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Proposed Capacity Enhancement by Modernization in Existing Grain Based Distillery (100 KLPD to 125 KLPD) & Co-generation Power Plant (3 MW to 3.8 MW) At Village: Chulkhana, Tehsil: Samalkha, District: Panipat (Haryana)
Pre - feasibility Report
M/s. Haryana Organics (A unit of Globus Spirits Ltd.) 1
PRE - FEASIBILITY REPORT
1.0 EXECUTIVE SUMMARY
(I) INTRODUCTION
Globus Spirits Ltd is one of the leading players in the alcohol industry in Northern India.
The company has an existing 100 KLPD Grain/ Molasses Based Distillery at Village Chulkhana, Tehsil
Samalkha, District Panipat (Haryana). Now, the company is proposing enhancement in capacity
from 100 to 125 KLPD within the same premises.
The proposed capacity enhancement by modernization is only about 25% of the present operation
capacity i.e. 100 to 125 KLPD; the same will be achieved by adopting improvement in fermentation
& distillation technology.
In addition to above, Vapour Integration Plant with the dryer will be installed for recycling of
water.
No additional land is required for the proposed capacity enhancement project, as the same will be
done within the existing plant premises.
No increase in water, steam, power and manpower requirement. The project is based on “Zero
Effluent Discharge.”
Table - 1
Salient Features of the Project
S. NO. PARTICULARS DETAILS
A. Nature & Size of the Project
Units Existing Capacity
Proposed
Capacity
Enhance
ment
Total Capacity
after
Enhancement
Grain Based
Distillery (KLPD)
100
or 75 KLPD Grain
based + 25 KLPD
Molasses Based
25 125
Co-generation
Power Plant (MW) 3.0 0.8 3.8
B. Category of the Project As per EIA Notification dated 14th September, 2006 and as amended from
time to time; the project falls in Category ‘A’, S. No. - 5(g).
C. Location Details
Village Chulkhana
Tehsil Samalkha
District Panipat
State Haryana
Latitude 290 12’ 59.64’’ N to 290 13’ 11.74’’ N
Proposed Capacity Enhancement by Modernization in Existing Grain Based Distillery (100 KLPD to 125 KLPD) & Co-generation Power Plant (3 MW to 3.8 MW) At Village: Chulkhana, Tehsil: Samalkha, District: Panipat (Haryana)
Pre - feasibility Report
M/s. Haryana Organics (A unit of Globus Spirits Ltd.) 2
Longitude 760 59’ 42.07’’ E to 760 59’ 76.24’’ E
Toposheet No. H43Q16,H43R3 & H43R4
D. Area Details
Total Plant Area
o Existing plant area: 17 acres (6.878 ha).
o No additional land is required for the proposed capacity enhancement, as
the same will be done within the existing plant premises.
Greenbelt / Plantation Area (ha) 33% of the total plant area has already been developed.
E. Environmental Setting Details (with approximate aerial distance & direction from plant site)
1. Nearest Village Chulkhana (1.5 km in SW direction)
2. Nearest Town Samalkha (2.6 km in NNE direction)
3. Nearest City Panipat (20 km in SE direction)
4. Nearest National Highway / State
Highway
NH-1 (2.0 km in East direction)
5. Nearest Railway station Samalkha Railway Station (2.6 km in NNE direction)
6. Nearest Airport New Delhi (74 km in South direction)
7. National Parks, Wild Life
Sanctuaries, Biosphere Reserves,
Tiger/ Elephant Reserves, Wildlife
Corridors etc. within 10 km radius
No National Park, Wild Life Sanctuary, Biosphere Reserve, Tiger / Elephant
Reserve, Wildlife Corridors etc. falls within 10 km radius of the plant site.
8. Reserved Forests (RF) / Protected
Forests (PF) etc. within 10 km
radius
No Reserved / Protected Forest lies within 10 km radius (Boundary to
boundary distance) of the proposed project site.
9. River / Water Body (within 10 km
radius)
Western Yamuna Canal - New Delhi parallel branch (5.5 km in West direction)
F. Cost Details
Total Cost of the Enhancement
Project
Rs. 10 Crores
Cost for Environment
Management Plan
o Capital Cost - Rs. 3.0 Crores
o Recurring Cost - Rs. 50 Lacs / annum.
G. Basic Requirements for the project Existing
Additional for proposed
capacity enhancement
Total after proposed
capacity enhancement
Water Requirement (KLD) 552 Nil 552
Source: Ground Water
Power Requirement (MW) 3.2 Nil 3.2
Source: Captive Thermal Power Plant, State Electricity Board & D.G Set (for
emergency).
Man Power Requirement 120 Nil 120
Source: Unskilled / Semi-Skilled - Local Area; Skilled - Outside Haryana.
H. Product Rectified Spirit, Extra Neutral Alcohol, Country Liquor & IMFL
I. Working Days 350 Days per Annum
Proposed Capacity Enhancement by Modernization in Existing Grain Based Distillery (100 KLPD to 125 KLPD) & Co-generation Power Plant (3 MW to 3.8 MW) At Village: Chulkhana, Tehsil: Samalkha, District: Panipat (Haryana)
Pre - feasibility Report
M/s. Haryana Organics (A unit of Globus Spirits Ltd.) 3
1.1 Environment Management Plan
Particulars Details
Air Management
Emissions � A stack of adequate height equipped with ESP is installed with the boiler to control the
particulate and gaseous emissions.
� CO2 generated during the fermentation process is being/will be collected by utilizing CO2
Scrubbers and sold to authorized vendor.
� Grain is being / will be stored in silos.
� All the roads are concreted to control the fugitive dust emissions.
� Proper servicing & maintenance of vehicles is being/will be carried out.
