubber Type: Sieve Trays Dia: 600 mm 1 AISI 304

2 Culture Vessel-I with Air Sparger

Type - Cyl/Vert Shell, Jacketed with Dished Ends.

1 AISI 304

3 Culture Vessel-II with Air Sparger


1 AISI 304

4 Culture Vessel-III with Air Sparger


Capacity- 15 m3

1 AISI 304

5 Cell Mass Transfer Pump with Motor

Type- Centrifugal with Trolley

Capacity- 15 m3

1

6 Fermenter with Agitator, SG, LG

Type- Cyl/Vert. Shell with Conical Top & Sloping Bottom,

Capacity- 400 m3

4 AISI 304

7 Molasses Broth Mixer for Fermenter

Type- Static Mixer 3 SS 304

8 Fermenter Recirculation Pump with Motor

Type- Centrifugal Capacity- 340

m3/hr

4+1 CF8

9 Fermenter Wash Cooler Type- PHE 4 Plates AISI 316

10 Pre fermenter /Yeast Activation Vessel with SG,LG

Type- Cyl/Vert. Shell with Conical Top & Sloping Bottom,

Capacity- 50 m3

2 AISI 304

11 Molasses Broth Mixer for Yeast Activation Vessel

Type- Static Mixer 2 AISI 304

34

12 Yeast Activation Vessel Transfer Pump with Motor


m3/hr

1+1 CF8

13 Yeast Activation Vessel Cooler

Type- PHE 1 Plates AISI 316 Frame MS

14 Wash Holding Tank Type – Cyl/Vert. Shell with Conical Top & Sloping Bottom,

Capacity – 250 m3

1 MS Epoxy

15 Wash Transfer Pump Type- Centrifugal Capacity- 30

m3/hr

1+1 CF8 (Wetted Parts Only)

16 Air Filter Type- HEPA 1+1 MS Frame

17 Air Blower with Motor Type- Watering Capacity- 280

Am3/hr

1+1 CI

18 Nutrient Dosing Tank with Agitator

Capacity- 2 m3 1 AISI 304

19 Nutrient Dosing Pump Type- Centrifugal Capacity- 1

m3/hr

1+1 CI

20 Acid Dosing Tank Type- Cylindrical, Vertical

Capacity- 1 m3

1 MS

21 Acid Dosing Pump Type- Centrifugal Capacity- 2

m3/hr

1+1 Wetted Parts Alloy 20

22 Antifoam Dosing Tank Type- Cylindrical, Vertical

Capacity- 2 m3

1 MS

23 Antifoam Dosing Pump Type: Gear Capacity- 1 m3/hr 1+1 CI

24 CIP tank Type- Cylindrical, Vertical

Capacity- 30 m3

1 AISI304

25 CIP Pump Type- Centrifugal Capacity- 15

m3/hr


26 Piping, Valves Instrumentation

As Per Standards Lot

DISTILLATION SECTION:

Sn . Description

MOC

Tech. Specs.

Qty.

1 Analyser Column (Rh Grid Trays)

AISI 304 Dia: 1400 mm No. of Trays : 19

1

35

2 Degasifying Column (Seive Trays)

AISI 304 Dia: 800mm No. of Trays : 5

1

3 Pre-Rectifier Column (Bubble Cap Trays)


1

4 Extractive Column (Bubble Cap Trays)


1

5

Rectifier Cum Exhaust Column (Bubble Cap Trays)

Shell : AISI 304 Trays AISI 304

Dia: 1100 mm No. of Trays : 72

1

6 Simmering column ( Bubble Cap)

Shell: DOW CU Trays : DOW CU ( Bottom Segment in SS 304

Dia : 800 mm No. of Trays 50

6 Recovery Column (Bubble

Cap)