� Greenbelt has already been developed all around the plant boundary and the same will be
further maintained & enhanced.
Monitoring Ambient air quality and stack emission is being / will be regularly monitored to ensure that ambient
air quality standards are being met all the time.
Water Management
Management � The project is being /will be based on “Zero Effluent Discharge”.
� Grain Slops (Spent Wash) is being / will be taken through Centrifuge Decanters for separation
of Suspended Solids separated as Wet Cake and which goes as cattle feed as it contains high
protein. (Also known as DWG – Distillers Wet Grains)
� Thin Slops from the Decanter Centrifuge is being/will be partly recycled back to process (30-
35%) and partly taken to Thins Slops Evaporation Plant for concentration of remaining solids to
form a Syrup. This Syrup is also mixed into the Wet Cake coming out of Centrifuge and forms
part of Cattle Feed. (Also known as Soluble - Collectively known as DWGS).
� DWGS Drier - Wet cake / DWGS is being / will be passed through steam tube bundle drier for
drying into cake with 10 - 12% moisture (max.) to give higher shelf life. Solid dry cakes are being
/ will be obtained finally.
� The Process condensate is being / will be cooled and collected into a neutralization tank with
sufficient residence time. After Neutralization and filtration (UF+RO) this process condensate
will be recycled into process use.
Noise Management
Management � Personal Protective Equipment like earplugs and earmuffs is being / will be provided to the
workers exposed to high noise level.
� D.G sets are being /will be provided with acoustic to control the noise level within the
prescribed limit.
� Proper maintenance, oiling and greasing of machines at regular intervals is being / will be done
to reduce generation of noise.
� Green Belt of appropriate width inside the plant premises and at the plant boundary has been
developed.
Monitoring Regular monitoring of noise level is being / will be carried out and corrective measures in
concerned machinery are being/will be adapted accordingly to the possible extent.
Proposed Capacity Enhancement by Modernization in Existing Grain Based Distillery (100 KLPD to 125 KLPD) & Co-generation Power Plant (3 MW to 3.8 MW) At Village: Chulkhana, Tehsil: Samalkha, District: Panipat (Haryana)
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M/s. Haryana Organics (A unit of Globus Spirits Ltd.) 4
Solid & Hazardous Waste Management
� Solid waste from the Grain based operations generally comprises of Fibres and proteins in the form of DDGS, which
are being / will be ideally used as Cattle Feed.
� Ash from the Boiler is being / will be sold to Brick manufacturers.
� Used oil & grease generated from plant machinery/Gear boxes as hazardous waste are being / will be sold out to the
CPCB authorized recycler.
Green Belt Development / Plantation
� Out of the total plant area (i.e. 6.878 ha), ~ 33% area has already been developed under green belt/ plantation. The
same will be maintained & further enhanced.
� Green belt development along with the road & plant boundary will attenuate noise level arrest dust and improve the
environment in surrounding.
� Native plant species has been planted in consultation with local horticulturist.
2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION
(i) Identification of Project and Project Proponent
Applicant : M/s Globus Spirits Limited
Registered Address : F-0, Ground Floor, The Mira Corporate Suites, Plot No. 1 & 2, Ishwar Nagar,
Mathura Road, New Delhi.
Globus Spirits Limited has enjoyed a good track record in the business of manufacture, marketing
and sale of Indian Made Foreign Liquor (IMFL), Industrial Alcohol comprising Rectified Spirit &
Extra –Neutral Alcohol and Country Liquor.
With headquarter in Delhi, the company markets its own IMFL brands in North Indian states of
Rajasthan, Haryana and Uttar Pradesh and also in union territory of Chandigarh. Company also
proposes to launch IMFL brands in three more states in North India. In South India it is already
selling in Kerala, Andhra Pradesh and Karnataka. The company also has an extensive brand
portfolio of its own brands in the country liquor segment.
Globus Spirits Limited (GSL) is having an existing 100 KLPD Grain Based Distillery or 75 KLPD Grain
Based & 25 KLPD Molasses Based Distillery at Village Chulkhana, Tehsil Samalkha, District Panipat
(Haryana). Environmental Clearance for the same has been obtained from MoEF, New Delhi vide
Letter No. J-11011/714/2009- 1A II (I) dated 28th Feb., 2011.
(ii) Brief description of nature of the project
Globus Spirits Limited is proposing capacity enhancement by modernization of grain based
distillery (100 KLPD to 125 KLPD) and Co-generation Power Plant (3 MW to 3.8 MW) at Village
Chulkhana, Tehsil Samalkha, District Panipat (Haryana).
The additional capacity of 25 KLPD will be grain based alcohol using grain as raw material which
are abundantly available in the state. The Project is based on zero effluent discharge. The distillery
has put up the most modern technology for treatment of distillery spent wash which ensures Zero
Proposed Capacity Enhancement by Modernization in Existing Grain Based Distillery (100 KLPD to 125 KLPD) & Co-generation Power Plant (3 MW to 3.8 MW) At Village: Chulkhana, Tehsil: Samalkha, District: Panipat (Haryana)
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M/s. Haryana Organics (A unit of Globus Spirits Ltd.) 5
discharge of distillery effluents. The distillery unit generates its own electricity by its co-generation
power plant.
As per EIA Notification dated 14th September, 2006 and as amended from time to time; the project
falls in Category ‘A’, S. No. - 5 (g).