AISI 304 Dia: 500 mm No. of

Trays : 50

1

7 Alcohol Scrubber AISI 304 1

Re boilers

1 Analyzer Column Reboiler Shell & Tube Type AISI 304 1

2 ED Column Reboiler Shell & Tube Type AISI 304 1

3 Rectifier Cum Exhaust Column Reboiler Shell & Tube Type AISI 304 1

4 Simmering Coloumn Reboiler Shell & Tube Type AISI 304 1

5 Pre Rectifier Column Reboiler Shell & Tube Type AISI 304 1

Co ndensers & Coolers

6 DG Condenser I Shell & Tube Type AISI 304 1

7 DG Condenser II Shell & Tube Type AISI 304 1

8 Analyser Condenser I & II Shell & Tube Type AISI 304 3

9 ED Condenser I & II Shell & Tube Type AISI 304 2

10 Recovery Condenser Shell & Tube Type AISI 304 1

11 Vent Condenser for Analyzer Shell & Tube Type AISI 304 2

12 PCV Condenser Shell & Tube Type AISI 304 2

13 Product Alcohol Cooler Shell & Tube Type DOW Cu 1

14 Product (RS) Cooler Shell & Tube Type AISI 304 1

15 TA Cooler Shell & Tube Type AISI 304 1

16 FO Cooler Shell & Tube Type AISI 304 4

17 R/E Alcohol Cooler Shell & Tube Type AISI 304 1

18 ED Feed Cooler Shell & Tube Type AISI 304 1

36

OUTLINE TECHNICAL SPECIFICATIONS FOR 45 KLPD ETHANOL

PHE's, Pumps

19 DM Water Preheater PHE SS 316 Plates /MS

Frame

1

20 Rectifier Feed Preheater PHE SS 316 Plates /MS

Frame

1

21 PR Feed Preheater PHE SS 316 Plates /MS

Frame

1

22 Analyser Bottom Transfer Pump

Centrifugal Type CF8 (Wetted Parts Only) 1+1

23 Rectifier Lees Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1

24 PR Lees Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1

25 Pre Rectifier Feed Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1

26 PR Refux Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1

27 Rectifier Reflux Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1

28 FO Washing Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1

29 ED Bottom Transfer Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1

30 Alcohol Transfer Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1

31 Recovery Feed Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1

32 Steam Condensate Pump Centrifugal Type CI 1+1

33 Vacuum Pump Water Ring Type CI 1+1

34 Emergency Water Supply Set Standard 1

Others

Sr.

No.

Description Tech. Specs. Qty.

1 FO Decanters As Per Standard 2

2 Mixing Bottle (For ED/Purifier

Column)

As Per Standard 1

3 Vapour Bottles As Per Standard Lot

4 Manometer Bottles As Per Standard 2

5 Seal Pot As Per Standard 1

6 Siphon For Recovery Column As Per Standard 1

7 TA Mixing Bottle As Per Standard 1

8 Pipes & Fittings, Valves and

Instrument

As Per Standard Lot

37

ABSOLUTE ALCOHOL PLANT:

Sr.

No.

Description MOC Qty. Tech. Specs.

1 Absorber Bed AISI 304 2 Diameter : 900 mm

2 Evaporator Column AISI 304 1 Diameter : 900

mm with Trays

3 Evaporator Column Re boiler AISI 304 1 Suitable

4 Feed Preheater AISI 304 1 Suitable

5 Regeneration Preheater AISI 304 1 Suitable

6 Product Condenser AISI 304 1 Suitable

7 Product Cooler AISI 304 1 Suitable

8 Regeneration Condenser AISI 304 1 Suitable

9 Regeneration Cooler Plates: SS

316

1 PHE

10 Super heater AISI 304 1 Suitable

11 Regeneration Receiver AISI 304 1 Suitable

12 Product Receiver AISI 304 1 Suitable

13 Vacuum Educator AISI 304 1 Suitable

14 Feed Pump with Motor AISI 304 1+1 Suitable

15 Regeneration Pump with Motor AISI 304 1+1 Suitable

16 Product Pump with Motor AISI 304 1+1 Suitable

17 Filters CS 3

18 RS Feed Tank MS 1 Capacity : 50 m3

19 Instrumentation Standard Lot

20 Piping and Valves Standard Lot

21 Electricals Standard Lot

Storage Section for RS, Ethanol Section-

Sr.