(iii) Need for the project and its importance to the country and or region
Advancement in science and technology has created so many products that have enhanced the
quality of human life in every passing year. The human race is largely dependent on
industrialization for up gradation in quality of life. Progress of the nation is judged through its
economic growth which is largely dependent on industrial productivity. In Indian economy (which
is agro based) many industries are dependent over agricultural produce for production of luxury
and need based commodities. Alcohol has assumed a very important place in the Country’s
economy. It is a vital raw material for a number of chemicals. It has been a source of revenue by
way of excise duty levied by the State Government on alcohol liquors. It has a potential as fuel in
the form of power alcohol for blending with petrol in the ratio of 20:80. The use of alcohol for the
purpose of potable liquor is as high as its use for industrial purposes. The Country Liquor is mainly
used by the common masses.
According to analysts, the Indian alcoholic beverages industry is expected to witness accelerating
growth in coming years with the consumer base likely to expand amidst rising disposable income.
The domestic alcoholic drinks market is estimated around $13 billion and has been growing at a
compounded annual growth rate in excess of 10% in the past few years. The growth rate is higher
than other major Asian markets like China and South Korea, etc.
In the path of company’s growth and development this project will serve as yet another
milestone.
(iv) Demand- Supply Gap
Not required in this project. This depends on excise department.
(v) Import vs. Indigenous Production
Indian market could not meet present alcohol demand. So they import alcohol 5-7% of total
demand. As far as ENA production is concerned, Indian market play a vital role at both domestic &
international level. So they require produce the more alcohol to meet the demand.
(vi) Export Possibility
There will be possibility of export of alcohol to African, European & Asian countries.
(vii) Domestic / Export Markets
Market depends on excise department.
(viii) Employment Generation (Direct and Indirect) due to the project
The total manpower requirement after the proposed capacity enhancement project will remain
same as existing i.e. around 120 persons.
Proposed Capacity Enhancement by Modernization in Existing Grain Based Distillery (100 KLPD to 125 KLPD) & Co-generation Power Plant (3 MW to 3.8 MW) At Village: Chulkhana, Tehsil: Samalkha, District: Panipat (Haryana)
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M/s. Haryana Organics (A unit of Globus Spirits Ltd.) 6
3.0 PROJECT DESCRIPTION
(i) Type of Project including interlinked and independent projects, if any.
There are no interlinked projects related to this capacity enhancement by modernization project.
(ii) Location (map showing general location, specific location, and project boundary & project site
layout) with coordinates
Figure - 1: Location Map
Proposed Capacity Enhancement by Modernization in Existing Grain Based Distillery (100 KLPD to 125 KLPD) & Co-generation Power Plant (3 MW to 3.8 MW) At Village: Chulkhana, Tehsil: Samalkha, District: Panipat (Haryana)
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M/s. Haryana Organics (A unit of Globus Spirits Ltd.) 7
(ii) Key Plan
Figure 3: Key Plan
Proposed Capacity Enhancement by Modernization in Existing Grain Based Distillery (100 KLPD to 125 KLPD) & Co-generation Power Plant (3 MW to 3.8 MW) At Village: Chulkhana, Tehsil: Samalkha, District: Panipat (Haryana)
Pre - feasibility Report
M/s. Haryana Organics (A unit of Globus Spirits Ltd.) 8
(iv) Details of alternative sites consideration and basis of selecting the proposed site, particularly the
environmental considerations gone into should be highlighted.
Since the proposed capacity enhancement will be done within the existing distillery plant
premises and no additional land will be required; therefore, no alternative site has been
considered.
(v) Size or magnitude of operation
Globus Spirits Limited is proposing capacity enhancement by modernization of grain Based
distillery (100 KLPD to 125 KLPD) & Co-generation Power Plant (3 MW to 3.8 MW) at Village
Chulkhana, Tehsil Samalkha, District Panipat (Haryana).
As per EIA Notification dated 14th September, 2006 and as amended from time to time; the project
falls in Category ‘A’, S. No. - 5 (g).
(vi) Project Description with Process Details
Project Description
Units Existing Capacity Proposed Capacity
Enhancement
Total Capacity after
Enhancement
Grain Based Distillery 100 25 125
Co-generation Power Plant (MW) 3.0 0.8 3.8
Process Description
Distillery Unit - Production from Grain:
• Grain storage
• Grain cleaning, milling and flour handling
• Slurry preparation & liquefaction
• Multi pressure distillation
• Alcohol (ENA & IA) daily receivers & bulk storage
• MEE & Dryer
MAIN PLANT & MACHINERY
1. Grain Storage :
Grains are procured from various sources, such as FCI Storage godowns through agencies and are
unloaded into large Storage Silos after Pre-Cleaning. Storage Silos are specially designed to keep
the Grains in good condition for longer durations and also avoid its deterioration and theft, etc. It
is being proposed to have 30 – 45 days of Grain Storage facility in the Distillery.
2. Grain Cleaning, Milling and Flour Handling :
The grain is lifted in bucket elevators, screened followed by removal of stones and iron matter.
Cleaned Grains are then milled using dry milling process in Hammer Mills. The flour is fed through
the bucket elevator and conveyed to the Batch Tipping Machine through a Screw Conveyor. The
Proposed Capacity Enhancement by Modernization in Existing Grain Based Distillery (100 KLPD to 125 KLPD) & Co-generation Power Plant (3 MW to 3.8 MW) At Village: Chulkhana, Tehsil: Samalkha, District: Panipat (Haryana)
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M/s. Haryana Organics (A unit of Globus Spirits Ltd.) 9
flour addition is metered through the Batch Tipping Machine with load cell arrangement, before
transferring the flour to the Slurry Tank through another Screw Conveyor (pre-masher) for slurry
preparation process. It is being proposed to have 2 x 8 TPH (+ 1 Standby option) as milling
paraphernalia for this Distillery.
3. Slurry Preparation & Liquefaction :
Grain flour and process water is fed at controlled rate to Initial Liquefaction tank. Mixed slurry is
taken to the Initial Liquefaction Tank where additional quantity of water is added as per
requirement. Viscosity reduction Enzyme and stabilizing chemicals and a portion of liquefying
enzyme are also added at this stage. This slurry is then “cooked” in the jet cooker.