No.

Equipment Technical

Specification

MOC Qty.

1 RS Receivers Capacity: 70 m3 MS 3

2 IS Receivers Capacity: 12 m3 MS 1

3 Ethanol Receiver Capacity: 70 m3 MS 3

38

4 RS Storage Tank with Vent Condenser & Flame

Arrestors

Capacity: 1200 m3 MS 2

5 Ethanol Storage Tank with

Vent Condenser & Flame

Arrestors


6 IS Bulk Storage Tank with


Arrestors

Capacity: 600m3 MS 1

7 FO Storage Capacity: 10 m3 MS 1

8 Alcohol Pumps with

Flameproof Motor

Centrifugal W Wetted Parts CF

8

Suita

ble

9 Issue Measures PD Flowmeters Standard 3

10 Piping & Fittings Standard Standard 1 Lot

INTEGRATED EVAPORATOR:

Sr.

No.

Description Qty. Technical data M.O.C.

1 Multiple effect

evaporator

Suitable Shell & Tube type,

Falling Film

SS304

2 Vapor Separator Suitable Cylindrical SS304

3 Surface condenser 1 Sheet & Tube type SS304

4 Circulation pump Suitable Double Mech Shaft Contact Part SS 304

5 Process Condensate

pump

1+1 Contact Part SS 304

6 Concentrated Spent

wash transfer pump


7 Condensate Pump 1+1 Contact Part SS 304

8 Vacuum pump 1+1 Contact Part SS 304

9 Piping & Valves Lot Suitable

10 Electrical &

Instrumentation

Lot With Std.

Specification

INDEPENDENT EVAPORATOR:

Sr.

No


1 Feed and Product Tank 2 Type:- Rectangular SS304

2 Feed Pump & Spent

wash pump

1 + 1 each Type - Centrifugal type

Suitable

SS 316

3 Evaporators Suitable Type : Forced circulation SS304

39

4 Vapor Liquid Separators Suitable Type : Gas

liquid separator

type

SS304

5 Evaporation Pump Suitable Recirculation pump SS 316

6 Surface Condenser 1 Type : shell & tube; SS 304

9 Vacuum Pump 1 + 1 Type - Water ring type SS 316

10 Condensate Tank 1 Capacity – Suitable SS 304

11 Condensate Pump 1 + 1 Type - Centrifugal type SS 316

12 Piping and Valve, Electrical and Instruments

UTILITIEs: COOLING TOWER:

Sr.

No.

Equipment Description Specifications Qty. (Nos)

1 Cooling tower for Fermentation plant 1400 M Kcal/hr 1

2 Cooling tower for Distillation 4000 M Kcal/hr 1

3 Cooling tower for Ethanol 800 M Kcal/hr 1

4 Cooling tower for evaporation 4200 M Kcal/hr 1

5 CW Recirculation pump for

Fermentation

Suitable. Centrifugal, 1+1

6 CW Recirculation pump for Distillation Suitable. Centrifugal, 1+1

7 CW Recirculation pump for evaporation Suitable. Centrifugal, 1+1

8 CW Recirculation pump for Ethanol Suitable. Centrifugal, 1+1

9 PRDS Suitable. 2

10 Instrument Air compressor & dryer Suitable capacity 1+1

11 Piping, Valves standard Lot

12 Instrumentation standard Lot

Slop Fired Incinerator Boiler & Turbine

Sr.

No.

Particulars Specification

1 Slop fired incinerator boiler with coal as supporting fuel

25 TPH, 45 Kg/Cm2 (g) Pressure

2 Turbine Suitable capacity of 1.5 MW back pressure with exhaust pressure of

4.5 Kg/Cm2(g)

40

Water Treatment Area Filtration Plant

1. Multi grade Sand Filter 1 No.

Pressure vessel internally painted with black

bituminous and externally with red oxide primer

:MOC

1 No.MS with epoxy coating

Piping works with valves 1 No.