The slurry is continuously pumped to a steam jet cooker where high-pressure steam rapidly raises
the slurry temperature. The mixture of slurry and steam is then passed through the Retention
Vessel. The retention vessel has sufficient capacity to provide the desired retention time at a given
flow rate. The cooked mash is discharged to a Flash Tank.
The cooking process, accomplished in the above manner, converts the slurry into a hydrated,
sterilized suspension and is therefore susceptible to enzyme attack for liquefaction.
The gelatinized mash from the Flash Tank is liquefied in the Final Liquefaction Tank where
liquefying enzyme (alpha-amylase) is added. The liquefied mash is cooled in Mash Cooler and
transferred to Saccharification cum fermentation section. This process initiates the formation of
sugar.
The gelatinized mash from the Flash Tank is liquefied in the Final Liquefaction Tank where
liquefying enzyme (alpha-amylase) is added. The liquefied mash is cooled in Mash Cooler and
transferred to Saccharification cum Fermentation section.
4. Hiferm-Nm Saccharification and Instantaneous Fermentation:
Yeast Activation:
Yeast seed material is prepared in water-cooled Yeast Activation Vessel by inoculating sterilized
mash with Active Dry Yeast. Optimum temperature is maintained by cooling water. The contents
of the Yeast Activation Vessel are then transferred to Fermenter.
Saccharification & Instantaneous Fermentation:
The Liquefied starch slurry comprising Dextrins is partly taken for Yeast development in Yeast
Activation vessel and majorly transferred into the Fermenter. Amyloglucozydase and other
nutrient Enzymes are first added to Saccharify the Starch Slurry causing formation of Sugars.
Immediately, the Active Yeast is introduced in the system for simultaneous Fermentation. The
process of fermentation is to convert the fermentable substrate into alcohol. To prepare the mash
for fermentation, it may have to be diluted with water. The pH of the mash is adjusted by the
addition of acid. Yeast is available in sufficient quantity to initiate fermentation rapidly and
complete it within the cycle time.
Proposed Capacity Enhancement by Modernization in Existing Grain Based Distillery (100 KLPD to 125 KLPD) & Co-generation Power Plant (3 MW to 3.8 MW) At Village: Chulkhana, Tehsil: Samalkha, District: Panipat (Haryana)
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M/s. Haryana Organics (A unit of Globus Spirits Ltd.) 10
At the start of the cycle, the fermenter is charged with mash and contents of the Yeast Activation
Vessel. Significant heat release takes place during fermentation. This is removed by passing
cooling water through the Fermenter PHE’s to maintain an optimum temperature. The
recirculating pumps also serve to empty the fermenters into Beer Well. After the fermenters are
emptied, they are cleaned with water and caustic solutions and sterilized for the next batch. The
carbon dioxide evolved during the process is vented to atmosphere after recovery of alcohol in a
scrubber.
5. Multi Pressure Distillation :
This process utilizes following columns namely the Analyser, Degassifier, Pre-Rectifier Column,
Stripper, Rectifier cum Exhaust, Extractive Distillation (ED) Column, Recovery Column and
Simmering Column in ideal heat integration in order to reduce the energy consumption.
The Analyzer & Degassifier Columns are operated under Vacuum whereas the Simmering, the
Recovery Columns are operated under Atmospheric condition. The Pre-Rectifier, Rectifier-cum-
Exhaust Columns are operated under Pressure.
The energy requirement for Analyser, Degassifier Column is met by Rectifier Column top vapours.
The Rectifier Column top vapours are condensed in a thermo-siphon reboilers connected to a flash
tank and then flash vapours are injected into Analyser Column.
The energy requirement of the Simmering Column is met by the top vapours of Pre-Rectifier
Column while that of the Recovery Column is through direct steam. The overall Technical Alcohol /
Impure Spirit Cut will be maintained at 7% max. The Distillation Plant shall be designed for use of
Grain starch route only.
6. Alcohol (ENA & TA) Daily Receivers & Bulk Storage :
The Extra Neutral Alcohol & Technical Alcohol (Impure Spirit) is first taken to Daily receiver
storage tanks, which is based on the State Excise laws, storage for three days considering the
weekly holidays of two days. Thereafter, the alcohol is transferred to Bulk Storage Tanks after
taking the daily receiver Dip. This is transferred using flameproof pumps. Final dispatch of alcohol
is metered and again is carried out using special flameproof pumps. The Bulk Spirit Storage is
proposed to be set up for 30 days.
EFFLUENT HANDLING SECTION
1. Decantation Section:
Decantation section comprises of Centrifuge Decanters, operating at high rpm which are used for
separation of suspended solids from Spent Slops coming out of Distillation section. The Wet cake
thus separated has 30-35% w/w solids, as removed from bottom of Decanters. This is directly
loaded on the trolleys parked below. Thin slops coming out of Decanter are collected in a tank and
are transferred for part recycle & further for Evaporation into thick syrup.
2. Integrated Evaporation Section:
Proposed Capacity Enhancement by Modernization in Existing Grain Based Distillery (100 KLPD to 125 KLPD) & Co-generation Power Plant (3 MW to 3.8 MW) At Village: Chulkhana, Tehsil: Samalkha, District: Panipat (Haryana)
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M/s. Haryana Organics (A unit of Globus Spirits Ltd.) 11
The suggested treatment scheme is a 2 FF + Finisher Evaporation Plant for Thin Slops Evaporation.
The following points will elucidate the basic working principle:
� Shell & Tube type Evaporators with highly efficient liquid distributor working on the
principle of Falling Film Evaporation have been used, with Plate type Preheaters for
preheating of FEED stream which serves the purpose of energy conservation.
� Analyzer vapour is fed to the first effect evaporator shell side at the given pressure and
temperature as the heating medium.
� The Feed from the Feed balance tank is taken to the PHCOND to make the best heat
recovery.
� The Feed after getting heated to the predetermined temperature in preheater is fed from
the first effect evaporator which is Falling Film Evaporator -1
� The flow path is given below.
INLET FEED - pH cond – E1 – E2 – OUTLET PRODUCT
� Vapours generated in 1st effect VLS (Vapour Liquid Separator) are used as heat source in
the 2nd effect.
� The product at the desired concentration of TS is obtained at the outlet of the second
effect, which is a Falling Film evaporator.
� A Shell & tube type Multi-pass Surface condenser is employed for condensing the shell side
vapours.
� The Pure and the process condensate are collected in receiving vessels.
� Highly efficient operating pumps will be provided for pumping the required fluid.
� The operation of the plant will be under vacuum. Vacuum is created with the help of a
water ring vacuum pump.
� The plant will have high level of automation to get consistent output at required
concentration.
� The system operates under vacuum. Water-ring vacuum pumps are used to maintain a
desired vacuum.
� Cooling water from cooling tower is used in the surface condensers for condensing the
vapours.
CONCLUSION
The thick syrup thus obtained is mixed with the Wet Cake obtained from Decanter Centrifuges
using specially designed Ribbon type mixer and this enriches the protein content in the fibrous
suspended solids separated earlier in Decanter. This Protein & Fibre rich DWGS is directly sellable
as Cattle / Poultry Feed. However, the DWGS By-Product has less shelf-life and needs to be
consumed within 2-3 days.
In order to increase the shelf life of such by-product, it is necessary to dry the product, with
minimum possible moisture content.
Proposed Capacity Enhancement by Modernization in Existing Grain Based Distillery (100 KLPD to 125 KLPD) & Co-generation Power Plant (3 MW to 3.8 MW) At Village: Chulkhana, Tehsil: Samalkha, District: Panipat (Haryana)
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M/s. Haryana Organics (A unit of Globus Spirits Ltd.) 12
SYSTEM DESCRIPTION FOR DWGS DRYER
Wet distiller’s grains shall be fed into the dryer housing at controlled rate through a suitable
feeding system. The Rotary Tube Bundle is enclosed in an insulated dryer housing and on its outer
flights are fixed. Dry saturated steam is to be supplied to the tube bundle through rotary joint at
one end & the condensate is discharged through rotary joint mounted at other end.
During the course of rotation, these flights pick up the material and shower them on to the tube
bundles. The heat transfer is primarily by conduction. The water vapours are exhausted through
an Exhaust Blower & passed through a cyclone separator for separating fines.
Dry product partially recycled back to Feed conditioner for feed conditioning through Product
Screw & Recycle Conveyor.
Entire operation of the Dryer is controlled through Control panel.
SYSTEM DESCRIPTION FOR COOLING & CONVEYING
� DWGS below product screw is discharged into charging hopper of pneumatic conveying
system.
� Rotary feeder feeds it into the conveying line.
� Ambient air is used for conveying.
� The material gets conveyed to product collector & discharged from rotary discharge
valve.
� Exhaust air is vented to atmosphere.
� The conveying system is lean phase suction type, using centrifugal blower as prime
mover. The conveying air quantity is designed considering cooling requirement & to cool
the product before discharge.
Figure - 3: Process flow chart For Grain Based Distillery
Proposed Capacity Enhancement by Modernization in Existing Grain Based Distillery (100 KLPD to 125 KLPD) & Co-generation Power Plant (3 MW to 3.8 MW) At Village: Chulkhana, Tehsil: Samalkha, District: Panipat (Haryana)
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M/s. Haryana Organics (A unit of Globus Spirits Ltd.) 13
(vii) Raw material required along with estimated quantity, likely source, marketing area of final
products, mode of transport of raw material and finished product.
(a) Raw Material Requirement
The raw materials required for the Grain based distillery can be broadly categorized as follows:
• Grain
• Enzymes & Chemicals
• Steam
• Fuel
• Power, etc.
The basic raw material for the manufacturing of ENA/RS will be Grain. In the present scenario,
grains with different starch content are used like broken Rice, sorghum, baira, maize etc. The
process requires the above grains to be milled into specific flour size. Small quantity of sulphuric
acid is sometimes required. The raw material for the boiler fuel will be Coal/Rice Husk.
S. No. Particular
Total Requirement after
proposed Capacity
Enhancement
Source & Mode of Transportation
1 Grain 265 MT/day Through vendors / By road
2
Chemicals
Near-by Markets / By road
Sodium Hydroxide (Caustic) 250 - 300 Kg / day
NH2-CO- NH2 (Nutrients) 300 Kg / day
Enzymes 200 Kg / day
Antifoam Agent 25 Kg / day
Yeast (Active Dry
Yeast/Distiller’s Yeast) 80 Kg / day
(b) Fuel Requirement
Name of Raw Material Total Quantity after Proposed Capacity
Enhancement (MT per day) Source & Mode of Transportation
Rice Husk 180 From Authorized Dealer / By Road
Note: Auxiliary Fuel will be used such as Coal, Petcoke etc.
(viii) Resources optimization/ recycling and reuse envisaged in the project, if any, should be briefly
outlined.