Graded filtering sand specifically selected and

graded

1 No.

2. Activated Carbon Filter 1 No.



:MOC

1 No. MS with epoxy coating


3. Softener 1 No.

Pressure with rubber lining from inside and

externally with red oxide primer

1 No.

Piping works with valves 1 set

Cation Exchange resign 1 set

Hardness test kit 1 set

Brine saturated tank of MS construction 1 No.

Brine distribution system 1 Lot

4. D.M. PLANT ( 1 No.)

1 Strong acid cation 1 No.

2 Degasser tower & pump 1 No.

3 Strong acid anion 1 No.

4 Mixed bed exchanger 1No.

Fire Fighting & Protection

Fire protection system to be offered based on site plan. The system is designed

as per International rules (NFPA) & equivalent standards.

Molasses Bulk Storage Section.

Sr.

No.

Equipment Technical Specification

Qty. M.O.C.

1 Molasses Storage Tank 4000 MT storage capacity.

2

Nos.

Mild steel, painted

2 Raw molasses Transfer pumps.

Gear type positive displacement pumps

2+2

Nos.

C.S.

41

3 Interconnecting piping. Carbon steel pipes. LOT MS

Sr.

No.


1 Raw Molasses transfer pump


1+1 CI

2 Day Molasses Tank Capacity- 250 MT 1 MS

3 Molasses Transfer Pump Type- Screw/Gear type Capacity- 20MT/hr

1+1 CI

4 Molasses Filter Type- Basket Strainer 1+1 MS

5 Molasses Receiving Tank Type- Cyl/Vert. Shell with

Open Top & Conical Bottom, Capacity- 3 MT

1 MS

6 Molasses Weighing System

Type- Load Cell Capacity 4 MT Per Trip

1 MS

7 Weighed Molasses Tank Type- Cyl/Vert. Shell with Conical Top & Sloping Bottom, Capacity- 20 MT

1 MS

8 Weighed Molasses Transfer Pump with Motor


1+1 CI

9 Molasses Diluter For Yeast Vessel

Type- Static Mixer 1 AISI304

Fermentation Section:

Sr. No.