The waste water generated from the industry is being /will be properly treated through most
modern technology i.e. Decantation followed by Vapour Integration Plant with the Dryer; and the
Proposed Capacity Enhancement by Modernization in Existing Grain Based Distillery (100 KLPD to 125 KLPD) & Co-generation Power Plant (3 MW to 3.8 MW) At Village: Chulkhana, Tehsil: Samalkha, District: Panipat (Haryana)
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M/s. Haryana Organics (A unit of Globus Spirits Ltd.) 14
condensate water is being / will be recycled back in the process & also, reused for greenbelt
development/plantation, which is being / will be results in ‘’Zero- Discharge’’.
(ix) Availability of water it’s source, energy /power requirement and source should be given.
(a) Water Requirement and Source
Existing water requirement for 100 KLPD grain based distillery is 552 KLPD.
Vapour Integration Plant with the dryer will be installed for recycling of water due to which there
will be no increase in water requirement after the proposed Capacity Enhancement. Thus, no
additional fresh water will be required for the proposed Capacity Enhancement.
Source of Water: Ground Water.
TABLE - A
WATER REQUIREMENT FOR GRAIN BASED OPERATION
S. No. DESCRIPTION WATER
CONSUMPTION (KLD)
1 PROCESS WATER IN LIQN & FERMENTATION 622
2 DM WATER FOR BOILER FEED 740
3 DM WATER FOR RS DILUTION 180
4 BLENDING 120
5 MISC. BOTTLE WASHINGS 30
6 COOLING TOWER MAKE UP SOFT WATER 351
TOTAL WATER REQUIREMENT (A) 2043
TABLE - B
TOTAL WATER OUTPUT
S. No. DESCRIPTION WATER CONSUMPTION
(KLD)
1 STEAM CONDENSATE 586
2 COOLING TOWER EVAPORATION LOSS 351
3 SPENT LEES (ENA) 180
4 SPENT LEES (RS) 150
5 WATER IN PRODUCT 120
6 MISC. WASHING 30
7 THIN SLOP 499
8 BOILER BLOW DOWN & DRIP LOSSES 40
9 WATER IN WET CAKE (DWGS) 87
TOTAL (B) 2043
Proposed Capacity Enhancement by Modernization in Existing Grain Based Distillery (100 KLPD to 125 KLPD) & Co-generation Power Plant (3 MW to 3.8 MW) At Village: Chulkhana, Tehsil: Samalkha, District: Panipat (Haryana)
Pre - feasibility Report
M/s. Haryana Organics (A unit of Globus Spirits Ltd.) 15
TABLE - C RECYCLING & UTILIZATION STREAM
S. No. RECYLCE & UTILIZATION STREAMS WATER CONSUMPTION
(KLD)
1 STEAM CONDENSATE 586
2 SPENT LEES (ENA) - COOLING TOWER MAKEUP 180
3 PROCESS CONDENSATE RECYCLED TO PROCESS 711
4 MISC.BOTTLE WATER 14
Total Recycling /Re-utilizations of water per day (C) 1491
TOTAL FRESH WATER INPUT (A-C) 552
Hence, Fresh Water Requirement is 552 KLD
* Water requirement for first run would be 2043 KLD
Proposed Capacity Enhancement by Modernization in Existing Grain Based Distillery (100 KLPD to 125 KLPD) & Co-generation Power Plant (3 MW to 3.8 MW) At Village: Chulkhana, Tehsil: Samalkha, District: Panipat (Haryana)
Pre - feasibility Report
M/s. Haryana Organics (A unit of Globus Spirits Ltd.) 16
Figure - 4: Water Balance chart For Grain Based Distillery
Proposed Capacity Enhancement by Modernization in Existing Grain Based Distillery (100 KLPD to 125 KLPD) & Co-generation Power Plant (3 MW to 3.8 MW) At Village: Chulkhana, Tehsil: Samalkha, District: Panipat (Haryana)
Pre - feasibility Report
M/s. Haryana Organics (A unit of Globus Spirits Ltd.) 17
(b) Power Requirement and Source
Existing power requirement is 3.2 MW and no additional power will be required for proposed
capacity enhancement project. Thus, the total power requirement after proposed capacity
enhancement project will remain same as existing.
Source: Co-generation Power Plant, Haryana State Electricity Board & D.G Sets (for emergency).
(c) Steam Requirement
Existing steam requirement is 31.0 TPH and there will be no additional steam requirement for the
proposed Capacity Enhancement project.
Source: Boiler - 2 in nos. (25 & 14 TPH).
STEAM REQUIREMENT
S. No. Purpose Requirement after Proposed Capacity
Enhancement (TPH)
1. Cooking & Liquefaction 3.3
2. Multi-pressure Distillation 17.7
3. Evaporation (Integrated) & DWGS Drier
(DDGS) 7
4. Boiler De-aeration 3
Total 31.0
(x) Quantity of waste to be generated (liquid and solid) and scheme for their management/disposal
o The proposed Capacity Enhancement project is being/will be based on “ZERO EFFLUENT
DISCHARGE”.
o Grain Slops (Spent Wash) will be taken through Centrifuge Decanters for separation of
Suspended Solids separated as Wet Cake.
o Thin Slops from the Decanter Centrifuge are partly recycled back to process (30-35%) and
partly taken to Thins Slops Evaporation Plant for concentration of remaining solids to form a
Syrup. This Syrup is mixed with the Wet Cake coming out of Decanter Centrifuge and forms
part of Cattle Feed. (Also known as Distillers Wet Grain Solubles - Collectively known as
DWGS)
o DWGS is taken to a dryer operating on steam and is dried to make it DDGS – Distillers Dried
Grain Solubles.
o The process condensate is cooled and collected into a neutralization tank with sufficient
residence time. After Neutralization, this process condensate will be recycled into process and
is used for green belt development within the complex.
o Two streams of low BOD lees (White Effluent) comes out is partly used as fermenter washing
and then sent for Cooling, treatment and utilized for RS dilution. The second part requires
only cooling and can be used as Cooling Tower water makes up directly.