1 CO2 Scrubber Type: Sieve Trays Dia: 500

mm

1 AISI 304

2 Culture Vessel-I with Air Sparger


1 AISI 304

3 Culture Vessel-II with Air Sparger


1 AISI 304

42

4 Culture Vessel-III with Air Sparger

Type - Cyl/Vert Shell, Jacketed with Dished

Ends. Capacity- 12 m3

1 AISI 304

5 Cell Mass Transfer Pump with Motor

Type- Centrifugal with

Trolley Capacity- 10 m3

1

6 Fermenter with Agitator, SG, LG

Type- Cyl/Vert. Shell with Conical Top & Sloping Bottom, Capacity-

300 m3

4 AISI 304

7 Molasses Broth Mixer for Fermenter

Type- Static Mixer 3 SS 304

8 Fermenter Recirculation Pump with Motor

Type- Centrifugal Capacity-

250m3/hr

4+1 CF8

9 Fermenter Wash Cooler Type- PHE 4 Plates AISI

316 10 Pre fermenter /Yeast Activation Vessel with SG,LG

Type- Cyl/Vert. Shell with Conical Top & Sloping

Bottom, Capacity- 40m3

2 AISI 304

11 Molasses Broth Mixer for Yeast Activation Vessel

Type- Static Mixer 2 AISI 304

12 Yeast Activation Vessel Transfer Pump with Motor


m3/hr

1+1 CF8

13 Yeast Activation Vessel Cooler

Type- PHE 1 Plates AISI 316 Frame MS 14 Wash Holding Tank Type – Cyl/Vert. Shell

with Conical Top & Sloping Bottom, Capacity –

200 m3

1 MS Epoxy

15 Wash Transfer Pump Type- Centrifugal Capacity-

25 m3/hr

1+1 CF8 (Wetted Parts Only) 16 Air Filter Type- HEPA 1+1 MS Frame

17 Air Blower with Motor Type- Watering Capacity-

220 Am3/hr

1+1 CI

18 Nutrient Dosing Tank with Agitator

Capacity- 1 m3 1 AISI 304

19 Nutrient Dosing Pump Type- Centrifugal

Capacity- 1 m3/hr

1+1 CI

20 Acid Dosing Tank Type- Cylindrical,

Vertical Capacity- 1 m3

1 MS

21 Acid Dosing Pump Type- Centrifugal

Capacity- 1 m3/hr


43

22 Antifoam Dosing Tank Type- Cylindrical,

Vertical Capacity- 1 m3

1 MS

23 Antifoam Dosing Pump Type: Gear Capacity- 1 m3/hr 1+1 CI

24 CIP tank Type- Cylindrical,

Vertical Capacity- 25

m3

1 AISI304

25 CIP Pump Type- Centrifugal Capacity-

12 m3/hr


26 Piping, Valves

Instrumentati

on

As Per Standards Lot

DISTILLATION SECTION:

Sr.

No.

Description

MOC

Tech. Specs.

Qty.

1 Analyser Column (Rh Grid Trays) AISI 304

Dia: 1200 mm No. of Trays :

19

1

2 Degasifying Column

(Seive Trays) AISI 304 Dia: 700mm No. of Trays :

5

1

3 Pre-Rectifier Column

(Bubble Cap Trays) AISI 304 Dia: 800 mm

No. of Trays : 56

1

4 Extractive Column

(Bubble Cap Trays) AISI 304 Dia: 600 mm

No. of Trays : 45

1

5

Rectifier Cum Exhaust Column

(Bubble Cap Trays)

Shell : AISI

304 Trays

AISI 304


72

1

6 Recovery Column

(Bubble Cap) AISI 304


50

1

7 Alcohol Scrubber AISI 304 1

Re boilers

1 Analyzer Column Reboiler Shell & Tube Type AISI 304 1

2 ED Column Reboiler Shell & Tube Type AISI 304 1

3 Rectifier Cum Exhaust Column Reboiler Shell & Tube Type AISI 304 1

4 Pre Rectifier Column Reboiler Shell & Tube Type AISI 304 1

Co ndensers & Coolers

5 DG Condenser I Shell & Tube Type AISI 304 1

44

6 DG Condenser II Shell & Tube Type AISI 304 1

7 Analyser Condenser I & II Shell & Tube Type AISI 304 3

8 ED Condenser I & II Shell & Tube Type AISI 304 2

9 Recovery Condenser Shell & Tube Type AISI 304 1

10 Vent Condenser for Analyzer Shell & Tube Type AISI 304 2

11 PCV Condenser Shell & Tube Type AISI 304 2

12 Product Alcohol Cooler Shell & Tube Type DOW Cu 1

13 Product (RS) Cooler Shell & Tube Type AISI 304 1

14 TA Cooler Shell & Tube Type AISI 304 1

15 FO Cooler Shell & Tube Type AISI 304 4

16 R/E Alcohol Cooler Shell & Tube Type AISI 304 1

17 ED Feed Cooler Shell & Tube Type AISI 304 1

OUTLINE TECHNICAL SPECIFICATIONS FOR 45 KLPD ETHANOL

PHE's, Pumps

19 DM Water Preheater PHE SS 316 Plates /MS

Frame

1

20 Rectifier Feed Preheater PHE SS 316 Plates /MS

Frame

1

21 PR Feed Preheater PHE SS 316 Plates /MS

Frame

1

22 Analyser Bottom

Transfer Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1

23 Rectifier Lees Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1

24 PR Lees Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1

25 Pre Rectifier Feed Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1

26 PR Refux Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1

27 Rectifier Reflux Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1

28 FO Washing Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1

29 ED Bottom Transfer Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1

30 Alcohol Transfer Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1

31 Recovery Feed Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1

32 Steam Condensate Pump Centrifugal Type CI 1+1

33 Vacuum Pump Water Ring Type CI 1+1

34 Emergency Water Supply Set Standard 1

Others

45

Sr.

No.

Description Tech. Specs. Qty.

1 FO Decanters As Per Standard 2

2 Mixing Bottle (For ED/Purifier

Column)

As Per Standard 1

3 Vapour Bottles As Per Standard Lot

4 Manometer Bottles As Per Standard 2

5 Seal Pot As Per Standard 1

6 Siphon For Recovery Column As Per Standard 1

7 TA Mixing Bottle As Per Standard 1

8 Pipes & Fittings, Valves and

Instrument

As Per Standard Lot

ABSOLUTE ALCOHOL PLANT:

Sr.

No.

Description MOC Qty. Tech. Specs.

1 Absorber Bed AISI 304 2 Diameter : 900 mm

2 Evaporator Column AISI 304 1 Diameter : 900

mm with Trays

3 Evaporator Column Re boiler AISI 304 1 Suitable

4 Feed Preheater AISI 304 1 Suitable

5 Regeneration Preheater AISI 304 1 Suitable

6 Product Condenser AISI 304 1 Suitable

7 Product Cooler AISI 304 1 Suitable

8 Regeneration Condenser AISI 304 1 Suitable

9 Regeneration Cooler Plates: SS

316

1 PHE

10 Super heater AISI 304 1 Suitable

11 Regeneration Receiver AISI 304 1 Suitable

12 Product Receiver AISI 304 1 Suitable

13 Vacuum Educator AISI 304 1 Suitable

14 Feed Pump with Motor AISI 304 1+1 Suitable

15 Regeneration Pump with Motor AISI 304 1+1 Suitable

16 Product Pump with Motor AISI 304 1+1 Suitable

17 Filters CS 3

18 RS Feed Tank MS 1 Capacity : 50 m3

19 Instrumentation Standard Lot

46

20 Piping and Valves Standard Lot

21 Electricals Standard Lot

Sr.

No.

Equipment Technical

Specification

MOC Qty.

1 RS Receivers Capacity: 50 m3 MS 3

2 IS Receivers Capacity: 10 m3 MS 1

3 Ethanol Receiver Capacity: 50 m3 MS 3

4 RS Storage Tank with Vent Condenser & Flame

Arrestors


5 Ethanol Storage Tank with


Arrestors


6 IS Bulk Storage Tank with


Arrestors

Capacity: 400m3 MS 1

7 FO Storage Capacity: 8 m3 MS 1

8 Alcohol Pumps with

Flameproof Motor

Centrifugal Wetted Parts

CF 8

Suitable

9 Issue Measures PD Flowmeters Standard 3

10 Piping & Fittings Standard Standard 1 Lot

INTEGRATED EVAPORATOR:

Sr.

No.


1 Multiple effect

evaporator

Suitable Shell & Tube

type, Falling

Film

SS304

2 Vapor Separator Suitable Cylindrical SS304

3 Surface condenser 1 Sheet & Tube type SS304

4 Circulation pump Suitable Double Mech Shaft Contact Part SS 304

5 Process

Condensate

pump


6 Concentrated Spent

wash transfer pump


7 Condensate Pump 1+1 Contact Part SS 304

8 Vacuum pump 1+1 Contact Part SS 304

9 Piping & Valves Lot Suitable

10 Electrical &

Instrumentatio

n

Lot With Std.

Specificatio

n

47

INDEPENDENT EVAPORATOR:

Sr.

No


1 Feed and Product Tank 2 Type:- Rectangular SS304

2 Feed Pump & Spent

wash pump

1 + 1 each Type - Centrifugal type

Suitable

SS 316

3 Evaporators Suitable Type : Forced circulation SS304

4 Vapor Liquid Separators Suitable Type : Gas

liquid separator

type

SS304

5 Evaporation Pump Suitable Recirculation pump SS 316

6 Surface Condenser 1 Type : shell & tube; SS 304

9 Vacuum Pump 1 + 1 Type - Water ring type SS 316

10 Condensate Tank 1 Capacity – Suitable SS 304

11 Condensate Pump 1 + 1 Type - Centrifugal type SS 316

12 Piping and Valve, Electrical and Instruments

UTILITIEs: COOLING TOWER:

Sr.