Proposed Capacity Enhancement by Modernization in Existing Grain Based Distillery (100 KLPD to 125 KLPD) & Co-generation Power Plant (3 MW to 3.8 MW) At Village: Chulkhana, Tehsil: Samalkha, District: Panipat (Haryana)
Pre - feasibility Report
M/s. Haryana Organics (A unit of Globus Spirits Ltd.) 18
o Solid waste from the Grain based operations generally comprises of Fibres and proteins in the
form of DDGS, which are being / will be ideally used as Cattle Feed.
o Ash from the Boiler is being / will be sold to Brick manufacturers.
o Used oil & grease generated from plant machinery / Gear boxes & D.G. Set is being / will be
partly used in oiling & greasing as lubrication of external parts of machinery & partly is being /
will be sold to the CPCB authorized recycler.
4.0 SITE ANALYSIS
(i) Connectivity
The plant is located at 4 Kms, Chulkhana Road, Village Chulkhana, Tehsil Samalkha, District
Panipat, Haryana. The capacity enhancement of the existing plant will be undertaken within plant
premises; hence no new land will be required. NH-1 (Delhi-Amritsar), approx. 2.0 km in E direction
from the proposed project site and nearest Samlakha Railway Station (2.6 Km NNE) from the
proposed project site have resulted in excellent connectivity of the village.
It has an easy access to raw material availability and other infrastructural facilities e.g. land,
power, water, transport and communication, approach through road & access distances from the
nearest highway, railway station etc. The site is well connected with communication facilities like
telephone, fax, wireless and telex and as such, no constraints are envisaged in this aspect also.
(ii) Land from Land use and Land ownership
Total plant area is 17 acres (6.878 ha). Since, the proposed capacity enhancement will be done
within the existing plant premises, thus, no additional land is required for the proposed capacity
enhancement project.
(iii) Topography
The topography of the area is almost flat.
(iv) Existing land use pattern (agriculture, non-agriculture, forest, water bodies (including area
under CRZ)), shortest distances from the periphery of the project to periphery of the forests,
national park, wild life sanctuary, eco sensitive areas, water bodies (distance from the HFL of the
river), CRZ. In case of notified industrial area, a copy of the Gazette notification should be given
Environmental Settings of the Area
S. NO. PARTICULARS DETAILS
(with approximate aerial distance & direction from plant site)
1. Nearest Village Chulkhana (1.5 km in SW direction)
2. Nearest Town Samalkha (2.6 km in NNE direction)
3. Nearest City Panipat (20 km in SE direction)
4. Nearest National Highway / State
Highway
NH-1 (2.0 km in East direction)
5. Nearest Railway station Samalkha Railway Station (2.6 km in NNE direction)
Proposed Capacity Enhancement by Modernization in Existing Grain Based Distillery (100 KLPD to 125 KLPD) & Co-generation Power Plant (3 MW to 3.8 MW) At Village: Chulkhana, Tehsil: Samalkha, District: Panipat (Haryana)
Pre - feasibility Report
M/s. Haryana Organics (A unit of Globus Spirits Ltd.) 19
6. Nearest Airport New Delhi ( 74 km in South direction)
7. National Parks, Wild Life Sanctuaries,
Biosphere Reserves, Tiger/ Elephant
Reserves, Wildlife Corridors etc.
within 10 km radius
No National Park, Wild Life Sanctuary, Biosphere Reserve,
Tiger / Elephant Reserve, Wildlife Corridors etc. falls within
10 km radius of the plant site.
8. Reserved Forests (RF) / Protected
Forests (PF) etc. within 10 km radius
No Reserved / Protected Forest lies within 10 km radius
(Boundary to boundary distance) of the proposed project
site.
9. River / Water Body (within 10 km
radius)
Western Yamuna Canal - New Delhi parallel branch (5.5 km in
West direction)
(v) Existing Infrastructure
Total plant area is about 17 acres (6.878 ha). Proposed capacity enhancement will be done within
the existing plant premises by adopting improvement in Fermentation & Distillation Technology.
Existing infrastructure will suffice the requirement of proposed capacity enhancement project.
(vi) Soil classification
The district has two types of soils viz-tropical arid brown and arid brown soils (solemnized). The
arid brown soils are found in major parts of the district whereas tropical arid brown soils are found
in north eastern part of the district especially in parts of Bapoli and Panipat blocks.
(vii) Climatic data from secondary sources
The district has a sub - tropical continental monsoon climate where we find seasonal rhythm, hot
summer, cool winter, unreliable rainfall and great variation in temperature. The rainfall
distribution is relatively satisfactory in relation to western parts of Haryana and it is mostly
restricted to rainy season. The district also gets occasional winter rains from cyclones. Air is
generally humid dry during the greater part of the year. Dust storms mostly occur during April to
June. Fog sometime happens dense in the winter season.
(viii) Social Infrastructure available
Nearest habitation are at Chulkhana village. The nearest town is Samalkha, which is approx. 2.6
km distance from the plant site. The nearest major city is Panipat about 20 km respectively from
the plant site.
At Samalkha town schools, dispensaries, small hospitals, places of worship etc are available.
Electrical power supply in most of surrounding villages is available.
Telephone, Medical facilities are available in the nearby towns. Almost all the villages in the
buffer zone are electrified. L.T. power is being supplied for drawing water from a large number
of tube wells sunk around the important village of the buffer zone, for irrigation purpose. Most
of the tanks and ponds as well as the river water are being utilized for irrigation.