No.

Equipment Description Specifications Qty. (Nos)

1 Cooling tower for Fermentation plant 1000 M Kcal/hr 1

2 Cooling tower for Distillation 2000 M Kcal/hr 1

3 Cooling tower for Ethanol 600 M Kcal/hr 1

4 Cooling tower for evaporation 3000 M Kcal/hr 1

5 CW Recirculation pump for

Fermentation

Suitable. Centrifugal, 1+1

6 CW Recirculation pump for Distillation Suitable. Centrifugal, 1+1

7 CW Recirculation pump for evaporation Suitable. Centrifugal, 1+1

8 CW Recirculation pump for Ethanol Suitable. Centrifugal, 1+1

9 PRDS Suitable. 2

10 Instrument Air compressor & dryer Suitable capacity 1+1

11 Piping, Valves standard Lot

12 Instrumentation standard Lot

Slop Fired Incinerator Boiler & Turbine

48

Sr.

No.

Particulars Specification

1 Slop fired incinerator boiler with coal as supporting fuel

14 TPH, 45 Kg/Cm2 (g) Pressure

2 Turbine Suitable capacity of 1.2 MW back pressure with exhaust pressure of

4.5 Kg/Cm2(g)

Water Treatment Area Filtration Plant

1. Multi grade Sand Filter 1 No.



:MOC

1 No.MS with epoxy coating


Graded filtering sand specifically selected and

graded

1 No.

2. Activated Carbon Filter 1 No.



:MOC

1 No. MS with epoxy coating


3. Softener 1 No.

Pressure with rubber lining from inside and

externally with red oxide primer

1 No.

Piping works with valves 1 set

Cation Exchange resign 1 set

Hardness test kit 1 set

Brine saturated tank of MS construction 1 No.

Brine distribution system 1 Lot

4. D.M. PLANT ( 1 No.)

1 Strong acid cation 1 No.

2 Degasser tower & pump 1 No.

3 Strong acid anion 1 No.

4 Mixed bed exchanger 1No.

Fire Fighting & Protection

Fire protection system to be offered based on site plan. The system is designed as

per International rules (NFPA) & equivalent standards.

49

Molasses Bulk Storage Section.

Sr. No.

Equipment Technical Specification

Qty. M.O.C.

1 Molasses Storage Tank 9300 MT storage capacity.

1

Nos.

Mild steel, painted

2 Raw molasses Transfer pumps.

Gear type positive displacement pumps

2+2

Nos.

C.S.

3 Interconnecting piping. Carbon steel pipes. LOT MS

ii Residential area (Non Processing area)

As the local people from nearby villages shall be engaged in project activity.

Therefore no housing / building is proposed.

iii Greenbelt

Approx 2 acres area has been covered with the good green belt. Further it is

proposed to cover 11 acres in next 05 years of time inclusive of sugar and

proposed distillery.

iv Social Infrastructure

Company shall evaluate the need base program under CSR and shall execute as

per the given plan.

v Connectivity

Site is well connected with by State Highway . .

vi Drinking water management

Drinking water will be supplied through bore well with proper RO system.

vii Sewerage System

The domestic waste shall be taken to soak pit and septic tank.

viii Industrial waste management

As described earlier.

ix Solid waste management


50

x Power Requirement and supply / source


7.0 Rehabilitation & Resettlement Plan

No R & R plan is required.

8.0 Project Schedule and Cost estimate

i. Likely date of start of construction and likely date of completion

After obtaining environmental clearance and water / air consent the company shall

start the project. Proposed date shall be July 2018 (subject to clearances)

ii. Estimated project cost along with analysis in terms of economic viability of

the project

a. Land & Site Development (Refer Annexure – 1)

NSPL has already earmarked 4.774 acres of land for the proposed fuel ethanol

plant. The site development expenses is estimated at Rs. 110.00 lakh which

include leveling, fencing, gates, internal roads, green belt development, etc

Civil Works

The main civil works for the fuel ethanol plant and their estimated costs are

indicated in the following table.