5.0 PLANNING BRIEF
Proposed Capacity Enhancement by Modernization in Existing Grain Based Distillery (100 KLPD to 125 KLPD) & Co-generation Power Plant (3 MW to 3.8 MW) At Village: Chulkhana, Tehsil: Samalkha, District: Panipat (Haryana)
Pre - feasibility Report
M/s. Haryana Organics (A unit of Globus Spirits Ltd.) 20
(i) Planning Concept (type of industries, facilities, transportation etc.) Town and country Planning/
Development authority classification.
The existing unit is distillery industry and proposed capacity enhancement will be done within the
existing plant premises by adopting improvement in Fermentation & Distillation Technology.
Facilities required for the proposed capacity enhancement project will be provided as per
requirement. Transportation of raw material and final product is being / will be done by road.
(ii) Population Projection
No influx of people will be there as the proposed capacity enhancement will be done by adopting
improvement in Fermentation & Distillation Technology.
(iii) Land use planning (breakup along with green belt etc)
Total Plant area is 17 acres (6.878 ha). Proposed capacity enhancement project will be set up in
the existing plant premises. No additional land will be required. About 33 % of the total project
area is being/will be covered under green belt & plantation in order to reduce dust & noise
pollution levels & to increase aesthetic beauty of the area.
(iv) Assessment of infrastructure demand (Physical & Social)
Globus Spirits Ltd. has assessed the demand of infrastructure (Physical & Social) in nearby area of
the plant site and development activities are being undertaken under corporate social
responsibilities program for rural development initiatives for the upliftment of the nearby
communities from time to time.
(v) Amenities/Facilities
Globus Spirits Ltd has developed and will further develop the Amenities/Facilities in nearby area
of the proposed capacity enhancement plant site as per requirement of local people of the
nearby area under corporate social responsibilities programs.
6.0 PROPOSED INFRASTRUCTURE
(i) Industrial Area (Processing Area)
No additional infrastructure will be required for the proposed capacity enhancement project as
the proposed project will be set up in the existing plant premises.
(ii) Residential area (Non Processing area)
No residential area is envisaged.
(iii) Green Belt
Out of the total plant area (6.878 ha), 33% has been developed under greenbelt / plantation area.
The same will be maintained & further enhanced for proposed capacity enhancement project, in
order to reduce dust & noise pollution levels & to increase aesthetic beauty of the area.
(iv) Social Infrastructure
Proposed capacity enhancement project will result in growth of the surrounding areas by ancillary
development and supporting infrastructure in the region.
Proposed Capacity Enhancement by Modernization in Existing Grain Based Distillery (100 KLPD to 125 KLPD) & Co-generation Power Plant (3 MW to 3.8 MW) At Village: Chulkhana, Tehsil: Samalkha, District: Panipat (Haryana)
Pre - feasibility Report
M/s. Haryana Organics (A unit of Globus Spirits Ltd.) 21
(v) Connectivity
The site is well connected with communication facilities like telephone, fax, and wireless as such,
no constraints are envisaged in this aspect as the Tehsil and District headquarters are near to the
site.
(vi) Drinking Water
5 KLPD water is being / will be required for drinking purpose and other use, which will be sourced
from Ground Water.
(vii) Sewage Treatment System
The waste water generated from the sanitary blocks is being/will be disposed off in soak pit via
septic tank.
(viii) Industrial Waste management
The grain based distillery project is being / will be based on “ZERO DISCHARGE”.
(ix) Solid Waste Management
o Solid waste from the Grain based operations generally comprises of Fibres and proteins in the
form of DDGS, which are being / will be ideally used as Cattle Feed.
o Ash from the Boiler is being / will be sold to Brick manufacturers.
(x) Power requirement and source
Existing power requirement is 3.2 MW and no additional power will be required for proposed
capacity enhancement project. Thus, the total power requirement after proposed Capacity
Enhancement project will remain same as existing.
Source: Co-generation Power Plant, Haryana State Electricity Board & D.G Sets (for emergency).
7.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN
(i) Policy to be adopted (Central/State) in respect of the project affected persons including home
oustees, land oustees and landless labourers (a brief outline to be given).
Proposed capacity enhancement will be done within the existing plant premises. No additional
land is required for proposed capacity enhancement project. Therefore, there will not be
displacement of people and hence, Rehabilitation & Resettlement is not applicable.
8.0 PROJECT SCHEDULE AND COST ESTIMATES
(i) Likely date of start of construction and likely date of completion (time schedule for the project
to be given).
The project will start only after obtaining Environmental Clearance and other statutory
permissions. Project will be completed in 12 months period after getting all the regulatory
approvals.
(ii) Estimated project cost along with analysis in term of economic viability of the project.
� Total cost of the Project: Rs. 10 Crores
Proposed Capacity Enhancement by Modernization in Existing Grain Based Distillery (100 KLPD to 125 KLPD) & Co-generation Power Plant (3 MW to 3.8 MW) At Village: Chulkhana, Tehsil: Samalkha, District: Panipat (Haryana)
Pre - feasibility Report
M/s. Haryana Organics (A unit of Globus Spirits Ltd.) 22
� Cost for Environment Protection Measues:
� Capital Cost: Rs. 3.0 Crores
� Recurring Cost/annum: Rs. 50 Lacs / annum.
9.0 ANALYSIS OF PROPOSAL
(i) Financial and social benefits with special emphasis on the benefit to the local people including
tribal population, if any, in the area.
Proposed project will result in growth of the surrounding areas by increasing ancillary
development and supporting infrastructure. Special emphasis on Financial and Social benefits will
be given to the local people including tribal population, if any, in the area.
Development of social amenities will be in the form of medical facilities, education to
underprivileged and creation of self help groups.
Haryana state will get revenues in terms of taxes. Business opportunities for local community will
be available like transport of alcohol to market, fly ash transport to Brick manufactures,
maintenance & house-keeping contract work etc.
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