Item Cost, Rs. Lakh

Main plant building, admin building, lab, Excise Office,

stores Weigh bridge, storage, distillery machinery

foundations, Structural for evaporation, distillation &

fermentation, Pipe Racks, Cooling tower civil works (Basin

Only), Raw water tank, Treated Water storage tanks, Fire

water storage tank, Raw & Concentrated Spent wash holding

tank, Condensate Polishing Unit civil work, Boiler

foundations & Axillaries, Turbine foundations DG set

foundation, structural work for Boiler & Turbine, Ash & Fuel

handling system foundations etc., staging structure and

foundations

600.00

Architect fees 12.00

Total 612.00

Based on the actual civil costs incurred for similar capacity fuel ethanol

plant and preliminary estimates from the project architect, the civil estimates

have been worked out at Rs. 612.00 lakh, including Architect’s fees. The

appointed architect for the project will work out detailed estimates and civil

drawings (based on the inputs received by the equipment suppliers and labour

/ material rates at the site location).

51

Equipment The main items of equipment for the fuel ethanol plant and their estimated

erected costs are given in the following table:

Item and brief specifications Estimated

Erected Cost,

Rs. lakh

1) 60 KLPD Capacity distillery plant, including incl.

Molasses storage & handling, Fermentation, Multi-Pressure

Distillation & Ethanol, Integrated & Independent

Evaporation for spent wash concentration, Utility

Equipment - Cooling Towers, Condensate Polishing Unit,

Blower, Alcohol Storage & auxiliaries, interface piping,

electrical & instrumentation, Air compressor, structural

work, Erection & Commissioning etc.

2200.00

2) 25 TPH Capacity, 45 kg/cm2 pressure slop fired

Boiler & auxiliaries

1300.00

3) 1.5 MW Capacity matching back pressure TG set &

auxiliaries 150.00

4) Molasses Storage Tank & Weigh Bridge 200.00

4) Balance of Plant equipment incl. PRDS, DCS, etc. 500.00 Sub-total including erection & commissioning, packing

forwarding, insurance, etc.

4350.00

Avg. Taxes & Duties (18 %) 783.00 Total 5133.00

Based on the budgetary offers received from reputed machinery suppliers &

possible negotiation margins, the estimated erected cost of plant and equipment

for the proposed fuel ethanol plant including Boiler & Turbine has been worked

out at Rs.5133.00 lakh

Item Year

1 2 3 4 5

Installed Capacity-KLPD 60 60 60 60 60

Number of shift/day 3 3 3 3 3

No. of days 270 270 270 270 270

No. of hrs. 24 24 24 24 24

Annual Installed Capacity 16200 16200 16200 16200 16200 Capacity utilization, % 85 85 90 95 95

Total Spirit, KL 13770 13770 14580 15390 15390

Net Production Fuel Ethanol,

KL

13082 13082 13851 14621 14621

52

Cost Summary

Based on the capital cost break up worked out, the project cost summary for

the entire integrated project is given in the following table

Particulars Distillery Plant (Rs. Lakh)

Land and Site Development 110

Buildings 612

Indigenous Plant and Machinery 5133

Miscellaneous Fixed Assets 124

Prelim. & Preoperative Expenses 254

Contingencies 125

Working capital margin 6358

Total

9.0 Analysis of Proposal (Final Recommendation)

Financial and social benefits with special emphasis on the benefit to the

local people including tribal population, if any, in the area.

From the foregoing analysis, it is observed that proposal is environmental

compatible and will helps to people improving their financial status,

performance and repayment capability. This also helps the company in

venturing into production of niche specialty products which will eventually

better their profits and also their ranking in the industry. CSR programme

shall be executed through the group discussion and need base programme will

be proposed for the area, by which people of the area will be benefitted.

Pre Feasibility Report For Molasses Based Fuel...

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Transcript of Pre Feasibility Report For Molasses Based Fuel...